Manual Mill

Table of Contents
License agreement............................................................................................................. 1
Getting started................................................................................................................... 2
Tutorial 1.......................................................................................................................... 4
Tutorial 2............................................................................................................................ 13
Tutorial 3............................................................................................................................. 17
Tutorial 4............................................................................................................................. 20
Tutorial 5.............................................................................................................................. 24
Tutorial 6............................................................................................................................... 28
Tutorial 7.............................................................................................................................. 32
Tutorial 8.............................................................................................................................. 35
Tutorial 9.............................................................................................................................. 41
Customizing CAPSmill
Tutorial 10............................................................................................................................... 44
Tutorial 11............................................................................................................................... 47
Tutorial 12................................................................................................................................48
License agreement
License
You have a non-exclusive right to use the software. This software can only be used on a single
computer. You may physically transfer the software from one computer to another, provided that the
software is used on only computer at a time. You may not electronically transfer the software from one
computer to another over a network. You may not distribute copies of the software and its
documentation to others. You may not modify, reverse engineer or translate the software or the
documentation without the prior consent in writing from the publishers Cadem Technologies Pvt. Ltd.,
hereinafter referred to as Cadem.
Backup
You may make one copy of the software solely for the purpose of backup. You must reproduce and
include the copyright notice on the backup copy. You may not transfer, sell, or lease the license to
another party without prior written consent from Cadem.
Copyright
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You may not copy the software or its documentation except for backup purpose and to load the
software on a computer as part of executing the software. All other copies of the software and its
documentation are in violation of the copyright.
Warranty
The software is provided “AS IS’” without warranty of any kind. The entire risk as to the results and
performance of the software is assumed by you. Cadem does not warrant, guarantee or make any
representations regarding the use of, or the results of the use of, the software in terms of its
correctness, accuracy, reliability, current ness or otherwise and you rely on the software and its results
entirely at your own risk.
CADEM does warrant to the original licensee that the physical media on which the software is recorded
be free from defects in material and workmanship under normal use and service for a period of 3
months from date of delivery evidenced by a copy of your receipt.
Cadem’s and its distributor’s entire liability and your exclusive remedy shall be replacement, or at
Cadem’s sole discretion, refund of purchase price. If the failure of the media has resulted from abuse,
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limited warranty.
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software and its documentation, its merchantability, or fitness for a particular use.
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this software be liable for any direct, indirect, consequential or incidental damages / loss arising out of
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Acknowledgements
CADEM acknowledges MS-WINDOWS as registered trademark of their respective owners.
CAPSmill 11 User's Manual 1 of 49 Cadem Technologies Pvt Ltd

Getting started
Learn how to use the program
Through Tutorials
The tutorials teach you how to use the program to generate NC programs and related documents. The
tutorials can be accessed through the Start menu (Start > Programs > Cadem) or from the Help menu.
Completing all the tutorials typically takes 1 day.
Reference jobs
The program is shipped with pre-made sample jobs. You can open these and view the tool path
simulation, generate NC programs or cycle times, etc.
Customize CAPSmill
Before starting to seriously use the outputs, you must first customize it to suit your requirement. If you
are evaluating the program and do not intend to use its output to cut parts, this step is not required.
Postprocessors
Posts may need to be configured so that the NC programs generated conform to your programming
practices and the format acceptable by your machines. This program is shipped with a number of posts
for popular controllers. These must be tweaked to include your machine data and codes. This is easy to
do. You can do this yourself or contact us or our resellers for help in making the posts.
When you want to generate outputs from the program, you must first select the machine from a list.
You must customize this list so that only your machines appear in it.
Tools and FS database

The database has a large collection of tools. You can customize the list – add any tools you use, or
delete tools that you do not require. Cutting parameters in the database may not be what you normally
use. You might wish to modify them to suit your requirement.
Get started
You can either use the Wizard or the regular interface. The Wizard is easier to use, but does not have
some advanced features like Single motions and Subprograms. We recommend that you use the wizard
initially, but switch over to the regular interface once you are proficient in the use of the program.

Tutorial 1- Face milling
This tutorial shows
Creating part and blank shapes.

Performing face milling, drilling and reaming operations.
Viewing tool path.
Generating NC program.
Generating documents.
Part drawing

Start a new part
If you have just started CAPSmill, Select Create a

New icon new part in the startup dialog box and click on OK.
If you have already started CAPSmill, select File >
New.
Work setup
Work setup icon The Work setup dialog box appears automatically
when you start a new part.
Setup data
• Enter the following data, leaving the rest
unaltered:
For Units select ‘MM’.
For Work piece material select any
material.
Documentation
• Click on the Documentation tab and enter
suitable data.
All the data except the Remarks will appear in the

NC program and in other documents like the cycle
time sheet. You can omit any or all of them. Any
field that you do not enter appears blank in the
shop documents generated by the program.
• Click on OK to exit from the Work setup dialog

box.
Save the File
Save icon • Select File > Save.

• Enter the File name as ‘Plate’. The file will now
be saved as Plate.cpm. All job files that you
create in CAPSmill will be stored with the
extension, dot cpm.

• Click on the Geometry button at the bottom left
of the screen.
Draw blank
Draw rectangle
• Select Draw > Shapes > Rectangle(Center –
Length – Width).
• Enter the following data:
Length = 200
Define blank icon Breadth = 150
Corner radius = 0
Rotation angle = 0
• Click on OK.
• At the prompt Specify the center point of the
rectangle, enter the coordinates 0,0 through
the keyboard and press the Enter key or Done.
Draw part
Draw points for 10mm diameter holes

Draw part icon • Select Draw > Point pattern > Points on Circle.
• Enter the following data and click on OK.

Diameter = 100
Angle of first hole = 0
Number of holes = 12
• At the prompt Enter the center point for this
pattern enter 0, 0 through the keyboard and
press Enter.

Zoom picture
• Select View >Zoom all to expand the view.
The part has now been defined; your drawing

should appear as shown.
Define blank shape
• Select Draw > Define blank.

• Click on Select contour button in the dialog box
that appears.
• At the prompt Select a contour click on the 200
x 150 rectangle drawn earlier.
• Enter the following data in the dialog box that
appears and click on OK.
Blank thickness = 80.0
Z coordinate at bottom = -75.0
The Minimum and Maximum X, Y coordinates are

picked up automatically from the selected
rectangle. Leave them unaltered.
The blank definition is optional. If it is not defined,

it is automatically assumed as a rectangular block
surrounding the area that is cut.
Steps in performing a machining operation:

Select the operation
Select the tool
Specify the area to be machined
Specify the machining parameters
You will find this sequence of steps repeated for

every operation.

Machining
Get into the machining mode by clicking on the

Machining button at the bottom left of the screen.
Face milling
Select the operation
Face milling icon
• Select Operations > Milling > Face mill.
Select the tool

• Click on New tool.
• In the Select tool type list, select a face mill

type with a square shoulder.
• In the Select tool list, click on the 125.0mm.
dia. face mill.
• Click on OK.
Specify the area to be machined

• At the prompt Select a contour click on the
rectangle, which was defined as the blank
earlier.
• Select Rectangle-Center point, length and
breadth from the select entity list and click on
done.
Specify the machining parameters

A machining parameters dialog box appears with
default values.
• Enter 5 for Material thickness.
• Click on OK.
• At the prompt Select a circle to specify the

machining start point click on the top right
circle.While defining the blank you specified the
blank thickness as 80.0 and Z coordinate at
bottom as -75.0 The extra 5.0 material is
removed in face milling, and the top of the face
milled surface of the part becomes Z0 after this

Default values and cutting parameters are
automatically selected from the database for the
selected tool type, tool material and work piece
material.
Drilling
• Select Operations> Hole > Drilling.
• Click on New tool. In the Tool type box expand

Drilling icon the 'Drill' list and select 'Twist drill'.
• Select a 9.8mm dia. drill and click on OK.
• At the prompt Select the points to be machined

click on any point on the point pattern, click on
Done.
Since the hole is part of a pattern, all the points in
the pattern get selected.
• Select No for the prompt Do you want to omit
any holes?
• For Work surface Z enter 0, and for Hole depth
enter 32.0.
• Click on OK.
For quick search, type the first numeral of the tool

size you are searching.

Reaming
• Select Operations > Hole > Reaming .
• Click on New tool. In the Tool type box expand

the 'Reamer' list and select 'Reamer'.
Reaming icon • Click on a 10.0mm dia. reamer, HSS tool
material and Click on OK.
click on any point on the point pattern, click on
Done.
• Select No for the prompt Do you want to omit
any holes?
• For Work surface Z enter 0 and for Hole depth
enter 30.0 Click on OK.
• Save the file.
Select a machine
Whatever you did so far (Work setup, Geometry
definition, Machining) is independent of any
machine.
Further functions like the NC program, cycle time,
etc. require the machine to be selected since they
use the machine’s mechanical data like feed rate
and spindle speed limits, spindle power, etc.
Select Machine.
Click on a machine from the list.
Select machine icon
Click on Select.

View tool path
• Click on the Toolpath button at the bottom left

of the screen.
• Click on to simulate till the end.

• Select to start simulation.
• After viewing the simulation try out the other
simulation options:
Modes: Solid or line mode

Views: Isometric, XY, YZ or XZ.
Simulate till: Next motion, next tool, next
operation or end of the program.
NC program
• Click on NC program on the menu bar. Click on

OK in the dialog box that appears.
NC program icon • Click on Edit to view the NC program.

• Select File > Exit to exit from the editor.
Power graph
• Select Documents > Power.
To see the exact spindle power for an operation,

move the cursor over its power bar.
If you think the spindle is being under or over
utilized in any operation, you can change the
operation’s cutting parameters.
Double click on the power bar for the operation. Its
cutting parameters are displayed.
Spindle power graph icon When you change the parameters and exit from the
dialog box, the new spindle power is displayed.
Click on Close to exit. If you have changed the

cutting parameters, you can now choose to either
retain the new values or discard them

Time study sheet
• Select Documents >Time study sheet.
• Click on View. Click on to enlarge the

view.
• Click on the buttons on the left to move
Cycle time study sheet icon between pages.
• Click on Export to export the report to Excel or
RTF format.
• Click on Print to print the report.
• To exit from the cycle time sheet click on
Close, then on OK.
Tools list
• Select Documents >Tool list.

Tool list icon
The options are as in the cycle time sheet.
Tool layout sheet
• Select Documents > Tool layout sheet.
• Click on the arrow buttons in the

menu bar to switch between sheets.
Tool layout sheet icon • Click on to print a sheet.

• Click on to exit.

Tutorial 2- Importing CAD file,machining
This tutorial shows

Face milling
Pocket milling
Side milling
Part drawing

Start a new part
New icon
Work setup
• For Units select ‘MM’.

• For Work piece material select any material
from the list. Leave the rest of the data
unaltered.
• Enter suitable data in the Documentation page.
Save the file with a suitable name.
Import DXF file.
• Select File > Import >DXF FILE.

• An open DXF file dialog box will appear.
• Select the .dxf and click on open.
• The DXF file import dialog box will appear, click
on OK.
• The DXF file opens.

Define the blank

• Click on Select contour and click anywhere on
the contour that we defined earlier.
• Enter the data shown below and click on OK.

Z coordinate at bottom = - 25.0
• Save the file.
Machining operations
• Switch to the Machining mode.
Face milling
Select the Face mill operation.
• Select an appropriate face mill.
• Select the blank contour as the area to be
milled.
Face milling icon • In the operation dialog box, for Process select
Roughing, for Work surface Z enter 0, for
Material thickness enter 5.0
Pocket milling
• Select the Pocket milling operation.
• Select a 32.0 dia. end mill.
Pocket milling icon • Select the small rectangle as the area for
pocket milling.
• In the operation dialog box, for Process select
Pocket depth enter 10.0, for Side allowance
after roughing enter 0.5.

Side milling – mill corners
• Select the Side mill operation.
• Select the small rectangle as the machining
area.
• At the prompt Specify the machining start
point click anywhere on the contour.
• At the prompt Mill the whole contour? Click
Side milling icon Yes.
• At the prompt Select a circle to specify the
side for milling click on the inside circle.
• In the operation dialog box, for Process enter
Side finish, for Work surface Z enter 0, for
Material width enter 0.5, for Material depth
enter 10.0.
• In the Tool entry / exit tab, for Entry distance
and Exit distance enter 5.0.
Select a machine
Select machine icon
View tool path
Switch to the Toolpath mode.
View NC program and other

documents
• Generate and see the power graph, NC

program, cycle time, tools list and tool layout
sheet.

Tutorial 3 - Slot milling
This tutorial shows

Milling a pocket with an island.
Milling a slot.
Part drawing

Start a new file
New icon Define the work setup
Save the file
Draw part
• Draw the octagon using Draw > Shapes >

Polygon.
• Draw the square using Draw > Shapes
>Rectangle.
• Draw the slot using Draw > Shapes >Slot.
The part looks as shown in the figure.
Shapes drawn in CAPSmill through its standard

drawing functions like rectangles, holes, polygons,
pattern of holes are ready for machining and need
not be defined as contours.
If you construct a part or a blank shape using lines,
arcs and circles, you have to chain them as
contours.
Draw blank
Define blank
• Draw the square for the blank.

• Define it as a blank with a suitable thickness
and Z coordinate
Machine part
Mill the pocket

• Check the prompt Do you want to specify
islands ? and click on OK.
• Select 50 X 50 rectangle for the prompt select
islands
• Press the right mouse button and select Done.
Mill the slot

• Select Operations> Milling > Slot mill.

View tool path
• Switch to the Toolpath mode.
View NC program and shop

documents
• Generate and see the power graph, NC

program, cycle time, tools list and tool
layout sheet.

Tutorial 4 - Pocket and side milling
This tutorial shows

Face milling
Pocket milling
Side milling
Part drawing

Start a new part
New icon
Work setup
• For Units select ‘MM’.

• For Work piece material select any material
from the list. Leave the rest of the data
unaltered.
• Enter suitable data in the Documentation page.
Save the file with a suitable name.
Draw the part
Switch to the Geometry mode.
Draw the rectangular pocket

Rectangular center length width
icon • Select Draw > Shapes > Rectangle (Center –
Length – Width).
• Enter the following parameters:
Length = 100.0
Width = 75.0
Corner radius = 12.5
• Click on OK.
• At the prompt Specify the center point of the
rectangle, enter the coordinates 0,0 through the
keyboard and press the Enter key or Done.
Draw R100.0 and R150.0 circles
• Select Draw >Circle > Center - radius.

• At the prompt Specify the center point enter 0,
0 and press Enter.
• At the prompt Specify the radius enters 100
Circle center radius icon and press Enter.
• Similarly draw a circle with radius 150.0 at

center point –300.0, 0.

• Select View > Zoom all.
The screen now looks like this.
Draw R 200.0 circles tangential to these two

circles
• Select Draw >Circle > Tangent – tangent –
radius.
• At the prompts Select the object and Select
next object, click on the upper halves of the
circles.
• At the prompt Specify the Radius enter 200.0.
Similarly draw another tangential R 200.0 circle,

this time by clicking on the lower halves of the
circles.
• Select View >Zoom all, to get all the objects

within the screen.
Define the contour

Construct the required contour using these circles.
Define contour icon • Select Draw > Define contour > Interactive
contour.
• At the prompt Specify the first object click on
one of the circles.
• Click on the other circles at the locations
shown each time the prompt Select the next
object appears.
• Click on Yes at the prompt Do you want to
save it as a contour?

Define the blank

• Click on Select contour and click anywhere on
the contour that we defined earlier.
• Enter the data shown below and click on OK.

Z coordinate at bottom = - 25.0
• Save the file.
Machining operations
• Switch to the Machining mode.
Face milling
Select the Face mill operation.
• Select an appropriate face mill.
• Select the blank contour as the area to be
milled.
Face milling icon • In the operation dialog box, for Process select
Material thickness enter 5.0
Pocket milling
• Select the Pocket milling operation.
Pocket milling icon • Select the small rectangle as the area for
pocket milling.
• In the operation dialog box, for Process select
Pocket depth enter 10.0, for Side allowance
after roughing enter 0.5.

Tutorial 5 - Rotary table machining
This tutorial shows
Machining a part on a rotary table on Horizontal machining center with operations on two faces.
Part drawing

Start a new file
Save the file
Draw part
• Draw the 4 corner holes and the 8 holes on a

PCD in the normal manner, on the same side
of the blank.
Draw blank
Define blank
• Draw the rectangle for the blank and define

the blank with a suitable thickness and Z
coordinate
Machine part
Define machining locations
• Double click on Machining location in the
Operation view. In the Table rotation tab click
on Add and enter these data:
Retract Z = 60.0
Table rotation angle = 0
• Click on Add again and enter these data:
Retract Z = 60.0
Table rotation angle = 180
• Click on the Machining locations tab
• Click on XY – plane, T0 and W1 and click on

Add.
This specifies a location in the XY plane at table
angle 0 with work coordinate system 1.
• Click XY – plane, T180 and W2 and click on
Add.
This specifies a location in the XY plane at table
angle 180 with work coordinate system 2.Click OK
to exit.

Face milling
• Do the face milling operation in the normal
manner, but before exiting from the dialog box
do this :
• Click on the Machining locations tab.
• Select the location XY-T0-W1 and click on Add.
• Click OK.
• Perform the face milling operation again.
Face milling icon The earlier machining parameters are selected
again by default.
• Click on the Machining locations tab.
• Select the location XY-T180-W2 and click on
Add.
• Click OK.
Drilling
• Do the drilling operation on the 4 X12.0mm
diameter corner holes and select the
machining location XY-T180-W2.
• Do the drilling operation on the 8 x 20.0mm
Drilling icon diameter holes on the PCD and select the
machining location XY-T0-W1.

View tool path
• Click on tool path button
• Click on Select operation for simulation

button.
• Select 0.00000 for table rotation.
• Click on OK button and check the tool

path.
• Similarly, check the tool path for 180
degrees table rotation by selecting
180.00000 for table rotation.
Select operation for simulation option lets

you to select any operations or any
machining locations, machining plane or
table rotation, for simulation
You can also view tool wise simulation by
checking on Tool wise option.

Tutorial 6 - Defining machining location
This tutorial shows
Machining multiple parts using local coordinate systems.
Part drawing

Table setup
Defining machining locations using the Local coordinate system

New icon Start a new file
Define the work setup
Save the file
Draw part
Draw blank
Define blank
Machine the part

Define machining locations
• Enter the Machining location definition by
double clicking on it. In the Local coordinate
system tab click on Add and enter the
following data:
X coord = 0
Y coord = 300
Z coord = 0
• Similarly add 2 more local coordinate systems
with X, Y and Z coordinates as (300, 0, 0) and
(300, 300, 0).
• Click on the Machining locations tab and add

the following combinations of machining
locations.
XY – plane and W1.

XY – plane, W1 and L1.
XY – plane, W1and L3.
• Click OK to exit.

Machining
Perform these machining operations and add all the

machining location in each operation.
Face milling
Face milling icon • Add the following machining locations:
XY – plane and W1.

XY – plane W1 and L1.
XY – plane, W1and L2.
Drilling icon Drilling

Same as above.
Counter boring
Counter boring icon Same as above.

Tutorial 7 - Subprogram for holes
This tutorial shows
Machining holes with coordinates specified as a subprogram.
Part drawing
All the hole machining operations are done on the same set of holes.
These hole locations will be defined as a subprogram which is called for each operation.

Start a new file
Save the file
Draw part
Draw blank
Define blank
Machine part
Define sub programs
• Select Operations > Subprogram > Define.
• Enter ‘Tappoints’ as the subprogram name.
• For Subprogram type select ‘Subprogram of
holepositions’.
Click on OK.
click on any one of the points. All the points
get selected. Click the right mouse button and
select Done.
• At the prompt Do you want to omit any holes?
• Select No.
Perform machining operations

Center drilling
• Select the Center drill operation and a suitable
90 degree spotting drill.
press ‘C’. Select the subprogram ‘Tappoints’
and click on OK. Ensure that the cursor is in
the drawing area (black portion of the screen)
when you press C.
• Click the right mouse button and select Done.
Center drilling icon
Select No.
• In the operation dialog box, for Work surface Z
enter 0, and for Chamfer diameter enter 5.0.

Drilling
• Select the Drill operation and ‘8.50mm drill’.

and click on OK. Click the right mouse button
and select Done.
Drilling icon Select No.
enter 0, and for Hole depth enter 12.0.
Countersinking
• Select the Countersinking operation and a 45
deg. Countersink tool.
and select Done.
Countersinking icon
Select No.
enter 0, for Chamfer diameter enter 10.0, and
for Dwell at bottom enter 2 spindle rotations.
Tapping
• Select the Tapping operation and M10.0 X 1.5
Tap.
and select Done.
Tapping icon
Select No.
enter 0 and for Hole depth enter 10.0.

Tutorial 8 - Subprogram for groove
This tutorial shows
Doing repetitive milling operations using a subprogram.
Part drawing

Start a new file
Save the file
Draw blank
Define blank
Machine part
Define subprograms
The subprogram is defined using single motions.

Single motions are commands, which can be used
to program individual motions or functions like
rapid traverse, linear and circular interpolation,
spindle on/off etc. separately for simple operations.
• Select Operations > Subprogram > Define.
• For Subprogram name enter Millslots.
• For Subprogram type select ‘Subprogram of

single motions , and then click on OK.
• Select Operations > Single motions > Rapid
traverse.
• Select Absolute, enter –5.0 for Z, leave X and Y
blank (the tool moves only in Z, at the current
X and Y), and Click OK.
• Similarly, make the following motions:

Feed to Y225.0 absolute at feed rate 0.25.
Rapid to Z10.0 absolute.
Rapid to X- 50.0 Y-250.0 relative.
Rapid to Z-5.0 absolute.
• Click on Done in the Single motions
subprogram dialog box.
You can modify a subprogram after defining

through Operations > Subprogram > Modify.
Motions in a subprogram can be added, deleted or

modified.
You can display the Single motions tool bar through

Select View > Toolbars. Check Single motions.

Perform machining operations
Following are the steps required to machine
this part:
Select the tool
Specify the spindle speed
Set the coolant ON
Position the tool at the initial point
Call the subprogram the necessary number of
times
• Select Operations> Single motion > Tool and

select a 25.0 end mill.
• Select Operations > Single motion> Spindle
speed, enter the 3500 RPM CW.
• Select Operations > Single motion >
Miscellaneous function > Standard and select
Coolant ON.
traverse, and Select Absolute, enter –37.5,
-25.0, 5.0 for X, Y and Z respectively.
• Select Operations > Subprogram > Call.
• Select the subprogram Millslots, enter the
Number of calls as 10.
traverse, and Select Absolute; enter 100.0 for
Z, leave X and Y blank.

Tutorial 8 - Engraving
This tutorial shows
Engraving.
Part drawing

New icon
Start a new file
Define the work setup
Save the file
Draw part
Define contour
Draw blank
Define blank
Machine part
• Select Operations > Milling > Engrave.
• Select a conical tool from the Engraving tool

type in the Form tool class.
• Select any one contour and enter suitable data
in the operation dialog box.
• Click OK to exit.
• Similarly engrave the other contour.
You can engrave alphabets and numerals in

different fonts. Text can be defined through Draw
> Text.

Tutorial 9 - Defining form tool
This tutorial shows
Defining a form tool and adding it to the tools library.
New icon Start a new file

Save the file
Defining Form tool
• Select Geometry mode.

• Draw half the profile of the form tool.
• Select File > Form tools > Export.
• At the prompt Select the object select all the
lines by clicking on them individually or by
enclosing them in a window. Click the right
mouse button and select Done.
• At the prompt Specify the reference point enter
0, 0.
• Enter the file name as ‘Conical tool 8.0mm dia.

Only one half of the shape of the form tool must be
drawn. CAPSmill internally revolves the shape to
form a solid tool.
Adding a Form tool to library
• Select Utilities > Tool and FS database; enter

‘cadem’ for the password.
• Select the General (MM) library, and then click
on Configure tool library.
• In the list of tool classes expand Form tool and
click on Form tool.
• Move the mouse to the Tool name list, right
click and select Add a new tool.
• Enter the following data :
Identification = Conical tool 8.0mm dia.
Cutting speed factor =1 for both Roughing and
Finishing.
Feed rate factor = 1 for both Roughing and
Finishing.
• Click on Tool geometry and enter the following

data:
Form tool class = End mill.
Shape file name = Conical tool 8.0mm dia.
Length from the holder face = 30.0
Effective cutting length = 10.0
Diameter = 8.0
Number of teeth = 2
Hand of tool = Right
• Click on OK repeatedly till you exit from the

Tools and FS database.
This tool will from now on appear in the tool

selection list in machining operations. You can try
opening tutorial 8 and replacing the earlier tool with
this one.

Customizing CAPSmill
Customizing involves the following:
• Configuring the Tool and FS library so that it has your preferred tools and FS.
• Configuring the List of machines that you will be using CAPSmill for.
• Configuring the Postprocessors for your machines.
• Configuring the DNC parameters if you are using the in-built DNC.

Tutorial 10 - Configuring Tools , FS
library
Configuring the Tools and FS library
The library has the following data:
• Tools
• Tool materials
• Work piece materials
• Cutting parameters
The file Caps.mdb contains the library. It is stored in the folder in which CAPSmill is installed.
Creating a new tool library
Whenever you create a new tool library it gets stored in Caps.mdb file. To create a tool library you can :
1. Create a new tool library and enter all the tools, tool materials and cutting parameters from
scratch, OR
2. Create a new library, copy the data from an existing library into it, then modify this library.
The latter is the faster method. To do this:
Create a new library

• Select Utilities > Tool and FS database.
• For the password enter ‘cadem’.
• Right click the mouse anywhere in the list of libraries list and select Add a new library.
• Enter an appropriate name at the prompt Tool library name.
• Select MM for Database units.
• Enter appropriate remarks. Remarks are optional, and can be left blank.
Copy data from an existing library

• Check Copy data from an existing library?
• At the prompt Copy from, select General – MM from the list.
• Click OK.
• After the copying is completed click on Done.
Adding a Work piece material

• Click on the Work piece material tab.
• Right click the mouse and select Add a new work material.
• Enter the name of the work piece material.
• Enter the Specific cutting forces for various operations. These are used in calculating the spindle
power. Just enter the values from the nearest equivalent material from the existing list.

Adding a Tool type
You can define your own tool types to make tool selection easier. Tool types in turn belong to tool
classes, which are fixed within CAPSmill..E.g., You can define Twist drill and Insert drill under the Drill
tool class.
• Click on the Tool library tab.

• Select the tool library to which you want to add tool class.
• Click on Configure tool library.
• Right click on a Tool class.
• Select Add a new tool type.
• Enter the tool type name.
• Enter the safe height. This will be common to all the tools of this type.
• Enter the feedrate in the Z direction, as a multiple of the feedrate in the XY direction. The cutting
parameters specified in the library are the feedrates in the XY direction.
• Click on OK.

Adding a Tool material
• You can add a tool material in any tool type.

• Click on the library, then on Configure tool library.
• Expand the tool class list that contains the tool type by clicking on the +.
• Click on the tool type.
• Right click anywhere in the Tool material list.
• Select Add a new tool material.
• Enter the name of the material.
Adding Cutting parametes
Cutting parameters are specified for each combination of Work piece material-tool type-tool material.
• Right click on the tool material in the Tool material list.

• Select Edit cutting parameters.
• Enter the parameters.
The parameters to be entered just are of two different types :

1. For hole machining tools like drills, reamers, taps etc, you can enter multiple Cutting speed and
feed rate for different diameter ranges.
2. For milling cutters like face mills, end mills etc, you can enter multiple Cutting speed, feed rate
and depth of cut for different diameter ranges.
Type 1
Example :
Feed rate
Dia. range = 3; Feed rate = 0.05
Cutting speed
Dia. range = 3; Cutting speed = 13
This means,
Feedrate = 0.05 mm/rev. for drills up to dia. 3.0
0.07 mm/rev. for drills larger than dia. 3 up to dia. 5
0.1 mm/rev. for drills larger than dia. 5.0
Cutting speed = 13mm/min. for drills up to dia. 3

15mm/min. for drills larger than dia. 3 up to dia. 5
18mm/min. for drills larger than dia. 5.0
Type 2
Similar to type 1, but additionally has depth of cut.
Adding a tool
• Select the Tool type.

• Right click the mouse in the tools list (under Tool name) and select Add a new tool.
• At the prompt Identification enter the name of the tool.
• Select the type of coolant that must be used as default for this tool. When you select the tool for an
operation this is selected as default, but you can change it.
• Click on Tool geometry and specify the tool geometry parameters.

Tutorial 11 - Customizing machines list
Customizing the machines list
The machines list is stored in the file Machines.mdb.
• Select Machine from the main menu.

• Click on Configure machines and enter the password ‘cadem’.
Add a machine
• Ensure that the postprocessor file (.gpt file) for the machine is in the folder in which CAPSmill is
installed.
• Click on Add.
• Enter the machine name.
• For Output folder specify the folder in which you want the machine’s NC programs to be saved.
Ignore the prompt if you want the files to be saved in the CAPSmill folder.
• For Machine data file select the postprocessor file for the machine.
Modify a machine
• Click on the machine and then click on Modify.
Deleting a machine
• Click on the machine and then click on Delete.

• The machine is removed from the list, but the postprocessor file is not deleted.

Tutorial 12 - Configuring postprocessors
Configuring a machine’s postprocessor
CAPSmill already has posts for most of the popular controllers. Usually this is what you would do to
make a post for your machine :
1. Copy an existing post closest to the one you require.
2. Make changes in the following areas of the post :
Machine mechanical data
Program start lines
Program end lines
Tool change lines
• Select Utilities > Postprocessor builder. Enter the password ‘cadem’.

• Select File > Open and open the post file.
Modify mechanica data

Click on Machine Data and set various parameters.
Modify program start lines
• Click on Block formats > Program start.

• Delete any blocks that you do not want.
• Add any blocks that you want.
• Add any constant strings that you want.
Modify program end lines
• Click on Block formats > Program end.

Modify tool change lines
• Click on Block formats > First tool change.

Repeat this for Tool change and Last tool change.
What are variables and constants ?
Variables
Anything in angular brackets is a variable. E.g., <#PROGRAM_NUM>.
# outputs the NC word with its address.
$ outputs the NC word without its address.
The address is specified in NC words.
To include a variable in a block format, click on the List variables button and select a variable.
Constants
Any text that is in a block format that is not a variable will appear as it is.

Cadem Technologies Pvt. Ltd.
264/75, 36th Cross, 8th Block, Jayanagar, Bangalore 560 070, INDIA.
Tel: +91-80-26634767 / 26650561. Fax: +91-80-22442732
E-mail : support@cadem.com
Internet : www.cadem.com

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Table of Contents

CAPSmill 11 User's Manual 1 of 49 Cadem Technologies Pvt Ltd

Tools and FS database

CAPSmill 11 User's Manual 2 of 49 Cadem Technologies Pvt Ltd

CAPSmill 11 User's Manual 3 of 49 Cadem Technologies Pvt Ltd

This tutorial shows

Creating part and blank shapes.

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If you have just started CAPSmill, Select Create a

All the data except the Remarks will appear in the

• Click on OK to exit from the Work setup dialog

Save the File

Save icon • Select File > Save.

CAPSmill 11 User's Manual 5 of 49 Cadem Technologies Pvt Ltd

Draw points for 10mm diameter holes

• Enter the following data and click on OK.

CAPSmill 11 User's Manual 6 of 49 Cadem Technologies Pvt Ltd

The part has now been defined; your drawing

Define blank shape

• Select Draw > Define blank.

The Minimum and Maximum X, Y coordinates are

The blank definition is optional. If it is not defined,

Steps in performing a machining operation:

You will find this sequence of steps repeated for

CAPSmill 11 User's Manual 7 of 49 Cadem Technologies Pvt Ltd

Get into the machining mode by clicking on the

Select the tool

• In the Select tool type list, select a face mill

Specify the area to be machined

Specify the machining parameters

• At the prompt Select a circle to specify the

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• Click on New tool. In the Tool type box expand

• At the prompt Select the points to be machined

For quick search, type the first numeral of the tool

CAPSmill 11 User's Manual 9 of 49 Cadem Technologies Pvt Ltd

• Click on New tool. In the Tool type box expand

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• Click on the Toolpath button at the bottom left

• Click on to simulate till the end.

Modes: Solid or line mode

• Click on NC program on the menu bar. Click on

NC program icon • Click on Edit to view the NC program.

• Select Documents > Power.

To see the exact spindle power for an operation,

Click on Close to exit. If you have changed the

CAPSmill 11 User's Manual 11 of 49 Cadem Technologies Pvt Ltd

• Select Documents >Time study sheet.

• Click on View. Click on to enlarge the

• Select Documents >Tool list.

Tool layout sheet

• Select Documents > Tool layout sheet.

• Click on the arrow buttons in the

Tool layout sheet icon • Click on to print a sheet.

CAPSmill 11 User's Manual 12 of 49 Cadem Technologies Pvt Ltd

This tutorial shows

CAPSmill 11 User's Manual 13 of 49 Cadem Technologies Pvt Ltd

• For Units select ‘MM’.

Save the file with a suitable name.