Version 14 : September 2020

2.5D Solids Tutorials

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 2.5D Solids Tutorials

2.5D SOLIDS TUTORIALS

About the Tutorials
This chapter contains step by step instructions for creating models for a variety of parts. The models
in this chapter will be machined in the Machining Exercises so be sure to save them for later use.

3
 #1: 2.5D Cap

#1: 2.5D CAP

1. Create a new part named Cap.vnc with

the mm dimensions shown.

2. Open the Solid Modeling

palette.

3. Open the Create Solid palette.

4. Open the Cuboid dialog.

5. Enter the data in the Cuboid dialog as

shown and Click the Do it button (or
press Ctrl+.).

Pressing the Stock Dim. button will enter most of the data so that only the Max Z field needs to be
changed.

6. From the Geometry Creation palette , select Shape then rectangle and create
the rectangle as shown. Change view to isometric (Ctrl+I).

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 #1: 2.5D Cap

7. Double-click the cube to place it in the Body Bag.

8. Switch to the home view (Ctrl+H).

9. Create the circle shown.

10. Select the circle and choose Plug-Ins > Geoedit

Split. Enter 4 for the number of sections then Click
(or press Ctrl+.).

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 #1: 2.5D Cap

11. Choose Modify > Transform > 2D Rotate, enter the values
shown. Double-click the circle to select all of it, then Click the
Do it button.

12. Close the Rotate dialog. Click away from the part to deselect and

from the Create Solid palette open the loft dialog.

13. Ctrl+click the sync points as shown below.

Method 1 - Shape Sequence Method 2 - Shape to Shape

Select each point in sequence and in the direction of the loft, from the circle to the
square, Click Do it.

Alignment points are used to determine how the shapes will be aligned and blended. Alignment
points must be selected in the right order. Alignment points can be selected in two ways,
selecting alignment points from shape to shape or select a single shapes alignment points, in
order, followed by the next shape in the same order.

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 #1: 2.5D Cap

14. Click the cube then Ctrl+click the loft shape. (Make sure Face selection is deselected
to select entire body).

15. Subtract the loft from cube.

16. Create a Rectangle with the Fillet Radius shown.

17. Click New CS from the CS list.

18. Create CS2 and label it XZ plane.

19. Open the CS palette.

20. Click the XZ button.

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 #1: 2.5D Cap

21. Switch to the home view (Ctrl+H).

22. Create the profile geometry in the XZ plane.

23. Switch to XY plane.

24. Switch to the isometric view (Ctrl+I) and Double-click the cube base to place it in the Body
Bag.

25. Select the profile and open the Sweep Solid dialog.

26. Place the Base Curve pointer on the

rectangle with fillets and Click the Do it
button (or press Ctrl+.).

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 #1: 2.5D Cap

27. Open the Rectangle dialog and enter the

following dimensions.

28. Select the square and create the extrusion

shown.

29. Subtract the tapered extrusion from sweep.

30. Switch to the XZ plane.

31. Create the points shown below.

32. Create the 40mm arc terminated

between the two points as shown.

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 #1: 2.5D Cap

33. Select the arc and Revolve the arc with the following
information.

34. Choose Modify >Transform> Translate and enter the following

values.

35. Select the revolve and Click the Do it button.

36. Subtract revolve from sweep.

Note that the sweep is now two disjunct shapes but one multi-lump body.

37. Select the sweep and Separate it.

38. Add the swept shapes to the

modified cube.

39. Save the part file.

10
#1: 2.5D Cap

11
 #2: Building a Spherical Ellipse

#2: BUILDING A SPHERICAL ELLIPSE

The Challenge
You need to create a concave elliptical where the lowest point is in the center.

The Problem

The print specifies values for one quadrant of

the 3D shape; this is how we might normally go
about building the part, one quadrant at a time.
We build the first quadrant and then create a
Coons Patch between the geometry. We then
duplicate and mirror the Coons Patch sheet
over the X and Y center lines and stitch the
sheets together. This result looks like the
finished shape we want.

However, there is a problem with this model

that cannot be clearly seen until the part is
machined. If you turn on “Show Edges”, you
can see the intersecting lines running through
the model. These intersecting lines run parallel
to the X and Y axes at the centerline. When the
part is machined, these lines will show up as if
they have been magnified. The model, not the
machining, is the cause of the problem.

Is this problem unique to GibbsCAM? No, this is the result of poor modeling techniques and will be
reproduced in any other CAD or CAD/CAM system unless a better set of modeling techniques is
used. GibbsCAM is machining the model exactly as it was built.

The Solution
To create a single continuous 3D flowing shape we will create a “3 Point Arc” on the XZ CS,
another “3 Point Arc” on the YZ CS and then Sweep a sheet over these two arcs. Create a 3 Axis
Vertical Mill part, X:–40/+40, Y:–30/+30, Z:–20/0mm. Follow the steps below:

Step #1
1. Create an XZ plane.
2. Create points at X–35, D0, Z0 then at X0, D0, Z–8 and lastly X+35, D0, Z0.

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 #2: Building a Spherical Ellipse

3. Select the points we just created.

4. Create a “3 Point Circle” (the circle will have a radius of 80.563mm).
5. Terminate the circle with the points at X–35 and X+35.

Step #2
1. Create a YZ plane.
2. Create points at Y–25, Z0, X0 then Y0, Z–8, X0 and Y25, Z0, X0.
3. Select the points we just created.
4. Create a “3 Point Circle” (circle will have a radius of 43.063mm).
5. Terminate the circle with the points at Y+25 and Y-25.

Step #3

1. Switch to the XY plane.

2. Open the Surface Modeling palette.

3. Open the Sweep Sheet dialog.

4. Set the sweep options as shown.

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 #2: Building a Spherical Ellipse

5. Place the base curve pointer on the curve

shown and double-click the other curve
as the drive curve.

6. Click the Do It button to create the sheet.

7. Create a cube based on the workspace stock dimensions.

8. Slice the cube with the swept sheet function.

Now you have a continuous shape which does not have quadrant intersections. Turn on Edge
Selection and you will only see the edges of the spherical ellipse at the top surface of the body.
There are no edges in the middle of the spherical ellipse like we saw with the quadrant building
technique. You may machine as desired (the sample part uses a lace cut) and you will not see
any lines in this area as you did before.

9. Save the file.

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 Replace History

REPLACE HISTORY
In this tutorial we are going to modify a model to create a pocket. We will machine the pocket with
saved processes. After we machine the part we will import a new body that represents a
redesigned pocket. Using Replace, we will recreate the model and redo the machining.

Part Creation
1. Open part file Swap Example.vnc.
This part file has 2 bodies — Block and Pocket. Pocket is currently not visible as it is in the Body
Bag.

Block Pocket

Saved Processes
The first thing we will do is make the saved processes available for use.
1. Open the Sample Parts\Solids\Required\SolidSurfacer\Swap & Replace folder and copy the Swap
Processes folder to My Documents .

Placing the saved processes here will make it easy to find them when we need them.

15
 Replace History

1. Right-click a Process tile and from the

menu choose Load Process List, then Set
Folder .

This will now be the default location that

processes can be loaded.

2. Navigate to the My Documents/

Swap Process directory and click
Select Folder .

Placing the saved processes here will make it easy to find them when we need them.

Unstitching and Subtracting “Pocket”

We are going to unstitch the body named Pocket to close

off the shape, thereby creating a core. The interior
topology is not important; it is the exterior shape we will
be subtracting from the Block.

Opposite isometric
view (Ctrl+Alt+I)

1. Turn on face selection and Right-click the bottom flat face of the pocket body.

2. Choose the Select> Select Faces Above option.

All faces inside the pocket except the flats on top of the bosses should be selected.

16
 Replace History

3. Select the two flat tops of the bosses, as shown

above.

4. Click the Unstitch button.

This results in two solids.
5. Select and Delete the smaller of the two resulting solids.

We do not need the core that was created, but we need the filled pocket body.

6. Subtract the filled pocket from the Block.

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 Replace History

Machining the Part

Loading Processes.

1. Right-click the Process list and select

Load Process List. This time the menu
will display files in the folder we set.

2. Choose 1) Rough Pocket.prc. There will be a slight delay as the Tool and Process that comprise
this pocketing process are loaded.

3. Select the faces in the pocket the same way we selected the faces for the unstitch. Create the
toolpath.

4. Deselect the Operation tile and Clear the process tile.

5. From the Processes menu select Load and choose 2) Finish Pocket.prc and create the toolpath.
6. Render the operation.
7. Deselect the operations and place the model in the Body Bag.

Modifying the Part

Importing the Changed Pocket
We are now going to import a model that is a different pocket shape. We will use the Replace
function to insert it where the filled Pocket body was used.

1. File> Import the file Large Cover.x_t from the Swap & Replace folder.

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 Replace History

Replacing the Model History

1. As with the smaller pocket shape, Right-click the bottom face and choose Select> Select
Faces Above and then select the tops of the two bosses.

2. Unstitch the solid to fill it and Delete the smaller solid.

3. Double-click the graphic to extract the smaller filled pocket

from the History of the Block.

4. Select the filled Large Cover solid then the smaller filled pocket. Click the Replace
button.

You will not see any changes but you may be wondering why we had to unstitch the larger
pocket. Shouldn’t we be able to just extract the original smaller body and replace that? The
answer is, in this case, no. The modeler is not able to match up the faces of the two bodies. If we
were using a function that was not face-dependent (translate, booleans, and so forth) we could
just select the two original bodies and perform a swap or replace.

5. Right-click the Block model and choose

Rebuild.

Redoing the Operations

Now we will update the operations based on the new model.

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 Replace History

1. Select Edit > Redo All Ops and render

the part.

2. Save the file; it is complete.

20
 Machining Solids

MACHINING SOLIDS
About these Tutorials
The part models for all of the following exercises were created in the Modeling Exercises chapter of
this manual. If you have not gone through those exercises and created the solid models for these
parts, you should do that now. We assume you are familiar with the interface and the principles
presented in the Mill and Advanced CS Modules. If you are unfamiliar with that information please
read through those manuals before attempting the following tutorials.
All parts in these exercises are assumed to be made of cast aluminum alloys. The feeds and speeds
are all defaults, based on the CutDATA™ values. The exercises do not provide a step for setting the
material but if you have CutDATA, please set the part material when you open the part file. If you do
not have CutDATA simply use the default material — stainless steel. The feeds and speeds may be
set by clicking on the calculation buttons.

Pockets and Contours

In this exercise, we will use a pocketing process to rough the part. The part will be finished using
Contour operations on the whole body and selected faces.

Part Setup

1. Open the 2.5D Solids part Cap.vnccreated in

modeling exercises. Set the Global Settings in the
Machining Preferences tab of the DCD as shown.

2. Ensure that the part has a Clearance value of 15mm.

3. Create the following tool list.

Bottom
# Type Total Length Diameter # Flutes Flute Length Material
Radius
1 Face Mill 50mm 50mm 0mm 5 11.5mm HSS
Rough
2 92mm 16mm 0mm 3 32mm TiN Coated
EM
3 Finish EM 66mm 10mm 2mm 3 16mm TiN Coated

21
 Machining Solids

Machining the Part

#1, Face Milling
First we will Face Mill the part.

1. Create this roughing

process with tool #1.

This will clear off the top of the part. Face Milling is not dependent on having a solid to machine.
Face milling machines either selected geometry or the workspace stock.
2. Create the toolpath.

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 Machining Solids

#2-3, Pocketing

1. Create this Roughing

process with tool #2.

23
 Machining Solids

When all of the options are set, create the operation.

The Use Stock option will trim the toolpath to the stock condition. Since this is an open pocket we
can get some drastically different results. If you wish to see the difference, try re-doing the
operation with Use Stock off.
The Rough tolerance setting allows us to generate toolpath faster with looser tolerances. This
will be fine since we are going to finish the surface in the next group of operations.
2. Create the toolpath and render.

This process creates two operations.

24
 Machining Solids

#4-5, Contouring
We will now do the first of two sets of contour operations to finish the profile.

1. Create this Contour process with tool

#3.
The Desired Z Step determines how
smooth the wall will be. Alternatively,
the Ridge Height option can be used to
specify the part’s smoothness. Often
the rendered part is far more accurate
in showing any scallops that are on the
part than our eyes can discern.

2. Create the toolpath and render.

This operation produces smooth toolpath that wraps around the walls of the part. When
rendered your part will look similar to the image to the right. Because we specified Depth First,
the toolpath is completed around one wall before rapiding over and machining the other.

#6, Contour
The last operation will contour the inner pocket.

25
 Machining Solids

1. Modify the existing

Contour process as
shown.

2. Turn on face selection mode.

3. Select the faces of the angled pocket.
4. Create the toolpath and render.

26
 Machining Solids

5. Save the part.

#2: The Hot Punch

The Hot Punch will only have one operation — a projected engraving operation. The part consists of
a stock body. We will create a text shape and project the contour toolpath onto the model.

Part Setup
Document Control Dialog
1. Open the Hot Punch.vnc part. Set the global settings in the Machining Preferences tab of the DCD
as shown.

2. Ensure that the part has a Clearance value of 15mm.

Tool List
1. Create the following tool.

Total # Flute
# Type Diameter Corner/Tip Material
Length Flutes Length
3.15mm Center
1 31.5mm 3.15mm 118° 2 1.9mm Carbide Solid
Drill

Creating Operations
#1: Engraving
We will create text and engrave the top face of the part. The contouring process provides for
centerline machining of all selected shapes which include text and artwork. Contouring
operation toolpaths can be projected on to sheets and bodies.
We will need to create text geometry that can be machined. The system can create spline
geometry from any TrueType font. You may need to set the directory that contains the fonts for
your system. There is a Font Directory item in the Preferences>File submenu which allows you to
designate a directory that contains your system fonts. The Moorpark TrueType font used in this
exercise is shipped with each order.

27
 Machining Solids

1. Open the Text Creation dialog from the

Shape palette in the Geometry Creation
palette.

2. In the Text Flow tab select the clockwise arc.

3. In the Text Flow tab enter the information shown.
4. Click the Do It button to create the text.

If you have any problems with text creation, refer to

the Text Creation Exercise in the Geometry
Creation Manual.

5. Select the text geometry.

28
Machining Solids

6. Create this Contouring process with tool

#1.
When more than one shape is selected
prior to creating a contouring process, the
system automatically assumes that you are
doing engraving. When this is the case,
several of the items in the Contouring
Process dialog will be grayed out. The Z
Stock option is used in this case so that the
engraving toolpath will cut into the selected
body. The toolpath generated by the
operation will be shifted down along the Z
axis only by the amount specified. The
toolpath itself will be projected onto the
surface of the body and then will be shifted
down in Z to cut into the body.

29
 Machining Solids

7. In the Solids tab enter the

information shown.

8. Ctrl+click the model.

The text and the model should both be selected. When 2D geometry and a solid or sheet are
selected for the cut shape of a process, the toolpath will be a projection of the 2D toolpath onto
the body or sheet.

30
 Machining Solids

9. Create the toolpath

10. Render the operation.

#3: The Base

About the Part
This part is intended to help you become familiar with two important tools - the Profiler and using
constraint shapes and faces.
1. Open the part file Base.vnc.
This part has an existing stock condition and two groups of operations including two drilling
operations and a roughing operation. Drilling in 2.5D Solids, as with the standard Mill package,
is accomplished with geometry or the Hole Wizard so we do not need to go over the Holes
process.

The roughing operation uses a combination of containment faces to achieve the desired results.
Let’s look at how this works.

31
 Machining Solids

Part Setup
The part should be ready for you to apply operations to it but to be safe we will go over certain
aspects.

1. Ensure that the part is using a 5 Axis Vertical Mill

MDD, that the Clearance Plane is set to 350mm
and that the Global Settings in the Machining
Preferences tab are as shown.

The part has four tools as detailed below.

Total Bottom Flute

# Type Diameter # Flutes Material
Length Radius/Tip Length
1 Drill 260mm 80mm 90° 2 n/a TiN Coated
2 Drill 260mm 40mm 118° 2 n/a TiN Coated
Rough
3 121mm 25mm 0mm 3 45mm TiN Coated
EM
Finish
4 72mm 10mm 0mm 3 22mm TiN Coated
EM

Machining the Part

Op 3, Roughing
1. Double-click operation #3.

2. Turn on Face Selection and deselect the

top flat face as shown.

32
 Machining Solids

3. Redo (Ctrl+,) the operation.

The results are very different. By
deselecting the face we have told the
system that face is a constraint and we
cannot machine by it.

4. Reselect the top face and Re-do the operation to return it to its original state.

Ops 4-6, Rough and Contour

We will now create a roughing and contouring process group to machine the angled face.
1. Switch to CS2.

33
 Machining Solids

2. Create this roughing

process with tool #3.
The Surface Z and Depth Z
values are acquired by
interrogating the top of the
circular boss and the large
flat angled face. If your
machining CS is set to
something other than CS 2
you may get different
results.

34
 Machining Solids

3. Create this contour process with tool #4.

35
 Machining Solids

As usual, the rotations information is automatically acquired.

4. Select All (Ctrl+A) the entire model, then deselect

the two faces that define the hole in the boss.

We have already drilled out this hole and we do not need to waste toolpath on it.

5. Create the operations.

You can see that we have some
toolpath that is not necessary. We
forgot to select the constraint
geometry.

6. Ctrl+double-click on the “air”

geometry and redo (Ctrl+,) the
operation.
These results are more desirable.

36
 Machining Solids

Op 7, Contouring with the Profiler

The last thing we will do is use the Profiler to machine a selected area of the part. Operation #3
leaves stock on the rounded wall.
1. Switch to the XZ plane.

2. Activate the Profiler.

3. Turn off the Coordinate system grid.
You will find it easier to see and work with the Profiler if the CS grid is off.

4. Right-click the profile grid and choose Profiler Depth.

5. Interrogate (Alt+click) the face shown and Click the Apply button.

U
nf
ortunately at this depth the
Profiler does not see the
rounded wall. We will have to
manually move the Profiler.

6. Click anywhere on the Profiler’s grid

and drag the Profiler to a location in the
center of the rounded wall, as shown
above.

37
Machining Solids

7. Create a Contour process with tool #4 as

shown.
The Final Z depth can be acquired by
interrogating the same face we tried to use
for the Profiler depth.

38
 Machining Solids

8. Click the Profiler and set the machining

markers as shown, then create the
operation.

You may find it necessary to go to the Home view to get the markers in the correct location.
9. Render the operations.

10. Save this part.

39
 Part Prints

PART PRINTS
Spherical Ellipse

40