Using Tutorials Tutorial 1in MM Tutorial 1in Inch Tutorial 2

Contents
Using Tutorials
Tutorial 1in mm
Tutorial 1in inch
Tutorial 2
Tutorial 3
Tutorial 4
Tutorial 5
Tutorial 6
Tutorial 7
Tutorial 8
Tutorial 9
Using tutorials
The tutorials guide you through the actual programming process for a few sample parts. When you complete all the tutorials you will be able to use
CAPSmill independently without any guidance.
To get the tutorials, click on the tutorials book in the help. A list of tutorials indicating the topics covered in it appears. Double click on the first
tutorial.
Perform the actions listed. At the end of each section, you will find a Back button, which leads you to the previous section, and a Next button, which
leads you to the next.
Clicking on underlined text leads to additional information on the topic.
If you need information not available in the Tutorial, use the context sensitive Help in the software.
The programming process consists of the following 8 steps:
Steps Operation Menu option

Step 1 Start new program File
Step 2 Define work setup
Step 3 Draw the part Geometry
Step 4 Define Blank Geometry
Step 5 Perform Machining Machining
Step 6 Select Machine Machines
Step 7 View tool path Tool path
Step 8 Generate NC program NC program
You will notice that till View tool path the order of the steps is the same as in the main menu and icon bar. To do a program you will be following this
order from Left to Right.
CAPSmill ver 7.0 1

Tutorial 1
In millimeters
This tutorial illustrates:

• Creating the part and blank shapes
• Selecting tools
• Performing face milling, drilling and reaming operations
• Viewing the tool path
• Generating NC program
• Generating documents
Part drawing in MM
View A-A
200 40
A
150
A 12 - φ10 holes
at 30° pitch on 75
PCD 100.
Material: Stainless steels, Austenitic.

All dimensions are in MM.
CAPSmill ver 7.0 2

Steps to NC program
Start a new program Start new program à Define work setup à Draw the part à Define Blank à Perform
Machining à Select Machine à View tool path à Generate NC program
• Start CAPSmill. To do this, double click on the CAPSmill icon

Or
Select Start → Programs → Cadem → CAPSmill.
• Select File → New .
The Work setup dialog box appears.
Steps to NC program
Define work setup Start new program à Define work setup à Draw the part à Define Blank à Perform
The Work set up data is divided into Setup data and General data. Setup data is required for machining, and General data is documentation
related to the program. Setup data must be entered, while General data is optional.
• Select the Units as MM by clicking on it.

• Select Stainless steels, austenitic, moderately difficult as the Workpiece material from the list.
• Leave the Work coordinate system unchanged. The numbers 1 to 6 in the list correspond to the work offsets G54 to G59 on the
machine.
• Leave the Clearance height unchanged at 100 mm.
• Enter the Tool change position as X=100, Y=100, Z=100.
Click on the General tab at the top of the dialog box and enter the general data as shown below.
• Enter the Part number as 567-0099.
• Enter the Part name as PLATE BOTTOM.
• Enter the Setup number as 1.
• Enter the Fixture name as FXT-9944.
• Enter the Programmer name.
• Enter the Remark as MODIFIED DUE TO DESIGN CHANGE NO. 7-A.
I A fast way of moving between edit boxes is through the TAB key. Press TAB to move to the next edit box, or SHIFT+TAB
(hold down the SHIFT key and press TAB) to move to the previous box.
Click on OK to exit from the Work setup dialog box.
Save the File
• Select File → Save .

• Enter the file name as PLATE.
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Draw the part
8 steps to NC program
Start new program à Define work setup à Draw the part à Define Blank à Perform Machining à Select Machine à View tool path à
Generate NC program
Select Geometry on the menu bar. The geometry menu appears, with options for drawing and editing the objects.
Draw the rectangle for face milling
Draw a rectangle of size 200 x 150
• Select Draw → Rectangle → Center – Length - Width .

• The prompt Specify the center point appears in the status bar located at the bottom left hand corner of the screen.
• Enter the coordinates 0,0 through the keyboard and press Enter.
• A dialog box appears for entering the size of the rectangle. Enter the size as shown below against the respective prompts.
Length = 200
Breadth=150
Corner radius=0
Rotation angle=0
• Click on the OK button.
Draw the points for the φ 10 holes
The points lie on a pitch circle diameter of 100 mm. The coordinates for any hole machining operations should be defined as Points.
• Select Draw → Machinable objects → Points on Circle .
• The prompt Specify the center point appears in the status bar located at the bottom left hand corner of the screen. Enter the value 0,0
through the keyboard and press Enter.
• A dialog box appears for entering the points data. Enter the following values against the respective prompts.
Diameter=100
Angle of first hole=0
Number of holes=12
Select Display → Zoom All to see the entire part.
The part has now been defined. It should appear as shown below.
CAPSmill ver 7.0 4

Define blank
Generate NC program
The blank is always defined as a rectangular block. It is displayed during tool path simulation. To define it,
• Select Define → Blank.
• At the prompt Select rectangle <Press ‘Insert’ key for dialog input> that appears in the status bar, click on the 200 x 150 rectangle drawn
earlier.
• Enter the following data in the dialog box that appears and click on the OK button.
Blank thickness = 80
Z coordinate at bottom = -75
The Minimum and Maximum X, Y coordinates are picked up automatically from the selected rectangle. Leave them unaltered.
This ends the definition of Part (Rectangular block) and Blank.
I
The blank definition is optional. If it is not defined, it is automatically assumed as a rectangular block surrounding the area
that is cut. The blank thickness entered here is 80 mm and the Z coordinate at bottom is -75 mm. This means that the blank
is at a height of 75 mm from the machine bed, which is the Z reference point for the program (i.e., the zero offset the along
Z axis).
Perform machining
Generate NC program
Select the tool for face milling

Click on Main to return to the main menu and then select Machining from the menu bar .
I If you use the menu to change from Geometry to Machining, Machining to Tool path, etc., you must come to the Main menu
each time before you select an option. Clicking on an icon takes you straight to the selected mode. Using icons is faster.
Select the face mill

• Select Tool → Face mill
• A dialog box appears with the default values. Enter the following data and leave the rest unchanged.
Enter Mill face against the prompt Process Name.
Against the prompt Manufacturer click on and select General - MM.
Against the prompt Tool material, click on and select Carbide.
Against the prompt Tool name click on and select Face mill Dia 80.0.
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Perform face milling operation
Select Milling → Face mill .

• At the prompt Select the area for face milling that appears on the status bar, click on the rectangle.
• A dialog box with the default values appear. Enter the following data and leave the rest unchanged.
Against the prompt Process, click on Finishing
Work Surface Z = 0
Material thickness = 5
Allowance after roughing = 0.5
Return to Z = 100
Click on Cutting parameters tab and enter
Depth of cut = 3
Notice that the cutting parameters are automatically selected from the database for the selected tool type, tool material and work piece material.
• The prompt Select the machining start point appears in the status bar and also 4 symbols indicating the machining points and direction
appear around the selected rectangle. Select the point at the top right corner as shown below.
Select
this point
Note : The Work surface Z to be specified for face milling is dependent on the blank definition. You had specified the blank thickness as 80
mm and the Z coordinate at bottom as -75 mm, while defining the blank. The remaining 5 mm over the blank is removed during the face milling
operation.
End the tool
A tool change is performed using the End option in the menu bar. To end the tool,
• Click on End in the menu bar . The dialog box for End of tool appears.
• Leave the data unaltered and click on the OK button.
This completes the face milling operation.
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Select the tool for drilling
• Select Tool → Drill

• A dialog box appears with the default values. Enter the following data leaving the rest unchanged.
Enter PCD DRILLING against the prompt Process Name.
Against the prompt Manufacturer, click on and select General - MM.
Against the prompt Tool material, click on and select HSS.
Against the prompt Tool name click on and select Drill Dia 9.8.
Perform drilling operation
• Select Hole → Drill .

• The prompt Select points to be machined appears in the status bar. Click on one of the points in the hole pattern drawn earlier, as shown
below.
Select
this point
Since the hole is part of a pattern, all the points in the pattern get selected.
• Click the right mouse button and select Done.

• The prompt Do you want to omit any holes? appear. Click on the No button.
• A dialog box appears with default values for some of the prompts. Enter the following data and leave the rest unchanged.
Operation name = Drill on PCD
Work surface Z = 0
Hole depth = 40
Return to Z = 100
• End the tool
This completes the drilling operation.
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Select the reamer
• Select Tool → Reamer .

• Enter the following data in the dialog box that appears leaving the rest unaltered :
Enter PCD REAMING against the prompt Process Name.
Against the prompt Manufacturer, click on and select General - MM.
Against the prompt Tool name, click on and select Reamer - Dia.10.
Perform reaming operation
• Select Hole → Ream .

• The prompt Select points to be machined appears in the status bar. Click on one of the points in the hole pattern drawn earlier. Since the
hole is part of point pattern, all the points in the pattern get selected
• The prompt Do you want to omit any holes? appears. Click on the No button.
A dialog box appears with default values. Enter the following data and leave the rest unchanged.
Operation name = Ream on PCD
Work surface Z = 0
Hole depth = 40Dwell at bottom = 1
Retract feed rate = 1
Return to Z = 100
• End the tool.
Save the file.

All the machining operations are now complete.
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Select machine
Generate NC program
The Work setup, Geometry definition, and Machining are independent of any machine. All functions after this are however dependent on the
machine since they use the machine’s mechanical data like feed rate and spindle speed limits, spindle power, etc. The machine must be selected
before executing the following functions:
• View tool path
• View power graph
• Generate NC program
• Generate Time study sheet
• Generate Tool list
To select a machine,
Select Main → Machines . A dialog box appears showing the list of machines
• Click on the machine you want to select.
View tool path
Generate NC program
To view the tool path,

• Select Toolpath from the menu bar . The tool path menu appears.
• By default, simulation starts in solid mode and isometric view.
• Select Simulation → Start or click on .
The mode can be solid or line mode.

The view can be Isometric, XY, YZ or XZ.
Simulation can be till the next motion, till the next tool, or till the end of the program.
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Generate NC program
Generate NC program
To generate the NC program,
• Click on Main to return to the main menu, then click on NC program on the menu bar.
• Enter the program number in the dialog box that appears.
• Select OK.
• A status box indicating the location and file name of the program generated appears. The file gets saved with the main file name and .PRG
extension.
• Click on the Edit button to view the NC program.
• Select File → Exit to exit the editor.
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Generate the time study sheet
To generate the time study sheet,

• Click on Documents → Time study sheet.
• A Time study sheet format dialog box appears. Click on any format listed and click on the View button.
Note: The preview section displays the format selected. You can export the time study sheet to different formats through the Export button.
• Click on the OK button to return to Time study sheet format dialog box and then click on OK to exit time study sheet.
Generate the tool list
To generate the tool list,

• Click on Documents → Tool list.
• A Tool list format dialog box appears. Click on any format listed and click on the View button.
Note: The preview section displays the format selected. You can export the tool list to different formats through the Export button.
• Click on the OK button to return to Tool list format dialog box and then click on OK to exit tool list.
Generate the power graph
To generate the power graph,

• Click on Power graph on the menu bar.
A graph indicating the power consumed for each operation is displayed.

Click on the Close button to exit power graph.
CAPSmill ver 7.0 11

Tutorial 1
In inches
The part is a rectangular block with twelve holes.
This tutorial illustrates:

• Creating the part and blank shapes
• Selecting tools
• Performing face milling, drilling and reaming operations
• Generating NC program
• Generating documents
Part drawing in inches

View A-A
8 1.2
A
A 12 - φ10 holes 3
at 30° pitch on
PCD 4.0
Material: Stainless steels, austenitic.

All dimensions are in inches.
CAPSmill ver 7.0 12

Steps to NC program

Or
Steps to NC program
The Work set up data is divided into Setup data and General data. Setup data is required for machining, and General data is documentation related
to the program. Setup data must be entered, while General data is optional.
• Select the Units as INCH by clicking on it.

• Select Stainless steels, austenitic, moderately difficult as the Workpiece material from the list.
• Leave the Work coordinate system unchanged. The numbers 1 to 6 in the list correspond to the work offsets G54 to G59 on the machine.
• Leave the Clearance height unchanged at 8 inch.
• Enter Tool change position as X=8, Y=8, Z=8.
General data
• Click on the General tab at the top of the dialog box and enter the general data as shown below.
• Enter the Part number as 567-0099.
• Enter the Part name as PLATE BOTTOM.
• Enter the Fixture name as FXT-9944.
• Enter the Programmer name.
• Enter the Remark as MODIFIED DUE TO DESIGN CHANGE NO. 7-A.
Tip: A faster way of moving between edit boxes is through the TAB key. Press TAB to move to the next edit box, or SHIFT+TAB (hold down the
SHIFT key and press TAB) to move to the previous box.
Click on OK to exit from the Work setup dialog box.
Save the File

• Select File → Save .
• Enter the file name as PLATE.
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Draw the part
Generate NC program
Select Geometry on the menu bar. The geometry menu appears, with options for drawing and editing the objects.
Draw the rectangle for face milling
Draw a rectangle of size 6.0 x 4.0
• Select Draw → Rectangle → Center – Length - Width .

• The prompt Specify the center point appears in the status bar located at the bottom left hand corner of the screen.
• Enter the coordinates 0,0 through the keyboard and press Enter.
• A dialog box appears for entering the size of the rectangle. Enter the size as shown below against the respective prompts.
Length = 6
Breadth=4
Corner radius=0
Rotation angle=0
Draw the points for the φ 0.495 holes
The points lie on a pitch circle diameter of 4 mm. The coordinates for any hole machining operations should be defined as Points.
• Select Draw → Machinable objects → Points on Circle .
• The prompt Specify the center point appears in the status bar located at the bottom left hand corner of the screen. Enter the value 0,0
through the keyboard and press Enter.
• A dialog box appears for entering the data. Enter the following values against the respective prompts.
Diameter = 4
Angle of first hole = 0
Number of holes = 12
The part has now been completely defined. It should appear as shown below.
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Define blank
Generate NC program
The blank is always defined as a rectangular block. It is displayed during tool path simulation. To define it,
• At the prompt Select rectangle <Press ‘Insert’ key for dialog input> that appears on the status bar, click on the 6 x 4 rectangle drawn
earlier.
• Enter the following data in the dialog box that appears and click on the OK button.
Blank thickness = 3.3
Z coordinate at bottom = -3
Click on the OK button.
This ends the definition of the Part (Rectangular block) and Blank.
I
The blank definition is optional. If it is not defined, it is automatically assumed as a rectangular block surrounding the area
that is cut. The blank thickness entered here is 80 mm and the Z coordinate at bottom is -75 mm. This means that the blank
is at a height of 75 mm from the machine bed, which is the Z reference point for the program (i.e., the zero offset the along
Z axis).
Perform machining
Generate NC program
Select a tool for face mill

Click on Main to return to the main menu and then select Machining in the main menu .
I If you use the menu to change from Geometry to Machining, Machining to Tool path, etc., you must come to the Main menu
each time before you select an option. Clicking on an icon takes you straight to the selected mode. Using icons is faster.
Select the face mill

• Select Tool → Face mill
Enter Mill face against the prompt Process Name.
Against the prompt Manufacturer, click on and select General - Inch.
Against the prompt Tool material, click on and select Carbide.
Against the prompt Tool name, click on and select Face mill Dia 3.0.
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Perform Face milling operation
• Select Milling → Face mill .

• At the prompt Select the area for face milling that appears in the status bar, click on the rectangle.
• A dialog box appears with default values against some prompts. Enter the following data and leave the rest unchanged.
Process: Click on Finishing.
Material thickness: 0.3
Allowance after roughing: 0.02
Return to Z: 4
Click on Cutting parameters tab.
Depth of cut: 0.1
Notice that the cutting parameters are automatically selected from the database for the selected tool type, tool material and work piece material.
The prompt Select the machining start point appears in the status bar and also 4 symbols indicating the machining points and direction appear
around the selected rectangle. Select the point at the top right corner as shown below.
Select
this point
Note: The Work surface z to be specified for face milling operation is dependent on the blank definition. You had specified the blank thickness
as 3.3 inches and the Z coordinate at bottom as –3 inch, while defining the blank. The remaining 0.3 inch over the blank is removed during the
face milling operation.
End the tool
A tool change is performed using the End option in the menu bar. To end the tool,
• Click on End in the menu bar . The dialog box for End of tool appears.
• Leave the data unaltered and click on the OK button.
This completes the face milling operation.
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Select the tool for drilling
• Select Tool → Drill

Enter PCD DRILLING against the prompt Process Name.
Against the prompt Manufacturer, click on and select General - Inch.
Against the prompt Tool name, click on and select Drill Dia 0.495.
• Select Hole → Drill .

• The prompt Select points to be machined appears in the status bar. Click on one of the points in the hole pattern drawn earlier, as shown
below.
Select
this point
Since the hole is part of point pattern, all the points in the pattern get selected.
Operation name = Drill on PCD
Work surface Z = 0
Hole depth = 1.2
Return to Z = 4
• End the tool
This completes the drilling operation.
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Select a reamer
• Select Tool → Reamer .

• Enter then following data in the dialog box that appears :
Enter PCD REAMING against the prompt Process Name.
Against the prompt Manufacturer, click on and select General - Inch
Against the prompt Tool name, click on and select Reamer Dia 1/2.
Perform reaming operation
• Select Hole → Ream .

• The prompt Select points to be machined appears in the status bar. Click on one of the points in the hole pattern drawn earlier. Since the hole is
part of point pattern, all the points get selected
Operation name = Ream on PCD
Work surface Z = 0
Hole depth = 1.2
Dwell at bottom = 1
Retract feed rate = 3
Return to Z = 4
• End the tool
• Save the file.

All the machining operations are now complete.
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Select machine
Generate NC program
The Work setup, Geometry definition, and Machining are independent of any machine. All functions after this are however dependent on the
machine since they use the machine’s mechanical data like feed rate and spindle speed limits, spindle power, etc. The machine must be selected
before executing the following functions:
• View tool path
• View power graph
• Generate NC program
• Generate Time study sheet
• Generate Tool list
Select Main → Machines . A dialog box appears showing the list of machines
View tool path
Generate NC program
To view the tool path,
• Select Toolpath from the menu bar . The tool path menu appears.
• By default, simulation starts in solid mode and isometric view.
• Select Simulation → Start or click on .
The mode can be solid or line mode.

The view can be Isometric, XY, YZ or XZ.
Simulation can be till the next motion, till the next tool, or till the end of the program.
CAPSmill ver 7.0 19

Generate NC program
Generate NC program
• Click on Main to return to the main menu, then click on NC program on the menu bar.
• Select OK.
• A status box indicating the location and file name of the program generated appears. The file gets saved with the main file name and .PRG
extension.
• Select File → Exit to exit the editor.
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Generate the time study sheet
To generate the time study sheet,

• Click on Documents → Time study sheet.
• A Time study sheet format dialog box appears. Click on any format listed and click on the View button.
Note: The preview section displays the format selected. You can export the time study sheet to different formats through the Export button.
• Click on the OK button to return to Time study sheet format dialog box and then click on OK to exit time study sheet.
Generate the tool list
To generate the tool list,

• Click on Documents → Tool list.
• A Tool list format dialog box appears. Click on any format listed and click on the View button.
Note: The preview section displays the format selected. You can export the tool list to different formats through the Export button.
• Click on the OK button to return to Tool list format dialog box and then click on OK to exit tool list.
Generate the power graph
To generate the power graph,

• Click on Power graph on the menu bar.
A graph indicating the power consumed for each operation is displayed.

Click on the Close button to exit power graph.
CAPSmill ver 7.0 21

Tutorial 2
This tutorial illustrates
• Face milling on a contour

• Using subprograms for hole machining
• Pocket milling a regular contour
• Side milling an irregular contour
The part drawing in mm

20
300 B
R15
0
75 75
125
R100
R200 (typ)
B
M10 X1.5 pitch
6 holes on 60 30
PCD, 60° pitch,
10 mm deep

Material: Cast iron, alloy, medium hardness.
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Steps to NC program

Or
Steps to NC program
Enter the data shown below in the work setup dialog box that appears.
• Select the Units as MM.
• Select Cast iron, medium hardness as the Workpiece material from the list.
• Leave the Work coordinate system unchanged. (The numbers 1 to 6 in the list corresponds to the work offsets G54 to G59 on the machine).
• Enter the Clearance height as 250 mm.
• Enter the Tool change position as X=0, Y=0, Z=400.
Click on OK, or enter the following General data and then click on OK (General data is optional).
• Enter the Part number as 540-103-00022.
• Enter the Part name as END PLATE.
• Enter the Fixture name as EP-540-808-011.
• Enter the name of the Programmer.
• Enter the Remark as IMPORTANT: CHECK THE COMPONENT HEIGHT.
Save the File
• Enter the file name as END PLATE.
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Draw the part
Generate NC program
Go to the Geometry menu.
Draw circles of radius 100 mm. and 150 mm.
• Select Draw → Circle → Centre - radius .

• The prompt Specify center of circle appears in the status bar. Enter 0,0 and press Enter.
• The prompt Radius appears in the status bar. Enter 100. Circle c1 is drawn.
• Draw the circle c2 with center point 300,0 and radius of 150 mm.
The part at this stage looks as shown below.
Note: Texts c1 and c2 are shown for clarity

and do not actually appear on the screen.
Circle C1
Circle C2
• To draw the circle c3 tangential to c1 and c2, Select Draw → Circle → Tangent-Tangent-Radius .
• At the prompt Select first object that appears in the status bar, select the circle c1 by clicking on its upper half.
• At the prompt Select second object, select the circle c2 by clicking on its upper half.
• Enter 200 at the prompt Specify the Radius that appears in the status bar. Circle C3 appears on the screen, which is drawn tangent to the
circles C1 and C2.
• Similarly, draw the circle C4 tangential to C1 and C2, with the same radius of circle C3 (200).
• Select Display → Zoom all , to get all the objects within the screen.
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The drawing at this stage appears as shown below.
Note: Texts c1, c2, etc. are shown for clarity

and do not actually appear on the screen.
Circle C3
C2
C1
Circle C4
Trim the circles
Break the circles at their points of tangency and erase the unwanted arcs.
• Break the circle C3: Select Edit → Break . The prompt Select the object to break appears. Click on C3.
• At the prompt Specify a point on the selected object that appears in the status bar, click on the right mouse button and select Intersection of.
• Click on the intersection point of C1 and C3, at point P1 as shown in the figure below.
• Another prompt Specify a point on the selected object appears in the status bar. Click on the right mouse button and select Intersection of.
• Click at the intersection point of the circles C2 and C3, at point P2.
C3 is now broken into two individual arcs.
• To erase the upper arc of C3 select Edit → Erase . The prompt Select objects [Press W to select through window] appear. Click on the
point shown in the figure below.
Click here to erase
after break
C3
P1
P2
C1 C2
C4
Click here to erase

after break
Click on the right mouse button and select Done.
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Similarly, break the lower circle C4 at the tangential points with circles C1 and C2 and erase the unwanted portion.
• Select Display → Redraw .
The drawing will now appear as shown below.
P3
P5
C1 C2
P6
P4
• Break the circle C1 at the points P5 and P6 as shown above and erase the inner arc.
• Break the circle C2 at the points P3 and P4 as shown above and erase the inner arc.
The drawing now looks as shown below.
Define the part contour

The drawing now is a combination of various arcs. For machining, it must be converted into a single contour (i.e., Machinable
contour).
• Select Define → Machinable objects → Auto .

• The prompt Specify the first point appears in the status bar. Click anywhere on the shape, as shown below.
• The prompt Select any one of the highlighted objects to continue contour creation appears.
• Click on the highlighted entities (entities in the form of dotted lines, as indicated below in the figure) till you get the message Do you want to
save the selected contour?
• Click on Yes.

Select this point for
contour creation.
Click here to
continue contour
creation.
The part shape is now converted to a single contour.
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Draw points for the tapped holes
The holes lie on a pitch circle diameter (PCD) of 60 mm.

• Select Draw → Machinable objects → Points on circle.
• Specify the center point as 0,0 against the prompt that appears in the status bar.
• Enter the data shown below in the dialog box that appears:
Diameter = 60
Angle of first hole = 0
Number of holes = 6
Draw the rectangle for the pocket
• Select Draw → Rectangle → Centre – Length - Width.

• Specify the center point as 300,0 at the prompt that appears in the status bar and press the Enter key.
• Enter the following data in the dialog box that appears:
Length = 125.
Breadth = 75.
Corner radius = 20.
Rotation angle = 0.
Check Save in machinable contour.
Tip: Select Display →Zoom All to shift the part you have drawn to the center of the screen..
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Define blank
Generate NC program
To draw the blank,
• Select Draw → Rectangle → Centre – Length - Width.

• Enter the center point as 175, 0 against the prompt that appear in the status bar and press Enter.
• Enter the data shown below, in the dialog box that appears, leaving the remaining entries unchanged:
Length = 550
Breadth = 300.
Check Save in machinable contour.
To define the blank,
• Select Define → Blank

• Select the 550 x 300 rectangle drawn earlier.
• Enter the data shown below, in the dialog box that appears:
Blank thickness = 35
Z coordinate at bottom = 70
Leave the maximum and minimum X, Y coordinates unaltered.
• Save the File .
The drawing will appear as shown below.
This ends definition of the part and blank.
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Perform machining
Generate NC program
Click on Main to return to the main menu and then Machining in the menu bar .
Machining involves:
1. Face milling the plate with a 50 mm diameter face mill.
2. Drilling with 9.8 mm diameter drill.
4. Countersink with 16 mm diameter countersink cutter
5. Tap with M10 x 1.5 tap
6. Pocket mill the inside rectangle with 20 mm diameter end mill.
7. Side mill contour with 20 mm diameter end mill
Performing a machining operation involves 3 steps:

• Select a tool
• Perform operation or operations
• End the tool
Here, we will first define the subprograms for hole machining operations.
The hole machining operations to be performed on this part are Drilling, Countersinking and Tapping.
The operations are performed on the same six hole locations. These hole locations can be defined in a subprogram and which is called for
different operations.
Define the Subprogram:
• Select Subprogram → Define from the menu bar.

• Enter Tappoints as the subprogram name.
• Leave the machining face as the Standard Face.
• Select Subprogram of point patterns as the subprogram type.
• The subprogram menu appears. Select Hole pattern → Select / Deselect.
• Click on any one of the points at the prompt Select points to be machined. All the points get selected.
• At the prompt Do you want to omit any holes? Select No.
Click on Machining to return to the machining menu.
The subprogram Tappoints with six hole locations has now been defined.
Note: If you have made a mistake in entering the data for any process, it can still be modified through the Edit menu in Machining.
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Perform face milling operation
• Select the tool : Select Tool → Face mill . Enter or select the following parameters in the Face mill selection dialog box that appears:
Process name: MILL FACE
Manufacturer: GENERAL-MM
Tool type: Face mill
Tool material: Carbide
Tool name: Face mill Dia 50.0

• Perform the operation : Select Milling → Face mill.
Click on the 550 x 300 rectangle at the prompt Select the area for face milling. Enter the data shown below in the dialog box that appears.
Leave the rest of the data unchanged.
Operation name: Face mill profile.
Process: click on Finishing.
Work surface Z: 100.
Material thickness: 5
Allowance after roughing 0.4.
Return to Z: 200.
Click on Cutting parameters tab.
Depth of cut: 5.

• Four ‘+’ signs appear around the selected rectangle. Select a suitable start point at the prompt Select the machining start point, by clicking on
any one of the ‘+’ signs.
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Select a drill
• Select the tool : Click on Enter the data shown below in the dialog box that appears:
Process name: Drill 9.8 Dia. Holes
Manufacturer: GENERAL-MM
Tool type: Drill
Tool material: HSS
Tool name: Drill Dia. 9.8
The location for the drilling operation will be specified as the subprogram Tappoints instead of actually selecting points.
• The following data in the Perform the drilling operation : Select Hole → Drill .
• At the prompt Select the points to be machined select Subprogram → Call.
• Select the subprogram Tappoints and click on OK.
• Select No at the prompt Do you want to omit any holes?
• Enter drilling dialog box that appears, leaving the remaining entries unchanged.
Hole depth = 20
Return to Z = 200
End the tool.
Countersink the holes:
• Select the tool : Select Tool → Countersink . Select the appropriate tool from the GENERAL-MM manufacturer.
• Perform the operation : Select Hole → Countersink . Call the subprogram Tappoints for the points to be machined, from the Subprogram
menu.
• Click on the right mouse button and select Done.
• Enter the following data in the countersink dialog box that appears, leaving the remaining entries unchanged.
- Work surface Z = 100
- Chamfer diameter = 16
- Dwell at bottom = 1
- Return to Z = 200
• End the tool.
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Tap the holes:
• Select the tool : Select Tool → Tap . Select the appropriate tool from the GENERAL-MM manufacturer.
• Perform the operation : Select Hole → Tap . Call the subprogram Tappoints for the points to be machined, from the Subprogram menu.
• Click on the right mouse button and select Done.
• Enter the following data in the Tap dialog box that appears, leaving the remaining entries unaltered.
Work surface Z = 100
Hole depth = 10
Return to Z = 200
• End the tool.
Perform Pocket milling operation
• Pocket milling operation is to be performed using an End mill.

• Click on Tool → End mill.
• Select a 20 mm diameter end mill from the GENERAL-MM manufacturer.
• The remaining tool selection parameters are automatically selected from the database.
• Select Milling → Pocket.
• Select the smaller rectangle as the area for pocket milling, against the prompt that appears in the status bar.
• At the prompt Do you want to specify islands?, Select No.
• Enter the data shown below, in the pocket milling dialog box that appears. Do not alter any other data.
Work surface Z: 100
Pocket depth: 20
Allowance after roughing Bottom: 0.2 Side: 0
Return to Z: 200
Click on Cutting method tab
Cutting method: Select ZigZag
Click on Cutting parameters tab
Depth of cut: 4

At the prompt ‘Select the start point of ramping INSIDE the pocket ‘ click inside the rectangle as shown below.
Click here
This completes the pocket milling operation. Do not End the tool now. The same tool can be used to perform Side milling operation along the
contour.
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Perform side milling operation
• Select Side mill from the Milling pull down menu.

• The prompt Select the contour/shape/line for side milling appears in the status bar. Click on the defined machinable object.
• The prompt Select the machining start point appears. Select a convenient start point on the contour.
• At the prompt Do you want to mill the whole contour?, select Yes.
• The prompt Click on the circle to specify the side for milling appears and also two circle appears on the selected contour. Click on the outer
circle to indicate side milling on the outer side of the contour.
• Enter the data shown below in the side milling operation dialog box that appears. Leave all the other entries unaltered.
Process: Click on Side finish
Cutting method: Select the first option (Multiple depth multiple width)
Work surface Z: 100
Material width: 3
Material depth: 30
Allowance after roughing Bottom: 0.2 Side: 0.2
Return to Z: 200
Check Output CRC for finishing?
Click on Tool entry / exit tab

Entry type: Select Line tangent Entry distance: 12
Exit type: Select Arc tangent Exit distance: 12
Exit arc angle: 80

Depth of cut: 4
• End the tool.
• Save the file.
This completes all the machining operations on the part. We have however made a mistake. The material thickness is 5 mm for the face milling
operation and the depth of cut too is 5 mm, which means that the entire material is removed in a single cut. Modify the operation to reduce the depth
of cut to 3 mm. To modify the process,
• Click on Edit .
• The Edit box appears with the list of all the tools selected and operations performed so far.
• Click on the operation Face mill profile, and then click on the Modify button.
• The prompt Do you want to reselect the machining area appears. Select No.
• The face milling dialog box appears with the data entered earlier. Change the depth of cut to 3.
• Click on the OK button to return to the Machining menu.
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Simulated part
Modify a process
• Click on Edit.
• An edit box appears with the list of all the tools selected and operations performed so far.
• Select the tool or operation that you want to modify by clicking on it. Click on the Modify button.
• If you have selected a tool for modification, the tool dialog box appears. Make the necessary changes and click on the OK button.
• If you have selected an operation for modification, a prompt Do you want to reselect the machining area appears.
- Select yes if you want to change the machining area for that operation. Reselect the machining area at the respective prompts.
- Click on No if you want to change only the dialog box entries and not the machining area.
• Click on the OK button after making the necessary changes.
• After all the changes are made, click on the OK button to return to the Machining menu.
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Tutorial 3
This chapter illustrates:

• Milling a pocket with an island.
• Milling a groove.
The part drawing is in mm
50
R6
20
R5
200
10
200
Material : Soft low carbon steel

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Draw the part
• Start a new file and define the work setup.
• Save the file as Block.
• Go to the Geometry menu.
• First draw the rectangle of dimension 200 x 200 (Refer the drawing for the coordinates).
To draw the polygon,

• Select Draw → Polygon.
• Specify the center point of the polygon against the prompt that appears in the status bar. To do this, click on the right mouse button→
Select Centre of.
• Click on the rectangle drawn earlier.
• Enter the following data in the dialog box that appears, leaving the rest unchanged:
Length of side: 60
Number of sides: 8
Corner radius: 5
Check Save in machinable contour
• Draw the second rectangle of dimension 60 x 60 (Refer the drawing for the coordinates).
• To draw the groove,
- Select Draw → Machinable objects → Groove .

- Specify the center point as 0,0
- Enter the data shown below in the dialog box that appears:
Length: 60
Breadth: 15
This completes the part shape.
Define blank
The rectangle of dimension 200 x 200 can be defined as the blank.
• Click on rectangle (200 x 200).
• Specify Blank thickness as 50 and Z coordinate at the bottom as 0.
Observe that the Work surface Z specified is 50 mm and the Z coordinate at the bottom is 0. This means that the zero offset on the machine along Z
axis is the machine bed.
This completes the Geometry part.
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Perform Machining
Go to the Machining menu.
The machining operations involve:
1. Mill pocket with 20 mm diameter end mill.
2. Mill groove with 12 mm diameter end mill.
First, select an end mill of dia. 20 mm. The tool is available in GENERAL-MM tool manufacturer.
To perform pocket milling operation,
• Click on Milling → Pocket.
• Select the octagon for pocket machining.
• At the prompt Do you want to specify islands? Select Yes.
• Click on the smaller rectangle (This rectangle is selected as the island).
Alter only the following data in the dialog box that appears:
Operation name: Mill pocket excluding islands
Work surface Z: 50
Pocket depth: 20
Allowance after roughing Bottom: 0.3
Return to Z: 100
Click on Cutting method tab
Select Cutting method: ZigZag.
Select Depth of cut: 2
• Click inside the polygon drawn earlier, at the prompt Select the point of ramping INSIDE the pocket
• Click on End on the menu bar to end the operation.
Perform groove milling operation
Select an end mill of dia. 12 mm. The tool is available in GENERAL-MM manufacturer.
To perform pocket milling operation,
Select Milling → Grooving .
• Click on the groove at the prompt Select the object for grooving.
• Alter only the following data in the dialog box that appears:
Operation name: Groove milling
Process: Click on Side finish.
Work surface Z: 50
Groove depth: 10
Allowance after roughing Bottom: 0.3
Return to Z: 100
Click on Tool entry / exit tab
Entry distance: 10
Exit distance: 10
Depth of cut: 2

• Select End on the menu bar to end the operation.
Save the file
This completes all the machining operations.

.
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Simulated part
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Tutorial 4
FACE 1 FACE 2
This tutorial illustrates performing machining operations on two faces of a job.

Depending on whether the part is being machined on a Vertical Machining Center (VMC) or a Horizontal Machining Center (HMC), the part
definition in CAPSmill varies.
On a VMC, after machining FACE 1, FACE 2 is placed beside FACE 1 and then machined using a different work offset number. There is no table
rotation in this case.
On an HMC, the component is clamped on the table that can rotate along an axis, Say B axis. After machining FACE 1, the table is rotated through
180º, and then FACE 2 is machined using a different work offset number.
The part is a regular contour having operations on two faces.
Part drawing
200 15 30
Face 1 Face 2
150 200 50 100
10
8 holes of dia.
20 with 25 dia 60
counterbore
100
Material: Low Alloy Cast iron.

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Draw the part
Create a new file and define the work setup.
• Save the file as FIXED PLATE.
• Go to the Geometry menu.
Draw the first face (Face 1) of the part in the standard face (Default face).
Draw the rectangle of dimension 200 x 200 (Refer the drawing for the coordinates).
To draw the points for the holes,
• Select Draw → Machinable objects → Points on Parallelogram.
• Enter -75, -75 at the prompt Specify start point that appears in the status bar.
• Enter the data as shown in the dialog box that appears, and click on the OK button.
Length: 150
Breadth: 150
Number of holes along length: 4
Number of holes along breadth: 2
Angle of length side: 0
Included angle: 90
• Define the rectangle (200 x 200) as the blank. Specify the Blank thickness Z as 105 and the Z coordinate at the bottom as -100 (Facing
allowance of 5 mm is provided on the blank, which will be machined during Face milling).
This completes drawing the part on Face 1.
Define FACE 2
Before drawing the part, the second face (Face 2) must be defined.
To define FACE 2 on a VMC,

• Select Machining faces → Add.
• Enter the data as shown below in the Machining faces dialog box that appears:
Face name: FACE-2
Work offset number: 2 (The numbers 1 to 6 in the list corresponds to work offset numbers G54 to G59 on the machine).
Table rotation angle: 0
Retract Z: 120
To define FACE 2 on an HMC,
• Select Machining faces → Add.

• Enter the data as shown below in the Machining faces dialog box that appears:
Face name: FACE-2
Work offset number: 2 (The numbers 1 to 6 in the list corresponds to work offset numbers G54 to G59 on the machine).
Table rotation angle: 180
Retract Z: 120
Do not alter any other data.

This completes defining Face 2.
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Draw the part on Face 2
First the face (FACE 2) must be made as the active face. To do this,
• Click on Machining faces on the menu bar.
• From the dialog box that appears, select FACE-2.
• Click on Set active and then select Done.
FACE-2 is now the current machining face and it represents the face opposite to the standard face.
• Draw the rectangle of dimension 200 x 200 (Refer the drawing).
• Draw the second rectangle of dimension 100 x 100.
• Draw the circle of dia. 50 mm (The circle must be defined as a machinable object).
• Define the rectangle (200 x 200) as the blank. Specify the Blank thickness as 100 and the Z coordinate at the bottom as –100 (No material is
left for face milling in this case).
Perform machining
Perform machining operations on FACE 1
Click on Main to return to the main menu and then go to the Machining menu.
The geometry on the Standard Face (Face 1) appears. Perform the machining operations as explained below. All the tools are available in
GENERAL - MM tool manufacturer database. Follow the prompts that appear on the status bar for all the machining operations and refer the drawing
for entering the machining parameters.
• Select a 50 mm diameter face mill

• Perform Face milling operation
• End the tool.
• Select a 20 mm diameter drill

• Perform Drilling operation on 8 holes
• End the tool.
• Select a 25 mm diameter end mill

• Perform Counter boring operation
• End the tool.
The machining operations on FACE - 1 (i.e. the Standard face) are now complete.
Perform machining operations on FACE 2
First, select the second face (Face 2). To do this,

• Click on Machining faces.
• Select FACE-2 from the list of machining faces that appears.
• Click on the OK button. The geometry on FACE-2 appears.
Perform machining operations on this face as explained below: All the tools are available in GENERAL- MM tool manufacturer database. Follow the
prompts that appear on the status bar for all the machining operations and refer the drawing for entering the machining parameters.

• Perform Pocket milling operation on the rectangle.
• End the tool.

• Perform Pocket milling operation on the circle
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• End the tool.
• Save the file.
All the machining operations on the part are now complete.
Select machine
• Select Main → Machines .

• A dialog box appears showing the list of machines
View tool path

• Select Toolpath from the main menu bar .
• Click on Machining faces and select Standard face by clicking on it and click on the OK button.
• Select Simulation → Start or Click on .
• After the simulation stops, click on Machining faces select FACE 2 by clicking on it and click on the OK button (The blank defined in the second
face appears).
• Select Click on . Simulation → Start
Generate the NC program
• Click on NC program on the menu bar.

• Select OK.
• A status box indicating the location and status of the program generated appears.
• Select File → Exit to exit the Editor.
The file gets saved with the main file name and .PRG extension.
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Select a machine
A machine must be selected for,

• Viewing the power graph
• Generating the NC program
• Generating the Time study sheet
• Generating the Tool list
To select a machine
• Select Main → Machines .

• A dialog box appears showing the list of machines
Tool path simulation
Toolpath simulation is done in a separate menu (Simulation menu). To get this menu, do the following:
• Select Toolpath from the menu bar .
Various options are available to simulate the toolpath.

To view the simulation in solid mode and isometric view (By default),
• Select Simulation → Solid mode
• Select Simulation → Go to → End .
• Select Simulation → Start .
Generate NC program

• Click on NC program on the menu bar.
• Select OK.
• A status box indicating the location and status of the program generated appears.
• Select File → Exit to exit the Editor.
The file gets saved with the main file name and .PRG extension.
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Simulated part
FACE 1 FACE 2
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Tutorial 5
This chapter illustrates, performing repetitive operations using Single motions in a subprogram.
• Start a new file and specify the work setup.

• Select appropriate work piece material.
• Save the file as Slot bed.
Part drawing
200
X0, Y0
Z0
12 12
12
70
525
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Draw the part
In this case, the slots in the part need not be drawn individually. You need to define only the blank. To get the slot, a tool equal to the width of
the groove can be selected and the tool movement can be traced using single motions, which are stored in CAPSmill’ s subprogram, and
repeated at various locations.
To define the blank,

• Draw a rectangle with the center point as -262.5,100 and dimension 524 x 200.
• Define this rectangle as the blank.
• Specify Blank thickness as 70.
• Specify Z coordinate at bottom as -70.
Drawing the blank is now complete.
Define the subprogram

This subprogram is defined using single motions operation. Single motions are commands which can be used to program individual motions or
functions like rapid traverse, linear and circular interpolation, spindle on/off etc. separately for simple operations. These motions can also be defined
in a subprogram and be called to perform repetitive operations on different locations.
• Click on Main to return to the main menu and then go to the Machining menu.
• Click on Subprogram in the menu bar and then select Define.
• Enter Millslots as the subprogram name.
• Select Standard face as the current face.
• Select Subprogram of single motions as Subprogram type.
In the subprogram menu,
• Click on Single motions → Rapid traverse .

• Enter the data shown below in the Rapid traverse dialog box that appears:
Select Absolute.
Enter -12 as the Z coordinate. Leave X and Y blank.
Similarly, follow the steps mentioned below for remaining motions:
Click on Single motions → Feed traverse to Y215 (Leave X and Z blank). Enter the feed rate as 0.15.
Click on Single motions → Rapid traverse. Select Relative. dX -50 (Leave Y and Z blank).
Click on Single motions → Feed traverse to Y-15.
Click on Single motions → Rapid traverse. Select Relative. dX -50 (Leave Y and Z blank)
Click on Single motions → Select NC block and enter G90.
Select Machining to end the subprogram definition and get to the machining menu.
This ends the subprogram definition.
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Subprogram definition
The motion of the subprogram defined earlier is as shown below.
Absolute Y215.0
Incremental X-50.0
Absolute X-37.5 Y-15.0
Absolute Z3.0
Incremental X-50.0
Absolute Y-15.0
Absolute Z-12.0
Perform machining
Since the tool motion is already defined in the subprogram, you only need to position the tool at the start point and repeat the subprogram for
the required number of times.
• Select a 25 mm diameter End mill.
• → Spindle speed
Click on Single motion→ ,and enter the spindle speed as 1200 (RPM ). Select the spindle direction as CW. Click on the
OK button.
• Click on Single motion→ → Miscellaneous function → Standard and select Coolant ON. Click on the OK button.
• Click on Single motion→ → Rapid traverse and enter X -37.5, Y -15, leaving Z blank. Click on the OK button.
• Click on Single motion→ → Rapid traverse and enter Z3, leaving X and Y blank. Click on the OK button.
• Click on Subprogram, then select Call.
• Select the subprogram Millslots from the list of subprograms that appears.
• Enter the Number of calls as 5.
• End the tool.
• Save the file.
This ends all the machining operations on the part.
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Simulated part
CAPSmill ver 7.0 48

Tutorial 6
Configuring databases
Configuring the databases involve,

• Adding a new Tool manufacturer in the database.
• Adding a tool to a tool manufacturer.
• Adding a tool material.
• Adding cutting parameters.
Here, you will configure the database for each functions mentioned above.
CAPSmill is shipped with a master database file Mill.MDB in which all the tool manufacturer database, tools and cutting parameters, tool and
workpiece materials, machine list are stored. This file is stored in the directory in which CAPSmill is installed.
Creating a new tool manufacturer
Whenever you create a new tool manufacturer it gets stored in Mill.mdb file. You can either create a blank tool manufacturer in which case you
will have to enter all the tools, tool materials and cutting parameters right from scratch. Building a tool manufacturer this way consumes a lot of
time.
Hence, the easier and efficient method would be to create a new manufacturer and copy the data from an existing manufacturer into it. This way
you will only have to modify the names of tools, leaving the cutting parameters and tool materials unaltered.
• Select Config {bmc arrow.bmp} Tool and FS database from the Main menu.
• At the prompt for password, enter cadem.
• Click on Tool Manufacturer button.
• A list of existing tool manufacturers appears. Click on the Add button.
• Against the prompt Manufacturer name, enter First manufacturer – MM. Note: This is the name which will appear in the list of
manufacturers.
• Select the units as MM.
• Specify the remarks as New tool manufacturer included during training session.
So far you have specified all the details to create a new manufacturer. But as explained earlier, you need to copy the data from an existing
manufacturer into this new manufacturer. To do this,
• Check Copy data from an existing manufacturer?

• Against the prompt Manufacturer to copy select General – MM from the list. All the data from General – MM manufacturer will be copied
into this manufacturer.
Note: The process of copying data from an existing manufacturer may take some time depending on the amount of data in the selected
manufacturer.
Notice that the new tool manufacturer First manufacturer – MM is created in the list of manufacturers. Select the manufacturer and click on
Tools button. Note that the tools available in this manufacturer are similar to that of General – MM manufacturer.
• Click on the OK button to exit this dialog box.
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Adding a new workpiece material
Workpiece material is independent of any Tool manufacturer.
• Click on the Workpiece material button. A dialog box with the list of existing materials appear.
• Click on the Add button.
• Enter the material name as New raw material against the prompt Workpiece material.
• Enter the Hardness factor as 0.8 and Machining exponent as 1. These are the parameters required to determine the material properties
and is used in Power graph calculation.
• Click on the OK button to exit workpiece material dialog box.
Adding a tool type in a tool manufacturer
Before you add a tool type, you need to understand the concept of Tool class and Tool type in CAPSmill.
Tool class
These are the basic category of tools which are used to perform an operation. E.g., Drill, Face mill, Boring tool, End mill etc.
Tool type
These are various types of tools under a tool class. E.g., Twist drills, Insert drills, Flat drills are all different types of tools under Drill tool class.
Tool classes are fixed within CAPSmill, and cannot be added, modified or deleted. Tool types can be defined by you to put tools in separate
categories (types) and make selection easier. A tool type is specific to a Tool manufacturer.
To add a tool type
• Select the newly added tool manufacturer First manufacturer – MM from the Tool and FS database dialog box.
• Click on the Tool types button. A dialog box with the list of existing tool types appear.
• Enter the name of tool type as New tool type against the prompt Tool type.
• Against the prompt Tool class, select Drill from the list.
• Enter the safe height as 3 MM.
Here, you have assigned the ‘New tool type’ to ‘Drill’ tool class. This means that New tool type belongs to the tool class drill and hence you can
select the tools from this tool type only when you select a Drill in the Machining menu.
• Click on the OK button. Notice that the tool type appears in the list.
• Click on the OK button to exit Tool types dialog box.
Adding a tool material in a tool manufacturer
• Select the tool manufacturer First manufacturer – MM from the Tool and FS database dialog box.
• Click on Tool material button.
A tool material is specific to a Tool type in a Tool manufacturer.

• Select New tool type from the list. This is the tool type newly added in the above manufacturer.
CAPSmill ver 7.0 50

• Enter New material against the prompt Tool material.
• Click on the OK button. Notice that ‘New tool material’ is included in the tool type ‘New tool type’.
• Click on the OK button to exit Tool material dialog box.
Adding cutting parameters
CAPSmill has a feature of automatically selecting the cutting parameters (Feed rate and cutting speed) for an operation. You configure the
parameters suitable to your machining conditions which will be automatically selected during machining.
• Click on Cutting parameters button.
Cutting parameters are specified for a combination of Workpiece material, tool type and tool material.
• Select the Workpiece material as New raw material.

• Select the Tool type as New tool type.
• Select the Tool material as New tool material.
Notice that when you select a tool type, the tool material configured under the selected tool type is only listed. This is because Tool material is
specific to a tool type.
• Click on the Parameters button.

• In the dialog box enter the following parameters.
Feed rate section Cutting speed section

Dia. Range = 50; Feed rate = 0.1 Dia. range = 50; Cutting speed = 60
Dia. Range = 100; Feed rate = Dia. range = 100; Cutting speed = 80
0.15
The above parameters specified means that,

1. When the drill diameter selected is upto 50 mm, select a feed rate of 0.1 mm/rev. and a cutting speed of 60 m/min.
2. When the drill diameter selected is above 50 mm and upto 100 mm, select a feed rate of 0.15 mm/rev. and a cutting speed of 80 m/min.
3. When the drill diameter selected is above 100 mm and upto 999 mm, select a feed rate of 0.2 mm/rev. and a cutting speed of 130 m/min.
• Click on the Ok button to save the parameters.

• Click on the OK button to exit cutting parameters dialog box.
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Adding a new tool in a tool manufacturer
• Click on Tools button. A list of tools appear under the current tool type.
• Select the Tool type as New tool type from the list. This is the new tool type added to the list earlier.
• Enter the Tool name as New tool. Click on the Tool geometry button.
Notice that the dialog box that appears is for specifying the Drill parameters. This is because when you added the tool type ‘New tool type’, you had
assigned it to Drill TOOL CLASS.
• Enter the following parameters to specify the drill geometry.
Nose angle = 118

Web thickness = 0
Flute length = 80
Total length = 120
Diameter = 60
Hand of tool = Left
• Click on the Show tool button to view the line diagram of the drill. Click on the OK button.
• Click on the OK button in the tool geometry, tool data and the Add tool dialog boxes in sequence to exit the dialog box.
• Click on the OK button to exit Tool and FS database.
So far you have completed configuring the database for a single tool, tool type etc. Now, you can select these objects from the database for a
component and check the output, which will make the concept of CAPSmill Database clear.
Checking the output with new tool manufacturer
To check the outputs, we go back to Tutorial 1. You will open tutorial 1 and save it in a different name and then insert a new drilling operation in it.
• Open the file Shaft.CPM (This is the name in which you saved tutorial 1).
• Select File {bmc arrow.bmp} Save As. In the dialog box, enter the filename as Database test and click on the Save button.
• Go to the Machining menu.
• Click on Edit. Select Work setup and then click on the Modify button.
• Change the Workpiece material to New raw material. Click on the OK button.
• Click on the OK button to exit Edit dialog box and then save the file.
• Select Tool {bmc arrow.bmp} Drill.
• In the dialog box, enter a process name.
• Select the Manufacturer as First manufacturer - MM. Select Tool type as New tool type.
• Select Tool material as New material and Tool name as New tool.
• Click on the Tool geometry button. Notice that the geometry specified when adding the tool to the database is automatically picked up. Click on
the OK button.
• Notice that depending on the Hand of tool specified, the spindle direction is automatically selected (Here, Hand of tool was set to Left and
hence the spindle direction is selected as CCW). Click on the OK button.
• Select a drilling operation. In the dialog box, enter the Hole depth as 20.
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Notice that the Cutting speed and Feed rate are automatically selected as 0.15 and 80 respectively. Cross check this with the parameters specified
in the Tool and FS database.
Manufacturer : First manufacturer - MM

Workpiece material : New raw material
Tool type : New tool type
Tool material : New material
Cutting parameters : You had specified the following parameters.
Feed rate section Cutting speed section
Dia. Range = 100; Feed rate = Dia. range = 100; Cutting speed = 80
0.15
When the drill diameter selected is above 50 mm and upto 100 mm, select a feed rate of 0.15 mm/rev. and a cutting speed of 80 m/min. Here the
drill diameter is 60 mm.
By now you should be understanding the relationship between Tool class and Tool type and how cutting parameters are related to Tool
manufacturer, Workpiece material, Tool material and Tool type.
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Tutorial 7
Customising the machines list
Adding a machine
• Select Config → Machines list from the Main menu. Enter the password as cadem.
If the postprocessor file of the machine is in the CAPSmill folder

• For Machine name enter a suitable name.
• Folder for output files is the folder in which you want the output files for the machine like NC programs, cycle time sheet for the machine to
be saved. Leave it blank if you want the files to be saved in the folder in which CAPSmill is installed. If you want them saved in a separate
folder for the machine, enter the full path of the folder.
• For Machine data file select the postprocessor file for the machine. The list contains all post files (with the extension .GPT) in the CAPSmill
folder.
If the postprocessor file of the machine is on the CAPSmill CD

Click on the Install posts button.
In the Install postprocessors dialog box Available posts are machine names corresponding to post files available on the CD. Installed posts are the
posts that are already in the machines list.
Click on Copy to copy a post file from the CD to the CAPSmill folder. Click on Remove to delete a file that is already in the machines list.
The source directory is the folder from where you initially installed CAPSmill. This is usually the CD drive.
Modifying a machine
In the Machines dialog box select Modify and enter the appropriate data.
The Machines list file

The machines list is stored in the file Machines.mdb.
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Tutorial 8
Configuring machine Data
Customising the machine data involves:
Configuring machine's mechanical data. The mechanical data is used in,
NC program generation. Programmed spindle speeds and federates which exceed the machine's limits are clamped to the specified
limits.
Generating the power graph. The available spindle power is displayed in the graph.
Machining time estimation. The rapid traverse rate, axes and spindle acceleration/ deceleration times and execution times for
miscellaneous functions are used.
• Configuring the NC program format. This consists of three sessions; Word format, Block format and Cycle format.
Word format: Used to specify a code for a function and the format in which it should be output like with or without decimal etc.
Block format: Used to specify the format for a block in the NC program like Tool change block, program start block etc.
Cycle format: Used to enable or disable the cycles and specify the format in which the cycles should be output.
Building a postprocessor from scratch is a long process, and the fastest method of making a post is to copy an existing postprocessor and change
only the relevant parameters. Here, you will open the postprocessor file Tutorial.GPM and change some settings and parameters.
Machine mechanical data
• Add a new machine to the machines list for the postprocessor file Tutorial.gpm.
• Select Config Postprocessor builder from the Main menu. Enter the password as cadem.
• Select File {bmc arrow.bmp} Open and open the file Tutorial.GPM.
• Click on Machine Data. In the dialog box, alter the following parameters leaving the remaining entries unchanged.
Machine name = Test machine
Rapid traverse rate = 18000
Tool change time in seconds = 2
• Click on Feed rate and Spindle speed tab.

Minimum feed rate = 0.01 0.0004
Minimum spindle speed = 50
• Click on Miscellaneous functions tab. Select Program stop and click on the Modify button.
• Enter the Function code as M02 and click on the OK button.
• Select Tool change and click on the Modify button. Enter the Function code as M06 and Execution time in secs as 2. Click on the OK
button.
• Click on History tab. Enter the following comment:
Postprocessor configured trial during learning session.
Machine: Test machine.
Control system: Fanuc 0MC.
Date of configuration: * * / * * / * *
Configured by: <ENTER YOUR NAME>
• Click on the OK button to exit Machine data. Save the file.

• Exit Postprocessor builder.
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Configuring NC program format
The NC program format for this postprocessor is configured for a standard Fanuc 0MC controller and hence you need not make any major
changes in it. You can make some minor changes to make it more specific to your machine.
Configuring the Word format
• Select Word format from the Postprocessor builder menu.

• Select Tool change and click on the Modify button.
• Change the tool numbers to 1 to 50.
• Click on the OK button and then click on the Save button.
• Click on the OK button to exit Word format.
Configuring the Block format
• Select Block format from the Postprocessor builder menu.
Here, the blocks that need to be altered to change the program output are,
Program start
Tool change
• Select Program start and click on the Modify button.

Notice that there are many variables that will be output as comments in the NC program like Program generation date, Workpiece material etc.
You can remove all the unwanted variables retaining the part name.
• In the dialog box, remove all the variables except the <#PROGRAM_NUM> variable.
• Position the cursor below <#PROGRAM_NUM> variable. To do this, press Enter.
• Click on List variables button. From the list of variables that appear, select COMMENTS_START_CHARS variable and then click on the
OK button. Similarly, insert the following variables in the dialog box, in the same line.
<#PART_NAME>
COMMENTS_END_CHARS
• Click on the Sample output button to view a sample of how the program would be output using these variables.
• Click on the OK button to exit this dialog box.
• Similarly, select Tool change block and click on the Modify button.
•
Here, you will configure this block to get an optional stop command (M01) before Process name in the NC program.
• Place the cursor at the end of third line (i.e. before <$PROCESS_NAME> variable) and press Enter.
• Select the variable <BLOCK_NUM> from List variables dialog box and click on the OK button.
• Enter the code M01 next to the variable <BLOCK_NUM>.
• Click on the Sample output button to view the sample and then click on the OK button.
• Click on the OK button to exit Block format.
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Configuring NC program format
Configuring the Cycle format
• Select Cycle format from the Postprocessor builder menu.

• Select Drilling cycle and click on the Modify button.
• Against the prompt Should the cycle be output? Select Yes.
• Change the Addresses for the following parameters as mentioned below:
Final depth to Z
Safe height to R
Dwell at hole bottom to P
• Click on the Cycle Block button and then click on the Sample output button. Check whether the sample output is Ok. Click on the OK
button.
• Click on the OK button to exit drilling cycle dialog box.
• Similarly, configure the following cycles,
Deep drilling cycle
Reaming cycle
Right hand tapping cycle
• Click on OK button to exit Cycle format dialog box.

• Save the file and exit Postprocessor builder.
This completes the configuration of machine data. Generate and view the NC program for any part. Notice the changes in the program after
modifying the postprocessor.
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Tutorial 9
Customising DNC
Customising DNC involves specifying the communication parameters (baud rate, parity, etc.) of the machine.
• To go to DNC menu, select Utilities {bmc arrow.bmp} DNC from the Main menu.
Test the COM port of the computer
Prepare a loop back connector with the pin configuration shown below. Use a 9 pin or a 25 pin connector depending on the type of connector on
the port to be tested.
9 pin connector 25 pin connector
2 2
3 3
7 4
8 5
1 6
4 8
6 20
• Select DNC {bmc arrow.bmp} Test ports.

• Select the port to be tested from the list.
• At the prompt Insert loopback connector in port, insert the connector in the specified port and click on the OK button.
• The handshake signals are first tested and then the transmit and receive signals. Transmit and receive are tested at all baud rates from
110 to 38400.
• If the port passes the test at all baud rates, a message Test completed. Port is OK appears in the status box. Click on the OK button to exit
test mode.
If the port is defective get it rectified. If the port is proper, proceed to set the communication parameters for the machine.
Adding a machine
• Select Settings {bmc arrow.bmp} Enable settings. Enter the password as cadem. The password is case sensitive.
• Select Settings {bmc arrow.bmp} Machine data. Click on the Add button.
• In the dialog box change the following parameters, leaving all the remaining entries unaltered.
Machine name = Machine 1
Control system = Fanuc
• Click on DNC param tab.
Select the port number which was tested, from the list.
Baud rate = 9600
Parity = Even
Data bits = 7
Stop bits = 2
Handshake = Hardware
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• Leave all the other settings in the remaining tabs unaltered.
• Click on the OK button. Click on the OK button to exit Add machine dialog box.
You have now configured the communication parameters on the PC. The similar settings must be made on the machine controller too. The
parameter settings to be made on the controller are Baudrate, parity, data bits, stop bits and communication mode (ie; set it to ISO).
You can also note the current setting on the controller and set it on the PC.
Transmitting a program from PC to machine
Communication can be in Manual, Auto or Simultaneous mode. Here you will try to transmit and receive a program to the machine in Manual
mode.
Whenever you do a communication, it is recommended to make the receiving end ready to receive the program. Here the receiving end is the
machine.
• Put the machine in Read mode.
On the PC,
• Select DNC {bmc arrow.bmp} Manual mode.
• Double click on the machine and select Transmit program from the menu that appears.
• In the dialog box that appears, select a program file (Program file will have an extension of .PRG).
• Click on the Open button.
If the communication is successful, DNC will give a message ‘Program transmitted’. Check the program on the controller.
Receiving a program from machine to PC
Now, the receiving end is the PC.
On the PC,
• Double click on the machine and select Receive program from the menu that appears.
• In the dialog box that appears, enter From machine as the file name in which the received program must be saved.
• Click on the Save button.
If the communication is successful, DNC will give a message ‘Program received. Check the program in the NC editor.
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Using Tutorials Tutorial 1in MM Tutorial 1in Inch Tutorial 2

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Contents

Tutorial 1in inch

Steps Operation Menu option

CAPSmill ver 7.0 1

This tutorial illustrates:

Material: Stainless steels, Austenitic.

CAPSmill ver 7.0 2

• Start CAPSmill. To do this, double click on the CAPSmill icon

• Select File → New .

The Work setup dialog box appears.

• Select the Units as MM by clicking on it.

Click on OK to exit from the Work setup dialog box.

Save the File

• Select File → Save .

CAPSmill ver 7.0 3

Draw the rectangle for face milling

Draw a rectangle of size 200 x 150

• Select Draw → Rectangle → Center – Length - Width .

Draw the points for the φ 10 holes

Select Display → Zoom All to see the entire part.

CAPSmill ver 7.0 4

Select the tool for face milling

Select the face mill

• Click on the OK button.

CAPSmill ver 7.0 5

Select Milling → Face mill .

End the tool

This completes the face milling operation.

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• Select Tool → Drill

Perform drilling operation

• Select Hole → Drill .

• Click the right mouse button and select Done.

This completes the drilling operation.

CAPSmill ver 7.0 7

• Select Tool → Reamer .

Perform reaming operation

• Select Hole → Ream .

Save the file.

CAPSmill ver 7.0 8

View tool path

To view the tool path,

The mode can be solid or line mode.

CAPSmill ver 7.0 9

To generate the NC program,

CAPSmill ver 7.0 10

To generate the time study sheet,

Generate the tool list

To generate the tool list,

Generate the power graph

To generate the power graph,

A graph indicating the power consumed for each operation is displayed.

CAPSmill ver 7.0 11

The part is a rectangular block with twelve holes.

This tutorial illustrates:

Part drawing in inches

Material: Stainless steels, austenitic.

CAPSmill ver 7.0 12

• Start CAPSmill. To do this, double click on the CAPSmill icon

• Select File → New .

The Work setup dialog box appears.

• Select the Units as INCH by clicking on it.