3 Axis CNC Router

CNC MILLING MACHINE
S T U D E N T. M A N UA L
Digital Fabrication Laboratory

Hours 10am - 3pm (Monday-Friday)
Email abp-fablab@unimelb.edu.au
Contact 9035 8663
105A, First Floor,

757 Swanston st
Faculty of Architecture
Building & Planning,
University of Melbourne
CNC Tool Pathing Manual, August 2013 | 1

CNC TOOL PATHING
STUDENT MANUAL
CONTENTS
Over view of Machining Methods .............................................03
Understanding the Machining Process ...........................................04
General Router Guidelines ..........................................................05
Examples of Accepted Rhino Geometry ...................................06
Examples of Incorrect Rhino Geometry .....................................07
File Submission Procedure ..........................................................08
Chapter 1 : Orientating your model ....................................... 09

Stock alignment guidelines ......................................................12
Chapter 2 : Creating containment regions ................................13
Chapter 3 : Tool Library ...............................................................14
Chapter 4 : 3 Axis Toolpaths - Horizontal Roughing ........... 15
Chapter 5 : 3 Axis Toolpaths - Parallel Finishing ................... 22
Chapter 6 : 2 ½ Axis Toolpaths - Profiling .............................. 29
Chapter 7 : 2 ½ Axis Toolpaths - Hole Pocketing ................... 37
Chapter 8 : 2 ½ Axis Toolpaths - Creating Bridges ................... 41
Chapter 9 : Simulating Toolpaths ................................................45
Chapter 10 : Editing Machining Options .....................................47
Glossary of CNC terms ......................................................................49
References .....................................................................................50

OVERVIEW OF
MACHINING METHODS NOTES :
If in doubt of which methods to

use, please discuss your project
with the Fablab staff beforehand
OVERVIEW OF MACHINING METHODS

Overview of Machining
The operations carried out in Methods
the CNC Router are either 2½ axis or the 3 axis milling.
2½ Axis: The tool can move in X and Y directions, while the Z level is fixed at set locations. The 2 axis tool paths cuts
along the XY plane , similar to that of a laser cutter but with the allowance for thicker materials.
Milling operations can be categorized as 2½ axis, 3 axis, 4th axis, and 5th axis milling.
Examples : Signage , Flat prefab pieces ( Furniture kit-of-parts )
2½ Axis: The tool can move in X and Y directions, while the Z level is fixed at set locations. Because 2½ toolpaths
No
do Overview
not relate to of Machining
either part or stock Methods
geometry, machining regions must be selected; these define the boundaries of
tool motions.
Milling operations can be categorized as 2½ axis, 3 axis, 4th axis, and 5th axis milling.
2½ Axis: The tool can move in X and Y directions, while the Z level is fixed at set locations. Because 2½ toolpaths
do not relate to either part or stock geometry, machining regions must be selected; these define the boundaries of
tool motions.
This type of machining is useful for machining prismatic parts – extrusions of curves along the Z axis. Because of its
straight sides, a prismatic part can be machined by locking the tool at the first Z level, performing XY motions, then
3 Axis:
repeating for The tool can
subsequent Z move simultaneously in all three directions X, Y and Z. This is appropriate for parts that have
levels.
complex, curved, and non-vertical surfaces . The machine is able to computate tool paths for models that consist of
Using this either
class NURBS surfaces oryou
of machining, mesh. Examples
can : Topographical
machine parts thatterrain , Mould for
are defined concrete
only by 2D and silicon casting
curves. 3D part geometry can be
This type
present, of machining
though it is not isnecessary.
useful for machining prismatic parts – extrusions of curves along the Z axis. Because of its
straight sides, a prismatic part can be machined by locking the tool at the first Z level, performing XY motions, then
3 Axis: Thefor
repeating tool can moveZsimultaneously
subsequent levels. in all three directions. This is appropriate for parts that have complex,
curved, and non-vertical surfaces.
Using this class of machining, you can machine parts that are defined only by 2D curves. 3D part geometry can be
present, though it is not necessary.
3 Axis: The tool can move simultaneously in all three directions. This is appropriate for parts that have complex,
curved, and non-vertical surfaces.
© MecSoft Corporation 14 www.mecsoft.com
© MecSoft Corporation 14 www.mecsoft.com

OVERVIEW OF
CNC MACHINE
UNDERSTANDING THE MACHINING PROCESS

Understanding the machining process will aid in the preparation of your 3D model. The file set up for the CNC machine allows
the user to tailor and customise each step and process to achieve the desired result. The following are the recommended
general steps for standard materials such as plywood and foam. Please refer to the detailed guidelineshgf and glossary for a
more indepth understanding of the machining process.
Load 3D model and create chosen

Load file & Create stock
stock material. Align model within
Orientate model created stock
INITIAL SETUP
Create Containment Regions

Draw or duplicate curve border , Containment regions are created to
containing machined region control the areas to be machined.
Set up machining options
The 3 axis roughing operations are

Horizontal Roughing used to remove most of the general
Create 3-Axis Toolpath material from the stock material ,
Roughing Operations leaving a rough approximation of
the surface.
It is recommended that you simulate

MACHINING OPERATIONS
your machining operations after

every setup to check for errors
SIMULATION
Parallel Finishing The 3 axis finishing operations are
Create 3-Axis Toolpath used to clean up and refine the Simulate removal of
Finishing Operations milled or carved surface material
The simulation function

enables you to observe
the various finishings
and operations you have
selected and it will highlight
The 2 axis toolpaths creates any possible errors which
Profiling you are then able to fix.
toolpaths that follow 2D lines,
Create 2-Axis Toolpath
or flat surface geometry, to cut
Profile Cut
around the outline of an object.
NO ERROR ERROR
Submit Identify
File problem &
Regenerate

GENERAL
ROUTER GUIDELINES
T11- BallNose
This is an example using Cutter 8 D1
the T11-BallNose Cutter NOTES:

toolbit to cut 80mm
Shoulder Tool
foam. Please refer to Length Length
The router moves up and down in the
50mm 124mm
the CNC Tool Library
Z (vertical) axis and along in the X and Y
Table, and CNC Tool
Library explanation
(horizontal) axis. It is limited to:
documents for the 1. the depth it can cut (material thickness)
specifications of each 80mm FOAM 2. the angle it can cut (ie no undercutting)
respective toolbit.
The depth in which the machine can cut

is determined by the length of the tool bit
Slot smaller chosen. Slots narrower than the router bit
than 124 mm
tool length holder must be less than the length of the tool
bit (124mm).
Where the slot is greater than the length of

the tool bit (124 mm) the router bit will crash
Slot larger into the edge damaging the material
than 124 mm
tool length
Slots greater than the length of the tool bit can

be cut only if there is a sloped profile which is
wide enough for the router housing to fit into
Cut The router will not read any geometry beneath

the surface and will only cut along the surface
of the volume.
unable to read
No undercutting - the router can only move

up and down and it cannot change the angle
of the router bit.
Very thin edges will be weak. Be aware that

they may break.

EXAMPLES OF ACCEPTED
RHINO GEOMETRY
EXAMPLES OF ACCEPTED RHINO GEOMETRY

It is important to submit a clean file without any unnecessary geometry. This will speed up the computation of the file’s cut
toolpaths.Below are examples of accepted rhino files.
1. NURBS model
This is an example of a simple NURBS model

created in Rhino.
2. MESH model
Select the mesh option best suited to the

outcome of your model. Note that the higher the
resolution of the mesh, the longer it will take to
computate the cutting toolpaths.
3. Multiple objects with boolean union
Clean unified object
If your model is made up of multiple objects, it is

advisable to boolean union them into one unified
object. This can be done by typing ‘ boolean
union’ in the rhino command bar.

EXAMPLES OF INCORRECT
RHINO GEOMETRY
EXAMPLES OF INCORRECT RHINO GEOMETRY

It is important to submit a clean file without any unnecessary geometry. This will speed up the computation of the file .Below
are examples of incorrect rhino files.
1. Multiple objects without boolean union
Intersecting NURBS
object that are not
unified
Multiple objects that are not unified will slow

down the computation of toolpaths.
2. Model with under cuts

The router will Router will not
detect and cut the detect volume
surface geometry beneath other
geometry
The router will detect and cut whatever geometry

that is seen from plan view ( top down ) . It will
not be able to read volumes beneath other
geometry.

FILE SUBMISSION
PROCEDURE
SUBMISSION PROCEDURE
How to submit files to the FABLAB

NOTES :
The CNC machines at the Melbourne School of Design are operated by the Fablab
Please ensure you have checked staff. Students can submit their 3D models for production at anytime online through
all these items before you the website link http://edsc.unimelb.edu.au/fab-lab.
submit your job.
The submitted file is placed within a job queue . The general service policy is a 24hr
The FABLAB staff has the right job completion except for busy periods. Students are able to pick up and pay for their
to turn away any job that has completed job by eftpos ( cash is not accepted ) at the Fablab between 10.00 am and
not been set up according to 3.00 pm, Monday to Friday.
the required standard.
Planning the size of your model
The maximum cutting size of the CNC machine is 2400 x 1200 mm.
Digital Fabrication The maximum thickness that can be cut depends on the length of the chosen tool bit.
Laboratory The approximate thickness is 100mm.
10am - 3pm
This thickness is dependent on the material thickness and the length of the chosen
(Monday-Friday)
[E] abp-fablab@unimelb.edu.au
tool bit. When considering sizes for a model, it is advisable to work with the standard
[P] 9035 8663 sheet sizes of materials from the Fablab to avoid waste of material and high purchase
cost:
105A, First Floor,
Architecture Building The Fablab stocks the following materials:
Faculty of Building & Planning
University of Melbourne
Material Dimension l x b x h ( mm )
Plywood 2400 x 1200 x 12
High Density Foam 2400 x 600 x ( 80 , 50 , 30 )
MDF 2400 x 1200 x ( 6 , 12 )
Please check with the FabLab material price list before submission for the price,
dimensions and availability of the requested material.
You are able to supply your own material but please note that any other material
consideration must be discussed with the Fablab staff beforehand .
File format
All CNC files must be saved as a rhinofile in the following order

Studentname_filename_projectnumber_CNC
E.g “DavidSun_Concretemould_01_CNC”

INITIAL FILE SETUP
ORIENTATING
YOUR MODEL
CHAPTER 1
FILE SETUP : ORIENTATING YOUR MODEL
1. Open a new file in rhino and launch RHINOCAM
Locate RHIINOCAM along the top tabs and make sure that both ‘machining operations browser’ and ‘machining objects
brower’ is selected. Ensure that the units are in millimeters.
RHINOCAM tab
RHINOCAM
Interface
Units :
millimeters
2. Import your model

Import only the geometry to be machined into the file , no hidden geometries or unnecessary layers as it will slow down
the computation of the model.
Align bottom left corner of model near origin point (0,0,0)
No unecessary
geometry or layers
Origin (0,0,0 )

INITIAL FILE SETUP
ORIENTATING NOTES :
YOUR MODEL Always remember to hide your
stock material. Please read the
guidelines for stock alignment for
the most efficient way of set up.
3. Draw stock material

Draw in your material , in this case we are using foam ( 2400 x 600 x 80 mm). Move the bottom left corner of material to
orgin point ( 0,0,0 ). Please refer to the Material Price List document for other material dimensions.
Align bottom left of

material to origin
( 0,0,0 )
3. Select stock drawn , right click stock icon and select ‘stock from selection’ material
Once you have selected your stock , it should be displayed as an translucent orange colour. If it does not appear , check
that your stock visibility toggle is switched on. Finally, hide the stock geometery ( this can be done by selecting your
geometry that was modelled in Rhino and type ‘hide’ in the command toolbar.
Stock
visibility
toggle
switched on

INITIAL FILE SETUP
ORIENTATING
YOUR MODEL
4. Align model within stock

Align your model within stock , leaving a border of minimum 30 mm . This is to ensure that there is enough space for
profiling ( cutting the model out of the stock material )
3 Axis - Model
min.
30mm
Ensure sufficient border

around model ( min 30 mm)
For a 3 axis model , the base of model should be aligned with the base of the
stock drawn.
or
2 Axis - Model
For a 2 axis model , the top of the model should be aligned with the top of the
stock material.
INITIAL FILE SETUP
ORIENTATING
YOUR MODEL
GUIDELINES FOR STOCK ALIGNMENT

To ensure the most efficient way of milling ( minimum wastage and shorter milling time), there are a few things to
consider when aligning your model within the stock material :
SCENARIO 1 :
Fixed base dimension
If the base of your model is a
specific and fixed dimension, Milled
it should then be aligned volume
to the base of the stock as
shown.
Consider using a thinner
stock material if there is a 80 mm
Foam
lot of material that needs to Fixed
be milled (as the example to dimension
the right).
SCENARIO 2 :
Flexible base dimension
If the base of your model
Milled
is a not specific , it is then volume
recommended to move and
align your model to the
top of the stock material.
In this case , the amount of Flexible
milled material is instantly 80 mm dimension
Foam
reduced, shortening your Redundant
milling time. material
SCENARIO 3 :
Flexible geometry
dimension
If the dimension of your
model is not specific , you Milled
might consider using a volume
thinner material so as to
reduce the amount of waste 30 mm Flexible
material. Foam dimension
No wastage
of material

CONTAINMENT
REGIONS
CHAPTER 2
CONTAINMENT REGIONS
Containment regions are created to control the areas to be machined. Multiple regions can be defined and selected in
an operation.
Containment Region
type ‘dupfaceborder’
in rhino command bar
to create containment
curves
SINGLE REGION :
A containment region is
created by replicating the
perimeter of your model
(drawing a rectangle or
closed curve). You can also
duplicate the border of
your geometry. This is done
by typing ‘dupfaceborder’
in the rhino command bar
and selecting the respective
surface.
Align and move the created

curves to the top of the
stock material.
Machined Machined Region

Region (Dome will be left
Entire surface untouched)
will be machined
MULTIPLE REGIONS :
Multiple regions can be
created if you have more
A B
than 2 objects in a file that
need to have the same
milling operation applied
to them. By altering the
containment regions, you
are controlling the area
that you wish to machine
or apply a certain milling
action.
i.e. Region A shows that

the entire region within the
square will be machined
while Region B will omit the
dome.
TOOL LIBRARY
NOTES :
Please ask for assistance in

selecting the right tool if you are
using a non standard material.
CHAPTER 3
TOOL LIBRARY : SELECTING THE RIGHT TOOLS
Download the latest tool library from the Fablab website. Please note that the tool library will be constantly updated with
new tools and settings and it is recommended to always download the latest set. To choose the appropriate tool for the
type of operation use the CNC Tool Library Explanation document found on the FabLab website.
Load tool library
Small Objects - Millimeters.3dm - Cutting Tools Information

This is an indicative list of tools from the library.
Name Tool Type Diameter Corner Radius Taper Flute Length Tool Length Tool # Material
Y
T1 - Flat Mill Down cutter 6.35 D1 Mill 6.35 mm 3.175 mm 0 deg 20 mm 46 mm 1 CARBIDE
T2 - Flat Mill Up cutter 6.35 D1 Mill 6.35 mm 3.175 mm 0 deg
IBR A R
20 mm 43 mm 2 CARBIDE
L
T3 - Ball Nose cutter 2 D1 Mill 2 mm 1 mm 0 deg 10 mm 61.5 mm 3 CARBIDE
O L
T4 - Ball Nose cutter 3 D1 Mill 3 mm 1.5 mm 0 deg 15 mm 36 mm 4 CARBIDE
E TO
T5 - Ball Nose cutter 6 D1 Mill 6 mm 3 mm 0 deg 20 mm 35.5 mm 5 CARBIDE
I V
T6 - Ball Nose cutter 12 D1 Mill 12 mm 6 mm 0 deg 30 mm 62 mm 6 CARBIDE
T7 - Compression Cutter 9.5 D1
IC ATMill 9.5 mm 0 mm 0 deg 22 mm 41.5 mm 7 CARBIDE
IND
T8 - Chip Breaker 12.7 D1 Mill 12.7 mm 0 mm 0 deg 52 mm 72.2 mm 8 CARBIDE
T9 - V Mill Alucabond Mill 3 mm 0 mm 45 deg 9 mm 33.5 mm 9 CARBIDE
T10 - Flat Mill Upcut Aluminium 6.35 Mill 6.35 mm 0 mm 0 deg 20 mm 50 mm 10 CARBIDE
T11 - Ball Nose cutter 8 D1 Mill 8 mm 4 mm 0 deg 40 mm 124 mm 11 CARBIDE

3 - AXIS MILLING
HORIZONTAL
ROUGHING
CHAPTER 4
3 AXIS MILLING : HORIZONTAL ROUGHING
This is the principal method of roughing in which the material is roughed out or removed in horizontal layers. This type of
machining is very efficient for removing large volumes of material, and is typically performed with a large tool. Roughing
is typically followed by semi-finishing or finishing toolpaths such as Parrallel finish.
Stock Material
Milled / Removed
Volume
Model
1. Create a new setup : Under ‘3 Axis Adv’ , select Horizontal Roughing.

3 - AXIS MILLING
HORIZONTAL
ROUGHING
A setup window will appear allowing you to enter all the settings, tools and parameters of the path via the different tabs
at the top. Work through each tab to input the settings. This process is used to create each tool path.
HORIZONTAL ROUGHING
PARAMETERS
Work through each tab to input
the settings best suit to the
cutting outcome that you are
trying to achieve.
2. Select and add your Drive / Containment regions

The number of regions selected should appear in the list of ‘Selected machining region(s)‘.
The active region(s) will be highlighted in green when selected. To add or remove regions, use the associated buttons.
Choose either
containment
regions or flat area
To remove
region(s)

3 - AXIS MILLING
HORIZONTAL
ROUGHING
3. Tool
Select your tool - in this case, we will be using T11-Ball Nose Cutter 8D1 for the 80mm foam. Note that the choice of tool
depends on the thickness of your material and the geometry you are milling. Please refer to the tool table on page 14
for a list of recommended tools and the router guidelines on page 5 to understand the various limitations of the router.
4. Feeds & Speeds

The less dense the material , the faster the permissible speed. In this instance , the settings are for foam.
The Spindle speed is always For feeds and speeds , refer

18000. The cut speed to tool library table on
depends on the material page 14.
density. Usually the denser
the material the slower the
speed required.
Cut Speed = 20 000

3 - AXIS MILLING
HORIZONTAL
ROUGHING
5. Clearance Plane
The clearance plane is an XY plane that the end of the router bit moves to in order to travel to the next milling location.
The plane will be automatically defined at a certain safety distance above the part geometry. This is done to prevent the
tool from touching the part being machined during transfer motions since these motions usually use a very fast or rapid
feed rate.
NOTE:
Other geometry in
model space will
affect clearance plane.
Hence it is important
that there is no other
geometry apart from
your model.
6. Cut Parameters
The cut parameters determine the various toolpath movements in the XY plane.
The Stepover Control section allows the user to define the spacing between the cuts.
The step over control is

typically 80% for any rough
finishing (horizontal roughing)
for foam . More refined actions
like the parallel finishing is
typically 15% for timber and
plywood.

3 - AXIS MILLING
HORIZONTAL
ROUGHING
7. Cut Levels
The Stepdown Control section allows the user to define the spacing between the horizontal cut levels for the roughing
operation. The spacing can be specified either as a percentage of tool diameter, a specific distance or as the total number
of levels desired.
Please see the

standard tool settings
to determine setting
for different materials
8. Engage / Retract 9. Advanced Cut Parameters

The user will be able to specify how the cutter engages The advanced cut parameters page is used to control the
and retracts when forced to engage into material. cuts for high speed machining. All of the options in this
section are designed to reduce rapid acceleration and
deceleration of the machine during the cutting process.
NOTE: NOTE:
Typically leave as default settings Typically leave as default settings

3 - AXIS MILLING
HORIZONTAL
ROUGHING
10. Generate
After setting the desired parameters, hit ‘ Generate ‘. By doing so , a toolpath folder is created with the various settings
and its respective generated toolpaths . You can alter every invidual process by double clicking the action under the
dropdown list from the main set up file.
Generate!
Created setup file Red lines indicate Blue lines indicate

for Horizontal the transfer paths the actual cut
Rouging of the toolbit paths

3 - AXIS MILLING
HORIZONTAL
ROUGHING
11. Simulate Toolpath

Check your output settings through simulation and make changes until you achieve your desired outcome. Refer to
Chapter 9 on page 45 to know more about simulating toolpaths.

3 - AXIS MILLING
PARALLEL
FINISHING
CHAPTER 5
3 AXIS MILLING : PARALLEL FINISHING
This is the most commonly used methods for pre-finishing or finishing parts after a general mill such as the ‘horizontal
roughing‘. A 2D linear pattern is generated on the XY plane above the part geometry. The tool moves along this cut
pattern, following the contours of the part geometry below. The tools typically employed in this operation are ball end
mills.
Stock Material
Refine Milled
Surface
Model
1. Create a new setup : Right click ‘3 Axis Adv’ and select Parallel Finishing

3 - AXIS MILLING
PARALLEL
FINISHING
PARALLEL FINISHING
PARAMETERS
trying to achieve.

The number of regions selected should appear in the list of ‘Selected machining region(s)‘.
The active region(s) will be highlighted in green when selected. To add or remove regions, use the associated buttons.
Choose either
containment
To remove
region(s)

3 - AXIS MILLING
PARALLEL
FINISHING
3. Tool
depends on the thickness of your material and the geometry you are milling. Please refer to the CNC Tool Library Table
and CNC Tool Library Explanation documents for a list of recommended tools and the router guidelines on page 5 to
understand the various limitations of the router.
4. Feeds & Speeds

The less dense the material , the faster the permissible speed. In this instance , the settings are for foam.
Press “Load From Tool” button to import the feed and speed settings for the selected tool.
NOTE:
The Spindle speed is always
18000. The cut speed Allways use the
depends on the material settings imported
density. Usually the denser will the tool. FabLab
the material the slower the staff will correct
speed required. these settings before
processing if they are
inappropriate.
Cut Speed = 20 000
Press “Load From Tool”

button to import feed
and speed settings for the
selected tool.

3 - AXIS MILLING
PARALLEL
FINISHING
5. Clearance plane
feed rate.
NOTE:
Other geometry in
model space will
geometry apart from
your model.
6. Cut Parameters
Global Parameters are set similar to Horizontal Roughing Operation.
The cut direction can be specified - Typically ‘mixed’ is used as this is the quickest option.
The angle of cuts can be specified as degrees (0-360).
The Step over Control section allows the user to define the spacing between the cuts which affects the overall resolution.
Default choice
Climb Conventional Mixed
Angle = 0 Angle = 45 Angle = 90
A more refined result is desired in

parallel finishing , hence the stepover
is reduced . ( recommended = 15 % )

3 - AXIS MILLING
PARALLEL
FINISHING
7. Entry / Exit
The Entry/Exit section can be used to control how the cutter enters and leaves during the cutting process.
The approach and departure distance can be specified. This distance is the distance from the cut start point where the
cutter switches from an approach feed rate to an engage feed rate for entry and from retract feedrate to departure
feedrate for exit motions.
NOTE:
Typically leave as
default settings
8. Z Containment
This feature allows the user to contain the toolpath in Z level by specifying High Z and Low Z values either by inputting the
values or by picking the Z height from the 3D model. If the Z level containments are not defined parallel finishing toolpath
takes the models Z height into consideration.
NOTE:
Typically leave as
default settings

3 - AXIS MILLING
PARALLEL
FINISHING
10. Generate
After setting the desired parameters, hit ‘ Generate ‘. By doing so , a setup file is created with the various settings and its
respective generated toolpaths . You can alter every invidual process by double clicking the action under the dropdown
list from the main set up file.
The order can be

altered by moving
the hierarchy of
the cutting path
folders
Generate!
Created setup Blue lines indicate

file for parallel the actual
finishing machinging paths

3 - AXIS MILLING
PARALLEL
FINISHING


2 - AXIS MILLING
PROFILING
CHAPTER 6
2- AXIS MILLING : PROFILING
This method machines open and closed regions (curves) by tracing along one side of their contours. You can define
offsets so that the tool makes multiple passes relative to the regions. Profiling can be used as a finishing operation after
a Pocketing or Facing toolpath, or it can be used alone.
Stock Material
Profile Cut
Model
1. Create a new setup : Under ‘2 Axis ’ , select ‘Profiling’ .

2 - AXIS MILLING
PROFILING
2-AXIS PROFILING
PARAMETERS
trying to achieve.

The number of regions selected should appear in the list of ‘ Selected machining region(s) ‘
The active region(s) will be highlighted in green when selected.
Choose either
containment
To remove
region(s)

2 - AXIS MILLING
PROFILING
3. Tool
depends on the thickness of your material and the geometry you are milling. Please refer to the tool table on page 14
for a list of recommended tools and the router guidelines on page 5 to understand the various limitations of the router.
4. Feeds & Speeds

The less dense the material , the faster the permissible speed.In this instance , the settings are for foam.
Press “Load From Tool” button to import the feed and speed settings for the selected tool.
NOTE:
The Spindle speed is always
18000. The cut speed Allways use the
settings imported
depends on the material
will the tool. FabLab
density. Usually the denser staff will correct
the material the slower the these settings before
speed required. processing if they are
inappropriate.
Cut Speed = 20 000
Press “Load From Tool”

button to import feed
and speed settings for the
selected tool.

2 - AXIS MILLING
PROFILING
5. Clearance plane
feed rate.
NOTE:
Other geometry in
model space will
geometry apart from
your model.
6. Cut Parameters
Global Cut Parameters section allows the user to set the tolerance value to be used in machining.
The Stepover Control section allows the user to define the spacing between the cuts. The total width to be cut can be
specified along with the step size for each cut by entering the value or using the sliding bar.
Tolerance is the
allowable deviations Stock is the thickness of
from the actual part the layer that will remain
geometry plus the on the side of the part after
Stock layer (if any). the toolpath is complete.
Roughing operations generally
The Cut Start Side leave a thin layer of stock, but
determines the side for finishing operations this
of the curve to be cut. value is zero.
The Stepover Control

section allows the
user to define the
width of the cut

2 - AXIS MILLING
PROFILING
7. Cut Levels
The Location of Cut Geometry or the curve used to define the geometry to be cut can be registered as being at the top
or bottom of the stock. Make sure if the curve is oriented to the top in rhino, “At Top” is selected.
The Cut Depth Control

enables the user to define
the depth of the cut ( i.e.
material thickness = 80
mm ) . In this case, it is set
to 79mm , which will leave
1mm of material that will
hold the piece in place
For each pass. Multiple

passes will be needed
for thick material as the
cutting edge of router bits
is usially only 20mm, even
if the actual bit is much
longer.
8. Entry / Exit
The user has the ability to set the tool Entry and Exit parameters using the following property page dialog. If necessary,
the Entry/Exit Motions can be set for each cut level by checking the box at the bottom of the screen.
NOTE:
The default
selection is no
entry/ exit motions.

2 - AXIS MILLING
PROFILING
9. Advanced Cut Parameters

The advanced cut parameters page is used to control the cuts for high speed machining. All of the options in this section
are designed to reduce rapid acceleration and deceleration of the machine during the cutting process. These parameters
allow smoothing of the toolpaths by introduction of arcs.
NOTE:
Typically leave as
default settings.
The user can define the use

of bridges along the part
boundary. Refer to chapter
8 on page 41 regarding
setting up of bridges.
8. Sorting
Allows the user to specify a sorting method. These methods can reduce the overall cutting time.
No Sort – Does not use a sorting method and uses the order in which the geometries are created or order in which the
machining regions were selected.
Sorts based on minimum

distance of start points
between 2 or more
geometries. The start point
can be set.
The directional sorting is

performed according to
the Primary and Secondary
sort directions. The
Primary Sort direction is
defined by the Start angle.

2 - AXIS MILLING
PROFILING
10. Generate
After setting the desired parameters, hit ‘ Generate ‘. By doing so, a setup file is created with the various settings and its
respective generated toolpaths . You can alter every invidual process by double clicking the action under the dropdown
list from the main set up file.
The order of the

setup files is the order
of the machining
process. In this case
, after horizontal
roughingand parallel
finishing , 21/2 Axis
Profiling takes place.
Generate!
Created setup Blue lines indicate

file for 21/2 Axis the machining
Profiling toolpath

2 - AXIS MILLING
PROFILING

2 - AXIS MILLING
HOLE POCKETING
CHAPTER 7
2- AXIS MILLING : HOLE POCKETING
This method is used to cut holes as a milling operation, much the same as drilling. Note that the diameter of the hole
pocketed must be bigger than the drill bit of the tool chosen.
Z
Y
X
ø = 20 mm
ø = 10 mm
1. Create a new setup : Under ‘2 Axis ’ , select ‘Hole Pocketing’ .

the settings best suit to the cutting
outcome that you are trying to
achieve.
HOLE POCKETING
PARAMETERS
trying to achieve.

2 - AXIS MILLING
HOLE POCKETING

In this case, the containment regions are the center points of where you want to create these holes . Because there are
2 different diameter sizes, 2 set up files must be created.
Points as containment regions

Create points at the center of each hole that you want to drill. This can be done by typing ‘ point’ in the rhino command
toolbar and selecting the centerpoints. For hole pocketing , every setup file is dedicated to one hole size.
Setup file 2 :
ø = 20 mm
Setup file 1 :
ø = 10 mm
Choose either
containment
regions or flat
area
To remove
region(s)
3. Select your tool

Select your tool according to the diameter of the holes you wish to create. Note that the hole diameter must be slightly
more (0.1mm) than the diameter of the selected bit. Please refer to the tool table on page 14 for a list of recommended
tools
Eg. The smallest

Diameter of
hole that can be
the tool bit
drilled with the T11
is 8.1mm

2 - AXIS MILLING
HOLE POCKETING
4. Cut Parameters
The Hole Depth and the Diameter can be specified for the hole using the corresponding edit boxes in the dialog box. The
hole depth (25.2 mm ) should be slightly deeper than the material depth ( 25 mm ) so that the drillbit will drill all the
way through.
NOTE:
The created center

points should be on
the surface of the
material where the
drilling should start(
NOT on surface
of the stock ) as it
will cause damage
by drilling into the
table.
ø = 20 mm
The hole depth (25.2 mm ) should be
slightly deeper than the material depth
( 25 mm )
5. Generate
After setting the desired parameters, hit ‘Generate‘. By doing so , a tool path folder is created with the various settings
and its respective generated toolpaths . You can alter every invidual process by double clicking the action under the
dropdown list from the main set up file.
Hole pocketing should

take place before
profiling in order to
keep the milled object
in place
Blue lines indicate the

machining toolpath
2 - AXIS MILLING
HOLE POCKETING
During hole pocketing

simulation, always check the
drill depth and make sure that
the drill bit does not damage
the CNC bed

2-AXIS PROFILING
CREATING
BRIDGES
CHAPTER 8
2-AXIS PROFILING : CREATING BRIDGES
Bridges are tabs created to help hold the model inplace within the stock material. Bridges are created under the 2-Axis
profiling machining option.
Bridge
Stock Material
Profile Cut
1. Under machining objects , Select your curve you wish to add bridges (tabs) to
In this instance, it is the same containment region drawn for the 2-axis profiling action.
Select curve
2. Select ‘Automatic bridge points on Selections’ tab

A browser will pop up where you can enter the number of bridge points .
‘Automatic
bridge points
on Selections’

2-AXIS PROFILING
CREATING
BRIDGES
3. You can edit Bridge points by selecting ‘ edit bridge points in selection ‘ tab.
You can manually position or adjust the bridge points . The created points are in red and upon selection, they turn blue,
allowing you to drag them into your new desired poistion.
‘Edit bridge
points in
selection’
4. Edit the 2 Axis Profile toolpath folder

Within the 2Axis toolpath folder, remove any existing active drive regions under ‘machining features / regions.’
Remove any existing

active drive regions
under ‘machining
features / regions.’

2-AXIS PROFILING
CREATING
BRIDGES
5. Add new curve region

Click on the ‘Select Predefined’ tab and select the new curve region that you have just created.
6. Advanced Cut Parameters

Within this tab, you can edit the height and length of each bridge.

2-AXIS PROFILING
CREATING
BRIDGES
Upon simulation, you

can see the created
bridges.

SIMULATING
TOOLPATHS
CHAPTER 9
SIMULATING TOOLPATHS
Users are able to simulate actual machining of the generated toolpaths. The output of this simulation is a true 3D cut
model. The simulation features allow the early detection and correction of programming errors. The following section
describes the material removal simulation functionality available in RhinoCAM.
1. Under ‘Simulation preferences’ , select ‘ Polygonal Model’.

This setting will display a more realistic , higher resolution simulated outcome.
Simulation
preferences
Fig 1. Voxel Model
Fig 2. Polygonal Model
2. Adjust Stock Model Transparency

Making the stock slightly transparent can be useful in observing simulations such at hole pocketing to check that the drill
depth is correct and not too much where it will damage the CNC bed.

SIMULATING
TOOLPATHS
3. Select the machining process you would like to simulate and click ‘play’.
This will display the actual machining toolpaths of the CNC machine . You are also able to simulate the entire process by
selecting the main setup file ‘Setup 1‘.
Speed of
simulation
4. Re-simulate all the operations and ensure that all the setup has been successful.
Simulate the entire process by

selecting the main setup file ‘Setup 1‘.

EDITING
MACHINING
OPTIONS
CHAPTER 10
EDITING MACHINING OPTIONS
Once a Machining operation is created it is listed under the RhinoCAM -MOps browser. Changes can be made to any of
the objects that make up the operation. The edits made to the operation are saved within the operation and will need to
be regenerated. A hypothetical error is created in this tutorial to show the steps taken to rectify the problem.
1. Locate the error file ( Errors will show up in red )

In this case, it shows that there are problems occuring during the 21/2 Axis Profiling.
2. Check machining process and identify the problem

In this case, it shows that the wrong tool has been selected. The T1-Endmill Down cutter tool length is too short for this
process and the tool holder is clashing into the material. Refer to the tool library table on page 00 for the right tool. Once
you have made and save any changes, it will show on the list as an exclamation.
Any changes
made will
show up as an
exclamation

3. Regenerate the changes made
Right click on the set up file to be regenerated and select the ‘ Regenerate’ option.
NOTE:
When the file is

resimulated, the
red error region
should no longer be
visible.

GLOSSARY
GLOSSARY OF CNC TERMS

2 1/2 Axis Machining: 2 1/2 Axis Machining creates toolpaths stepdown.
that follow 2D lines, or flat surface geometry, to cut to a
programed depth. Cuts are determined by the X and Y Roughing: Roughing operations are used to remove the bulk
coordinates at each point along the surface edge or line. Cuts of material in faster, less accurate passes. Incremental cuts are
are made in depth increments to fit the tool’s cutting capacity made in a series of depths that are within the tools cutting
i.e. to cut 30 mm plywood it will be cut in 5mm passess. 2 1/2 capacity. Finishing passess are required to achieve optimum
axis milling is used primarily for cutting sheet materials. You accuracy.
should model flat surfaces.
Horizontal Roughing: Roughing operations are needed when
3 Axis Machining: 3 Axis Machining creates toolpaths that cutting deep into hard materials such as woods, plastics, and
follow 3d surfaces to carve objects. Cuts are determined by metals. Incremental cuts are made in a series of depths that
the X,Y and Z coordinates for each point along the surface of are within the tools cutting capacity. Roughing operations
your 3D Model. are time consuming but neccessary parts of machining solid
geometry in hard materials like wood.
Climb Cut (aka downcut): In a climb cut, the cutter motion is
downriver, opposite its rotation—the cutter rotates clockwise Origin: In Rhino, this is the world 0,0,0 coordinate. On the CNC
but is fed conter-clockwise and away from the rotation. The machine you establish this point when you zero out the bit on
resulting cut can produce a finer surface edge but climb the material. When you do this you must zero out all three
cutting is extremely hard on bits and can be easily overdone. coordinates. Once you have established this origin, the CNC
Climb cuts should only be made with extreme caution and in will interpret that origin to be the position of the 0,0,0 origin
special situations. in your Rino file.
Conventional Cut (aka upcut): In a conventional cut, the Parallel Finishing: Parallel Finishing make cuts in line with
cutter rotation and tool motion are in parody, the cutter is fed each other, at a consistent step over.
upstream into the material, producing a robust cut but with
a tendency to tearout. Conventional cutting is the standard Pocketing: Pocketing toolpaths cut away all of the material
cutting direction and should be used in most situations. inside of a selected region to create pockets.
Cutting Edge: The sharpened edge of the tool used for cutting Post (or postprocess): The process by which Rhinocam
converts tool paths into numeric code which are interpretable
Feed Rate: The rate at which the cutter moves from point A to by the CNC machine.
point B. Expressed in mm/minute.
Profiling: Profiling toolpaths follow the edges of surfaces to
Flute: The grooves cut into the tool to allow chip removal create profiles.
during cutting. The number of flutes usually ranges between
1 and 2. Region: The area in Rhinocam you use to designate a milling
area. Generally, regions are closed curves on or around the
Finishing: Finishing operations are created to accurately carve geometry you wish to mill. Think of a region as a way to tell
your geometry. The toolpath is created to follow the surface of Rhinocam where to look for milling geometry.
your model precisely removing a thinner layer after the bulk
has been removed by roughing passes. Spindle: The rotating motor that spins the cutting tool.
G-Code: A system of numeric code and machine instructions. Stock: The material that will be machined on the CNC Router.
When you Post a file, Rhinocam will produce G-Code. Once
the file is posted a plain text file will open in a new notepad Toolpath: A definition of the motion of the tool as it makes a
window. This is the G-Code. Do not alter this code! You will given cut. In Rhinocam, the toolpath itself is expressed by a
notice the file type is .nc, this stands for numeric code. light green line. Each green line represents one linear motion
of the tool and defines the center location of the bit at any
Horizontal Finishing: Horizontal Finishing will create toolpaths one time.
that follow the contours of your model at a consistent Z

REFERENCES
REFERENCES
The following are links to more indepth information about RHINOCAM software and the milling machine.
http://www.mecsoft.com/guest/Training/TrainingManual-RhinoCAM.pdf

3 Axis CNC Router

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CNC MILLING MACHINE

Digital Fabrication Laboratory

105A, First Floor,

CNC Tool Pathing Manual, August 2013 | 1

Understanding the Machining Process ...........................................04

General Router Guidelines ..........................................................05

Examples of Accepted Rhino Geometry ...................................06

Examples of Incorrect Rhino Geometry .....................................07

File Submission Procedure ..........................................................08

Chapter 1 : Orientating your model ....................................... 09

Chapter 2 : Creating containment regions ................................13

Chapter 3 : Tool Library ...............................................................14

Chapter 4 : 3 Axis Toolpaths - Horizontal Roughing ........... 15

Chapter 5 : 3 Axis Toolpaths - Parallel Finishing ................... 22

Chapter 6 : 2 ½ Axis Toolpaths - Profiling .............................. 29

Chapter 7 : 2 ½ Axis Toolpaths - Hole Pocketing ................... 37

Chapter 8 : 2 ½ Axis Toolpaths - Creating Bridges ................... 41

Chapter 9 : Simulating Toolpaths ................................................45

Chapter 10 : Editing Machining Options .....................................47

Glossary of CNC terms ......................................................................49

CNC Tool Pathing Manual, August 2013 | 2

If in doubt of which methods to

OVERVIEW OF MACHINING METHODS

© MecSoft Corporation 14 www.mecsoft.com

© MecSoft Corporation 14 www.mecsoft.com

CNC Tool Pathing Manual, August 2013 | 3

UNDERSTANDING THE MACHINING PROCESS

Load 3D model and create chosen

Create Containment Regions

Set up machining options

The 3 axis roughing operations are

It is recommended that you simulate

your machining operations after

The simulation function

CNC Tool Pathing Manual, August 2013 | 4

the T11-BallNose Cutter NOTES:

The depth in which the machine can cut

Where the slot is greater than the length of

Slots greater than the length of the tool bit can

Cut The router will not read any geometry beneath

No undercutting - the router can only move

Very thin edges will be weak. Be aware that

CNC Tool Pathing Manual, August 2013 | 5

EXAMPLES OF ACCEPTED RHINO GEOMETRY

This is an example of a simple NURBS model

Select the mesh option best suited to the

3. Multiple objects with boolean union

Clean unified object

If your model is made up of multiple objects, it is

CNC Tool Pathing Manual, August 2013 | 6

EXAMPLES OF INCORRECT RHINO GEOMETRY

1. Multiple objects without boolean union

Multiple objects that are not unified will slow

2. Model with under cuts

The router will detect and cut whatever geometry

CNC Tool Pathing Manual, August 2013 | 7

How to submit files to the FABLAB

All CNC files must be saved as a rhinofile in the following order

CNC Tool Pathing Manual, August 2013 | 8

2. Import your model

CNC Tool Pathing Manual, August 2013 | 9

3. Draw stock material

Align bottom left of

CNC Tool Pathing Manual, August 2013 | 10