Multi-Task

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

September 2008
Proprietary Notice
This document contains propriety information of Gibbs and Associates and is to be used
only pursuant to and in conjunction with the license granted to the licensee with respect to
the accompanying Gibbs and Associates licensed software. Except as expressly permitted in
the license, no part of this document may be reproduced, transmitted, transcribed, stored
in a retrieval system, or translated into any language or computer language, in any form or
by any means, electronic, magnetic, optical, chemical, manual or otherwise, without the
prior expressed written permission from Gibbs and Associates or a duly authorized
representative thereof.

It is strongly advised that users carefully review the license in order to understand the
rights and obligations related to this licensed software and the accompanying
documentation.

Use of the computer software and the user documentation has been provided pursuant to a
Gibbs and Associates licensing agreement.

© Copyright 2008 Gibbs and Associates, Inc. All rights reserved. The Gibbs
logo, GibbsCAM, GibbsCAM logo, Virtual Gibbs, Gibbs SFP, MTM, SolidSurfacer,
and "Powerfully Simple. Simply Powerful." are either trademark(s) or registered
trademark(s) of Gibbs and Associates in the United States and/or other countries.
Windows Vista and the Windows logo are trademarks or registered trademarks of
Microsoft Corporation in the United States and/or other countries. All other brand
or product names are trademarks or registered trademarks of their respective
owners. Contains Autodesk® RealDWG by Autodesk, Inc., Copyright © 1998-2006
Autodesk, Inc. All rights reserved.

Acknowledgements:

Written by Will. Gaffga

Thanks to Bill Gibbs, Charles Kindall, Jeff Castanon, Gary Esser, Andy Heffner, Israel Klain
and Jeff Myers for their input and assistance as well as Chris Romes, Bob Dunne, John Sare
and Peggy Shin for their support.

Printed in the United States of America

Modified: September 2008

 Table of Contents

Table of Contents
INTRODUCTION 1
Overview of Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
MTM Workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

INTERFACE 7
Standard Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Main Palette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Multiple Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Multiple Tool Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Document Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tool Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Additional Tile Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Machining Palette Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Spindle Display List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Sync Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Render Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

PART SET-UP 15
Document Control Dialog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Stock & Tool Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Initial Condition of the Machine When Starting a Program . . . . . . . . . . . . . . . . . . . . . . . . 21
MDD Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
MDD Improvements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

GEOMETRY CREATION 25
Setting Up Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
WorkGroups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Coordinate Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Geometry Colors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Changing Coordinate Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Setting Geometry Between Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
How do I get geometry from one spindle to another? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Using Part Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

MACHINING OVERVIEW 35
What can be done with MTM?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

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Machining With MTM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Important Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Tool Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Sync . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Swiss-Style Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Operation Moves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Inter-Op Moves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Same Tool Inter-Op Moves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Tool Change Inter-Op Moves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Switching Spindles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Coordinate Systems & Input Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Process Dialog Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Utility Process Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

TOOL CREATION 47
Tool List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Tool Dialogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Insert Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Advanced Machines Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Setting Cut Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Mill Tool Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
New Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Lathe Utility Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

PROCESSES 57
Machining Process Dialogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
All Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Lathe Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Utility Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Utility Process Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Utility Process Common Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Load Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Load Spindle Type Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Load Spindle Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Unload Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Unload Spindle Type Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Unload Spindle Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Part Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Part Shift Type Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Part Shift Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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Sub Spindle In. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Sub Spindle In Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Sub Spindle Return. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Sub Spindle Return Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Parts Catcher In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Parts Catcher In Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Parts Catcher Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Part Catcher Out Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Move Tool Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Concepts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
What the Move Tool Group Process Can Do:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Move Tool Group Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Standard Interactions Around Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Using the Move Tool Group Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Examples of MTG Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Various MTG Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

OPERATIONS 83
Operations List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Sort Ops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Operation Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Sync Control Dialog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Uniform Tile View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Sync Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Op Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Spindle Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Checker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Time Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Sync Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Recalculate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Flow Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Flipping Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Utility Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

RENDER CONTROL 95
Stock Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Render Control Palette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

POST PROCESSING 101

Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

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Posted Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Post Processor Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Post Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Label Definitions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Code Issues: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

PART CREATION 109

Part Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Spindle Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Geo Creation & Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Sub Spindle Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120

TOOLING TUTORIALS 123

Basic Tool Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Tool Group 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Face Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Face Drill Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Tool Group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
OD Roughing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
OD Groove and Finish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Mill Turn Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
OD Mill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
OD Drills. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Dual Spindle Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Swiss-Style Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

MULTI-TASK MACHINING TUTORIALS 149

Single Spindle Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Setting up the Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Front Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Grouping Ops by Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Control of Flows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Syncing Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Milling Ops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Hex Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Dual Spindle Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Part Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Tool Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Setting up the Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

iv
 Table of Contents

Front Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168

OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
OD Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Cut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Utility Ops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Sub Spindle Ops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Ordering Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
OD Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
Hexagon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Drilling ops TG1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Drilling Ops TG2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Swiss-Style Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Setting up the Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
ID Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Main Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Milling Ops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
OD Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Sub Spindle Ops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Transferring to the Sub Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Unload Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Sub Spindle Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Load the Main Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Re-Applying Toolpath. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Verify Syncs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Auto-Flip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Flipping Tool directions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Upper to Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Syncing the new flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

PART PRINTS 221

APPENDIX 229
Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
FAQ (Frequently Asked Questions). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236

v
 Table of Contents

INDEX 239

vi
INTRODUCTION
 Introduction

CHAPTER 1 : Introduction
The Multi-Task Machining option allows for the definition and creation of multi-turret,
multi-spindle parts. There is no limit to the number of spindles, turrets or axes defined by
the system. This includes lathes that are multi-axis (4 or more axes), machines that can
work on multiple parts simultaneously, and Swiss-type machines.

Why the term “Multi-Task Machining”? Traditional 2-axis lathes and 3-axis mills do one
thing at a time. In order to perform more than one task the setup needs to be changed on
these machines. Multi-Task machines can perform more than one machining operation at a
time or sequentially without a setup change or user intervention.

Multi-Task Machining (MTM) is an add-on option to the Virtual Gibbs Lathe module.
Other GibbsCAM modules and options can add functionality, reinforcing the Multi-Task
Machining concept. The Mill module is required for Mill/Turn functionality, the Rotary
Mill option is required for 4th-axis simultaneous milling and Advanced CS is required for 5-
axis positioning.

Before using MTM, you should be familiar with the basic GibbsCAM Lathe or Mill modules.
If you have not read at least the Geometry Creation and Lathe manuals, please do so before
continuing with this product. This manual will only refer to items that are detailed in other
manuals.

OVERVIEW OF FEATURES
Actual Multi-Task Machining features include detailed machine definition, accurate cycle
time calculation, better support for multiple spindles, multi-flow program creation, Cut
Part Rendering, and program optimization, Utility Operations, and custom post
processing. Additional functions and features include:

• Each Multi-Task Machine is fully defined (page 22)

• Each machine has its own Machine Definition Document (MDD) that fully
describes the machine’s layout and capabilities.

• Program parts easily using the standard lathe interface first (page 4)

• All spindles, coordinate systems and accompanying geometry are displayed or can be
hidden (page 13)

• Drag and drop associative tool tiles with turret & position assignment (page 49)

3
 Introduction

• Utility operations for full time awareness & simulation (page 59)

• Synchronization of operations (page 86)

• Real time display of a multi-flow synchronous program with zoomable time-line

and gaps for tool change time that includes positioning, tool and part rotations as
well as the tool change.

• Associative with tool and operation changes:

• Interactive feed and speed changes

• Interactive optimization of program run-time, operation / spindle order, tool

turret and position assignment

• Point and click Sync insertion/removal

• Point and click RPM spindle control assignment

• Real time update for all changes

• Very accurate time calculations: rapid moves, CSS run-times, dependent operation
RPM CSS run-times, independent axes rapid rates, turret, unlock, index, and lock
times

• Real-time synchronized Cut Part Rendering with multiple spindles and tools (page 98)

• Mill support for Y axis and B axis (page 37)

• Post processors that don't require editing (page 104)

MTM WORKFLOW
The Multi-Task Machining option works no differently than any other GibbsCAM product,
it simply has additional functionality and features. As such, there is not a set way to create
parts but there are some guidelines. A file needs to be open before creating a part; there
needs to be geometry to machine before machining processes can be created; tools need to

4

be defined in order to make processes; finally, machining operations need to be post
processed to be sent to the control.
Lathe & Mill
The method most often
recommended to create a
part in the GibbsCAM Lathe
or Mill modules, (the
method used in the
manuals), follows the order
shown below.
• New File / Open existing •
file
• Create/modify geometry
• Create tool list
• Create operations
• Verify & Cut Part Render
• Post the file
Introduction
Multi-Task Machining
The sequence shown to the left is basically still true for
MTM, but working with multiple spindles and multiple Tool
Groups makes things a little more difficult. We recommend
that while learning MTM, parts should be programmed as a
simple 2-axis lathe first, then duplicate and move the
geometry to non-primary spindles, sort tools to different
Tool Groups and reprocess the part. The modified workflow
would be like this:
New File / Open existing file
• Create geometry on primary spindle
• Create tool list, all tools in one turret
• Create operations
• Create / Modify geometry to be used on other spindles
• Sort tools to various turrets for optimal workflow
• Synchronize the operations & run the Sync Checker
• Verify & Cut Part Render
• Post the file
5
 Introduction

6
INTERFACE
 Interface

CHAPTER 2 : Interface
STANDARD INTERFACE
New users and those who have only used the GibbsCAM Lathe module may not be familiar
with the Level 2 interface. It is suggested that you review this topic in the GibbsCAM
Getting Started manual before continuing. The Multi-Task Machining module functions
only from the Level 2 interface. Any elements of the interface that are not thoroughly
covered in a prerequisite manual, (Getting Started and Geometry Creation) are discussed in
this manual.

Items that are unique to the Multi-Task Machining interface include two extra buttons in
the Top Level palette, additional data shown on tiles, the display of multiple spindles in the
Workspace, a Spindle Display list, and the Sync Control dialog. Additionally, there are
modifications to the Document Control and Tool dialogs, there is a new process type in the
Machining palette as well as additional options in the Cut Part Rendering palette.

1. Main palette items 3. Multiple Spindles 5. Synchronization dialog

2. Additional Tile data 4. Spindle list 6. New Process type
Figure 1: Modifications to the GibbsCAM interface for MTM.

9
 Interface

MAIN PALETTE
The Main palette has two additional buttons when creating a Multi-
Task Machining part. The buttons are located at the bottom of the
palette. These buttons access the Sync Control dialog and Spindle Sync Dialog
Display list. The Sync Control dialog and the Spindle list are Spindle List
discussed below.

MULTIPLE SPINDLES
The Multi-Task Machining option enhances the
standard GibbsCAM interface and Workspace to
allow for an unlimited number of spindles. Each
spindle has a number, a type, and other
parameters needed to fully describe the spindle,
based on its type. Once loaded with a part, any
machining operation can be performed on a
spindle (within the Tool Group and tool
constraints defined). The system will manage
multiple work pieces being machined on
different spindles through a part load-move-
unload set of utility processes. The number of
spindles available is defined by your machine
and the MDD. The spindle set up is accessed
through the Document Control dialog. More
information on this may be found on page 13 and
also on page 18. Figure 2: 2 spindles in workspace and
rendering.
MULTIPLE TOOL GROUPS
“Tool Group” is the term used to refer to a turret, gang or slide. Multi-Task Machining
(MTM) extends the basic functionality of GibbsCAM to provide the ability to program
multiple Tool Groups machining parts on the same or different spindles. Each machining
operation is programmed for a specific spindle with a tool group and parallel operations
(operations that happen concurrently on the machine) are controlled through the Sync
Control function. The number of Tool Groups available is defined by the MDD and set up
in the Document Control dialog. More information on this may be found on page 21,
page 39 and page 49.

10
 Interface

DOCUMENT DIALOG
When creating a Multi-Task
Machining part the Document
dialog is modified to allow for the
set up of multiple spindles and
Tool Groups. Each spindle set up is
accessed through a button that
cycles through the available
spindles. Each available spindle
has settings for the initial stock
size and condition and the
available Tool Groups. More
information on the Document
Control dialog may be found in the
section “Part Set-Up” on page 15.

TOOL DIALOG

Tool dialogs have been modified

for Multi-Task Machining parts.
The tool dialogs include pop-up
menus for selecting the Tool
Group that holds the tool and the
position within the Tool Group.
Additionally, there is a new tool
type, the Utility tool. More
information on the Tool dialog
may be found in the section “Tool
Creation” on page 47.

11
 Interface

ADDITIONAL TILE DATA

Items in Tile lists have been expanded to
include additional data. The Tool tile
displays the Tool Group the tool is in and
the tool’s position in the Tool Group. The
1. Tool Group Assigned 3. Spindle the Op is on
Process tile displays the Tool Group and
2. Tool’s Position in TG 4. Flow the Op is in
position of the tool as well as the spindle
being used. The Operation tile displays the Flow number, position of the tool as well as the spindle
being used.

MACHINING PALETTE PROCESSES

The Machining palette has an
additional item when working
with Multi-Task Machining
Utility Process
parts, the Utility process. Utility
processes create non-cutting
operations such as loading and
unloading spindles, returning
sub spindles and moving
tailstock in and out. Some
Utility processes need a tool
associated with the process,
such as a Utility tool that
represents a bar stop, but most
do not. More information on
Utility processes may be found
in the section “Processes” on
page 57.

12
 Interface

SPINDLE DISPLAY LIST

The Spindle list is
accessed from the Main
palette. The Spindle list
controls the display of
spindles on the screen. There
is one entry in the list for each
spindle on the machine.
Spindles are shown and
hidden by double clicking on
the eye icon next to the name
of the spindle. The contents of
this dialog cannot be modified,
only marked as hidden or
seen. The contents are
defined in the MDD and are
machine specific.

When viewing the Figure 3: Two of three spindles are displayed

Workspace, the Spindle
Display toggles the wireframe display of the stock space, but not the geometry. Geometry
may be hidden or shown by using the Workgroup display list. When rendering the Spindle
Display list can completely hide a spindle and all operations performed on the spindle.
What makes this function truly useful is when it is used in combination with view control.
When an unzoom is done and all spindles are displayed, the system will zoom out far
enough to show all spindles. However, if only one spindle is displayed the unzoom will fill
the Workspace with that spindle. This is very convenient when creating geometry and
operations by limiting the area being worked in, providing the largest image possible.

13
 Interface

SYNC CONTROL
The Sync Control dialog,
accessible by clicking on
the Sync Control button
in the Top Level palette,
displays all operations in a run- Actual run-time of
time format, including time for the Operation
tool changes and allows the Shown as Scaled
user to synchronize machining Operation Tiles
by tool turrets on a specific
spindle. This will allow the
user to specify that OD and ID
operations are done
simultaneously or to ensure
that two turrets will not collide Op Syncs
when moving into position.
Time needed for
Greater detail on the use of the
the Tool Change
Sync Control dialog may be
found in the section
“Operations” on page 83. A Fit
View menu item is available by
right clicking on the Sync
Control title bar, this selection
will fit all operation tiles into
the MTM Sync Control Dialog
box.

RENDER CONTROL
The Render Control (CPR) System
palette can display the cut time Syncs

14
 Interface

as well as the operation number of specific flows. See “Render Control” on page 95 for more
information.

15
 Interface

16
PART SET-UP
 Part Set-Up

CHAPTER 3 : Part Set-Up

The set up of a part is more crucial in the Multi-Task Machining module than in other
GibbsCAM products. The set up in MTM more completely defines what actions may be
performed and the capabilities of the machine being used. In other GibbsCAM products,
such as the Lathe and Mill modules, the set up is relatively generic — all that is needed is
the type of machine (e.g. a horizontal lathe or a 4-axis vertical mill), the size of the stock
and clearance data. In the MTM module more machine information must be provided. This
includes the machine’s workpieces’ orientation and axes as well as the machine’s Tool
Groups’ orientation and axes. Each and every machining center needs its own parameters.
As such, the set up is more detailed. Fortunately this is made simpler because all of the
machine’s data is stored in an MDD (Machine Definition Document) file and is used to
define the part. The MDD is selected in the Document Control dialog from the Machine
list.

DOCUMENT CONTROL DIALOG

The top part of the dialog remains unchanged from the other GibbsCAM modules, the only
difference being the choices in the Machine list. When a MTM Machine is chosen, the
second part of this dialog changes significantly. When creating a Multi-Task Machining
part an MTM Machine Definition Document (MDD) must be selected. Each MTM MDD is
made for a specific machining center’s parameters and manufacturer’s recommendations
— this includes the number of spindles and turrets in each Machining Center. The MDD
controls many things in the software, including the quantity, position and display of
spindles, the availability of turrets and which spindles they can access and the number of
tool positions in a turret, drill cycles and coolant. You will receive an MDD with each post
processor for each different machine you have. For more information on MDDs and Multi-
Task Machining see the section “MDD Support” on page 22.

17
 Part Set-Up

STOCK & TOOL CHANGE

The second part of the Document Control dialog has been modified for the MTM module
to accommodate multiple spindles and multiple turrets. The components of the Document
Control dialog are described on the following pages.

1. Spindle Selection 3. Tool Group Selector

2. Initial machine condition 4. Visual part distance
when starting a program
Figure 4: Elements of the lower part of the Document Control dialog

Spindle Selection: This item is used to select a spindle so its stock size, location and
condition may be configured and the tool change position may be set for each spindle.
Click one of the blue scroll arrow buttons to cycle forward or backward through the
available spindles. The stock size and condition of each spindle in the machine must be
defined.

18
 Part Set-Up

Stock Diagram: The Back of Stock Z Front of Stock Z

Stock diagram is (Facing Allowance)
significantly different
for Multi-Task Diameter or Radius
Machining parts. The Measurement
spindle is represented
Part Distance
by the light cylinder
From Spindle
around the stock. In
addition to the Chuck Face
standard Xradius or Thickness
Xdiameter value and
the –Z & +Z values, there is a text box marked Z. This item specifies the distance from
the spindle’s face to the edge of the stock. If the part is being cut from bar stock and
fully sticks out of the spindle this value will be greater than the total length of the part.
The value may also be smaller than the total length of the part. This can be true if only
the front of the part extends out of the spindle face because the part is to be transferred
to a sub spindle to cut the back end of the part. The set up in the Document Control
dialog should reflect the actual set up on your machine. The Back of Stock Z (shown as
–Z in the following image) is not the part length. This value only controls the length of
the displayed stock. The Chuck Face Thickness is an optional item. Enter the Z
thickness of the chuck or “0” if no chuck is used.

The orientation of the stock diagram does not change with each spindle, the view is
always the “Home” view of the spindle’s ZX coordinate system. Basically, all spindles
will be shown on the left with the stock extending to the right, regardless of where the
spindle really is in the machine. When you are first learning to set up a part file this
may not be immediately obvious or helpful. Just imagine that for each spindle you
move to the same place relative to the spindle.

Let’s look at this another

Spindle 1 Spindle 2
way because setting up
your part correctly is
critical. Let’s use a dual-
spindle machine as an
example and use a
different graphic to Pick Off
explain the elements of
the stock diagram. In all
likelihood, the stock Z Depth 1 Part Distance Part Distance Part Origin
conditions of the spindles Part Origin From Spindle From Spindle
will be different, one
spindle will have bar stock and the other will have a partially cut piece of stock that has
been transferred to the spindle. The system needs different information for these

19
 Part Set-Up

conditions. Spindles with uncut stock (a spindle designated as having Initial Stock) is
used to define the size of the part and how far it sticks out from the face of the spindle.
Spindles that will hold transferred stock (a spindle set with Initial Stock off) need to
have the part’s origin and distance from the spindle face designated. The remaining
length of the part is assumed to be used for the pick-off and is in the spindle’s chuck or
collet.

Let’s use an example with real

numbers. We have a part stock
that is 52mm long with 1mm on
the Z+ side of the origin. The
part sticks out of the spindle by
55mm. We will face off the
1mm, making the part stock
51mm long, sticking out of the
spindle by 54mm and the face is
now at the origin.

When we transfer the part we

will pick-off the part at Z-
25mm. That will leave 26mm
sticking out of the sub spindle
face, 1mm of which will be faced
off later, leaving Z0 at the face.
The stock diagram for such a
part would look like the following image.

If the part is held in a chuck, add the Z-thickness of the chuck to the total part length.

Graphic Part Face Distance: This setting allows you to set the distance of the display of
available spindles. This is the graphic distance between the spindles. The actual distance
between spindles is fixed by the machine and defined in the MDD. However, for ease of
viewing the spindles may be brought closer together. This way when unzoomed, the parts
are not difficult to see because of their size. Enter the distance you want between opposing
part faces on the screen. This has no effect on the actual program. The setting is a value in
part units, inches or millimeters.

Clearance Data: This section of the dialog has two states, with and without Auto Clearance
selected. When Auto Clearance is on, the system will calculate positioning moves between
operations. The positions will be changed as the part is machined. The value entered is an
offset amount from the current part stock that the system will use to always keep an
adequate clearance from the material.

20
 Part Set-Up

When Auto Clearance is off, a fixed clearance position may be entered in the X and Z text
boxes for each spindle. The text boxes specify the X and Z location that a tool will rapid to
and from during a tool change. This position will also be used when moving from one
approach type to another.

X Dimension Style: This selection determines whether X values for the part are input as radii
or diameters. Some text boxes in particular dialogs specify that the value entered is either a
radius or a diameter value, regardless of the selection made here. X values entered in text
boxes are usually based on the radius unless specifically labelled Xd.

Tool Change Position: The Tool change position is generally handled by the MDD. Some
MDDs provide text boxes for specifying the X and Z values for the tool change position. In
this case, a different value may be entered for each turret. Each available turret is accessed
by clicking through the blue scroll arrow buttons. You will need to set all Tool Groups for
each spindle the TG can be used on. The values are absolute values from the part origin to
the Tool Group/Turret datum. Most MTM MDDs do not have an option of specifying
where a tool change is performed. These MDDs will move the Tool Group to a pre-defined,
hard-coded position that may not be overridden.

INITIAL CONDITION OF THE MACHINE WHEN STARTING A PRO-

GRAM
The starting conditions specify whether stock is or is not loaded into the machine and
whether the stock is ready to be machined or has to be fed into position. This is controlled
by two checkboxes, Initial Stock and Preloaded.

Initial Stock: This item tells the system which spindle or spindles start with unmachined
material in this program. If a part is going to be transferred to the currently active spindle
then this item should remain unchecked. When Initial Stock is off, the system expects that
the plug will be moved from another spindle to the spindle being defined, (such as from the
main spindle to the sub spindle). When Initial Stock is off, the Stock diagram values to be
entered are the Z value that specifies the part’s distance from the spindle face (the Z value is
the length of the part sticking out from the spindle after being picked off) and any material
beyond the part origin, such as material to be faced.

Preloaded: This item is only available when there is Initial Stock on a spindle. The
Preloaded checkbox specifies how the machine is currently set up. When Preloaded is
unchecked the system is told that there is no material in the chuck and a Load Spindle will
need to be programmed by the user before machining can be programmed. When checked,
the system expects that the first bar feed has been done and that the material is ready to be
machined as soon as the program is started. At some point in generating operations a load
spindle command will need to be generated, usually after all the operations are made. With

21
 Part Set-Up

Preloaded checked you are telling the system to assume that you will take care of this detail
later and to start with the material in place.

MDD SUPPORT
A Machine Definition Document (MDD) controls many things in the software, including
the number of, position of, and display of spindles, the availability of turrets, the number of
tool positions in a turret, drill cycles and coolants available. Because MDDs for Multi-Task
Machining parts are machine-specific and the programming of a part is also dependent on
a particular machine’s capabilities, a copy of the MDD data is stored with the part file. If the
part file is moved to another computer and the MDD associated with the part is not stored
on that computer, the system will automatically generate the required MDD. MDDs are
kept in a folder labelled “mdd” in the application folder.

An MDD must be available for each machine that will be used with the MTM product. This
is because each machine has different parameters and abilities. A Gildemeister 3+1 spindle
machine is very different from a Hardinge Twin Turn which is different from a Miyano 6
spindle machine. That is not to say that a part originally programmed for a Star SV-series
machine could not be easily modified to be machined on a Eurotech Elite. In fact, to make
the change would likely only take a new MDD, a double check of tool assignments and
redoing the Utility operations. You will probably receive a finished MDD from the same
person that provides your post processor.

MDD IMPROVEMENTS
A number of new machine parameters are required in the MDD file for MTM. These
include items to define each Tool Group, spindle and axis of motion. Additional
information about feed rates and tool changes will be required for calculating accurate
cycle times. All of this data is stored in the MDD, which is a text file. It is highly

22
 Part Set-Up

recommended that you do not alter this file. Making modifications to this file could
produce errors in output or cause your MDD to not work at all.

23
 Part Set-Up

24
GEOMETRY CREATION
 Geometry Creation

CHAPTER 4 : Geometry Creation

SETTING UP GEOMETRY
When working with multiple-spindle parts, geometry must be set up for each spindle. Each
spindle has its own set of coordinate systems that define the primary planes you may work
in, based on the options installed. There are several different methods to prepare geometry
for Multi-Task Machining. The rule is that the geometry must be properly positioned
relative to the spindle it will be used on. This is best achieved by using the coordinate
systems associated with a specific spindle. The methods include:

• Create one finished shape at Spindle 1. Duplicate and move the geometry to the other
spindles. Just as in the Lathe module, you can usually define your roughing operations from
the final shape geometry.

• Create different shapes for each spindle at Spindle 1 then move the geometry to the other
spindles.

• Create the shapes at the spindle you intend to use the shape on.

27
 Geometry Creation

• Any combination of the above.

Figure 5: Geometry as set up for the main and sub spindles.

One of the things you do not need to be

concerned about is defining a stock
condition for each spindle with geometry.
While you can make a non-cylindrical
stock body (as documented in the Lathe
manual), such as a casting for the initial
stock on the primary spindle, all sub
spindles calculate the stock remaining
from previous operations and generate the
condition of the stock as it exists when
transferred to a spindle in Cut Part Rendering. This is illustrated below. The image shows
the condition of the stock on Spindle 1 after being machined and how Spindle 2 will look
when Cut Part Rendering begins on it. This includes milling operations. This feature is
automatic and fully associative. It establishes the Material Only starting condition for
machining on a spindle.

28
 Geometry Creation

WORKGROUPS
From the Geometry Creation manual, you
should already be familiar with Workgroups.
Workgroups are a means of storing and
separating geometry or defining custom stock,
such as a revolved or extruded shape. The Part
Stock setting in the Workgroup dialog may be
used to define the original stock as being a
custom shape, such as hexagonal bar stock or a
casting. When defining custom stock in MTM
you must designate which spindle is to receive
the stock definition and Initial Stock must be
activated in the Document Control dialog. See the Lathe and Mill manuals for more
information on setting custom Part Stock.

COORDINATE SYSTEMS
If you have used the Mill/Turn or Advanced CS options you should already be familiar with
Coordinate Systems. A coordinate system (CS) is the plane in which geometry lies.
Depending on the options installed, you will have different coordinate systems available.
All MTM systems will have at least one coordinate system per spindle. These coordinate
systems represent the primary planes on which a part can be machined. Some of the
various combinations of default Coordinate Systems follows. The actual coordinate systems
you have available may differ, depending upon your machine configuration.

Lathe & MTM: 1 ZX plane per spindle

Mill/Turn & MTM: 4 planes per spindle, the ZX, XY

front face, XY back face and YZ.

29
 Geometry Creation

Mill/Turn, MTM & Advanced CS: 4 planes per spindle, the ZX, XY front face, XY back face
and YZ plus the capability to make an unlimited number of additional coordinate systems.
Spindle 1

Spindle 2

GEOMETRY COLORS
Geometry in the current coordinate system is displayed in light blue. Geometry that is
visible but that is in a coordinate system other than the currently active CS is displayed in
magenta (a pinkish color). Geometry in a non-active CS may be edited and modified but all
actions are performed relative to the current CS.

CHANGING COORDINATE SYSTEMS

Moving geometry to another spindle can be achieved by XYZ translation or by the Change
CS command. Keeping shapes assigned to the target spindle’s CS is the recommended
method.

However, unlike workgroups, simply getting geometry into a coordinate system may be
just the beginning. Geometry may still need to be reoriented within the new target CS. The
geometry may need to be translated, mirrored and/or rotated.

There are two commands in the Modify menu that allow you to easily move geometry to
another CS. These commands are Change CS XYZ and Change CS HVD. While similar,
these items modify geometry in different ways.

Change CS XYZ: This command will change the geometry from its currently assigned CS to
the currently active CS, such as from the ZX to the YZ coordinate systems. The geometry
will remain in the same XYZ location, it will not move.

Change CS HVD: (Ctrl-\) This menu item is available when geometry is selected. Choosing
this command will change the CS to which the geometry belongs, and will move the
geometry relative to the new coordinate system’s origin and orientation HVD stands for
Horizontal, Vertical and Depth. The arrows at the CS origin indicate the H+ and V+
30
 Geometry Creation

directions. There is also a small + or – at the origin showing the side the D+ axis arises from.
Using the Change CS HVD command keeps the HVD values the same in the new CS. Thus
if a circle was in the ZX plane at Z–1, X–1, Y0 it would also be at H–1, V–1, D0. When moved
to the YZ plane the circle would now be at Y–1, Z–1, X0 or still at H–1, V–1, D0 but oriented
differently. Using this command will change the geometry to lie in the currently selected
CS.

T Note that the Home view of the shape in the first CS

I before the Change CS HVD is identical to the Home view
P of the shape in the second CS after the change.

Moving geometry between coordinate systems is similar to moving geometry between

Workgroups. Geometry may be cut (Ctrl-X), copied (Ctrl-C) and pasted (Ctrl-V)
between Coordinate Systems (CS’s) by switching from the original CS to the target CS and
pasting. Using the paste method replicates the geometry at the same point in space in the
original coordinate system. Once the geometry is pasted the Change CS command can be
used to switch to the current CS. More and advanced information on coordinate systems
may be found in the Advanced CS manual.

SETTING GEOMETRY BETWEEN SPINDLES

The coordinate systems and the orientation of the coordinate systems are identical for each
spindle. The ZX plane is the primary turning plane. The spindle is always to the negative
side of the Z axis, thus the spindle rotates about the Z axis with the positive end of the Z
axis projecting out from the spindle face. Again, all spindles are oriented this way.

HOW DO I GET GEOMETRY FROM ONE SPINDLE TO ANOTHER?

There are several ways to accomplish this. The method detailed below involves duplicating
the geometry to be moved, changing the geometry to a CS on the target spindle, mirroring
the geometry and then translating the geometry. While this may seem to be a cumbersome

31
 Geometry Creation

method, it is actually very powerful. Using this method you may specify what feature will
be at the origin of the target spindle.

1. Select and Duplicate the geometry to be transferred (double click and Ctrl-D).

2. Select the Coordinate System for the target spindle in the CS list (typically this is the ZX
plane for the target spindle, such as CS 5: ZX plane - S2: Spindle 2).

3. Select Change CS (HVD) from Spindle 1

the Modify menu (Ctrl-\).

4. Open the Mirror dialog from

the Modify menu and mirror
the geometry about Z0 Spindle 2

5. Open the Translate dialog from

the Modify menu.

6. Place the cursor in the Z text

box. Alt-Click the point that
is to be at the origin of the
target spindle. This will load
the Z coordinate of the point.

7. Change the interrogated Spindle 1

coordinate point to be a
negative value.

8. Click Do It.
Spindle 2
The part must be mirrored because
the depth axes of the spindles face
each other. When the geometry is
moved to the target spindle it is
automatically flipped to match the
depth orientation of the target CS.

If the part origins are at the

opposite ends of the part shape,
you may change step 4 to mirror
about a –Z value equal to half the
parts length. Thus if the geometry is 40mm long, it should be mirrored about Z-20. This
allows you to skip steps 5, 6 and 7.

32
 Geometry Creation

USING PART SHIFT

Part Shift is a Utility Process that allows you to pull or push a part in and out of a spindle,
(see “Part Shift” on page 64). When Part Shift is used, new geometry must be created that
represents the new part position. The new geometry should be offset in Z by the same
amount that the part will be shifted.

33
 Geometry Creation

34
MACHINING OVERVIEW
 Machining Overview

CHAPTER 5 : Machining Overview

This chapter discusses general information on how machining with the Multi-Task
Machining module is different from the rest of the GibbsCAM products. The methods used
are not that different from the basic Lathe or Mill/Turn products: a tool and a process are
defined, geometry is selected and an operation is created. In fact, the processes are
identical. However, with MTM there is more detail in what can be done, just as is true when
comparing a simple lathe to a Multi-Task Machine. The specifics on using MTM are
covered in the following chapters.

WHAT CAN BE DONE WITH MTM?

Many things can be done with MTM. This includes turning, milling, Mill/Turn functions
(Y-axis), and Rotary Milling (A-, B- and C-axis functions). It all depends on the capabilities
of your machine. Chances are that if your machine supports a function and there is an
MDD for your machine, then MTM supports the function. The base enhanced capabilities
brought to the system by the Multi-Task Machining product include multiple Tool Groups
simultaneously cutting on a single spindle.

Figure 6: An example of Simultaneous

cutting.

37
 Machining Overview

MTM functionality also includes support for multiple spindles and multiple Tool Groups.
This includes Swiss and Multi-Tool Slave process cuts.

MTM is also capable of supporting more advanced machines, such as 3-spindle indexing
machines.

Figure 7: A Three spindle set up

MACHINING WITH MTM

Creating operations with the Multi-Task Machining option is no different than working
with the Lathe or Mill/Turn options. What makes the MTM option different is the ability to
control multiple turrets working on multiple spindles. This is accomplished through tool
definition, spindle setup and operation synching.

It is recommended that when making operations, the actual setup of which tool is on what
turret and the synching of Tool Groups be ignored until the operations are complete. This
will aid in visualizing and organizing the part.

38
 Machining Overview

There are several items and terms you need to become familiar with to fully understand the
Multi-Task Machining option. This includes the concept of a “Flow,” what a “Tool Group”
is, and the different types of Syncs.

IMPORTANT TERMINOLOGY
Flow
Multi-Task Machines have multiple flows. Typically there is one flow per turret. Some
machine manufacturers may refer to this as a “channel” or “program.” A flow represents the
sequence of moves you want a CNC machine to make. All actions by a turret are a part of its
flow. Some machines require different files for each flow, and others combine all flows into
a single file.

A flow is equivalent to a simple CNC program. A mill is a single flow program. A simple
lathe is a single flow program. Only one tool moves or cuts at a time. One thing at a time is
the hallmark of a single flow. When two tools can move and cut at the same time, the
program will have two flows. For example, if a lathe has two independently programmable
turrets that can cut at the same time, the program will need one flow for each, or two flows.
In general there is one flow for each Tool Group, though there are exceptions. Specifically,
there is one flow for each group of tools that can cut at the same time.

Tool Group
A Tool Group is a turret, gang, slide or mill-style tool changer. A Tool Group is any
collection of tools that are dependent upon each other. These tools do not need to be in the
same gang to be dependent. The key is that only one tool from the group may be used at a
time. The number of Tool Groups is a determining factor in the number of flows a multi-
task machine has. The following image represents a machine with a single flow.

Figure 8: Example of a single Tool group, single

Flow setup.

39
 Machining Overview

The following figure illustrates two examples of machines with two flows. These are just
two of the many possibilities.

TG1
TG1
S1 S2
S1

TG2 TG2

40
 Machining Overview

Sync
A sync is where one flow waits for 1. Real time scale
another. Once the synced Tool 2. One column per Flow
Groups are in position the 3. Gap for inter-op moves
machining may begin again. There 4. Proportional tile sizes
are three types of syncs, the
Operation Sync (Op Sync), the
Stroke Sync and the System Sync.
Op Syncs and Stroke Syncs are set
by users in the Sync Control
dialog. The Sync Control dialog is detailed later in this chapter.

Op Sync: Op Syncs are synchronizations entered to control the interaction of

operations. An Op Sync is applied to operations in different flows to cause one to wait
until another operation either starts or finishes. The Op Sync is shown in blue. The
pointer shows which op is being synced to which. You may sync the start or end of an
op to the start or end of another op.
Pointer to the ops
being synced

Stroke Sync: With a Stroke Sync, every stroke of

a tool is to be matched with another tool in
another Flow. This can be used to match OD &
ID turning at the same time. Stroke Syncs are
shown in black. There are three ways the
operations may be synced, all of which are
controlled through the Stroke Sync dialog. The
Stroke Sync dialog is accessed when a Stroke
Sync is applied.

System Sync: The System Sync is applied to a set of operations and

can be seen in the Sync dialog, shown in light blue. System syncs
are created by the program in situations where the flows must
work together or stay out of each other’s way. This is automatically
done by the system to make things easier for you. The following
image shows a series of Utility Operations that are automatically
synced.

41
 Machining Overview

SWISS-STYLE PARTS
In the MTM system, Swiss-style parts are displayed as if they were a fixed head-stock part.
The part does not move in the display or render, even though a part shift may be
programmed. This is because rendering is part-centric, not tool- or machine-centric. The
part does not move; it is the tool and the area around the part that changes.

CLEARANCE
MTM uses the same clearance concepts as the standard Lathe module. Part Clearance
refers to clearance data that is used when moving around the part. The Part Clearance is
determined either by the Auto Clearance setting (in the Document Control dialog) or by
the part’s CP1 setting. We need a quick review of GibbsCAM Clearance terminology before
getting further into MTM Clearance information. There are three clearance positions (CP)
used by the system.

CP1: The Master clearance plane defined in the Document Control dialog. This is the
position the tool will rapid to and from during a tool change and when changing
approach types, e.g. moving from an OD to Face operation.

CP2: The Entry clearance plane set in the process dialog.

CP3: The Exit clearance plane set in the process dialog.

When Auto Clearance is active the system will use the Auto Clearance value to calculate a
constant distance above and past the current stock condition. Auto Clearance completely
replaces CP1, 2 & 3.

OPERATION MOVES
Operations begin with the tool positioned over the start point, at a clearance position (CP1
or the prior CP3) referred to as the Op Start position. The first move is from the Op Start to
CP2 then to the Start Point (SP) of the toolpath. The toolpath continues to the toolpath's
End Point (EP). Once at the End Point the tool moves to a clearance position (CP3). Let's
call this the Op End position.

INTER-OP MOVES
There are two types of inter-op moves, tool change, and non-tool change. The movement
as detailed on the following pages are generalizations. They do not include possible part
rotations and clearance moves in two or three linear axes.

42
 Machining Overview

Same Tool Inter-Op Moves

If the last op and next op are on the same part OP2 SP, Op1 CP3 Op1 CP3
side (+X OD to +X OD), the tool will rapid to
Op2 CP2
the last operation’s CP3, into position over
the new SP, then rapid to CP2. Op2 SP Op1 EP

If the ops are not on the same CP1 Xd CP1

side, the tool will exit to the
Part Clearance (CP1), move all
the way around the Part Op1 EP
Clearance to the next
operation’s SP Xd value, then CP1 Z
rapid in to the new operation’s Op2 CP2
clearance (CP2) and finally to Op2 SP
the new operation’s SP.

Tool Change Inter-Op Moves

When the next CP1 Xd value Tool Change Position
op uses a
different tool, the
tool will rapid Op1 EP
out to the Part
Tool Change
Clearance, and
Position
then around the
Part Clearance as CP1
needed until it
reaches a suitable
exit point. Rapids
from the exit
point are in X
and then Z for
maximum safety
due to the CP1 Z value
Op2 SP
possibility of a Op2 CP2 Xd
sub spindle being Op2 value
43
 Machining Overview

on the part. When the tool arrives at the tool change position, the tool change will take
place. The move logic is reversed as the tool moves to the clearance over SP position for the
next op.

Utility operations have exceptions to this rule as many Utility ops don't move a tool. Utility
ops without tools begin before their first effect, and end after their last effect. Utility ops
that do move tools (e.g. Load Spindle with a Stop or Position Turret), may have their inter-
operation moves checked against the Part Clearance. Other than moving around the part in
the event of an intersection, the inter-op moves will simply be “out” (+X) then “over” (Z).

Switching Spindles
When a Tool Group moves from Spindle 1 Spindle 2
one spindle to another it passes
through both the standard tool Standard TC position tool Standard TC position
change location of both spindles. change occurs here
Thus, a tool will retract to the
standard tool change location,
rapid to the other spindle and
then move to the other spindle. If
a tool change is required, the tool
will change at the first spindle’s tool change location.

COORDINATE SYSTEMS & INPUT VALUES

The system has two types of coordinate systems. There are part coordinate systems (a set
for each spindle) and spindle coordinate systems. The part Coordinate Systems are visible
in the Workspace. The only difference between the coordinate systems is the Z position of
the origins. MDD values are entered in spindle CS values by the post creators, which never
changes with a new part. Part file values are entered in the appropriate part CS, with one
notable exception detailed in “Utility Process Data” on page 45. When entering data into
dialogs it is important to understand the orientation of the data to the coordinate system,
or the approach axis. All geometry is input in Part Coordinate System values, meaning +X
for top of centerline and -X for below centerline.

PROCESS DIALOG DATA

Process dialog X values are not entered in part coordinate system polarity, but rather in
“tool side” polarity. Since most cutting is done from the X side the tool is on, most
processes use +X values. An +X location will be on the +X side for an +X tool, and on the –X
side for an –X side tool.

44
 Machining Overview

This convention allows the user to change a tool’s cut

side or switch the tool to a different Tool Group and have + Side Approach
the operation flip X sides without reprocessing. This is
explained in more detail under “Setting Cut Side” on
page 53. Essentially, you can move a tool from the plus
side to the minus side and re-post immediately. With
“tool side” X polarity for OD work, +X moves the tool
away from the part, X- into the part.

Turning and Milling operations are basically the same.

• Lathe processes are input in Tool Side X values,

– Side Approach
meaning +X is interpreted as being away from
centerline towards the tool, regardless of whether the
op is being created on the top or bottom side of the part.

• Mill processes interpret depth values with + being towards the tool side.

Utility Process Data

The X values in Utility processes are in Part coordinate system values, not Tool
Side, where X- is entered for a X- side position. The exceptions are flagged with a
small icon (seen to the right) showing a plus arrow to the tool side. This indicates
that the specific X value needs to be entered in Tool Side polarity. This only occurs in the
Move Tool Group Utility operation and is so that the tool can be moved without
reprocessing. Utility operations do not automatically flip with tool redefinition, with one
exception. That exception is the Move Tool Group User Position X value which is flagged
with a “Tool Side” icon. The X value is interpreted as a Tool Side value, and will
automatically flip with a tool redefinition.

Item Spindle Side

Geometry Creation Part Coordinate System
Turning Processes Tool Side
Milling Processes Tool Side
Utility operations that do not use a tool Part Coordinate System
Utility operations (except Move Tool Group) that use a tool Part Coordinate System
Move Tool Group Utility Op, Standard Tool Change Part Coordinate System
Move Tool Group Utility Op, Machine Home Part Coordinate System
Move Tool Group Utility Op, User Position Tool Side

45
 Machining Overview

46
TOOL CREATION
 Tool Creation

CHAPTER 6 : Tool Creation

Creating a tool in MTM is almost identical to the Mill or Lathe modules. In fact, this
chapter will only cover data specific to MTM because the method and the tools are
identical. With the Multi-Task Machining module, however, it is very important to have
greater tool definition than in other GibbsCAM products — more information about the
tool is needed. The information needed includes which Tool Group (a turret, gang or slide)
the tool belongs to, the tool’s position within the Tool Group and which spindle the tool is
oriented to. These changes are reflected in the Tool list as well as the Tool dialog.

TOOL LIST
The Tool list has been widened to allow for more information to
be displayed at a glance. The additional data displayed includes
the Tool Group number and the tool’s position in the Tool Group.
Both of these items are set within the Tool dialog and will show
up in other tile lists.

It is recommended that tools in the same Tool Group be put Tool Group #
together in the tool list and that there be a space separating the
Tool Groups. As there will generally be more tools used in MTM
parts sorting through tools can be a chore. To aid in this there is a Tool Position
new contextual menu item for tool tiles, the Sort Tools command.
When selected, tools will be sorted by Tool Group and Tool
Groups will remain separated by spaces between tiles.

TOOL DIALOGS
The Milling and Turning Tool dialogs have been modified to include items specific to the
Multi-Task Machining option. These items allow the definition of which Tool Group the

49
 Tool Creation

tool belongs to, the tool’s position in the Tool Group, the side of the part the tool will cut
on and how the insert is aligned to the spindle.

1. Assigned Tool Group 3. Approach Side

2. Tool Group Position 4. Insert Direction
Figure 9: Lathe Tool dialog and the MTM spe-
cific options.

Assigned Tool Group: This pop-up menu may be found in both lathe and mill Tool dialogs.
There is an entry for each available Tool Group as defined by the current MDD (Machine
Definition Document). Select the Tool Group the current tool will be assigned to. The
actual name of each Tool Group will depend upon your MDD.

Tool Group Position: This pop-up menu may be found in both lathe and mill Tool dialogs.
There is an entry for each available position in the Tool Group as defined by the current
MDD. Select the position in the gang, slide or turret that the tool occupies or will be placed
in. Each position may hold more than one tool. This way, you can define a mini-gang of
tools at one turret position. Each tool would have a different offset number.

T A “Mini Gang” may be created by creating multiple tools that are in the
I same position, each with different offsets. This can be one tool used
P with four different offsets or four different tools.

Orientation Spindle: This option is not available on all machines. This selection lets you set
which spindle is used to orient the tool. See “Advanced Machines Only” on page 53 for
more information.

Cut Side: This item may be found in lathe tool dialogs. If you are familiar with the
GibbsCAM Lathe module, you are accustomed to seeing a Clockwise/Counter Clockwise
(CW/CCW) option in the Lathe Tool dialog. For the MTM option, lathe tools do not have this
setting but instead have an Approach Side setting that works with the Insert Face Up

50
 Tool Creation

setting. Together these items specify from which side of the spindle the tool will approach
and cut the part, either the +X or –X side. From this data the system automatically
calculates the spindle direction. The actual cut side may be overridden in the Process
dialog. See “Insert Orientation” on page 52 for clarification.

Tool ID#: Tool ID # is used to specify a Tool Group position that is serviced by an ancillary
mill style tool changer. Enter the tool number you want loaded into a specific Tool Group
position.

Insert Face Up: This item is found in the Turning Insert Face Up Insert Face Down
Tool dialogs. This setting specifies whether an
insert is Face Up or Face Down in a tool holder. If
this item is unchecked the system assumes the
insert is Face Down. The selection made here will
toggle the tool display picture to show the insert
as Face Up or Face Down. See “Insert Orientation”
on page 52 for clarification on insert direction.

You should visualize a machine set up as if you are standing in front of it. We call
this view the Spindle 1 ZX Coordinate System Home View. This view is the same as
the trackball “T” or top view for MTM parts. Use this view to determine Cut Side,
T Insert Face Up and Orientation for all spindles. Do not use the specific spindles’ ZX
I CS Home View.*
P
*Unless you have an Orientation Spindle selection in the Tool dialog, which is
offered for some multi-spindle machines (as determined by their MDDs)

B Rotation: This item allows you to set the B-axis rotation needed to move the current tool
to the orientation specified in the tool dialog. This is only available in MDDs for machines
that have a B-axis capable turret with unusual tool arrangements.

Milling Tools at B0 are pointing at the OD of a part.

The B Rotation for a milling tool should be
determined solely from its orientation in the
machine at the GibbsCAM B0 position. For example,
the tool arrangement shown below includes an
endmill at B0 and a boring bar that is mounted
parallel to the endmill. These tools use the same ID#
but different offsets. The boring bar must have a B
Rotation of -90 to match the orientation designated in the tool dialog. The Super HiCell
has an arrangement similar to this.

51
 Tool Creation

A turret set at B0 is the standard turning orientation. Turning tools should be defined
as they will be used. First set the tool orientation as it is to be used (not as it is arranged
in the turret) and then set the B Rotation required to get the tool into position. Turning
tools may be at any arbitrary angle entered in the B Rotation text box. If both tool
arrangements shown below were to be used as boring bars, the second tool would need
to be rotated by -90˚ to get into position.

INSERT ORIENTATION
The orientation of a tool is very important to properly set up a tool. By default, all tools are
oriented to the main or primary spindle. That means that the tool orientation in the tool
dialog should be set to match the tool’s actual position when looking at the spindles from
the front of your machine.

Main Spindle Sub Spindle

This image shows tools that are oriented to 1 3

the Main Spindle. The tool’s selection in the Down Up
Tool dialog insert prientation diagram is as
shown below, either Face Down or Face Up.
The tool orientations are set as they actually
appear. Up Down
Main 2 4 Sub
Tools 1 & 4 are designated as Insert Face Spindle Spindle
Down. Tools 2 & 3 are designated as
Insert Face Up.

Tool 1 Tool 2 Tool 3 Tool 4

52
 Tool Creation

Advanced Machines Only

There are some machines and MDDs that 1 3
may allow an override of the typical behavior
for insert orientation. In the following image,
tools 1 and 2 are oriented to the Main Spindle,
while tools 3 and 4 are set with the sub
spindle being the orientation spindle. With
this arrangement the Tool Orientation
Main Spindle 2 4 Sub Spindle
diagram would be set differently. The tools on
the sub spindle need to be set as if looking
from the back of the spindle, the Home View of its ZX CS.

Tools 1 & 4: Are designated as Insert Face Down. Tools 2 & 3: Are designated as Insert
Face Up.

Tool 1 Tool 2 Tool 3 Tool 4

Please note that tool number 3 and 4 above are oriented the same as tools 1 and 2. All
four tools are oriented to point to the spindle they are cutting on.

This Orientation Spindle choice is only made available on complex machines.

SETTING CUT SIDE

When creating your part, it is possible to set up all of your tools without worrying about the
cut side of the tool. This is because toolpath is associative to the tool’s definition. If a tool is
first set to approach from and cut on the +X side of the part but then switched to approach
and cut from the –X side, the toolpath will automatically update to reflect this change.
Changing the tool’s Cut Side, Insert Face Up and Insert Orientation settings (as well as a
likely change in Tool Group) are required to flip the toolpath. This is illustrated in the
Auto-Flip tutorial.

MILL TOOL ORIENTATION

The orientation of a mill tool is a very important aspect in properly setting up a tool. By
default, all tools are oriented to the main or primary spindle. That means that the tool

53
 Tool Creation

orientation in the tool dialog should be set to match the tool’s actual position when looking
at the spindles from the front of your machine.

Main Spindle Sub Spindle

Milling tools are slightly easier to set up than turning tools because there are fewer
variations. There are only four positions — two each for horizontal and vertical. Please note
that the orientation specified is when the B-axis is zero. For machines with B-axis support,
the tool may be used in a range of orientations, and this is controlled by the Machining CS
setting found in Process dialogs.

Approach towards the face of the main Approach away from the face of the main
spindle. spindle or back side milling.

Approach from the +X side. Approach from the –X side.

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 Tool Creation

NEW TOOLS
LATHE UTILITY TOOLS
A new tool type called the utility tool will be used for utility processes such as move part
and move tailstock in/out, which may require a tool position. The tool is a non-cutting
place holder. It can represent a stop, probe, part gripper or dummy tool to help set up the
part. Utility Tools are used with Utility Processes. Not all Utility Processes need a tool, but
certain ones will, depending on your setup. Such a setup might be a bar feed with a stop.

55
 Tool Creation

56
PROCESSES
 Processes

CHAPTER 7 : Processes
This chapter discusses creating processes for parts made with Multi-Task Machining and
modifications made to the existing process dialogs for MTM support. As in other modules
of the GibbsCAM product line, toolpath is generated by setting up a process with a tool and
specifying where on the part the toolpath should be created. All of this is covered in the
Lathe and Mill manuals, and there is no need to discuss it here as the processes are
identical. The major topic of this chapter is Utility processes which are quite different from
regular, toolpath generating processes. Utility processes generate operations that allow you
to control other, non-cutting motions on your machine.

MACHINING PROCESS DIALOGS

Generating MTM processes is no different than defining processes for any other module.
Process parameters need to be defined including clearances, speeds, the type of cut to be
made and where to perform the cut. Turning operations are always performed in the ZX
plane and a machining coordinate system must be selected for milling processes. For MTM
there is simply a little more that needs to be defined, such as the spindle that a process will
be created on and the side of the part that the tool approaches from.

ALL PROCESSES
All processes (turning and milling) in the MTM module have a spindle selection pull-down
menu. This pull-down menu lets you set which spindle this process will be machined on.

LATHE PROCESSES
Modifications made to lathe process dialogs for the MTM module include the display of
what side of a spindle the process is to be performed on. There is also an override checkbox
to Cut Other Side.

The Cut Side is determined by the Cut Side selected in the Tool dialog. Toolpaths are
created on the cut side, unless the Cut Other Side box is checked. We will use an +X OD
tool as an example. Selecting the Cut Other Side item would allow you to use this tool to
cut the same OD but on the –X side. The spindle direction will automatically reverse. The
Process Cut Side is associative with the Tool Cut Side, if you change a tool’s Cut Side, the
toolpath changes sides automatically.

UTILITY PROCESSES
A Utility process is a process found in the Lathe Machining palette of MTM parts. The
Utility process provides the ability to program a number of new operations for loading/
unloading spindles, turning spindles on/off, controlling the tail stock, bar feed, and other
59
 Processes

miscellaneous operations on advanced lathes. Whether a Utility Op needs a tool is defined

by the MDD. The system will inform you if the Utility operation requires a tool.

Utility processes may create operations in many or all flows but no more than one
operation per flow. These are a multi-op Utility processes and they create post output in all
flows to which they belong.

UTILITY PROCESS SETTINGS

The options found in the Utility process dialog will depend on
your machine and MDD. The basic functions include the ability
to load and unload a spindle, shift a part in Z, move the sub
spindle on and off the part and to control a parts catcher. These
items are discussed in detail on the following pages. When a
process type (i.e. Load Spindle) has been selected, the icon in
the process list will change from a “U” to an icon that reflects
the process. Please note that items with the notation NO
TOOLPATH do not generate toolpath and cause the Tool Group to
retract to home.

Utility Process Common Items

Spindle: Each process type has a selection for either Spindle or Main Spindle. The actual
available choices will depend upon your machine and the MDD. This setting lets you select
which spindle the utility process will be performed on.

Main Spindle / Sub Spindle: Each process type has a selection for Spindle or Main Spindle.
The actual available choices will depend upon your machine and the MDD. This setting is
available in utility processes that involve multiple spindles. This setting lets you select
which spindle holds the part and which spindle will move to hold the part. The Main
Spindle setting is used for the spindle that holds the part, the Sub Spindle setting is used
for the spindle that will be moving.

60
 Processes

LOAD SPINDLE
The Load Spindle process
should be created at least once
in every part program, either at
the beginning or at the end of
the operations. The dialog
allows you to set which spindle
is being loaded, which Tool
Group is assisting (if any), how
far from the stop should the
stock begin feeding, and how
fast the stock will be moved.
The Type setting specifies the
Load method to be used. Only
types that are available on your
machine will be displayed. See
“Part Shift” on page 64 for
another Load option.

Load Spindle Type Descriptions

Manual Chuck: This item will pause the program to allow a new piece of material to be
loaded into the chuck. Opening and closing the chuck is done by hand. NO TOOLPATH

Auto Chuck or Collet: This item will pause the program and open the chuck to allow a new
piece of material to be loaded into the chuck. Opening and closing the chuck is
programmed. NO TOOLPATH

Bar Feed: This will use a bar stop, (typically a defined utility tool) with a bar feeder to
advance the bar stock for a new part. The stop will rapid close to the part face prior to
feeding, the collet will open, the bar stop will make a feed move out in Z+ to the new
position, and the collet will close. This process requires a Utility tool.

Auto Bar Feed: Stock feeds to a specified Z for a new part. NO TOOLPATH

Bar Pull: A bar puller, (typically a defined utility tool) works with a bar feeder to feed the bar
a specified distance for a new part. The spindle will be stopped. NO TOOLPATH

Sub Spindle Pull: This operation uses a sub spindle and a bar feeder to advance the bar for a
new part. The sub spindle must already be in, and the sub spindle must be unloaded.

Robot: This will use a robot to load a new piece of material into the spindle.

61
 Processes

Load Spindle Settings

Feed Distance: Enter the incremental Z distance to feed the stock (part off width + stock)

Feedrate: This is the rate at which the bar puller feeds on and pulls back or the rate at
which the bar stop or sub spindle retracts.

Grip Z: This is the Z position the bar puller will feed onto or the position at which the sub
spindle will grip the bar. The sub spindle will rapid or feed to this position depending on
the MDD.

Initial Face Z: This is the bar face position (in Z) before the bar pull or feed, left by the prior
cut off.

Spindle On: This checkbox allows you to specify whether the spindle is spinning (“On”) or is
stopped. If the spindle is on, you must specify whether the spindle is turning Forward or in
Reverse.

Spindle Speed: This is the speed in RPMs at which the spindle is spinning.

Time: This is the amount of time (in seconds) required for the Utility operation.

X Position: Enter the X value for the bar puller or bar stop

Z Clearance: Enter the Z position to which the sub spindle, bar puller or bar stop will rapid.
This setting is in part coordinates.

It is important to be sure that your Load Spindle data creates the initial
T spindle conditions described in the Document Control dialog.
I Specifically, the distance of the stock face from the spindle face is
P extremely important.

UNLOAD SPINDLE
The Unload Spindle process sets a post command to clear a spindle and dictates how to do
so. This is typically set once per program. For most setups, a flow and the spindle to unload
is selected. Additionally, the Type setting must be selected as appropriate for your machine
as well as the rate of travel and Feed Distance. This process is typically used with a Utility

62
 Processes

tool and may also control a part catcher. See “Sub Spindle In” on page 67 for another
Unload option.

Auto Chuck options

Part Gripper options

Unload Spindle Type Descriptions

Manual Chuck: This option pauses the program to allow for manual removal of a finished
part from the chuck or collet. Opening and closing the chuck is done by hand. NO TOOLPATH

Auto Chuck: This option pauses the program and opens the chuck to allow for manual
removal of a finished part from the chuck. Opening and Closing the chuck or collet is
programmed. NO TOOLPATH

Part Catcher: This option will position a Part Catcher, unload the finished part into the
catcher and withdraw the Part Catcher. This option is used when the part drops from the
spindle into a Part Catcher. NO TOOLPATH

Part Gripper: This option uses a part gripper to unload the part from the specified spindle.
This option will advance the Part Gripper (typically a defined utility tool), stop the spindle,
63
 Processes

grip the finished part, unload the spindle, and release the part in the specified location.
This is frequently used in conjunction with a Part Catcher, which is also programmed by
this Utility Op.

Robot: This option will use a robot to unload a finished part from the spindle.

Unload Spindle Settings

Grip Z: This setting is the depth at which the part gripper will hold the part. The gripper will
feed from the Z Clearance to this location.

Time: This is the amount of time (in seconds) required for the Utility operation.

X Drop: This setting is the X position from the origin, for the part gripper to rapid to for
dropping the part.

X Position: This item is the X setting for the gripper to move to when gripping the part.

Z Clearance: This setting is the distance from the part origin at which the gripper will stop
rapiding and will begin feeding to the part.

Z Drop: This setting is the Z position from the origin, for the part gripper to rapid to for
dropping the part.

Z Retract: This setting is the depth to which the gripper will retract when moving the part
from the spindle.

PART SHIFT
The Part Shift process is used to pull the stock out of the chuck by a specified amount to
perform work on areas that were inside or blocked by the chuck. Specify the spindle to

64
 Processes

work from to determine the flow the process will reside in. Additional settings will depend
on the method used to perform the part shift.

Sub Spindle Pull options

Bar Feed options

Shifting the part in Z does not automatically create a new coordinate system or a
T new origin. You will have to create and/or move geometry into the correct position
I for machining. Values such as the face clearance plane Z should be specified from
P the unshifted part origin.

Part Shift Type Descriptions

Manual Chuck: This option will pause the program for the operator to manually shift the part.
Opening and closing the chuck is done manually. NO TOOLPATH

Auto Chuck: This option will pause the program and open the chuck while the operator
shifts the part. Opening and Closing the chuck or collet is programmed. NO TOOLPATH

65
 Processes

Bar Feed: This will use a bar stop, (typically a defined utility tool) with a bar feeder to shift
the part by the specified amount.

Auto Bar Feed: This item will use the automatic bar feed function to advance the part by the
specified amount. NO TOOLPATH

Bar Pull: This item will use a bar puller, (typically a defined utility tool) and bar feeder to
shift the part by the specified amount.

Sub Spindle Pull: The sub spindle will be used to pull the stock out of the chuck and will
support the extended stock. The sub spindle will automatically match the Spindle On and
Forward/Reverse settings made for this process. The sub spindle should already be in when
programming this. See “Part Shift” on page 64 for information on this. NO TOOLPATH

Robot: This choice will use a robot to shift the part.

Part Shift Settings

Feedrate: If using Bar Feed, it is the rate at which the bar stop will pull back. If using Bar
Pull this is the rate at which the puller will feed on and pull back. If using Auto Bar Feed,
this is the rate at which the bar will be advanced. The rate is typically set at the auto bar
feeder, not in the G-code. This setting will be used to calculate the operation run-time. If
using Sub Spindle Pull this is the rate at which the sub spindle will pull back.

Grip Z: This setting is the depth at which the bar puller or sub spindle will hold the part.
The bar puller or sub spindle will feed from the Z Clearance to this location. The sub
spindle will rapid or feed to this position depending on the MDD customization.

Initial Face Z: This is the bar face position in Z from the origin left by the prior cut off, before
the part shift or pull.

Load: If the part is being shifted far enough so that there will be a new length of bar ready to
be machined after the part cut off, check the Load box.

Shift Distance: Enter the distance to shift the part in Z.

Spindle On: This checkbox allows you to specify whether the spindle is spinning, (“On”) or
is stopped. If the spindle is on, you must specify whether the spindle is turning Forward or
in Reverse.

Spindle Speed: This is the speed in RPMs at which the spindles are spinning.

Time: Enter the time the part shift will take.

66
 Processes

X Position: This item is the X setting for the bar stop or bar puller to rapid to.

Z Clearance: This setting is the distance from the part origin at which the bar puller, bar
stop or sub spindle will stop rapiding and will begin feeding to the part.

T If Auto Clearance is not active, the Master Clearance

I Plane (CP1) set in the Document Control dialog must be
P in front of the part’s maximum shifted position.

SUB SPINDLE IN
The Sub Spindle On Part
process can be used in several
ways including as a support for
the primary spindle when
machining. Sub Spindle In may
also be used as the first step in
transferring the part to a sub
spindle, typically after a cut off.
Specify the Main and Sub
spindles (these may be pre-
specified by your MDD), the
speed of the sub spindle, the Z
location to grab the part as well
as the distance from the part
face that the sub spindle will
begin feeding. NO TOOLPATH

Sub Spindle In Settings

Part in Main: If there is a part in the main spindle prior to moving the sub spindle in, check
this box. This is normally activated when moving a part from the main to the sub spindle

Part in Sub: If there is a part in the sub spindle prior to moving the sub spindle in, check this
box. This is only activated with a reverse transfer or if your machine has a “push out”
unload.

To perform a “push out,” both spindles would be checked as having the part and the
Unloads Spindle item should be checked. We assume the part is being unloaded from
the sub spindle. The tile will have a special red arrow signifying a spindle unload is part
of this Sub Spindle In. This should only be used for machines with this capability.

67
 Processes

Spindle On: This checkbox allows you to specify whether the spindle is spinning, (“On”) or
is stopped. If the spindle is on, you must specify whether the spindle is turning Forward or
in Reverse.

C Synced: Activating this checkbox will cause the spindles to synchronize their C-axis prior
to a transfer. This will allow for precise positioning of the part for milling operations. This
is used in situations such as drilling holes on the Main Spindle then transferring the part
and tapping the same holes on the sub spindle. If milling operations are not used or are not
related between flows, you may turn this option off.

Unloads Spindle: Selecting this item tells the system that you will be performing a push out
unload. If this item is not checked the part will not be unloaded.

T Performing a Push Out Unload requires that Part In Main, Part In

I Sub and Unloads Spindle are all active. If Unloads Spindle is not
P selected there is the chance of interference.

Spindle Speed: This is the speed in RPM at which the spindle is spinning.

Z Clearance: This setting is the distance from the part origin at which the sub spindle will
stop rapiding and will begin feeding to the main spindle.

Feedrate: This is the sub spindle’s feed rate towards the main spindle from the Z Clearance
to the Grip Z.

Grip Z: This setting is the depth at which the sub spindle will grip the part. Data entered for
Grip Z must match data set in the Document Control dialog. One way to check this is to
display the sub spindle geometry on the rendered image of the sub spindle being

68
 Processes

machined. Any mismatch indicates that Grip Z Data does not match Document Control
dialog data.
1. Part Length Spindle 1 10
Spindle 2
2. Spindle 1 Face
3. Spindle 1 Stock Face
4. Spindle 1 Z 0
5. Stock Face Z Geometry
6. Spindle 1 Face Stock
Allowance
7. Grip Z
8. Cut Off Clearance
9. Cut Off Width
Stock in the Part – cut &
10. Spindle 2 Stock Face
Chuck
11. Spindle 2 Z0
12. Spindle 2 Face Stock
Allowance

Check the Extras folder of 9

your GibbsCAM CD for an 12

interactive PDF of the above
graphic that will help you set
up your part’s values. 11

SUB SPINDLE RETURN

The Sub Spindle Return process
can be used to simply return
the sub spindle after supporting
a part or it may be used to move
the part to the sub spindle.
Specify the Main and Sub
spindles as well as the rate of
travel. If the spindle is
returning with the part be sure
to select that option. This will
allow rendering to display the
stock condition on the sub
spindle. NO TOOLPATH

69
 Processes

Sub Spindle Return Settings

Spindle On: This checkbox allows you to specify whether the spindle is spinning, (“On”) or
is stopped. If the spindle is on, you must specify whether the spindle is turning Forward or
in Reverse.

With Part: Check With Part if you want the sub spindle to take the part with it on returning.

Open Main Collet: Check Open Collet if you need to open the main spindle to move or
remove the part.

Main Loaded: Check Main Loaded if the main spindle is loaded with stock when the sub
spindle returns with the part.

The Double Pull. If you have programmed a Sub Spindle In, a Part Shift, a
T Cut Off and a Sub Spindle Return, you can have the system easily generate
I stock in the Main Spindle. Simply activate the Main Loaded option. Be sure
P that the Part Shift is twice the length of the part. This can be seen in the part
file Double Pull.vnc, found with the MTM sample parts.

Spindle Speed: This is the speed in RPMs at which the spindle is spinning.

Feedrate: This is the sub spindle’s feed rate when moving away from the main spindle after
passing the Clearance Z plane specified in the Utility process that moved the sub spindle in.

PARTS CATCHER IN
The Parts Catcher In process
lets you set the command to
bring a part catcher in during
an unload process. Specify the
flow and which spindle the
catcher is moving to. This is
typically used in conjunction
with an Unload Part and a Parts
Catcher In process. NO
TOOLPATH

Parts Catcher In Settings

X In Position: This item is the X
position from the origin for the
part catcher to move to for unloading the part.

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 Processes

Z In Position: This item is the Z position from the origin for the part catcher to move to for
unloading the part.

PARTS CATCHER OUT

The Parts Catcher Out process
returns the parts catcher.
Specify the flow and which
spindle the catcher is moving
from. This is typically used in
conjunction with an Unload
Part and a Parts Catcher In
process. NO TOOLPATH

Part Catcher Out Settings

X In Position: This item is the X
position from the origin for the
part catcher to move to for
unloading the part.

Z In Position: This item is the Z position from the origin for the part catcher to move to for
unloading the part.

MOVE TOOL GROUP

The Move Tool Group Utility process provides non-cutting positioning control over a tool
and its Tool Group. Typical uses are to move the tool to a location at which you plan to wait
(with a sync), temporarily change the location at which you want to change tools, or create
a sequence of moves to avoid an obstacle. A Move Tool Group operation overrides a
following tool change location with it’s position.

Concepts
Tool Change Locations: All tool change locations may be categorized as either a “standard
tool change location,” or an “MTG tool change location.” The standard tool change position
is defined by the MDD. This is potentially either Machine Home, a fixed position, or a user
defined position in the Document Control dialog, all of which are typically somewhere “off
part.” Conditions that trigger the automatic move to a Tool Change Location are:

• Tool position change (e.g. indexing a•
turret)
• Tool offset change, or turning offsets on•
• Op Program Stop
Spindle change (tool goes from S1 to S2)
Tool ID# change in the target position
(tool ID#s are used with mill style tool
changers)

71
 Processes

• Program Start at Home, before first• B-Axis rotations

operation
Users should make the standard tool change position the
T location that will be the most useful, i.e. the location that is used
I most of the time. The MTG utility process will be used for
P special conditions or overrides.

Move Tool Group Locations: A tool will go to a Move Tool Group (MTG) tool change
location if the operation occurs after an MTG operation. MTG operations simply move a
tool to a specified location. The user may specify this location to be with or without tool
offsets, depending on the settings used in creating the operation. MTG will typically be
used to take the tool to an off part location. The term “off part location” refers to a tool
position outside the normal clearances around the part being machined. The Move Tool
Group Utility operation allows you to select from three location options:

1. Machine Home location

2. The Standard Tool Change Location for this part

3. X and Z location of your choice

What the Move Tool Group Process Can Do:

• Move a tool to a location “off part.” Any location inside of Off Part
the stock boundary is referred to as “On Part.” If Auto
Clearance is not used, On Part is considered anywhere
within the Clearance settings in the Document Control On Part
dialog.

MTM will automatically move a tool to an Off Part

Location when any one of several conditions occurs,
such as a tool change. This automatic positioning move occurs between operations.
MTM will move the tool to the Standard Tool Change Location unless the preceding
operation is a Move Tool Group operation. If this is the case, the tool will not move to
the standard tool change position but will remain at the MTG location. MTM doesn't
need to move the tool “off part,” if the programmer has already done so with an MTG
op. All tool change location events will cancel tool offsets on their way to the tool
change location. A tool is moved off part when any of the following items occur:

• Tool position change (e.g. indexing a • Tool offset change, or turning offsets
turret) on
• Spindle change (tool goes from • Program Start at Home (before the
Spindle 1 to Spindle 2) first operation)

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 Processes

• No Path Utility operations • B-Axis rotations

• Op Program Stop • Tool ID# change in the target
position
• MTG operations override the next tool change location, including the starting position of a
Tool Group if an MTG operation is the last operation in a flow.

A very important detail to remember is the condition of Tool Groups at the start and
T end of a program. At the start of a program, Tool Groups are expected to be at their
I tool change location. At the end of a program all first tools are put into play and the
P Tool Group goes to the tool change position.

• An MTG operation will eliminate a following No Path Utility operation that would send a tool
to the Tool Change Position (for example, Sub Spindle On Part sends the Tool Group home)

Move Tool Group Settings

Standard Tool Change Location:
Selecting this item will move
the Tool Group to its standard
position for a tool change.

New Location: This item allows

for moving the Tool Group to a
position other than its standard
tool change location.

Xr & Z Settings: For both the

Xr and Z positions, you may
send the Tool Group to its
Machine Home position or
a User specified position.
Once a position has been
selected the reference coordinate system (CS) and Control Point settings must then be
selected. Machine Home is defined as the origin of the Tool Group coordinate system,
(which is defined relative to the Spindle 1 Machine Home) and each turret has a single
home position. This preset is a different location for every Tool Group on the machine.
The position is defined by your machine and is known to the MDD. User may be any
value relative to part or spindle coordinates.

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 Processes

CS Selection: This setting specifies whether the Spindle 1 Spindle 2

new location is based upon the spindle’s ZX
Chuck or Collet
coordinate system or the part’s ZX axis. The
Spindle ZX setting refers to values measured
from the Machine Home, which is the spindle Stock
origin (the face) of chosen spindle. The Part ZX
setting refers to values measured from the part User
origin as defined in the Document Control Machine Home
dialog. Machine Origin

Control Point Settings: This setting specifies whether the Tool Group control point or
the tool tip goes to the specified location.

Tool Group Datum: A single point per

Tool Group that can be Offset
represented or specified regardless
of tool position. The specified
point is what will go to the tool
change position. Offsets are Offset
measured from this point. The
following set of images illustrate possible Tool Group datum positions, a turret’s
Tool Group datum point could be on either side of the center of the turret or at the
base of the tool holder. The datum for a gang may be at a specific corner. This
option is recommended when the Tool Group will be sent far from the part. The
offset for each tool is measured from this point. Be sure that the Tool Group is far
enough from the part to ensure that there is no interference between the holders
and the part. Offsets are cancelled when using this option.

Tool Tip: If Tool Tip is selected, the Tool

Group will retract so the current tool’s
touch off point is at the specified location.
This is the recommended option if you
are working near the part as there is little
chance of interference. If the location you
have selected is very near the part you
should be aware of what tool is being used Touch Off Point
as this setting can over-travel.

74
 Processes

The following image is an

example of the difference
between selecting Spindle
ZX or Part ZX. There is a
part that is 100mm long
with the origin at the part
face. The Move Tool Group
process is set to retract by
125mm in Z along the
Spindle’s ZX axis and the
control point is the tool
tip. The net result is that
the tool will be 25mm from
the part face at the point 100
labelled “A.” If Part ZX was 125
selected as the reference 125
coordinate system the tool
would have retracted
further in Z, to the point labelled “B.”

Standard Interactions Around Operations.

Using the full potential of the Move Tool Group process requires an understanding of the
typical interactions of processes and tool movements. The following graphic shows the
normal interactions of processes and other movements on operations.

• Syncs are at the start or end of an operation, at the maximum clear position. The
maximum clear position is the position farthest away from the part given the operation.
This may be Machine Home, the Master Clearance plane or the Exit Clearance plane.

• At the start and end of operations, tools are located over the start or end point at a
clearance value, typically CP1. If two consecutive operations are on the same side of the
part using the same tool, the tool will be at CP3.

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 Processes

• Inter-operation moves (such as tool moves) occupy the time between ops and are
represented by gaps in the Sync Control dialog.
Sync at Start
OP
Sync at End Inter Operation Moves
OP
Tool Change Op Start = CP 1 Start Point or CP3 for ops that
OP are the same Tool on the same Side
Op End = CP 1 End Point or CP3 for ops that

• Tool Changes take place between operations as well. The Move Tool Group Process
allows you to create an operation that will provide you with alternatives to this.

Using the Move Tool Group Process

The Move Tool Group (“MTG”) process creates an operation
that is zero seconds in length and does not generate toolpath.
It can be thought of as a synching operation that lets you tell
the Tool Group to move. When the Sync Control dialog is in
Uniform View, you will clearly see the operation, but when in
normal view (time-based), an operation tile will not be visible,
but the operation number will be.

MTG is a “no path” operation. “No path” operations trigger a Tool Group retract. When a
No Path operation follows an MTG operation, the MTG process overrides the retract.
Utility processes that are “no path” are labelled as such in this manual for your
convenience.

Examples of MTG Use

• I want to have a tool wait close to the part

76
 Processes

You can have a tool wait close to the

part for another tool to begin or finish
cutting. This is the default behavior in
MTM when a sync is set. Other than
setting the sync, there is no work
needed to accomplish this. In the
following image, a tool that will face
the part is waiting for a set of drilling
operations to finish.

• I want to have a tool wait away from the

part

You can have a tool wait away from the part for another tool to begin or finish cutting,
providing a greater amount of clearance and safety. This requires a Move Tool Group
operation. Create a MTG process using the tool you wish to have wait and enter the
position at which you want the tool to wait. Place the MTG operation before the
operation that is to wait. Sync the start of the MTG operation to the end of the prior
operation. You will need to have the Sync Control dialog in Uniform View mode to sync
the MTG operation as it takes up no time and will only appear as a number in the
normal, time-based view. The following example shows a synced MTG operation and
the tool waiting away from the part. Once the drilling operation has finished and the
tool is retracting the insert will move in to face the part.

• I want to override a tool change position

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 Processes

A tool change
is something
that you
ordinarily do
not have to be
concerned
with. The
system handles
the retract to
the tool change
position, which
is specific to
your machine
and is known
to the system.
However,
should you wish to override that, the MTG Utility operation will let you do so. Create
the operations then add a MTG operation that is assigned the tool that will be
deselected, not the tool that will be used next. The MTG operation should be placed
before the operation that requires a tool change. Always remember that a MTG
operation affects the following operation. In the example below, we have created a
drilling operation followed by a roughing operation. Rather than have the drill retract
to the normal tool change position, we have specified that the tool move out by about
100mm to Z100 Xr0 and perform the tool change there.

If you were to use Tool 2 in the MTG operation you would get a very different result.
The drill would retract to the tool change position, the insert would be put into play,
the Tool Group would then move to Z100 Xr0 and then move in to the part.

• I want to change the locations a tool passes through when moving to a different spindle

As stated in the
Spindle 2
“Machining Standard TC location Entry clearance
Overview” chapter,
when a turret
performs a spindle
change, the tool will
Spindle 1
retract and pass
Custom TC
through the standard
tool change position Spindle 1 Spindle 2
of both spindles. You Custom TC Custom TC
can override this
using two MTG

78
 Processes

operations. One MTG operation must be created for each spindle. The MTG ops must
specify the points the tool will pass through. If only one MTG operation is made, such
as a custom location for Spindle 1, the tool will move to the standard tool change
location, and then move in to cut on spindle 2. See the part file “MTG Comparison.vnc”
for examples of this functionality.

• I want to delay the tool change when moving the turret to a different spindle

If a tool change 1. Spindle 1 Exit Position

occurs when 2. Standard Tool Change
moving a turret Position
to a different 3. Spindle 2 Entry Position
spindle, the 4. Spindle 2 Custom Tool
tool change Change Position
normally
occurs at the Normal
standard tool
change
location. To
create an
override that
will change
tools at the Custom
second spindle,
create an MTG operation. The MTG operation should position the first tool somewhere
around the second spindle. This will cause the tool to retract from the first spindle,
move to the standard tool change position, then move to the position you designate in
the MTG process.

• I want to start & end at Machine Home

At Program Start all Tool Groups go to the standard tool change position as defined by
the MDD. This is potentially either Machine Home, a fixed position, or a user defined
position in the Document Control dialog. At Program End, all Tool Groups go back to
the standard tool change position and the first tool is made active. By doing this, the
machine is prepared for the next run of the program as programs are essentially loops.

T Please note that G28s are supported, the tool goes

I to the standard position. However, G30s are not
P supported.

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 Processes

Because programs are loops

1 Tool Change
and are generally made to
cut more than one part, 1
programs can be thought of Tool Change
2 MTG 3 1
as being circular. Instead of
starting and ending your 2 3 1 Tool Change
program at the standard TC 2 Tool
location, you can have MTG 3 Change 3 2
start the program at 2 2
Machine Home. Simply 3
create an MTG operation set MTG 3 Tool Change
to Machine Home at the end Tool Change
of your operation list. Be
sure that the MTG operation is assigned the same tool that is used in the last operation.

You will not get the same result if you place the MTG operation at Operation 1, the
beginning of the operations list. Instead of starting and ending the program at Machine
Home, the program will start at the standard tool change position, move to the MTG
position (Machine Home), and then move to the first cutting operation.

Various MTG Results

Here we look at various results when making an MTG operation.

• Move a tool to the standard tool change position, perform a tool change and wait at the
tool change position until the next operation. This may be used to force a tool to wait
away from the part until an operation in another flow finishes.
1st Op
Tool 1
Sync start to
other flow
MTG
Tool 2

2nd Op
Tool 2

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 Processes

• Move a tool to a specified tool change position, perform a tool change and wait at the
specified tool change position until the next operation. Similar to above but the tool
changes and waits near the part.
1st Op
Tool 1
Sync start to
other flow
MTG
Tool 1

2nd Op
Tool 2

• Move a tool to a specified tool change position, perform a tool change, move the tool to
wait near the part for the following operation to begin. Similar to above except that the
second tool will move into its entry clearance position as soon as the tool change is
finished.
1st Op
Tool 1

MTG
Tool 2 Sync end
to other
flow
2nd Op
Tool 2

81
 Processes

82
OPERATIONS
 Operations

CHAPTER 8 : Operations
As in other modules in the GibbsCAM product line, Operation, or toolpath, are created by
generating processes. A turning operation in the Lathe module is really no different from a
turning operation in the MTM module except that the turning operation in MTM may be
cutting on the –X side of the part or on another spindle. Additionally, MTM operations may
be synched to another operation. Standard Lathe parts have only one flow of tools to worry
about. The order in which you see the operations in the Operations list is the order in
which they will be used. This is basically still true with MTM but there are more flows to be
concerned with and the timing of the operations is essential. The main focus of this chapter
is to discuss synching operations to help set the timing of an MTM part.

OPERATIONS LIST
Operation tiles in Multi-Task machining are very
different from the base GibbsCAM products. In addition Sync at start of the op
to displaying the Flow Number (typically the same as the
TG#), Tool Number, Tool Group Position and Spindle
being used in the operation, any and all Syncs are shown
on the tiles.
Sync at end of the op
Syncs are displayed as boxes in the top left or bottom left Master Utility operation
corners of tiles and they may be colored.

Uncolored Boxes: Boxes that are uncolored are Op syncs,

Stroke syncs, or Utility Data. Uncolored syncs at the top Slave Utility operation
left corner are syncs at the start of the operation while
uncolored syncs at the bottom left of a tile are syncs at
the end of the operation.

Utility Ops: Utility operations may have syncs in both corners. This is because many Utility
processes create two syncs, one for the start of the op and one for the end of the op. These
are System Syncs. The box at the top of a system sync is either blue or green. Blue boxes
state that the operation is a Master while a green box signifies that the operation is a Slave.

Utility processes often create multiple operations, signifying that the process spans
multiple flows, one operation being in each flow. Whenever a process creates operations in
more than one flow, one of the operations is flagged as the master. The master operation
contains information such as speeds and clearances for all of its slave operations. For more
information see “Utility Data” on page 93.

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 Operations

SORT OPS
The Sort Ops function in MTM sorts operations by flow and separates individual flows with
a space in the Operations list. The operations within the flows are also sorted by their order
within the flow.

OPERATION SYNCHRONIZATION
Multi-Task Machining lets you manage the run-time ordering of operations on multiple
turrets and multiple spindles by setting constraints on the start or end of operations. This
includes functions for creating, modifying and erasing synchronization constraints
between any numbers of operations from different Tool Groups. This is accomplished
through the Sync Control dialog. All sync information set in the Sync Control dialog will be
used, displayed and stored by the cut part rendering, post and optional Machine
Simulation to provide the correct run-time information about the program to the user.

SYNC CONTROL DIALOG

When it comes to synching and managing operations, the Sync Control dialog is your best
friend. This simple dialog is very powerful. It displays operation tiles sized according to
their individual run-times in the order in which they will be executed. The Sync Control
dialog allows you to add Op and Stroke syncs to your operations, edit the syncs, recalculate
cut times on one spindle to match another and easily modify when the operation will take
place. The dialog lists all available flows and the operations that are in the flows. The
operations may be selected and modified depending on the mode you are currently in. The
dialog also displays the current run-time calculation. The run-time will automatically be
updated with all modifications you make.

1. Uniform Tile 4. Spindle Mode 7. Checker

2. Sync Mode 5. Sync Controls 8. Zoom Time
3. Op Mode 6. Spindle Select 9. Recalculate
Figure 10: Elements of the Sync Control dialog

86
 Operations

One of the more complex aspects of some MTM machines is that they can do more than
one thing at the same time. These machines are literally running multiple G-Code
programs at the same time. The sync dialog graphically displays this for you. A Flow is
usually one Tool Group, more specifically, it is the program for one turret. The length of an
operation is its run-time. The gap between operation tiles is the time of the inter-operation
moves.

An operation begins with the tool over its cutting start point, at a clearance position. An
operation ends with its tool over its end point at a clearance position. The clearance
position may be specified or automatically calculated by the Auto Clearance option in the
Document Control dialog, just as in the standard Lathe module. The inter-operation moves
will include the moves to a tool change position and tool change tile as well as all rapid
moves.

UNIFORM TILE VIEW

The Uniform Tile view button switches the view between a real time scale and equal
sized tiles. This view can be useful when you have very small or fast operations.

MODES
At the top of the Sync Control dialog are three buttons, the Sync Mode, Op Mode and
Spindle Mode buttons. These buttons toggle the dialog between three states. The content
of the dialog does not change but the appearance and functions of the dialog change with
the mode. Each mode offers a different tile selection and functionality. Sync mode allows
you to create and delete syncs, causing ops to wait for other ops. Op Mode provides a real-
time view of your Operation list for program editing and reorganization. Spindle mode lets
you select which ops control the spindles. Each mode is detailed below.

87
 Operations

Sync Mode
A “sync” is an instruction in the G-code program telling one flow to wait for another. In
practice, all flows synced together will wait for the last flow to arrive. For example, a twin
turn machine has two turrets/Tool Groups and one flow for each of them. If we sync two
operations together, the first to arrive at the sync instruction in the G-code will wait for the
other TG to arrive at its corresponding sync point in its G-code flow. This is graphically
displayed for you in the Sync dialog.

Tile Selection: In Sync Mode, the top or bottom halves of a tile are selectable. You may only
make one selection per flow. Multiple selection in the same flow is disabled. The top half of
a tile selection represents the start of the operation. The bottom half of a tile selection
represents the end of the operation.

In Sync mode the Sync Control dialog is used to 1. Add Op Sync

add and edit Op Syncs and Stroke Syncs. Syncs 2. Add Stroke Sync
are set using the Sync Controls. The Sync 3. Clear Sync
Controls consist of three buttons, one for adding
Op Syncs, one for adding Stroke Syncs and one
for clearing syncs.

Op Sync: Operation Syncs (Op Syncs) let you synchronize operations in multiple flows.
You may “sync” the start or end of any operation to the start or end of an operation in
another flow. In fact, you may sync as many operations as you have flows.

To set a sync, select the ops and click the Op Sync button. When you have made your
selection, a blue line with pointers will be drawn, linking the operations. The small
triangle pointers on the blue line indicate whether the sync is to the start of the
following op or the end of the prior op. All run-time calculations are automatically
updated, and the tiles will shift position. It is that simple.

Op Start / Op Start Op End / Op End Op End / Op Start

To clear an Op Sync, select the side of the operation that it is synced to and click the
Clear Sync button. You do not have to select all the ops involved to clear a sync.
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 Operations

Stroke Sync: Stroke Syncs

let you synchronize the
individual strokes of
operations in multiple
flows. When the
operations are selected
and the Stroke sync button
is clicked, a black line is
drawn, linking the
operations and the Stroke
Sync dialog opens. Stroke Syncs are always applied to the start of operations no matter
how you select them. This causes the operations to start each stroke together.
Additionally, you can set the behavior of the operations through the following options.
To open the Stroke Sync dialog after it has been set, right-click one of the black arrows.

Wait at End: When selected, whichever tool gets to the end of a stroke first will wait
at the end of a stroke for the other tool to get to its end position. The tools will
retract and position to the start of the next stroke together.

Adjust Feed To End Together: The Feed rate of the operations will be adjusted so that
the tools maintain the dwells specified.

Neither Wait at End nor Adjust To Feed Together: The tools will simply start each
stroke at the same time.

Both Wait at End and Adjust Feed To End Together: The tools will start and end each
stroke at the same time and will feed at the same rate. While this may seem
redundant, it is not if a dwell was applied to one or both operations or one
operation is simply much longer than the other. This way the operations will always
end together, even if one must wait for the other to “catch up.”

Flow 1 & Flow 2 Start Dwell: Each operation may be given a specific dwell (in
revolutions) to wait before an operation starts.

Creating a stroke sync can have several effects on posted output. If a stroke synced
T operation is created with Canned Cycles, the Canned Cycle will not be output in the
I G-Code. CSS is not deactivated if used, but one of the operations will have to be
P given control over setting the CSS in the Spindle Mode setting.

89
 Operations

Op Mode
In Op mode the Sync Control dialog behaves just like
the Operations list, but in a time-based format that
shows Tool Groups and relationships between flows.
Operations may be selected and moved via drag and drop.
Double-clicking an operation will load the process and
right-clicking will bring up the Operations list contextual
menu. Everything you do in the Sync Control while in Op
mode will be reflected in the Operations list. Please note
that operations cannot be dragged across flows. You must
recreate the operation or change the tool group the
operation belongs to, to change the flow it is in.

Tile Selection: In Op Mode you select and deselect an

entire operation tile using standard Windows
modifiers (Single-Click = Toggle Selection,
Command-Click = Multiple Selection, Shift-Click =
Range Selection). Selected tiles are shown highlighted
in both the Operation List and the Sync Control dialog.
You may use both lists at the same time,
interchangeably. The following image illustrates
multiple, disjunct operations selected in the Sync
Control and thus selected in the Operations list.

Spindle Mode
Spindle mode allows you to specify which Flow has control over a spindle. This is used
when more than one Tool Group will be cutting on a spindle at the same time. This
includes RPM, direction and C-axis for milling. When in Spindle Mode the Spindle
Selection button becomes active. This button cycles through the available spindles, letting
you set each spindle individually.

When in Spindle Mode, any operation being performed on the spindle is available for
selection, while operations that are not being performed on the spindle are grayed out. In
Spindle Mode you select and deselect an entire operation tile using standard Windows

90
 Operations

modifiers, (Single Click = Toggle Selection, Command Click = Multiple Selection, Shift
Click = Range Selection).

Figure 11: Comparison of setting controlling operations in

Spindle Mode

When operations in two separate flows are cutting on the same spindle there may very well
be a conflict in RPM or direction set by the operation. If nothing is set there will be no
spindle commands output. To give an operation in a flow control over a spindle’s RPM,
simply select the operation and ensure that any operation cutting at the same time is
deselected. Then click the Recalculate button.

You could give an entire flow the priority over setting RPM this way. If overlapping
operations are selected, both flows will output spindle commands with random results.
This is not recommended.

You should pay careful attention to which flow has control over a
T spindle’s speed. If a tool is cutting deep and spindle control is
I given to a different flow the sudden change in RPM could damage
P the tool and/or part.

CHECKER
The Checker is a means of manually running a check on operations in MTM parts.
The checker will look for conflicts in operations, (trying to turn and mill at the same
time for example), bad syncs and conflicts in RPM settings. Conflicts in RPM settings can
occur when more than one Tool Group or Flow is machining a spindle at the same time. If
the operations were created with different RPM settings, as is common with roughing and
drilling operations, the system needs to know which operation has control over the RPM of
91
 Operations

the spindle. A check is done every time you open the Sync Control dialog. This button
allows you to check your work. Dragging operations that are already synced can result in
crossed syncs. This is one type of error the Checker looks for.

TIME SCALE
The Time Scale is a set of blue arrows, one to expand the flow time line, the other to
compress the time line. All operations within each flow will be proportionately
stretched to make viewing the time line easier. When the Sync Control dialog is
closed and re-opened, the time line will automatically scale to fit within the dialog.

Do not close the Sync Control dialog if you wish to maintain the
T current Time Scale. Doing so will recalculate the Time Scale to fit the
I current operations the next time the dialog is opened. Try minimizing
P the window to minimize onscreen clutter and maintain your current
Time Scale.

Sync Preferences
Right clicking on the Sync Control title bar allows you
to open the Sync Prefs dialog which controls how much
and how fast the time scale changes.

Delay Time: This item controls how fast the zoom action
works. A “tick” is 1/60th of a second so the default value
of “5” will cause the scaling function to occur 12 times
each second.

Scale: This item controls how much of a change occurs to each operation with each click.

RECALCULATE
The Recalculate button looks like a clock. This button is used to apply any changes
you have made that may affect cut times. The system will automatically recalculate
many things but not everything.

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 Operations

FLOW DISPLAY
The flows are represented with all of the operations within
each flow with a time line to the left of the flows. Items within
the flows are selectable and, depending upon the mode you are
in, have different functions. Each tile represents an operation
and the amount of time that operation takes, including all
movement between CP1 and the start or end points. The space
between tiles represents the time required for a tool change
and inter-operation moves. The operation tiles will then
account for the time for all movement from CP2, all the feeds and rapids needed to cut the
part and the move out to CP3.

FLIPPING OPERATIONS
A very powerful feature of MTM is that there is no “right” way to make your part. Different
people will set up their part geometry for a multi-spindle part in different ways; some may
make all of the geometry on one spindle and then move it to a sub-spindle, others may
create the geometry from scratch on each spindle. Even moving the geometry from spindle
to spindle can be performed numerous ways. The same is true of operations, that is, the
part can be programmed in different ways. One of the functions that allows this flexibility
is the associativity between tools and operations that allows you to “flip” the operation. The
associativity will automatically update the cut side of an operation’s toolpath depending on
the tool setup. If you change a tool’s definition to cut on the –X side instead of cutting on
the +X side, the operation will automatically reflect this. For more information on flipping
an operation, see “Setting Cut Side” on page 53.

UTILITY DATA
All operations may have Utility Data
manually added that will be output in
the post, such as a stop command. It is
highly recommended that you do not
change the Utility Data automatically
created, such as sync keywords. A
mistake made when changing this data
can cause critical errors in the program
and potentially cause serious damage
to the machine. All data in these Utility
Data dialogs is customized for each
MDD. The data shown below may not
appear in your MDD.

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 Operations

Op Comment: A comment you may enter about the operation that will display in the posted
output. For example, enter “Start of Sub Spindle In” at the beginning of a Sub Spindle In
Utility operation.

At Op Start: This number is the internal sync number at the start of a sync. This is used to
keep track of syncs. Do not edit this data. Making an edit to this data that is not correct can
cause catastrophic machine errors.

At Op End: This number is the internal sync number at the end of a sync. This is used to
keep track of syncs. Do not edit this data. Making an edit to this data that is not correct can
cause catastrophic machine errors.

Go To Master button: This is found on slave Utility operations. This button will bring you to
the Operation Data for the master Utility operation.

94
RENDER CONTROL
 Render Control

CHAPTER 9 : Render Control

Visually verifying a part and its operations is critical, especially in MTM. This is done
through Cut Part Rendering. Rendering fully supports Multi-Task Machining functions,
from displaying multiple spindles and Tool Groups to accurate tool rendering and retracts.
Additionally, with Multi-Task Machining, the Render function has been expanded to
include additional features including modifications to the Render Control palette.

Rendering displays the stock condition on all spindles as it currently exists in run-time. If a
spindle has stock, the stock condition will be displayed. If there is no stock on a spindle,
such as before a load or after an unload, stock will not be displayed. Because the system is
part-centric, the actual movement of a part from spindle to spindle is not shown, simply
the stock’s presence and condition.

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 Render Control

STOCK DISPLAY
Multi-Task Machining parts accurately render the stock conditions of all spindles. When
stock is moved from the primary to a sub spindle, the stock shown on the sub spindle will
accurately display the end condition of the stock from the primary spindle. This includes
any milling operations performed on the part. What is not rendered are the results of any
tapping or threading operations.

Figure 12: Example of initial stock on the primary spindle (1), the final condition of
the stock on the primary spindle (2) and the initial condition of the sub
spindle stock after a part transfer (3).

To show stock, a spindle must have some sort of a load command, in the form of a Utility
operation. The one exception is if a spindle is designated as “Preloaded” in the Document
Control dialog, (see “Initial Condition of the Machine When Starting a Program” on page 21
for more information). To create operations, or even to run operations on a spindle, the
spindle does not need to have stock explicitly loaded. This may seem odd at first, to have
tools running on a spindle with no stock, but on a first run of a part, a machine likely does
not have any stock on the Subs Spindle. If you think there should be stock displayed and
none is displayed, it is likely to be because of a lack of a Utility operation loading or
unloading a spindle, an incorrect Utility operation or a lack of checking “Initial Stock” or
“Pre-Loaded.”

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 Render Control

RENDER CONTROL PALETTE

The Render Control context menu offers several ways
to display information on the part currently being
rendered. The palette can display the current run-
time or the number of the current operation in the
selected flow. Additionally, the rendering can
automatically be stopped before a Load or Unload
Utility operation occurs.

Set Op Stop #: The guess work can be taken out of

stopping cut part rendering at a specific location.
Selecting the Set Op Stop # command allows you to
set a point before which the rendering should stop.
Rendering will stop at the end of the operation before
the number specified in the dialog. This is activated
and deactivated by the Use Op Stop option.

Use Op Stop: Selecting the Use Op Stop option will cause Cut Part Rendering to stop before
the operation specified in the Set Op Stop # dialog. If this option is not active, the Set Op
Stop # is ignored.

Stop before Load/Unload: Selecting this item will cause Cut Part Rendering to stop
rendering the part before a Load or Unload Utility operation as well as before any part
transfer. This function is very useful for seeing the end condition of the stock on a spindle
before the final unload.

Show Time: When active, the Render Control palette will display the current program run-
time location instead of the current operation number.

Show Flow #: This function may be used instead of Show Time. The user may choose to
show operation numbers within a specific flow instead of the program run-time. Because
operations on different spindles can overlap, the user must select which Flow’s operation
numbers are to be displayed.

99
 Render Control

100
POST PROCESSING
 Post Processing

CHAPTER 10 : Post Processing

Post Processing with the Multi-Task Machining option is more specific than the standard
GibbsCAM system. Instead of being able to post a Mill VNC part with any mill post
processor, MTM parts are very specific to their MDD and matching post processor. The
post for each machine is custom made to match a particular machine and its capabilities.
When re-posting to a different MTM machine, it is recommended that you first change the
MDD to the appropriate machine and check the VNC carefully.

Machine Type from the

Document Control dialog

Post Selection from the

Post Processing dialog

Figure 13: Examples of a machine-specific MDD and Post Processor file.

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CONCEPTS
GibbsCAM, in general, offers a standard interface for a machine type that is unconcerned
with the specifics of one model of CNC. Instead, the user learns and programs in
GibbsCAM standard axes, axes polarities, coordinate systems, orientations, and terms.
With a single standard interface, the post processor is responsible for translating from
GibbsCAM standards into specific machine formats. This provides a high level of
interchangeability between machines. A mill or lathe part can be posted for a wide variety
of machines without reprogramming. A new programmer needs to be taught only one
standard to be able to program a variety of machines. An experienced GibbsCAM
programmer can program a new machine without learning a new standard. This is the
GibbsCAM interface philosophy, develop a single standard to support an entire class of
machines.

Multi-Task Machining causes a new set of problems with an incredible new level of
machine variation and detail to be handled. Time is an incredibly important factor in
MTM. In MTM time requires an accurate definition of things that move. These things are
machine specific and time must be exposed in the interface. Additionally, there are
machine-specific details which must be supported. These details are typically supported
with Utility operations. MTM adds new MDD capabilities to accommodate these
complexities. While this new format greatly complicates file interchangeability, the
fundamental GibbsCAM interface philosophy is unchanged. MTM represents a single
interface in GibbsCAM standard terms. Every XYZABC value is entered in GibbsCAM
standard orientation and polarity. While they will correspond to a specific machines
physical orientation, they will ignore machine specific orientations and polarities. A user is
always entering GibbsCAM standard values.

MTM posts require no editing from the user. All features found in a machine are fully
supported by the MDD. Minor changes made to a post for a specific machine by Gibbs and
Associates may be made for individual clients (such as adding polar interpolation), but this
should be set in the parameters when a post is first made. When MTM is purchased, all of
the information on the machine and many of the user’s post style preferences are collected
and implemented.

POSTED OUTPUT
MTM programs typically have multiple flows. How the flows are output will depend on
your machine. G-code programs for each flow may be contained in one file or separate files,
depending on the machine.

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POST PROCESSOR DIALOG

The functions of the
Post Processor dialog
are largely unchanged
from earlier versions of
the system The MTM
Post Processor dialog is
essentially the same as a
Lathe or Mill/Turn Post
Processor dialog.

Selected Ops: Selecting

this option will output
only the operations that
are currently
highlighted in the
Operations list. 1. Post Processor selection 3. Post text window
2. NC file name 4. CNC communication
Starting Program
Number: This is the starting program number for post processor formats that use a program
number. This data will be ignored if the post processor does not label the output.

Sequence Numbering: These items specify the starting sequence number and the value by
which the number will be incremented. This is used to number the lines of output used on
most CNC formats, commonly referred to as an “N” number. Values of 1 and 1 would
increment the lines by N1, N2, N3, etc. while values of 5 and 10 would increment the lines by
N5, N15, N25, etc.

Minimize Line Numbers: This option will cause the post to only use “N” numbers with
tool changes and canned cycles as required, not on every line. This will not be used by
some post processors and will vary on others.

Output: Posts automatically default to generate the post in the units defined by the part.

Insert Comments: When active, this option will cause the post to place tool and operation
comments in the output file.

Insert Optional Stops at Tool Change Positions: When active, this option will automatically
place optional stops (typically an M01) at each tool change position.

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POST NAMES
Multi Task Machining post names use letters to signify their capabilities. The designation
specifies the post's capability. Following the letter designation is a unique number for this
post.

The general format of a post can be described as shown below. A metric post will end with
an “m”.

<control name><machine name>[client initials]<letter>###.##.pst

A post for a Fanuc 18i running a Hardinge Conquest Twin Turn may look like the following
example.

Fanuc 18i Hardinge Conquest TT 65 (VG) NIAML.1150.22.6.pst

The following is a description of how Multi Task Machining Posts are named and what they
do. Also included are brief explanations of code issues that might be encountered in Multi
Task Machining Posts.

A Multi Task Machining post supports both milling and turning operations in the same
part. A 2-axis lathe post is no longer needed if a Mill/Turn post is available.

LABEL DEFINITIONS:
A description of each label is presented here, followed by an example of the use of most
labels.

AML: This designates a Multi Task Machining post.

S: This designates a Multi Task Machining post that segments rotary arcs into linear moves.

Fanuc 16T [VG] SML800.19.pst

I: This designates a Multi Task Machining post that supports Polar and Cylindrical
Interpolation. A Polar and Cylindrical Interpolation Mill/Turn post will output a G2 or G3
with rotary moves.

Fanuc 16T [VG] IML800.19.pst

Y: This designation is for a 4-axis Multi Task Machining machine that has a linear Y-axis.

Fanuc 16T [VG] YIML800.19.pst

Fanuc 16T [VG] YSML800.19.pst

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P: This designates a C-axis positioning post. A Multi Task Machining positioning post will
rotate the part and then move in X and Z. It will not rotate and cut simultaneously.

Fanuc 16T [VG] PML800.19.pst

N: This designates a Multi Task Machining post that does not use subprograms. This is
known as a “Long Hand post”. Subprograms are frequently used for multi-process drilling,
C-repeat drilling, Z-repeat milling, C-repeat milling, Patterns (OD only), etcetera.

Fanuc 16T [VG] NSML800.19.pst

Fanuc 16T [VG] NIML800.19.pst

B: This designates a B-axis rotation post. This supports the creation of coordinate systems
that has the tool rotate about the B-axis.

Super Hicell 250 HS [JMC] BSML1082.19.7.pst

CODE ISSUES:
• Tool Orientation

• When using a mill tool on the Face or OD, it is important to define the orientation
of that tool correctly. When Milling or Drilling on the face, make sure the
orientation of the tool is perpendicular to the face. When Milling or Drilling on the
OD, make sure the orientation of the tool is perpendicular to the OD. If the tool is
not oriented properly, the output will not be correct.

• C-Axis And Y-Axis Output

• The radio buttons Position and Rotary Milling in the Rotate tab determine whether
C-axis moves or Y-axis moves are output during Rotary Mill operations. If the
Position radio button is selected, the system calculates Y-axis moves. If the Rotary
Milling radio button is selected, the system calculates C-axis moves.

1. If your machine does not have a Y-axis, then you need to select the Rotary
Milling radio button.

2. If your machine has a Y-axis, this capability can be added to any Mill/Turn post.

• Rotary Feedrates

• Most rotary feedrates are calculated in Degrees Per Minute per rotary segment
based on its length. Since the length of each segment is variable, the system outputs

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a different feedrate for each segment. The resulting rotary feedrate can be a large
value based on the Degrees Per Minute calculation.

1. Certain CNCs, such as Haas and Mazak, calculate rotary feedrates using Inverse
Time. Any Mill/Turn post can be modified to use Inverse Time for feed rates.

Polar Interpolation posts use inches per minute for rotary feed rate calculations. Any Mill/
Turn post can be modified to use Polar Interpolation with inches per minute feed rates.

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PART CREATION
 Tutorials On Part Creation –

CHAPTER 11 : Part Creation Tutorials

This section is intended to help you learn how to set up and create part geometry. As the
variety and arrangements of machines are so great, the tutorials in this manual are
created using special training MDDs. These MDDs are incapable of posting but
accurately represent a dual-spindle, dual-turret machine and a swiss-style machine with
2 spindles, 2 turrets and a fixed post. Please use these MDDs as you may find that the
MDD for your machine has a very different setup and you may not be able to complete
the tutorials with it.

Please note that the background color and several elements of many of the graphics have
been modified for maximum image clarity. The background color on your screen will
always be black.

PART SET UP
In this exercise we will introduce you to setting up a part. We will make a very simple
part but will go into detail on the various elements.

Tutorials
• Create a new part file
named “Dual Spindle.”

• Open the Document

Control dialog.

• Select the Training Twin

Turn MDD.

This is a basic two-turret, two-spindle

machine.

Don’t worry if your MDD has more than two spindles and/or turrets. When
programming a part you do not need to take advantage of all of your machine’s
capabilities. In this case we simply won’t be needing all those axes.

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 Tutorials On Part Creation –

If, however, your machine has one spindle this particular exercise has minimal
benefit to you. Machines with a single spindle are very easy to set up in MTM. You
should follow along in the exercise and simply skip over what you cannot program.

SPINDLE SETUP
• Enter the following parameters
for Spindle 1.

We should discuss these settings

in detail. First of all, we are
programming the part using a
diameter measurement. We’ve
stated that there is Initial Stock,
meaning this is the spindle that
will begin working from uncut
stock. The Preloaded box is
checked, meaning that the
machine has stock loaded. There
will not have to be a command to
load stock. Essentially we are
telling the program, “Don’t worry
–

about it, trust me, there will be

stock to cut, I’ll take care of it myself.”

The stock diagram has a lot of important information, including that we are defining
the stock on Spindle 1, the stock is 2" in diameter and the part is 3.2" long. How do we
know this? Easy. What is the total distance in Z? The –Z value is –3.1" and the +Z
value is 0.1." Thus the total length is 3.2." We have also specified that the face of the
part sticks out from the spindle by 3.5." This means we have 0.3" of bar stock sticking
out of the spindle. When we feed the bar for the next run of the program, we feed out
approximately 3.2", depending in the width of the cut off tool.

While the setup shown above may at first appear to have the part floating in space
away from the spindle face, we should remember that these values set up the stock
display size, not just the actual stock size. These values have been set to contain the
part and any material to come off the part face. The extra 0.3" could be added to the –
Z value but is not necessary and in many cases is undesirable. It is undesirable
because of the size of the stock when unzooming the part.

The Auto Clearance and Tool Change settings are not our primary concern right now
as we are only concerned with setting up the part and not defining machining
parameters. You may either leave the values at their default or enter the following
values.
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 Tutorials On Part Creation –

• Click the Spindle selection button to change the Document

dialog to setting up Spindle 2.

The DCD should display Spindle 2’s initial set up as being identical to Spindle 1’s. This
is convenient if you are cutting multiple parts at the same time on separate spindles.
This will need to be changed to accurately reflect the part’s condition after being
transferred from the primary spindle.

• Enter the parameters for

Spindle 2 as shown.

Again, we should discuss these

settings in detail. The Radius and
Diameter radio buttons are still
available. You cans still change
this setting, but all spindles will
be programmed using the same
measurement system.

For Spindle 2 we’ve stated that

Initial Stock is off, meaning that

–
there is no stock on this spindle
and at some point a transfer will
be made. Because there is no
stock, the Preloaded box is not
needed.

When Initial Stock is turned off the stock diagram changes dramatically. The +Z and
–Z text boxes are removed because they are no longer needed. These settings are no
longer needed because we are only concerned with the amount that sticks out of the
sub spindle from the pick off. The values remaining are asking you to define how far
the part sticks out from the spindle and how much stock is on the positive side of the
origin. This part of the part setup needs to be carefully considered.

In this case we’ve specified that 0.85" sticks out from the spindle. Our finished length
part geometry is exactly 3.0" long. Assuming that 0.1" gets faced off on Spindle 1 and
0.1" is removed during the cut-off, we have a part that is 3.0" long. By specifying that
the part sticks out by 0.85" we are implying that the chuck is holding the rest of the
part and the part is picked off at Z–2.15". This information is important when setting
up a part transfer.

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 Tutorials On Part Creation –

Sometimes when setting up a part, you may wish to change this setting during or
after your machining has been created.

The remaining data, Tool Change and Auto Clearance may be skipped for the time
being. As for the Graphic Part Face Distance setting, we’ll get into that next.

• Close the Document Dialog so you can see all of the Workspace.

Both spindles are

visible. The
default distance
between the
origins of the
spindles is the
scaled distance
in your MDD.
This distance can
be visually
changed with the
Graphic Part
Face Distance
–

setting.

Spindle 1 Spindle 2
• In the
Document dialog, click the Graphic Part Face
Distance checkbox and enter the value shown.

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 Tutorials On Part Creation –

Now that the

spindles appear
larger on screen
you will have an
easier time
working with
them. This
function acts only
as a change in
display. The
actual distance
between spindles
is a fixed value in
your MDD and is
defined by your
machine.

When a part is
created, the system

–
generates one or
four coordinate
systems for each
spindle. If you have
Lathe and Multi-
Task Machining the
system creates one
coordinate system
per spindle, the ZX
plane. Note that the
depth of the CSs
project out towards
the other. The
negative depth of
the ZX axis is always
toward the spindle face.

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 Tutorials On Part Creation –

If you have Mill/

Turn and Multi-
Task Machining the
XY HY backside
system generates
four Coordinate
Systems — the ZX,
XY, HY backside
and YZ planes. The
XY, HY backside
and YZ planes are
shown in the
following set of YZ
graphics.
–

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 Tutorials On Part Creation –

GEO CREATION & ARRANGEMENT

In this exercise we will create geometry
in the part from Exercise 1 and transfer
it to the sub spindle. For those with a
single spindle machine, this exercise
can be seen as a review of how to create
and modify geometry.

The part we will make looks like the

following image. Don’t worry if you do
not have Advanced CS or Mill/Turn
functionality to complete the milling
features of the part, because the
exercises are designed with this in
mind.

• Use the part print “Main Spindle”

on page 223, create the geometry
in CS1, the ZX plane.

–
When using the Multi-Task
Machining product it is often
convenient to have geometry on both
sides of the part’s centerline. This is
particularly convenient when
performing –X side machining. While
you can select geometry on the +X
side, the toolpath will show up on the –X, thus it is good to have geometry to
compare the toolpath against. There is an example of this in the machining tutorial
section.

• Select the geometry (Ctrl-A).

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 Tutorials On Part Creation –

• Duplicate And Mirror the geometry about the Xd at 0.

We will now copy the geometry to the sub spindle.

• Select and duplicate all of the geometry (Ctrl-A, Ctrl-D).

Having the geometry for both sides of the part can be very helpful, especially
T when creating operations that cut on the –X side of the part. Having geometry
I on both sides of the center line allows you to actually set the machining markers
P on the –X side in addition to comparing toolpath against part geometry.
–

You now have two overlapping sets of geometry: the original, which is unselected and
the duplicated geometry, which is highlighted.

• Open the CS list.

• Select the ZX plane as the target spindle from the

CS list.

Changing coordinate systems changes the color of the

geometry in Spindle 1’s ZX plane. Geometry that is
magenta (pink) is in a non-current coordinate system
but is still in the same workgroup.

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 Tutorials On Part Creation –

• Choose Modify > Change CS (HVD) (Ctrl-\).

The Change CS (HVD) command moves and aligns currently selected geometry to
the current CS. The geometry is placed in the target CS at the same position relative
to the target CS’s origin as the geometry was in the original CS. In other words, if the
geometry is a point at Z-1, X1 in CS1, it will be placed at Z-1, X1 in the target CS.

The duplicated geometry has now been moved to the ZX plane of the target spindle.

The geometry is mirrored and now needs to be flipped to align the geometry
correctly.

• Choose Modify > Mirror and mirror the geometry about Z0.

This has flipped the geometry over so that it is facing the correct direction, we will

–
now translate the geometry into place.

• Choose Modify > Translate.

We will now interrogate the Z value of a geometric element that is supposed to lie at
Z0.

• Interrogate the Z
coordinate (Alt-click) of
the point shown.

• Change the interrogated

value to a negative value.

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 Tutorials On Part Creation –

• Click the Do It button.

The transferred geometry is now aligned properly.

SUB SPINDLE GEOMETRY

This part of the exercise will modify the current part file to add on backside geometry. In
making these modifications we will be working in a different coordinate system than you
may be accustomed to. Despite this, you will find that this is no difference than working
in the standard ZX plane.

We need to make modifications to the

part file. We will be defining the ID
geometry as shown in the cutaway view
of the part below.
–

We need to modify the geometry that

was duplicated and moved to the sub
spindle. We do not need the part profile
that is on the -X side of the sub spindle.

• Switch to the Home View

(Ctrl+H).

The Home view changes the current

view to be looking down the depth of the current CS. This flips your view of the part
so that the sub spindle is on the left and the main spindle is on the right. Your view is
now from the back of the machine.

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 Tutorials On Part Creation –

• Delete the geometry on the -X side of CS5: ZX plane - S2: Spindle 2.

• Use the part print “Sub Spindle” on page 224 to create the geometry for this
exercise in CS5, the ZX plane.

–
• Duplicate and mirror the geometry about X0.

The geometry for the part is complete. Save the part as Dual Spindle.vnc.

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–

122
TOOLING TUTORIALS
 Tutorials On Tooling – Basic Tool Set Up

CHAPTER 12 : Tooling Tutorials

This section of the manual instructs you on the creation and setup of tools for the Multi-
Task Machining system. There is a total of three exercises. The first exercise is for a single
spindle, dual turret machine. The second exercise is for a dual-spindle, dual-turret
machine. The last exercise is for a swiss-style machine. The first two tutorials are created
using the generic Multi-Task Machining MDD called Training Twin Turn (2T-2S). It is
recommended that you go through all of the tutorials, even if you do not have a machine
that matches the tutorial’s description. Each of these parts will be used in the “Multi-
Task Machining Tutorials” chapter. You may either complete all of the tooling tutorials
and then work on the machining exercises or you may do a tooling tutorial then move to
the matching machining exercise.

BASIC TOOL SET UP

In this exercise you will be introduced to setting up tools for Multi-Task Machining
parts. In this exercise we will create a part that is machined on a single spindle, dual
turret machine. We will start with a part file that already has geometry. We will be

Tutorials
creating six tools for OD and ID turning as well as OD milling. Once the tool creation is
complete we will machine the part (“Single Spindle Part” on page 151).

• Open the part file named Single

Spindle.vnc.

If you do not have the part file you

may create it using the geometry
found in “Single Spindle Part” on
page 225.

Pay careful attention to the tool

orientation diagram and the Tool
Group selection. if a tool is pointing
down it will be in the upper turret
and if it is pointing up, it will be in the lower turret.

Upper Lower

• Open the tool list.

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 Tutorials On Tooling – Basic Tool Set Up

TOOL GROUP 1
• Double-click space #1 in the Tool list to create a new tool that will be used to
face the part.

Face Tool
• Create Turning Tool #1 as shown.

The tool is assigned to Tool Group 1, is

in the first position and is aligned to the
primary spindle. The tool will be cutting
on the +X side of the part and since the
spindle runs counter-clockwise, the
insert is Face Down. The insert
Orientation is set to use a horizontal
Tool Group 1 – Face Tool

toolholder and the insert is set to cut

down.

The tool diagram shows the insert on

the backside of the tool holder because
the tool is face down.

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 Tutorials On Tooling – Basic Tool Set Up

Face Drill Tool

• Create Milling Tool #2 as
shown.

This drill is set to drill the face of

the part. The drill is in Position 2
of Turret 1 and aligned with
Spindle 1.

We will now create a tool that

will be used for ID roughing and
contouring.

Tool Group 1 – Face Drill Tool

• Create Turning Tool #3 as
shown.

We will now create a tool that will be

used for ID roughing and contouring.
This tool has a similar setup to Tool 1 but
the insert is at the top of the holder.

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 Tutorials On Tooling – Basic Tool Set Up

TOOL GROUP 2
OD Roughing
• Create Turning Tool #4 as shown.

This tool will be used for OD

roughing. This is the first tool we have
defined in Tool Group 2 and is in
Position 1. This tool is set to cut from
the –X side of the spindle. Because the
tool is cutting on the –X side, the
Insert is Face Up.
Tool Group 2 – OD Roughing

• Create Turning Tool #5 as shown.

This tool will be used in a Material

Only OD Roughing operation.

This tool is in the second position of

TG2. The set up is identical to Tool #4,
the tool is cutting on the –X side of the
part and is Face Up.

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 Tutorials On Tooling – Basic Tool Set Up

OD Groove and Finish

• Create Turning Tool #6 as shown.

This groove tool will be used to cut the

grooves and finish the part. The tool is
set to cut from the bottom of the part
but will cut from the back of the part.
We will now organize the Tool list.

Mill Turn Tools – OD Mill

• Right-click any of the Tool tiles
and choose Sort Tools.

The tools are sorted by Tool Group.

• Save the part. If you do not have the Mill option, skip to
the next exercise.

MILL TURN TOOLS

OD Mill
• Create Milling Tool #8 as
shown.

This endmill will be used to mill

a hex on the OD of the part from
the +X side.

The next two tools will drill

holes on the OD from the -X
side in TG2.

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 Tutorials On Tooling – Basic Tool Set Up

OD Drills
• Create Milling Tool #9 as
shown.

• Create Milling Tool #10

Mill Turn Tools – OD Drills

as shown.

• Right-click a tool tile

and choose Sort Tools
again.

• Save your part file.

This part will be

machined in “Single
Spindle Part” on page 151.
You may either continue
on to the next tooling
exercise or move on to the
machining of this part.

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 Tutorials On Tooling – Dual Spindle Set Up

DUAL SPINDLE SET UP

In this exercise we will set up the tools for cutting the dual-turret, dual spindle part
created in Part Creation “Geo Creation & Arrangement” on page 117. The MDD (Machine
Definition Document) we are using is a dual-spindle, dual-turret machine. Turret 1 and 2
may access either spindle. Turret 1 is on the +X side of Spindle 1 while Turret 2 is on the –
X side of Spindle 1. The tooling we will set up will have Tool Group 1 accessing only
Spindle 1 and Tool Group 2 will access both spindles. We will define both turning and
milling tools. As with previous exercises, you do not need the milling option to do this
exercise. We will define a total of 21 tools to cut this part.

• Open the part file Dual Spindle.vnc.

• Open the Tool list.

Mill Turn Tools – OD Drills

The tools are created in the order of their accompanying operations, by Tool Group. This
is done strictly for convenience in this exercise and does not need to be true for other
part files.

• Create Turning Tool #1 as shown.

This tool is Face Down in Position 1 of

Tool Group 1. As with all tools in TG 1,
this tool cuts on the +X side of the
part. This tool will be used to face and
rough the OD.

The tool and insert orientation as

described above is similar to the following
image. The insert is Face Down,
approaching from the top of the spindle.

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 Tutorials On Tooling – Dual Spindle Set Up

• Create Turning Tool #2 as shown.

Mill Turn Tools – OD Drills

• Create Turning Tool #3 as shown.

The tool is oriented to cut from the

spindle towards the face of the part.

• Create Turning Tool #4 as shown.

The arrangement of this tool is identical to tool #3.

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 Tutorials On Tooling – Dual Spindle Set Up

• Create Milling Tool #5 as

shown.

Note that, for clarity, the

correct orientation is circled.

Mill Turn Tools – OD Drills

• Create Turning Tool #6 as
shown.

This tool will rough the ID of the part.

• Create Turning Tool #7 as shown.

This trigon will be used to finish the

ID of the part. This tool’s
arrangement is identical to tool #6.

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 Tutorials On Tooling – Dual Spindle Set Up

• Create Turning Tool #8 as shown.

We will now create the tools

contained in Tool Group 2. Tool
Group 2 approaches the part from the
–X side. Most of the tools will be set to
cut on Spindle 2 but several will access
Spindle 1.
Mill Turn Tools – OD Drills

• Create Turning Tool #9 as shown.

This tool will be the last tool used in

the program.

This tool is being placed in Position 1

of TG2. Second, the tool is oriented to
Spindle 1. That means the Insert
Orientation will be set in relation to
Spindle 1, not Spindle 2. Third, this
tool is cutting from the –X side, as are
all tools in Tool Group 2. Lastly, note
that this tool is designated as being
Insert Face Up. Were this tool being
used on Spindle 2 this setting would
be Face Down but Tool Group 2 is
moving to Spindle 1 for this operation,
As the spindle moves counter-
clockwise and the tool is below the
spindle, the insert should be Face Up.

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 Tutorials On Tooling – Dual Spindle Set Up

• Create tool #10 as shown.

This tool will be used to rough the OD

of the part once transferred to Spindle
2.

• Create Turning Tool #11 as shown.

Mill Turn Tools – OD Drills

This will be used in an OD Threading operation. The alignment is identical to Tool
#10.

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 Tutorials On Tooling – Dual Spindle Set Up

• Create Turning Tool #12 as shown.

This tool will create the part’s OD

grooves. The alignment is identical to
Tool #10.
Mill Turn Tools – OD Drills

• Create Turning Tool #13 as shown.

This tool will be used for cutting the

part’s ID grooves.

Perhaps you were wondering how a

tool that is intended to be used on the
ID can be defined with the Insert
Orientation diagram shown in the
above image. And perhaps you
noticed that the Insert Orientation
diagram and the overlapping graphic
are different. The overlapping graphic
shows how the insert holder would
look in reality. The Insert Orientation
diagram simply is used to show how
the insert will be held, not how the
holder is set.

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 Tutorials On Tooling – Dual Spindle Set Up

• Create Milling Tool #14 as

shown.

This drill will make a hole at

the back of the part.

Spindle 1 is the Orientation

Spindle for this tool. This drill
will be cutting on Spindle 2,
therefore the Tool Orientation
diagram is set to cut away from
Spindle 1, as shown in the
image above.

Mill Turn Tools – OD Drills

• Create Turning Tool #15 as
shown.

This tool will be used to rough the ID.

• Create Turning Tool #16 as shown.

This tool will be used to finish the ID.

If you do not have Mill capabilities, you have completed the tool creation for this
part. You may move on to the Machining tutorials. If you do have Machining
capabilities we will now define these tools.
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• Create Milling Tool #17 as

shown.

This tool will be used to create

the hex on the back of the part.

The next four tools are drills.

The first two tools will be
created in TG1, the others in
TG2.
Mill Turn Tools – OD Drills

• Create Milling Tool #18 as

shown.

Note that this tool is in TG1.

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 Tutorials On Tooling – Dual Spindle Set Up

• Create Milling Tool #19 as

shown.

Note that this tool is also in TG1.

Mill Turn Tools – OD Drills

• Create Milling Tool #20 as
shown.

Note that this tool is in TG2.

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 Tutorials On Tooling – Swiss-Style Set Up

• Create Milling Tool #21 as

shown.

Note that this tool is in TG2.

The tools for the Dual-Turret,

Dual-Spindle machine exercise
are now complete. Save the file
as we will be using it later.

SWISS-STYLE SET UP
This exercise is designed to
introduce you to setting up tools for
Mill Turn Tools – OD Drills

Swiss-style parts. You will find that

setting up a Swiss part is not really that different than a single or dual-turret part. Thus,
anybody can perform this exercise. If you do not have the Mill module then simply skip
over those sections of the tutorial.The geometry for this part has already been created for
you. If you do not have the part file you can create it using “Swiss Style Part” on page 226.
Unlike the other tutorials, this exercise uses the MDD entitled Training Swiss.mdd.

• Find and open the file named Swiss Tutorial.vnc that was installed with your
sample parts.

This part is created using the TG2

Training Swiss MDD, which is based
upon the Star KNC 32 sliding head
machine. The machine has two
opposed spindles, two turrets and a
fixed post. Both turrets can hold
turning and milling tools. The sub
spindle is capable of rear machining
on the upper turret (TG2) or on the
fixed tool post (TG3). Sub
Main TG3

TG1

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 Tutorials On Tooling – Swiss-Style Set Up

This is a metric part

112mm long. We
will use Auto
Clearance and
designate the
machine as
Preloaded.

We will now make

the tools for this
part. We will define
the tools by Tool
Group, in the order
they are set in the

Mill Turn Tools – OD Drills

Tool Group.

• Create Turning
Tool #1 as shown.

• Create Turning Tool #2 as shown.

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• Create Turning Tool #3 as shown.

The next three tools will be used to

cross drill the part. These tools include a
center drill, a drill and a tap. Each tool
will be in TG1.
Mill Turn Tools – OD Drills

• Create Milling Tool #4 as

shown.

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 Tutorials On Tooling – Swiss-Style Set Up

• Create Milling Tool #5 as

shown.

Mill Turn Tools – OD Drills

• Create Milling Tool #6 as
shown.

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 Tutorials On Tooling – Swiss-Style Set Up

• Create Turning Tool #7 as shown.

• Create Turning Tool #8 as shown.

Mill Turn Tools – OD Drills

This tool will perform finishing operations from the -X side of the part.

We will now create tools in TG2.

• Create Milling Tool #9 as

shown.

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• Create Milling Tool #10 as

shown.

You may have noticed that tool

9 and 10 are in the same position
in the Tool Group. As long as
the machine supports multiple
tools in the same position the
output will work.

Mill Turn Tools – OD Drills

• Create Turning Tool #11 as
shown.

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 Tutorials On Tooling – Swiss-Style Set Up

• Create Milling Tool #12 as

shown.

This tool we will create is a key

cutter that will cut a 2mm slot at
the front of the part.

The last five tools will all be

used to cut on the sub spindle.
This includes both turning and
face drilling operations.
Mill Turn Tools – OD Drills

• Create Turning Tool #13 as

shown.

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 Tutorials On Tooling – Swiss-Style Set Up

• Create Milling Tool #14 as

shown

The next three tools we will

define in TG3, the fixed post.

Mill Turn Tools – OD Drills

• Create Milling Tool #15 as
shown.

• Create Milling Tool #16 as

shown.

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 Tutorials On Tooling – Swiss-Style Set Up

• Create Milling Tool #17 as

shown.

We now need to sort these tools

so that when we create the
machining operations in “Swiss-
Style Part” on page 195 our tools
are ready to be used.

• Right-click a tool tile and

choose Sort Tools.
Mill Turn Tools – OD Drills

The tools are now sorted into three groups separated by a space, representing each
Tool Group.

Note that we entered a comment for each tool that describes its
purpose. We did this because that data shows up in the tooltip
when the cursor is held over a tool tile. This is very convenient
for long tool lists with many similar tools. This information can
help you quickly find the tool you are looking for.

Comments are entered at the bottom of the

tool dialog in the Comment text box.

• Save this part for the machining tutorials.

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MULTI-TASK
MACHINING TUTORIALS
 Tutorials On Multi-Task Machining – Single Spindle Part

CHAPTER 13 : Multi-Task Machining Tutorials

This section of the manual will introduce you to generating machining operations in
Multi-Task Machining parts. There are three tutorials in this chapter with each
increasing in complexity, starting with a single-spindle part, progressing to a dual-
spindle part and finishing with a swiss-style part. The tutorials are made using generic
training MDDs (Training Twin Turn.mdd & Training Swiss.mdd). As such, anyone can
create these parts, even if you do not have a machine of this type. It is recommended that
you do all of the tutorials to maximize your familiarity with the system. Please note that
these training MDDs may have options (particularly Utility operations) that are you may
not see when creating a part using your machine-specific MDD. This is typically because
your machine does not support this function. Also, these training MDDs are generic and
do not have a post processor thus, they cannot produce G-code.

SINGLE SPINDLE PART

In this exercise you will be introduced to creating
machining operations for Multi-Task Machining

Tutorials
parts. We will use the part single-spindle, dual-
turret part file created in “Basic Tool Set Up” on
page 125. This exercise will help you become
acclimated to working with multiple flows and
create simple operation synching. The exercise is
designed for any user. You can complete this part
whether you have Lathe or Mill/Turn functionality.
Users with the basic Lathe package will complete
the part shown above right. Once that is complete,
users with Mill/Turn functionality will further
machine the part to create the drill holes and Hex
head (right below).

SETTING UP THE OPERATIONS

Front Face
• Open the file Single Spindle.vnc.

This exercise does not use Auto Clearance. Auto Clearance is not used because of a
relatively small amount of clearance available for ID cutting. This is the only exercise
that does not use Auto Clearance.

• Open the Tool list and machining lists.

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We will begin this tutorial by creating a facing operation followed by a drilling and ID
turning operations. All of these operations will be made with tools from Tool Group 1.
To face off the part we will need to add a line on which to set out machining markers
because the front face of the part is an arc.

• Create a vertical line at Z0.

It doesn’t matter how you get the

line. For this example we used the
mouse line tool.
Setting up the Operations – Front Face

The length of the line is not

important because machining
markers will specify the start and
end points of the operation.

• Create a Lathe Contour Process

with tool #1 as shown.

This creates a tile in the list that

displays the tool number and Tool
Group information.
Tool Group
Tool Group Position

Orientation Spindle

Note that the process states that it

will be cutting on the +X side of the
part.

• Select the line you created for the contour.

• Set the machining marker as shown.

Drag the Start marker to a point above the stock and the End marker
to just below the middle of the stock as shown in the image to the
left.

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 Tutorials On Multi-Task Machining – Single Spindle Part

• Create the toolpath to face the part.

We will now create a drilling operation to remove material from the center of the
part. After the drilling operation we will create ID roughing and contouring
operations to finish the ID.

• Deselect the operations.

• Clear the process list.

ID
• Create a Lathe Hole

Setting up the Operations – ID

Process with tool #2 as
shown.

The Tip Z value of -66mm

was determined by interrogating the Z depth of the ID.

• Create the drilling operation.

We will now create a Rough and Contour combination process with the same tool.

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 Tutorials On Multi-Task Machining – Single Spindle Part

• For Process #1 create a Lathe

Rough Process with tool #3 as
shown.

We use an Entry & Exit Clearance

value of 12.2mm because that is the
Minimum Bore clearance required
for the boring bar we have
specified.
Setting up the Operations – ID

The value of 10.5mm is determined by interrogating the same point from the previous
process. This depth ensures we will clear out all of the material at the back of this
hole.

• For Process #2 create a Lathe

Contour Process with tool #3 as
shown.

We will now set the machining

markers for the processes. The
operation will extend from the arc
at the front of the part to the back
of the ID.

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 Tutorials On Multi-Task Machining – Single Spindle Part

• Select the arc and set the

machining markers as shown.

The tool cuts on the outside of the

shape, heading towards the inside of
the part.

• Create the Rough and Contour

operations.

Setting up the Operations – ID

• Render the operations.

As you can see, the basics of Multi-Task Machining are the same as a standard lathe.
We will now create roughing and plunge roughing operations on the OD of the part
from the –X side.

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• Deselect the operations and clear

any existing Process list items.

OD
• Create a Lathe Rough Process
with tool #6 as shown.

Use tool #5 if you do not have Mill/

Turn.

Note that the process is set to cut

from the –X side of the part. This is
because the tool we are using is
Setting up the Operations – OD

designated as cutting from the –X

side. This value can be over-ridden,
if desired, by clicking on the Cut
Other Side checkbox.

Other than the information that the process is cutting from the bottom of the part,
the information in this dialog is set up no differently than any other process dialog.
We now need to set the machining markers for this operation.

• Set the markers as shown.

Select the arc on the –X side of the front

of the part. Be sure that the end point
marker goes all the way to the back of
the stock.

• Create the toolpath.

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 Tutorials On Multi-Task Machining – Single Spindle Part

We could have very easily set the

machining markers on the +X side as
shown and the same toolpath would be
generated. It may be more convenient
to have the markers in the same place as
the toolpath. There is no real difference,
as shown, but if there was no geometry
on the –X side of the part the toolpath
could not be visually verify.

The Shape Axes restriction in the

process dialog is not supposed to make any –X moves along the part yet it would
seem that the toolpath does this. In fact, the toolpath does not make any –X moves

Setting up the Operations – OD

along the shape.

All of the toolpath is first generated from the +X side of the part and then “flipped” to
the –X side for graphical accuracy.

If you consider the axes as being arbitrary names, the turrets on the +X and –X side
each see the part from the same point of view. The turret on the bottom of the part
is potentially performing the same moves that the turret on the top of the part
T would make, except bottom turret is mirrored. Therefore, it does not matter where
I the toolpath is first generated. It is easier to always visualize the toolpath as first
P cutting on the top of the part and then being moved, rather than always trying to
remember exactly which direction the tool is coming from and thinking around
that. If you watch the toolpath generation closely, you may even see the toolpath
being generated on the +X side then getting flipped to the –X.

We will now continue generating toolpath on the –X side of the part by clearing out
the recess not cut in the previous operation.

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 Tutorials On Multi-Task Machining – Single Spindle Part

• Create a Lathe Roughing Process

with tool #7 as shown.

Use tool #6 if you do not have Mill/

Turn.

• Enter the information shown in

the Plunge dialog.
Setting up the Operations – OD

• Set the machining markers as

shown.

Be sure that the end point marker goes all the way to the back of the stock.

• Create the toolpath.

The next operation will use the

groove tool to cut the grooves and
finish the OD. This process will cut
from the back of the part to the front.

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 Tutorials On Multi-Task Machining – Single Spindle Part

• Create a Contour Process with

tool #8 as shown.

Use tool #7 if you do not have Mill/

Turn.

Setting up the Operations – OD

• Set the machining markers as
shown.

Be sure that the end point marker is

in the middle of the arc at the front of
the part. Click Do It when you are
finished.

• Create the toolpath.

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 Tutorials On Multi-Task Machining – Single Spindle Part

• Render the operations.

Grouping Ops by Flow

We are now going to organize
this part better.

• Click the Sort Ops button in

the machining palette.

The operations in this list are

Control of Flows – Syncing Operations

now divided and sorted by

flows.

The Operation Data dialog allows you to

enter information about the operation that
will show up in the post, set overrides to
values and lock values so other users
cannot override your settings. Additionally,
syncs are shown at the bottom in the
Utility Data section. We recommended
that you do not change sync data the
system creates here.

CONTROL OF FLOWS
Syncing Operations
• Open the Sync Control dialog.

This Sync Control dialog displays all of the operations in the part. The operations are sorted into
flow columns. Each operation tiles length is an accurate representation of the time needed for the
operation. This is where we will set syncs to control the operations in each flow.

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 Tutorials On Multi-Task Machining – Single Spindle Part

If we look at the rendering, the start of the two flows is

simultaneous. Even though there shouldn’t be any
interference among the turrets, we will put a sync in to make
the OD roughing operation wait until the face contour
operation is complete.

Control of Flows – Syncing Operations

• Ensure the sync mode is on.

While in Sync mode each operation tile has two selections, the start and end of the operation. To
select the operation start, select the top of the tile. To select the operation end, select the bottom of
the tile.

• Select the bottom (Op end) of Op1 in Flow 1.

• Select the top (Op start) of Op6 in Flow 2.

• Click the Operation Sync button.

• Click the Recalculate button.

Both flows are updated and Flow 2 will now

start once Operation 1 has finished. The run-
time of the part has also been updated. Setting
syncs is that easy.

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 Tutorials On Multi-Task Machining – Single Spindle Part

You may notice that the run-time of

Op 1 is different after the sync is set.
Before the sync was set two flows
were cutting on the spindle at the
same time — one flow was
performing a facing op and the
other flow was performing an OD
Rough, each using the Constant
Surface Speed setting. Since both
operations cannot have control over
the spindle speed at the same time,
the system gave Flow 2 the spindle
control. By setting the sync, the
run-time for Op 1 is recalculated.

• Save the part file.

Milling Ops – Hex Head

If you do not have the milling

option, you have completed this
exercise and may move on to the next tutorial (page 167). If you do have the milling
option we will now mill and OD drill this part. First we need to sort the tools to get
the mill tools into order.

• Close the sync dialog.

If the dialog is left open some warnings may appear. We will fix all the sync errors at
the end.

MILLING OPS
Hex Head
• Switch to Workgroup 2: Milling and
CS4: YZ plane.

All of the geometry for the mill

components of this part are contained
in Workgroup 2 and belong to CS4: YZ
plane. This includes a point at the
middle of the line at the bottom of the
recess of the part and a point and line
that will be used to mill a hexagon
near the back of the part.

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 Tutorials On Multi-Task Machining – Single Spindle Part

The first milling operation we will create will be to mill a hexagon by using six rotary
positioned contour cuts.

• Create a Milling Contour

Process with tool #4 as
shown.

Milling Ops – Hex Head

• Select the horizontal line.

• Set the markers as shown.

This will be a centerline cut from

the +Y to the Y– side of the part.
The tool should cut on-center

• Create the toolpath.

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 Tutorials On Multi-Task Machining – Single Spindle Part

Be sure you are not cutting from the Y– side. To cut down on the amount of
movement by the tool, experiment with the placement of the machining markers to
optimize the amount of feeding required.

The next set of operations will spot and drill three holes in the recess of the part.

• For Process #1 create a Mill Hole

process with tool #9 as shown.
Milling Ops – Hex Head

• For Process #2 create a Mill Hole

process with tool #10 as shown.

The Full Diameter Z value is

determined by interrogating the
same point used for the ID drill
depth. There is no need to enter
rotary positioning information for
this process. Linked processes have
the same positioning information by
default.

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 Tutorials On Multi-Task Machining – Single Spindle Part

• Select the point shown.

Milling Ops – Hex Head

• Create the toolpath.

Even though these drills are

approaching from the bottom of the
part, we can still use geometry
defined at the top of the part. The
post will simply handle the position
of the spindle when the program is
run.

One thing that will not be handled

by the post or the machine is two
milling operations occurring on the
same spindle at the same time. We
need to sync the contouring and
drilling operations. Additionally,
we have a milling operation happening concurrently with a turning operation.

• Open the Sync Control dialog.

When the Sync Control dialog is

opened we get a warning that
there is an conflict with spindle
control. We will simply set a sync
and fix the problem ourselves.

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 Tutorials On Multi-Task Machining – Single Spindle Part

• Select the start of operation #9 and the end of operation

#11.

You may need to click the blue arrow that points down to
expand the time line to see operation #11 more clearly.

• Click the Operation Sync button.

• Click the Recalculate button.

The operations have now been synced.

• Render the operations.

Milling Ops – Hex Head

• Be sure to save the part.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

DUAL SPINDLE PART

In this exercise we will machine the part created in “Geo
Creation & Arrangement” on page 117. This tutorial will
create a part using both turning and milling operations. As
with other tutorial exercises, you do not need to have the
milling option to complete the exercise. In this tutorial we
will have Turret 1 perform machining operations on the
+X side of Spindle 1 only. Turret 2 will primarily cut on
Spindle 2 except for the part cut-off or if you are
performing the milling operations. Turret 2 is set up to cut
on the –X side of the part. When complete, the part will
look like the following images.

PART SETUP

Part Setup – Tool Change

Tool Change
• Open the part file Dual Spindle.vnc.

The tooling for this exercise was set in “Dual

Spindle Set Up” on page 131. If you have not
completed this exercise, please do so now.

We first need to check our Clearance and Tool Change settings. We will be using
Auto Clearance for this part. The tool change position for both spindles will be Z2"
and Xd+/–3" from the origin. The Xd value will depend on whether the turret is the
Upper or Lower turret.

• Enter the information in the

Document dialog as shown.

• Switch to TG2: Lower and enter

the settings shown.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Switch to Spindle 2 and

enter the information
shown.

• Open the Tool list and

Machining palette.

• Open the Spindles list.

Setting up the Operations – Front Face

• Hide Spindle 2.

• Unzoom (Ctrl+U).

The main spindle is now the only spindle in the Workspace.

Showing and hiding spindles will make creating parts much
easier.

SETTING UP THE OPERATIONS

Front Face
• Create a Lathe Rough Process with
tool #1 as shown.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Set the machining markers as

shown.

• Create the toolpath.

OD
We will now rough the OD of the part.
To do this we will make four operations,
two roughing and two contour
operations.

• Create a Lathe Rough Process

with tool #1 as shown.

Setting up the Operations – OD

• Set the machining
markers as shown.

This will cut from the

front to the back of the
first groove.

• Create the toolpath.

The next set of

operations will
continue to machine
the OD of the part. We
will rough and finish
the back side of the

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 Tutorials On Multi-Task Machining – Dual Spindle Part

front flange with tools 3 and 4 in a multi-process operation, Perhaps you recall that
these tools were set to cut from the back of the part to the front.

• For Process #1 create a Lathe

Rough process with tool #3 as
shown.
Setting up the Operations – OD

• For Process #2 create a Lathe

Contour process with tool #4 as
shown.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Set the machining markers

as shown.

This will generate toolpath

that will cut from the middle
of the part to the front of the
flange.

• Create the toolpath.

The next operation we will

make use of the contouring
operation that we just used.

Setting up the Operations – OD

• Delete the Rough Process
from the list.

• Change the tool in the last

Contour process to tool #2.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Set the machining markers

as shown.

This will cut from the front of

the part to the back of the first
groove, as shown below.

• Create the toolpath.

Note how the tool will rapid

over the area that has been
finished by operation #4.
Setting up the Operations – ID

• Switch to the isometric view

(Ctrl+I).

• Render the
operations.

Image 1 shows
Operation #2 near
the end of its last
pass. Image 2
shows Operation
#4, a contouring
operation,
finishing the back
of the flange.
Image 3 shows
Operation #5
performing a
Material Only
Contouring
operation to finish
the OD and Image
4 shows the part
condition after the
first five operations.

ID
Our next set of operations will be to Drill, Rough and Finish the ID of the part.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Create a Lathe Holes

process with tool #5 as
shown.

• Create the toolpath.

This will drive the tip of the

drill to the back of the part.

The next set of operations

will be a multi-process
operation consisting of a
Rough and a Contour process.

Setting up the Operations – ID

• Create a Lathe Roughing process
with tool #6 as shown.

Be sure to enter a stock value for

the Contouring operation to clean
up.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Create a Contour process with

tool #7 as shown.
Setting up the Operations – OD Thread

• Set the machining markers

as shown.

• Create the toolpath.

• Rendered the Operations.

OD Thread
The last turning operation we will perform on Spindle 1 will be an OD thread at the front
of the part.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Create a Lathe Thread

process with tool #8 as
shown.

Setting up the Operations – Cut Off

• Create the toolpath.

• Render the operations.

Cut Off
That completes the turning operations on the primary spindle. We now need to cut off
the part and transfer the part to the sub spindle.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Create a Lathe Contour process

with tool #9 as shown.
Setting up the Operations – Utility Ops

• Set the machining

markers as shown.

This will cut the back of

the part.

• Create the toolpath.

At this point we should

create Utility operations to
place the sub spindle on
the part and return with
the part after the cut off is
performed. While this can
be created at any time, we
will do this now so that we
can render operations we will create on the sub spindle. While operations can be
created on a spindle that does not have stock, rendering will not show up if stock has
not been transferred to the spindle.

Utility Ops
• Drag a Utility function tile to the Process list.

The Utility process tile seen in the CAM palette is a capital “U”. When the tile is
placed in the Process list the icon changes to match the type of Utility operation
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 Tutorials On Multi-Task Machining – Dual Spindle Part

being created. By default this is typically “Load Spindle” but depending on your MDD
may be something else. The first Utility operation we will make is Unload Spindle.
Before bringing our sub spindle to the main we want to be sure the spindle is empty.

• Create an Unload Spindle

operation as shown.

Setting up the Operations – Utility Ops

• Create a Sub Spindle In operation
as shown.

The Grip Z value specifies the depth

at which the sub spindle will grab the
part. The sub spindle will grab the
part 0.100" from the first groove. If
you look at the Operations list you
will see that these Utility processes
actually created two operation tiles
each. This is for synching purposes;
the operations represent the start
and end of the Sub Spindle On Part
operation. We will now generate two more Utility Operations. The first will return
the sub spindle to its normal position and bring the cut off part with it, and the
second operation will load stock into Spindle 1.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Create a Sub Spindle Return

operation as shown.

Be sure to click the With Part

checkbox.
Setting up the Operations – Utility Ops

• Create the Utility operation

shown.

We should re-order the operations

we have just created because we’ve
created a sequence of operations that
cuts off the part before the sub
spindle actually grips it.

• Drag Op #10 (the cutoff) between Ops #14 & #15.

The Load Spindle operation may be kept at the bottom of the

operations and will be the last operation performed in the program.
We do not need to create this operation at the start of the program
because we specified that the machine was Preloaded in the
Document Control dialog. In fact, the load command may be at the
start of the end of a program.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

SUB SPINDLE OPS

OD
We will now create the sub spindle operations.

A recommended method for creating operations is to create all

T ops on the primary spindle first. Once the operations are
I complete and valid, they may be changed to the sub spindle. This
P is an excellent method for new users as it minimizes the
complexity of the part.

All milling operations will be created last. We will be moving the operations performed
on the sub spindle to the empty tile slot so we may leave the empty space.

• Open the Spindles list and show Spindle 2.

Sub Spindle Ops – OD

• Switch to CS 5: ZX plane of Spindle 2.

• Switch to the Home view

(Ctrl+H).

This will re-orient your view of the

ZX plane of Spindle 2.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Create a Lathe Rough process with tool #10 as shown.

Sub Spindle Ops – OD

• Set the machining

markers as shown.

• Create the toolpath.

The operation we just

created will rough the
backside of the part. The
machining markers were
set on the bottom of the
part for ease of visualizing
what the tool will do.
Remember that all tools
in Tool Group 2 are
approaching from the
bottom. The next
operation we will create will machine the OD grooves.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Create a Lathe Contour process

with tool #12 as shown.

Sub Spindle Ops – ID

• Set the machining markers as
shown.

The groove tool simply dips into

each of the grooves.

• Create the toolpath.

We will next generate the ID

machining, including drilling
roughing and finishing operations.

ID
• Create a Holes process with tool
#14 as shown.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Create the toolpath.

The next set of operations will be a

multi-process operation consisting
of a Rough and a Contour process.

• For Process #1 create a Lathe

Rough process with tool #15 as
shown.
Sub Spindle Ops – ID

• For Process #1 create a Contour

process with tool #15 as shown.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Set the machining markers as

shown.

• Create the toolpath.

Sub Spindle Ops – ID

• Create a Contour process with
tool #13 as shown.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Set the machining markers as shown.

• Create the toolpath.

Ordering Operations
We need to reorder the sub spindle operations so they occur prior to the Utility
Sub Spindle Ops – OD Thread

operations.

• Select Operations 20 through 25 (the ID and OD operations on

Spindle 2), and move them to the empty tile at position #10.

• Change the Lathe rendering to show a Half Cutaway.

Because we have a Utility operation that loads material into Spindle 2 we are able to
see the condition of the stock when these operations start. If we had not created the
Utility operations we would not see the stock when rendering is run.

OD Thread
The last turning operation we need to create is the OD thread on the sub spindle.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Create a Lathe Thread

Process with tool #1 as
shown.

• Create the toolpath.

Sub Spindle Ops – Hexagon

• Place the OD thread operation
before the Utility operations in
the Operations list.

• Click the Sort Ops button in the

machining palette.

This organizes your operations.

• Save the part file.

This completes the turning operations on this part. We will now create several
milling operations. The first operation we will create is the hexagon on the backside
of the part. To generate this operation we will need to create some geometry.

• Switch to CS8, the YZ Plane of Spindle 2.

Hexagon
• Create a horizontal line at Z: -
0.5’, Xd: 0.75".

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Create a Mill Contour process

with tool #17 as shown.
Sub Spindle Ops – Hexagon

• Set the machining markers as

shown.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Create the toolpath.

• Move the Mill Contour

operation between
operations #20 and #21.

This will cause the mill contour

to occur before the threading
operation.

Sub Spindle Ops – Drilling ops TG1

• Render the operations.

Drilling ops TG1

We will now create drilling operations on
Spindle 1 with tools in both Tool Groups. To
perform these operations you must have
the Advanced CS option. We will be
creating a new CS to drill on the B-axis of
this part.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Create a new CS based on

CS4, the YZ plane of Spindle 1.

• Switch to Spindle 1.

• Select the point shown and

click the Change CS Origin
button.

• Create a horizontal line at Z0.

Sub Spindle Ops – Drilling ops TG1

This line will be used to help

align the CS.

• Select the two lines shown

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Click the Align CS Plane

button.

We will now rotate the CS 180˚

around its depth axis.

• Deselect all geometry and

click the Align CS Plane
button again.

Sub Spindle Ops – Drilling ops TG1

This will open the CS Align
dialog.

• Rotate the CS as shown.

• Rename the CS “B-Axis Drilling”.

We now need to create a point for the drilling operations we will be creating.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Create a Mid-Point for the line

shown.
Sub Spindle Ops – Drilling ops TG1

• For Process #1, create a

Milling Holes Process with tool
#18 as shown.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• For Process #2, create a Holes

process with tool #19 as shown.

Sub Spindle Ops – Drilling Ops TG2

• Select the mid-point and
create the toolpath.

Drilling Ops TG2

We will now create drilling
operations from Tool Group 2 using
the processes from Tool Group 1.

• Change the tool used in

Process #1 to tool #20 and
modify the Process as shown.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Change Process #2 to use tool #21

and modify the Process as shown.

• Deselect the previous operations.

• Create the toolpath.

We now need to sync the drilling

operations because otherwise we
will have two milling operations
trying to perform tasks on the same
spindle at the same time.
Sub Spindle Ops – Drilling Ops TG2

Additionally, we need to move the

operations into the flows, meaning
the operations need to be placed
within the bounds of the utility operations.

• Drag the ops with tools 18 and 19 to the space between Ops 9
and 10.

This will put the operations before the Utility operations begin.

• Drag the ops with tools 20 and 21 to the space between

Operations 23 and 24.

This will put the operations after the sub spindle OD thread and
before the Utility operations end.

Spindle 2 Ops

Spindle 1 Ops

Cut Off

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Open the Sync Control dialog.

An error message that says there

is a spindle control conflict at
Op 7. That is because we
currently have turning and
milling operations happening on
Spindle 1 at the same time.
When we moved the last two
Holes operations we
inadvertently caused this

Sub Spindle Ops – Drilling Ops TG2

potential conflict.

To fix this we will sync the drilling operations. We will have the Tool Group 2 drill
and tap wait for the Tool Group 1 tools to finish. That will fix the conflict and put our
drilling operations in order.

• Switch to the uniform view.

This will allow you to select time line scale so that you can
see the operations at the end of both flows.

• Select the Op end (bottom half) of Operation 11 and the

Op Start (top half) of Operation 24.

• Click the Operation Sync button.

The TG2 drilling ops will now wait for the TG1 to finish.

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 Tutorials On Multi-Task Machining – Dual Spindle Part

• Render the operations.

• Save the part.

Sub Spindle Ops – Drilling Ops TG2

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 Tutorials On Multi-Task Machining – Swiss-Style Part

SWISS-STYLE PART
In this exercise we will machine the swiss-style part that was set up in “Swiss-Style Set
Up” on page 140. If you have not completed the tool set up, please do so now. This
tutorial will create a part using both turning and milling operations. You do not need to
have the milling option to complete the exercise.

SETTING UP THE OPERATIONS

ID Drill
• Open the part file Swiss Part.vnc.

Setting up the Operations – ID Drill

This part is created using the TG2
Training Swiss MDD, which is
based upon the Star KNC 32
sliding head machine. The
machine has two opposed
spindles, two turrets and a fixed
post. Both turrets can hold
turning and milling tools. The
sub spindle is capable of rear
Sub
machining on the upper turret
(TG2) or on the fixed tool post Main TG3
(TG3).
TG1
We will be using Tool Group 1 to
cut on the -X side of the part.
Tool Group 2 will be used to cut
on both spindles and Tool Group
3 will be used to face drill the
part on the sub spindle.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

• For Process #1 create a

Lathe Hole process with
tool #10 as shown.

The center drill will make a

7mm chamfer on the front of
the part.

• For Process #2 create a

Setting up the Operations – ID Drill

Lathe Hole process with

tool #11 as shown.

The full diameter of the tool

will drill 21mm deep.

• Create the toolpath.

We will now make the first set of contouring operations. The contouring and
finishing of the part will actually be broken up into three sections. This is done to
allow for the tools that are cutting on both sides of the part to take a roughly even cut
depths.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

MAIN SPINDLE
OD
For Process #1 create a Lathe Contour
processes with tool #12 as shown.

Tool 12 will leave 2mm of stock on the

Xr and 0.1mm of stock in Z.

Main Spindle – OD
• For Process #2 create a Lathe
Contour processes with tool #8
as shown.

Tool 8 will finish the part.

The tools are essentially identical

but are in different Tool Groups.
Tool 12 cuts on the +X side of the
part while Tool 8 cuts on the –X
side.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

• Set the machining markers as shown.

Do not delete the process tiles when you are

finished.

• Create the toolpath.

If you were to look closely at this part, you would

see that both tools will be removing a roughly
even amount of material. The total depth of cut
is 4mm and we specified that Tool 12 will leave
Main Spindle – OD

2mm.

Please note that if you happen to make a mistake

you will need to delete and re-create the
operation. You may leave the process data and
toolpath alone, but due to Material Only
calculations you will not get the same results
with Redo. Once we have synced these operations we will not encounter this issue.

This set of processes will machine

the next section of the part in the
same manner as operations 3 and 4.

• Change Process #1 as shown.

This will leave 1mm of stock on the

Xr.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

• Change Process #2 as shown.

• Set the machining markers as

Main Spindle – OD
shown.

• Create the toolpath.

If you look closely at this

part, you will see that both
tools will be removing a
roughly even amount of
material. The total depth of
cut is 2mm and we specified
that Tool 12 will leave 1mm.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

• Create a Lathe Contour process

with tool #12 as shown.

• Set the machining markers as

shown.
Main Spindle – OD

• Create the toolpath.

This last contouring operation will

complete the machining of the OD of the
part.

Looking at the toolpath for the last three

sets of operations we can see how they
work together to machine the OD of the
part.

To make these
operations work
together, we need
to set syncs in the
Sync Control
dialog.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

If we open the Sync Control dialog we can see that although

operations 3 and 4 are created together, they do not cut
simultaneously. This is because they are in separate flows.
We need to synchronize operations 3 & 4 as well as
operations 5 & 6.

• Select the top half of op #3 and 4 and set a Stroke Sync.

The Stroke Sync button opens a dialog that allows us to set

how we want each stroke of the operations to sync.

• Set the Stroke Sync as shown.

Main Spindle – OD
You can see that the Sync Control dialog has been updated,
the operations are synced to begin at the same time but with
Flow 1 lagging by 1 revolution.

We now need to sync op 5 & 6.

• Select the top half of op #5 and 6 and set a Stroke Sync.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

• Set the Stroke Sync dialog as shown in the following image.

You can see that the Sync Control dialog has been updated,
the operations are synced to begin at the same time but with
Flow 1 lagging by 2 revolutions.

When rendered you can see the two tools working together
Main Spindle – OD

to cut the part.

We will now create two threading operations, three cross-

drilling operations and two milling operations to complete the part. If you do not
have the milling module simply skip those operations and continue to the next
section you can complete.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

• Create a Lathe
Threading process
with tool #7 as shown.

• Create the toolpath.

Milling Ops

• Create a Mill Contour

process with tool #13 as

Main Spindle – Milling Ops

shown.

Make sure you set the

Machining CS (found under
Rotate) as the YZ plane.

• Switch to WG 2.

WG2 contains the geometry for

milling operations.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

• Set the machining markers as shown.

Main Spindle – OD Drill

• Create the toolpath.

OD Drill
• For Process #1 create a Mill Holes
process with tools #6 as shown.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

• For Process #2 create a Mill Holes

process with tool #5 as shown.

This process and the tap do not get

repeated. Both processes go all the
way through the part.

Main Spindle – OD Drill

• For Process #3 create a Mill Holes
process with tool #4 as shown.

• Switch to WG1 and select the

point shown below.

• Create the toolpath.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

Note the rapid toolpath around the part.

• Create a Mill Contour process

with tool #15 as shown.
Main Spindle – OD Drill

• Switch to WG 2.

• Set the machining markers as

shown.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

• Create the toolpath.

• Create a Threading
process with tool #3.

Main Spindle – OD Drill

• Create the toolpath.

We now need to set a

few syncs. We have
milling and turning
operations happening at
the same time
(operations 8 & 9), and
we have some milling
and drilling operations
happening at the same time. While this is often not a problem, some of these
operations involve rotating the part.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

• Open the Sync Control dialog and set an Op sync at the

end of op #8 and the start of op #9.

• Set an Op sync at the end of op #9 and the start of op #10

and another op sync at the end of op #12 and the start of
op #13.
Main Spindle – OD Drill

• The last sync we need to set is at the end of op #13

and the start of op #14. this will avoid a conflict
between milling and turning operations.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

When rendered we can see

the results of our operations.
The first image below shows
an OD thread and the slot at
the front of the part. The
second image shows the
cross drilling operations.
The third image shows the
milling operation and the
last OD thread.

The last operation we will

perform on the main
spindle, other than a cut-off,
is to cut the grooves near the

Main Spindle – OD Drill

back of the part.

• Create a contouring
operation with tool #2, the
groove insert.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

• Set the machining markers as shown and create the

toolpath.

• Render the operations.

SUB SPINDLE OPS

OD
Sub Spindle Ops – OD

We will now create the operations that are to

be performed on the sub spindle.

• Switch to CS5: ZX plane S2: Sub Spindle.

• Create a Contouring process

with tool #14, a triangular insert.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

• Set the machining markers as shown in the

following image and create the toolpath.

• Create a set of face drilling processes with tools 17, 18 and 19.

Sub Spindle Ops – ID

ID
• Process #1, using the center
drill, should be set as
shown below.

• Process #2, using the drill,

should be set as shown
below.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

• Process #3, using the tap,

should be set as shown
below.

• Create the toolpath.

• Render the operations.

You don’t see anything on the sub spindle, do

you? You may even have noticed that the material
only contouring operation did not generate any
Sub Spindle Ops – ID

toolpath. That is because we have not transferred

the stock yet. We need to generate the utility ops
to do this, which we will do now. The first Utility
operation we will create will unload the sub
spindle. This way when we need to transfer the part we are sure of having an empty
spindle.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

TRANSFERRING TO THE SUB SPINDLE

Unload Spindle
• Create the Utility process as
shown.

• Create the operation.

Transferring to the Sub Spindle – Unload Spindle

The next Utility process will move the
sub spindle onto the part.

• Create the Utility process as

shown.

This will bring the Sub Spindle

In.

• Create the operation.

Although we have generated

milling ops on the part, they
do not have any significance to the sub spindle. If we had to grab the part on a flat or
at a certain location we would need the C Synched option to align the spindles. Thus
we could leave C Synched off. The Z Clearance is the distance in front of the part at
which we will begin feeding. We have specified that we will grab the part at Z-82mm.
The part is 107mm overall, that means the part will stick out of the sub spindle by
25mm.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

Cut-off
• Create a Lathe Contour process
with tool #1 as shown.
Transferring to the Sub Spindle – Sub Spindle Return

• Set the machining markers as

shown.

• Create the toolpath.

Sub Spindle Return

• Create the Utility process as shown.

• Create the operation.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

Load the Main Spindle

• Set the Utility process as shown in
the following image. Click Do It.

• Create the operation.

• Sort the Op list.

Transferring to the Sub Spindle – Verify Syncs

Re-Applying Toolpath
• Choose Edit > Redo All Ops.

This will update our operations,

including the Contour operation on the sub-spindle that did not generate any
toolpath.

• Render the operations.

When rendered is
restarted, you should see
the uncut stock on the
main spindle and the
transferred stock in the
sub spindle.

From the reverse-isometric

view (Alt+Ctrl+I).

Verify Syncs
We should now check our
operations to ensure that we don’t
need any more syncs.

• Open the Sync Control dialog.

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 Tutorials On Multi-Task Machining – Swiss-Style Part

Looking at the Sync Control

dialog, we see that we do not
need any syncs. The operations
we added are turning
operations and do not cause any
conflicts. The Utility operations
are synced and do not need
modifications.
Transferring to the Sub Spindle – Verify Syncs

• As a final check, perform a

manual run of the Sync
Checker.

We find that all checks have

passed their tests and the
part is complete.

• Save the part file.

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 Tutorials On Multi-Task Machining – Auto-Flip

AUTO-FLIP
This exercise is intended to familiarize you with
modifying tool information to automatically flip
toolpath across X0. Some people find MTM to be
easier or more familiar by setting up the part as if it
were a regular lathe part, and then modify the
operations. The exercise uses a pre-made part
called Auto-Flip.vnc (the part print, can be found

Transferring to the Sub Spindle – Verify Syncs

on page 227). We will modify three of the tools to
flip the existing toolpath from the +X side to the –X
side.

We will modify the last three tools to flip the OD

Plunge rough at the back of the part, the OD Thread and ID Contour operations. After
we’ve flipped the operations we will sync them.

Looking closely at the last three tools in the list (tools 5, 6 and 7), you can see that each of
the tools is in Tool Group 1. These tool positions also conflict other tools. Since these
tools are not on a mini-gang of some sort, we have simply used these numbers for
convenience since we will be changing the Tool Group these tools are assigned to.

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 Tutorials On Multi-Task Machining – Auto-Flip

FLIPPING TOOL DIRECTIONS

Upper to Lower
• View the toolpath for Op #5.

We are simply loading it so you can

see the “before and after” results.
Flipping Tool directions – Upper to Lower

• Modify tool #5 as shown.

• Choose View > Redraw to redraw

the toolpath. ( Ctrl-R).

The toolpath is automatically

updated to cut on the –X side.

We will now update tool number 6

& 7.

• Select Ops #6 & 7.

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 Tutorials On Multi-Task Machining – Auto-Flip

• Choose View > Redraw. ( Ctrl+R)

You can see that both operations

cut on the +X side of the part.

• Modify the TG, cut side and

insert settings of tool #6 and 7.

Flipping Tool directions – Syncing the new flow

Make sure you choose Insert Face
Up setting.

Tool #6 Tool #7

• Redraw the workspace.

You can see that the toolpath is

automatically updated to cut from
the –X side.

We now need to add two syncs to the

part. The first will make Operation 6
start after Operation 2.

Syncing the new flow

• Open the Sync dialog and click the Uniform Tile button.

• Create a sync at the end of Op #2 and the start of Op #6.

The next sync will cause the ID Contour to wait for the drilling to
finish.

• Create a sync at the end of Op #4 and the start of Op #7.

Now that we have our syncs set we should check the run-time. Since
we have different Tool Groups trying to control the spindle’s RPM at
the same time, we should specify which operations have control over
the spindle speed.
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 Tutorials On Multi-Task Machining – Auto-Flip

• Turn off Uniform View.

• Switch to the Spindle Mode.

The highlighted operations currently have control over the spindle. We will now give
Operations 1, 2, 4 and 6 control over the spindle speeds.
Flipping Tool directions – Syncing the new flow

• Ctrl+click Ops 1, 2, 4 and 6 and deselect any other

Ops.

• Recalculate the run-time.

The run-time should now take a little over five minutes.

• Render the new operations.

220
PART PRINTS
 Part Print 1A: Main Spindle
3.00"
2.00"
0.40"
0.25"

R 0.50" Z-1.618", X+0.750"

147°

Z-0.882", X+0.000" R 0.50"

1.90" 0.50" 1.00" 1.25" 1.75" 1.90"

153°

R 0.05" R 0.05"
0.05"

R 0.10"
2.25"
2.30"
2.35"
2.40"

223
 Part Print 1B: Sub Spindle
0.25"

0.10"

1.13"

1.50" 1.00" 0.50"

R 0.50" 0.05"

153°

0.40"

R 0.50"

224
 Part Print 2: Single Spindle Part
R 0.25 mm R 1.25 mm
R 2.5 mm
R 2.5 mm

R 13 mm

5 places
R 1.25 mm

44 mm 11 mm 33 mm 13 mm 44 mm 19 mm 50 mm 44 mm

44 mm

3 mm

8 mm
34 mm
37 mm
40 mm
49 mm
66 mm
76 mm

225
 226
mm 5 mm 6
mm 7 mm 24 mm 1 mm 7
mm 9 mm 26 mm 01
mm 77 .pyt 531
mm 97
mm 28
mm 48
mm 78
mm 701
Part Print 3: Swiss Style Part
 227
mm 0.76
mm 0.61
mm 0.1 R
¡522
mm 0.9 mm 5.2
¡921 ¡921
mm 5.5
mm 0.2 mm 0.2 R
mm 0.21 mm 0.6 mm 0.02
mm 5.2 mm 5.2 mm 0.5 R
mm 0.54
mm 5.35
mm 2.1 R
mm 0.8
Part Print 4: Auto-Flip
228
APPENDIX
 Appendix

CHAPTER 15 : Appendix
GLOSSARY
This section is intended to provide an overview of terms used throughout the Multi-Task
Machining manual. Some of these terms may be industry standard but are reproduced here
to ensure correct understanding. Italicized items may be found in the glossary.

Axis, Axes 1) Math: X, Y and Z axes of a coordinate system. 2) CNC machine axes:
the labels of things that can be programmed to specific linear or polar
locations in a G-code program. Labels are occasionally similar to the
math definitions. 3) CNC specific: Specific machines may have multiple
machine axes moving along the same math axes. Specific machine labels
can apply any letter to any machine axis. This is not to be confused with
math or CS axes.

CNC rotary axes: A rotates around the X-axis, B rotates around the Y-
axis, C rotates around the Z-axis.
Balanced Turning Two tools work on the OD but both use the same depth of cut and no
dwell. The second tool effectively cuts nothing but supports the part.
Channels See “Flow”.
Coordinate System 1) A right-handed orthogonal XYZ coordinate system orientation.
(CS) Sometimes applied to a 2D 2-axis orientation and origin definition. 2) A
GibbsCAM VNC data definition, numbered as CS1, CS2, etc.
Dual Tool OD Two tools work on the OD, usually with a small “Z lag” difference in
Roughing position. The second finishes before the first and retracts, waiting for the
1st. Rough the part in half the time. This can be programmed using
GibbsCAM MTM Multi-tool processes.
Flow A sequence of machining operations associated with a Tool Group, i.e.
one Tool Group = one flow, two Tool Groups = two flows, etc. Also
sometimes referred to as Channels. G-code programs for each flow may
be contained in one file or separate files, depending on the machine.
Form Tool User defined insert shape primarily used for plunging.
Full Retract A pre-defined machine axis position (in every axis that has one). This is
usually at a travel limit. Usually accessible with a G28 Fanuc-style
command.
G28 A Fanuc-style command to move specified axes to their home location.
G30 A Fanuc-style command to move specified axes to a location specified by
the user in the control.

231
 Appendix

Gang Tools A linear row of tools. Gang tools may be stationary (either fixed or a
stationary tool post) or able to move in a single axis.
Guide Bushing Part of a Swiss-style machine that allows the stock to move in & out of
the spindle. The diameter of the bushing must match the stock
diameter. The length of the bushing limits Z-pull back distance. Also
known as Screw Bushing.
Head Stock Describes the machine body which contains the main spindle on a lathe.
It can be bolted to the machine bed (“Fixed Head Stock”) or it can be
mounted on a slide (“Sliding Head Stock”) with or without a Guide
Bushing.
Home See “Full Retract”.
Load/Unload Used in Utility processes to load or unload spindles. “Load” refers to the
Spindle † loading of the initial material into a machine. “Unload” refers to
removing the finished part.
Machine Definition A GibbsCAM file which defines either a generic class of machines (e.g. 3-
Document (MDD) † Axis Horizontal Mill) or a specific machine configuration, including
number of spindles, number of Tool Groups, axes configuration, number
of tools, etc. Multi-Task Machining MDDs are typically machine specific.
Machine An optional product separate from Multi-Task Machining. It allows for
Simulation the precise definition of a machine, its setup and its tools. It simulates
machine and tool motion, with collision detection and movie playback.
Machine Zero 1) CNC: An arbitrary position defined by a machine tool builder for a
collection of axes to use as their origin. The main spindle face and
centerline is a common machine zero. G53 is sometimes used as a
predefined work fixture offset to facilitate G-code programming from
this position. 2) MTM: This is the GibbsCAM MTM concept of the main
spindle CS. All other CSs are measured from here. MTM’s Machine Zero
is a math origin, not a machine axes origin.
Motile Spindle † Part holding spindle that is not fixed in relation to the machine tool (i.e.
has one or more axes of motion). This is frequently used with stationary
tools.
Index Spindle or An indexing lathe moves a group of spindles between tool positions
(Tool Groups), typically in a rotary manner. Each tool position is
Multi-Spindle assigned a spindle number. Indexing these spindles has the effect of
moving the part from one spindle to the next, loading a new part into
(3, 5, 6 or 8 the first position and unloading a part from the last position.
spindles)

232
 Appendix

Multi-Task A class of machining done on machines that can perform multiple tasks
Machining (MTM) at the same time, typically referring to multi-spindle, multi-turret lathes
with live tooling.
Multi-Tool Process, A special rough turning process and corresponding operation where the
Multi-Tool system allocates alternate machining cuts to multiple tools in a
Operation † coordinated method. This provides an efficient way to program “dual
tool rough” machining.
Off Part Location Tool change location or a position away from the part.

Standard off part location: The off part location defined in the MDD for
each TG per spindle, to be used for automatic moves to an off part
location. This is triggered by events such as a tool change and occurs
between operations. The actual location is set in the MDD.

MTG tool change location: A location away from the part that the user
has specified with an MTG Utility operation. If an automatic move to an
off part location is triggered immediately after an MTG operation, the
event will occur at the MTG location instead of a move to the standard
off part location.
Operation Process for controlling multiple machining operations to start or end at
Synchronization a particular time in relation to another process (simultaneous cutting).
(Op Sync)
Origin The 0 point of all the axes in a CS.
Part Coordinate This is a plane the part is in. It is the same plane as the Spindle CS except
System the Z origin is shifted based on part placement. Several Part CSs per
spindle can be found in the CS List, each representing the appropriate
primary plane for specific machining operations (ZX, XY, YZ, etc.).
Part Shift Used in Utility processes to partially move a part out of the spindle
during operations (i.e: the front of the part is machined close to the
spindle and then advanced or “shifted” further out to do more
machining or to machine between spindles/tailstock etc.)
Pick-Off Spindle See “Sub Spindle”
Pinch Turning OD/ TG1 roughs the OD. TG2 roughs the ID. Dwell is 0.0. Both tools begin
ID each stroke together. The purpose is to provide support for a long part
away from the chuck. The ID or OD cut may finish sooner depending on
the length of cuts and feedrates. Not useful in a Swiss spindle.
Program Sometimes used to describe a single flow, especially in machines that
require a separate text file for each flow.

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Screw Bushing Part of a screw spindle that holds the part and allows the stock to move
in/out of the spindle. The diameter of the bushing must match the stock
diameter. The length of the bushing limits Z-pull back distance. See also
“Guide Bushing”.
Screw Machine A machine tool with a fixed headstock/spindle, typically cam operated
with several (4–6) “cross slides” using form tools arranged around the
spindle. Used to produce large quantities of parts. Also known as Cam
Machines and Automatic Machines. See also “Swiss-Style Machine”.
Sliding Headstock See “Swiss-Style Machine”
Machine
Spindle A spindle is a place where a part is held, spun and machined.
Spindle Coordinate The axis definition for each spindle that, per GibbsCAM standard, places
System the Z positive axis exiting the spindle face and the origin at the center of
the spindle face. GibbsCAM Clockwise/Counter-clockwise is defined by
looking at the spindle in the Z- direction.
Standard Spindle A spindle with no linear axis motion, may have a C rotary axis for
milling.
Start & End Sync † Operation syncs that are positioned at the start or end of an operation,
respectively.
Stroke Synching † A special form of a Sync Process where two or more operations start each
cutting stroke simultaneously
Sub Spindle Any spindle that a part may be transferred to, typically opposite the
main spindle.
Swiss Spindle Part-holding spindle that has a linear motion axes (typically a Z axis)
parallel to the spindle axis of rotation and which moves the part in and
out of the guide bushing.
Swiss-Style A machine tool with a “sliding” spindle, typically used to produce small
Machine screw-like parts. Also known as a Swiss screw machine, Swiss lathe and
Automatic lathe. See also “Swiss Spindle” and “Guide Bushing”.
Sync Marker † The special symbol shown in the Op Sync dialog to represent an
Operation Sync.
Sync Process † Process for controlling multiple machining operations to start or end at
a particular time in relation to another process (simultaneous cutting).
System Sync † Special type of Operation Sync where the system creates the sync
automatically as a result of a special process or operation. Often used in
multi-tool processes and utility processes.
Tail Stock Describes the machine body opposing the Head Stock on the same
centerline to support long workpieces or shafts on a lathe.

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Tool ID # In a simple mill or lathe part, the tool number is the list position.
Optionally, a user may override this with a Tool ID #. In MTM, the Tool
(Identification) ID # consists of TG #, and a TG position #. Both are displayed on Tool,
Process, and Operation tiles.
Tool Group (TG) † Any collection of tools, of which only one may be used at a time. The
tools in a TG typically move together (there are exceptions). A typical
TG is a turret or a gang slide.
Tool Offsets An XZ shift for each tool, typically from the TG/turret datum to the tool
tip.
Tool Tip Location used when Offsets are on. G-code position values include the
tool offset values because the tool offsets have been programmed “on.”
See also “Turret Datum”.
Turret A common lathe tool changer and Tool Group where tools are rotated
into position.
Turret Datum Location used when Offsets are off. G-code position values do not
include the tool offset values because the tool offsets have been
programmed “off” and therefore represent the TG datum position. See
also “Tool Tip”.
Utility Process Special processes that are typically not cutting operations, but ancillary
machine controlled functions (e.g. part mover, part catcher, tailstock
Utility Operation † controls).
Utility Tool † Special tool used for utility processes. Allows assignment of tool position
to a tailstock or Sub Spindle (optional).
VMM † Virtual Motion Macro. The VMM is a file that provides the link between
the MDD and the Post Processor to implement custom utility
operations. A machine specific MDD will reference the matching VMM
for MTM machines.
Work Fixture Work Fixture Offsets allow the user to enter a shift for every axis in a
Offsets machine, usually from machine zero or from machine home. The goal is
to set up a part CS so the G-code can be programmed from a part origin
in each spindle. This shift amount is typically from the TG/turret datum
to the part origin, relying on tool offsets to provide the shift for each tool
from the TG/turret datum. Typically G54-G59 on a Fanuc.
† Denotes a term used by GibbsCAM.

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FAQ (FREQUENTLY ASKED QUESTIONS)

In the following section you will find answers to questions and problems that may arise.

• This operation is not generating any toolpath! What is wrong?

Typically, an operation will not generate toolpath under several conditions, including
the tool is too large or you have specified that an operation is Material Only and there is
no material to be cut. With MTM there are some additional possibilities.

1. Open the Tool dialog for the tool you are trying to make an operation with. Check
to make sure the tool is oriented correctly (coming in from the correct side of the
part) and that the insert is on the correct side of the holder.

2. Check to ensure the operation is set to cut on the correct spindle.

3. Check to ensure the operation is set to cut on the correct side, i.e. +X or –X.

4. Check the current coordinate system. In some cases being in the wrong CS will
prevent toolpath from being generated.

• When I activate rendering, I do not get any stock on a sub-spindle. How do I fix this?

There are several possible solutions to this problem.

1. If you have not transferred the part to the sub spindle you must create a set of
Utility operations that perform this, e.g. Sub Spindle In, cut off, Sub Spindle Return.

2. Your Unload Spindle Operation is set to the wrong spindle.

3. Your Sub Spindle Return that is supposed to move the part does not have With Part
selected.

• After a Sub-Spindle Return operation, the transferred part is rendered in the wrong place.

Check the Grip Z value of the Sub-Spindle In Utility

operation and the Part Distance From Face setting for
the sub spindle in the Document Control dialog. In all
likelihood, the Grip Z value plus the part face distance
from the spindle do not add up to the part length. If
you have a 50mm part and you grip it in the middle
(Z-25, assuming the part face is at the origin) with the

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 Appendix

sub spindle, it is sticking out of the sub spindle by 25. The setting in the Document
Control dialog should reflect that.

• After a Part Shift operation, the part is rendered in the wrong place.

Check the Sub-Spindle In Grip Z value and the Shift Distance in the Part Shift Utility
Operation.

• There are red X’s over my utility operations. What does this mean?

There are two possibilities. You may have changed the MDD used by the part to an
MDD that does not support those Utility operations. Switch back to an MTM MDD that
does support the Utility operations. If this is not the case, the VMM file that
accompanies the MDD has been damaged, removed or not installed. Each MDD has an
accompanying VMM. The MDD and VMM files are normally named identically but
with different extensions (e.g., Hard_Conquest65_0001.mdd and
Hard_Conquest65_0001.dll). An MTM MDD will not work without its
accompanying VMM and the VMM must be kept in the VMM folder.

• I typed in a rotation angle of 270˚ and my post output -90˚. Why is this?

GibbsCAM always makes the shortest rotation to minimize cut time.

• I post and I get warnings that certain operations are invalid. What is wrong with the
operations?

Chances are, there is nothing wrong with your operations. In all likelihood, you are not
using an MTM post processor. Select a different post, make sure it is an MTM post, and
try again. MTM posts have the code AML included in their name.

• I have created my part but I need to change the set up. What do I need to look out for?

The stock size settings in the Document Control dialog may need to be updated to
change a part. Especially important are the Spindle 2 settings for part transfers.
Additionally, check any Grip Z values in Sub Spindle On Utility operations.

• My rendering sequence is odd. One spindle renders, resets (or reloads) then the second
spindle starts to machine.

The sequence of your operations is set so that the load command is in the middle of
your program. Move your load/unload sequence to the start or end of the program.

237
 Appendix

238
INDEX
 Index

Control Point: 73–74

A Coolant: 22
Adjust Feed To End Together: 89 Coordinate Systems: 27, 29–31, 44, 233–234
Approach Axis: 44 Definition: 231
Approach Side: 50 CP1: 42
Auto Chuck: 61, 63, 65 CP2: 42
Auto Clearance: 20, 42, 72, 87, 114 CP3: 42
Auto Collet: 61 Custom Stock: 29
Axis, definition: 231 Cut Other Side: 59
Cut Part Render: 14, 28
Retracts: 97
B Stock: 98
B Rotation: 51 Tool: 97
Balanced Turning: 231 Tool Group: 97
see also Multi-Tool Slave Process Cut Side: 50, 53, 59
Bar Feed: 21, 59, 61, 66
Auto: 61, 66
Bar Pull: 61, 63, 66 D
Boxes in Lists Delay Time: 92
Uncolored: 85 Dimensions: 13
Bushing: 232, 234 Document Control dialog: 18
Drill Cycles: 22
Dual Tool OD Roughing: 231
C
Dwell: 89
C Synced: 68
Casting (stock shape): 28
C-Axis Output: 107 E
Change CS: 30–31 End Point: 42
How To: 32
Entry Clearance: 42
HVD: 30, 119
Exit Clearance: 42
XYZ: 30
Exit Point: 43
Channels, see Flow
Clearance: 112
Clearance Data: 20 F
Clock, see Recalculate Run-Time Feed Distance: 62

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 Index

Feedrate: 62, 66, 68, 70 Initial Face Z: 62, 66

Flow: 39, 87–88, 90, 93, 99 Initial Stock: 11, 20–21, 29, 98, 112–113
Definition: 39, 231 Input Values, by user: 44
Sort: 86
Insert
Form Tool: 231 Direction: 50
Full Retract: 231 Face Down: 51
Face Up: 51
Orientation: 52
G Insert Direction: 51
Gang: 74, 232 Insert Optional Stops: 105
see also Tool Group Inter-operation moves: 76, 87
G-code
G28: 79, 231
G30: 79, 231 L
syncs: 88
Lathe Manual: 28–29
Geometry: 13
Load: 66
Geometry Creation Manual: 9
Load Spindle: 61, 178
Geometry on both sides of centerline: 118 Process: 61
Geometry, colors of: 30
Geometry, flipping: 157
Geometry, moving: 30–32 M
Getting Started Manual: 9 Machine Definition: 17
Go To Master: 94 Machine Home: 73–74, 80
Graphic Part Face Distance: 20, 114 Machine Zero: 232
Grip Z: 62, 64, 66, 68 Machining Center: 17, 29
Machining Markers, side to set on: 157
Machining palette: 59
H Main Palette: 10
Head Stock: 232 Main Spindle
Home View: 120 Utility Process Selection: 60
HVD: 30 Main Spindle Loaded: 70
Manual Chuck: 61, 63, 65
Master Clearance Plane: 42
I Master Operation: 85
Index Spindle: 232 MDD: 17, 21–22, 60, 103, 232, 235
242
 Index

Mill Manual: 29
Mill/Turn functions: 37
P
Minimize Line Numbers in Post: 105 Part Catcher: 63
Motile Spindle: 232 Part Clearance: 42–44
Move Tool Group: 71–78, 80 Part Gripper: 63
Multiple Spindles: 27 Part in Main: 67
Multi-Task Machining (MTM): 233 Part in Sub: 67
Definition: 3 Part Origin: 21
Sequence to create: 5 Part Shift: 33, 64, 233
Multi-Tool Process: 233–234 Part ZX: 74–75
Multi-Tool Slave Process: 38 Parts Catcher
In: 70
Out: 71
N X In Position: 70–71
N Number: 105 Z In Position: 71
No Path Utility operation: 73, 76 Pick-Off Spindle: 233
No Toolpath: 60 Pinch Turning: 233
Non-Cutting Positioning Control: 71 Polar Interpolation: 108
Post
Comments: 105
O Label Definitions: 106
Output Units: 105
Off Part: 72
Definition: 72 Selected Ops: 105
Location, defined: 233 Sequence Numbering: 105
Op Comment: 94 Post Editing: 104
Op Mode: 87, 90 Post Processor: 103
Open Collet: 70 Posted Output, comments in: 94
Operation Data: 160 Posting Concepts: 104
Operation Synchronization: 85, 88, 233–234 Preloaded: 21, 98, 112–113
Operation, Flipping: 93 Process Creation: 59
Orientation Spindle: 51, 53 Program: 233
see also Flow
Origin: 233
Push Out Unload: 67–68
Over Travel: 74

243
 Index
R Show & Hide: 13
Recalculate: 92
Recalculate Run-Time: 91–92
Render
By Flow #: 99
see also Cut Part Render
Show Time: 99
Stop before an op: 99
Stop before Load/Unload: 99
Reverse Transfer: 67
Robot: 61, 64, 66
Rotary Feedrates: 107
Rotary Milling: 37
RPM: 91
Run-Time: 99, 162
S Spindle, Standard: 234
Scale: 92
Screw Machine: 234
Shift Distance: 66
Slave Operation: 85
Slide, see Tool Group
Sliding Headstock: 234
Sort Ops: 86
Sort Tools: 49
Spindle: 234
Alignment to ZX plane: 31
Display Multiple: 97
Display when rendering: 13
Load Command: 98
Loading & Unload: 59
Multiple Spindles: 10
On & Off: 59
Set Up: 10–11
244
Set-Up: 10
Side to cut on: 59
Used in Operation: 85
Utility Process: 60
Spindle Control: 162
Spindle Display List: 9–10
Spindle Distance Display
see Graphic Part Face Distance
Spindle list: 13
Spindle Mode: 87, 90
Spindle On: 62, 66, 69–70
Spindle Position: 22
Spindle Selection: 18, 59, 90
Spindle Size: 22
Spindle Speed: 62, 66, 69–70
Spindle ZX: 74–75
Spindle, Sub: 234
Standard Tool Change Position: 72
Start of a Program: 73
Start Point: 42, 44
Starting Program Number: 105
Stock
Bar Stock: 19
Condition: 18, 28
Definition: 19
Initial. see Initial Stock
Load Stock: 21
Location: 18
Non-Cylindrical: 28
Size: 18
Stock Advance: 21
Transferred: 20
Uncut: 20
 Index

Stock Diagram: 19, 112 Synchronizing Machining: 14

Stock Setup, +Z: 19
Stock Setup, –Z: 19
Stroke
T
Adjust Feed To End Together: 89 Tail Stock: 59, 234
TG Start Dwell: 89 The: 13
Wait at End: 89 Tile, items displayed on: 12
Stroke Sync dialog: 41 Time: 62, 64, 66
Stroke Synching: 85, 88–89, 234 Recalculate: 86
Sub Spindle: 235 Time Line: 93
Sub Spindle Return: 69 Time Scale: 91
Sub-Spindle On Part Process: 67 Tool
Sub-Spindle Pull: 66 Probe — See Utility Tool
Utility Process Setting: 60 Stop — See Utility Tool
Sub Spindle On Part: 67 Tool Change: 21, 44, 112, 114
Sub Spindle Pull: 61, 66 Tool Change Location: 71, 73
Swiss Machine: 232–234 Tool Dialog: 11, 49, 52, 54
Swiss Spindle: 234 Tool Group: 10–11, 39, 49, 85, 231, 235
Swiss-Style Parts: 42 Definition: 39
Switching Spindles: 44 TG Tool is assigned to: 50
Sync: 39, 41, 85–86 Tool is assigned to: 50
Definition: 41, 88 Tool’s Position in: 50, 85
Op Sync: 41 Tool Group Datum: 74
Operation: 86, 88 Tool ID#: 51, 235
Operation Sync: 41 Mill: 51
Stroke: 86, 88–89 Tool Number, in tiles: 85
Stroke Sync: 41 Tool Offsets: 235
System Sync: 41, 85, 234 Tool Orientation: 52–53
Sync Control: 10 Tool Positions: 22
Sync Control dialog: 9–10, 14, 41, 86–87, 90, Tool Tip: 74, 235
92, 160
Toolpath, Associative: 53
Sync Marker: 234
Toolpath, Flipping: 53
Sync Mode: 87–88
Top Level Palette: 9
Sync Preferences: 92
Turret: 74, 235
Sync Process: 234 see also Tool Group

245
 Index

Turret Datum: 235 Xdiameter: 19

Turret Selection: 21 Xradius: 19
X Drop: 64
X Position: 62, 64, 67
U
Uniform Tile View: 76, 87
Unload: 67 Y
Unload Spindle: 62 Y-Axis Output: 107
Utility Data: 85, 93
At Op End: 94
At Op Start: 94 Z
Utility Operation: 44, 85, 98 Z Clearance: 62, 64, 67–68
Load & Unload: 99 Z Drop: 64
Utility Ops: 85 Z Retract: 64
Utility Process: 12, 55, 59, 234–235
Utility Tile Appearance: 176
Utility Tool: 11, 55, 235

V
VMM: 235

W
Wait at End: 89
With Part
Sub Spindle Return: 70
Work Fixture Offsets: 235
Work Planes, see Coordinate Systems
Workgroup Display: 13
Workgroups: 29
Part Stock: 29

X
X Dimension Style: 21
246