Mill Standard & Pro Manual - BobCAD-CAM

BobCAD-CAM Version 25 Getting Started Guide 

About this Workbook 

BobCAD-CAM 

6 7, 2013 

Copyright © 2013 by BobCAD-CAM Inc., All rights reserved. No part of this work may be reproduced or 

transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, or 

by any information storage or retrieval system without prior written permission of BobCAD-CAM Inc. unless 

such copying is expressly permitted by federal copyright law. This document may be downloaded from 

www.bobcad.com and printed for personal use. Address inquiries to Documentation Department, BobCAD- 

CAM, Inc., 28200 US HWY 19 N., Suite E, Clearwater, Florida 33761 

AutoDesk, ACIS, Rhinoceros, ParaSolid, Predator CNC Editor, 

Predator Virtual CNC, and SolidWorks are all trademarked by their respective companies. 

2 Real CNC Programming Solutions for Global manufacturing |Copyright (c) BobCAD-CAM, Inc. 2012



TABLE OF CONTENTS 

ABOUT THIS WORKBOOK ................................................................................... 9 

INSTALLATION .................................................................................................. 10 

WINDOWS (MINIMUM) ..................................................................................................................................... 10 

WINDOWS (RECOMMENDED) .............................................................................................................................. 10 

SPECIFICATIONS -RECOMMENDED VS. MINIMUM. ................................................................................................... 11 

CHECKING SYSTEM REQUIREMENTS ...................................................................................................................... 11 

UPDATING THE COMPUTER SYSTEM ...................................................................................................................... 11 

TO CHECK FOR WINDOWS UPDATES, FOLLOW THESE STEPS: ....................................................................................... 11 

UPDATING THE GRAPHICS CARD DRIVER ................................................................................................................ 12 

INSTALLING & REGISTERING BOBCAD SOFTWARE ............................................. 13 

INSTALLING BOBCAD-CAM ............................................................................................................................... 13 

REGISTERING BOBCAD-CAM ............................................................................................................................. 13 

SETTING UP THE TOOL DATABASE FOR MILL & ROUTER .................................... 15 

ADDING A TOOL HOLDERS & TOOLS ......................................................................................... 15 

TO ADD A TOOL TO THE TOOL LIBRARY, FOLLOW THE INSTRUCTIONS BELOW. .................................................................. 16 

USING TOOL CRIBS ............................................................................................................... 16 




MACHINE SETUP & POST PROCESSOR INSTALLATION ........................................ 17 

INSTALLING POST PROCESSORS ................................................................................................ 18 

ADDING YOUR MACHINE(S) ................................................................................................... 19 

INTRODUCTION ................................................................................................................................................. 19 

PART 1) ADD A NEW MACHINE ........................................................................................................................... 21 

PART 2) LOCATING THE MACHINE DEFINITION FILES ................................................................................................ 23 

PART 3) THE MACHINE DEFINITION DIALOG BOX - DEFINE THE Y-AXIS PARAMETERS ..................................................... 26 

PART 4) DEFINE THE X-AXIS PARAMETERS ............................................................................................................. 28 

PART 5) DEFINE THE A-AXIS PARAMETERS ............................................................................................................. 29 

PART 6) DEFINE THE Z-AXIS PARAMETERS ............................................................................................................. 30 

PART 7) ADD THE MACHINE BASE ........................................................................................................................ 31 

PART 8) ADD THE Y-AXIS GEOMETRY .................................................................................................................... 34 

PART 9) ADD THE X-AXIS GEOMETRY.................................................................................................................... 35 

PART 10) ADD THE A-AXIS GEOMETRY ................................................................................................................. 36 

PART 11) ADD THE Z-AXIS GEOMETRY .................................................................................................................. 37 

PART 12) ABOUT THE DYNAMIC ELEMENTS ............................................................................................................ 38 

PART 13) ABOUT THE COLLISION CHECK ................................................................................................................ 43 

PART 14) ADDITIONAL MACHINE PARAMETERS ...................................................................................................... 45 




MACHINE SETUP CHECKLIST ............................................................................. 46 

MACHINE NAME: _________________________________________________ .................... 46 

CONTROLLER MAKE AND MODEL: ___________________________________ ......................... 46 

TYPE OF MACHINE: __________________________________________ ............................... 46 

MAXIMUM SPINDLE SPEED: _____________________________________ ............................. 47 

MAXIMUM FEED RATE: __________________________________________ ......................... 47 

NC FILE EXTENSION: __________________________________________ ............................. 47 

DIRECTION VECTOR: ............................................................................................................. 48 

X AXIS DIRECTION:............................................................................................................................................. 48 

Y AXIS DIRECTION: ............................................................................................................................................. 48 

Z AXIS DIRECTION: ............................................................................................................................................. 48 

MINIMUM & MAXIMUM VALUES FOR AXIS TRAVEL: .................................................................... 49 

X____ _____ ................................................................................................................................................. 49 

Y____ _____ ................................................................................................................................................. 49 

Z____ _____ ................................................................................................................................................. 49 

ROTARY AXES: .................................................................................................................... 50 

DIRECTION OF POSITIVE ROTATION ON ROTARY: .......................................................................... 51 

1ST ROTARY ROTATION: ..................................................................................................................................... 51 

2ND ROTARY ROTATION: .................................................................................................................................... 51 

ROTARY CENTERS: ............................................................................................................... 52 

1ST ROTARY AXIS: ____ ____ ____ ................................................................................................................... 52 

2ND ROTARY AXIS: ____ ____ ____ .................................................................................................................. 52 

ROTARY AXIS G-CODE PREFIX: ................................................................................................ 53 

1ST ROTARY AXIS: _________ EXAMPLE: “A” ..................................................................................................... 53 

2ND ROTARY AXIS: _________ EXAMPLE: “B”..................................................................................................... 53 

MINIMUM & MAXIMUM ROTARY DEGREES: .............................................................................. 53 

1ST ROTARY AXIS: ______ ______.................................................................................................................... 53 

2ND ROTARY AXIS: ______ ______................................................................................................................... 53 

STL FILES (OPTIONAL) .......................................................................................................... 54 

ADDING YOUR MACHINE ..................................................................................................................................... 55 




POSTING .......................................................................................................... 62 

POST PROCESSOR ................................................................................................................ 62 

TOOL PATTERN ................................................................................................................... 62 

NC FILE PATH ..................................................................................................................... 62 

PROGRAM ......................................................................................................................... 62 

ABSOLUTE/INCREMENTAL ...................................................................................................... 62 

SEQUENCE NUMBERS ............................................................................................................ 62 

SUBPROGRAM NUMBERS ....................................................................................................... 63 

OUTPUT ARCS IN 4-AXIS NC PROGRAM .................................................................................... 63 

MULTI-AXIS POSTING ....................................................................................... 65 

ANGLE PAIR ....................................................................................................................... 65 

MACHINE LIMITS ................................................................................................................. 66 

POLE HANDLING .................................................................................................................. 67 

TOOL REPOSITIONING ........................................................................................................... 67 

POINT INTERPOLATION .......................................................................................................... 68 

FEED MOVE ..................................................................................................................................................... 68 

RAPID MOVE .................................................................................................................................................... 68 

MACHINE DEFINITION ZERO ................................................................................................... 69 

MOVE LIST WRITER.............................................................................................................. 69 

ADDING GEOMETRY TO YOUR MACHINE (OPTIONAL) ................................................................................................ 70 

MATERIAL LIBRARY FEEDS & SPEEDS ................................................................ 72 

ADDING & EDITING MATERIALS .............................................................................................. 72 

SELECTING MATERIAL ............................................................................................................ 72 

DRILLING OPERATION SETUP ............................................................................ 73 

DRILLING PARAMETERS ......................................................................................................... 73 

ADDING AND REMOVING TOOLS FROM OPERATIONS .................................................................... 74 

WORKING WITH TAPS ........................................................................................................... 75 




THE STOCK WIZARD & PART ORIENTATION FOR MILL, ROUTER, PLASMA, LASER 

AND WATER-JET ............................................................................................... 76 

IMPORTANT INFORMATION .................................................................................................... 76 

HOW TO ACCESS THE STOCK WIZARD ........................................................................................ 76 

THE STOCK WIZARD DIALOG BOXES ......................................................................................... 76 

HOW TO SELECT THE STOCK TYPE ............................................................................................. 77 

WIREFRAME ..................................................................................................................................................... 77 

SOLID MODEL .................................................................................................................................................. 77 

STL FILE .......................................................................................................................................................... 77 

THE STOCK DEFINITION DIALOG BOX ........................................................................................ 78 

THE MACHINE SETUP DIALOG BOX .......................................................................................... 78 

SELECT THE MACHINE SETUP ............................................................................................................................... 78 

HOW TO SELECT THE MACHINING ORIGIN .............................................................................................................. 78 

HOW TO SET THE MACHINING ORIGIN USING THE ENTER METHOD ............................................................................. 80 

HOW TO SET THE MACHINING ORIGIN USING PICK FROM EXISTING UCS ..................................................................... 80 

OTHER SETTINGS ............................................................................................................................................... 80 

MILL & ROUTER TUTORIAL ............................................................................... 81 

HOW TO ADD A TOOL PATH .................................................................................................... 81 

HOW TO POST CAM FEATURES............................................................................................... 81 

HOW TO SIMULATE .............................................................................................................. 82 

LATHE TUTORIAL .............................................................................................. 83 

HOW TO CREATE STOCK USING THE STOCK DIALOG BOX ............................................................... 83 

ADDING TURNING FEATURES ............................................................................................................................... 84 

HOW TO POST CAM FEATURES ........................................................................................................................... 88 

HOW TO SIMULATE ........................................................................................................................................... 88 

SENDING FILES TO THE MACHINE ...................................................................... 89 

SAVING FILES TO A DISK ........................................................................................................ 89 

MILL ............................................................................................................................................................... 89 

LATHE ............................................................................................................................................................. 89 

RS-232 SETUP .................................................................................................................... 89 




ADD-ON MODULES OVERVIEW ......................................................................... 91 

BOBART ............................................................................................................................ 91 

NESTING ............................................................................................................................ 91 

4 & 5 AXIS ........................................................................................................................ 91 




ABOUT THIS WORKBOOK 

This workbook is meant to be read in order, the lessons are progressive and build upon themselves; this 

workbook is also intended for use in conjunction with the included training videos. The videos contain 

additional instructions as well as additional features offered in BobCAD. The sections marked with an icon 

have a video that is associated with them along with the title of the video. 

This section covers the terms that are used within this manual. It is necessary to read this portion of the 

document in order to interpret the training manual correctly. More information about specific commands and 

functions can be found within the Help system included within the BobCAD-CAM software. 

• Click - means to Click with the left mouse button. 

• Right-Click - means to Click with the right mouse button. 

• Compute a Toolpath - means to generate Toolpath. 

• Click-Pause-Click - means to slowly Click the mouse button twice. 

• Start – This refers to the Start menu which is usually located on the Bottom Left of the computer screen. 

• Double-Click – This means to rapidly Click the mouse button two times. 

• Post Processor – This is a unique “driver” specific to the CNC controller it’s intended to work with. The Post 

Processor controls the format of the G-code produced by BobCAD-CAM. 

•Chain Select – This means to hold the Shift-key on the keyboard and Click on a line. This will select a loop of 

entities that will form a chain. 

•Window Select – This means to hold the Left Mouse button down and then drag over the entities to be 

selected releasing the Left Mouse button after the entities to be selected are Highlighted. 

Notes: All of the parts files that are used and referenced in this documentation are available on Cd’s included 

with this training set. All contexts that have an associated video are labeled with the video name in red. All 

part files that are associated are indicated in green. 



Installation 

INSTALLATION 

For BobCAD-CAM to run efficiently it is critical that all necessary files are present on the computer. 

BobCAD-CAM Uses the latest technology available, for this reason it is imperative that the Windows System 

and Hardware drivers on the computer are up to date. 

Before Installing BobCAD software, first insure that the computer meets or exceeds our system requirements. 

Windows (Minimum) 

1GB RAM 

128 MB Graphics Adaptor* 

Intel® or AMD® Processors** 

2GHz Processor 

Windows XP SP3, Windows Vista or Windows 7 

Windows (Recommended) 

 

 

 

 

 

6GB RAM 

1GB Graphics Adaptor* 

Intel® or AMD® Processors** 

2+GHz Processor (Multi-core) 

Windows 7 x64 

*BobCAD-CAM’s stability is dependent on the graphics card ability to process information, integrated memory 

graphics cards may work but are not recommended. 

ATI® or NVIDIA® graphics cards with dedicated memory are recommended. The graphics card’s software driver 

must be updated to the current software drivers released by the graphics card manufacturer. 

**BobCAD-CAM is not supported on Apple Macintosh® -based machines. Some customers have shown success 

in running BobCAD-CAM in a Virtual Windows environment on Mac computers using Boot Camp. While the 

end user may choose to run Windows on a MAC®, this is not supported by BobCAD-CAM Inc. 



Installation 

Specifications -Recommended Vs. Minimum. 

The Minimum specifications means that BobCAD-CAM software will open and work, the minimum 

requirements do not gauge performance and stability. For BobCAD-CAM to preform reliably at its best, it is 

highly recommended to meet or exceed the recommended specifications. 

Checking System Requirements 

Click on the Windows Start button, In the Search box type “dxdiag” (without the quotes) then press 

Updating the Computer System 

Note: Even new computers usually require software and driver updates. These updates are released on a 

weekly and monthly basis, before installing BobCAD software you should check that your Windows 

system and graphics card driver are up to date to avoid future problems. Should you not be able to 

do this for any reason do not worry, just proceed with the installation of BobCAD and if a software 

stability problem arise you may need to re-visit obtaining and installing these updates. 

Windows Updates 

Windows updates are necessary to insure a stable working environment for the BobCAD software to perform. 

There are different kinds of updates. Security updates or critical updates protect against vulnerabilities to 

malware and security exploits. Other updates correct errors that aren't related to security, or enhance 

functionality. 

Windows Updates are normally provided over an Internet connection, although there is provision for updates 

to be installed on computers without an Internet connection. If your computer is not or cannot be connected 

to the internet you should consult an IT professional for help with how to obtain these updates. If the 

computer is or can be connected to the internet, then check for and run all of the available updates from 

Microsoft. Your computer is up to date when you've installed the latest updates for Windows and your 

programs. 

To check for Windows updates, follow these steps: 

Open Windows Update by Clicking the windows Start button, Clicking All Programs, and then Clicking 

Windows Update. In the left pane, Click Check for updates, and then wait while Windows looks for the latest 

updates for your computer. If any updates are found, Click Install updates. Administrator permission required 

if you are prompted for an administrator password or confirmation, type the password or provide 

confirmation. 


Updating the Graphics Card Driver 


Installation 

The graphics card driver is one of the most crucial dependencies for the software to preform properly. 

It is a common misconception that Windows will update the graphics card driver. The graphics card driver 

must be updated manually. To update the graphics card driver, the latest driver must be obtained from the 

graphics card manufacturer. 

To update the graphics card driver you will first need to know the make and model of the graphics card, to 

obtain this information, Click on the Windows Start button, In the Search box type “dxdiag” (without the 

quotes) then press enter. This will display a control panel that shows the processor, memory and graphics card 

information. 

Write down the graphics cards make and model, and then search the internet to find the manufactures 

website. Once you have found the manufactures website you can then follow their instructions on 

downloading and installing the newer driver if available. If you are unable to locate a newer driver for the 

cards you have do not worry this just means you are probably already running the latest update. 



Installing & Registering BobCAD Software 

INSTALLING & REGISTERING BOBCAD SOFTWARE 

Installing BobCAD-CAM 

To install the Software locate your BobCAD-CAM installation disk and place it in the CD drive. The CD should 

play automatically, and then follow the onscreen instructions to complete the installation. 

Registering BobCAD-CAM 

The BobCAD-CAM software will need to be installed to your computer before registration, after the original 

installation you will have a 5 day trial period where all modules will be registered before you are required to 

activate the software’s license. 

There are two methods to active BobCAD-CAM’s license, using the internet or by Phone. 

To register by using the internet, follow the instructions below. 

Step 1. To open the software, Double-Click the BobCAD-CAM icon on the desktop or in the Start menu, Click 

All Programs and select BobCAD-CAM. 

Step 2. Trial Mode 

When the software is first installed, all modules inside the software are licensed for a five-day trial period. If 

you are within the first five days of installing the software, the Trial Mode dialog box is displayed. 

The following two options are available. 

Run as Trial – the software is unlocked for you to use for five days. 

Register Online – starts the online registration process. 



Installing & Registering BobCAD Software 

Demo Mode 

Once the five-day full unlock expires, the software begins running in the Demo Mode. This allows you to still 

use the software, but without the ability to post NC programs, and any files that are saved in Demo Mode 

can't be opened in the licensed version of the software. The Demo Mode dialog box appears when the 

software is first launched. 

The following two options are available. 

Run as Demo – the software is run in Demo Mode. 

Register Online – starts the online registration process. 

Click Register Online to continue registering the software. 

Step 3. Type the License ID and the Password that were provided on the invoice with the software package. 

If you are registering multiple computers, you will need a License ID and Password for each computer that you 

are registering. 

Step 4. Click Activate. At this time the software attempts to connect to a server to obtain authorization. When 

the connection is made successfully, and the License ID and Password are valid, a dialog box is 

displayed indicating that the software has been successfully licensed. 

Step 5. When the dialog box indicating a successful activation has occurred, Click OK to continue. 

The License Status dialog box is displayed with a list of which modules were licensed, as well as the customer 

information. 

Note: If an error occurred during the Online Activation, please contact BobCAD-CAM Registration 

Department by phone at (727) 442-3554 or by email at registration@bobcad.com. To register by 

using the phone, from your computer with BobCAD installed call 877-262-2231. 



Setting up the tool database for Mill & Router 

SETTING UP THE TOOL DATABASE FOR MILL & ROUTER 

Note: For adding Lathe tools, skip ahead to the lathe tutorial. The Milling Tool Library contains all of the 

available system tools. The tools contained within the tool library are all of the tools that you can 

use from within the BobCAD-CAM tool path features. This library is set up and customized by you, 

the end user. While it is not necessary to set up a tool library it is recommended, that at this point 

you add at least some of the tools you will be using. Tools can also be added to the software later at 

any point in time. 

Note: The only tools that must be entered to the library before using them are the Tapping tools. This is 

made so that the machine feed rates can be properly calculated. 

Adding a Tool Holders & Tools 

To add a tool holder to the tool library, follow the instructions below. 

To access the Milling Tool Holder Library, in the CAM tree, Double-Click CAM Part, Right-Click Milling 

Tools, and Click Holders. 

From here you can find Add Arbor and Add Holder, Holders and arbors are entered here and a drawing of 

them is generated dynamically as you build the Arbors and Holders. 

Note: Arbors and Holders are not only used for simulation purpose for 2 – 3.5 axis toolpaths at this time it 

is not necessary to set up a holder nor an arbor, the default ones that come pre-installed with 

BobCAD-CAM can be used. Additional Information & Tutorials on adding Tool Holders and arbors 

can be found within the BobCAD-CAM help system by Clicking on help then help topics and 

searching for the term “Arbor” or “Holder”. 



Setting up the tool database for Mill & Router 

To add a tool to the tool library, follow the instructions below. 

To add a tool to the tool library, follow the instructions below. 

To access the Milling Tool Library, do the following: 

In the CAM tree tab, Double-Click CAM Part. Right-Click Milling Tools, and Click Tools. 

In the left pane select a tool type, then Click on Add to add a new tool. Fill out the Add tool dialogue box using 

the information that you have about your tools. 

Note: The BobCAD-CAM Software’s tool library includes a limited amount of tool types that BobCAD-CAM 

software supports. Certain Unsupported or Custom tooling can be added to the library. If you add 

unsupported tools to the tool library you must use an existing tool type for entry to the database, 

use the Tool label (tools description) to identify these tools. Unsupported tools must be manually 

accounted for within your CAD drawings and machines offsets. 

Using tool Cribs 

The Milling Tool Crib is comparable to the tool changer on a machine. It adds two advantages to the milling 

system. First, the Milling Tool Crib can be loaded and saved before you create milling features. When the 

milling feature operations are created, the system automatically selects the appropriate tool from the Milling 

Tool Crib. Second, when selecting tools for milling operations, the tool crib shows all tools that are currently 

defined. By having the tools already defined, you can eliminate the need to search the Milling Tool Library. 

To add tools to a tool crib, follow the instructions below. 

To access the Milling Tool Crib, do the following: 

In the CAM tree, under CAM Part. Right-Click Milling Tools and Click Tool Crib. Use this method to 

view all the tools currently loaded in the Tool Crib. 

Click on Add Tool From Library, and select the tool to add then Click OK. 

Note: In order to load tools into the Milling Tool Crib before creating milling features, you must create the 

tools in the Milling Tool Library. When tools are created in the Tool dialog box, of a milling wizard, 

that are not pre-loaded into the Milling Tool Crib, the tools are then automatically added. When the 

Milling Tool Crib is accessed by Clicking Tool Crib from a milling wizard Tool dialog box, the list 

automatically shows only the available tools for that operation type. 



Machine Setup & Post Processor Installation 

MACHINE SETUP & POST PROCESSOR INSTALLATION 

It is important to properly define your machines within BobCAD-CAM. The machine file controls several 

aspects of the software. 

The machine file controls the following Items… 

Simulation 

Post-Processor used 

Gouge & Collision Checking 

Min. & Max. Feed Rates 

Multi-Axis Posting Settings 

Min. & Max. Spindle Speed 

Machines Physical Definition & Limits Unit Output 

BobCAD Software Defaults 

Sequence Numbering. 

Sub‐Program Output 

The file extension for G‐code files. 

These Items must be configured for your software to work properly. 

The example used in the upcoming lesson is for a 3 axis mill with a 4 th axis rotary table. The steps used in the 

lesson will be the same steps used in creating any milling machine within BobCAD-CAM. 

BobCAD-CAM supports all g-code based 3-5 Axis milling machines, the orientation and configuration of these 

machines are determined by the machine configuration within BobCAD-CAM. 

It is strongly recommended that you first complete the tutorial in the next section before attempting to setup 

your machine within BobCAD-CAM. 


Installing Post Processors 



A post processor is the translator that formats the G-code output by BobCAD-CAM into the language that your 

CNC machine can read. It is important that you locate and install a post processor as soon as possible, without 

post-process BobCAD-CAM software cannot program the CNC machine. 

Post-processors can be found & downloaded from the BobCAD-CAM website, http://www.bobcad.com. 

To install a post-processor, open your web browser and go to http://www.bobcad.com. Click on Support and 

then Post –Processors. Follow the on-screen instructions to use the post-processor wizard to download your 

post processor, make sure to save the file. After the post processor has been saved to your computer, locate 

the file you had saved and Double-Click the file to begin the installation. 

The post installation copies the post file to the BobCAD-CAM software’s post directory, its default location 

which for V25 Mill is in C:\BobCAD-CAM Data\BobCAD-CAM V25\Posts\Mill. 

Note: After the installation is complete you will now be able to locate the file when you need to access it 

when setting up a machine. After Installation is complete there should be no visible change, proceed 

to adding your machine. 


Adding Your Machine(s) 



Introduction 

This tutorial covers how to create a machine. Machine creation starts with a machine definition to define each 

element of the machine. Then the parameters are defined for each element of the machine, such as the 

moving direction and limits. The machine parameter values are used in posting. For each element, geometry 

(.stl) files are added to define what appears in the simulation window. 

There are two levels of machine simulation: Standard Simulation and Pro Simulation. If you have purchased 

the 4 Axis Pro, 5 Axis Standard, or 5 Axis Pro module, then you have the Pro Simulation. Regardless of what 

level of machine simulation you have, you must still create a proper machine definition. The only difference is 

that with Standard Simulation, you can’t add geometry items to the machine definition that is used for 

simulation. 

The following image shows the 4-axis machine that is created in this example. 




The following image shows all of the individual geometry files (.stl), together in one Workspace. This is shown 

to help you understand how each geometry item is aligned in the Workspace when creating the geometry files 

for the machine. The second image, the view is made transparent and zoomed in to show the coordinate 

system used to align the machine elements. 


Part 1) Add a New Machine 



Step 1. In the CAM Tree, Click to expand the CAM Part folder. Right-Click Milling Tools, Click Default, 

and Click Current Settings. 

Step 2. On the left side of the Milling Settings dialog box, make sure that Machine Parameters is selected. 

Step 3. On the right side of the dialog box, in the Machine group, Click Add. 




Step 4. In the Add/Modify dialog box, next to Machine Name, type the name of your machine. For this 

example, the name is 4 Axis Example. 

Step 5. Next to Axes, select the 4 Axis Machine. To close the dialog box and add the new machine, Click OK. 

Step 6. The Make list now shows the new machine is selected and the Number of Axes should display the 

number 4. 

Step 7. In the Machine Parameters group, define the parameters for your machine. 




Part 2) Locating the Machine Definition Files 

Step 1. When you create a new machine, a folder is automatically created along with an XML file of the 

machine definition, in the BobCAD-CAM Data folder. The default location is: C:\BobCAD-CAM 

Data\BobCAD-CAM V25\MachSim\Machine Name.... This is the same location in which the geometry 

files for the machine must be stored. 

Step 2. For the purposes of this tutorial, the next step is to copy the geometry files from the default machine 

that is provided by BobCAD-CAM. 

Step 3. Open the following folder: C:\BobCAD-CAM Data\BobCAD-CAM V25\MachSim. Notice the folder 

named 4 Axis Example has been automatically created. If you open the folder, you will see the 4 Axis 

Example.xml file that is created to save all of the machine information. 




Step 4. Open the BC_4x_Mill folder, and select all of the files except the .xml file. Press CTRL+C to copy the 

selected files. 




Step 5. Open the 4 Axis Example folder and press CTRL+V to paste the copied files into the folder. These files 

are now available to add to the Machine Definition. 




Part 3) The Machine Definition Dialog Box - Define the Y-Axis Parameters 

Step 1. On the left side of the Milling Settings dialog box, Click Machine Definition. 

Step 2. Notice the Machine group in the middle of the dialog box. The machine tree shows all of the machine 

elements that have been automatically created. This definition includes the linear axes, the rotational 

axis, and the dynamic holder and workpiece elements. 

Step 3. The items in the tree are used to define or modify the parameters of each component. For example, in 

the tree, Click Y. Notice on the right, in the Machine Data group, the parameters for the Y-axis are 

displayed. 

Step 4. The Direction and the Limits for the Y-axis must be defined. By default the Y-axis Direction is defined 

by the vector X0Y1Z0. This defines the direction as the positive Y-axis. The machine being built requires 

the vector to be negative. Under Direction, next to Y, Click in the box, and change the value to -1. The 

Y-axis vector is now X0Y-1Z0. 




Note: The vector direction for the axes is determined by the type of machine. For machines that the table 

(and not the head) moves in the X- and Y-axes, generally these values are negative. For machines 

where the head (tool) moves in the X- and Y-axes, generally these values are positive. The direction 

is determined by the relationship of the machine elements and which way they need to move to 

make the tool move in a positive direction in each of the X, Y, and Z axes. 

Step 5. Under Limits, to the right of Min, Click in the box, and type the distance that this machine element can 

move along the defined direction. For this example, type -10. This defines 10 inches of travel in the 

negative Y-axis direction. 

Step 6. To the right of Max value, Click in the box and define the maximum distance that the element can 

move along the defined direction. For this example, type 10. This defines 10 inches of travel in the 

positive Y-axis direction. 

Step 7. Set the Initial Value for this element to represent the elements starting position. For this example, 

type 0. This sets the initial position to the origin or zero location of the Y-axis. 


Part 4) Define the X-Axis Parameters 



Step 1. In the Machine group, Click X to select the linear X-axis. In the Machine Data group, next to X, change 

the value to -1. Again, this defines that the X-axis elements must move in the negative X-axis direction 

in order to cause the tool to move in the positive direction in reference to the part. 

Step 2. Under Limits, next to Min, Click in the box, and type -29. This value defines 29 inches of travel in the 

negative X-axis direction. 

Step 3. Next to Max, Click in the box, and type 11. 

Step 4. Next to Initial Value, Click in the box, and type 0. 


Part 5) Define the A-Axis Parameters 



Step 1. In the Machine group, Click A to select the rotary A-axis. In the Machine Data group, notice that the 

Direction is defined as X1Y0Z0. This defines rotation around the X-axis. 

Step 2. Notice that the Centerpoint is defined as X0Y0Z0. This defines the center point of rotation in reference 

to the machine zero. Because the geometry was aligned to the zero of the reference point, this 

distance is zero. 

Step 3. The next step is define the rotary limits. Under Limits, next to Min, Click in the box and type -100,000. 

You must set this value to the degrees of rotation supported by the machine. 

Step 4. Next to Max, Click in the box and type 100,000. 

Step 5. Next to Initial Value, Click in the box and type 0. 


Part 6) Define the Z-Axis Parameters 



Step 1. In the Machine group, Click Z to select the linear X-axis. In the Machine Data group, notice that the 

Direction is defined as X0Y0Z1. This defines movement along the Z-axis. 

Step 2. Under Limits, next to Min, Click in the box and type -9. 

Step 3. Next to Max, Click in the box and type 25. 

Step 4. Next to Initial Value, Click in the box and type 18. 


Part 7) Add the Machine Base 



When creating geometry, the files must be saved using the .stl file extension. 

Important: The Pro Simulation is included with the 4 Axis Pro, 5 Axis Standard, or 5 Axis Pro modules. If 

you do not have Pro Simulation, you can't add geometry as shown in the following steps. 

Step 1. In the Machine group, Right-Click the top tree item 4 Axis Example, and Click Add Geometry. 




Step 2. In the Open dialog box, navigate to the 4 Axis Example folder, and select BC_4x_Mill_Rot-X_Base.stl, 

and Click Open. 




Step 3. The geometry item is added to the tree. In the tree, Click geometry so it is selected. In the Machine 

Data group, next to ID, Click the name (geometry) and change the name to mh_Base. Because the 

prefix mh_ was added, the visibility of this item is changed using the machine housing view toggle (in 

the simulation window). 

Step 4. Notice that the parameters for the geometry item are displayed in the Machine Data group. The 

parameters for the added geometry can be modified from this location. For example, if you needed to 

change the .stl file, in the left column Click Geometry. Notice that the icon appears next to 

BC_4x_Mill_Rot-X_Base.stl. You can Click to display the Open dialog box and select a new geometry 

file. 


Part 8) Add the Y-Axis Geometry 



Step 1. In the machine tree, Right-Click Y, and Click Add Geometry. 

Step 2. In the Open dialog box, select BC_4x_Mill_Rot-X_Y Axis Base, and Click Open. 

Step 3. The geometry item is added to the tree. In the Machine Data group, next to ID, select the name 

(geometry) and type Y Axis Base. 

Step 4. Click Color, and on the right, Click . In the Color dialog box, select a color for the element and Click 

OK. When you run simulation, the Y-axis base will be shown with the selected color. 

Step 5. In the machine tree, Right-Click Y, and Click Add Geometry. 

Step 6. In the Open dialog box, select BC_4x_Mill_Rot-X_X Axis Base, and Click Open. 


(geometry) and type X Axis Base. 

Step 8. Set the color used for the base. 


Part 9) Add the X-Axis Geometry 



Step 1. In the machine tree, Right-Click X, and Click Add Geometry. 

Step 2. In the Open dialog box, select BC_4x_Mill_Rot-X_Table, and Click Open. 


(geometry) and type Table. 

Step 4. Set the color for the element. 

Step 5. Click Reflect Map, and on the right side, Click . In the Open dialog box, select the 

TableReflection.bmp file and Click OK. Image files used for the Reflect Map must use the .bmp file 

extension. 

Step 6. In the machine tree, Right-Click X, and Click Add Geometry. 

Step 7. In the Open dialog box, select BC_4x_Mill_Rot-X_Rotary_Base, and Click Open. 


(geometry) and type Rotary Base. 

Step 9. Set the color for the X-axis base. 


Part 10) Add the A-Axis Geometry 



Step 1. In the machine tree, Right-Click A, and Click Add Geometry. 

Step 2. In the Open dialog box, select BC_4x_Mill_Rot-X_Rotary_Face, and Click Open. 


(geometry) and type Rotary Table. 

Step 4. Set the color for the element. 


Part 11) Add the Z-Axis Geometry 



Step 1. In the machine tree, Right-Click Z, and Click Add Geometry. 

Step 2. In the Open dialog box, select BC_4x_Mill_Rot-X_Z Axis Spindle and Click Open. 


(geometry) and type Spindle. 




Part 12) About the Dynamic Elements 

The dynamic elements are the elements that can change with each program. The Workpiece Transform 

contains the first set of dynamic elements in the tree. This transform includes the toolpath, stock, fixture, and 

the workpiece. You do not have to define geometry for each of these items because they are defined by each 

program that you create. This is also true for the Holder Transform elements. These dynamic elements are 

automatically created for you when you create a new machine. 

Step 1. In the Machine group, under the Workpiece Transform, Click Initialstock. Notice the parameters in the 

Machine Data group. As with the other geometry items, you can define a color for the element. It is 

helpful to define a different color for each element that appears in simulation. 




Step 2. In the Machine Data group, next to Transparency, Click in the box and change the value to 40. This 

makes the initial stock item that is shown in simulation appear with forty-percent transparency. When 

this item is fully visible, it will still appear slightly transparent which makes it easier to tell it apart from 

the stock or workpiece items. 




Step 3. In the Machine group, under the Workpiece Transform, Click Stock. 




Step 4. In the Machine Data group, notice the name in the Geometry row. For each program that you create, 

when you simulate, the stock.stl (and the workpiece.stl) files are automatically created and placed in 

the machine's folder with the other geometry files (as shown earlier in this example). These files are 

created using the defined stock and the selected geometry for the program. 




Step 5. In the Machine group, under the Holder Transform, Click Tool. Notice the parameter displayed in the 

Machine Data group. You can change the color for each part of the tool and tool holder, as well as the 

transparency and reflectivity. 


Part 13) About the Collision Check 



At the bottom of the Machine tree, there should be an item labeled CC. This is the collision check that is 

automatically added to the tree when you created the new machine. This item defines the dynamic elements 

that are included in the collision check. 

Step 1. To add a collision check to the tree, Right-Click the top tree item 4 Axis Example, Click Add CollCheck, 

and Click Tool-Workpiece. This adds a collision check to the tree that is automatically set between the 

workpiece and the tool. 

Step 2. In the Machine group, Click the new collision check item (CC1). Notice the information in the Machine 

Data group. There are three boxes displayed. The larger box on the left side contains all of the items 

that are available to add to a collision check group. The two boxes on the right, Group 1 and Group 2, 

define the items that are collision checked. Any items in Group 1 are collision checked with the items in 

Group 2. The Workpiece-Tool collision check that was added automatically places the Workpiece in 

Group 1 and the Tool is placed in Group 2. 




Step 3. To add an item to a collision check group, in the list on the left side, Click the item to add. Next to the 

Group box to which the item is added, Click . 

Step 4. To remove an item from a collision check, Click the item to remove, and then next to the Group box, 

Click . 

Step 5. If you add a User Defined collision check, no items are automatically added to the Group 1 and Group 

2 boxes. 

Step 6. To finish the machine creation and save the information, at the bottom of the Milling Settings dialog 

box, Click OK. 




Part 14) Additional Machine Parameters 

After your machine has been created, you also need to define the Posting parameters for the machine. To 

learn about the remaining options in the Milling Settings dialog box, view the Milling Settings Default dialog 

box help topic. 

This concludes the tutorial. 



Machine Setup Checklist 

MACHINE SETUP CHECKLIST 

In order to configure your machine there is some information you will first need to gather. The check list 

below will help you gather this information. 

Machine Name: _________________________________________________ 

This is the name of the machine. 

Controller Make and Model: ___________________________________ 

This is the model of the machine and make of the controller. 

Type of Machine: __________________________________________ 

This is the type of 4 th / 5 th axis machine. 

Example: 

4 th Axis Vertical Mill 

4 th Axis Horizontal Mill 

Table – Table 

Head – Head 

Head – Table 

Head – Head Nutating 

ETC... 




Maximum Spindle Speed: _____________________________________ 

Fastest speed (RPM) the spindle can rotate. 

Maximum Feed Rate: __________________________________________ 

Fastest allowable feed rate (IPM) the machine can travel. 

NC File Extension: __________________________________________ 

This is the file extension that the machine requires to load the NC program into the controller. 




Direction Vector: 

Most machines follow what is known as the “Right Hand Rule” when it comes to directions of motion when 

using the Cartesian coordinate system. We will use the standard “Right Hand Rule” as our base when 

comparing your machines movement to complete the following questions. Please keep in mind that all of the 

following questions refer to the direction the TOOL moves in the workpiece. 

X axis Direction: 

When you jog your machine in the positive direction does the tool move to the Right? 

Yes__ / No__ 

(Yes = Tool Motion Matches Right Hand Rule) 

Y axis Direction: 

When you jog your machine in the positive direction does the tool move to the Back? 

Yes__ / No__ 


Z axis Direction: 

When you jog your machine in the positive direction does the tool move Up? 

Yes__ / No___ 





Minimum & Maximum Values for Axis Travel: 

X____ _____ 

Y____ _____ 

Z____ _____ 

The minimum and maximum absolute coordinates for each axis. These values are from the rotation zero. This 

zero is a virtual machine zero used by BobCAD and is not necessarily the machine home. 

**To pull the values for the limits of the machine** 

These measurements are done with the machine spindle empty. 

X-Axis: 

Line the center of the spindle up with the edge of the face of the indexer or the center of the platter and set as 

zero. Now move the machine to the max positive then the max negative amount in X. Record these numbers 

above. 

Y-Axis: 

Line the center of the spindle up with the center of rotation and set as zero. Now move the machine to the 

max positive then the max negative amount in Y. Record these numbers above. 

Z-Axis: 

The BobCAD machine zero for Z is the face of the spindle down at the center of the rotation axis. Move the 

machine to this position and set zero. Now move the machine to the max positive then the max negative 

amount in Z. Record numbers above. If the machine cannot get there, take as far down as it can and measure 

from center of rotation to spindle face. This does not have to be exact. However you want it as close as you 

can get it. If needed can use ruler. Now you can measure the Max positive movement in Z. 

For instance the spindle can only come down to 3” above rotation center. 

The max travel for Z is 15”. Then record above Max Z = 15” and minimum Z= +3” 




Rotary Axes: 

The rotary axes of your machine need to be correctly defined for the internal mathematics of our post 

processing engine to function correctly. Again here we will reference the “Right Hand Rule” for defining your 

rotary axis components and we will also define the prefix used in the G-Code to operate them. 

Like the X Y Z axes the rotary axes of a machine tool can be referenced using the standards of the Right Hand 

Rule. The following image illustrates this as well as the following description. Please note the following axis 

identification is not the prefix used in the G-Code but how we identify the rotary axis components for building 

your machine. The prefix for each axis is defined in the next section. 

A axis – This is a rotary axis that rotates around the X axis of the machine. 

B axis – This is a rotary axis that rotates around the Y axis of the machine. 

C axis – This is a rotary axis that rotates around the Z axis of the machine. 

1st Rotary Axis – Using the above image what is your 1st rotary axis? __A__B__C__ 

2nd Rotary Axis – Using the above image what is your 2nd rotary axis? __A__B__C__ 




Direction of Positive rotation on rotary: 

When facing the machine place a mark on the axis being rotated. Whether it is marker or tape and rotate the 

rotary axis positive. When following the Right Hand Rule standard axis rotation is counterclockwise when 

looking at the axis from the positive direction. 

1st Rotary Rotation: 

When you rotate the 1st axis positive does your machine rotate toward you in the positive direction? 

Yes__ / No__ 


2nd Rotary Rotation: 

When you rotate the 2nd axis positive does your machine rotate toward you in the positive direction? 

Yes__ / No__ 





Rotary Centers: 

1st Rotary Axis: ____ ____ ____ 

2nd Rotary Axis: ____ ____ ____ 

X, Y, and Z center of rotation point for each rotary axis. 

Click Here for information on How to find the Rotation for the rotary axis. 

BobCAD Machine Zero to Center Of Rotation: 

This is a measurement from where we are going to define zero for our system’s calculations. This location is 

NOT where you have to define your work offset locations. The values for this option will vary based on 

machine configuration. All values are measured with the 4th & 5th axis of your machine at Zero location. 

Table/Table – For this machine type the values are measured from the center of the rotary platter at the face 

of the rotary platter going to the center of rotation for the 4th & 5th axis unit. 

Head/Head – For this machine type the values are measured from the face of the spindle to the center of 

rotation for the 4th & 5th axis. 

Head/Table – For this machine type the values are measured in one axis from the face of the spindle to the 

center of the rotating axis which tilts the spindle. The second rotation center will be aligned with the spindle 

face so a value of zero should suffice, but values are available here if necessary. 




Rotary Axis G-Code Prefix: 

1st Rotary Axis: _________ Example: “A” 

2nd Rotary Axis: _________ Example: “B” 

What is the prefix (letter) used to identify your rotary axes? 

Minimum & Maximum Rotary Degrees: 

1st Rotary Axis: ______ ______ 

2nd Rotary Axis: ______ ______ 

What is the minimum (- direction) and maximum (+ direction) travel limits for each of your rotary axes? 

Rotary Axis limits: 

What is the limit of rotation for the rotary axis I.E. +9999.999 and 

-9999.999 or is there another limit? Or is it unlimited. Distance before it has to stop and rewind. 


STL Files (Optional) 



STL Drawing files of each part of the machine. These are not required but helpful and can only be added for 

use with the full machine simulation. The full machine simulation is included with- 4 Axis Pro, 5 Axis Standard 

and 5 Axis Pro. 

Machine Base – _________________________________________________ 

X-AXIS – _________________________________________________ 

Y-AXIS – _________________________________________________ 

Z-AXIS – _________________________________________________ 

1st Rotary Axis – _________________________________________________ 

2nd Rotary Axis – _________________________________________________ 

More or less files can be used; this varies by the amount of detail desired and machine type. 


Adding your machine 



Step 1. Gather all data from the Machine Setup Check-list. 

Step 2. Launch the BobCAD-CAM software. 

Step 3. Expand CAM Part. 

Step 4. Right-Click Milling Tools and Select Default > Current Settings. 




Step 5. From the Machine Parameters select add. 




Step 6. Enter the Name of your machine. 

Step 7. Choose the number of axes and type for your machine, Click OK. 

Note: For 2 axis machines select 3 Axis Machine the z values will be removed by the post-processor. 




Step 8. In machine parameters enter the data for the rest of the parameters listed. 

 

 

 

 

Maximum # of Tools - sets the number of tools the machine can use for one program. 

Tool Change Position - this setting is not currently in use. 

Maximum Spindle Speed - sets the maximum speed rate for the spindle. 

Maximum Cutting Feedrate - sets the maximum feed-rate for cutting. 




Step 9. Select machine definition under machine. 




Step 10. Click on each axis label under your new machine; enter the Direction vector, Limits, Initial value and 

Center Point. 

 

 

 

ID – The axis name 

Direction - This determines the direction an axis travels. 

Limits - The limit or minimum & maximum absolute position for the axis. 




Step 11. Select Posting and then select the post-processor to use with this machine, and then choose the 

other options desired. 



Posting 

POSTING 

Post Processor 

 

Select - displays the Open dialog box for you to locate and select a (.MillPst) post processor to use for the 

selected machine. 

Tool Pattern 

 

Select - displays the Open dialog box for you to select a tool pattern file (.tpatt) that is used for to save the 

tool pattern information for milling. 

NC File Path 

 

 

Select - displays the Browse For Folder dialog box for you to locate or create a folder in which the posted 

NC program is stored. 

NC File Extension - allows you to specify a file extension that is automatically added to the NC program 

file. 

Program 

 

Number - is the program number as it appears in the posted NC program. 

Absolute/Incremental 

 

 

 

Post Setting - uses the post processor settings to define absolute or incremental posting values. 

Absolute - uses absolute values only for posting. 

Incremental - uses incremental values only for posting. 

Sequence Numbers 

 

 

Start Number - designates the starting line number for events in the NC program if the machine is 

configured to output them. 

Sequence # Increment - sets the number added to each subsequent line number for the next line. 


Subprogram Numbers 


Posting 

 

Output Subprograms 

Selected - Select this check box to generate repetitive subprograms in the posted NC program, if the 

post processor is set up to do so. 

Cleared - Clear this check box when not generating subprograms. 

The following two options are only available when the Output Subprograms check box is selected. 

 

 

Subprogram Start # - sets the first subprogram number used in the NC program. 

Subprogram # Increment - if more than one subprogram is generated, this value sets the number added to 

the previous subprogram number for the next. 

Output Arcs in 4-Axis NC Program 

 

GCode 4 Axis Arcs OK 

Selected - Select this check box to output arcs in the NC program for 4-axis machining. 

Cleared - Clear this check box to output only points and line segments in the NC program for 4-axis 

machining. 



Posting 

Step 12. If you are using 4 or 5 axis pro then select Multi-Axis Posting then select the options desired. 



Multi-Axis Posting 

MULTI-AXIS POSTING 

Angle Pair 

For many 5-axis machines there are two possible solutions to any point in a toolpath. The solution here refers 

to the angles used for each rotational axis. The following images show a part with the two possible Angle Pair 

solutions (this is the tool orientation for the toolpath starting point). The tool orientation to the part is the 

same in each situation; however, the table is rotated 180 degrees. The Angle Pair options control which 

solution is used. The purpose of the Auto Angle Pair is to use the solution that creates the least amount of 

tool-axis orientation change from the previous toolpath position. Keep in mind that some machine can't use 

both pairs based on rotational limits. 

First Solution 

Other Solution 

 

 

Auto Angle Pair 

Selected - Select this check box to make the Start Angle Type options available. 

Cleared - Clear this check box to make the Other Angle Pair check box available. 

Other Angle Pair 

Selected - Select this check box to use the Other Angle solution. 

Cleared - Clear this check box to not use the Other Angle solution. 




 

Start Angle Type 

 

Select Between Two Solutions - allows the software to select between two possible solutions. 

 

Use - allows you to select one of the two following options. 

First Solution - is the solution that results in the least amount of axis orientation change from 

the toolpath start point or the previous toolpath orientation. 

 

Other Solution - is the solution opposite to the First Solution. 

Instead of using Select Between Two Solutions, you can provide a preferred First- and Second-Axis 

Rotation Angle, the software selects the solution closest to that value. Positive and Negative values can be 

used and the solution that is closest to the Provided Rotation Angle is used. For example, if you set the 

First Rotation Angle to 80 degrees, and the two possible solutions are: C = 90 degrees or C = -90 degrees, 

the post uses C = 90 degrees. 

 

 

Provide First Rotation Angle - allows you to type a preferred starting angle for the first rotational axis 

in the Rotation Angle Value box. 

Provide Second Rotation Angle - allows you to type a preferred starting angle for the second rotational 

axis in the Rotation Angle Value box. 

Rotation Angle Value - type the preferred starting angle for the First or Second Rotation Angle. 

Machine Limits 

The Machine Limits are used to confirm that the machine limits are not exceeded. When a program exceeds 

the set limits, it does not post. To set the Machine Limits, select a limit group from the Limits box and then 

type values for the following two parameters. 

 

 

 

Angle Tolerance For Using Machine Limits - type a value from which the selected Machine Limits can vary. 

If you set Machine Limits for an axis between 0 and 90 degrees, and set an Angle Tolerance of 2, then the 

possible range becomes -2 to 92 degrees. 

Angle Change Limit - type a value in degrees to limit the amount of angle change from one toolpath 

position to the next. If an angle change exceeds this limit, then a retract move is applied in the post. 

Limits box - select one of the following options to be affected by the Angle Tolerance and Angle Change 

Limit parameters: 

No Limits 

Translational Limits 

Rotational Limits 

All Limits 




Pole Handling 

When a five axis machine is used to run a 3-axis toolpath, there are certain situations that make the C-axis 

value arbitrary. What this means is that by changing the X- and Y-axis values appropriately, any C-axis value 

used creates the same results. For example, when a cylinder is located in the center of the table, depending on 

the machine, there are multiple ways to cut the profile of the cylinder. The rotation axis can be fixed while the 

linear axes are used to cut the part. On the other hand, the linear movements can be fixed, while the table is 

allowed to rotate in order to cut the part. This situation where the C-value is arbitrary, because the spindle 

direction and the table direction are collinear, is called a singularity or pole. The Pole Handling options are 

used to control these situations as follows. 

Freeze Angle Around Pole - fixes the rotational axis in order to use the linear axes movements. 

 

 

 

 

 

Use Rotation Angle Around Pole to Stay Within Linear Axis Limits - is used when a program exceeds the 

linear axis limitations. The extents of the linear movements are fixed in order to use the rotational axis as a 

substitute for the linear movement limitations. 

Linear Interpolation of Rotation Angle Around Pole - calculates rotational axis values to make the changes 

from one value to the next in a linear fashion. The linear distribution is based on the tool tip position from 

one toolpath point to the next. This is useful when a 3-axis toolpath is converted to a 5-axis toolpath. For 

example, when a toolpath transitions from linear motions to rotational motions (from 3-axis to 5-axis), an 

abrupt change can result because of the conversion. This option is used to avoid these abrupt changes by 

setting a constant (linear) rate of change for the rotational axis. 

Smooth Interpolation of Rotation Angle Around Pole - similar to Linear Interpolation, this option also 

manipulates the table rotation speed to create a more fluent transition. 

Force Table Rotation - uses table rotation moves instead of linear moves when a multi-axis toolpath 

approaches 3-axis positioning. 

Pole Angle Tolerance - controls the angle between the tool axis orientation and the pole or main spindle 

direction (for example the Z-axis). It controls how far the tool can tilt from the pole and still be considered 

parallel, in order to be used as a pole. 

Tool Repositioning 

In certain scenarios, when machine limits are reached, a retract move is needed. Tool Repositioning affects 

the retract move. 

Tool Retract - type a value for the tool retract distance when the Retract Tool to Maximum check box is 

cleared. 

Retract Tool To Maximum 

Selected - Select this check box to retract the tool to the maximum distance set for the machine. 

Cleared - Clear this check box to type a retract distance in the Tool Retract box. 


Point Interpolation 



 

Interpolation Type - select one of the two following options. 

By Vectors - creates the interpolation between the two endpoints of a toolpath segment in the 

shortest possible way. The movement happens in a flat plane. 

By Machine Angles - creates the interpolation between the two endpoints of a toolpath segment 

gradually with respect to the machine kinematics. The movement does not necessarily happen in a flat 

plane. 

Feed Move 

 

 

Max Distance 

Selected - Select this check box to type a maximum distance value for feed moves for the selected 

interpolation type. 

Cleared - Clear this check box to disable the Max Distance box. 

Max Angle 

Selected - Select this check box to type a maximum angle value for feed moves for the selected 


Cleared - Clear this check box to disable the Max Angle box. 

Rapid Move 

 

 

Max Distance 

Selected - Select this check box to type a maximum distance value for rapid moves for the selected 


Cleared - Clear this check box to disable the Max Distance box. 

Max Angle 

Selected - Select this check box to type a maximum angle value for rapid moves for the selected 


Cleared - Clear this check box to disable the Max Angle box. 


Machine Definition Zero 



 

 

Real Machine Zero - the posted NC program uses the actual machine zero location. 

Work Offset Position - the posted NC program uses the location defined by the work offset. 

Move List Writer 

The Move List Writer options control what appears in the posted NC program. These options are used to set 

machine limits that are not exceeded in the posted NC program. Some machines don't have rotational limits, 

and some don't except large angle values. You can limit the angle values used. 

 

 

 

First Rotation Axis Angle Limit - limits the values used for the first rotational axis. Select: No Limits, Limit 

Between 0 and 360 degrees, or Limit Between -180 and 180 degrees. 

Second Rotation Axis Angle Limit - limits the values used for the second rotational axis. Select: No Limits, 

Limit Between 0 and 360 degrees, or Limit Between -180 and 180 degrees. 

Move List Coordinates - controls how the coordinates are output in the posted NC program. 

No Machine Compensation - outputs the moves in machine coordinates. No compensation is handled 

by the machine controller. 

Machine Compensation in Z Only - outputs all moves based off of the absolute machine zero point 

with Tool Length Compensation in Z only. This mode is commonly used with G43 Tool Height 

compensation at the controller. 

Machine Hybrid Compensation (Mixed Mode) - outputs all moves based off of the absolute machine 

zero point with Tool Length compensation along the tool axis. 

Part Based (Common for TCP) - outputs all moves based off of the workpiece-zero point or machine 

setup origin. This mode is commonly used with machine controllers that support TCP (Tool Center 

Point Compensation). 

Step 13. Click OK, your machine is ready to use. 




Adding Geometry to your machine (Optional) 

Step 1. Open the windows explorer, locate your .STL files for the machine, copy these file to the machine 

directory of the new machine you have created in… 

C:\BobCAD-CAM Data\BobCAD-CAM V#\MachSim\ ‘Your Machine Name’ 

Note: When the machine is added BobCAD automatically generates a folder with your machines name. 

Step 2. Launch the BobCAD-CAM software. 

Step 3. Expand CAM Part 

Step 4. Right-Click Milling Tools and Select Default Current Settings. 

Step 5. From the Machine Parameters select the machine you have created. 

Step 6. Select machine definition under machine. 




Step 7. Right-Click on each axis label under your machines name, choose Add Geometry and select the 

appropriate STL that you have created. Repeat this for each STL file that you want to add. 

Step 8. Click OK, your machine is ready to use. 



Material Library Feeds & Speeds 

MATERIAL LIBRARY FEEDS & SPEEDS 

Feeds and speeds are calculated based on the material type selected; BobCAD-CAM comes with hundreds of 

pre-configured materials that are accurately set up based on the Machinist Toolbox. The feeds and speed 

references within BobCAD-CAM have been calculated based on the Machinist Handbook and the book 

Mathematics at Work. 

Note: The feeds and speeds that are suggested are a starting point only, many variables need to be taken 

into account for when properly calculating feeds and speeds such as, tooling, material, and machine 

rigidity and tool-path technique. 

Adding & Editing Materials 

You may need to add or modify materials within the database, to do so follow the instructions below. 

To access the Stock Material Library, in the CAM tree tab, under Milling Stock, Right-Click Stock 

Material (such as Wrought Alum), and Click Edit. The Stock Material Library dialog box appears. 

To create a Material Group, in the Material Group, Click Add Group. The Add New Material Group dialog box 

appears. To name the group, in the Material Group Name box, type My Materials, and Click OK. 

To add a new stock material to the group, in the Material Group, Click My Materials. In the Material List area, 

Click Add Material. The Stock Material Feeds and Speeds dialog box appears 

Note: Full documentation on all of the Stock Material Feeds and Speeds dialogue can be found within the 

built in help system. To locate this information launch the help system by Clicking on Help then Help Topics 

from within BobCAD. Search for the term “stock material”. 

Selecting material 

The material being used within the CAM tree will set the feeds and speeds used by BobCAD-CAM. 

To select the stock to be used follow the instructions below. 

To access the Material Selection dialog box, in the CAM Tree, under Turning Stock, Right-Click Stock 

Material and Click Edit. 

You can now choose the material to be cut. 



Drilling Operation Setup 

DRILLING OPERATION SETUP 

The drilling operations within BobCAD-CAM are multi-tool or compound operations meaning, that if you 

choose to drill a hole the software by default will use first a center drill and then a drill or if you tap a hole, by 

default they software will Center Drill, Drill then tap the hole. These features can be fully customized to 

include multiple tools or to only use single tools. 

To edit the Tools used within features follow the instructions below. 

Drilling Parameters 

Much of the drilling done by BobCAD-CAM is automated. BobCAD automatically accounts for items such as 

drill tip angle and through holes and adds depth to the drilling operations. Before creating a program for 

drilling you should first understand exactly what BobCAD is going to do when drilling. The drilling parameters 

used by BobCAD can be customized to suit your needs, see the information below to see how to access the 

drilling parameters and how to change or edit them. 

The drilling parameters are configured within Cutting Condition Parameters see below for instructions on 

how to access them. 

To access the Cutting Condition Parameters, in the CAM tree, under CAM Part, Right-Click Milling 

Tools, Click Part or Default, and Click Cutting Conditions. If you selected Part, only the current part or file is 

affected. If you selected Default, the default software settings for all new files are affected. 

Note: Full documentation on all of Cutting Condition Parameters dialogue can be found within the built in 

help system. To locate this information launch the help system by Clicking on Help then Help Topics 

from within BobCAD. Search for the term “Cutting Condition”. 




Adding and Removing Tools from Operations 

To access the Tool Pattern Global dialog box, in the CAM Tree, under CAM Part, Right-Click Milling 

Tools, Click Default, and Click Tool Pattern. 

To Add an Operation: 

 

 

 

 

 

In the Feature list on the left side of the dialog box, select the feature you want to edit. 

In the Operations list on the right, Click the operation that is below the desired location for the new 

operation. (The new operation is inserted before the selected operation.) 

In the Select item to edit list, select the new operation to add. 

Click Insert. 

The new operation is added to this feature. 

To Change an Operation: 

 

 

 

 

 


In the Operations list on the right, select the operation that you want to change. 

In the Select item to edit list, select the new operation. 

Click Change. 

The selected operation is changed to the new one. 

To Remove an Operation: 

 

 

 

 


In the Operations list, select the item you want to delete. 

Click Delete. 

The selected operation is removed from this feature type entirely. 

The changes made using any of the previous examples do not affect existing features, you must insert a new 

feature to use the new settings. 

Note: Full documentation on all of the Tool Pattern dialogue can be found within the built in help system. 

To locate this information launch the help system by Clicking on Help then Help Topics from within 

BobCAD. Search for the term “Tool Pattern”. 


Working with Taps 



Taps must be added to the system through the tool library then connected to a drill size within the Hole Sizes 

settings; this enables BobCAD to associate drills and taps. This Tap Hole Sizes dialog box allows you to view 

and edit Tap definitions in the Tap Library. 

To add a tap first add the tap to the tool library then follow the instructions below to set up the Hole Sizes 

To access the Tap Hole Sizes dialog box, in the CAM Tree tab, in the CAM Part folder, Right-Click Milling 

Tools, and Click Hole Sizes. 

Then Click on Add Tap and enter the information about your tools. 

Note: Full documentation on all of the Hole Sizes dialogue can be found within the built in help system. To 

locate this information launch the help system by Clicking on Help then Help Topics from within 

BobCAD. Search for the term “Hole Sizes”. 



The Stock Wizard & Part Orientation 

THE STOCK WIZARD & PART ORIENTATION 

This help topic describes the layout of and provides navigation through the Milling Stock Wizard tutorials. 

Important Information 

Before creating any milling features, you must create milling stock from which the part is cut. If you try to 

insert a milling feature before creating stock, you are prompted to first run the Stock Wizard. 

The Stock Wizard parameters are explained in the Stock Wizard help topic. 

How to access the Stock Wizard 

The Stock Wizard is displayed in the 

Data Entry tab. To open the Stock Wizard, do one of the following: 

In the CAM Tree, Right-Click Milling Stock, and Click Stock Wizard. 

In the CAM Tree, under Milling Stock, Right-Click Stock Geometry, and Click Re/Select. 

The Stock Wizard Dialog Boxes 

Stock Type 

Select the stock type. 

Stock Definition 

Defines the stock size, shape and orientation in the Workspace. 

Machine Setup 

Select the Machine Setup, set the machining origin for the stock, and other machine settings. 


How to Select the Stock Type 



In the Stock Type dialog box, select the appropriate Stock Type, and Click 

Definition dialog box. 

next to go to the Stock 

Rectangular/Cylindrical 

These stock types both create stock by bounding the selected geometry in a rectangular or cylindrical stock. 

There are three methods used: 

 

 

 

Auto from Workspace - automatically detects geometry. 

Pick - is used to manually select geometry. 

Enter - is used to type values for the stock size and location. 

Wireframe 

This type is used to extrude custom stock shapes from 2D geometry chains. 

 

Pick Geometry - enables selection mode for you to select the geometry used to create the stock. 

Solid Model 

This type is used to create stock that is the same shape as a solid model in the Workspace. 

 

Pick Solid Model - is used to select the solid model in the Workspace. 

STL File 

This type is used to create stock that is the same as a previously saved .stl file. 

 

Browse - is used to locate and open an .stl file to use as the stock. 


The Stock Definition Dialog Box 



This dialog box is used to set the size and orientation of the stock geometry. After geometry is selected, the 

stock coordinate system is placed at the top and center of the stock. This coordinate system is only used a 

reference for setting the stock size and orientation and it is not related to the machining origin of the part. The 

page contains three groups: Size, Stock Orientation, and Offset. 

After setting the Stock Definition, Click 

next to go to the Machine Setup. 

The Machine Setup Dialog Box 

This help topic describes using the Machine Setup dialog box of the Stock Wizard. You first select a Machine 

Setup, then define the machining origin of the part, as well as selecting a Work Offset, Clearance Plane, and 

Rotary Axis. 

Select the Machine Setup 

The Machine Setup group at the top of the dialog box lists all the Machine Setup items currently in the 

CAM Tree. Click the Machine Setup arrow and select the appropriate setup from the list. 

How to Select the Machining Origin 

The Machine Setup dialog box is used to set the Machining Origin or zero location of the part on the machine. 

When this dialog box is opened, the stock shows the bounding box made of lines and points. These lines and 

points are automatically created, for your convenience, to use when setting the machining origin. By default, 

the machining origin is located at the WCS or world coordinate system (X0 Y0 Z0) as shown next. 




 

 

This image has shading turned off to better show the bounding box selection entities. 

If you want to use the top and center of the stock as the machining origin, Click Reset to Stock 

Coordinate. This uses the stock origin from the Stock Definition dialog box. 

 

To change the Machining Origin to a different location, in the Machining Origin group, Click Origin and 

select the desired location from geometry in the Workspace. Once you pick a point, the move is 

automatically executed without the need to Click OK. 

Note: The bounding entities that are created in the Machine Setup dialog box are for your convenience in 

setting the machining origin. You are not limited to using these entities when setting the machining 

origin. 

 

The machining origin is now set to the lower-left corner on the top of the stock. To finish the Stock 

Wizard, Click OK. You are now ready to insert milling features. 




How to set the Machining Origin using the Enter Method 

In the Origin group, select Enter Origin, and type a value in the X, Y, and Z boxes to define the origin 

location. The values are from the WCS. 

The default directions of the Machining Origin follow that of the WCS. 

To change the direction of one the coordinate system axes, Click next to X, Y, or Z Direction to 

reverse the positive and negative direction of the corresponding axis. 

How to set the Machining Origin using Pick From Existing UCS 

 

 

In the Origin group, select Pick From Existing UCS. The UCS list becomes available. 

Click the UCS list arrow and select the desired UCS. 

Other Settings 

This group provides default settings that are used for all features inserted in the selected Machine Setup in the 

CAM Tree. 

 

 

 

Work Offset - Click the arrow to select the proper work offset from the list. 

Clearance plane - type a value to set the distance above the part for rapid tool movements between 

features. This is an absolute value from the machining origin for the setup. 

Define Rotary Axis - opens the Define Rotary Axis dialog box for you to set the rotary axis. 

To finish the Machine Setup, Click OK. 



Mill & Router Tutorial 

MILL & ROUTER TUTORIAL 

The mill tutorial Video will guide you through importing a simple part beginning to end, below are the steps to 

add Toolpath, post and simulate any part. 

How to add a tool path 

To launch the tool path wizard, : in the CAM Tree, Right Click on Milling Stock then select the type of tool 

path to add (Drill, Mill 2 Axis or Mill 3 Axis). 

In the first dialog box of the wizard, you select the feature type. 

Select a feature type, and Click Next to go to the Geometry Selection dialog box. 

Using the mouse Select the geometry, then Right Click and then Left Click OK to confirm the selection. 

Click Next in the wizard and fill out each dialogue box and then Click next until complete. 

Click Compute Toolpath. 

How to Post CAM Features 

To post a Milling program after completing the Milling wizard: in the CAM Tree, Double-Click CAM Part, 

Right-Click Milling Tools, and Click Post. 



Mill & Router Tutorial 

How to Simulate 

To simulate after completing the Milling wizard: in the CAM Tree, Right-Click Milling Stock, and Click 

Simulate. 

Note: Full documentation on all of the CAM and Toolpath dialogues can be found within the built in help 

system. To locate this information launch the help system by Clicking on Help then Help Topics from 

within BobCAD. Search for the term “CAM”. 



Lathe Tutorial 

LATHE TUTORIAL 

The lathe tutorial video will guide you through creating a simple lathe part using an imported file, below are 

steps to create stock, adding turning features, post G-code and simulate for any part. 

How to Create Stock Using the Stock Dialog Box 

The turning stock is set to a two inch diameter cylinder by default. There are two methods to use when 

defining the turning stock geometry. When defining a standard cylindrical stock geometry, you use the first 

method. In order to define a custom stock shape, you use the second method. 

Step 1. In the CAM tree, Right-Click Turning Stock and Click Edit. The Stock dialog box is displayed. 

Step 2. Type values in the Stock dialog box to define the stock as described in the Lathe Stock Dialog Box help 

topic. 

Step 3. Click OK. The stock is automatically drawn. To show the stock preview, Click Turning Stock. 

Example 

Stock Definition Values 

Face Z 0.00 

Cutoff Z 

End of Stock 

Z 

Stock 

Diameter 

Internal 

Diameter 

- 

4.25 

- 

6.00 

3.50 

0.75 

Stock Preview 




Adding Turning Features 

When you insert a Turning feature by Right-Clicking Turning Stock, it is added to the CAM Tree. Each 

feature item in the tree represents some aspect of the machining process. You Right-Click these items to 

display a shortcut menu. Because the Turning features share many of the same tree items, all the items are 

explained together in this help topic. 

Rough Feature Example 

A Turning feature in the CAM Tree looks something like the following. 

Feature Rough 

Geometry 

Rough 

Rough 

The following labels are used to explain the shortcut menus in the next section. 

Feature Type 

Geometry 

Feature Parameters 

Operations 




The Feature Shortcut Menus 

The bullet points listed next are the shortcut menu commands for each feature item in the tree. 

Feature Type 

 

 

 

 

 

 

 

 

 

 

 

 

 

Insert Rough- inserts a Rough feature. 

Insert Finish - inserts a Finish feature. 

Insert Groove - inserts a Groove feature. 

Insert Thread - inserts a Thread feature. 

Insert Drill - inserts a Drill feature. 

Insert Cutoff - inserts a Cutoff feature. 

Insert Stock Feed- inserts a Stock Feed feature. 

Delete - removes the selected milling feature. 

Save Feature - allows you to save the selected feature to a file. 

Load Feature - allows you to add a previously saved feature. 

Post Yes/No - controls whether or not the feature is included in the posted NC program. 

Blank/Unblank Toolpath - hides or shows the computed feature toolpaths. 

Rename - allows you to change the feature name. 

Geometry 

 

 

Re/Select - enables selection mode for you to select geometry in the Workspace that is used to create 

the feature operations. 

Remove - eliminates the geometry association with the feature. 

Drill Depth Point/End Point/Start Point 

 

 

Re/Select - enables selection mode for you to select geometry as the location (or depth) for the 

feature. 

Remove - eliminates the geometry association with the feature. 

Feature Parameters 

 

Edit - opens the Feature dialog box for you to modify the settings used to create the Toolpath. View the 

Turning Features to learn about the available options. 

Important: This is how you access the Feature dialog boxes to define the feature. 

 

 

Compute Toolpath - calculates the toolpath defined in the feature. 

Post Yes/No - controls whether or not the feature is included in the posted NC program. 




Feature Operations 

 

 

Color - opens the Color dialog box for you to change the color of the Toolpath. 

Blank - hides or shows the computed Toolpath. 

The Turning Features 

The following list contains all of the Turning features. Click the links to view an example image. 

 

Rough - removes material from the stock while leaving an allowance for finishing operations. 

 

Finish - finishes the profile after the Rough operation. It also operates like a pattern repeat cycle when 

multiple passes are used. 




 

Groove - creates a slot or groove on the face or the diameter of the part, based on the orientation of 

the selected geometry. 

 

 

Thread - creates a threading operation. 

Drill - drills a hole in the center of the face of a part. 

 

Cut Off - cuts a finished part from the bar stock. 

 

Stock Feed - utilizes the bar feeder, on lathes equipped with the option, to advance the stock. 




The Turning Feature Dialog Boxes 

After inserting a Turning feature you Right-Click Feature, and Click Edit to open the Feature dialog box. All of 

the parameters that are used to create Turning features are explained in the dialog box help topics listed next. 

How to Post CAM Features 

To post a Lathe program after completing a Turning feature, in the CAM Tree, Double-Click CAM Part, 

Right-Click Turning Tools, and Click Post. 

How to Simulate 

To simulate after completing the Lathe features: in the CAM Tree, Right-Click Turning Stock, and Click 

Simulate. 

Note: Full documentation on all of the Lathe dialogues can be found within the built in help system. To 


BobCAD. Search for the term “Lathe”. 



Sending Files to the Machine 

SENDING FILES TO THE MACHINE 

Saving Files to a Disk 

Mill 

To post a Milling program after completing the Milling wizard: in the CAM Tree, Double-Click CAM Part, 

Right-Click Milling Tools, and Click Post & Save As, then choose the location to save the file. 

Lathe 

To post a Lathe program after completing a Turning feature, in the CAM Tree, Double-Click CAM Part, 

Right-Click Turning Tools, and Click Post & Save As then choose the location to save the file. 

Rs-232 Setup 

Follow the steps below to set up the Rs-232 Communication Between BobCAD-CAM and your CNC machine. 

Step 1. Gather all necessary data. 

In order to set up the communications you must first have the following information. 

Baud Rate: 

Data Bits: 

Stop Bits: 

Parity: 

Flow Control: 

The Computer's Comm Port Number: 

Step 2. Ensure the serial cable correctly configured. 

The cable must be properly configured "wired" for your machine. Cables can be purchased through BobCAD or 

through your machine dealer. 

Step 3. Make sure your serial port is installed correctly configured. 

The serial port should have its own baud, parity, data bits, and flow control. These settings must be set to 

match your machine settings 

To access the Device Manager, use any of the following methods: 

- Click Start, Click Run, and then type "devmgmt.msc" (without the quotation marks). 

- Right-Click My Computer, and then Click Properties, Click the Hardware tab, and then Click Device Manager. 



Sending Files to the Machine 

To check the Comm Port Properties 

-In the device manager look under Ports>COMM and LPT Right-Click the comm port then Click on Properties. 

(You should now be able to view and change the settings.) 

Step 4. Set your machine to Receive. 

-If you are not sure how to do this you will need to consult your machine manual or dealer. 

Step 5. Launch the communication software (Predator Editor). 

To launch the editor use any of the following methods: 

- From BobCAD Click on Modules then Edit CNC. 

- From BobCAD Right-Click in the Posting Manager then Click Edit. 

- From the Windows desktop Double Click the PEditor Shortcut. 

Step 6. Configure the communication software (Predator Editor). 

From the editor Click on DNC then Properties set the Port, Baud, Parity, Data, Stop and Flow Control Values. 

Click Next 4 times then Click finish. (The settings on all but the first page need not be changed. Only the Values 

described above.) 

Step 7. Send a file to the Machine. 

From the editor Click on DNC then Send To CNC. 

Trouble Shooting Notes: 

1. A "standard" RS-232 null modem cable from an electronics store will not work. The cable must be wired 

properly for the machine. 

2. The cable must be a serial cable. A parallel cable will not work. 

3. USB to serial adapters can be problematic. An internal serial card is always a better solution. 

4. If you do not know the proper settings for your machine, contact your machine manufacturer as they will be 

able to provide the proper settings to you. 

5. If no port appears in the device manager, you will need to install or reinstall your serial port device. 

6. If using a USB to serial adapter (not recommended!), ensure the driver disk has been loaded and the 

settings (baud, parity, data bits and flow control) are the same as set on your machine. 

7. If the cable is improperly configured sometimes it is possible to send but not receive, and vice versa. 

8. If running in a DNC mode you may need to include a line delay amount. Set this value to 0 for standard RS- 

232 communication. 



Add-On Modules Overview 

ADD-ON MODULES OVERVIEW 

BobArt 

The BobART module provides enhanced tools for creating, modifying, and maintaining embossed models and 

vectorized geometry. The BobART Tree is used to load images, vector image files, BobART (.bart) files, and to 

create embossed models. 

Note: Full documentation on all of the BobART dialogues can be found within the built in help system. To 


BobCAD. Search for the term “BobART”. 

Nesting 

The BobNEST module is a complete nesting solution for nesting parts and creating toolpath for optimized 

material utilization. 

Note: Full documentation on all of the Nesting dialogues can be found within the built in help system. To 


BobCAD. Search for the term “Nest”. 

4 & 5 Axis 

The 4 & 5 Axis modules are fully documented (including tutorials), to locate this information launch the help 

system by Clicking on Help then Help Topics from within BobCAD. Search for the term “Multiaxis”.

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