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USER'S MANUAL

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COPYRIGHT / RESPONSIBILITY

Copyright  1992-2020 Bertrand Lenoir-Welter / All rights reserved

No part of this software and user's manual may be reproduced or

transmitted, in any form or by any means, for any purpose whatsoever, without
the written permission of the author. To do so constitutes a piracy, punishable
under local law and international copyright treaties.

Any person legally acquiring this software is permitted to make copies of it

on the condition that it is strictly in accordance with the terms of licensing
agreement in their possession; namely that it is for evaluation purposes only
and not for commercial gain. Integrating this software, either totally or in part,
with another piece of software constitutes a breach of copyright. Moreover, no
part of the software may be disassembled or de-compiled, in any way, without
the written consent of the author.

Galaad is supplied as is, and no guarantee is given or implied as to the

results obtained by its use, or regarding overall satisfaction with the end
product. Galaad is a complex piece of software and has been extensively
tested, however, these tests are not guaranteed to have removed all bugs and
minor errors from the software. Finally, no guarantee can be given that
subsequent versions will necessarily be compatible with existing versions.

Purchasers are solely responsible for their choices, how they set up and use
the software for the intended purposes, and whether the results match their
expectations. No responsibility will be attributed to Galaad, its authors or
distributors, for any damage caused, either directly or indirectly, to the
machine tool, any peripheral devices, cutters, computers, stored data, or any
other object including hardware and software involved in the usage of Galaad.

Obviously none of the above terms and conditions affect the purchaser's
statutory rights under current law or legislation.

Note: in general, and without enumerating them here, are fully recognised all registered
trademarks that are mentioned in this manual, with the corresponding rights.

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TABLE OF CONTENTS

FOREWORD
Brief Curriculum Vitæ . . . . . . . . . . . . 12
Topography of this manual . . . . . . . . . . . 13
Conventions used . . . . . . . . . . . . . 14
System configuration . . . . . . . . . . . . 15
User's licence . . . . . . . . . . . . . . 16
Be inquisitive! . . . . . . . . . . . . . . 18

1 - INSTALLATION
Set-up . . . . . . . . . . . . . . . . . 1-20
The lay of the land . . . . . . . . . . . . . 1-22
Moving Galaad . . . . . . . . . . . . . . 1-23
Uninstalling Galaad . . . . . . . . . . . . . 1-23

2 - LEARNING TO DRAW
Contact . . . . . . . . . . . . . . . . 2-26
Baby steps . . . . . . . . . . . . . . . 2-28
Simple coordinates . . . . . . . . . . . . . 2-29
Snapping to positions . . . . . . . . . . . . 2-31
Handling objects . . . . . . . . . . . . . 2-32
The magnetic grid . . . . . . . . . . . . . 2-35
De profundis . . . . . . . . . . . . . . . 2-36
Zoom . . . . . . . . . . . . . . . . . 2-38

3 - LEARNING TO MILL
Roadworthiness inspection . . . . . . . . . . . 3-40
Guided tour of the launch pad . . . . . . . . . . 3-41
Workpiece origin . . . . . . . . . . . . . 3-43
Blast-off . . . . . . . . . . . . . . . . 3-47

4 - LEARNING TO SAVE FILES

Current drawing . . . . . . . . . . . . . . 4-50
Files and folders . . . . . . . . . . . . . . 4-51

5 - ADVANCED DRAWING TECHNIQUES

Numerical coordinates . . . . . . . . . . . . 5-54
Partial constructions . . . . . . . . . . . . 5-55

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Editing object geometry . . . . . . . . . . . . 5-57

Locking objects . . . . . . . . . . . . . . 5-58
Associating objects . . . . . . . . . . . . . 5-58
Protecting objects . . . . . . . . . . . . . 5-59
Anchoring objects . . . . . . . . . . . . . 5-59
Selecting and handling points . . . . . . . . . . 5-60
Selecting and handling segments . . . . . . . . . 5-63
Moving groups of points . . . . . . . . . . . 5-65
Duplication and cloning . . . . . . . . . . . 5-65
Red (or blue) cross . . . . . . . . . . . . . 5-68
Rapid data palettes . . . . . . . . . . . . . 5-69
Keyboard shortcuts . . . . . . . . . . . . . 5-70
Display functions . . . . . . . . . . . . . 5-72

6 - TOOLPATHS
Tool parameters . . . . . . . . . . . . . . 6-74
Tool compensation . . . . . . . . . . . . . 6-81
Hatching and pocketing cycles . . . . . . . . . . 6-88
Connecting objects into one toolpath . . . . . . . . 6-91

7 - ADVANCED MILLING FUNCTIONS

Tool parking positions . . . . . . . . . . . . 7-94
Normal pass, final pass, cutting pass . . . . . . . . 7-96
Fixed values . . . . . . . . . . . . . . . 7-98
Miscellaneous parameters . . . . . . . . . . . 7-99
Moving the axes . . . . . . . . . . . . . . 7-102
Defining the workpiece origin . . . . . . . . . . 7-105
Machining options . . . . . . . . . . . . . 7-109
Resetting the axes . . . . . . . . . . . . . 7-110
Managing the inputs/outputs . . . . . . . . . . 7-112
Spindle on/off . . . . . . . . . . . . . . 7-113
Automatic tool measurement . . . . . . . . . . 7-115
Workpiece origin from direct electrical contact . . . . . 7-120
Plotting the origin with a video camera . . . . . . . 7-122
Tool change . . . . . . . . . . . . . . . 7-123
Semi-manual milling commands . . . . . . . . . 7-125
VCR-Seek . . . . . . . . . . . . . . . 7-126
Manual jogging . . . . . . . . . . . . . . 7-128
Test of the inputs/outputs . . . . . . . . . . . 7-129
Managing collisions with obstacles . . . . . . . . 7-130

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8 - APPLICATION WORKSPACE
General settings . . . . . . . . . . . . . . 8-132
Restrictions for training purposes . . . . . . . . . 8-137

9 - USING A NETWORK
Sharing disks and folders . . . . . . . . . . . 9-142
Main workstation . . . . . . . . . . . . . 9-143
Secondary workstations . . . . . . . . . . . . 9-144
Exchanging files . . . . . . . . . . . . . . 9-145

10 - DRAWING ICONS
Rubbing out . . . . . . . . . . . . . . . 10-149
Points . . . . . . . . . . . . . . . . . 10-149
Lines . . . . . . . . . . . . . . . . . 10-151
Polylines and spline curves . . . . . . . . . . . 10-153
Rectangles and polyhedrons . . . . . . . . . . 10-155
Arcs and cyclic shapes . . . . . . . . . . . . 10-157
Texts . . . . . . . . . . . . . . . . . 10-159
Selections . . . . . . . . . . . . . . . 10-161
Special effects . . . . . . . . . . . . . . 10-164
Milling data . . . . . . . . . . . . . . . 10-167
Zoom . . . . . . . . . . . . . . . . . 10-167
Visual dimensions . . . . . . . . . . . . . 10-169

11 - MENU FUNCTIONS
"File" menu . . . . . . . . . . . . . . . 11-174
"Machining" menu . . . . . . . . . . . . . 11-182
"Edit" menu . . . . . . . . . . . . . . . 11-192
"Design" menu . . . . . . . . . . . . . . 11-201
"Display" menu . . . . . . . . . . . . . . 11-231
"Text" menu . . . . . . . . . . . . . . . 11-241
"Parameters" menu . . . . . . . . . . . . . 11-243
"Help" menu . . . . . . . . . . . . . . . 11-249
Shortcut icons . . . . . . . . . . . . . . 11-251

12 - MACHINE PARAMETERS
Main parameters . . . . . . . . . . . . . . 12-256
"Table" page . . . . . . . . . . . . . . . 12-258
Rotary milling on A axis . . . . . . . . . . . 12-259

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Steerable blade on C axis . . . . . . . . . . . 12-260

Parallel axes . . . . . . . . . . . . . . . 12-261
Additional axes . . . . . . . . . . . . . . 12-262
"Controller" page . . . . . . . . . . . . . 12-263
Arduino GRBL controllers . . . . . . . . . . . 12-267
AxeMotion controllers . . . . . . . . . . . . 12-268
Isel-Automation "IMC" controllers . . . . . . . . 12-270
Isel-Automation "CNC-API" controllers . . . . . . . 12-271
SM-Motion controllers . . . . . . . . . . . . 12-272
Soprolec controllers . . . . . . . . . . . . . 12-273
K40 controller . . . . . . . . . . . . . . 12-274
Generic controllers . . . . . . . . . . . . . 12-274
Customised controller . . . . . . . . . . . . 12-275
"Spindle" page . . . . . . . . . . . . . . 12-276
Tachometric spindles (with speed control) . . . . . . 12-277
Special spindles . . . . . . . . . . . . . . 12-279
Spindle command script . . . . . . . . . . . 12-279
External control programme . . . . . . . . . . 12-281
"Speeds" page . . . . . . . . . . . . . . 12-282
"Advanced" page . . . . . . . . . . . . . 12-284
Manual jogging from an external device . . . . . . . 12-286
Installation of a ShuttleXpress handwheel . . . . . . . 12-288
Mechanical corrections . . . . . . . . . . . . 12-289
Kinematics post-calculation . . . . . . . . . . 12-293
Automatic tool changer . . . . . . . . . . . . 12-301
"Inputs/Outputs" page . . . . . . . . . . . . 12-303
Extended inputs/outputs . . . . . . . . . . . 12-308
Local manual drive . . . . . . . . . . . . . 12-310
External driver . . . . . . . . . . . . . . 12-311
Post-processor format . . . . . . . . . . . . 12-313

13 - PLASMA TORCH
Constants of use . . . . . . . . . . . . . . 13-318
THC . . . . . . . . . . . . . . . . . 13-319
Ignition acknowledgement . . . . . . . . . . . 13-321
Critical inputs . . . . . . . . . . . . . . 13-323
Soprolec controller . . . . . . . . . . . . . 13-324
ThunderCut controller . . . . . . . . . . . . 13-330
Nozzle management . . . . . . . . . . . . . 13-336

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Calibrations . . . . . . . . . . . . . . . 13-338
Workpiece origin and related functions . . . . . . . 13-339

14 - SPECIAL APPLICATIONS
Laser engraving and cutting . . . . . . . . . . 14-342
Oxycutting . . . . . . . . . . . . . . . 14-343
Liquid dispensing . . . . . . . . . . . . . 14-344
Other intermittent tools . . . . . . . . . . . . 14-345
3D printing . . . . . . . . . . . . . . . 14-346

15 - "LANCELOT", STANDALONE USE

Galaad and Lancelot . . . . . . . . . . . . 15-348
Lancelot and Kay . . . . . . . . . . . . . 15-350

16 - "KAY", 3D CNC DRIVER

General . . . . . . . . . . . . . . . . 16-352
Coordinates and file origin . . . . . . . . . . . 16-353
Multiple tools . . . . . . . . . . . . . . 16-355
Workpiece origin . . . . . . . . . . . . . 16-356
Parameters . . . . . . . . . . . . . . . 16-358
Milling process . . . . . . . . . . . . . . 16-360

17 - "GAWAIN", TURNING CAD/CAM

Drawing module . . . . . . . . . . . . . 17-364
Tools . . . . . . . . . . . . . . . . . 17-366
External, internal and lateral sides . . . . . . . . . 17-367
Threading . . . . . . . . . . . . . . . 17-368
Lathe parameters . . . . . . . . . . . . . 17-369
Guided tour of the launch pad . . . . . . . . . . 17-370
Workpiece origin . . . . . . . . . . . . . 17-373
Semi-automatic commands . . . . . . . . . . . 17-375
Automatic process . . . . . . . . . . . . . 17-377
Turning on a 4-axis mill . . . . . . . . . . . 17-378

18 - "KYNON", MOTION PROGRAMMER

Automaton for axis controls . . . . . . . . . . 18-380
Programming technique . . . . . . . . . . . 18-383
Motion commands . . . . . . . . . . . . . 18-385
Switch and pause commands . . . . . . . . . . 18-387

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Jump commands . . . . . . . . . . . . . . 18-388

Macro-commands . . . . . . . . . . . . . 18-390
Programme management commands . . . . . . . . 18-391
Manual drive teach-in . . . . . . . . . . . . 18-392
User-defined buttons . . . . . . . . . . . . 18-394

19 - "PERCIVAL", PRINTED-CIRCUIT ENGRAVER

General features . . . . . . . . . . . . . . 19-396
Gerber files . . . . . . . . . . . . . . . 19-397
Excellon files . . . . . . . . . . . . . . 19-397
Tools . . . . . . . . . . . . . . . . . 19-398
Automatic functions . . . . . . . . . . . . . 19-400
Adjusting layers . . . . . . . . . . . . . . 19-401
Isolation contours . . . . . . . . . . . . . 19-401
Limitations . . . . . . . . . . . . . . . 19-403
Hatching empty zones . . . . . . . . . . . . 19-403
Card cut-out contour . . . . . . . . . . . . 19-405
Milling . . . . . . . . . . . . . . . . 19-405
Dispensing weld-paste . . . . . . . . . . . . 19-406

20 - "OWEIN", GRAPHICAL TOOLPATH BROWSER

21 - FIRST AID
Drawing . . . . . . . . . . . . . . . . 21-410
Jogging and milling . . . . . . . . . . . . . 21-412
Printed circuits . . . . . . . . . . . . . . 21-414

22 - TECHNICAL MATTERS
Command-line arguments . . . . . . . . . . . 22-416
Integration into an automated chain . . . . . . . . 22-419
Message-transmitted commands . . . . . . . . . 22-420
Interface with Windows . . . . . . . . . . . 22-421
TrueType and Galaad fonts . . . . . . . . . . . 22-423
Parameter files (and other files) . . . . . . . . . 22-424
Downloading updates . . . . . . . . . . . . 22-426

23 - A FEW TIPS FOR BEGINNERS

24 - GLOSSARY OF TERMS

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FOREWORD

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GALAAD 3 —————————————————————————————

Brief Curriculum Vitæ

Galaad is a CAD/CAM/CNC software suite (Computer Aided Design /

Computer Aided Manufacturing / Computerised Numerical Control), the point
of which is to enable you to design, i.e. draw, then manufacture, i.e. mill,
parts or objects that you need. In view of the geometrical nature of most
components and the associated toolpaths, this requires a classical approach to
the design work. Galaad is a single integrated package that covers all
aspects from drawing through to controlling the milling machine, and not
simply a collection of different applications with different interfaces. This
integration in a homogeneous set offers many advantages, making it easier
both to learn and to use, even for absolute beginners.

It is important to mention here that, in spite of its name, Galaad 3 is not

3D design software. Its application domains are mainly engraving and
cutting works on flat materials. Galaad provides special functions that create
3D wiremeshes, for example cut profiles or curve surfaces; it accepts 3D
handling and effects; it can import and mill 3D external files, but it cannot
create, handle, import or mill volumes that are made of facetted or NURBS
surfaces. Only 3D vector trajectories that represent a toolpath are accepted.
Therefore if you already have a 3D CAD system that handles surfaces and
volumes, you need an intermediate module that can convert these shapes
into vectors which define a final toolpath. Only then can you mill these 3D
vectors using Galaad.

Galaad can drive a number of CNC machines with 2, 3, 4 or 5 axes, either

directly or by using an external driver programme. Consequently, Galaad can
be considered an open application.

Additional programmes and icons appear when installing Galaad, enabling

you to make non-indexed turning, automatic motion programming, printed-
circuit engraving, or 3D milling up to 5 axes. These extra modules are
described in the last chapters, but most of this manual is dedicated to the main
application "Galaad", i.e. the integrated suite for CAD/CAM, design and
machining for 2½D workpieces.

Answer to a frequently asked question: Galaad does not

produce STEP / DIR signals on LPT port for addressing a power stage. You
must add a dedicated numerical controller that can produce these signals.

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Topography of this manual

The heart of Galaad software is its main module, which icon is

named "GALAAD (mill)". This module lets you design 2½D work-
pieces and then mill them on your machine. So, most of this user's
manual concerns this design module and its milling partner which is the
subcontractor for the operator's manual control and for supervising the
automatic process on the machine.

In early chapters, you will learn how to draw different kinds of shapes
from this main module, then how to quickly prepare and launch the machining
process for what you have drawn, then how to save your works. The purpose
is to help you getting started and become familiar with the working methods of
the software.

Then come the descriptions of functions that will enhance your design and
machining capabilities, allowing you to boost your work, of parameters for
engraving, milling or cutting tools, of tool radius compensation and how to
mill pockets. This ends with workspace and network settings.

Drawing icons and menu functions are then reviewed one by one with
more indications about their use and features.

A big chapter is dedicated to the machine parameters, with all possibilities

that some CNC cards or devices offer, along with big tips and little subtleties
for fine tuning. This section is probably the most important for an advanced
user who needs to optimise his machine functions.

Plasma cutters will find a complementary chapter for their own business.

Lastly, for the unenlightened people who have purchased a limited licence,
snubbing such a real marvel that Galaad main design module is, last chapters
are devoted to Kay module (3D milling), Gawain module (turning), Kynon
module (motion programming), Percival module (printed circuits) and Owein
module (3D viewer). Yet, designing workpieces with Galaad does not concern
you and therefore you may skip corresponding chapters. However, sections
that are dedicated to workpiece origins, milling process or machine parameters
remain valid and will at least bring you much useful information, even if they
fail to motivate you for upgrading to a higher licence.

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Conventions used

On a Cartesian milling machine, there can be several ways to

identify axes. An industrial standard more or less accepted
consists of defining the X axis as the longest of the machine, Y
and Z axes then making a direct orthogonal framework from
X. A more classical model, not always compatible with that
standard, consists of adopting the operator's point of view: the
X axis increases from left to right, the Y axis from front to rear of the
machine, and Z axis from bottom to top. However, be aware that confusions
often remain frequent for beginners.

Galaad displays directions as cardinal points: west is on the left side (X-),
east is on the right side (X+), south is on the front side (Y-), and north is on
the rear side (Y+). So the X axis increases from the west to the east and the Y
axis from the south to the north. This does not mean that you need a compass
for drawing or driving your machine, but the drawing board and the machine
bed appear as a geographical map. For Z axis, we can simply talk about "high"
and "low", which looks quite intuitive. If you wish to comply with the
standard that identifies X as the longest axis, then the best solution is to put the
operator's station at the appropriate location.

Warning! Do not consider the motion of the machine table if it is mobile,

but always the apparent motion of the tool on the table, which inverts the
direction. When a mobile table moves towards front side, in fact the tool is
virtually moving backwards, to "the north".

The distance and speed units are settable. The distances can be dis-
played in millimetres (mm), centimetres (cm), inches (") or a user-defined unit.
Speeds can be displayed in metre-per-minute (m/mn), millimetre-per-minute
(mm/mn), millimetre-per-second (mm/s), centimetre-per-second (cm/s), inch-
per-minute("/mn), inch-per-second ("/s) or a user-defined unit. Defining a
custom unit supposes that the scaling factors on the machine or in the file
exchanges are coherent with that unit.

All angles are displayed in degrees, the reference point being the trigono-
metric zero, direction X+ (3 o'clock in the aviation lingo).

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System configuration

For those who are interested in raw details, Galaad 3 was a continuous
creation between 1998 and 2020, developed using Borland C++ 5.02 OWL on
PCs with various processors and various versions of Microsoft Windows. The
code was compiled as native 32 bits for Windows graphical user interface. In
simple terms, this means that Galaad 3 will run indistinctly under any
version of Windows 32-bits or 64-bits.

The software was duly tested and validated under Windows 95, 98 and ME
for old 16-bit based systems (but some of these will not be able to access USB
ports), under all 32-bit kernel systems from Windows 2000 onwards, including
server versions, i.e. 2000, XP, Vista, Seven, and under 64-bit kernel systems
Vista, Seven, Windows 8 and Windows 10. Unfortunately there are no native
versions of Galaad for Linux or Mac, but the software was tested successfully
on Wine and Parallels Desktop emulators, including machine driving. Using it
on a Windows tablet is even possible, with an internal option for managing a
touch screen.

Galaad does not work under Windows TSE systems (Terminal Server
Emulation) which anyway are not used very often nowadays.

Concerning the hardware, Galaad does not require a very powerful

processor for its internal calculations, unless you must handle drawings
featuring hundreds of thousands coordinates. Consequently, there is no need
to purchase a supercomputer for using the software comfortably. Better
invest in a good size screen with high resolution for the pleasure of your eyes.

Talking about screens, the absolute minimum graphical resolution for

displaying Galaad frame windows is 800×600 pixels (highly condensed mode
which will be very uncomfortable for working unless you are a very patient
person). This makes it possible to use on a NetBook or a tablet with a small
screen for drawing and for driving a machine. Supervising an automatic
milling process requires only a very low calculation capability. An old PC can
do if you have a workstation for drawing and another workstation elsewhere
for driving the machine.

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User's licence

As with most software, Galaad is the result of a looooong development

work and is therefore not freeware. If you are reading this manual in its paper
format, it is likely that you have legally obtained a copy together with a
licence. The terms of this licence concern you all the same as you may need to
make authorised copies of the software.

Galaad user's licence is always in the form of an electronic key,

commonly called a dongle and generally attached to the spring
binding of this manual. That dongle must be plugged into a USB
port of your computer. Then only, Galaad will be able to read and
establish your user's rights, and thereby give you full access to all
features with no restrictions.

Not having a dongle is in effect not having a user licence, which will
prevent Galaad from communicating with the outside world. In this case, it
will neither be possible to execute a complete milling process, nor export any
drawings to another software application. You will however be able to save
and print drawings, and also drive your machine manually, with no time limits.
This restricted use lets you copy the software so it can be evaluated by third-
parties. Furthermore, a Galaad purchaser can install the application on several
computers dedicated to design tasks, without the licence, and one connected to
the milling machine, with the licence. A non-licensed version remains no less
subject to current legislation on copyright.

For professional licences, the dongle does not need to be plugged in

permanently. Galaad just refreshes the licence every month. Then it displays
a message asking for a momentary plug of the key into the port, so it can be
read and renewed.

You may copy Galaad 3 for yourself or for third parties. This is
provided that the contents are not modified in any way, that all copy-
rights are acknowledged, and that there is no possibility, even indirectly,
of manufacturing the drawings being created with the software without a
user licence.

There are three types of user's licence available. The professional licence
is the main one, and is for those who wish to use the software to design and
manufacture objects for commercial gain. There are no restrictions with this

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licence. The educational licence, as its name implies, is restricted to use in a

training environment where there is no commercial gain, either directly or
indirectly, from any objects manufactured. Finally there is the hobby licence,
which has milling time restrictions and can be sold only to individuals or
associations with no professional activity having any relation to the use of a
CNC machine. Using an educational or hobby licence must have no
commercial purpose, even indirect.

There are no differences in the functionality of the software under the

different licences. All offer the same functionalities and features. Only the
terms of use are different and so the workpieces created must remain strictly in
a non-profit area. Consequently, using an educational or hobby version for
professional or commercial purposes, even indirectly, is a flagrant
violation of the licensing agreement.

Some subsets of Galaad may be sold separately at a lower price, in which

case the corresponding licence is valid for these modules only. Conversely the
normal user's licence of Galaad covers all modules. This is not a forced sale of
useless modules, simply the standard Galaad licence provides access to all
features.

If you have any questions relating to the licence that you have been
supplied with, please do not hesitate to contact your supplier. Remember that
if you have been sold a copy legally it will come with a dongle.

Like most protected software, if you lose that dongle, then you lose your
licence, it is as simple as that. However, in some specific cases, not guaran-
teed, the lost dongle might be replaced, under conditions that you provide a
proof of purchase (i.e. the invoice), a written certificate of loss, and the serial
number of the lost licence. Nevertheless this replacement cannot be be taken
for granted. Take care of your dongle! Si you think it could be stolen, put a
small USB extension cord with the dongle at its end, eventually glued or
locked inside the PC, making it unreachable.

For further information, or in case of difficulty we invite you to

visit the official Galaad website: www.galaad.net

—————————————————————————— Foreword — 17
GALAAD 3 —————————————————————————————

Be inquisitive!

Whatever you may get out of this manual, you will no

doubt learn mostly by actually using the software. There will
always be those complex functions that you will have to refer
to the manual to find your way through, however, your best
bet, both now and in the future, is probably to follow your
instinct.

Galaad is house trained and so will not actually bite when you make a big
mistake. At worst, it will send you a disapproving warning, which will no
doubt be bearable in view of the good relationship you should have established
with it, at least from Galaad's point of view. Take for granted that, whatever
you do, including pure provocation, you will really have a hard time offending
it. Consequently, if you find a function, an icon or a button and do not know
what it is for, well, the best is to simply try it. Of course you can open this
user's manual; that works too.

So do not hesitate in learning what Galaad

can do. There is no shame in being a beginner
and no good reasons for being shy. If you have
any doubts about how a function is presumed to
work, then the best way to find out is to jump in
and try it, even if the end result is quite
unexpected. You can always undo an unfortu-
nate operation if things do not seem to go to
plan. Trial-and-error is often the best way to
learn how software really works. Galaad is no
exception.

18 — Foreword ——————————————————————————
——————————————————————————————————

———————
1
00001

INSTALLATION

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GALAAD 3 —————————————————————————————

Set-up

Galaad 3 is generally supplied on a CD, which

contains all the files that will be transferred onto
your hard disk. The installation programme will
normally start automatically a few seconds after the
drive door has been closed.

Under certain circumstances, the "AutoRun" may fail to start, depending

on your Windows configuration. In this case it is necessary to run the
SETUP.EXE programme on the CD, using the "Start" button and the "Run"
option. If your CD drive corresponds to the D unit, which generally occurs on
a basic PC, type D:SETUP and click on OK.

When the SETUP programme

is run, be it automatically or
manually, it produces a blue
window and a series of dialogue
boxes to enable the installation to
be configured according to your
wishes.

The first one asks the usual

question regarding where you
wish to install Galaad on your
hard disk. The default folder is
C:\GALAAD, but the choice
remains yours.

If you wish to install Galaad into another folder, simply type in its name or
use the "Browse" button, which will open a small window enabling you to
browse the directory tree and select a destination folder. It is not necessary to
install Galaad in the default directory or even on a local hard disk. What is
more Galaad does not modify any files other than those in its own folder,
except for desktop shortcuts to it. In particular, the innumerable system files
associated with the Windows galaxy are not affected by the installation of
Galaad onto your hard disk.

Important detail, Galaad will require full write access in its own
installation folder, even if your drawing files are stored elsewhere. If you

1 - 20 — Installation ————————————————————————
 ————————————————————————————— GALAAD 3

intend to use the software in a Windows session with restricted rights (i.e. not
the system administrator's session), it is very important that the installation
directory remains accessible for write-operations in that user's session,
otherwise the process will be affected (current drawing and parameters not
saved, mainly). The "C:\Program Files" tree is indeed not appropriate for
receiving the software.

A standard installation of Galaad 3 requires 100 Mb

of space available on your hard disk, plus some for
storing your own drawings. The complete installation
that is downloadable from Galaad website contains in
a compact block the same components as the CD for a
given language.

Finally, the SETUP programme performs the little additional Windows

tasks, namely the addition of shortcuts for starting Galaad and the association
of GAL files with Galaad so that opening them from Windows File Explorer
will start Galaad automatically. If you do not require these additional features,
uncheck the corresponding boxes at the bottom of the window.

Now click on the "Next >>" button.

It is now necessary to tell

Galaad the general charac-
teristics of your CNC machine, if
one is actually connected to this
workstation. If not, do not waste
your time going into details, just
validate this page as it is.

Please keep in mind that these

parameters can be modified after
Galaad has been installed. Any
error can therefore be fully
corrected later.

If you are installing Galaad onto a workstation that is connected to a CNC

machine, select the option that will allow you to specify the type of machine
and the communications port to which it is connected.

———————————————————————— Installation — 1 - 21
GALAAD 3 —————————————————————————————

Click on the "Next >>" button one last time. A final dialogue box will
appear, confirming the folder into which Galaad will be installed and showing
the software licensing agreement, which you are, of course, already familiar
with, having read the previous chapter.

Now click on the "Install" button, which will start the installation process
and transfer files from the CD or from the downloaded block to your hard
disk. This can take from a few seconds to one minute, depending on the
performance of your PC. A small window shows how things are proceeding
and a message will confirm when the process is complete.

Following this message you can start Galaad for the first time and thereaf-
ter by using the icon that has been placed on the desktop or the shortcut
created in the "Start" menu. Your installation is now ready for use.

Note: Galaad requires no drivers, except for dongle keys dated 2016 and
older. On the other hand, some numerical controllers, especially connected to
USB ports, may require a driver for being recognised by Windows. These are
provided along with the CD, but not installed automatically. When you plug in
the machine and Windows asks you where the driver can be, here you can
guide the system towards the CD. These drivers are not present in the
downloadable installation.

The lay of the land

Remember that the installation does not add any files other
than to its own folder, except for the shortcuts on the
desktop and in the "Start" menu. These are the classic
LNK files destroyed by Windows when you delete
the shortcuts.

Additionally, and if it can make you feel more comfortable, the only
modification to the Windows Registry is the association of GAL (drawing
files) and GLI (object libraries) files with Galaad, which allows it to be started
by double clicking on "GAL File" type files. This association also adds the
Galaad mini icon to GAL files, visible in the File Explorer and Windows
dialogue boxes used for file handling, thus simplifying file identification. The
above adds a grand total of three little keys to the Registry.

1 - 22 — Installation ————————————————————————
 ————————————————————————————— GALAAD 3

Moving Galaad

If necessary, it is possible to move the

installation to another folder with the help of
Windows Explorer by simply renaming the
target folder or cutting/pasting it to another
drive or subdirectory, including via a USB
memory stick. No problem with this, that
software is easily moved. But do not forget to
manually redirect the Windows shortcuts on the
desktop and in the "Start" menu towards the new target
location.

Uninstalling Galaad

It was not felt necessary to create a programme to automatically uninstall

Galaad, due to the simplicity of the installation and the absence of any files
except those in the folder into which it was installed.

To remove Galaad, it’s a case of deleting its folder using

Windows Explorer or a similar tool. It’s that simple. You
can then manually delete the icons from the desktop and
the shortcuts in the "Start" menu, which will remove all
trace of Galaad from your hard disk. Never again will
you be bothered by Galaad. It’s your loss.

If you feel unhappy with the idea of three keys

remaining in the Windows Registry, it is pretty easy to
delete them: these keys concern the links between *.GAL files (Galaad
drawings) and GALAAD.EXE programme; *.GLI files (Galaad libraries) and
GALAAD.EXE; and between *.GAW files (Gawain turning drawings) and
GAWAIN.EXE. These keys are of no use once Galaad has been removed from
your hard disk, they will take up no space or system resources, nor will they
interfere with other applications, but you have the right to remove even the
smallest dust Galaad may have left on your computer.

———————————————————————— Installation — 1 - 23
GALAAD 3 —————————————————————————————

On Windows Vista and older, open Windows Explorer and select the
"Folder options" command (generally found in the "Tool" menu, depending on
your Windows version), then "File types" page. Look for the GAL, GAW and
GLI extensions and remove them with the "Delete" button. A greyed button
means that the key is already erased. The next boot of Windows will clean this
up for good.

On more recent Windows versions, clean-up is made automatically when

deleting the target application. You worried for nothing.

1 - 24 — Installation ————————————————————————
——————————————————————————————————

———————
2
00010

LEARNING TO DRAW

——————————————————————————————————
GALAAD 3 —————————————————————————————

Contact

When started, Galaad displays the drawing board of the last work you have
made, exactly in the same state as you have left it (we will review that point).
You will soon become more familiar with this central window for drawing and
controlling.

At first sight it may seem that there is a great deal here, but you will soon
get to know your way around. Each icon and each display area has its particu-
lar use. In addition, you can easily pick up the key functions available in the
menus and drawing icons. All will be clarified later on in this manual when
you learn how to restrict the information displayed in the workspace, but for
now, let us neither anticipate nor concern ourselves with all that appears on the
screen.

Small tip: your Galaad version, more accurately its date of compilation, is
displayed at the bottom left corner of the window, at start-up or when no
drawing function is in progress.

2 - 26 — Learning to draw ——————————————————————

 ————————————————————————————— GALAAD 3

The working area is divided into five distinct zones.

- At its centre is your drawing board. This modest receptacle shows the
result of your creativity, ready to be sent to the CNC to be manufactured
with no further ado. It is in this area that your artistic talents will take
shape with Galaad's humble contribution. That drawing can be viewed
from above in plan, or by using the lateral and 3D views.

- At the very top of the screen is a classic menu bar. This provides access to
all functions from file handling, through access to the CNC, to
manipulation of the display, and is arranged in terms of functionality.
Nothing really original here, apparently even in the southern hemisphere
the menu bar is at the top.

- Immediately below is the equally classic tool bar. Each icon displayed
here is a shortcut for a function in one of the menus, which saves having to
navigate through the maze of submenus. Just to give Galaad a proper non-
conformist feel, some of these icons also have "fly out" icons underneath,
that pop up when the mouse meets its mother. However, a "Touch Screen"
mode can be enabled in the workspace parameters.

- On the far left of the screen are the drawing icons. There you will find
plenty to stimulate your creativity, providing an array of tools for
constructing the objects that will allow you to create your drawing. When
the mouse pointer is passed over these icons, a group of icons will "fly
out", offering a wider range of associated functions.

- Finally, relegated to the very bottom of the screen is the display zone. An
Aladdin’s cave of information about the current drawing including
coordinates, dimensions and angles, packed in higgledy-piggledy.

Note: Please keep in mind that the aim of this manual ‒ even these
initiatory pages ‒ is not to teach you about the current Windows interface,
which at the time of writing this manual is supposedly nearly finished or at the
very least the ground work is complete. However, several little reminders will
be given here and there, totally free, but all the same, do not hold out for an
advanced technical course on the inner workings of Windows, which are
varied, twisted and even sometimes perfectly logical.

—————————————————————— Learning to draw — 2 - 27

GALAAD 3 —————————————————————————————

Baby steps

As you will discover, drawing with Galaad is not all that complicated and
does not require much aspirin. However, it is necessary to remember that the
object of the exercise is to generate a toolpath for a machine cutter to
follow and not just a pretty drawing to be simply printed. Do not compare this
with an image editor like PaintBrush, PaintShop, PhotoShop, etc. for bitmap
files, which works on a mosaic of lifeless pixels instead of moving
coordinates.

Galaad CAD module is a vector graphic editor, i.e. a line is constructed by

defining the two points at its extremities then linking them; it is not simply an
alignment of black pixels. This calls for greater precision, and for the work to
be approached from a graphical point of view as opposed to an artistic one. If
you have already used vector drawing software, such as CorelDraw or Adobe
Illustrator, you will have no problem in becoming familiar with Galaad. The
modus operandi is quite conventional.

Let us begin by opening the "File" menu and clicking on the

"New" command. The current drawing will be removed and
replaced by an empty board. Vertigo of the blank page.

Galaad then requests the overall

dimensions of the new workpiece.
Measure your material and enter the
dimensions in the appropriate place.
These dimensions can be modified at any
time by using the following command,
"File / Material dimensions" in the same
menu. Check the values and click on
OK. We will see more settings later on.

Let us begin with something simple, like a stupid straight line. Locate
the "line" icon in the drawing icons on the left hand side of the screen,
ignoring the multitude of other icons that fly-out, the basic icon will do fine.
Click on it and return to the drawing board.

The cursor will have changed from the oblique white arrow to a red cursor,
complete with crosshairs. Move the mouse and the red cursor will follow its
movement along with the crosshairs which indicate the current position on the

2 - 28 — Learning to draw ——————————————————————

 ————————————————————————————— GALAAD 3

rulers. In addition, the numerical coordinates are indicated at the bottom of the
screen and updated when the position settles. Click somewhere on the board
and release the mouse button.

This fixes one end of a line and as you move the mouse, you will see a
moving line connecting the first point to the cursor. As well as the absolute
position of the cursor, its position relative to the start point of the object is also
indicated in both Cartesian and polar coordinates at the base of the screen.
Position the cursor wherever you wish then click and release the mouse button.

Galaad is then immediately ready to repeat the operation for another line.
Try again, but this time using another method; press and hold down the mouse
button at the starting position, drag the cursor to an end point and release the
button. The result is identical: you may click-release, move and click-
release, or click, move and release. Choose the method that you prefer.

Continue drawing simple lines, and with the crosshair cursor visible on the
board try using the arrow keys on the keyboard instead of the
mouse. Every time an arrow key is pressed, the cursor will move by one step
on the side rulers.

Simple coordinates

Moving on a little further. Rather than either using the mouse or the
spacebar, press and a dialogue box will appear that will allow you to
directly enter the numerical coordinates.

Just enter the value for the X

coordinate then press the tab
key to quickly move onto the Y
coordinate value below. Enter the
required figure and click on the OK
button with the mouse or simply hit
key to confirm and finish.

—————————————————————— Learning to draw — 2 - 29

GALAAD 3 —————————————————————————————

It is worth mentioning that pressing and simultaneously reverses

the direction of movement and will allow you to return to the previous entry
point. This is not just confined to Galaad but works in all Windows
applications. The key validates the whole dialogue box as it is.

Note: the orientation system defines as "west" / "east" the negative

(towards the left) / positive (towards the right) X directions; "south" / "north"
the negative (towards the foreground) / positive (towards the background) Y
directions; and "down" / "up" the negative (towards deep) / positive (towards
retraction) Z directions. This corresponds to the mathematical standard.

This standard orientation remains

valid for machine control. Warning: a Z
greater value for the depth therefore
corresponds to a lower Z axis towards
negative direction, even if Galaad reads Y
and displays the depth in absolute
value. X
You will no doubt have noticed that the dialogue box provides drop down
boxes for setting the origin of the point entered. Therefore it is possible to
define a Cartesian value relative to a point other than the origin of the board,
(0, 0), which is, by default, situated at the southwest corner (bottom left). Bear
in mind that if you enter a dimension that is relative to a given point located
right/above, then it will probably be a negative value.

Returning to our cursor, you will now see it has been fixed at the point
defined in the dialogue box and that the mouse click has been applied. You
now know how to fix something at any absolute position using Cartesian
coordinates.

To enter a value in polar

coordinates (for the second point
only), you must press
simultaneously. This will open a
similar dialogue box, but for
coordinates in the form (R,) as
opposed to (X,Y).

2 - 30 — Learning to draw ——————————————————————

 ————————————————————————————— GALAAD 3

As for Cartesian coordinates, the numerical values of the current position

of the cursor are shown when the dialogue box is first opened.

At this stage of the apprenticeship, you know how to use the drawing
cursor and define points numerically. Practice drawing by using some of the
other drawing icons, for example rectangles and circles. However, do not
spend too long at this early stage and stick to the white drawing icons as the
others (yellow, green and blue) are not directly involved with the drawing
process as you will see a little later.

Snapping to positions

If you already have something visible on the board,

perhaps a simple line, you will have noticed that locating
the cursor in the neighbourhood of an existing object
pops up a small red point. A short tip about the logical
position will also appear.

By pressing the space bar on the keyboard, you automatically

snap the cursor to the small red point, i.e. you directly validate the
corresponding position. This is very useful when dealing with a lot of pointing
tasks, particularly on polyline vertices, intersections, arc centres, etc. If there is
no small red point, then the validated point will simply correspond to the
current cursor position.

The middle button (or wheel button) of a three button mouse has the same
function, rather than requiring a keyboard input even though the space bar is
not too difficult to find. To perform a snap operation that would correspond to
a click using the right mouse button, press simultaneously the key (Caps
arrow key). This is also valid for the mouse middle button (or wheel button).

A little bit more complicated, but worth mentioning,

you may undertake a two-stroke snapping, i.e. snap to the
X coordinate of a small red point then move somewhere
else on the board to snap another Y coordinate or the
coordinate of the current cursor position.

—————————————————————— Learning to draw — 2 - 31

GALAAD 3 —————————————————————————————

You only have to locate the cursor close to the first concerned point so that
it is highlighted, then press the or key to temporarily store the X or
Y coordinate. A vertical or horizontal red axis appears across the board, but
nothing is stored at this moment. You may redo the same operation using the
same key to validate another point in case of error, or even cancel it by making
an ordinary point. Move the cursor and highlight a new red point at another
location and press the other or key, the one you have not used yet.
Galaad will immediately display in a dialogue box the position of the point
that corresponds to this couple of X and Y coordinates that were temporarily
stored, a position that you can then validate.

Handling objects

Let us stop scribbling now and see what can be done with objects that have
been previously created.

Move the cursor to the left and click on the yellow selection icon,
ignoring the others that fly out. The cursor returns to a
white arrow and the last object drawn is framed by a matrix of
eight red blocks. Try clicking on other objects here and there on
the board: the red frame moves from one to another, the outline
of the object also turns red for ease of identification. The drawn
item within the red frame is then said to be a selected object, an
expression which will be used very often in this manual.

This point is fundamental. With Galaad, it is necessary to first select an

object and then specify the action that will be applied to it. With some other
CAD software, exactly the opposite is true, and the action is specified first,
then the target object must be plotted. Each approach has its advantages and
disadvantages, which we are not going to discuss here. However, for many
drawing functions, Galaad also accepts the opposite method when nothing is
already selected.

An object is not modified by being selected, though its colour

temporarily changes to enhance it. But it is possible to manipulate it with the
help of the numerous tools that Galaad offers. Let the fun begin.

2 - 32 — Learning to draw ——————————————————————

 ————————————————————————————— GALAAD 3

The first and most obvious thing that can be done to a selected object is to
delete it. What could be easier? Press the key or use "Edit / Delete". The
object and the selection matrix disappear. You can undo this deletion using
the key (Backspace) that is generally located just above the key on
an ordinary keyboard, or by calling "Edit / Undo" or the corresponding icon of
the top toolbar.

The second and no less obvious thing is that the object can be repositioned
at another location. Simply move the cursor to inside the selection frame, click
and hold down the left mouse button and move the mouse. The selection frame
follows your movements, and so does the selected object itself. Release the
mouse button to place the object in a new position. The crosshairs show the
position on the rulers and the coordinates in the display zone are updated
during this operation.

Now try clicking on one of the red median blocks of the selection frame
with the left mouse button and whilst keeping it held down, move the cursor
then release the mouse button. The frame is either enlarged or reduced in size,
depending on the movement, and the dimensions of the object are also
changed similarly. When using the diagonal blocks (i.e. the corners), you will
see that all the dimensions change but the aspect ratio is maintained. This
allows you to vary the overall size of an object without changing its general
appearance.

Snapping to positions (bis repetita): when you move, enlarge or reduce a

selected object, the presence of another object in the vicinity shows orange
axes for Cartesian alignment, near its borders or centre. To automatically align
the selected object on an orange axis, just press the bar on the
keyboard without releasing the mouse button. The or keys make a
partial snap so you may align only one axis when both are displayed. Once an
axis has been snapped, the object moves only along the other axis until you
release the mouse or snap to another position.

You will no doubt remember that the key opens a dialogue box to
allow a position to be defined from the keyboard. This little feature is also
available for all drawing and object manipulation functions in Galaad. Now
press the key.

—————————————————————— Learning to draw — 2 - 33

GALAAD 3 —————————————————————————————

This time a different dialogue box

appears in the middle of the screen.
You can define the position of your
object in the upper part and its
dimensions in the lower part.

By default the XY position of

your object, shown in the dialogue
box, refers to the southwest corner of
the selection frame, but you can also
use any of the other reference points
by clicking on the red blocks.

You will quickly realise that Galaad does not really like it if your objects
extend beyond the edge of the board, especially when entering a coordinate
from the keyboard. Since your board represents the raw material to be
machined, it seems somewhat logical that creating toolpaths outside of this
workpiece makes no sense.

At this stage of the proceedings, you know how to draw basic objects,
snap to existing points, enter dimensions for their positions, select objects,
delete and manipulate them.

Now we are going to select several objects simultaneously so that they can
be manipulated as a group. There are several ways of doing this. The first
consists of clicking on our selection icon (if the crosshair cursor is currently
displayed) then defining a rectangular area of the board. To use this method,
press and hold down the left mouse button, drag the cursor a little way
eastbound and release the button: a red rectangle has framed the area. All
objects fully inside this area have been selected. If instead you move the
mouse westbound after clicking, the rectangle is green and all objects at least
partly inside the area will be selected. If you only caught one or none at all,
try again. You now have several objects selected that can be manipulated as if
they were one: position, size, delete, etc.

2 - 34 — Learning to draw ——————————————————————

 ————————————————————————————— GALAAD 3

Another way is to start by selecting one or more objects, then press and
hold down on the keyboard and select some other objects. Unlike earlier,
the new objects are selected without deselecting the ones already selected. You
can continue like this until all objects are selected, including selections from
zones. Reciprocally, if you click on one object already selected among
others with this key pressed, it will be removed from the selection.

On the other hand, when you click a location where several

objects could be selected (or deselected), Galaad will pop up a
small menu to help you do your shopping. Let us mention that there
are many other selection methods, particularly with an automatic filter, and
also a locking function that prevents selection. That will be described later on.

Tip: when one or several objects are selected, pressing cursor arrows
on the keyboard directly move the selection frame ‒ including the
objects ‒ by one step on the rulers (even if these are not displayed), as when
moving the drawing cross cursor. This may eventually help you adjust objects
more accurately than with the mouse and leads us to the functions of the
magnetic grid.

The magnetic grid

As you will certainly have noticed, both the drawing cursor and selected
objects can only be moved in discrete steps that correspond to the graduations
of the rulers along the edges. This is a common feature of vector drawing
software, which provides a grid of invisible points that are not linked to the
graphical resolution of the display and cannot be addressed directly by pixel
coordinates. Although this grid is invisible, its influence on the drawing is no
less effective.

The default value for the graduation is 1 mm unless your board is very big
or very small. At first sight it may appear that it is not possible to construct or
position the drawing cursor or an object anywhere other than on a grid point.
However, please note that numerical values entered from the keyboard are
never rounded. The smallest step is 1/1000th, which should be sufficient for
most needs. Galaad considers that if you have entered a numerical value for a
position, then this is where you wish that point to be and the magnetic grid is

—————————————————————— Learning to draw — 2 - 35

GALAAD 3 —————————————————————————————

not applied, hence it is possible to select any position on the board even when
the grid is active. The entered position remains unchanged.

If entering a numerical position is not suitable for a particular situation,

then simply change the grid step size by using the function "Design / Magnetic
Grid / Set" from the menu bar (a quick shortcut also exists among the
command icons of the top bar).

A small dialogue box allows you to

independently set the X & Y steps, i.e. the values
to which positions are rounded up/down. If you
leave a value empty (or "auto"), then the
rounding will be to the smallest graduation on the
ruler that varies with the zoom. This is probably
the best mode of operation because you can zoom
in/out and stop worrying about the grid. The
polar grid rounds the slope angle of the line that is currently under
construction, when pressing key.

You can also completely disable the grid and work directly at a pixel
resolution, but this is not recommended for precision work, especially since
the step will vary along with the zoom. This grid is there for your convenience
and using it will certainly make life easier. Do not neglect it.

De profundis

Your artistic creations must not be made without forgetting that the
ultimate aim, even if a long way away, is for Galaad to drive a CNC milling
machine. This naturally requires additional information, namely the machining
depth, feedrate and details of the cutter tool to be used. Those three define the
extra dimensions that Galaad needs to manage, compared to a classical 2D
CAD system that is presumed to talk to a printer. They are all reachable
simultaneously.

Click on the green icon on the left of the board, again without
worrying about the other fly-out icons.

2 - 36 — Learning to draw ——————————————————————

 ————————————————————————————— GALAAD 3

A new dialogue box will then pop up, which will let you enter the cutter
tool that will be used to manufacture the objects that will be drawn hereafter,
and their milling depth along with their feedrate.

Enter a new machining depth for your chosen objects. Note that you can
select the "Cut out" option to link depth to actual board thickness. Further
options are also accessible from this dialogue box, that we will see later on.

If you are not yet familiar with calculating feedrates, then let Galaad do it
for you automatically. By default, the software calculates an approximate
value and takes into account the hardness of the workpiece, the physical
characteristics of the cutter and the depth of every stage. Over time you will
gradually learn to estimate feed speeds without running the risk of breaking
cutters, often caused by going too fast. You will soon develop a feel for the
correct values required. Conversion of the entered feedrate into classical units
like m/min or mm/s is displayed below. This may help you feel comfortable
with both these units which are the most commonly used.

When you validate this dialogue box by clicking on OK (or pressing ),

the selected objects immediately get the new values indicated. If no objects
were selected, then your change did not go to the bin and will affect the next
objects that you are about to create with drawing icons and until you call up
this dialogue box again.

Important corollary: you can have as many different depths and speeds
as there are objects on the board. These two parameters are completely
independent of each other and not connected with either a given tool, colour or
milling pass as with some other 2½D CAD/CAM software. In addition, you
can have as many objects on the board as you like, limited only by the memory
size of your computer, which can be huge. The practical limit is likely to be

—————————————————————— Learning to draw — 2 - 37

GALAAD 3 —————————————————————————————

your creativity. Let us also mention that you can even draw 3D objects, which
indeed have a varying depth, as we will soon see. But let us not anticipate
because it might then become a bit more complicated, and the purpose of this
chapter is just help you get started.

You now know how to draw objects, delete them, reposition them,
enlarge/reduce them, and finally precisely define their milling parameters.
So you are ready to use the milling machine that has been impatiently
fidgeting and pulling on its cable. One last effort, a minor detour via the zoom,
and we will be there.

Zoom

It is useful to be able to enlarge part of the board to check or adjust the

objects. A set of functions is going to help you there, for now we will
limit our review to the first one: you may have seen it, this blue icon
which looks familiar. Click on it and then you can define an area of the board
to enlarge, or a simple point, around which Galaad will apply a magnification
factor of 2. In the latter case, it is sufficient to click and release on the same
point of the board.

Small tip: it is possible to perform a fast zoom using the (or ) key.
Galaad will automatically enlarge the zone around the mouse cursor without
aborting the drawing operation that is in progress. This can be reiterated, and
you can zoom out using (or ).

If you have a wheel mouse, which is probable nowadays, a backward or

forward rotation of the mouse wheel calls the same zoom functions without
touching the keyboard. This is often helpful to ease snap operations in
crowded zones: several fast zooms magnify the location where a snap point is
available, the snap is performed then a zoom out is made if necessary to enter
the next point of the object under construction.

The zoomed window can be moved with the mouse middle button (or
wheel button): just click, hold down and drag the view in a given direction.
This possibility remains valid even while drawing, when the red crosshair
cursor is active.

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3
00011

LEARNING TO MILL

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GALAAD 3 —————————————————————————————

Roadworthiness inspection

Before firing up your machine, it may be worth casting an eye over the
settings within Galaad. There will inevitably be some misunderstandings, for
example in cases where parameters are out of range. Proceed immediately to
the menu and select the function "Parameters / Machine / Basic data". This
should open a dialogue box for a model which displays a summary of the key
technical characteristics of your machine.

If all is well, you will find

that these are the same as you
used when defining the CNC
during the installation of Galaad.
If this is not the case, then it is
not too late to change any of the
parameters displayed.

It is assumed that you know

the model of your machine, or at
least the type of controller it
uses. If not, then it is time to contact your distributor after first of all carefully
checking that the model number is not marked somewhere, possibly in the
most inaccessible of places. Entering the wrong machine type is not a
serious problem. Neither your machine nor your computer will suffer. In the
worst case, it will not respond and simply ignore you. If in doubt, then give it a
try. Have courage!

An important detail, you have probably already installed a cable between

your computer and your CNC. If not, Galaad could find it difficult to control
the machine. Progress in wireless information technology is certainly rapid,
but it is unfortunately still necessary to have physical connection between
most machines and Galaad. And whilst on the subject, certain old machines
require a special asymmetrical cable (with hardware handshake loops at
machine end) of which the correct end must be connected to the PC and the
other to the machine.

To send information through this cable, Galaad must at least know which
communication port to use. Even if fashion is in the USB, still many
machines receive their instructions down a serial RS-232 link. It is important
to tell the software to which port the cable is connected. On an old computer,

3 - 40 — Learning to mill ——————————————————————

 ————————————————————————————— GALAAD 3

the machine should be connected on COM1 or COM2 serial port in most cases.
On a recent computer, it is more probable that you will use a USB-Serial
converter, which will be seen from software applications as a classical serial
port, but with its number above COM2. In its drawn-down list, Galaad
displays an asterisk beside the existing COM port numbers, real or virtual.
It is up to you to try, and remember that it will not cause collateral damage to
the computer nor installed applications, even those already running.

You will notice that the dialogue box for configuring the machine
connection allows you to tinker with the baudrate of the connection. If you
have chosen an existing model from the list of known machines, it is best not
to meddle with it. Using a higher communication speed will not make your
CNC run any faster.

Possibly you have no machine connected to your PC. In this case, select
"No machine" as model number and "None" as communication port. The
machine will be virtual but you can follow the logical machining process on
the screen all the same.

Validate this dialogue box by clicking on OK if you have changed

anything, otherwise still click OK just in case.

Guided tour of the launch pad

Your board contains the wonders of your creative genius; the parameters of
your machine are correct; the launch window is clear and your seat belt is
fastened. There is no longer any reason to delay the milling. Authorisation for
ignition and blast off is found in "Machining / Standard machining on 3 axes".
Clear for lift off.

A minor digression, already: check that you have not forgotten to turn your
machine on. The age old adage "it might work better if you turned it on"
sometimes makes miracles. Fortunately, polite machines are in the habit of
letting you know when they are powered up. If nothing is illuminated as such,
then you have Galaad's permission to remove your seat belt and investigate.
Incidentally, certain commands also require the drives to be powered and the
safety covers to be closed so check these as well.

—————————————————————— Learning to mill — 3 - 41

GALAAD 3 —————————————————————————————

In the meantime Galaad has collected a large amount of information and

displayed it in the window shown below. Do not panic and do feel free to
experiment, as you cannot do any harm, yet!

At this stage we are not going to examine all the options available in this
window. You will have already noticed that your drawing is also displayed
here. The only machining parameter that interests us at the moment is the tool
sequence, which is displayed above the drawing.

If you have drawn objects with several different tools, the corresponding
blocks in the tool matrix will be highlighted. In the absence of any defined
sequence, the boxes are a uniform yellow and await your selection. Simply
click on the tools required in the order that you wish them to be used. When a
tool is selected for use it is circled in green and those yet to be selected have a
red cross through them. Once a tool has finished its work, it is crossed out in
yellow.

This function is indeed important: it is up to you to specify the sequence

in which tools are used and objects machined. Lacking a user defined

3 - 42 — Learning to mill ——————————————————————

 ————————————————————————————— GALAAD 3

sequence, indicated by all the boxes remaining yellow, the tools will be used
in their numerical order, though these numbers are non-significant.

A summary of the tool characteristics is shown below the tool selection

matrix. When the cursor passes over a tool that has been used in your drawing,
its parameters are shown, whether or not it is selected for use. The rest of the
time it shows the characteristics of the first tool to be used.

It is possible that you have only used one tool. In this case, the tool
sequence cannot be used to control the order in which the objects will be
machined, so move on to the next phase. Mount the appropriate tool into the
spindle and click on the "Workpiece origin" tab, or press .

Workpiece origin

The machining parameters page disappears and is replaced by the page for
setting the workpiece origin, which is also packed with control options. A
small message box appears from nowhere, to remember which cutter tool is to
be used in the process. Click on OK, you
have no choice.

Communication between your favourite

software and your favourite CNC is opened
upon accepting the above message. This
initialisation may take several seconds depending on the machine and if it has
just been rudely awakened.

If this initialisation fails, a small message box will appear informing you
on the nature of the problem. Galaad will spend up to ten seconds trying to
initialise communications with the CNC, and in case of failure offers to retry.
But first of all attempt to establish why it did not work, using the following
check-list: Is it switched on? Is the cable connected correctly between the
computer and CNC? Are the machine parameters set correctly in Galaad?

Assuming that all is well and communications are successfully established

with the CNC, Galaad may warn you that it needs to make the machine
perform a short reset so as to find the zero point of each axis. Let us return to
the workpiece origin.

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GALAAD 3 —————————————————————————————

It is now necessary to tell Galaad where to find the workpiece on the bed
of the machine. You can see it, certainly, but Galaad cannot. It only knows the
dimensions and the toolpaths that it must follow. Therefore we must give a
reference point XYZ and tell it precisely where to find the workpiece in
relation to this point.

In fact, do not forget to mount the workpiece, but if you just want to have a
dummy run without breaking anything, then that is fine.

The process consists of driving the machine manually, one axis at a time,
until the tool is situated at an edge or on the surface work, as explained below.
Use the buttons arranged in a circle, situated at the top right side of the control
window, for X and Y motion, and the triangular buttons for Z (up and down)
movement. When you press a button, the movement is continuous until the
button is released. You can use the small arrows and keys on
the keyboard to produce the same movements.

Important: the right mouse button moves axes at slow speed (or the
key). Very helpful for finishing the workpiece origin approach on a given axis.
If you need to make a movement of a fixed distance, use the radio-buttons on

3 - 44 — Learning to mill ——————————————————————

 ————————————————————————————— GALAAD 3

the right hand side to select the distance. The movement stops when you
release the button or when the distance has been covered.

Secondary, but convenient: the mouse wheel moves by increments of

1/100th of millimetre (or 1/1000th of inch depending on the unit) the last axis
that moved, provided that this occurred less than one minute ago. Very useful
for fine approaches, especially for Z.

In the preview window, a cursor with

crosshairs moves at the same time as the axes. If
you do not have a machine connected, it is the
only thing that moves. You can also set a position
by double-clicking directly in the preview
window. The coordinates of the position will be
shown by the LED display immediately below.

You can also enter a numerical position by clicking on these LED

displays, or by pressing one of the X, Y or Z keys on the keyboard.

However, the aim is more than just to make the machine move along its
axes as, although Galaad may always know where the cutter head is, it still has
to be told where to find on the machine flatbed the workpiece that is going to
be milled.

Move the X and Y axes so that the spindle is positioned above the
workpiece, somewhere towards the middle. Then use the Z down button to
lower the cutter until it is a small distance above the surface of the workpiece,
say 1 or 2 mm. Go slowly, cutters are expensive and accidents easily happen.
Next, use the right mouse button or select the radio button for 1/10th mm steps
and carefully lower the cutter to the position where it is just gently touching
the top surface of the workpiece, but not actually cutting into it. Eventually
perform the final approach with the mouse wheel. A thin sheet of paper placed
under the tool helps a lot: when you can no longer move it without tearing it,
then you are done.

You have now found the Z value of the workpiece origin. Click on the
green button to validate the Z position:

—————————————————————— Learning to mill — 3 - 45

GALAAD 3 —————————————————————————————

The Z position is
then uploaded to the
workpiece origin box. Now re-select continuous movement and lift the cutter a
small amount, if Galaad did not already do it, then bring the cutter to the left
hand side (west) of the workpiece.

When close to the edge, reset the step size to 1/10th mm, or use
slow motion with the right mouse button, and carefully position the
cutter so that the point is directly above the edge of the workpiece. It
often helps to lower the cutter to improve accuracy.

If using a cylindrical or hemispherical cutter, it is easier to find

the edge of the workpiece with the side of the tool. Galaad knows the
diameter of the tool and can automatically correct the position.

In the latter case, do not forget to select the option "Tool edge" instead of
"Tool centre", situated just above the large yellow start button. Galaad needs
to know which method to use in order to make the correct adjustment. The tool
profile is not necessary.

You have now found the X value of the workpiece origin. Click on the
corresponding green button:

Finally, repeat the above operation but for the Y axis, and using the south
edge of the workpiece, again confirming the position with the appropriate
button. With a conical cutter, it is possible to save time and find the X and Y
positions simultaneously at the southwest corner of the work, then confirm
both positions simultaneously. It is possible to do all three axes together, but it
is recommended that the Z axis is set towards the middle of the work
rather than at a corner, as it is more accurate.

Without going into detail, note that you can also

use several other positions on the board, besides the
southwest, for the reference point. Simply tell Galaad
by selecting one from the combo box below the green
buttons.

When you confirm the position of the workpiece origin, indeed Galaad will
know the coordinates and therefore the position of the origin, but it is still
necessary to tell it where this is in relation to the workpiece, e.g. at the

3 - 46 — Learning to mill ——————————————————————

 ————————————————————————————— GALAAD 3

southwest corner. Generally either the southwest or the northwest corners are
used, but there may be times when another position would be more
appropriate. The important point is that the origin used when drawing is
consistent with the origin set on the machine. If not, Galaad is going to mill by
the side of the workpiece, eventually on the clamps with a very unpleasant
noise of tortured metal. Likewise, if you have approached the workpiece top
surface and validated "Z - ok" whilst indicating that it was the machine bed,
then Galaad will mill the air above the workpiece. Much more serious is the
case where you indicate that you have approached the top surface whilst the
tool was actually touching the machine bed. In that case ‒ unfortunately not so
rare ‒ you are going to mill deep in the machine bed through the workpiece
and probably pronounce big swearwords against a stupid piece of software
which just applies your guidelines.

Blast-off

The workpiece origin has been set for all three

axes. Galaad now knows all that it needs to know;
namely where to find the origin point and where
to find the material in relation to that point. Fasten
your seat belt, lift-off is imminent. Now you can
click on the big yellow button labelled "Start
Machining", the one you’ve been itching to press
for ages.

The cutter is retracted if it is low, and one

last message warns you that machining
process is about to start. You may still cancel
the process here, but this is your last chance
to chicken out.

Pressing OK starts the automatic machining process straight away. If

your spindle does not start automatically, now would be a good time to switch
it on and set the required rotation speed. As soon as the message is
acknowledged, the tool is moved towards the entry point of the first object to
be milled, then plunges down to the contact with the workpiece top surface,
drills into the material and starts feeding horizontally, then lifts up for reaching

—————————————————————— Learning to mill — 3 - 47

GALAAD 3 —————————————————————————————

the next object. The sequence followed corresponds to the order of drawing,
but we will see that there are several ways of tinkering with that sequence. We
will try to remember to say a word about it later on.

Several small buttons at the bottom of the window allow you to override
the Z position or the feedrate in increments.

When the machining cycle is finished, Galaad

stops the spindle and sends the tool back to its park
position. The workpiece can then be removed from
its fixings, unless there are other cutters yet to be
used. In this case, the software returns to the
workpiece origin window.

Your workpiece is machined, and you now know how to do it. You can
return to the other parameters and advanced machining functions later. For
now we have covered the essential points of the process.

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4
00100

LEARNING TO SAVE FILES

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GALAAD 3 —————————————————————————————

Current drawing

Before moving on to more elaborate creations, temporarily quit Galaad.

Click on the window close button or use the menu command "File / Exit
Galaad". Galaad quickly shuts down, this software certainly knows who is the
boss here.

Now restart Galaad by double clicking on the icon on the desktop or from
the Start menu, by using "Start > Programs > Galaad". After using Galaad a
few times you will soon realise that when it starts it restores itself to the same
workspace conditions that existed when it was last closed, with exactly the
same drawing on the board. This is a peculiarity of Galaad that allows it to be
closed without first asking you so save your current work. You can therefore
work on the same drawing many times before having to save it.

On the other hand, if you call for a new

file or open an existing one, then you will be
given the option of saving the current drawing
first or indeed risk losing it forever.

If due to principle, habit, shared resources or some other reason you are
unhappy with the automatic save feature, then you can disable it using the
menu function "Parameters / Workspace / General settings". The choice is
yours, but remember that it is activated by default when Galaad has just been
installed.

The automatic timed backup during normal work, set in "Parameters /

Auto-save", are stored as part of the working environment and not in a named
Galaad drawing file.

In addition, double-clicking on a GAL file will automatically start Galaad

with that new file. However, if the current drawing has not yet been saved,
then Galaad will give you the kind opportunity to save it before proceeding
any further. In fact, this double-click on a file is equivalent to starting Galaad
and opening that file. Therefore you can fearlessly double-click on any GAL
file that appears in Windows Explorer. This is probably not a very useful
feature, but it is well worth mentioning.

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Files and folders

A complete installation of Galaad, complete with all the examples, is

spread across several folders. Organising the folders in the directory tree on
your hard disk into a clear logical structure is a good way to ensure that your
files will be easily found in the future. This is preferable to simply saving your
files onto your hard disk, haphazardly, like throwing old clothes into a drawer.
Both Windows Explorer and Galaad provide tools to help you organise file
storage. When opening a file the dialogue box will also let you delete and
rename both files and folders at will.

As far as Galaad is concerned, it suggests that you save your drawings

within a sub-folder named FILES, in the software installation folder, which
itself already contains several sub-folders of examples. Without doubt the best
thing is to follow this lead, also placing your drawing folders in this FILES
sub-folder, that way they will appear at the same tree level as installed
samples. This may help copy a complete installation from a workstation to
another one, including drawing files. Also, it appears to be more convenient
when using the gallery. Thus, Galaad does not impose any disk management
model, the location of your folders and files remains your choice. Galaad is
polite and will always send the file selection box into the last disk and
directory location you used, to avoid spending time climbing up and down the
disk tree, be it local or distant. Memorising the last default location remains
valid for most file and libraries functions.

The function "File / New folder" prevents you from having to leave Galaad
to use Windows Explorer for creating new folders.

Here, you are asked simply to

provide a name for the new folder.
This will then be added into the list
of available folders. You can also,
if you wish, choose a different
path for it.

There remains nothing more for you to do than to save your many future
drawings into this folder, whose name will now appear on the list of folders
available. You can obviously create as many folders as you wish, but be sure
to arrange them into some sort of logical order. This is only a tool. To delete a
folder, use Windows Explorer or the "Open" and "Save as…" dialogue boxes

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GALAAD 3 —————————————————————————————

that will allow this to be done by selecting the folder or file then pressing the
key. In the rubbish bin nothing is lost ‒ as long as it is not emptied.

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5
00101

ADVANCED DRAWING
TECHNIQUES

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GALAAD 3 —————————————————————————————

This chapter is intended to introduce you to the subtleties of the drawing

techniques with Galaad. It is recommended that all users, even experienced
ones, read the section covering the basics before proceeding any further, as it
contains several useful tips that are often overlooked, so obvious that you do
not even notice them.

Numerical coordinates

An important feature when designing parts that are to be manufactured is

the ability to specify numerical positions and dimensions accurately. You will
not have forgotten that pressing the key opens a dialogue box that allows
the position of the cursor to be set without being affected by the current
magnetic grid.

Small tip, by the way: you may enter any numerical value using a
mathematical expression, e.g. a chain of dimensions 12+31.2+4*6.35 written
like this in its edit zone. Hence you do not need to search for Windows
calculator and copy/paste your result in an edit zone. This subtle facility
applies to any numerical value you have to type. Please refer to the chapter
"Special functions" hereafter, for the syntax and the function identifiers that
Galaad maths formula analyser can understand.

Now imagine that we wish to construct a rectangle, 65.4  32.1 mm, with
the southwest corner at (12.3, 45.6) mm. The first point is easy, simply press
the key and type in the coordinates. The second point is slightly more
difficult as we need to calculate the coordinates of the corner diagonally
opposite by adding the dimensions to the coordinates of the point already
entered. Galaad understands an arithmetical expression, here an addition, but
should do this menial work for you.

This example of a simple rectangle was perhaps not a good choice as it is

possible to position the second point using relative dimensions in two ways.
Firstly by entering the dimensions, indicating that these are relative to the first
point, and secondly by drawing the rectangle in roughly the correct place, then
selecting it and numerically modifying the dimension of the selection frame.
The effort remains minimal, but all the same there is room for improvement
and there is a better way. Try the following: construct a rectangle by entering

5 - 54 — Advanced drawing techniques —————————————————

 ————————————————————————————— GALAAD 3

the first point whichever way you like (with the mouse or numerically) then
press the key to position the second point.

Now, instead of displaying a

dialogue box for the coordinates of
the second point, Galaad will have
anticipated what you intended to do
and provides a dialogue box to
input the rectangle size directly,
along with its starting corner position. Simply enter the width and height of the
rectangle, which can be negative if westbound and southbound. Actually
Galaad follows your work and attempts to anticipate your requirements,
frequently offering context sensitive responses. Consequently, on constructing
a rectangle, after entering the position of the first corner, there is a strong
probability that you would prefer entering the actual dimensions of the
rectangle rather than the absolute coordinates of the second point. Likewise,
when constructing other shapes, such as a horizontal line or a circle, Galaad
will try to pop up a dialogue box that looks appropriate to the occasion.
However, if you still wish to enter the numerical position of the pointer and
nothing else, then simply use the combination which will open the
ordinary dialogue box for a classical XY position.

Partial constructions

Constructing a complex geometric figure usually requires several stages.

These stages are different in the case of a figure that is constructed
progressively, such as an ellipse. First the base is defined and then the form is
added to produce the final result.

It may be that you need to interrupt the construction process before the
final stages, quite simply because the shape that you are constructing only
requires the basic part of the icon full function. Take, for example, an open
elliptical arc starting from a centre point, which has four distinct stages and
requires the following data: firstly the centre point; secondly the major and
minor Cartesian radii (X and Y); thirdly, the angular start point of the arc and
fourthly the angular end point of the arc. The result should look like an
elliptical arc.

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GALAAD 3 —————————————————————————————

Now imagine that you wish to construct a centred full

ellipse (i.e. completely closed). There is not a drawing
icon specifically for this simpler construction, so steps 3
and 4 of the above process will have to be skipped.
Consequently we need to interrupt the construction
without losing what has already been drawn and without
aborting the whole process.

Furthermore, some drawing functions are repetitive and have no definite

last stage. The simplest example is a polyline, which requires a start point then
an indefinite series of additional points. It is up to you to decide which point
will be the last. When every new point is clicked, the software adds it to the
polyline and awaits the next point, until you decide to indicate the final point
by clicking with the right mouse button. There are other repetitive figures that
follow this pattern, such as Beta-Splines (which have a maximum number of
256 nodes) and Bézier curves which have no such limits on their nodes.

Remember then that entering the last point of any endless construction
(like a polyline) is simply a case of clicking with the right mouse button. This
is also true for shapes drawn using a progressive construction technique. If
you wish to stop drawing a given construction before its last stage, use the
right mouse button as in the following example.

In the case of a closed ellipse it is simply a question

of fixing the X and Y radii with the right mouse button,
which terminates the construction process there. Note
that the start and end points will be at the standard
trigonometric zero position, i.e. at 3 o'clock.

It is also possible to stop the process one step further

on which will allow the start and end points to set at any
angle required.

The construction of other shapes also works in a similar fashion, for

example, a star (before defining the internal circle), radii (before the internal
circle and angular spacing) or a spiral (before the internal circle).

In any case, please remember that you can end the construction of a shape
at anytime, without losing what has already been drawn, simply by clicking
with the right mouse button to indicate the last stage.

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Editing object geometry

Nobody is perfect and sooner or later you will find that you need to modify
a drawing without starting from scratch. A typical example is a Bézier curve
where the positioning of a node has an effect on the previous one and depends
on the distance between them. Almost certainly there will be times when the
result is not quite what you had imagined and you will wish to make
adjustments to obtain the desired shape.

Four types of object retain the ability to be edited geometrically: arcs (of
circles or ellipses), Beta-Splines, Quadra-Splines and Bézier curves. The
last three still show their nodes after being constructed and can be edited
immediately, however, this does not mean that they cannot also be edited at a
later date. Arcs do not show these straight after construction, but can
nevertheless be edited later on.

Construct an arc or an ellipse, either opened or closed,

using the appropriate drawing icon of your choice. Then
press either the key or select the object to leave the
drawing mode. Now click inside the shape with the right
mouse button and a special edit frame will appear around
the object.

Note that the mouse double-click does the same if the object below the
mouse is alone. You can then modify the shape by moving the red blocks, this
allows the centre, radii, start and end points to be edited. Alternatively, you
can press the key to open a dialogue box and access the parameters
numerically. When you are finished, select another object or simply press the
good old key.

Note that, in the case of Beta-Splines, you can vary the weight (power of
attraction) of any node by simply pressing the or keys. You can also use
the key to move between them.

For other objects, that are not editable in this way, clicking with the right
mouse button will select a segment or a point. See the specific paragraph on
this feature.

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GALAAD 3 —————————————————————————————

Locking objects

This old but nonetheless useful function allows objects to remain visible
without being selected and hence not changed in any way. Simply select an
object ‒ one last time ‒ and click on the locking icon, shown here. Once
locked, an object cannot be selected, nor can any part of its
composition. This is particularly useful when you wish to work on a group of
objects without affecting others that are within the same area. The locked
objects remain visible (displayed in pink) and will be machined normally, but
cannot be selected.

To unlock objects, it is necessary to use the menu command "Edit /

Unlock" or click on the icon again for unlocking all of part of them: if no
object is currently selected when you click on that yellow locking icon, then
Galaad understands that, instead, you want to unlock objects that you are
going to point one by one or in a zone.

Associating objects

Another classic selection feature is the ability to group some of the objects
together then treat them as though they were a single entity. One for all and all
for one. This function can be found, quite logically, among the other
selection icons. Draw several objects and select them all, then click on
this icon. Henceforth, they will act as a single object and selecting any object
of the group will also select all the others. Note that text blocks use a
different system in order to maintain characters together. However, text blocks
can be associated with other text blocks and also non-text objects.

To break the association, it is necessary to use the menu command "Edit /

Ungroup" which provides a range of self-explanatory methods. If no object is
currently selected, the association icon switches to the reverse operation and
lets you point to the targets. Finally if all selected objects are already
associated, then clicking on the icon breaks the whole community.

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Protecting objects

It can sometimes be useful to provide an object with a limited degree of

protection, to avoid leaving it alone on the torture table but still keeping
it available for selection and position. The protection function, with its
little shield, allows only limited operations to be performed. This feature
prevents an object from being deleted or subject to any manipulation other
than being positioned or dimensioned, neither of which actually change the
basic shape. Galaad considers that these operations do not alter the actual
geometry of the path and therefore allows them. On the other hand, the path
can neither be cut, incised, reshaped, nor have additional segments
welded to it.

To unprotect an object use the menu command "Edit / Unprotect" or click

once more on the icon. Protected items can be identified on the board with a
small shield located near to their start point, by using the menu command
"Display / Trace / Protection".

Anchoring objects

Inevitably there will be times when, in order to position them, it is not very
convenient to create a group of associated objects. Conversely, there may be
times when you wish to fix an object to an absolute position even though it
belongs to a group and the others are to be moved. So, Galaad provides two
adaptable methods for this: the absolute position of an object on the board
can be fixed or, alternatively, the position of an object relative to other
objects can be fixed, without creating an association.

The absolute anchoring of an object freezes its position and prevents any
further attempts to move it. Draw two objects and anchor one in
position, then select both objects and move them both. Still selected, the
anchored one will not want to move; this is very irritating.

Anchoring objects relative to each other is less restrictive. The

position of each object can be changed, but moving one object by any
means, mouse, cursor arrows or numerical position, will result in all objects
anchored to it being also moved by an equal amount. For example, draw three
objects, select them and anchor them together, i.e. relatively to each other.

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GALAAD 3 —————————————————————————————

Now select only one of them and move it: the others will also move by the
same amount, even though they were not selected at that moment, which can
look confusing. As well as its practical use for positioning a group of objects,
the relative anchoring function has some interesting side effects that will be of
interest later on, when we look at the selection and manipulation of points and
segments.

To release anchored objects it is once again necessary to use the menu, this
time "Edit / Free anchors". As with protected objects, objects anchored in
position can also be identified, this time with a small anchor, by using the
menu command "Display / Trace / Position anchors ". The corresponding icon
can also be used for releasing anchored objects, if none are currently selected,
to be pointed one by one or in a zone.

Selecting and handling points

We have seen how to select and handle drawn objects. Whilst this type of
selection is fundamental when using Galaad for defining the target of a given
operation or change, it is not the only one. Several construction, snapping and
manipulation functions require that one or even two points be selected, so that
the position can be reused as a reference.

More generally, Galaad has three distinct selection methods for objects,
points and segments. Then, for each of these three, there are two possibilities,
the selection in red, which is the primary method, with the selection in blue as
secondary method, therefore giving a total of six possibilities, each with a
different purpose. What is more, as several of these selections may be
present simultaneously, Galaad shows the "focus" on only one of them at any
one time.

This focus takes the form of a

contour in the selection frame. Note
that the objects selected in red have
priority and always have the focus.
Shifting the focus to another selection
or returning to the drawing mode
deselects these objects.

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The objects selected in blue can never have the focus as they cannot be
manipulated in any way and only serve as a reference for other functions, but
points and segments selected in blue can have the focus. Returning to point
selection, they help to draw, locate accurately and even modify trajectories.

Both the red and blue point selection icons can be found in the group of
selection icons. Let us start with the red one. A straightforward example
is to draw a simple polyline or a rectangle. Click on the icon shown above then
on one of the vertices of your shape. For it to work, the tip of the arrow
(cursor) needs to be very close to your chosen vertex. If all goes well, there
should now be a red spot on the vertex with a ring around it showing that it
has been selected and has the focus.

Big tip: instead of using the selection icon, simply click directly on the
vertex with the right mouse button. If the key is held down during this
operation the point will be selected in blue instead of red. As described earlier,
clicking on arcs and curves with the right mouse button allows their geometric
features to be edited. It is therefore necessary to press the key
simultaneously in order to select a red point on one of these figures ( still
being necessary to select a blue point).

How to use a selected point. Select a red point and click on it with the left
mouse button and whilst keeping it held down, drag it to a new position then
release the mouse button. The whole object will also follow to this new
position. Now try the same thing but with the right mouse button, this time
only the point itself is moved, the rest of the object is unaffected.

As you would expect by now these operations can also be performed from
the keyboard. The now familiar key opens a dialogue box designed
specifically for positioning the selected point, alone or the with the entire
object, this is equivalent to using the right and left mouse buttons. The usual
keys allow the whole object to be moved along with the point and
simultaneously pressing the key results in only the point being moved.

If a point is selected in red, then pressing the tab key will cause the
selection to move on to the next point in the object or the connected objects. If
the is pressed simultaneously, then the direction of travel will be reversed.
Using the key over this moves immediately to the end point and
to the start point. These keys are convenient for following step by step the
coordinates of a connected path.

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Next feature: with a point selected in red, press the key. This will
simply delete that point and thus change the shape of the object. The
selection then moves to the preceding point if one exists. This function may
help you practice some surgical strikes on the objects.

Slightly more difficult, draw two simple straight lines with an extremity of
one at, or very near, an extremity of the other. They are distinct objects that
can be selected individually. Now select a red point at the end where they meet
and use the command "Design / Object / Weld " from the menu. Galaad will
join the two objects at the red point to form a new single object, try selecting
one of the original ones. The operation can be reversed by using the menu
command "Design / Object / Split" which will also work on the intermediate
vertices of any polyline. You have two objects again. It goes without saying
that only end points can be welded together and only intermediate points can
be split. Please note that certain objects cannot be joined in this way and that it
is only possible to weld objects that have the same properties, e.g. an arc and a
polyline. However, dissimilar objects can be connected using other methods as
will be seen later.

Note that the point selected in red maintains its position and becomes the
common point for the new object, this is most apparent in the case where the
two original points had different depths and where one point has to change its
depth. What is more, should they have different machining speeds the new
object also takes its speed from the object that contained the red point.
Obviously, when two objects are split, both the position and speed values
remain unchanged.

Now let us consider the blue points. Once again,

draw a simple polyline or a rectangle, and place both a
red and a blue point anywhere on it but of course on
different vertices. Now move the blue point with the
mouse. You will notice that the red point remains
fixed, the object rotates around it and is also scaled
relative to it.

Without the presence of the red point to act as the

anchor point the blue point cannot be moved.

Very important: the effects of the blue point are much greater than at first
sight. Select a blue point on another object and move it. Although the red point

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is on a different object, it still acts as the pivot point. What is more, if the blue
point is placed on an object within a group of objects that are anchored
together, all those objects will pivot at the same time. This can help when
making fine adjustments.

Apart from being able to snap to, or numerically position, a blue point,
there is not much else you can do with one except delete it.

Selecting and handling segments

In the same way as with points, individual segments can also be selected
and have their own special functions, notably for the construction of new lines
based upon them (parallel, perpendicular, etc.). Selected segments are always
oriented, that is to say they have a direction, indicated by a start point and an
arrow head, which helps when entering details numerically. Warning: the
direction of a selected segment is not correlated to the direction of the
toolpath of which it forms part.

As usual, look in the yellow selection icons to find the segment

selection icons. As with points, segments can be selected by clicking
with the right mouse button, but this time aiming for the segment away from
a vertex. If the segment is particularly small, simply zoom in a bit. The other
features also apply, i.e. using the key to select a blue segment and the
key forces the selection of segments on objects that are sensitive to the
right button. In fact, the only difference between selecting points and segments
is where you click. If you are aiming at a point then that is what you will get,
otherwise it will be a segment. All accessories are the same.

As you might have expected, the key moves between segments in a

forward direction and the addition of the key reverses the direction.
Adding the key moves directly to the start or end segments.

Click on one of the extremities of a red segment with the left

mouse button, keep it pressed down then move it. The segment
can be enlarged or reduced, but only along its axis, without
affecting the rest of the object. Both ends of a segment can be
manipulated in the same way.

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Now do the same thing with the right mouse button. This
time the segment can be rotated round its other end without
changing its length. Combining the use of both mouse buttons
effectively allows you to change the polar coordinates of a
segment.

Segments selected in red are used by many of the drawing icons, notably
when constructing lines, parallels, perpendiculars, intersections and others, but
when it comes to manipulation and adjustments, segments selected in blue are
much more powerful. Now select a segment in blue from a polyline in your
drawing. As you can see on the screen, and unlike with a red segment the
whole object is either scaled or rotated around a point when the extremities
of a blue segment are dragged with the mouse, left or right button keeping the
same functions as for handling the red segment, i.e. rotating and stretching.
This may also help you to scale and adjust objects according to a basic pair of
coordinates.

Moreover, if other objects are anchored to the one

containing the blue segment being manipulated, then they are
all resized and rotated together, as with blue points. This can
help rotate objects around a pre-set point. Anchor all of the
objects together and to a segment created specifically for the
operation. Select this segment in blue and rotate it
accordingly. Numerical dimensioning using the key is
essential for an accurate result.

Consequently, it is possible to undertake a difficult adjustment in polar

coordinates relative to a point that was not even existing on the target object,
for example by snapping the other end of the segment onto the shape to be
adjusted, or elsewhere depending on your needs. Once the adjustment is
accurately done, the adjusting segment can be deleted or set as "visual" (i.e.
not machined) since it was created only for that purpose.

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Moving groups of points

This unique little icon from the selection series is well worth a passing
mention. This icon allows you to select part of one or
several objects so their appearance can be changed without
modifying the points one at a time. First, it is necessary to
define a selection zone and all points within it, no matter
what object they belong to, will be
selected and can be moved or scaled,
repositioned or stretched independent of
the rest of the drawing. Except moving,
framing and deleting, no operations can be performed on
groups of points. Special effects are not available
either. You can also select a group of
points without going through this icon, by
plotting a classical selection zone with the
mouse right button.

Duplication and cloning

Duplication is a vital feature of drawing software. Obviously, using the

copy & paste feature will allow a degree of redrawing. However, a special
function is required if multiple copies are to be placed at regular intervals.
Galaad also introduces a feature, the virtual duplication, intended to save
both calculation time and memory space. Something your computer should
love, then.

Start as usual by drawing an object. If you copy the object and paste the
copy back onto the board, it will then contain two completely independent
copies of that object. Modifying the original has absolutely no effect on the
copy and vice-versa.

Once again select the object, (or the copy if you prefer) and apply the
function "Edit / Duplicate / Add one virtual copy" from the menu. Galaad will
display a selection frame for the copy, allowing you to position it accurately
(of course the key remains available as usual). When you have placed this
copy, try selecting it. As it does not actually exist, it is impossible to select it,

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GALAAD 3 —————————————————————————————

only its image is visible, however, it can still be machined. Do not worry
about it, just because it is virtual it still retains the machining parameters of the
original.

Next select the original object and move it, the

copy also moves by the same amount. Modify the
shape of the original using any function you like,
(there are plenty to try), and the copy takes on the
same shape. If you select a point on the original and
either move or delete it, then the copy is also changed
accordingly.

In fact, most duplications in Galaad are virtual by default. Also when you
place a series of copies at regular intervals, the copies are all virtual copies and
will therefore be modified at the same time as the original. This is most useful
when modifications have to be made, as only the original needs changing and
all the copies will follow suit.

Having said that, copies do not have to be virtual copies and if you wish,
independent copies can be produced. The dialogue box for duplication gives
you both options: virtual or real. What is more, you can make virtual copies
real so that they become independent objects. The "Edit / Duplicate" menu
contains all the necessary functions to undertake this, but remember that the
reverse process is not possible, real copies cannot be made virtual so you must
decide beforehand.

We will not dwell on the simple duplication methods, (in line, matrix,
circle or special) which can easily be understood by trying them, but instead
move on to the more advanced features.

The mirror duplication makes a copy of the selected

object about a variety of axes of symmetry, opposite side of
a red segment, leaving the original object in place. It is even
possible to make the duplication about a red point or a red
cross. As the process produces an inverted copy, it is not the
same design and therefore cannot be virtual.

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Duplicating along a blue trace places multiple copies of

an object selected in red, along the length of a trace selected
in blue. Optionally, they can be oriented to lie on the tangent
of the trace, but in this case the copies will not be identical to
the original because they will have rotated so cannot be
virtual. Real objects will be produced then.

A duplicate trace between points takes the portion of an

object located between a red and a blue point and makes a
single copy of it. Obviously the points must lie on the same
object or connected path.

Cloning is a less sophisticated function than

duplication because it simply produces a single,
virtual copy of the selected object, mirrored in one of
the four quadrants. This can help in constructing
perfectly symmetrical shapes without having to
specifically draw the other half. It goes without
saying that the clone is machined in the same way as
the original and inherits the same machining
parameters.

An cloned object is always stuck to one Cartesian border, and cannot be

moved any further, which may limit the interest of such a function. You
should weigh up the advantages and disadvantages against those of the mirror
duplication, which does not suffer from being stuck to a border but, on the
other hand, makes a real and consequently independent copy. Mirror
duplication or cloning, it is up to you to choose the right function.

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Red (or blue) cross

When a point is selected in red or blue, you

may enter numerical coordinates ‒ using
key, you got it ‒ that take it as a reference.
You may also decide to set your origin on that
point if it can be useful for something, for
example resuming a milling process after the workpiece has been moved. But
a selected point is part of a drawn path, even visual. You may get rid of that
limitation by positioning somewhere on the board a red or blue cross, using
the corresponding icon. This cross has no relation to the shapes drawn. It
can be located anywhere and of course you can snap the plotter or dimensions
for positioning it. In the same manner, you can use it as a reference for adding
visual dimensions or for setting the workpiece XY origin, for example if the
raw material is not a cuboid and therefore impossible to approach from a
corner or two borders.

When setting the workpiece origin,

if a red cross exists somewhere on the
drawing board, then Galaad asks if you
want to use it as reference. This can be
disabled in the workspace parameters.

To remove the red cross, just click again on the icon and, instead of
pointing a new position, cancel the function by pressing key. A bit faster,
you can also click on the icon whilst pressing key.

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Rapid data palettes

When creating a complex drawing, it soon becomes difficult to deal with

all machining parameters, object by object, using the green icon to access them
one at a time. Therefore Galaad provides a shortcut for this. This function is
very important.

Draw several objects on the board using a variety of depths, feedrates and
cutters so that they are all different. Now use the menu command "Display /
Data Palette / Machining depths".

A small horizontal line of data blocks will have been added to the display
between the board and the speed buttons. This shows all the machining
depths that you have used with the current default being highlighted by a
green border. When you select an object its depth is highlighted with a red
border. Now click on another depth shown in the data palette and the depth of
the selected object will be set to this new value without having to go via the
dialogue box. With two clicks of the mouse you can change any depth to any
other depth currently used in the drawing. This feature also works with layers,
tools, feedrates, colours and line thicknesses.

Even better, click on one of the blocks within the data palette with the
right mouse button and keep it pressed. Only objects which correspond to
that depth remain visible. Double-clicking with the right mouse button
selects all these objects.

To add or remove a palette, in addition to the standard menu, you can click
on the left block that displays the palette type (layers, tools, depths, etc.) with
the right mouse button, which will open a pop-up menu. For vital space
reasons, Galaad can display a maximum of ten palette blocks, possibly even
less if your vital space is reduced.

If you are displaying layers on the palette, which is rather common, keep in
mind that when objects are selected, clicking on another layer in this
palette changes the active layer and transfers the selected objects into that
layer. The selection remains identical so it does not show.

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Keyboard shortcuts

We recommend you to print this list out and keep it close to your work
station. Not all key combinations may be of use to you, but the main ones most
certainly will be.

Default:
- / (or / , or mouse wheel) zooms in around the cursor.
- opens a position (or position + dimensions) dialogue box.
- opens the dialogue box for tool / depth / feedrate.
- (or ) interrupts the current operation or deselects.
- deselects all: objects, points, segments, blue or red.
- (backspace) undoes the last operation, including pointing.
- redoes the last operation (except pointing).
- moves the cursor or selection by one step of the grid.
- moves the zoomed view.
- / sets the magnetic grid sizes 10 times smaller / larger.
- sets the magnetic grid sizes to automatic (ruler divisions).
- (tab) makes the selection jump to the next object, point or segment.
- makes the selection jump to the previous object, point or segment.
- refreshes the display.
- + quad view or 3D view icon shows a rotating 3D view.

Drawing mode (crosshair cursor visible):

- opens a polar position dialogue box.
- snaps to the small red point.
- (backspace) cancels the last pointing.
- when pointing a line, applies the polar magnetic grid.

With selected objects:

- + mouse select adds to selection.
- select all (in the active layer).
- deletes the selected object.
- / increases / decreases the depth (0.01 mm by default).
- / sends the object to the first / last place in the sequence.
- inverts the selected object.
- inverts the selected object about the X/Y bisector.
- / selects in red the object start point / segment.

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With selected points:

- moves only the selected point.
- / increases / decreases the depth (0.1 mm by default).
- selects the last point.
- selects the first point.
- deletes the point.
- selects the whole object.
- selects the segment starting from this point.

With selected segments:

- selects the last segment.
- selects the first segment.
- deletes the segment.
- selects the start point of the segment.
- selects the entire object.

When editing arcs:

- / sets the direction as clockwise / counter-clockwise.

When editing a Beta-Spline:

- / increases / decreases the weight of a node (attractive power).
- deletes the node.
- inserts a new node.

When editing a Bézier curve:

- + movement of a control point breaks the tangent at the node.
- + movement of a control point locks the angle of the tangent.
- deletes a node.
- inserts a new node.
- cuts the curve in two at the highlighted node.

When setting the rotation or inclination of an object:

- / or / increases / decreases the angle by one degree.

Tip: function keys F1 to F12, alone or combined with , plus the keys
on the numerical pad, can be easily customised and directly associated to menu
commands using "Parameters / Function keys".

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Display functions

A screen filled with objects can be very disconcerting, when all of them
have different and hidden machining characteristics, and having to select each
object in turn to display its tool, depth, feedrate, etc. soon becomes very
tedious. Galaad provides alternative ways of displaying this data.

As you may have already noticed, the "Display" menu is not the smallest
around and consists of numerous commands buried in an array of submenus. A
selection of the most popular features is detailed below.

The trace functions change the appearance of drawn objects. This allows
you to make all trajectory points visible, or just limit it to the points on a
toolpath where objects are connected. In addition, a small numerical identifier
can be displayed at the start point of each object, showing the tool number,
depth, feedrate, etc.

For example, you may want to display the depth of an

object at its starting point or all the variations along the
trajectory. The same applies to the tool, the feedrate, and the
machining sequence number of each object.

In addition you can use colours to highlight differences instead of just

having a single colour. Each tool can have a colour assigned to it and Galaad
can be set to show objects in the colour corresponding to their cutters.
Alternatively, Galaad can highlight all objects using the current default
machining parameters (whether this be the tool, the depth or the feedrate). In
this case, there will only be two distinct colours on the board. For example, if
the display colour is set to "Default tool" then all objects on the active layer
that use the current default cutter will be displayed in black with all other
objects displayed in grey. You can assign a fixed colour to any object once
and for all. In any case, keep in mind that this has very little interest for actual
millings.

Please also note that selected objects are always displayed in red (or blue),
locked objects in pink, visual (not machined) objects in grey, and tool
compensated paths in brown. This will remain unchanged unless you mess
with "Parameters / Colours".

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6
00110

TOOLPATHS

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Tool parameters

Galaad uses 10 tool libraries, each containing up to 50 different cutters, for

a total of 500 cutters. This should cover most needs. Filling this library is one
of the first jobs that should be done after the software has been installed.
The number and type of cutters will depend on how you intend using your
machine. Start by filling it with the cutters that you wish to use right now and
simply leave the rest empty until you wish to add more tools. What is
important is that the tools you actually mount in the spindle of your machine
correspond exactly to those you have set in the tool library.

A reliable old method is to lay out your tools in a numbered rack and
ensure that the numbers correspond to those in Galaad. In this way, you can
rapidly find the references for each tool used and also quickly lay your hands
on the cutter that Galaad asks you to load. Having said that, you can also add
the name of your choice to each cutter, this will be displayed beside the cutter
number. Note that, in the library, a tool number can be left unused, even
between two assigned numbers. Tool numbers are simply identifiers and
have no numerical meaning, except for a sorted listing.

The management of the tool library relies on two separate commands:

The first one, acces-

sible from "Machining /
Tool library", opens a
passive window that
shows which tools have
been defined and which
tools are actually used in
the current drawing. All
displayed values are read-
only.

This window provides an overview of the tool library, with the tools that
will be used for the current workpiece indicated by a tick. Simply click on any
tool number to display a summary of the tool parameters. Access to editing the
full details is via the "Parameters" button. Please note that Galaad allows the
use of a tool that has not been defined, but in this case it will not be possible
to calculate any contouring toolpaths or automatic feedrates, and it will be up
to you to decide what to mount below the spindle at the time of machining.

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The second command for managing tools gives access to tool definitions.
A given tool is defined when at least its two main parameters have been set,
namely the diameter and the profile. This is sufficient for Galaad to calculate
the correct compensated toolpath and approach from the workpiece origin, but
this should not prevent you from entering a full description of the other
physical properties of a cutter.

The alternate and faster way to access the details of individual cutters is via
the menu command "Parameters / Tools". This pops up a dialogue box, which
allows all 50 tools in each rack to be defined one by one simply by scrolling
through the "Tool number", which can be found in the top left corner of the
window.

When you are happy with the changes and new tool definitions, then click
on OK which validates all changes including masked ones, otherwise click on
Cancel to retain the previous settings.

Note: selecting a tool to modify its parameters will neither change the
default tool nor the tool used by any selected objects. The tool library is
completely independent of any drawing. The cut depth and feed speed largely
depend upon the physical characteristics of the tool (as well as the hardness of
the material to be cut).

When Galaad is installed, a tool library comprising only one pre-defined

cutter exists. It is likely that your personal collection of cutters will have much

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GALAAD 3 —————————————————————————————

more. Simply change the parameters of this tool and create the others. To
avoid cluttering up the list, you may delete previously created tools that are no
longer of any use to you, by clicking on the "Rubout" button to leave that tool
number empty. Alternatively, if you would like to compact the tool library by
moving all of the tools down by one position click on "Del. <<", or on
"Ins. >>" to insert a tool in the middle of the list. The last button "Delete next"
clears all the following tool numbers in the library after the current one (not
included).

Be aware that you can use only one single tool rack at a time for a given
file. Drawn objects only refer to a tool number and not a rack number. If you
switch to another rack, these numbers will not be affected but the compensated
paths may have to be recalculated.

Each cutter can also be given a name and a colour, which is only
displayed if the mode "Display / Path colour mode / Tool dependant" is
selected. The name of the tool appears in the list and is displayed in the
message before setting a workpiece origin. This has no other function than to
remember which tool this number corresponds to.

The key parameter of any tool is the diameter and leaving it blank tells
Galaad that the tool is not yet defined, so there is no point in entering any of
the other information as it will not be stored in the tool library until a diameter
is entered. It is important to be as accurate as possible with this figure, which
should be measured over the largest diameter of the active cutting part of the
tool. If the tool is not cylindrical, for example with a conical engraving cutter
or a 3D hemispherical cutter, this is frequently the same as the shank diameter.
For a cutter with a special profile, e.g. a surface mill in reversed "T" or a
pyramid tool, the right value will be the maximum active diameter.

The profile of a cutter, closely linked with its diameter, determines how
the width of the cut will vary with the depth. Profile families are: cylindrical
(drilling, boring, cutting, flat milling), conical (engraving or chamfered
cutting), hemispherical (3D milling ball-end), pyramidal (reversed conical
cutter for surfacing), and arcade (conical tool with fillet borders). With a
cylindrical tool the width is constant, irrespective of the depth, but with a
conical or hemispherical cutter the width will get wider as the cut depth
increases, up to the maximum diameter that the tool can cut.

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With a conical tool, it is necessary to accurately specify the

point angle. This angle is the full included angle, measured from
side to side and not the half angle from the centre line. If the two
sides are unequal, measure the largest half angle, then double it as
when the tool rotates about its axis it will describe a cone swept out
by the largest side.

For conical tools with flat or shaved end, you may indicate the
minimum diameter at the bottom of the cone, and the software
will integrate this in its calculations, in particular for the
compensation trajectory (tool offset). If the end is rounded, then the
best is to choose the closest option according to the profile angle,
with or without the minimum diameter (sharp or wide angle).

The automatic calculation of feedrates is also based on the number of

teeth and the speed of rotation of the cutter, as parameters of secondary
importance. It is true that feed speeds are supposed to be based on these two
factors when cutting metallic components. But the fine tools used in engraving
or for cutting softer material are very fragile and demand that other factors are
of primary importance, namely the tool diameter, profile and cut depth. Galaad
takes this approach in its calculations. The spindle speed is displayed
immediately before machining, and controlled directly from the software
where this is possible, i.e. if a remote speed control is available and of course
correctly set in Galaad. See chapter "Machine parameters", spindle section,
for more details.

If you indicate a suggested feedrate, then it will be possible to choose that

option in the dialogue box for setting depths & speeds. In that case, the speed
can be changed here later on.

The main parameter that prevents expensive cutters being broken is the
maximum depth per pass, which defines the deepest cut that the tool can
make in any one stage. In the case of a cylindrical cutter, the theoretical depth
is equal to the length of the cutting (fluted) part, but that supposes that the tool
is solid. It is preferable to stick to something a little closer to twice the
diameter of the tool to prevent unwelcome surprises and assorted expletives. If
the tool is conical (engraving javelin) or hemispherical (3D ball-end), its
maximum depth is simply the height of the cone or the radius of the
hemisphere, assuming that the teeth extend that far.

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Warning: the maximum cut depth per pass also depends on several other
factors, not least the resistance offered by the material. In addition, it goes
without saying that a brand new carbide tool will have a much better
performance than an otherwise identical, but well used, HSS tool. The
unsupported length of the cutter, (i.e. that protruding below the collet), must
be taken into account. The longer the length, the slower it should cut to
prevent excessive deflection and a broken cutter. Then there is vibration,
directly proportional to the spindle speed, it can be detrimental to the quality
of the finish and fatal to the cutter. Clearly the less cut depth, the less work the
tool has to do removing material and the less resistance it will feel. Galaad
takes this into account when calculating feedrates.

Note that Galaad manages increasing depth stages and avoids passing
twice in deep paths that have been already milled during previous stages. In
the case of 3D paths, the tool then only does the active part of the trajectory
for the current stage, this also applies for the ending bottom right point. So
there no time is wasted with a tool passing several times in the same final path.
It is also possible to ask for a cleaning pause before every new stage, the
time for a quick blow of vacuum cleaner. If enabled, this pause will actually
pop up a message for the operator which will have to be acknowledged before
the process can be resumed.

On the right hand side of the dialogue box is a section which contains
several parameters applicable to vertical motion only i.e. when a tool is
plunging or drilling into the material. It also covers the positions for drilling
cycles used for clearing material out of deep holes. The first parameter, the
preliminary plotting, forces the tool to drill the material for a small depth that
you can indicate here, with the corresponding speed. Obviously, the operation
is performed only if the path depth is greater than the plotting depth. This
function is useful only with certain tools and very hard materials.

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Next, Galaad allows the plunge speed, speed at which the tool drills
vertically into the material, to be set independently from the horizontal or 3D
feedrate given to each object. This speed is linked to the characteristics of the
cutter itself and can be set at a fixed value once and for all. Whatever its
shape, a milling or engraving cutter does not drill as well as a proper drill bit.

In essence, the machining process follows this sequence: the tool moves
horizontally at a safe height above the workpiece and at a rapid speed, V1, to a
position immediately above the start point of the first object to be machined. It
then moves down at a rapid speed, V2, to just above the surface of the work
before plotting at a very slow speed, V3, and entering the material at the
plunge speed, V4. The part is then machined (2D or 3D trajectory) at the
feedrate, V5, and finally the tool is retracted vertically at a rapid speed, V6, to
a point above the workpiece. The speeds V1, V2 and V6 are not related to the
workpiece, but depend on the performance of the machine, hence these
parameters can be found in machine parameters. The feedrate, V5, of each
object is determined when it is constructed. The plotting and plunge speeds,
V3 & V4, are set as discussed in this chapter.

Nevertheless, the plunge speed can also be set in the other traditional way,
namely as a percentage of an object feedrate. In this case you just have to
indicate this ratio in the corresponding edit box, in percentage of feedrates.
The two methods are mutually exclusive therefore entering a percentage value
will delete an absolute value and vice-versa. At the end of the day, the choice
is entirely yours and is likely to be influenced by the type of work that you
undertake. Note that it is only possible to have automatic plunge speed if the
feedrate itself is set to auto and the plunge speed is set to a percentage of the
speed.

The deburring cycle is a classic drilling operation, which repetitively

retracts the drill completely out of the hole after it has cut a predetermined
amount, and returns it back to the depth it has just reached ready to take the
next cut. This cycle is repeated until the required final depth is reached. The
purpose of this operation is to prevent a build-up of swarf, which can have
detrimental effects and is particularly important with deep holes at very
accurate diameters. Of course, this also depends on the material.

Another very similar routine is the chip-breaking cycle, the difference

being that the drill is only retracted by a very small amount and is not lifted
completely clear of the hole. The purpose of this is to break up the long spirals

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of swarf produced by certain materials, into shorter lengths that will be thrown
clear.

For drilling works with drill bits having conical ends,

you may set an overdepth for simple drills that corre-
sponds to the Z height of the lower cone, so the diameter
at bottom is the same as the top. Indeed this digs craters
in the machine bed under the workpiece.

If the tool cannot plunge vertically into the material, which often occurs
with a cylindrical cutter, then you may define an oblique plunge slope, set in
degrees of angle. Galaad will make the tool touch the workpiece top surface
without plunging, and then will start the XY feed path following the Z slope,
with a return backwards to the start point along the plunge. The XY length of
the path is calculated according to this slope angle. If the path is too short, then
the process is repeated until the target depth is reached.

For a closed path with one single Z coordinate, which is very common for
cutting jobs without support bridges, the option "Chain Z stages", at bottom
right of the machining parameters window, enables a progressive helix
lowering for penetrating the material, i.e. a continuous slope around the path,
a classic of metal milling. We will see that later on.

Finally, the bottom right area of the dialogue box shows some basic
statistics about the use of each cutter. These statistics can be active if you
want: Galaad will ring the bell when a wearing limit has been reached, defined
in machining time, milled path length or number of plunges. This software is
well-educated and will not interrupt a machining cycle because a tool
trespassed one of these limits. It will just warn you, before launching a new
cycle, that the tool about to start has run through a red light, but ultimately you
are the one in control.

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Tool compensation

When you construct an object with Galaad, the drawing is supposed to be

an accurate representation in space of the cutter path. This means that it
displays the path followed by the point of the tool (or the central axis at its
lowest extremity), but not necessarily the actual finished part. Let us look at a
suitable example:

Construct a simple five-point star, remembering

that Galaad has an icon specifically designed for this
purpose. Imagine that you now wish to cut out this
star accurately from a thin sheet material, so you set
the cut depth to the thickness of the material and select
the best cutter for the milling process. Then you are
ready to start cutting. Or are you?

The drawing represents the actual path taken by the

centreline of the tool, and the tool does not have an
infinitely small diameter, so the finished result will be
a bit smaller than it was actually drawn. The difference
is half the diameter of the cutter used and as we
wanted the star to have precise dimensions the result
can be scrapped.

In fact, the toolpath must pass to one side of the

path drawn, on the outside if you want the star itself,
or on the inside if you want the material with a star
shaped cut out. The cutter path must therefore be
modified accordingly and moved by half the diameter
of the tool. This is called tool compensation and
thankfully, Galaad does it for you.

Select your star and find the menu command "Machining / Tool
Compensation / Define toolpath" which opens the inevitable dialogue
box and provides the necessary controls. This function also has a handy
shortcut that can be found in the command icon bars at the top of the screen.
All that is left to do is define the path that the cutter will take around an
object. Start by indicating whether the cutter will be offset to the outside (if
you wish to keep the object intact) or the inside (if you wish to produce a cut

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out, the size of the object) of the shape. If several objects are selected, then
perhaps a group can be composed of an
external path to be cut outside with some
islands to be cut inside. Enabling the
appropriate option, you can set the whole
group without having to redo the reverse
operation.

Then specify the direction of the toolpath,

clockwise or counter-clockwise. This is very
important as the machining will only be done
in this direction, and a little arrow is shown at the start point of the toolpath to
indicate in which direction the cutter will travel. With a cutter rotating
clockwise, this equates to a clockwise toolpath when cutting on the inside of a
closed shape, and counter-clockwise when cutting on the
outside. Moreover, Galaad chooses the direction
automatically, but if you want to change the direction, you
can do so as you have the last word.

The rotation of the tool combined with

its direction of travel is important as it
influences the whole cutting process. If
the cutter approaches the work as shown
to the left it is called "conventional
milling", the opposite is "climb milling ".

With a light milling machine, conventional milling is likely to produce the

best quality finish. But there can be big exceptions to that principle, depending
on the material to be machined and the cutter used. For a classical cutter with
helix flutes, turning clockwise seen from above for extracting the chips
upwards, which is rather common for spindles, it is then better to set a
clockwise path when the tool must cut inside the path, and counter-clockwise
when it must cut outside.

This small dialogue box for tool compensation contains a big drawer that
you can open by clicking on the button for "Advanced options". These options
are many, but do not panic, we are going to explain everything in detail.

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With first option, you can specify

how external angles are to be machined.
Galaad can produce either sharp angles,
by extending the toolpath far away to the
intersection point of offset segments, so
that the tool loses contact with the work,
or rolled angles by rolling the cutter
around the vertex to keep it in contact
with the work. The latter method is often
preferred as it helps to reduce burrs.

To avoid letting the cutter plunge in the material when near the border of
the shape you are creating, which can leave a visible print, you can then define
an input path at the feed-in point, a little way from the actual finished shape,
and eventually an output path at feed-out point, each of them being possibly a
segment or an arc. If you select the "Automatic" option, then Galaad will apply
what has been predefined in the calculation parameters, shown later on. You
may also add a feed-in or feed-out segment that you will locate yourself on the
board, by calling "Machining / Tool compensation / Feed-in point" or the

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corresponding icons. But if the calculation of the tool compensation needs to

be reset, for example if you change the tool for the selected
objects, this manually added
segment may be removed. On the other hand,
those you preset here are integrated to the basic
calculation and will remain valid.

In the same frame, the option for oblique Z

plunge makes a slope of the feed-in segment or
arc, from the workpiece top surface down to the
target Z depth (or the staged depth if any). The
same reverse function exists for the tool bottom right at output if you do not
want the tool to exit vertically. The path recovery distance builds a tool
compensation path with the output trespassing the input point.

A cutting operation may require a first pass

with a roughing tool, being fully understood that
the finishing tool is always the one defined for
the object (and also its feedrate), displayed as a
read-only reminder. Concerning the roughing, you
can call a different tool that feeds at a different
speed, and leave a small XY lateral approach margin, i.e. a thin remaining
material that will be taken away when the finishing tool feeds, and also an
eventual depth margin for reducing the Z coordinate to be reached by the
roughing pass. At last, you can ask for a finishing tool plunge at roughing
start point where the material has already been drilled. In this case, a small
linking segment will be added. If the tool is used for both roughing and
finishing passes, then it will not even be lifted up.

Keep in mind that the tool sequence has the highest priority, particularly
concerning tool compensated cycles with roughing and finishing passes. If you
set a roughing pass with a different
tool, then think about inserting it in
the machining sequence before the
finishing tool to avoid putting the cart
before the horse. Nevertheless, if your
drawing contains a double tool
compensation with roughing and
finishing paths, even before setting the tool sequence, Galaad will warn you
that a priority order of occurrence must pre-empt this sequence and will offer

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an automatic set-up. But you always have the last word and, consequently, you
may modify the sequence according to your wishes. If by chance you insist on
choosing to break the roughing /
finishing sequence for one or more tool
compensations, a last warning message
will ask you to confirm that you know
what you are doing. This is your
ultimate chance to return to rationality.

When performing the final cut-out of a workpiece that is supposed to have

been strongly attached to the machine flatbed, nature's and Murphy's laws
being what they are, the cut part often tends to seek a freedom from which it
has been unjustly deprived, preferably even before
the cutting path has been completed. In order to
restrain these emancipating impulses, Galaad can
put support bridges here and there on the cutting
path. The software will leave a small thickness of
material between the two parts each side of the
groove so they remain connected to one another. Therefore, the cut part
remains attached to the main part that is fixed on the machine. A support
bridge can either clear the tool over the workpiece so the path is completely
interrupted, or leave a small thickness of material at the bottom of the groove,
so at that location, the milling depth will be lesser than the cutting depth. For
example, if the workpiece thickness is 3 mm and you ask for leaving a
thickness of 0.5 mm, the cutting groove will be at 3 mm depth along the path,
except at the support bridge where it will be at 2.5 mm only, leaving at the
bottom a thin connecting bridge.

The automatic positioning of support bridges is made either by setting a

number of bridges that will be located on a regular basis along the path, or
conversely a maximum distance between bridges, in which case the number
of bridges will depend on the path length, or only on segments which have a
minimum length. The bridge width corresponds to the part of the path that
will be milled above the cutting depth (the groove width being obviously the
cutter diameter).

These support bridges can also be positioned manually on the path using
the function "Machining / Tool compensation / Support bridges" or the
corresponding fly-out icon in the top bar, under the tool compensation
icon. But, like manual feed-in and feed-out segments, recalculating the tool

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compensation may delete them. Those defined here in the dialogue box are
integrated to the calculation and therefore maintained whatever happens.

Before closing this big dialogue box for tool

compensation, a few little options will let you
enable the following functions:

- Avoid associated neighbours prevents the calculated

contours of neighbouring objects overlapping one another,
giving a possible unexpected result on the machined work-
piece, especially when roughing contours are milled with
cutters having big diameters. This option enables, for each
calculation, the search for collisions with other contours and
eventually builds an overall contour path for close shapes.
But this can work only if colliding paths are to be made with
cutters having the same diameter at current depth.

- Manage self-colliding paths for the object is useful only for a 3D path
where the trajectory crosses or closely overlaps itself . The typical case is a 3D
spiral for which the contour at every turn covers the neighbouring turn. In
2½D, the calculation would eliminate any part of the contour that would be too
close to the whole path (current, previous or next turn). In 3D, the overlapping
can be accepted since the turns do not have the same depth.

- Add angle lines, for a conical tool, adds a bevel with carving
effect in sharp angles. The tool ending cone lifts up obliquely
for reaching the deep of an inside corner. If the tool is cylindri-
cal, then this option adds a mid-line for clearing the rounded
corner.

- Set automatic startpoint lets Galaad choose the feed-in point in the
contour. This function will be pre-empted by input/output paths if you enable
them (see above). The chosen point will be the sharpest inside corner for an
inner tool compensation, or the sharpest outside corner for an outer tool
compensation, so the point of plunge is as far as possible from the machined
contour path.

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At bottom right of the extended dialogue box, a button "Calculation

parameters" gives you access to the internal mechanics of the tool compensa-
tion:

On the left hand side, you can set display parameters for the tool compen-
sated trajectories, the threshold angle for rolling around sharp angles and their
overrun if the path has been set for not rolling. On the right hand side, you can
define how the automatic input/output paths will be calculated. These values
remain available in the parent dialogue box. For understanding how they
apply, the simplest is to try on some object featuring inside and outside
corners, for example a star. The automatic startpoint, when enabled, lets
Galaad choose where the contouring path will begin (and also end). A classical
way is the sharpest angle, which can then be overrun for a little distance,
leaving the tool plunge a bit beside the useful part.
Note: it is not possible to modify the geometry of a tool compensation
contour that has been calculated by Galaad, except by modifying the shape it is
related to. However, a few additional functions allow you to adapt the path to
specific needs. To do so, once the trajectories are displayed, just look for the
function which interests you in "Machining / Tool compensation" submenu.
Here you can create a new offset object from the calculation of a tool
compensated path, and this new object will be fully independent from the
original one. If the selected object already has a tool compensation path, then
this path will instantly become the new object without asking anything.
Otherwise you will be prompted to indicate an offset distance and a few more
classical parameters for the calculation.

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To delete a tool compensation trajectory, just call "Machining /

Tool compensation / Remove toolpath" or click on the corresponding
fly-out icon under the tool compensation icon in the top bar.

Hatching and pocketing cycles

When engraving, there is frequently a need to highlight an area by clearing

out its inside. In addition, milling operations sometimes require an area to be
hollowed out, to leave what is known as a pocket, for example a surface
between two engraved borders such as letters or any closed shape.

Galaad provides two possible ways to accomplish this. Hatching is the

most classical and consists of engraving a series of shallow parallel lines
across it, very close to each other. Alternatively, pocketing is more mechanical
and uses a normal slot drill (or similar) to remove all the material within the
pocket down to the required depth. Let us start with hatching.

Find the icon for constructing closed polylines and construct a large one
with at least six or seven vertices. Then add a smaller one that is entirely inside
the first one. Now select the two polylines, or just the outer one if you prefer,
and choose the command "Design / Hatching" from the menu. The
dialogue box that opens will let you define the parameters that will be
used to hatch out the area enclosed by the outer polyline. There are not too
many options and they are not very complicated, or at least they should not be
after a little practice. The first edit box
sets the interval between two
adjacent hatch lines. In general this
distance is presumed to vary with the
diameter of the cutter tool used. If you
leave the value set to "Auto" Galaad
sets this distance to half the diameter
of the tool. Then hatches will have an
overlapping ratio of 50%. Remember
that this varies with the cut depth
when you are using a conical engraving cutter. However you can change it if
you so desire.

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Hatch lines can also be inclined at any angle, positive or negative, with
respect to the vertical, which is the default zero setting. Remember that a
positive angle produces a counter-clockwise (trigonometric) rotation and that
classic italic text, which slopes to the right, therefore defines a negative angle.
You can also enable the option "Auto vertical/horizontal" so the software will
calculate both hatchings and will keep only the one that requires less tool
bottom right operations.

In some types of engraving the hatching out of the interior is not done at
the same depth as the outline, therefore Galaad lets you set the hatch depth as
a percentage of the outline depth. By using a relative depth as opposed to an
absolute one, you can work more easily with a collection of objects that have
many assorted depths. The option for anchoring links the hatch lines to their
contour so they all move together.

The style of hatching produced is affected by the choice of either zigzag or

hatching. Zigzag is simply a hatching of which the adjacent lines are joined at
alternate ends. This results in a shorter machining time as the cutter does not
have to retract, move to the start of the next line, then feed in again between
each line. However, you might want all the hatch lines to be independent, in
which case you can also specify the direction they take.

On the right hand side, you can

choose if the hatching should
ignore (i.e. cover) or avoid internal
islands, for example this polyline
inside another one that will be
saved. Important: to be considered
an island, the inner polyline must
be closed. The dialogue box lets
you filter islands depending on their
relative depth.

It is also useful to be able to choose whether the hatching is machined

before or after the outline. Milling the outline last produces a sharper
definition of the contour, however as usual, it is entirely up to you.

You can select all the hatching within a given drawing by using the
filtered selection icon.

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Cancel the hatching operation, or make use of the fact that the hatch lines
are currently selected and simply delete it. Now we will look at the pocketing
cycles so find the menu command "Design / Pocketing cycle". Do not
search too much: the command is just below the hatching in the menu
or the shortcut icons.

Once again the distance between

adjacent passes is required, this time
referred to as the stepover. The
default (or automatic) value is
classically set to half the tool
diameter for a 50% recovery of the
paths, but of course you can override
this if you so wish.

Progressive Z lowering is a bit like the duplication function but with the
addition that the depth is progressively lowered with each step towards the
centre of the pocket, producing a 3D effect. As with the contouring operation,
on which this function is based, it is necessary to define the direction of the
toolpath, which is normally clockwise for internal paths. Likewise you can
also choose whether external corners on islands are rolled or sharp.

A pocket can be cut out in two

basic ways, from the inside to the
outside or the other way around;
Galaad gives you the choice for that
sequence. In addition you also have
the option to leave any internal is-
lands intact and anchor the pocket
lines with the contour path, like the
hatching function.

One final parameter, link passes, produces a short link between successive
contours within the pocket, so that the tool remains at the cut depth. This is
similar to zigzag hatching as described above and leads to shorter machining
times. This can become quite complicated when there are internal islands
involved but Galaad will try to do its best. The hatching function sometimes
gives better results than the pocketing cycle in critical cases, i.e. outline
polylines that are made of very small and erratic vectors.

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Connecting objects into one toolpath

You have seen how the software can produce a contour, or clear out an
area, defined by a single object. The operation is somewhat more complicated
when the path is made up of several different objects. It will work if the
objects are drawn (or rearranged) so that they are in the correct machining
sequence. Alternatively, you could weld the objects together, but however,
there is a problem: when welded together, objects of a different nature lose
their geometric properties and this makes it difficult to modify them later.

For example, take a drawing comprising an open

circular arc followed by a simple polyline then a
Bézier curve, which also links back to the arc to form
a closed shape. Here we have three independent
objects, two of which (the arc and the Bézier curve)
have intrinsic geometric properties, but only a single
path to contour or clear out.

Galaad offers an interesting alternative to simply welding them together.

This will not affect the properties of the individual objects. It integrates the
different objects into one single toolpath, by simply connecting the
neighbouring ends of path components.

Select an end point of one of these objects and apply the menu command
"Machining / Toolpath / Connect objects" and if all goes well the object will
now be joined. This will be confirmed if you try to select either of them
individually, you will now find that they act as a single entity. However, it is
much quicker to apply this command globally by first selecting all of the
objects.

Nothing seems to have changed except for the

appearance of small dots at the connecting points
where the objects join, provided that the menu
command "Display / Trace / Paths / Link points" is
ticked. You now have one single continuous
toolpath made from the group of shapes, which can
be handled as a single object.

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GALAAD 3 —————————————————————————————

This command also has a shortcut icon in the command toolbar at

the top of the screen.

Now that you have this continuous path, it can

be contoured, hatched or pocketed just like a
single object. However, please note that a toolpath
may remain open (as with our previous example) as
you can connect and contour along an open shape.
The aim is to define a macro-object that Galaad
will see as a single entity, without having to resort
to the less friendly welding technique.

When disconnecting objects, you will find that each object regains its
independence, and also its geometric properties that it had prior to being
connected. Your objects have not been harmed in any way.

There are other associated functions for working with connected toolpaths.
For example, you can select a connecting point in red and define it as the start
point of the toolpath, or perhaps change the overall direction in which it will
be machined, without affecting the end result. If this turns out to be necessary,
you can permanently weld the connections, but in this case, the objects will
lose their geometric properties and be converted into simple polylines.

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———————
7
00111

ADVANCED MILLING
FUNCTIONS

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GALAAD 3 —————————————————————————————

Tool parking positions

We have briefly seen the basic functionality of the integrated machining

module. You have probably already machined something successfully with it
and wish to know more about the features available, it is therefore time to
delve deeper. Take some drawing of your choice then start the machining
module, or the simulation if your CNC is currently unavailable because one
happy and selfish colleague does not want to share it.

No doubt you are very familiar with this screen and already know how to
control the tool sequence. If not then you have arrived here a little prematurely
and skipped the chapter "Learning to mill", then return here when ready for
more details. Hurry up, we will wait for you.

Consequently, we are not going to return to the now quite familiar tool
sequence occupying the lesser half of the window. But before looking at the
numerous parameters on the right, let us quickly review the buttons that
control the position of a tool after it has completed a machining cycle.

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Click on the "Tool change" button. A

small dialogue box will appear, to allow
the tool change position to be specified.
Unless told differently, this position is
given in absolute coordinates, relative to
the machine's fixed zero point. It
represents the position where the cutter is
sent at the end of a machining cycle when
another tool has to be loaded.

If you do not want the tool to move from its position at the end of a cycle,
that is, directly above the exit point of the last object machined, simply select
the option to remain at the current position. Otherwise you need to enter the
coordinates for each axis. Note that if you enter a value beyond the physical
travel of an axis, obviously Galaad may find it a little difficult to comply with
your instructions and will not trespass the limits.

Usually the tool change position is chosen to provide easy access to the
spindle for the operator, preferably in a well retracted position towards the
front of the machine or at least near the operator.

The default speed is the same as that specified for the XY rapid and the Z
bottom right moves, but you can set a different value if you wish, for these
cycle end movements.

The neighbouring button "Tool parking" defines the position where the
very last tool goes to, after having completed its machining cycle. Given that it
is assumed that the process is finished ‒ or abandoned, yes this can occur ‒
this position is normally set to park the tool away from the operator so as to
allow better access to remove the workpiece. Parameters of this new dialogue
box are the same as the previous one, with identical functions.

If you park the tool near to zero on one or more axes, it is recommended
that you leave a small distance (say 1 mm), so as not to leave the machine
pressing on a limit switch. This can increase the lifetime of the mechanical
contacts. Thank you on their behalf.

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If your machine has no end-switches, or if you do not wish to work using

absolute coordinates with a machine reset, it is obvious that you are not
concerned by these previous paragraphs.

Nevertheless, in this case, you can set cycle

end positions. These become relative to the one
and only existing zero point: the workpiece
datum. The coordinates can then be positive or
negative. Beware that a negative value for the Z
axis means that the position is somewhere
below the workpiece origin. It is always worth
mentioning…

 Normal pass, final pass, cutting pass

The first parameter frame, at the top right of the window, is entitled passes.
Unfortunately, this term has several different meanings, the most common
being each pass that the cutter makes across the workpiece. In Galaad
terminology, the cyclic machining operations are defined as follows, starting
from the top:
- the tool sequence, defined by you,
- the passes, based on the order of work (eventual final pass and cutting),
- the stages, based on the maximum depth a tool can cut (except final pass),
- the cutting order of the objects or paths, based on the drawing itself.

A complete machining operation is therefore a repetitive sequence,

comprising finding the workpiece origin then automatically milling the part
with a series of tools. Each tool can have a 1st pass, an eventual 2nd pass which
can be finishing if there has been a roughing, and then a cutting-out pass.
When making the 1st pass and the cutting out pass, it is necessary to adhere to
the maximum cut depth that the tool is able to make, but not during the final
2nd pass. Finally, either at each such depth the appropriate paths are machined,
or for each object all depth levels are machined. Both possibilities exist as we
are going to see. Notwithstanding this, a simple machining operation might
only use one single tool, only have one single pass and one single depth stage.

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We have already seen the tool sequence, so let us return to the passes.
When you draw an object in Galaad, you give it a milling depth. If this depth
is greater than the material thickness, then it is limited to this value and the
object is marked as "cut-out". In this case, changing the thickness of the
material will also change the depths of objects to be cut-out. Therefore, on one
hand we have objects to cut out, and on the other, objects to engrave or mill
at a lesser depth. 3D paths like wiremeshes are not concerned since their depth
varies along the vectors.

For practical reasons, Galaad schedules all cutting-out operations last in

the sequence for each tool. The reason for this is simple: when a piece is cut-
out, there is a chance that it will not remain in place whilst other objects are
being machined. When the work comprises a mixture of milling and cutting-
out, it is obviously better to leave the cutting-out until last, otherwise you
could end up with a piece that has just been cut-out, getting loose, catching a
cutter and getting ruined or breaking the cutter. Consequently Galaad
overrides the sequence defined in the drawing, and places the objects into two
groups: engraving/milling, and cutting-out. Within each group, the drawing
sequence is followed. But you can still disable this option, in which case there
will be no cutting pass as such: all objects will be machined as milling,
whether they are cutting the workpiece or not.

It is often useful to take a cut in more than one pass, rather than just a
single pass at the full depth, by starting with a heavy rough cut followed by a
light finishing pass. Let us consider an object to be cut at a depth of 10 mm.
We could make a single cut at 10 mm or start with a rough cut of 9.9 mm, and
follow it with the final cut at the full depth. The normal passes of the cutter
will remove most of the material from the grooves machined and the final pass
just removes the 0.1 mm remaining material, and any glued chips remaining
from the normal pass. During the final pass, the cutter has little work to do and
consequently the feedrate can be much higher. Obviously, this depends on the
material.

Therefore, you can choose to make a final pass with objects

that are not cut out (engraving or milling at limited depth).

For objects that are to be cut-out, there is no point in making a final pass
since the cut depth is already equal to the thickness of the workpiece. So there
is no final thickness to be removed for getting a good cutting aspect. On the
other hand, you could make the cut a little deeper to ensure that the piece is

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cut-out cleanly. Depending on the material, this overdepth could well

correspond to the thickness of the adhesive fixing the material on to the
machine bed. There is no need to exaggerate this overdepth beyond reasonable
limits. Your machine bed will appreciate that.

The feed speeds for both roughing and finishing passes are adjustable
overall. You can specify a multiplication factor for each of the speeds without
having to modify the speed of each object individually. These multipliers will
be universally applied to the speeds of all objects, whether they were set by
you or calculated by Galaad. If you choose to include such a finishing pass,
then in general a multiplication factor of 200% or 300% would probably be
appropriate, depending on the thickness of the remaining material that has to
be removed. Logically, the cutting pass is submitted to the normal pass
multiplier.

In summary, let us consider a piece to machine, comprising a profile to cut-

out and some paths to mill. If you decide to make a final pass, the tool cycle
will machine engraving paths at corresponding depths minus the thickness for
final pass. Then that final pass will be machined faster, at the full depth, and,
last of all, the contour cut-out at the workpiece thickness plus the overdepth
for cut-out paths. If a separate finishing pass is not required, then the normal
pass will be directly machined at the full milling depth, the cut-out remaining
unchanged.

 Fixed values

It may be that you have to machine a workpiece design using feedrates and
milling depths other than those specified for the objects. You can, of course,
return to the drawing, select all objects and change the machining parameters.
However, Galaad offers a shortcut allowing you to override these values with
fixed feed speed, depth, stages, and drilling cycles which can be disabled.

For example, you have a drawing which contains a whole range of depths
and feedrates to be machined with a tool that makes stages of 2 mm (maximum
depth per pass) with deburring cycle. However, you now wish to machine the
drawing with this tool in one pass, at a final depth of 1 mm, at a speed of
5 mm/s, with neither depth stages nor deburring cycles. In this case simply
specify a fixed depth of 1 mm, a feedrate of 5 mm/sec, stages of 5 mm (or

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1000 mm to make sure that the threshold is overrun, do not worry about it,
Galaad will target the depth value anyway) and tick the "No drilling cycles"
option. The machining cycle will now use these new values and ignore those
specified in the drawing.

Note: the "Fixed values" do not

change any of the drawing or tool
parameters in Galaad.

This feature can also help you make last minute depth and speed changes
according to the tool to be used.

 Miscellaneous parameters

The last machining parameter frame contains a variety of features to

manipulate the result. The first one allows the scale to be changed and applied
at the time of machining, without having to modify the drawing itself if it does
not match the final dimensions of the physical workpiece you have actually
prepared. Just indicate a different scale, and let it go. Note that the depth Z
scale is set separately for easier control. The resulting dimensions (text box
directly below) are immediately changed to show the effects of the new scale,
alternatively you can enter the new dimensions directly and the new scaling
factor will be displayed. Remember that you may still enter a mathematical
formula in these edit zones.

When engraving on the reverse side of a piece of transparent material, it is

easier to select the X mirror feature when machining, rather than producing
your drawing already reversed. With Galaad, the user is free to concentrate on
the finished result and leave this sort of detail until the machining stage.
Likewise, if you need to rotate the complete drawing in 90-degree steps, this
can also be left until machining. The small preview will assist in obtaining the
correct orientation.

Very important: the Z clearance height sets the vertical distance to which
the cutter will be lifted before making lateral XY moves to start points of other
objects to be machined. This height is the absolute value of the distance
above the top surface of the workpiece. If the surface is not flat, or if there are

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any obstacles, such as clamps, then you must specify a value that will allow
the cutter to clear them safely, or else there will be trouble. On the other hand,
making this distance too large will unnecessarily increase the time taken to
machine, unless your machine is able to move at very fast inactive speeds.
Changing this value remains memorised for the next processes.

On the same lines, the Z contact margin allows you to define the stop
point for the rapid move down before entering the material (speed for rapid
move down is settable in machine parameters). Zero corresponds to the
workpiece top surface. A small margin, still in absolute value, may avoid a
hard contact. The slow plunge into the material will begin from that point. If
you do not set a value, then the tool moves down at rapid speed until it touches
the workpiece top surface, and it will plunge from there at slow speed. This
value offsets upwards the start point of the slow plunge. Obviously, the target
depth remains unchanged.

Galaad has the option to restrict machining to selected objects only, which
is useful if you are returning to a job that has been interrupted, or only wish to
machine part of a drawing. This function is like a filter; you simply select the
objects required and tick the appropriate checkbox. Galaad will ignore any
objects that are not selected. You can also start a machining process at a given
point located inside an object if that point is selected in red in the drawing, and
in the same way you can stop a process at a point selected in blue, both options
being independent.

Similarly you can filter out layers, remembering that, by default, objects
in the active layer will be machined, and them only. The objects that will be
actually milled during the current tool cycle appear in black in the little
preview window at bottom left. Other objects, that correspond to other tools,
rejected layers or filtered on selection, appear greyed in this preview.

The option for machining support bridges only lets you resume a process
already finished by milling directly the support bridges that were left intact.
This option also exists in the cycle-end message if bridges were found in the
process just completed. If you enable that option, then Galaad will not do the
normal machining cycle but will only seek the position of every support bridge
and will mill them one by one for removing them. This supposes at least that
you have something better than your fingers for keeping the parts which often

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have a good sense of freedom, and also that the workpiece has not moved from
its previous position (or that you reset its origin point).

Important feature: just below, chaining Z stages breaks the default

sequence which normally goes through all objects
for every stage of depth. If enabled, then instead,
the machining cycle will make all depth stages for
every object, before dealing with the next object.
In fact, this option pops up a sub-window that
offers several related possibilities. In the top
frame, you can set the maximum number of
chained stages or decide that the cutter remains
down in the material and will not bottom right for
beginning the next stage. For open paths to be
milled with stages, you can also allow path zig-zags to gain time: once the
cutter is at the end point, it plunges down to the next stage for returning
backwards, etc. In the bottom frame, for closed paths, which is rather common
when cutting, you can choose to make plunges in continuous helix slope, so
that the tool never plunges vertically in the material. In this case, it just goes
down touching the workpiece top surface and then starts feeding while moving
down gradually, the coordinate of every stage being fetched when it passes
again at the start point. Once the final
depth coordinate is reached, it makes a
last loop at constant Z for finishing the
job and then lifts up. That final bottom
right can also be done itself along a slope, the feeding direction remaining
unchanged here.

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 Moving the axes

We have nearly finished reviewing the machining parameters and all that is
left to do is say a short prayer before experimenting with your fragile cutters
on a somewhat more robust workpiece. Before becoming an expert in setting
these parameters, it is inevitable that you will suffer a few cold sweats and
broken cutters. Do not forget that you can either run a simulation, or perform a
dummy run without the workpiece in place so that you can see the path the
tool will take and gain an understanding of the complete machining process.
Now move on to set the origin by clicking on the "Workpiece origin" tab or by
pressing the key.

You will have no doubt noticed that the top right section of this window is
for manually moving the axes of the machine. The Z and A (rotary axis)
buttons may or may not be active, depending on the number of axes fitted to
your machine.

After initialising the CNC and performing a reset of the axes to check the
machine zero, you can use the jog buttons. Actually there are three possible
ways of moving the axes, by using the appropriate buttons on the screen.

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There are several motion possibilities: clicking the displayed buttons with the
mouse, pressing the corresponding arrows on the keyboard, tilting the joystick,
turning a special handwheel, or special inputs for manual control. The
movement can be continuous or a fixed distance but in either case it is
immediately interrupted if the button, key, joystick or handwheel is released.

When using the keyboard, the X and Y axes can be moved, either along the
axes or diagonally, by using the numeric keypad or cursor arrows. The Z axis
is controlled with the and keys on the numeric keypad. When the Caps
key is pressed simultaneously, these keys and move the A axis.
When is pressed, the B axis is moved, if it exists.

Without wishing to sound too obsessive, it is difficult not to expound the

virtues of a joystick, or a gamepad, as a practical means of controlling the
movements of a machine. Its more or less long cable allows you to leave the
computer and move closer to the machine. This makes it much easier to
approach the workpiece origin points without breaking cutters. Using a
joystick is simple, just incline the stick along an axis or diagonal and the
machine will move in that direction until you return the stick to the central
position. With the default configuration – but you can change it according to
your needs – if you press and hold button #1 (the fire button), pushing the
stick forward or pulling it back will move the Z axis up or down, the opposite
of an aircraft (except if flying on its back). If you press button #2, all
movement X, Y or Z will be made at a reduced speed. Of course both buttons
can be pressed simultaneously to combine their functions.

Another interesting interface is the incremental handwheel for making a

fine microstep approach, very practical for positioning to the contact. The
settings of these interfaces are described in the chapter "Machine parameters"
a bit later on.

Back to axis motion, now let us look at the radio buttons, which set the
movement distance. The default setting is continuous which results in an
axis moving as long as the button remains depressed, though it will obviously
stop when it gets to the end of its journey. Unless your machine parameters are
incorrect, the halt should be soft and gently decelerated. An alternative and
frequently easier way of finding the reference point is to move in predefined
steps for which Galaad provides the necessary features. These buttons limit the
movement to the distance selected, for example if you specify a distance of
1 mm then this distance will not be exceeded (in each step). If you release the

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button before the distance is reached then the motion will stop
immediately at its current position, not the target position. So you can
move the Z axis down, by say 10 mm, without fear of breaking the tool and
having to constantly monitor the distance, even if you had less than 10 mm
clearance between the tool and the workpiece. Of course the axes are also
stopped in this mode before brutalising their end-stoppers.

For diagonal movements, the distance specified refers to the distance that
each axis will move and not the length of the resulting path. For example, if a
distance of 10 mm is specified and a diagonal move is made in the X and Y
axes then the length of the actual path will be about 14.142 mm if Pythagoras
was right. He certainly was.

Keeping a button pressed loops the incremental movement after a short

pause. This loop is settable in machine parameters, once again see later on.

The speed at which manual movements take place is set by the little sliders
situated on the left hand side of the window; the range being dependant on the
CNC in use. When this window opens, the sliders are set at the default values
that have been defined in the machine settings, at the bottom of the "Speeds"
page. For incremental movements step-by-step, speed is fixed to 1 mm/s
unless the cursor speed is lesser, in which case it applies. A double-click on
the speed value, right hand end of the cursor, lets you enter a numerical
speed.

You will remember that, if required, it is possible to click directly on the

axis position LED display at the bottom, and access a dialogue box to input a
position directly from the keyboard. In addition there are hidden commands,
namely a double-click in the preview area which sends the axes to the
corresponding X and Y position, and the (backspace) key which goes
back to the last position. Motion speeds are those for manual sliders.

You now know all the ways of driving the machine manually.

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 Defining the workpiece origin

You have already seen the ins and outs of setting the workpiece origin in
Galaad. Without going into the details of this, remember that the software
needs to know where to find the workpiece that it has to machine and
consequently asks where to find the reference point and where the workpiece
is situated in relation to it. The coordinates of this point are given in 2, 3 or 4
axes depending on your machine and the type of work you are doing. They are
displayed at the top of the workpiece origin frame.

If you know in advance the exact position of the origin, you can click on
one of these text boxes and obtain a dialogue box to enter the values
directly.

Important: it is not necessary to actually locate the cutter at the origin

point to confirm it. The physical position of the axes and the position of the
workpiece origin are totally independent, although several buttons serve as a
bridge between the two. Certainly, you may need to move the axes initially to
find where the workpiece origin is situated, but once it has been established
and confirmed to Galaad, you can move the axes without the slightest effect on
this origin. On the other hand, you may indicate a workpiece origin point
without having to locate the tool there, provided that you are absolutely sure
about these coordinates or had memorised it.

Remember that the classic way of finding this datum is to manually drive
the Z axis until it is over the workpiece then bring it down until the tip of the
cutter is skimming the upper surface of the workpiece, or alternatively, the
machine flatbed (or whatever the workpiece is on). This is best performed near
to the centre of the work. Once this has been done as accurately as possible,
and do not forget that the mouse wheel can make fine incremental
movements, you can click on the green button marked "Z - ok". The current
position will then be transferred to the textbox for the Z workpiece origin. Do
not forget to indicate whether this refers to the upper or lower surface of the
work, using the combo box provided just below the green buttons. If you have
approached and validated the workpiece top surface but left the position
combo to "Lower surface", the tool cycle will be made in the air, the
workpiece being just scratched by cutting paths if any. Well, it is wrong but

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without consequence. Conversely, if you have approached the machine bed

and validated "Upper surface", then there is a big risk of damage since Galaad
will believe that the workpiece top surface is much lower than it actually is.
The tool will plunge straight to the flatbed and even deeper, the spindle noise
trying in vain to drown out your swear-words.

Now, raise the Z axis, so that it is clear of the work and any obstacles so
other approaching movements are not scratching the workpiece or the machine
bed. By default, this is automatic: an option for lifting up the axis when
pressing "Z-ok" is available in machine parameters, "Advanced" page. You
can set the X and Y values in a similar way with green buttons. XY
coordinates of the workpiece origin are updated.

First, we are interested in the combo box that sets the location on
workpiece of the origin point. There are no connections between the
drawing origin, the machine zero and the workpiece origin, these three
references are absolutely independent. Conventionally, the drawing XY origin
is located at the southwest corner of the drawing board, but the machine zero
point could very well be at another corner. The workpiece origin can be
anywhere on the workpiece but Galaad needs to know where to find the
work in relation to this point. Consequently the combo box allows you to place
the origin in any of the four corners, in the centre of the four sides, in the
centre of the workpiece or at a reference point within the drawing, for example
a selected point or a fixed cross, red or blue. When you change the reference
point, which appears as a small blue marker, the preview window shows the
position of the workpiece in relation to it.

You do not have to determine the X and Y position with reference to the
centre of the cutter. You can just as well work from the edge of the tool and
Galaad will correct the position, based on the radius of the cutter. It goes
without saying that if you are using a conical or hemispherical tool then the
correction will be based on the maximum diameter. This option is not
available if you use the centre of the workpiece instead of the edge or a corner
as the reference point because Galaad will not know in which direction to
make the correction. Note that changing the method (tool edge or centre) is not
taken into account after you have clicked on the green buttons: if you confirm
a position and then change the method of defining, it is necessary to reconfirm
the position.

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Possibly, in fact probably, you will have fitted a reference corner to your
machine, comprising two stopper bars accurately mounted along the X and Y
axes of the machine, forming a corner at the northwest or southwest of your
bed. The position of the resulting corner will never change whatever the
workpiece is fitted into it, consequently there is no point in measuring it each
time, though it may be worth checking it occasionally. The Z value may have
to be determined each time, as it will vary with the thickness of the workpiece
(already taken into account) and the length of the cutter. Beware that these
stopper bars must be perfectly parallel to the X and Y axes, the best being
moreover to give them two strokes of a flat-end cutter driven in manual mode
on their whole length so they go straight.

The blue button lets you define a double origin point if

your workpiece is not perfectly Cartesian when fixed on the machine bed, for
example if resuming a machining process. A typical case is the printed circuit
with a side already engraved and drilled, that must be reversed for engraving
the other side. You can legitimately worry about the accuracy of the pad
positions around already drilled holes, especially if the card was cut a bit
roughly. Here you just have to plot a
second reference, for example a drill far
from the origin point, and click on that
button. The machining paths are going
to rotate so they perfectly match the
origin point, which is the centre of
rotation, and the secondary reference.
You must first point out and validate the primary origin to get this blue
button enabled.

It is useful to actually go to an origin point to check that it is correct. To do

this simply click on the "Drive to" button and confirm the values in the
dialogue box that appears. This dialogue box allows you to reduce the Z axis
movement rather than actually make contact with the workpiece. The
movement and the associated limitation do not have an effect on the origin
itself. Just in case, remember that you can stop a motion with the
bar before it turns into a nightmare for the tool.

If you have several possible reference points, you can save the settings
until they are needed again. When an origin has been determined and
confirmed, simply click on the "Memorise" button and supply a name to refer

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to it. To use a previously stored position click on the "Recall" button and
select it using the name you gave it. Galaad also displays the 5 last workpiece
origins used with their dates and hours, that you can retrieve directly.

In the top left of the main driving window, above the speed sliders, there
are four command buttons relating to functions specific to the machine.
These buttons can also be accessed from the keyboard using F5 and following
keys, unless you have reassigned these keys (see later on, in machine
parameters, how to programme an external keyboard). We are now going to
explore these commands.

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Machining options

The first of these command buttons gives you access to a few

advanced options for the machining process, in a dialogue box.
Here you can start a delayed cycle, like a washing machine, and even shut-off
the PC after the cycle has ended. This is good for the planet. If the numerical
controller allows it, you can also
upload the whole machining cycle into
its local memory. In this case machin-
ing will not be started immediately, but
stored in the local memory for later use
without the supervision of Galaad. You
will have to press the "Start" button on
the machine anytime you want the
process to be completed. Since this
process is completely local, the PC can
then be switched off.

It is possible to perform the

machining task repetitively at the same
location. This is for a production run of the same drawing and allows you to
set a delay between every cycle. You can decide if the spindle should be left
running and if a homing reset is required before starting a new workpiece so
the machine zero is checked. Ensure that you allow enough time to load the
new workpieces and remove your hands, unless you want a harsh manicure. If
your drawing contains auto-incremented texts, then the starting text will have
to be set before launching the process, and its content will be incremented at
every new cycle. Another type of repetition available here is the serial
machining, which produces multiple copies of the same workpiece laid out by
the machine where the margin defines the distance between the edges of
adjacent boards and that the small preview helps you visualise how the results
will be laid out. Auto-incremented texts are managed likewise.

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Resetting the axes

The next command button triggers a reset of the axes on the

machine zero point, if it exists. Under that click, the dialogue box
lets you decide to choose the axes that should be reset. The operation resets
the position counters of the numerical controller.
Since limit switches are fixed, the corresponding
position does not vary. It is the mechanical reference
for having absolute coordinates. Galaad supposes that
these contacts are located at the end of linear axes, and
preferably at the top for the Z axis. So it is not possible
to have coordinates varying from negative to positive
or reciprocally by going beyond that zero point.
Furthermore, since Galaad knows the length of each
axis, it applies strict stoppers at XY opposite ends,
which cannot be trespassed (also on Z axis, but the presence of the tool under
the spindle reduces a lot the interest of a software stopper). For rotary axes,
either there is an angular sensor (inductive or with a cam), or there are no
sensors but you can nevertheless reset the machine zero for these axes A and B
on the current position. Rotary axes can obviously have negative and positive
coordinates, the angular zero point being passable.

In fact, Galaad uses two working modes for driving a machine: floating
coordinates or absolute coordinates. The floating coordinate system is the
simplest. You just have to jog the axes to the workpiece origin point which
will become the unique reference point. Galaad resets to 0 the axis counters at
the position of the validated workpiece origin. But a major drawback of this
mode is that Galaad never knows where axes are located in the machine
workspace, and therefore cannot check if machining paths are indeed all
contained in that space. Consequently, the operator must make sure that the
complete tool cycle is possible from that point without bumping any axis
stroke limits.

On the other hand, working in absolute coordinates offers several advan-

tages for a classical milling job. First, having an absolute reference allows
using and reusing fixed positions, the most important one being the workpiece
origin of the last process made. If stopper bars have been mounted on the
machine bed for fixing a reference corner, then it is no longer necessary to
reset the workpiece origin at every new process, and you waste little time

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jogging axes manually. It is the same for the Z axis as long as the tool remains
unchanged.

But, for managing absolute coordinates, it is necessary to have a function

for resetting the axes on their zero points. The whole coordinate system is
based on the reliability and the repeatability of this reset. In the same manner,
if the machine has drifted for whatever reasons, a reset becomes mandatory.
And obviously, if the numerical controller has been switched off, the current
position is forgotten. When opening the dialogue with the machine, Galaad
reads the position counters. If the controller says that all axes are at zero, then
the software cannot know whether they actually are, or if this is because the
machine has just been switched on and therefore all counters are set to zero
though the axes can be anywhere for their part. In this case, Galaad automati-
cally launches a mechanical reset. If the machine was already at its zero point,
then it does not take much time. To avoid triggering a reset of axes at every
new dialogue, the best is to fix an end of cycle parking position slightly before
the limit switches, for example X=1 / Y=1 / Z=1 mm so the axes are parked
near but not at the zero point. During the next initialising procedure, Galaad
will read this position and will conclude that there is no need to reset the axes.
But you can also trigger that reset at several moments, by setting the appropri-
ate options in the machine parameters, "Numerical controller" page.

The sequence for resetting an axis is as follows:

1- If the sensor is released, the axis runs towards its direction at rapid speed.
2- As soon as the sensor is triggered, the axis initiates a braking ramp.
3- The axis moves backwards at slow speed.
4- As soon as the sensor is released, the axis stops without braking.
5- Eventually, a little offset margin is added.
6- The position counter is reset to 0 in the numerical controller.

Possible malfunctions: if an axis runs towards the wrong direction at

normal speed, then it is or should be reversed ("Advanced" page of the
machine parameters). But if it does at slow speed, then it is just moving
backwards, step 3 of the above sequence, and either the end-switch or its
wiring is failing, always triggered, or the polarity of its input is inverted
("Active NO" / "Inactive NC") in the special parameters of the controller
("Controller" page, small button "More" at top right). Corollary of the whole,
if the axis runs towards the correct direction at slow speed, then both problems
are cumulated. Last, if the axis does not stop in its end-switch, then forget all,
it is simply the assigned input number which is incorrect.

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If the dialogue with the machine was interrupted due to an unrecoverable

error, for example an unplugged cable or an emergency stop, then clicking on
that button reinitialises the communication. This avoids losing time closing
and reopening the machining window. In addition, pressing the key when
clicking on that button gives access to machine parameters, which will also
reinitialise the communication.

Managing the inputs/outputs

When in basic manual control, the inputs and outputs are accessible
in the main window and consequently this button is not displayed,
but there is not much room in the workpiece origin window and eventually
you may need to check these inputs/outputs there. Remember that the red
boxes correspond to inputs, digital or analogue (ADC for Analogue-Digital
Converter), which
are read regularly
(twice per second)
and therefore are not
clickable, and the
green boxes corres-
pond to outputs that
you may trigger by
clicking on them.
The analogue outputs (DAC for Digital-Analogue Converter) or PWM outputs
(for Pulse Width Modulation) also remain available for a click and you can
make them vary by clicking inside (or click and move inside).

Galaad reads the outputs (yes, the outputs) when opening the dialogue with
the numerical controller, to know in which state each output is and maintain
the coherence between the screen and the machine. When jogging axes, even
for a workpiece origin, it also reads the inputs after every manual move-
ment, which lets you check if a sensor is working properly, for example a
surface probe or an end switch when you are in "Manual unblock" mode with
no axis limits.

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Spindle on/off

Starting and stopping the spindle is possible in manual mode from

this button. If the rotation speed is not under control from the
software, then each click will alternatively start and stop the motor. In this
case, or even if the spindle start is not automatic, Galaad displays a message
before launching the machining process, to
warn the user that the spindle must be
switched on and set to the given speed.
Otherwise Galaad will open a control
window for setting the rotation. The spindle
controller can be driven through a 0-10 V
DAC output (most common case) or a PWM
signal, multiplexed outputs or an external
control programme or whatever, the window
remains the same.

The speed can be driven from a click on the small buttons that increase or
decrease by 100, 1000, 10000 and 100000 rpm. The mouse wheel does the
same with an increment of 500 rpm. and keys of the numeric keypad
change the speed by 1000 rpm. If key (Caps) is pressed, the variation is
100 rpm. It is also possible to enter directly a speed value with two digits,
pressing one single number being considered a zero followed by the number
after 2 seconds, like a TV remote control. At last, if you have an external
handwheel, that wheel acts like the mouse wheel.

The small buttons "Break-in" and "Heat-up" allow you to make the spindle
turn at low speed, then progressively increase the speed, then maintain the
high speed. The three durations are
programmable in minutes. There are
two different buttons simply because
Galaad will memorise two settings that
you can choose to recall by clicking
either one.

The control for the spindle rotation speed is an open loop, i.e. the
software sends to the machine a command for setting the speed via an
analogue output or its equivalent, but it cannot guarantee that the displayed
speed is actually correct. So you must accurately calibrate the match between
the value displayed in percentage and the actual rotation speed. Furthermore,

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all controllers do not compensate the loss of speed due to the hard work of the
tool in the machined material.

But before trying to set the spindle rotation speed under the control from
the computer, you should start questioning seriously about the real
usefulness of such control. The fact that the software can start and, particu-
larly, can stop the spindle at the end of a cycle, this is normal and even
strongly recommended: thus it becomes possible to launch very long machin-
ing cycles, knowing that the spindle will be switched off once the process has
ended (you can even ask Galaad to switch off the computer itself). The spindle
speed is generally set when starting the process and, even if it is under control,
Galaad displays the dialogue box for setting the speed. Consequently, the
speed setting is manual or semi-manual. Once the automatic process is started,
it is easier to turn a potentiometer than click on digits at the bottom of the
screen. Since many machines have numerical controllers that cannot manage
high priority commands while they are moving the motors along a milling
path, the click effect will be delayed in buffer mode with a local memory.
Obviously, if the potentiometer of the spindle controller is not accessible when
the machine door is closed, then it is a good reason for keeping the control
within reach from a mouse click.

In fact, the only case where the software control for the spindle speed is
necessary, is when the machine integrates an automatic tool changer (see later
on). A machining process calling up several tools will probably require
different rotation speeds. Here, controlling the speed is really essential. If you
do not have an automatic tool changer, then think about not wasting too much
time with a spindle speed control which would just become a nice little gadget
without any practical interest.

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Automatic tool measurement

Your machine may have been fitted with a device for acquiring the
tool length. This device generally looks like a small box topped with
a contact surface that triggers some internal sensor, often a basic mechanical
switch but it can also be something more elaborate such as an inductive sensor.
A controlled lowering of the tool on that sensor then indicates the position of
the tool bottom on the Z axis. In that case, it is no longer necessary to perform
a Z approach when setting the workpiece origin, even if you have changed the
material thickness or the tool length.

To gain a little space on the screen, only the button for measuring
the tool automatically is available from the workpiece origin
window. The tool sensor calibration button, as displayed here, appears only in
the manual control window, i.e. not when preparing a machining cycle. But, if
necessary, you may still access the calibration function from the workpiece
origin window by clicking on the normal measurement button while also
pressing key.

Galaad can manage a fixed sensor and a mobile sensor. A fixed sensor
is generally located at a corner or a border of the machine, and this location
will not change. Furthermore, it can deal with two different calibrations, for
example one for a flat machining process on 3 axes, and the other for a rotary
machining process on 4 axes. Of course, Galaad can use a fixed sensor only
when working in absolute coordinates, meaning that there is a machine zero
point which allows memorising the XY position of the sensor. Using only
floating coordinates (with no limit switches) allows you to use only the mobile
sensor that will be manually laid on the workpiece top surface, under the tool,
every time you need to measure it.

1 - Fixed sensor:

Calibrating a fixed sensor begins with indicating the XY position of the

sensor in the machine workspace. You must bring the tool right above the
sensor, as near to the centre as possible. Lowering Z axis so the tool is close to
the sensor helps positioning optimally. Once the tool is right above the centre
of the sensor, you can click on the calibration button.

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The dialogue box for setting the

tool sensor lets you choose two
possible calibrations for a fixed
device, that can be named (this
name will be displayed when the
automatic measurement function is
called).

Click then on "Validate this

XY position as tool sensor
centre", phase 1 of the setting, then
validate all by clicking on the
button "OK".

At the bottom left of the screen, the preview of the machine workspace
displays a small round blue icon representing the tool sensor.

Galaad must then calibrate the Z offset between the trigger point of the
sensor and the machine bed on which the workpieces normally sit. Bring the
tool back over the bed and make a very precise Z approach of the platform
with the tool tip. Here, accuracy is extremely important: any error at this
moment will interfere with all future tool length measures, until you redo this
calibration process.

Once the tool gently touches the bed, click again on the sensor calibration
button and skip to phase 2 of the procedure, now clicking on the option
"Validate this Z position as touching the machine bed", and click on "OK".
Do not change the sensor type at that moment, otherwise Galaad will mix your
different calibrations.

As soon as you have validated the

phase 2, Galaad wants to measure the
vertical difference between the current
position where the tool touches the
machine bed, and the trigger point of the
sensor.

The tool is going to be lifted up to the top of the Z axis, then moved
laterally to the XY position of the sensor ‒ let us hope that your positioning at
phase 1 was correct ‒ and go down slowly until the sensor is triggered. If you

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see that it does not plunge at the right location, hurry up to the bar
of the keyboard or the emergency stop of the machine if you do not want to
apologise to your priceless tool. Probably the best you can do is a dry test,
pressing directly the sensor before the tool reaches it, so you can make sure
without causing any damage that the sensor is indeed connected and its input
number properly set in the machine parameters. Better still would be to put in
the spindle an old tool or a suitable piece of dowel that does not risk much and
would cause no regrets in case of accident. The accuracy will not be affected
anyway.

We are going to suppose that everything goes well and that the tool stops
before slaughtering the sensor. By the way, please do not switch the spindle on
before measuring the tool, just for seeing what it makes (it makes a crater).
Once the sensor is triggered, the tool brakes for smoothly stopping its plunge,
then lifts up slowly and stops accurately at the trigger point. Then Galaad
requests the position counter of the machine, so it can calculate the offset
between the touch point on the flatbed, that you have set just before, and the
precise trigger point of the sensor. This Z offset will remain memorised until
you perform a new calibration.

If you planned to build the tool sensor yourself, using some push-switch, it
is better to have 2 or 3 mm extra stroke beyond the trigger point so the tool can
perform its braking ramp. Otherwise you must set a slow lowering speed (see
the machine parameters, "Speeds" page) so the tool does not get stuck in a
stopper which would cause an inaccurate measurement and coordinate offsets.
Also, think about using a switch that provides an excellent repeatability, just to
avoid making your sensor a new source of problems that will probably lead
you to blame very unfairly a splendid piece of software. Vandalproof push-
switches with an accuracy of 0.01 mm are easy to find.

Important: if you surface the machine bed because it begins to be too

damaged, the Z position of its top surface is obviously lowered by the
thickness that has been removed when surfacing. Here it is necessary to redo
the Z calibration of the tool sensor which is no more valid. Galaad does not
cancel the calibration when you are performing an automatic surfacing of the
machine bed. It probably should, but it does not and it is up to you to decide.
On the other hand, this changes absolutely nothing for a mobile sensor, since it
has no relations with the machine bed. By the way, try to avoid surfacing the
sensor with the bed. It would probably not appreciate that.

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Equally important: if you have tools with offsets ("Extensions" button of

tool parameters), calibrating the XY position of the fixed sensor must be done
with the tool #1. It is recommended to always use that tool #1 as a reference
and therefore not assign any offsets to it.

2 - Mobile sensor:

Calibrating a mobile sensor is easier. Since the operator puts the sensor
on the workpiece top surface just under the tool, Galaad has only to know
the Z offset between the sensor click and the surface it lays on. So just move
the tool down so it touches any surface, anywhere, the location is not impor-
tant. Once the tool is into contact, open the dialogue box for the tool sensor
calibration.

Select "Mobile sensor" at the

top. Then, in the frame for phase 2,
click on option "Validate this Z
position as touching the machine
bed", no matter if the touched
surface is in fact not the bed: only
the offset between the surface and
the click is of interest. You must
also indicate the sensor height
using an exaggerated value. This
helps Galaad lift up the tool high
enough so you can put the sensor
box under.

As for a fixed sensor, the tool is then

going to be moved down until it triggers the
sensor. The distance between the surface at
bottom and the click point now becomes the Z
calibration offset, used for future automatic
measurements.

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3 - Automatic measurement:

Once the sensor has been positioned and calibrated, you can use the
button for measuring the tool. Galaad will just have to lower the
tool down to the sensor until the trigger point is reached, and add the cali-
brated offset for having a reference point Z. In the case of a fixed sensor, this
position will correspond to the tool touching the machine bed (or any work-
piece support, or the 4th axis) with the same tool, making it possible to
calculate the position of the top surface since the workpiece thickness is
known. With a mobile sensor, this position corresponds directly to the surface
on which the sensor box has been placed. We can suppose that it is the
workpiece top surface.

Measuring the tool on the sensor automatically changes the Z value in

the workpiece origin position. You have nothing to validate or confirm then:
do not click on green button "Z - ok" which would cancel the result of the
measuring operation by validating instead the current position of the Z axis.

If, in addition to the tool sensor, you have fixed stoppers or rulers for
wedging your workpiece always at the same XY corner, then you will not
have to jog axes anymore. When arriving in the workpiece origin set-up
window, just initiate a tool measurement and launch the cycle. Of course this
is valid only for a fixed sensor. By the way, this measurement can be done
automatically, by setting option "Always measure the tool before workpiece
origin" in Galaad advanced workspace functions.

Using the tool sensor requires a few adjustments with Kay module which
cannot know the workpiece thickness since this is not formally indicated in
machining files. But let us not anticipate, we will get back to it in the chapter
dedicated to 3D millings with Kay.

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Workpiece origin from direct electrical contact

It is possible to perform an approach of the workpiece with an

automatic stop when the cutter touches its surface or one of its
lateral sides. Of course, an electrical contact must close between the cutter and
the workpiece, wired to a binary input of the machine. A couple of crocodile
clips will do: one will clamp the spindle chuck or even the spindle
itself it it has a metal body; the other one will be connected to the
workpiece. If that workpiece is not made of a conducting material,
then a trick consists of sticking at the right location a metallised
adhesive tape with a folded edge for clipping. Warning: if the body
of the machine is connected to the 0 V ground and the inputs use a positive
voltage (+5 V, +12 V or +24 V), then it will be necessary to galvanically
isolate the spindle from the rest of the machine, to avoid seeing the numerical
controller emit smoke.

Locate the tool above or beside the workpiece, then click on the button
shown at the top of this page (or press F12). A big dialogue box will pop up:

Here you must set up the input of the numerical controller that corre-
sponds to the electrical contact, and also the polarity which should be "Active
(NO)" since the circuit is presumed normally opened. If you are in doubt about
this input, a short trip to the function "Parameters / Machine / IO test" will do
you the greatest good. The input indicated here remains memorised. If you are
using a thick metallised adhesive tape or even a conducting blade that you
press against the surface to be touched, then also indicate its thickness to be
added to the position measured.

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Three operating modes are available:

1 - Approach on 1 axis: this is the simplest, you just have to

locate the tool somewhere above or beside the workpiece,
then choose a direction of approach on X or Y or Z. As
soon as the dialogue box is validated, the tool moves slowly until
it touches the workpiece, and there stops immediately. The option "Validate as
workpiece origin point" avoids clicking on the green buttons "X/Y/Z - ok". If
the approach is driven for X or Y laterally, then Galaad will automatically
change the location on the workpiece for facing the motion direction and set
the mode to "Tool edge" instead of "Tool centre". If the approach is done for
the Z axis, then the location on workpiece remains unchanged since it is
possible to touch the machine bed as well as the workpiece top surface.

2 - XY origin XY on 2 axes: this lateral approach is done by

positioning the tool under the workpiece top surface, outside
one of its corners, far enough away so the tool can move
along the lateral sides without touching them. Galaad moves
the Y axis quickly northbound or southbound depending on the
chosen corner, so the tool faces a side of the workpiece. Then it moves slowly
along X axis eastbound or westbound until it touches the edge, closing the
electrical circuit that stops the motion. The measured position validates the X
origin. Then the tool moves backwards, returns to its starting position and does
the same operation for the other side, touching the workpiece edge and
validating the Y origin. So, if you stick a metallised adhesive tape on the edge
of the workpiece, of course it must cover both contact zones. The distance
from the corner is extended by twice the tool diameter because the start point
is indeed beyond that corner.

3 - XYZ origin on 3 axes: this is the most complete mode, which

validates the workpiece origin on the all axes. The tool must be
positioned approximately above a corner of the workpiece.
Galaad is going to move it a bit towards the centre where it
will touch the top surface and validate Z, then move up and
go outside the workpiece, get under the top surface and move
slowly until it touches the edge for validating X and Y successively. If you
have to stick a metallised adhesive tape, that will be on the workpiece top and
lateral sides where the tool will perform its approaches. Do not forget to link
them all to the circuit. The distance from the corner sets the lateral touching
positions.

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Pointing the origin with a video camera

Still in the series of commands, this buttons enables or disables the

video camera whose display is embedded in the manual control
window. The option for pointing with a video camera and the few related
functions are settable in the advanced machine parameters that we will see
later on. If you have no webcams in your parameters, then this button does not
appear.

The purpose of the video assistance

is to ease pointing on workpieces where
the XY origin is not in a corner,
rendering the stoppers and any clamp-
ing device useless, for example a
printed circuit board that has been
reversed for engraving the other side,
targeting a drill hole. It can also help
for workpieces on which pointing the
XY origin is difficult for any reasons.

Galaad provides a small video display that overlaps the application

window, including crosshairs. But it may not work with all webcams so you
can also use any external programme that will be indicated in the machine
parameters. The camera must be accurately vertical, parallel to the Z axis
if it moves with the machine. If the alignment is not perfect, then moving the
axis up and down will result in an XY offset of the image centre to the sides
and your pointing will be inaccurate. So, if your webcam has been mounted on
the Z axis, then make sure that its support is stable despite the vibrations, and
that fine tuning its apex is easy enough.

Obviously, the XY offset between the tool centre and the position of the
camera must be calibrated with care. A special function exists in the machine
parameters, "Advanced" page. If a video camera has been set, even if it is not
activated, when you validate the pointing of the workpiece origin, Galaad will
ask you whether you have pointed with the tool
or with the camera, to avoid a harmful confu-
sion. But you can disable this in these webcam
parameters.

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Tool change

Since a milling process can integrate several tools according to the

sequence that is defined in the machining parameters, Galaad can
obviously chain the cycles. If your machine does not have an automatic tool
changer, then the button here is just for sending the axes to the tool change
position and nothing else. Let us remember that this position is settable in the
machining parameters page, not far from here, the small blue button "Tool
change" under the tool sequence table.

Now, if your machine is equipped with

an automatic tool changer, the sequence
of which is programmable (see this in tool
parameters or in machine parameters),
clicking on this button will pop up the
dialogue box for managing the tool
changer.

When a machining cycle has been

abruptly interrupted with the tool left on
the spindle chuck, then this function helps
you bring it back semi-manually to its
position in the rack.

Be careful never to park a tool in a position already occupied, since there

are no tests performed for checking if the position is available. Conversely,
trying to pick a tool in an empty position will have no consequences except
leaving the spindle disappointed.

When opening the workpiece

origin window, Galaad asks you
if a tool may have been left in the
spindle chuck, to avoid a possible
conflict. If the chuck is empty,
the software will grab the first
tool in the sequence before you
can set the workpiece origin (with an eventual measurement of the tool on the
sensor). If a tool was mounted in the chuck and it is the one that is about to
start working, then Galaad goes to the workpiece origin validation. If there is a
tool but not the one needed, Galaad will park it and pick the good one from the

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range. Also, if an external tool, i.e. not belonging to the rack, is present in the
chuck, then Galaad will invite you to remove it before grabbing the good one,
provided that it is a member of the restricted brotherhood of automated tools.

In a machining process that is organised in a smart way, and therefore

driven by Galaad, the automatic tool change requires no operator's action.
Either the tools are all calibrated and their relative Z offsets will be considered,
or they are not and the measurement on the tool sensor is necessary. Obvi-
ously, only a fixed sensor is usable since the mobile sensor remains semi-
manual. So, an automatic tool changer requires a tool sensor for measuring the
lengths and validating the Z origin, as well as a remote control for the spindle
rotation speed. If you are lacking one of these two, then the tool changer will
avoid the operations for removing/mounting the tool from/into the chuck, but
resuming the workpiece origin and tuning the spindle speed before each cycle
will remain manual.

At the end of the last cycle of a process that called several tools, Galaad
stores the last one used back to its position in the automatic changer rack,
unless you have defined this end another way, then sends the axes to their
parking positions. However, and whatever the set-up is, if the process
required only one tool, Galaad will not store it back at the end of the
cycle. This is for easing multiple processes avoiding useless movements to and
from the rack. And it renders more important the dialogue box for checking if
something is present in the spindle chuck before each process.

The set-up and the driving scripts for the tool changes are described in the
chapter "Machine parameters", section "Advanced".

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Semi-manual milling commands

Still in the "Commands" frame at top left of the manual drive or workpiece
origin windows, in a second line, you have access to four buttons that help you
make brief millings in semi-automatic mode, at the current position of the
axes, which consequently supposes that you have first moved the tool
manually to the correct location on the workpiece, including Z axis to the
contact with the surface to be machined. Be aware that, if you are in the
workpiece origin window, these commands do not consider the validated
origin but only the current position of the tool in the machine workspace.
Obviously, the spindle is switched on before milling and switched off after:
"semi-automatic" does not mean "completely manual".

Let us review these commands briefly:

The button "Point" makes a basic drill, at given depth and speed. No
deburring or chip-breaking cycles apply here.

The button "Line" mills a segment with the cutter tool, from the
current position to a target XY position, at given depth and speed.
Plunge speed is also available. This function can be useful for milling X and Y
stopper bars beside the machine bed, to which the workpieces can be clamped,
and make them perfectly aligned on the axes.

The button "Rectangle" uses the same parameters as the button

"Line" but will mill a rectangle rather than its diagonal.

The button "Circle" mills a circle with given diameter, which centre
is defined by the current position.

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VCR-Seek

Hidden at the bottom left of the workpiece origin window, this small and
discreet option is important and even practical for helping you find the
resuming point of an interrupted machining or run a partial machining.
Click on it and launch a normal process (it is also available when simulating).
At the bottom of the machining window, new buttons appear:

We are seeking the path from which the machining process must restart. If
there has been an interruption of the previous cycle and the drawing remains
unchanged, then Galaad suggests a resuming at this memorised path that is
highlighted. Then you just have to validate if it looks correct. The resuming
path is displayed in red, the previous paths in the sequence that will not be
machined are in black, and those that will follow hereafter are in blue. The
cyan buttons allow you to jump to the previous or next path, or 10 or 100
paths backward or ahead for speeding up. Every time, the software moves the
machine to the start point of the highlighted path. This positioning corresponds
to the laser spot or the video camera if any has been configured, otherwise for
the tool itself. The Z axis remains wisely at clearance height. You can also
click directly on a path appearing on the screen to choose it as the resuming
path. It is possible to zoom on the path or return to the main view using the
white button at left hand side.

When the path has been found, then you can validate it at its start point by
clicking on the green button (or stop all by clicking on red button
or on the emergency stop). In this case, the resuming will start at that
entry point with no more questions. But you can also explore inside the path
for finding a more accurate resuming point further than the start point, by
clicking on the yellow button at centre. This will avoid wasting time
redoing long paths, and it is an absolute necessity when cutting with a plasma
torch since it is then not possible to cut again over paths already made. The
bottom of the screen is going to change consequently, with new yellow
buttons:

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Here the expression "VCR-Seek" makes sense, at least for those who can
remember which paleolithic device it refers to. The buttons allow you to move
the tool (or the laser spot or the video camera)
along the path, forward or backward, at slow,
medium or fast speed. These three motion
speeds are available from the white button
at left hand side, and their values
remain memorised.

The yellow button at centre lets you stop the movement along the
path when you think you have found the proper resuming point. Anyway it is
possible to reverse the motion direction to ease the finding. When the machine
has been positioned to the resuming point, you just have to click on the green
button (or press on the keyboard).

If the path has been validated at its start point, then the resuming is
performed directly, with no entry trajectory. But if you have used the VCR
buttons for seeking inside the path, then
you can add an entry segment or arc, to
avoid marking the workpiece
at the resuming point. This is
particularly valid for cutting
works using a plasma torch
where the ignition digs a
much greater hole than the
expected kerf. Here it
becomes much better to fix
the resuming point at a small
distance away from the path. The screen displays the entry
segment or arc as it will be machined. Now, in classical milling, a last dialogue
box lets you indicate at which depth stage the resuming must be done, to avoid
long useless paths before reaching the material.

Once you have validated the resuming point, the VCR-Seek remains
enabled. If you were just seeking one single resuming point, then you can
disable it while it machines the path. The rest of the process will be managed
normally.

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Manual jogging

Besides the workpiece origin for a machining process with a tool, Galaad
also offers the possibility to drive the numerical controller manually, just for
the fun or for checking that it indeed works, we never know. Just call function
"Machining / Manual control" for finding the main control items for the
machine, all gathered in a new window.

We are not going to spend much time on control objects that you already
know. Let us just point out that you can check the statuses of the inputs by
clicking on the red button "Peek", or on the button "Loop" which starts a
cyclic read of the inputs, allowing you to monitor any status changes. You can
trigger the outputs by clicking on green boxes. Caution! One of them may start
the spindle or any dangerous peripheral device. You can also set the value of
the DAC (analogue) and PWM outputs by clicking in their green boxes at a
given location, or clicking and moving the mouse with the button pressed.

Note that the function "Machining / Manual unblock" gives access to an

even freer manual control, because the machine does not reset its axes on the
zero point and therefore does not manage any limits on any side of the axes.

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This function has several possible uses: after a machining process that ended
abnormally, you may need to move the machine avoiding an automatic axis
reset; you may also check the limit switches or simply need to know which
one is connected to which input with which polarity. Just move towards the
limit switch, going slowly in the final phase (right mouse button, you remem-
ber), sink the switch and see on the screen which input red box has changed,
take its number and note if it is on ("Enabled - NO" polarity) or off ("Disabled
- NC" polarity) when the contact is triggered. Now you have only to transfer
these values into the machine parameters, "Numerical controller" page and
small button "More…" at top right).

Test of the inputs/outputs

A bit in the same way as the manual unblocking, if you need to check the
connection of switches, relays and other electric devices connected to the
machine, the command "Parameters / Machine / I-O test" lets you open a
dialogue with the machine in a restricted mode, with no motion commands nor
position feedback. Functions are identical to the control frame of the manual
drive, with a cyclic read of inputs (twice per second) which loops immediately
after initialisation.

For testing the connection and the polarity of a contact that is opened or
closed, for example a limit switch, a tool sensor or a safety device, you just
have to trigger it and read on the screen which red box has changed. The
number corresponds to the input seen from Galaad. The polarity is given as
"enabled" if the box turns to light red when the switch is triggered and returns
to dark red when the switch is released; it is "disabled" if the box is by default

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light red and turns to dark red when the switch is triggered. The ADC box
displays the status of the analogue input, if any.

As for the manual control, you can click on green boxes that correspond to
outputs, to checkout how your peripheral devices work and if they are indeed
under control from Galaad.

Managing collisions with obstacles

You may define, either on the machine flatbed (absolute position) or

on the workpiece itself (relative position), obstacles that the tool
will avoid when it is moved. These obstacles have a very basic shape,
rectangle or circle, but they can be combined for representing more complex
zones. For each obstacle, you must indicate a Z-height. When moving
above the workpiece, the spindle will lift up high enough to avoid a collision.
You may draw the machine bed directly within Galaad (the dimensions of the
drawing must correspond to the strokes of the axes X & Y) with rectangles
and circles, then select them and call "Machining / Obstacles / On the ma-
chine". You can also, when jogging the axes manually, bring the tool above
the centre of an obstacle and click on the button here for memorising it.

If some fixed obstacles have already been defined, displayed in orange on

the view of the machine bed, then you may click on them with the right
mouse button for relocating them, or use the pop-up menu under the right-
click for editing or deleting them. On the other hand, the obstacles that are
related to the workpiece can be edited only in the drawing (accessible from a
right-click).

In all cases, the option "Physical obstacles to avoid" must be enabled in the
machine parameters, "Advanced" page.

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———————
8
01000

APPLICATION WORKSPACE

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GALAAD 3 —————————————————————————————

General settings

This chapter is concerned with the parameters that control the working
environment of Galaad, namely how the information is presented on your
screen, but excluding the display functions discussed earlier. Use the menu
command "Parameters / Workspace" to access these features, the first of which
covers the basic application settings.

The underlying dialogue box can be extended via the button "Advanced"
for accessing all options. And they are many.

At top left, the frame "Units" lets you indicate your length and speed
units. The units for the length are passive and do not actually affect anything,
only serving to provide the symbol to be displayed after the numerical value.
On the other hand, the speed changes all values that have been used until now.
The software stores the speeds as integers that represent mm/minute. If you
wish to use another unit, then it is converted before displaying or after entering
a given speed. If you change the speed unit, the internal encoding remains in
mm/min and does not vary. Only the display does.

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In the frame "Miscellaneous", just below, you can define the maximum
number of recent files that will be shown at bottom of the "File" menu (10
maximum), and the size of the undo/redo stack, i.e. the maximum
number of successive drawing operations that can be cancelled. The
limit is 50, but a smaller number will speed up certain operations and
conserve memory usage. In fact, it is very unusual to have to back-
track so far, but you may seek a better balance point between processing speed
and undo comfort. If your workstation is recent and fast, it is probably better
to use the maximum value. The default is 10, which looks reasonable.

The drawing timer pause controls the duty cycle of this counter which is
displayed at the bottom left of the main drawing window. When you stop
drawing, the timer automatically stops after
this preset delay to avoid counting your
lunch break. The time is set in minutes, but
you choose how long. The timer itself
remains under the control of "File / Elapsed
time".

Displaying the complete file names adds to each file name the disk path
to it for the title bar and the recent files. Displaying the info tip about the
green selection corresponds to the small help tip when the mouse flies over an
object that it highlights in green, to check its geometry, tool number, depth and
feedrate without requiring further selection. Displaying crosses at the arc
centres adds a grey cross indicating the centre of a circle or an arc, with sub-
parameters for that option. Inverting the mouse wheel direction for zooming
lets you change the zoom in/out function using the wheel, to match your habits
with other software applications almost as good as Galaad. The option for
selecting only the pre-highlighted objects forbids the selection in the simple
Cartesian zone of an object: the mouse must be located on the actual path, and
therefore highlighted in green (remembering that a small menu pops up if there
are several possibilities, even if one single object is highlighted). Freezing the
selection frame if it is out of the zoom window blocks any movement of the
selected objects if the selection frame is completely out of the view, to avoid
unwanted repositionings. If you wish to keep the workspace environment
when exiting, which is the default after installing, then you do not need to
save your current drawing when you quit Galaad: when restarting the soft-
ware, you find again the same drawing in the same state. The option for
saving the selections within the GAL files, when enabled, keeps the selection
frame and the selected segments or points in the saved file. Opening the

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machining process with the workpiece origin automatically skips the page
of machining parameters (of course you may return to it), except if there are
several tools to be sequenced in the calling table or if an unusual option is
enabled, for example a fixed value or an adjusted scale. Suggesting to set the
XY origin on the red cross pops up a message asking you if you want to have
that red cross used as the datum point for the workpiece origin, supposing that
there is a red cross in the drawing. At last, the automatic zoom on the object
to be machined magnifies each path when the tool is about to mill it. It is a
simple gadget, we can admit that, since it is too late to stop the process when
the display shows something wrong. Unfortunately, there are no "Undo"
functions for a machined workpiece. There is room for invention here. On the
other hand, the function "Redo" is well-known to machining beginners.

You can choose to place the main plan view in any of the four positions of
the quadruple view. When you change its position, the view on the main
screen, remaining visible behind the dialogue box, is immediately changed so
that you can see the result. At the same time you can also change the
orientation of the lateral views, namely the position of the upper surfaces that
correspond to Zo.

When this dialogue box is extended to the right hand side with the button
"Advanced >>>", then the top frame sets the two system sound functions that
are called to produce a warning "zap" when you make an error – which of
course occurs rarely – or a confirmatory "OK" when a long operation finishes
without a problem, which does happen sometimes. The choice corresponds to
the event sounds set in the Windows Control Panel.

Closely related to your Windows environment, drawing texts with

TrueType fonts uses some graphical parameters. First, the general
density of the automatic hatching for filling up character surfaces,
which calls Galaad hatching function, and second, the basic
resolution of Quadra-Spline curves that are part of the TrueType
format. If a text is selected when these parameters are modified, it
will be rebuilt according to the new settings. Note that these
values have no relations with the few Galaad fonts that are pre-
hatched and do not use Quadra-Splines.

Mainly designed for the screen or the printer, TrueType or OpenType fonts
that are used by Windows cannot encode simple lines without thickness. For
example, a basic capital "I" sans-serif will be represented as a rectangle, or two

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zigzag lines if the thickness is null, but never with one single vector. The
starting and ending points of a TrueType path always match, defining a closed
contour. If the font was built without thickness, i.e. null weight, then Galaad
searches and deletes overlapping lines for each drawn character, to build up
an optimal path with single vectors and no useless zigzags.

Clipboard scales apply to drawing entities that transit from and to

Windows clipboard for exchange with other software applications. Objects
that are copied and pasted from Galaad to Galaad without
closing the application are not concerned. They even carry more
properties such as the tool, depth, feedrate, etc. that cannot get through the
standard clipboard.

The lower frame "Options" provides a long list of settings. The seek a
software update defines after how long Galaad automatically searches on its
own website for a more recent update and, if there is one, will offer to
download it. The big dialogue boxes for the file selections give access to all
folders on the left hand margin, not just a drop-down list.

Direct snapping to the neighbouring points are these small red points
that appear near the cursor when you are drawing and that can catch the
coordinate when pressing the bar on the keyboard or
clicking the mouse central button, as you already know (if
not, then please see the section "Learning to draw" a few
pages back). You can disable them or limit direct snapping
to the active layer only if your drawings are heavily loaded
and the objects in the background layers are not of interest for drawing.
Limiting rapid data palettes to the active layer only decides if the objects
that are present in the background layers must or must not appear in the quick
data palettes at the top of the screen. If enabled, your palette may become
saturated by all quotes. On the other hand, this helps you quickly assign to an
object the same value as another object in an alternate layer. The Shift
key for transferring between layers lets you duplicate from one layer to
another one using the rapid palette. Allowing the automatic zoom shift slides
the visual window when you are moving a selection and the mouse comes
close to the border of the view. If you activate the touch-screen mode, in
which case the mouse cannot fly over a parent icon, then underlying icons
appear when you click ‒ or touch ‒ the parent icon, its own function being
called up only if you re-click on it. Displaying the stack of the last icons
used displays at the left hand side of the screen the last drawing icons that

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have been clicked, below the normal icons. Calculating the closed B-Splines
for smoothing changes the calculation mode for the Beta-Splines when their
path is closed. Normally, the ends are the only points
that the path actually match, other points being
attractors. But if the path is closed, then we can
considerate that the starting/ending point is also a
simple attractor and, in this case, there will be no sharp angle.

Concerning functions that are related to the machining process, you can
decide to always measure the tool when arriving at the workpiece origin
window, which avoids clicking on the button. This automatic measurement
can also be made afterwards, at the process start, namely when clicking on
the big yellow button. If you have a variable support for your workpieces, then
the tool measurement on a fixed sensor must be corrected after asking for the
thickness of the machine bed which can be variable. Then, when arriving at
the workpiece origin window, Galaad will ask which bed is under the work-
piece, or rather its thickness, for
correcting the measured Zo origin.
Finally, asking for the origin offset on
"Z-ok" will pop up a small dialogue
box when you click on the green button
for validating the Z position of the
workpiece origin, in which you may clarify that the origin point is actually not
where the tool is, but lower in the workpiece material, at a coordinate that
cannot be reached.

Important: in a dialogue box or even a complete parameter window, when

the text of a checkbox ends with suspension dots, this indicates that a sub-
dialogue box will pop up like a furuncle if you enable that option, and only in
that case. This means that when you disable the checkbox, nothing happens.
To access this sub-dialogue box when the option is already enabled, either you
click twice on it, once for disabling and once again for re-enabling, which will
open the underlying dialogue box, or you press key when clicking. In this
case, the option is not disabled and the dialogue box appears.

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Restrictions for training purposes

Galaad gives the possibility to modify its own appearance for the user's
eyes. The software is richly supplied with icons and functions, but this wealth
can become layer of complexity so you have the means for depleting it. By
default, Galaad offers its full palette of flavours without restrictions, but
suggests that you trim it according to the needs of your educational project.
Who can do the most can do the least. The purpose is nothing less than
suppress the functions that you consider useless, and impose limits to the
user. This aims to slim your software, at least in its appearance.

The trimming is done through the command "Parameters / Workspace /

Restrictions / Change". As its name suggests, the game will consist of
eliminating menu functions and drawing icons. Three restriction levels are
pre-defined, that you may pick directly without having to set them up. These
levels correspond to files "Level-N.cus" that you can modify as you wish (see
later on). You can also open a restriction set that has been previously defined.
This gives you access to a set-up window for this workspace:

When this command is called, Galaad disappears and leaves the unoccu-
pied room for a new window where you can select all features. This window
uses the same menus and the same drawing icons as the central application,
plus a few buttons that give access to complementary settings. You can save a

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set of restrictions from the definition window, using "Save" button, and
"Open" for loading it back.

For suppressing the access to a command in a

menu, you just have to open the menu and tick-off
the line by clicking on it. For example, if you want
to delete the line "New folder" of the "File" menu,
click on it to remove its checkmark. When you will
return to the normal drawing window, that line will
have disappeared in the menu.

If all commands of a cascaded submenu have

been suppressed, Galaad itself will then suppress the
corresponding parent line in the previous menu, to
avoid displaying an empty submenu. Will remain
visible only the menu lines headed by a check-
mark or which open a non-empty cascaded sub-
menu, one single line being then sufficient for
keeping the parent line.

Neither is it complicated for drawing icons. The window displays two

bunk matrixes. When you click on a parent icon at the left hand margin, then
all available icons of the series are displayed in the top matrix, at their default
location. Just drag and drop the icons of interest down to the bottom
matrix, choosing for each one the location that is right for you. Conversely,
drag up an icon from the bottom matrix to the top one for removing it from
your list.

Galaad abhors emptiness. Consequently, it demands that you do not leave

any boxes blank in your personal matrix. The number of lines and columns
must be homogeneous, with no blank icons. Anyway the software quickly
finds them and marks them with an infamous red box. Clicking another parent
icon at the left hand side is sufficient for validating a matrix. But, as long as
you have left a red empty box, you cannot validate. You must arrange your
icons for obtaining a compact set. It is possible to move the icons in the
bottom matrix for changing the arrangement.

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The yellow button for disk access opens a

dialogue box that helps you manage the
authorisations for accessing all disks available
from the user's workstation. In addition to the
local disk drives, a networked computer can
eventually read and write from/to the distant
disk of the main workstation. If you disable
these checkboxes, then you forbid the access to
other directories and restrict access for read,
write and overwrite operations.

The green button for parameter

access calls up the dialogue box that
decides whether the user is allowed to
modify some sensitive technical settings.
The few restricted dialogue boxes that
have been defined substitute, for the
most used, light versions. So they limit
the access to corresponding data and
help towards a progressive understanding. Only some complex dialogue boxes
have their equivalents restricted. The password for accessing the restrictions
allows you to forbid any change in the given restrictions, except for the user
who has the password. This password is "galaad" when installing (case not
sensitive). Do not shout it from the rooftops, but if you lose your password,
then you can recover it from the file PASSWORD.TXT in Galaad installation
directory.

The blue button for maximum

values opens the dialogue box which
will let you fix some limits to the
numerical data that the user is allowed
to enter. These values concern the
board size and the machining data
(depth and feedrate) for the objects
drawn, plus a maximum stopper for the
workpiece Z origin.

Do not forget that you may forbid the use of another tool than the current
one, with the dialogue box which is related to the green button (see above).

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Now let us summarise the restrictions that you can impose on Galaad from
this parameter window:

- Suppression of lines deemed unnecessary in menus. The surviving lines

that will remain displayed are headed with a checkmark; the lines that open
cascaded submenus disappear if the submenu has been emptied.

- Set-up of drawing icons. For each series of icons, the bottom matrix
shows those that will be displayed and their layout.

- Disk access authorisations. The operations of files are regulated for the
local disk drive and for eventual networked disks.

- Permission for modifying parameters. The access to machining technical

data is subject to a set of authorisations.

- Guidance for numerical dimensions. Limits are imposed to the data that
the user may enter.

With these restrictions, you will see that it is possible to build up a very
undressed Galaad, and return to a normal display without losing your customi-
sations by calling the command "Parameter / Workspace / Ignore restric-
tions" (this command is password-protected, if any). Ignoring the restrictions
rebuilds a full-power Galaad.

You can also save your restrictions

using commands "Parameters / Save
parameters" and "Load parameters"; or
transmit them from one workstation to
another one using "Parameters / Quick
transfer / Send parameters" and "Receive
parameters". Then a small dialogue box
helps you filter the set of parameters you
have received.

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9
01001

USING A NETWORK

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GALAAD 3 —————————————————————————————

Sharing disks and folders

One of the important functions in Galaad concerns the interconnection of

several workstations and the means of exchanging drawings and parameters.
The professional user will find it advantageous to reserve one computer for
design work and dedicate another specifically to the machining work. In an
educational environment, it is useful to be able to prepare the working
environment for all students, including the drawing and organisation of their
files, from one single workstation.

Logistically, it is necessary for all the computers to be

connected to a local area network and able to run
Windows. This network does not need a
client / server architecture or any particular hierarchy.
as Galaad defines its own hierarchy between the master
workstation and all its slave units.

Let us consider the following network, with a master machine M, and

several slave units S1, S2, S3, etc. Galaad is installed on M, in the folder
C:\GALAAD, and also on all the S slave units in folder C:\GALAAD. As well as
accessing its local hard disk C:, each slave unit S can also access the hard disk
C: on the master computer M, which will be remapped to another drive on the
slave units, for example X:. In this way, Galaad running in the folder
C:\GALAAD on workstation S1 sees the copy of Galaad installed on the master
machine as being in folder X:\GALAAD. Thereafter, the slave unit can load its
parameters, and current drawing, from the master machine M instead of taking
them from its local hard disk. This gives the user of the master machine M the
ability to control the configuration of each slave machine S. What is more, the
slave units S can store their work centrally on the master machine instead of
on their local hard drives.

To enable data to be exchanged between workstations, each

slave unit must be able to access the hard disk on the master
computer, or at least the folder where Galaad is installed. It is
assumed that your network is already configured and that disk
sharing has been enabled. If not, see the file sharing parameters in Windows
Control Panel.

However, the point is not to have a close look at your network, but simply
to show the principle that part of the hard disk on the master computer has to

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be accessible to each slave unit. If this is not the case then you should consult
your network administrator. Note that it is not necessary for the master
workstation to be able to access the hard disks on the slave machines, as
Galaad does not need this.

Main workstation

To use Galaad on a network, it is necessary to define one workstation as

the master and all others as slaves to it. The slave units will copy the working
environment on the master computer by taking their parameters from it, and
possibly save their drawings back to it. It is normal for the CNC to be
connected to the master machine but this is not mandatory. You have probably
only got one dongle for the whole work group. The dongle must be plugged
into the master computer. By loading their parameters from across the
network the slave units will see the licence and will validate it locally.

If your network only comprises two computers, one for design work and
one for the machining process, plug the dongle into the machining computer
and consider this to be the master, the drawing computer does not need a
licence except for exporting files. It is better for this master computer to be
running when you start Galaad on the secondary machine, so that it will be
able to access the dongle and allow exports.

The master workstation acts as the model that the slave units will copy
when Galaad is started on them, and consequently is the same as a stand-alone
installation. It operates the same whether or not a network is present. The slave
units collect their parameters from the master machine; it does not send them
to the slave units one by one. There are no messages exchanged between
computers through the network, but only an access to the main computer
from the secondary computers.

Configuring a master installation is done in the simplest way possible. In

the network parameters, simply indicate that this computer is a master or
standalone, that is it.

The user of a master installation of Galaad ‒ generally the teacher ‒ opens

the software and configures the working environment to suit themselves, or

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perhaps loads a profile, saved somewhere. He or she can also open a default
drawing, that secondary workstations will get when starting their own Galaad.
He/She then uses the "Parameters / Network / Upgrade workspace" command
to save the changes to disk. The users of the slave units ‒ usually the
students ‒ then start Galaad, which having copied the parameters from the
master computer, display the default drawing.

Secondary workstations

You have seen that the students need to load their environment parameters
from the copy of Galaad installed on the teacher's workstation. This requires
them to have access to the hard disk on the teacher's machine via the local area
network. For a simpler installation, with functions limited to down-loading the
master parameters, you can restrict access to the Galaad folder on the master
workstation, but the other functions would require write access.

Defining a workstation on a
network is done from the
"Parameters / Network / User"
command. The dialogue box
that appears then allows you to
choose the type of workstation,
main or secondary, and control
the functionality for a slave
installation. All computers can
also have an ID.

Off-topic: if you do not have a network but several Galaad installations

coexist on one single computer with different settings, for example to control
several machines, then the ID of the computer (here in fact of the
installation) will be displayed in the window title bar, to help you remember
which Galaad you are currently running. Nothing forbids storing the files
related to these different installations in a common folder. But let us come
back to the use of a network.

If your workgroup comprises several slave workstations, it can be useful to

specify here also the identity of the workstation. We will see the point of this a

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little later. The most important parameter is obviously the definition of the
Galaad directory on the master workstation, as seen from each slave unit.
For example, if Galaad has been installed in the folder C:\GALAAD on the
master computer, this folder can be mapped as X:\GALAAD or \\PC-1\GALAAD
or other on the secondary workstations. You can search for this distant drive
by clicking on the "Browse" button. It is obvious that access to the network
must be available in order for you to browse it.

All that is left is to define which parameters will be copied from the master
installation. Besides the main environmental and machining parameters, it is
also possible to retrieve the current drawing from it. In this case, the copy of
Galaad on the slave unit will open and display the drawing that has been
previously prepared by the teacher.

If the network is down or there are difficulties accessing the master

workstation, the slave units will temporarily revert to stand alone mode and
forget about the master installation until they are restarted. This allows the
group to carry on working in the event of a network problem. It is pointless
dwelling on the effects of the network restarting, as the slave units will return
to their normal mode of operation.

When the parameters have been changed on the master machine, it is not
absolutely necessary to restart the copies of Galaad currently running on the
slave units in order to update the workspace. Simply use the "Parameters /
Network / Upgrade workspace " command on the master machine then on
each slave unit to first save the current environment then load the new
parameters.

Exchanging files

Using Galaad on a network is not limited to downloading the environment

parameters. To help workgroups, the software allows files to be stored
centrally on the master computer. The method is very simple, but of course
best explained with an example: Galaad is installed in the folder C:\GALAAD
on the master workstation, which will be mapped as, say X:\GALAAD (or
\\TEACHER\GALAAD) when seen from the slave unit "TOTO". In addition, the
teacher has designated the workgroup as "4B".

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This workgroup name, not previously

mentioned, is set by the "Parameters / Net-
work / Workgroup" command. The dialogue
box asks for a name and offers a list of those
previously used.

One or more students can work on "TOTO" and run Galaad, with their
workspace parameters loaded from X:\GALAAD. They will open and modify
the drawing, which can then be saved under the name "DRAWING" (for
example). Given that their restrictions only allow them access to the hard disk
on the master computer, their work will be saved to the master folder
X:\GALAAD\PUBLIC\4B\TOTO\DRAWING.GAL. However, the teacher will
collect all the drawing files of that workgroup into his/her master folder
C:\GALAAD\PUBLIC\4B, with each sub-folder being allocated to a workgroup.
If the workgroup changes, for example from 4B to 3A, the drawing from
workstation "TOTO" will be saved into folder X:\GALAAD\PUBLIC\3A\TOTO.
Therefore there will be no confusion between the different groups using the
same workstations.

To check the work produced by the students working on the workstation

"TOTO", the teacher opens their drawings in the corresponding subdirectory.
They can be corrected or marked ready for the next session. Most importantly,
he/she can open them to start the machining operation. At the end of the year,
the teacher tidies up by deleting folders 4B and 3A, using either Windows
Explorer or Galaad, and can then go away on holiday with a conscience as
clean as the hard disk.

The teacher also has the option to save some public files
in his/her own local folder C:\GALAAD\PUBLIC\4B.
These files can then be opened by the students
using the "File / Network / Open a public file"
command. They will then be saved into a public file
available to the entire group.

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———————
10
01010

DRAWING ICONS

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GALAAD 3 —————————————————————————————

This chapter does not aim to go into a lot of details about special drawing
techniques for every icon, but to provide a brief overview of their use and add
a few clarifications in some cases. They are particularly numerous and we are
not going to cut trees down for more pages. The best way to become familiar
with their purpose is to actually use them rather than simply read about them.

As a reminder, let us start with a few constants already forgotten since the
far off chapters 2 and 5:
- When you draw an unfinished shape (isolated points, polyline, curves, etc.),
you must click the ultimate point with the right mouse button for stopping the
construction.
- When you draw a shape with several different steps (ellipse, star, radii, etc.),
you can freeze the construction as is by clicking here again with the right
mouse button (or press or buttons after the last point has been
clicked).
- The key (backspace) undoes the last click without cancelling the
construction in progress.
- Once the shape has been completed, whatever it is, the drawing functions
reiterate the construction of a new shape of the same type. To stop there, press
key or the yellow icon for selecting (parent icon at left).
- The keyboard arrows move the plotting cursor by one unit on the
magnetic grid towards the corresponding direction. The / keys set the
magnetic grid to a step 10 times smaller / bigger. The (star) key resets the
grid to automatic mode, which always corresponds to the smallest scales of the
rulers, whatever the zoom level is.
- The mouse central button and the bar on the keyboard snap the
plotter position to the suggested point that appears in orange near the cursor. If
there is no suggested point, then the current cursor position is validated as is.
- The shapes that need a line drawn from the previous point (dotted line, line,
polyline, circle radius, etc.) are submitted to the polar magnetic grid when you
keep key pressed while moving the mouse.
- In the same way, the combination of keys pops up a dialogue box
for a polar dimension (distance and angle).
- You can zoom in or out without leaving the current drawing function, using
the mouse wheel or / (Page Down / Page Up, or / ) keys. This
helps a lot for snapping to a suggested point among a big jungle of objects.
- Finally, you can shift the zoom window, without interrupting the drawing
function in progress, by clicking-moving with the mouse central button.

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Rubbing out

The series of rubbing icons gets Galaad a bit closer to classical applications
for drawing bitmap images. Be careful not to leave little bits of paths almost
invisible on the screen or a printer, but that will no less be machined. The
function "Edit / Select the smallest object" may eventually help you clean up
the drawing board.

Rub - lets you erase directly everything that is located under the
mouse cursor, which then takes the form of a rectangular eraser. You
can click and release for a one-shot erasure under the rectangle, or click-and-
move for erasing more.

Rub zone - erases everything that is under a rectangle to be defined by

a classical pointing.

Lasso rub - erases everything that is inside a zone to be contoured

manually by the mouse cursor while the left button is held down.

Mask inside - erases everything that is located inside the boundaries

of the selected object.

Mask outside - erases everything that is located outside the bounda-

ries of the selected object. Really everything, be careful!

Points

This series of tools allows you to create points, to indicate where holes
have to be drilled. When drilling, a feedrate (that is the horizontal motion
speed) is meaningless, unless the plunge speed is expressed as a proportion of
the feedrate. See the command "Parameters / Tools".

Single points - allows points to be placed anywhere on the board.

Each point is a completely independent object, but if you are using the
yellow icon "Group selection" on a set of single points, then they will fuse into
one single object.

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Line of points - places points at regular intervals along a line. The

group of points is a single object.

Rectangular array of points - creates a rectangular matrix of points at

regular intervals.

Circular array of points - creates concentric circles of points, each

point remaining at a minimum distance from its nearest neighbours,
which defines the number of points per radial layer (single object).

Fill with points - places points at regular intervals (to be defined)

inside the boundaries of the selected objects.

Bored point - drills a hole of a given diameter by integrating the tool

compensation immediately. Either the drill-down and bottom right can
both be performed at the centre, or the drilling can be helical. A zoomed 3D
preview will show the detailed result.

Points on a trace - drills points at regular intervals along a trace

selected in red. It is possible to add a small random variation of the
distance, to create irregular intervals.

Points on vertices - drills points at the vertices of a polyline selected

in red.

Connect points - makes the reverse operation by creating a polyline

that links the group of selected points.

Helix boring - makes an helical plunge for boring or threading using a

thread-milling cutter, integrating the tool compensation. A roughing
pass is possible, and also a prior drilling with a drill bit. The boring or
threading can be outside a cylinder.

Helix plunge - adds a progressive helical plunge near the entry point
of a path to be pointed. Yet again, a zoomed 3D view will show you
the detailed result.

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Lines

This collection of drawing tools is particularly rich and with good reason,
as there are many ways in which choosing a couple of coordinates to draw a
line across a battlefield can be done. However, it is probably not useful to state
here the various possibilities for plotting, snapping or entering positions of
ends, whatever the line may be.

Simple line - constructs a basic line between two points by clicking

with the mouse or snapping to existing coordinates. Pressing the
key applies the polar magnetic grid.

Horizontal line - constructs a horizontal line whatever the vertical

position of the cursor when adding the second point.

Vertical line - as above, except that it is now for a vertical line,

wherever the mouse is on X axis.

Dashed line - constructs a line comprising regularly spaced dashes, at

intervals defined by yourself.

Dot-dash line - as above, but comprising alternate dots and dashes, at

intervals defined by yourself.

Segments - constructs a series of segments as defined by you along

the path of an object selected in red.

Duplication - constructs a copy of the segment to be pointed. The

copy must be positioned on the board from the segment starting point.
If a segment is already selected in red, it is the one that will be copied.

Parallel - constructs a line parallel to the segment to be pointed first,

and passing through a point to be positioned then. If a segment is
already selected in red, it will be the actual reference.

Tangent at point - constructs a line on an axis that is tangent to a

vertex, which must be pointed first, and passing through another point
to be positioned then. If a point is already selected in red, it will be the actual
reference.

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Bisector - constructs a line parallel to the angular bisector of the

vertex to be pointed. If a point is already selected in red, it will be the
actual reference.

Bisector of segments - constructs a line whose axis is the bisector of

the vertex between the segments to be pointed first, and defined by
two points to be positioned then. If two segments are already selected in red
and blue, they will be the actual references.

Angular - constructs a line at an angle that you must indicate, from

the segment to be pointed, then defined by two points to be posi-
tioned. If a segment is already selected in red, it will be the actual reference.

Perpendicular - as above, except that the angle is fixed to 90° relative

to the pointed segment.

Intersection - constructs a line from a point defined by you to a

segment to be pointed first. If a segment is already selected in red, it
will be the actual reference.

Chamfer - breaks the angle between two joined segments to be

pointed, on a length to be defined.

Sheaves - creates a sheaf of lines at regular intervals between an

object selected in red and one in blue. If the lengths of both objects
are different, then the interval entered corresponds to the red object. If there is
no object selected in blue, then the sheaves are constructed between the object
selected in red and a free point to be positioned. See also 3D meshes or the
function "Design / Transmutation".

Arc tangent - constructs a line whose starting point slides along the
arc of circle to be pointed first. Both tangents to the full circle that
support the arc are displayed, one of them being chosen after the final pointing
(you can then cancel for keeping both). If a segment is selected
in red, then a dialogue box offers the possibility to refer to it
for creating the tangent that would also be parallel to that red
segment.

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Trimmed arc tangent - as above and following the

same sequence, but also trims the arc to the point of
intersection once validated. The part of the arc to be deleted has
to be selected.

Double arc tangent - constructs a tangent to two arcs

to be first selected in green. There are four possible
tangents between two circles, including the crossing ones.
The one you want to keep has to be selected.

Double arc tangent with single trim - as above, but also trims the first
arc selected to the point of tangent, with the choice of which part must
be kept.

Double arc tangent with double trim - as above but also trims both
arcs to the point of tangent.

Polylines and spline curves

The small family of polyline shapes includes basic polylines, and several
non-circular mathematical curves, as well as the shortcuts possible.

Polyline - constructs a simple open polyline by successively plotting

its vertices. All position snaps are valid, and pressing the key
while plotting applies the polar magnetic grid.

Closed polyline - as above, but the polyline drawn remains closed

automatically.

Beta-Spline - constructs a Non-Uniform Rational Beta-Spline by

plotting the vertices. The NURBS curves have two end points the
path goes to, and a various number of attractor points. When the curve is
edited (double-click or right mouse click or "Design / Object / Geometry
handles"), all points can be weighted to increase their attractiveness, by
pressing and keys. It is possible to jump from point to point forward or
backward with or keys. The NURBS curves are easy to handle.
Whenever possible, it is better to limit the number of attractor points and

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rather change their weights: this is much easier and often more efficient. Note
that, for a closed curve, only the ends are part of the
actual path, but if you have enabled the option
"Calculate the closed Beta-Splines for smoothing" in
the workspace parameters, then even these end points
will become simple attractors, and the curve will have no sharp angle.

Quadra-Spline - constructs a quadratic curve with joined tangents by

plotting the nodes. Warning: editing is sometimes difficult. Note that,
when handling a tangent point, pressing key allows you to break the curve
by dropping the alignment of the facing neighbour, for example to make an
inside corner after plotting.

Bezier curve - constructs a curve by plotting the control nodes, the

semi-tangents being calculated automatically. As for the B-Spline or
the Q-Spline, it is possible to jump from point to point forward or backward
with or keys, for example for splitting the curve or conversely
for inserting a new sector. By the way, pressing key when handling a
semi-tangent lets you freeze its angular direction, and the key lets you
break the curve by dropping the alignment of semi-tangents.

Manual trace - constructs a basic polyline by following the mouse

cursor while the left button is held down. Not very useful unless you
have children.

Sine curve - constructs a sine curve along an axis between two points
with user-defined amplitude, period and number of cycles.

Hyperbole - constructs a hyperbolic curve by plotting directly its

amplitude, and then its length and direction.

Link/Trim - extends or cuts a segment to be pointed, for

adjusting its end onto a second segment, also to be
pointed. In the case of a trim, Galaad asks you to indicate the
segment side to be deleted.

Insert vertex - adds a vertex in a segment to be pointed. That vertex

can be repositioned immediately. The double-click with the right
mouse button does something almost equivalent.

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Insert arc - replaces a segment to be pointed by an arc whose passing

point can be repositioned immediately.

Insert B-Spline - replaces a segment to be pointed by a NURBS curve

with one single attractor point which is pre-positioned at the intersec-
tion of the axes of the neighbouring segments.

Insert Bezier curve - replaces a segment to be pointed by a Bezier

curve whose semi-tangents are pre-positioned in the axes of the
neighbouring segments.

Simple link - constructs a polyline link between two segments to be

pointed, through the projected point of intersection. If two segments
are already selected in red and blue, they will be the actual references.

Beta-Spline link - constructs a NURBS curve with three points,

linking two segments to be pointed, and using the projected point of
intersection as attractor point.

Quadra-Spline link - constructs a curve with two nodes, using the

segments as semi-tangents.

Bezier curve link - constructs a Bezier curve with two nodes, using
the segments as semi-tangents.

Rectangles and polyhedrons

This abundant collection of tools includes several non-Cartesian shapes

and also ones that have not got much at all to do with rectangles, other than
being regular closed polylines.

Rectangle - constructs a Cartesian rectangle in the classic way by

defining one of its diagonals.

Centred rectangle - constructs a Cartesian rectangle by defining the

centre and one corner.

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Rectangle with chamfered corners - constructs a Cartesian rectangle

with an extra pointing of a chamfer applied to corners.

Rectangle with fillet corners - as above, except that the corners are
rounded with 90° arcs.

Rectangle with inverted corners - constructs a Cartesian rectangle

with the corners turned inwards.

Rectangle with clipped corners - as above, except that the corner can
be placed anywhere within the rectangle up to the centre point.

Rectangle with inverted fillets - constructs a Cartesian rectangle, with

fillet radii that are inverted about their points of tangency.

Oblique rectangle - constructs a non-Cartesian rectangle by drawing

two adjacent sides. Remember that pressing while pointing
applies the polar magnetic grid.

Oblique square - constructs a non-Cartesian square by drawing one

side then indicating the direction to complete the square.

Cartouche with two sharp sides - constructs a non-Cartesian polyhe-

dron, with 90 end angles, by drawing two adjacent sides.

Cartouche with two fillet sides - as above, except that ends are semi-
circular instead of angular.

Parallelogram - constructs a non-Cartesian parallelogram by drawing

two adjacent sides.

Diamond - constructs a diamond by defining one of the diagonals of a

Cartesian rectangle that surrounds it.

Centred equilateral triangle - constructs an equilateral triangle by

marking out a circle that inscribes it.

Equilateral triangle - constructs an equilateral triangle by marking

out one side and a general point in connection to this side.

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Isosceles - constructs an isosceles triangle by marking out its base

followed by its height.

Star - constructs a star with N points, to be defined by the external

circle in which it inscribes, then the interior circle which inscribes in
it. Important: click the first circle using the right mouse button to freeze the
construction as it is.

Crossed star - as above, except that the transverse lines of the vertices
are self-crossing.

Centred polyhedron - constructs a regular polyhedron, defined by

drawing the circle in which it is inscribed.

Arcs and cyclic shapes

The large and powerful tribe of arcs gives access to tools for constructing
all kinds of circular curves by a variety of different methods. Some trigono-
metric curves are also included in this series. It should be remembered that
when drawing a toolpath for machining purposes, circles are not hermetically
closed shapes but open 360 arcs that have a start point and an end point,
defining how the cutter will travel.

Circle - constructs a closed circle by plotting its centre and a point on

its circumference that will become the start/end point. Here again,
pressing the key when setting the start point position, applies the polar
magnetic grid.

Inscribed circle - constructs a circle by defining one of its diagonals

within the Cartesian rectangle that inscribes it. The start point is set at
0° according to the trigonometric reference (3 o'clock in the aviation lingo).

Three points circle - constructs a closed circle by plotting three points

on its circumference. The starting point is at 0° and the path runs
counter-clockwise.

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Ellipse - constructs an open Cartesian ellipse by defining its centre, X

and Y radii, and start and end points. To draw a closed ellipse, right
mouse click or key in due course.

Inscribed ellipse - constructs an open Cartesian ellipse by defining

one of the diagonals of its inscribing rectangle.

Pie sector - constructs an open Cartesian ellipse (as above), then

closes it by drawing the radii from the start and end points. The whole
path consists of two lines and one elliptical arc.

Arc from three points, end point last - constructs an open arc by
plotting the start point, then an intermediate point, and finally the end
point, clicked last.

Arc from three points, intermediate point last - constructs a circular

arc by plotting the start point, then the end point, and finally the
intermediate point. Probably more efficient than the previous icon.

Arc from centre and aperture angle - constructs an open arc by

plotting its centre, then its start point (giving the radius), and last its
end point direction, the radius then varying no more.

Arc from aperture angle and two points - constructs an open arc by
plotting its ends with a pre-defined aperture (the centre is floating). Be
careful with the plotting sequence: the arc always turns counter-clockwise.

Arc from tangent - constructs a circular arc, tangent to the endpoint of

a segment selected in red, by plotting its end point.

Arc sliding on two tangents - constructs an arc with variable radius,

tangent to two pointed segments, then positioning the centre.

Arc with fixed radius on two tangents- constructs an arc with a given
radius, tangent to two pointed segments.

Arc with fixed radius on two tangents, with trims - as above, except
that the tangent segments are trimmed.

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Arc from three tangents - constructs an arc defined by three tangent

segments to be pointed.

Arc from two tangents on curves - constructs a linking arc by

pointing two tangents paths that can be either lines or curves. When
several solutions are possible, then the closest to the click position is validated.
Then, for each tangent curve, the software asks which part must
be kept, the other one being deleted. To keep both parts, just
press key for closing the small window.

Radii - constructs a group of radial lines by defining the inner & outer
enclosing circles and the start & end angles with the cursor. Right
mouse click for freezing the construction as is.

Gear wheel / Rack - constructs a simple rack or pinion by defining the

key parameters and positioning the result with the cursor. In the case
of a gear wheel, a coaxial circle is added to the construction.

Epicycloid - constructs an epicyclical curve within a circle defined

with the cursor. The shape can be built regardless of its size, then
extended or reduced.

Rosace - constructs a cyclic shape with petals inside a circle defined

with the cursor.

Spiral - constructs a spiral from a number of turns, to be defined, and

by plotting the inner & outer enclosing circles with the cursor. Right
mouse click freezes the spiral at the first circle (i.e. external).

Text

The tools for working with text are few. Except for the initial creation and
manipulation of individual letters, most work is performed with the text editor,
as it remains in text form for later editing, unless converted by you to simple
polylines. Please refer to the "Text" menu and its advanced functions, plus the
"AutoText" argument from the command line for automatic updates on the
board (see the chapter that explains the technical matters, at the end of this
manual).

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Important: a straight text or a text written along a path keeps its own
properties unless it suffered a geometrical torture. So you can modify its style
or its content afterwards.

Text block - creates a paragraph of text with the current font settings,
contained within a rectangle defined by the cursor. It is possible to
write vertically or reverse the text by setting the corresponding parameter in
the text entry dialogue box.

Text on trace - places text along the path of a shape selected in red.
The text is written from the start point to the end point of the shape,
that represents the water-line. The shape remains memorised even after it has
been modified or deleted.

Arrange letters - selects individual letters in a piece of the already

selected text, so that they can be dimensioned or repositioned one by
one by pressing keys or simply using the mouse. You can jump quickly
between letters with the tab key (next) or (previous). Warning:
these manual changes are lost if the text or its style are modified thereafter.
Note that a click on a text with the right mouse button lets you handle
directly the pointed letter.

Edit - opens an edit and format box for the red-selected text so that it
can be modified, including its layout in a paragraph. A double-click
on a text block does the same, and also the key combinations that are indicated
in the lines of the "Text" menu.

Auto-incremented text - allows you to write a block of text that will

be incremented automatically during the milling process, single or
serial. When starting the cycle, all auto-incremented texts are reviewed and
you are prompted to give their new starting content. A normal text that has
already been written and selected in red can also become auto-incremented
afterwards, using this icon.

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Selections

The selection tools cover an area much wider than simply highlighting
objects, points and segments, offering specialised functions linked to the
editing routines.

Select objects - switches from drawing plotter mode to selection mode

(selection mode is the default). The cursor is shown as an arrow. The
key does the same to return from active drawing to selection mode. If an
object has just been drawn, then clicking on this icon selects it immediately. In
the same way, if only one object of the drawing can be selected when clicking
this icon, then it will be.

Lasso selection - manually traces the contour of a zone in which will

be selected all objects of the active layer that are completely inside the
boundaries. The contour follows the mouse in clockwise direction (red) while
the left button is held down, just like a manual trace. In counter-clockwise
direction (green), the objects partly inside are also eligible.

Select equal depths - selects all objects with the current machining
depth, or with the same depth as the current selection. See also the
rapid data palettes with right mouse double-click.

Filtered selection - selects objects by their machining parameters or

by selected graphical characteristics.

Swap red/blue objects - makes objects selected in red become blue

selected objects, and vice versa. Pressing the key while pointing
an object (or a segment or a point) selects it directly in blue. Blue selections
are used as secondary selection, for example for duplicating a selected object
along a blue-selected path.

Lock selection - locks all objects selected in red, which avoids them
being selected in the future. See also "Edit / Unlock" menu.

Select range of points - allows you to handle together a set of points

that belong to various objects. Please refer to the chapter "Advanced
drawing techniques" for moving and stretching groups of points. Also note
that selecting a zone with the right mouse button makes a selection of the
group of points.

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Group selection - associates together all objects currently selected in

red so that they can be handled as a single item in the future. If all
selected objects are already associated, then Galaad asks if you actually want
to ungroup them without going via the "Edit" menu. Please refer to the chapter
"Advanced drawing techniques" for a more detailed description of this icon
and the following ones.

Protect selection - protects all objects selected in red, which prevents

deletion and changes made to their shape. If all selected objects are
already protected, then Galaad asks if you actually want to unprotect them
without going via the "Edit" menu.

Anchor to position - anchors all objects selected in red to their current

position on the board. They can, however, be re-scaled. If all selected
objects are already anchored to position, then Galaad asks if you actually want
to free them without going via the "Edit" menu.

Anchor together - ties together two or more objects selected in red so

that they maintain their relative position and act as a group. This
means that when you are moving a selected object and other objects are
anchored with it but are not selected, they are also moving. If all selected
objects are already anchored together, then Galaad asks if you actually want to
free them without going via the "Edit" menu.

Copy position & dimensions - loads the position and dimensions of

the selection frame, so they can be injected after into another selection
(see related icon just below).

Paste position & dimensions - applies the previously copied position

and dimensions into the current selection frame.

Plot red cross - places a fixed red cross on the board as a reference
marker when drawing or as the workpiece origin. This cross is plotted
directly on the board and has no link with any objects. For suppressing a red
cross, just click again on that icon and abort the plotting
operation with key (or press ). If a red cross
already exists, Galaad suggest repositioning it. And when
objects are selected, instead of pointing the position,
Galaad can snap it onto a selection frame handle.

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Select red point - selects a point in red, even on objects that have
geometrical properties (arcs and curves). The right mouse click on a
polyline vertex or a single isolated point directly selects that vertex or point
with no need to call up this icon, except if the whole object is itself already
reactive to the right click.

Select red segment - selects a segment in red, even on objects that

have geometrical properties. The right mouse click on a segment
directly selects that segment with no need to call up this icon, except if the
whole object is itself already reactive to the right click.

Plot blue cross - like the red cross, mentioned above, but in blue so
that a second reference marker is available. That blue cross can be
helpful for the drawing or the workpiece origin, for example for setting a
double origin allowing adjustments.

Selection blue point - does the same as above for a blue point. The
right mouse click on a polyline vertex or a single isolated point, while
keeping key pressed, directly selects it with no need to call up this icon,
except if the whole object is itself already reactive to the right click.

Select blue segment - does the same as above for a blue segment. The
right mouse click on a segment, while keeping key pressed,
directly selects that segment with no need to call up this icon, except if the
whole object is itself already reactive to the right click.

Swap red point/segment - jumps from red point selection to red

segment selection, and vice-versa.

Flip red segment - reverses the direction of the segment selected in

red, without changing the overall toolpath of the object that it is on.

Swap red/blue points - turns a point selected in red into one selected
in blue and vice-versa.

Swap red & blue segments - turns a segment selected in red into one
selected in blue and vice-versa.

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Swap blue point/segment - jumps from blue point selection to blue

segment selection, and vice-versa.

Flip blue segment - reverses the direction of the segment selected in

blue, without changing the overall path of the object that it is on.

Special effects

The special effects provide a comprehensive set of tools that allow the
objects selected in red (and these only) to be tortured according to your darkest
fantasies. Manipulation can be from simple 2D positioning to 3D bending,
including miscellaneous rotations and projections. Please note that objects lose
their geometrical properties (arcs, curves and texts) if the torture applied
changes their shape.

Cartesian move - allows the object selected to be moved in all

directions by values entered for X, Y & Z.

Polar move - allows the object selected to be moved in the X & Y

directions by values entered for the angle and radius.

Centre horizontally - centres the selected objects about the vertical

axis of the cursor. See also "Design / Align-centre" that allows you to
use many references on the board. Clicking on this icon while keeping
key pressed makes an automatic centring on the board X centre.

Centre vertically - centres the selected objects about the horizontal

axis of the cursor. See also "Design / Align-centre" that allows you to
use many references on the board. Clicking on this icon while keeping
key pressed makes an automatic centring on the board Y centre.

Centre both - simultaneously centres the selected objects about both

the horizontal and vertical axes of the cursor.

Flip horizontally - inverts the selected object about the vertical axis
within the selection frame.

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Flip vertically - inverts the selected object about the horizontal axis
within the selection frame.

Flip diagonally - exchanges the X and Y coordinates of the selected

objects, without changing the frame origin (southwest corner).

Rotation 90° - rotates the selected objects by 90 counter-clockwise,

maintaining the original position of the selection frame.

Rotation - rotates the selected objects around the centre point of the
selection frame. Very important: the key allows you to enter
directly of the angle value or change the pivot without ending the operation.
Tip: you can rotate the selected objects around the centre of the selection
frame directly from the mouse wheel along with the key for a rotation
of 1° per increment of the wheel, or 5° per increment if you also press
key. This can help you optimise the wastage by nesting objects manually:
positioning and rotating are then available from the mouse.
Small tip, delightfully useless: along with + keys, the rotation
icon animates the drawing by rotating continuously the red selected objects
(counter-clockwise) and the blue selected objects (clockwise). The rotation
speed of each object is in proportion to its depth, 1 mm corresponding to
45 °/s. Each object turns around its own centre of symmetry, unless it is
associated with other objects, in which case it turns around the centre of
symmetry of the group. The key ends the animation. This function can
simulate the rotation of a set of pulleys or gears, but even so it does not verify
the validity of the speeds. Among the files that are supplied with Galaad,
SAMPLES \ ROTARYGEARS.GAL gives a good example.

Slant - tilts the selected objects about the vertical axis at the centre of
the selection frame. The key allows the direct entry of the angle.

Wrap - rolls up the selected objects along a double circle. The

operation follows several steps: plotting the wrapping centre, plotting
inner and outer radii, plotting the aperture angle (right mouse button for
ending), and last of all plotting the orientation.

Vanishing point - modifies the selected object so that segments in the

chosen direction project back to the vanishing point.

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Perspective - modifies the selected object so that it appears to have

depth and disappear into the page.

Panoramic - modifies the selected object so that it appears to be a

wrap-around, panoramic view.

Bend - modifies the object selected in red so that its Y profile follows
the variations of the object selected in blue. The blue object must
occupy on the board a horizontal space X at least as large as the red object to
be modified. On the other hand, its Y position has no importance. This remains
valid for the next three icons.

Stretch - as above, but only applied to the top of the object selected in
red, for expanding it vertically.

Compress - as above, but only applied to the base of the object

selected in red, reducing it vertically.

Modify Z depth - modifies the object selected in red so that its depth
follows the Y path of the object selected in blue. The XY path of the
blue object becomes the XZ reference for distorting. So the appearance seen
from the top remains unchanged.

Project onto cylinder - modifies the object selected in red to produce

a 2D visual representation of its projection onto a transparent cylinder.
Be aware that this icon and the two next do not make 3D distorsions but
simple projections for artistic effects.

Project onto cone - modifies the object selected in red to produce a

2D representation of its projection onto a transparent cone.

Project onto sphere - modifies the object selected in red to produce a

2D representation of its projection onto a transparent sphere.

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Milling data

Within this small group of features the first one will probably be used
frequently. The pop-up items are little gadgets that may actually turn out to be
practical in some cases. See also the rapid data palettes to copy/paste depth,
feedrates and tool numbers.

Machining data - gives access to the milling tool, the depth and the
feedrate. If some objects are selected, then the new values apply to
these objects, otherwise to the next objects to be drawn.

Colour / thickness - defines trace colour and thickness as default

settings or for selected objects. Of course this is useful only for the
screen display and the printout.

Copy machining data - copies the tool, depth and feedrate of the
selected object for later use. See below.

Paste machining data - applies the previously copied tool, depth and
feedrate to the selected object. See above.

Zoom

The zoom icons allow you to change the magnification of the view so that
the drawing can be seen more clearly without affecting the objects. Several
successive views are memorised, therefore allowing you to backtrack, which is
entirely independent of the Undo/Redo functions in drawing mode. Note that
fast zoom in/out features around the cursor are also available using the /
(or / ) keys without losing the current drawing function. If your mouse has
a central wheel, which is highly recommended for the 21th century, then the
wheel has the same quick zoom function.

Zoom in - magnifies the plotted area. Defining this Cartesian zone

must be done by keeping the mouse button pressed (click-drag-
release). If you click and release the mouse button at the same location, then
the zoom is made by a factor of 2 around the clicked point.

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Global view - cancels the current zoom and returns to the view of the
whole board.

Temporary zoom - magnifies the plotted area as "Zoom in" above, but
it is cancelled by the next click of the left mouse button (not right
button). This helps make visual inspections here and there.

Magnify selection - magnifies the view so that the selected object fills
the screen with a small margin.

Magnify ends - magnifies the ends of the selected object, so you can
check whether it is opened or closed.

Undo previous zoom - cancels the last zoom operation, whatever the
direction was. There are four levels of cancellation, and these have no
link with the "Edit / Undo" function.

Redo previous zoom - redoes the last zoom operation cancelled by the
previous command.

Zoom out ×2 - reduces the magnification by a factor of 2 (visible

objects appear smaller).

Move view - slides the window when the mouse is moved with the left
button held down. This function has no interest if you have a mouse
with three buttons (or two buttons plus wheel): click & drag with the central
mouse button (or the wheel) moves the view without ending the current
drawing function.

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Visual dimensions

These icons have no link with machining functions, but represent a little
bonus for technical drawing. You can use them to add numerical indications
on the board, and they can be printed. Visual dimensions are dynamic, i.e.
they are updated automatically while changes are made on drawn objects.
Their style can be changed using the "Parameters / Visual dimensions"
dialogue box. Other commands are also available through the "Display /
Visual dimensions" menu.

Multi-purpose - is a single, multiple use icon for setting most visual

dimensions. The scenarios are various:
- As a preamble, you can consider a clickable point the centre of a rectangle or
a circle, even if the path does not go through it.
- If you plot a point with the right mouse button, then you get a single
coordinate dimension. If you have clicked very close to the point, it will be an
XY arrow dimension according to the table modulo 45°. If you have clicked a
bit on the left hand or right hand side of the point, then it will be a Y dimen-
sion alone. If you have clicked a bit above or below the point, then it will be
an X dimension alone. Both can be positioned later.
- If you plot two points (or vertices), then you get a distance dimension.
Depending on the location where you will then plot the dimension, that will be
either a horizontal, or vertical, or oblique distance.
- If you plot a point and a segment (whatever the order is), then you get an
oblique distance dimension, perpendicular to the segment.
- If you plot two parallel segments, then you get a distance dimension
between these segments.
- If you plot two non-parallel segments, then you get an angle dimension
between these segments.
- If you plot a segment with the right mouse button, then you get a slope
angle dimension for that segment.
- If you plot a closed circle, then you get a horizontal diameter dimension,
between vertical reminder lines.
- If you plot a closed circle with the right mouse button, then you get
directly an arrow dimension, for a diameter if you have clicked outside the
circle, or for a radius if you have clicked inside.
- If you plot an open arc of circle, then you get an arrow dimension, posi-
tioned at the nearest angle modulo 45°. If, when clicking, the mouse cursor is
outside the arc, then it will be an external diameter dimension, otherwise it will
be an internal radius dimension.

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- If you plot an ellipse, then you get an arrow dimension for radii, to be
located according to a table modulo 45°.
- When you try to plot an item, pressing key simultaneously avoids
catching a circle or an arc.
- When fixing the position of a distance dimension, the left mouse button sets
the numerical dimension at the centre of the double-arrow, and the right
mouse button sets it at the clicked position, without going outside the arrow
head (if you click outside the reminder lines, the position of the numerical
dimension will be on the border but inside).

Very important: visual dimensions are reversible, i.e. you may double-
click on a dimension for editing its value, which will act on the drawing. For
example, for a distance dimension, you can change the
value for adjusting the items that have been dimensioned,
eventually indicating if one of them must remain fixed at
its current position.

Equally important: the right mouse click on an existing visual dimension

pops up a small context menu which lets you edit the dimension (see above) or
relocate it, or even simply delete it. Of course, you must
catch the dimension successfully, without letting
Galaad consider that you want to select a point or a
segment or edit the geometrical properties of the
neighbouring object.

Note: at the very first click of the day on any

visual dimension icon, a reminder message pops
up for refreshing your knowledge of all the above
mentioned. You will have to wait until the day after
to see again that message, unless you press
simultaneously + keys while clicking on
the icon, in which case it kindly appears.

Now we can see the other icons of that series.

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Concerning the next three icons, it is possible to get the same result from
the multi-purpose icon, already seen, and the right mouse click when plotting
(see all details above).

Abscissa - adds a vertical axis with a numerical indication of the

corresponding coordinate.

Ordinate - adds a horizontal axis with a numerical indication of the

corresponding coordinate.

XY position - displays a couple of numerical values over a position

arrow, associated to a vertex or point you have to select.

XY intersection - adds an XY position couple at the intersection point

of two segments you have to select, which is not possible with the
multi-purpose icon. The operation can be done from one single plotting on the
intersection, which highlights the two segments concerned. If, during later
manipulations, it appears that the segments do not cross each other anymore,
then the dimension is suppressed without mercy.

Custom indication - adds a mark with a free comment somewhere on

the board, with no links to existing objects. Even if all objects are
deleted, this indication remains at its location. The text cannot exceed 80
characters. The direction and the length of the arrow are settable, and can be
modified later on.

Change location - allows you to move a visual dimension that has

been previously positioned on the board, without changing what it
refers to. If the visual dimension is a broken arrow, then the corresponding
dialogue box is recalled. Otherwise the positioning function is restarted. You
can get the same thing with a right mouse click on the visual dimension,
through the small context menu.

Concerning the next five icons, it is again possible to get the same result
from the multi-purpose icon with or without the right mouse click.

Arc centre - displays the position of the centre of an arc of circle or

ellipse, to be selected.

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Diameter - displays an external arrow dimension that points to the

circumference of an arc.

Circle radius - displays a dimension arrow between the centre and the
circumference of an arc.

Angle between segments - displays an angular dimension between

two segments to be selected, the arrows being outside, which makes it
different from the multi-purpose icon.

Segment angle - adds an arrow dimension to a segment, indicating its

slope angle with a horizontal axis. The value keeps the indicated
orientation even if the angle has changed.

Delete - erases visual dimensions to be pointed, more easily accessible

from the right mouse click and the small context menu. See also the
"Display / Visual dimensions / Delete all" command.

Like everything else, trial and error is the best way way to learn how
Galaad’s visual dimensions work, and particularly the multi-purpose icon,
with left and right mouse clicks.

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11
01011

MENU FUNCTIONS

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Here follows a complete list of all the commands found in Galaad menus,
together with a brief summary of their function. They are too numerous to
describe in full here. Anyhow the best way to understand their actions is to
actually use them, crossing your fingers.

In the following descriptions, when a function is also accessible from a

shortcut icon in the top bar just below the menus, that icon is show, or even
two icons if the one of interest is dropped down from a parent icon. All icons
in this top bar are also described together at the end of the chapter.

"File" menu

File / New - initialises a new board and lets you override the default
values for the material and machining parameters (material type and
size, choice of tool, cut depth, feedrate). You may set the default values from
"Parameters / New file defaults". Simultaneously pressing the and
keys when the command is called on (or its corresponding icon) opens a new
board with the same dimensions and milling values as the current one, in this
case the dialogue boxes do not appear.

File / Open - loads from the disk an existing drawing under Galaad
format (.GAL). The default directory in the file selection dialogue box is
the last one accessed for opening or saving.

File / Gallery - displays all files in a given folder and allows

you to select one by double-clicking.

File / Save - saves the current drawing to the disk. If it has not yet been
named, this function is the same as "Save as", detailed below.

File / Save as - saves the current drawing to the disk, prompting

you to give it a name.

File / New folder - creates a new folder in which to save drawings. It will
be located within the "File" folder of the installation directory.

File / Merge with - loads an existing file and adds what it contains to the
current work, with possible offset of its XY coordinates.

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File / Templates / Open template - loads a template drawing to

be completed, from the "Templates" folder.

File / Templates / Template gallery - displays all files in a given template

folder.

File / Templates / Save as template - saves the current drawing as a new

template in a folder.

File / Network / Open a public file - loads a drawing from the appropriate
workgroup (if one has been defined) located in the "Public" folder on the
master computer. Please refer to the chapter dedicated to network functions for
more details.

File / Network / Save as public file - saves the current drawing in the
appropriate workgroup (if one has been defined) located in the "Public" folder
on the master computer.

File / Quick transfer / Send drawing - performs an immediate

save of the current drawing to a removable disk or a mapped
network drive, using a default filename (not visible), so that it may be quickly
transferred to another workstation, using the corresponding "Receive drawing"
function of the same submenu. One single file can be transmitted at once since
the next sending overwrites the previous file on the transfer disk. The drive
and directory are to be set every time (defaults remain the last used).

File / Quick transfer / Send tool library - performs an immediate save of

the tool library to a removable disk or a mapped network drive, like the above
function for the drawing file.

File / Quick transfer / Receive drawing - replaces the current

drawing with one previously sent from another workstation to a
removable or network disk. If the current drawing has been changed, you are
prompted to save it. File name is not transmitted since it may refer to a
directory tree that does not correspond on the local recipient.

File / Quick transfer / Receive tool library - replaces the current tool
library with one previously sent from another workstation to a removable or
network disk, like the above function for the drawing file.

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File / Material dimensions - displays a dialogue box allowing

the dimensions of the raw material to be entered. If you have
already drawn objects, you cannot specify dimensions that leave any of them
outside the board. You may also rescale the whole drawing, including from an
adjustment between two points whose distance is known.

File / Comment - allows you to add a comment to the drawing in the top
left of the screen. This remains visible irrespective of the magnification unless
it is turned off with "Display / Comment". It is not machined.

File / Warnings - prompts you to indicate free comments that will be

displayed when the operator, who might be you, opens the file, or sets the
workpiece origin, or launches the machining cycle.

File / Elapsed time - shows the time spent working on the drawing (the
elapsed time is displayed at the bottom left corner of the screen) and lets you
pause or reset the timer. Every new active drawing operation restarts the timer
for three minutes (this duration is settable in "Parameters / Workspace /
General settings").

File / Print - defines the print parameters for the drawing, and launches
the printer selection process. If the printout scale is left undefined
("Scale" edit zone not ticked, or scaling factor set to "auto" or empty), then
Galaad will try to fill up the whole available space on the paper. All other
printing parameters remain memorised, including general identification data.
The accurate set-up of
the printing is done from
"Trace" page. Here you can
set the X and Y scales that
correspond to your printer,
to get accurate dimensions
on the paper. Many other
parameters let you define
the pen style for each
object, or print the 3D view.
A custom page frame can be
defined from the "Frame"
tab of the printout dialogue
box, this frame will be

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located at the bottom right corner of the page and will display the identifica-
tion texts that will be written at corresponding positions (title, date, reference,
etc.) using the style selected for each. The custom frame must be drawn
separately and saved under Windows Enhanced Meta-File (EMF) vector
format or bitmap image (BMP). Therefore you can add your logo or any
invariable information to this frame drawing. Galaad will stretch or compress
the custom frame so that it matches the predefined frame dimensions. XY
positions of the identification texts are relative to the top left corner of the
custom frame. Even though there is a preview available, you will probably
waste a bit of paper before it looks perfect. Or use a PDF output.

File / Import - loads a vector drawing saved by another CAD

software package as a standard 2D, 2½D or 3D exchange
format. This drawing can include points, lines, arcs, curves, etc. but neither
images nor 3D surfaces are loadable.
After selecting the file, a dialogue box
lets you set a scaling factor for the import,
which will remain memorised for every
format used. You may import the entire file
or filter one particular tool, the concept of
tool being substituted for the pen colours for
classical drawing formats. You may also
ignore the colours/tools and assign all objects
a given tool (the current tool if none is
specified), and also for the drawing layers
(the current layer if you enable the option but
specify no layer).
The coordinate system of an imported file
can be different from the one Galaad uses,
which does not allows negative coordinates,
so you can activate an automatic reframing which will relocate the drawing in
the board, but then absolute positions will be lost and adjustments of succes-
sive imports must be handled manually. You may also offset the input
coordinates directly. The isolated segments or shapes can be connected for
obtaining continuous paths. You may eliminate overlapping clones that are not
visible on the screen but cause useless redundancies when milling, or group
together isolated points, or anchor them together with paths that are contouring
them. You can ignore texts, for example in a DXF file which contains many
visual dimensions. Finally, for ISO G-code files, you may enable a basic tool

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compensation (simple tool offset) without the advanced collision management.

Some highly specialised formats use other sets of parameters.
Importing a file adds to the existing drawing without replacing what
already exists on the board, and all objects of the newly imported drawing are
automatically selected, even if they spread over several layers. Galaad offers a
quite large number of import/export formats, which should ease transfer
operations in both directions. If you do not succeed in loading a file under a
given format, then the best solution is to try another. Available formats are as
follows:
- HPGL is a format dedicated to HP plotters and has become a little standard
for 2D vector basics. Galaad is compatible with 2½D extensions that encode Z
depths and drilling speeds, mainly used by GravoGraph and Roland tables.
- PS HPGL is derivated from HPGL, integrating Z coordinates for 3D paths. It
is used mainly by Roland engraving machines.
- Text-DXF is the AutoCad data exchange format, almost a standard for CAD
software. This format can contain surface information that makes no sense for
Galaad, which will therefore load only the vector paths (lines, arcs, curves,
etc.). Please note that successive versions of DXF may have quite important
differences. In certain cases, Galaad may read more easily one version of DXF
than another. The best bet is to try and hope.
- Converted-DXF is a variant of the above, to be used when Text-DXF fails.
Its analyser performs two passes so it is slower for big files.
- DWG is the AutoCad software native format and can be imported directly
by Galaad. Well, in most cases…
- IGES is a somewhat older format which manages drawings projected onto
different planes. If the file is a cylindrical projection, then Galaad tries to pick
the flat development, machinable as is with 4 axes.
- EPS is the Adobe Encapsulated PostScript format for 2D vectors, based on
straight lines and Bezier curves. It is dedicated to printers and other graphical
systems.
- AI is the Adobe Illustrator format, extension of the EPS format above
mentioned. An AI file may also contain bitmap images and font definitions,
which Galaad will not read.
- WMF is the old 16-bit Windows Meta-File format and should not be used
much now. Its encoding possibilities are limited.
- EMF is the Windows Enhanced Meta-File format for 2D vectors, including
colours and line thicknesses, with a relative accuracy. It is more focused on
graphics than real technique. Galaad does not import images that are
encapsulated in EMF files.

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- NCP is an Isel-Automation proprietary format for 3D vectors, dedicated to

Isel-Remote drivers and software applications. This format is specific for Isel
CNC machines.
- ISO G-Code is the standard format for files that are dedicated to CNC
machine tools. In the drawing module, Galaad will load only 2½D or 3D files
with XYZ or XAZ coordinates.
- G-Code / NUM is a variant of the above that includes arcs with absolute IJ
coordinates (centre of arcs). If your ISO import displays fanciful arcs, then try
the other available version of the format among those two.
- G-Code for turning is another variant for 2 axis lathes that uses XZ
coordinates instead of YZ, but for importing in an XY plane.
- NCI is the 2½D and 3D data exchange format for MasterCam software,
dedicated to CNC drivers.
- ACL is the vector 3D format for MecSoft VisualMill, dedicated to post-
processors.
- ESSI, B3 and MDA are 2D formats for cutting metal sheets with plasma
torches or high-pressure water jets.
- EXL is the format of Excellon-Automation machines that are dedicated to
drilling operations on printed circuits. This format contains only XY
coordinates for drill points, with tool numbers. Two variants exist, depending
on the data format, with or without trailing zeros to the right. If your import
displays a fanciful result, then try the other available version.
- GBR is the format of Gerber Scientific Instruments machines that are
dedicated to flashing operations of printed circuits. In the drawing module,
Galaad reads only XY coordinates regardless of the shapes and sizes of the
plotter aperture. See the Percival module for printed circuit works. Percival
loads all Gerber file data and allows you to engrave contours.
- UIUC is the format of Airfoil Coordinate Database that is dedicated to
wing profiles for aeroplanes (DAT files), as defined by the Aerospace
Engineering Dept. of the University of Illinois at Urbana-Champaign.
- OMA is the 2D polar format of Essilor machines that are dedicated to cutting
operations on lenses. Two variants exist, with 400 or 800 points, or in
complete polar coordinates OMA-3.
- CLC is the 2D format for cutting solar masks for glasses, developed for
Opti-3 / ColorClip.
- SSL is a format for cutting 2D slices constructing a 3D workpiece assembled
layer by layer.
- DIS is a 3D Cartesian wire mesh format that is used by the French Institut
Géographique National for topographic coordinates between two referenced
altitudes.

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- DEM is the 3D Cartesian wire mesh format for geographic or topographic

coordinates that are constructed from satellite pictures through the ISTAR
stereoscopic system.
- MNT is a 3D format for topographic applications containing clouds of points
with XYZ coordinates in Lambert projection. Galaad is able to build up a non-
rectangular wiremesh from these points.
- TXT is a filter for importing coordinate files in decimal text format, each line
corresponding to an isolated point or a polyline vertex. The coordinate
separators and the line separators are fully settable.
- BUG is an appendix for re-importing into Galaad a debugging file that has
just been extracted after a problem when machining, for checking its coordi-
nates graphically, including tool-up movements. The workpiece dimensions
correspond to the axis range, and the drawing may be inverted depending on
the position of the machine zero point (inverted vertically if at north, horizon-
tally if at east). Before prejudging that Galaad has made an ugly offset error
while driving your machine during a milling cycle, preferably on an expensive
workpiece, you can check this way that coordinates are coherent and perhaps it
is rather the machine that drifted by itself.

File / Export - saves the current drawing under a standard

vector format, for transmission to another CAD software. Please
note that only the drawn objects are exported: the visual dimensions and the
background image are not exportable.
After choosing the target folder and
the file name, the export function gives
the possibility to set up a few parameters.
If changed, the scaling factor will remain
memorised for the selected format,
separately from the import. The arcs of
circles in the drawing can be generated as
arcs or as simple polylines (vectors). The
other options are quite self-explanatory
and do not require a long speech.
Concerning milling-oriented formats, it is
possible to set the tool clearance height
and the cleared tool speed.
Most import formats are also available for export, except a few specialised
geographical formats. It would be useless to list again all these formats. Please
refer to what has already been exposed above for the import function. In

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addition to these, Galaad offers the following export formats:

- KYN is the text format of programming files in the Kynon module, which
allows you to create a programmed path from the Galaad drawing module.
Only motion commands will be exported.
- CM3 is the vector format for Roland DG CAMM-3 or MDX engraving
machines, which accepts 3D interpolations.
- EGX is the vector format for Roland DG Modela EGX, which accepts 3D
interpolations.
- SML is the data format for Suregrave machines.
- CBR is the data format for Colinbus machines.
- XYA (G-Code for cylindrical revolution) allows you to produce a revolving
wiremesh with a transmutation of a red-selected profile to a blue-selected
profile. The axis of revolution is the bottom of the drawing board (coordinate
Y=0). It is possible to make several revolutions, with a progressive X offset,
for example to produce a screw.
- STL can export surface facettes of a Cartesian 3D wiremesh that has been
drawn using the wiremesh functions of Galaad.
- C is a text format that uses the MoveTo(…) / LineTo(…) instructions of a
programming language based on the same syntax as the C language, which is
rather easy to transcode into another language. Note that there is nothing better
than C except C++ (sorry, private joke for developers).
- Post-Processor is the custom format that you can define from the big
dialogue box available from "Parameters / Post-processor". Almost all
syntaxes and coordinates systems are allowed, provided that they are based on
decimal or hexadecimal text.
- BMP is the Windows standard bitmap image format, for a non-vector output
of the drawing.

File / Batch conversion - helps you convert a set of files located in a

directory or a whole tree, including Galaad files, into another format. This
avoids a big conversion work of a whole library of old files.

File / Exit Galaad - saves the current working environment, including the
current drawing, and exits the software.

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"Machining" menu

Machining / Standard machining on 3 axes - gives access to the

automatic milling process for the current drawing (in fact on 2 axes XY
or 3 axes XYZ depending on the machine type), using either the internal
machining module, namely Lancelot program, or the predefined external
driver. There is probably no need to revisit that function since it has been
widely described in the previous chapters. In case of doubt, then please go
back to the chapter "Learning to mill" and "Advanced milling functions".

Machining / Cylindrical machining on 4 axes - replaces

the above command if the raw workpiece was
defined as cylindrical. Y coordinates in the drawing
become A coordinates, the board becoming a
cylinder. If you wrap this cylinder on 360°,
then the board is completely wrapped and the
coordinates at the top match the coordinates at the bottom.
The automatic diameter that is suggested makes the board Y height
coincide with the resulting circumference. It is possible to use a blue selected
object for defining a non-cylindrical overall profile (Z depth then vary
depending on this object). That profile runs from left to right and
must not overlap itself. Its position has no importance, only its
variation is considered, being fully understood
that the indicated diameter corresponds to the
highest point of the blue object. The function "Display /
3D view" helps you visualise the projection of the drawing
onto the cylinder or the profile of revolution.

Machining / Multi-sided milling on 4 axes - gives access to

the milling process on 4 axes of the current drawing, splitted in
several normal cycles on 3 axes XYZ, each cycle being driven from different
positions of the A axis. The rotary axis turns on an angular value to be defined
before the process is resumed. The cycles can be identical (repeated machining
on all sides), or correspond to different drawing layers, each layer correspond-
ing to a single side. Since the workpiece can have a rectangular section, it is
possible to define offsets for Y and Z axes for each side, so the origin point
can be located at a corner and obviously Z coordinates will compensate the
difference when the top surface of a side is higher than the one on which the
workpiece origin has been made.

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Machining / Simulate - simulates the normal milling process

for the current drawing, using the internal machining module.
Process steps are identical to the real milling cycle, except that there are no
dialogues with the machine nor a chaining to an eventual external driver.

Machining / Upload - starts the normal milling process for the current
drawing, but stores all commands in the local memory of the machine. This is
the same as launching the cycle after having enabled "Upload machining to the
controller memory" in the options of the milling module. The process is the
same, but the start is automatic (tool retraction height and current workpiece
origin are preset here). Obviously the functions for storing the cycle in the
machine memory must be available, and this memory must be big enough. If it
is not the case, then this function does not appear in the menu.

Machining / Milling zone - allows you to define a rectangular area for

milling in your drawing board. The workpiece will be confined to every object
inside this zone. This function can help make successive and shifted machin-
ings on a workpiece which does not fit in the machine space. A zone is
machined, then the workpiece is shifted by the width of that zone and the
machining is repeated, etc. Obviously, the physical offset of the workpiece
must be supervised with the best accuracy and, whenever possible, it is better
not to split drawing paths that will be marked at the joint if they are dispatched
in two different cycles.

Machining / Manual control - displays a control panel allowing the

machine to be controlled manually, thus with no relation to the
drawing. In addition to the ability to jog axes, the manual control can be used
as a test to check the communication with the machine. See also the "Parame-
ters / Machine / I-O test" function in this case.

Machining / Manual unblock - does the same as above, except that the
control does not reset the axes on the machine zero point and consequently
uses floating coordinates, so with the risk of bumping the stoppers at the axis
ends. The purpose is to make the machine move freely, for example if a tool
remained stuck in a workpiece, or for checking manually the axis end switches
(here they can be approached one by one until they are triggered and the
screen displays which input has changed).

Machining / Surface / Table - allows the top surface of the machine's

removable bed to be cleaned up to provide a good flat working face. The

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default surface range corresponds to the active length of XY axes but you may
change it. The angle cross avoids leaving the tool fillet in the corner that will
be used as the XY workpiece origin, the lateral borders becoming stopper bars
for the workpieces. When setting the origin before surfacing, it is necessary to
do the flatbed approach manually and validate with "Z - ok" button.
Important: After surfacing the flatbed, the Z calibration of the fixed tool
sensors is invalidated since the reference has changed. If indeed you are using
a fixed tool sensor, then you must calibrate again its phase 2 (Z offset).

Machining / Surface / Workpiece - allows the top surface of the current

workpiece to be cleaned up to provide a good flat face. The Z origin must be
done on the raw surface.

Machining / Surface / Thickness - rectifies the workpiece so it matches

the parametered thickness in the drawing. The material layer to be removed
must be indicated by its excess. It will help manage the stages and the tool
clearance height.

Machining / Digitise / Surface - calls the 3D digitising process on 3 axes

XYZ for a Cartesian volume. This allows a reverse engineering of an existing
workpiece to be copied. The function in Galaad creates a rectangular wiremesh
from automatic probing measurements of points on the piece. The machine
driver module being independent
from the drawing module, it will
create a new file for that wiremesh,
under a format, a density and
parameters to be defined.

The technical characteristics of

the probe that are defined here will
remain memorised. Two types of
probes can be used:
- A binary sensor, generally an
on/off switch connected to an input
of the controller. For every point to
be measured, Galaad lowers the Z
axis quickly down to the contact
with the piece, then lifts up slowly
until the trigger point is reached, reads the Z position, then quickly lifts up and

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moves the X or Y axis towards the next point.

- An analogue sensor, generally a measuring laser connected to the ADC input
of the controller. It is necessary to enter the conversion factor between the
analogue value and the distance unit. Galaad will just position the sensor
above every point to be measured, moving the Z axis only for keeping the
sensor inside its linear stroke. It is possible to oversample the measurement to
get rid of the noise. On the other hand, it is not possible to grab fly-out
samples along the continuous X or Y movement.
Once the parameters have been validated, the process is absolutely
identical to a workpiece origin for a standard machining, except that the piece
is already machined and the tool sensor is not usable. You must set the origin
point for the volume to be digitised, using the green buttons that validate the
positions, and the sensor stem must touch the piece or the flatbed instead of
the tool (with an analogue sensor, just lower it to the linear stroke). When the
origin is set, then the process starts like a normal machining cycle.

Machining / Digitise / Cylinder - calls up the 3D digitisation process on

4 axes for a cylindrical volume. This process is identical to a surface digitising
process, except that the A axis replaces the Y axis, so with a workpiece origin
that is the same as a 4-axis machining. But the wiremesh created this way will
be unwrapped into a flat XYZ.

Machining / Digitise / Manual - calls the digitisation process requiring

you to manually control the machine and confirm every point. The major
interest of this function is to physically pick up one by one the coordinates of a
shape that has been placed on the machine. The three available entities are the
isolated point, the polyline by its vertices, and the 3-point arc. The coordinates
are absolute, the origin being the machine zero, so you must reframe the result
once the digitising is completed. Newly digitised entities are appended to the
file, so that it is possible to resume a digitising process.

Machining / Timers - displays the status of the machining timers that can
be used to monitor the cumulative time spent on different projects. Each timer
can be set and activated, and several counters can run simultaneously.

Machining / Tool library - opens a window where you can choose the
tool rack if several have been defined, shows the key parameters of the tools
currently defined within that tool rack, and indicates which are used in the
current drawing. Access is also available to set the full parameters. The "List"

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button generates a text output of the list into a file named "GALAAD.TXT" that
can be printed from Windows Notepad, which is opened automatically.

Machining / Recent tools - browses a list of the tools used in the current
drawing plus the last five.

Machining / Sequence / Set as first - moves the selected object to the

first position in the machining sequence (tool cycle and main machin-
ing pass). If several objects are selected, of course the internal sequence of the
group is unchanged. This remains valid for all other sequence commands that
are listed below. Always keep in mind that the drawing sequence set here is
not absolute: by default, the machining process will follow first the tool
sequence and, for each tool, the cut-out paths will be made last (when object
depths are greater or equal to the workpiece thickness). It is only inside these
main passes that the machining sequence may be changed. You can display the
position of each object in the sequence by using "Display / Trace / Identifiers /
Sequence".

Machining / Sequence / Set as last - moves the selected object

to the last position in the machining sequence.

Machining / Sequence / Table - pops up a

table of all objects present in the drawing, by order
of appearance. These objects are displayed in the
same colour as the lines, i.e. red for the objects
selected in the table (not related to the eventual
selections in the drawing), in black for those that
precede, and in blue for those that follow. So you
can select objects in the table and drag them in the
sequence or use the corresponding buttons on the
right hand side.

Machining / Sequence / Mouse select successively - allows

you to set the machining sequence by pointing objects one by
one from the first to the last. Sequence numbers are displayed during the
operation, near the start point of each object.

Machining / Sequence / Set order of appearance - allows the selected

object to be placed in any position in the machining sequence.

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Machining / Sequence / Reverse - reverses the order of the selected

objects, within the selection only. Objects not selected are not affected.

Machining / Sequence / Optimise - rearranges the machining order of all

objects to minimise the inactive movements between them. The drawing is
divided into several zones depending on a matrix that you define, and all
objects in each zone will be completed before passing on to the next zone, for
limiting the cumulated distance by always seeking the nearest. The first object
in the sequence is unaffected. Open objects may have their toolpaths reversed
to start from the nearest end.

Machining / Sequence / Sort by increasing depths - makes an automatic

sequence related to the depths of each object (you can then reverse the order if
necessary by using "Machining / Sequence / Reverse" above mentioned).

Machining / Sequence / Inner objects before their contours - sets in the

order of appearance all objects included inside a path before that path, even if
they have not been given a tool compensation.

Machining / Sequence / Order by layers - sets the order of appearance by

placing all objects of the layer #1 as first, then all objects of the layer #2, etc.
The internal sequence of each layer remains unchanged.

Machining / Toolpath / Connect objects - creates a single toolpath to

join independent objects that are adjacent to each other. This single
trajectory can be used for contouring or hatching, but unlike objects that are
welded together, they can be disconnected and regain their independence and
geometric properties (arcs and curves). Please refer to the previous chapter
"Toolpaths" for more details about connected paths and related features.

Machining / Toolpath / Disconnect objects - disconnects

objects that have been connected using the above command.

Machining / Toolpath / Set path object

after object - lets you point one by one the
objects that cross one another. These objects
will be incised at their intersections for
constructing the path. The split parts left
beside the path are not deleted.

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Machining / Toolpath / Weld connections - welds together all connected

objects into a single trajectory. The objects having geometric properties (arcs
and curves) lose these properties and become simple polylines. Only
neighbouring arcs that share the same centre and radius, or neighbouring
Bezier curves, can be welded together without loss of properties. But Beta-
Spline and Quadra-Spline curves cannot be welded unless they become simple
polylines.

Machining / Toolpath / Define as start point / The red point,

the point to be clicked - allows the end point of an object or
connected toolpath to be redefined as the start point. In the case of an open
object, of course that point can be only one of its ends.

Machining / Toolpath / Define as start point / The highest point, the

lowest point, the point which is more at centre, at north, etc. - sets as start
point of the selected object or path the one that is the closest to the chosen
reference. If the object is open, then the closest end is used. Objects having
geometrical properties are not cut.

Machining / Toolpath / Define as start point / The sharpest external

vertex - sets as start point of the selected object or path the one that corre-
sponds to the sharpest angle outwards.

Machining / Toolpath / Define as start point / The sharpest internal

vertex - sets as start point of the selected object or path the one that corre-
sponds to the sharpest angle inwards.

Machining / Toolpath / Close path - closes the trajectory by adding a

segment or adjusting ends.

Machining / Toolpath / Set clockwise - sets the machining direction of

selected objects to clockwise.

Machining / Toolpath / Set counter-clockwise - sets the machining

direction of selected objects to counter-clockwise.

Machining / Toolpath / Reverse direction - reverses the machining

direction (clockwise or counter-clockwise) of selected objects or connected
objects.

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Machining / Tool compensation / Define toolpath - sets an inner or

outer contouring trajectory of the selected object or path, depending on
the tool diameter and profile. Please refer to the previous chapter "Toolpaths"
for full details of tool compensations.

Machining / Tool compensation / Remove toolpath - removes

the compensated toolpaths of the selected objects.

Machining / Tool compensation / Recalculate toolpath - rebuilds the

contour trajectory of the selected objects, removing any entry or exit paths that
have been added manually.

Machining / Tool compensation / Create a new offset object - creates a

new independent object from the
internal or external tool compensation
applied to the selected object. If this
selected object already has a tool
compensation, then its offset contour
trajectory becomes the new object
without asking more. If not, then you
are prompted to define the offset with
simplified calculation parameters.

Machining / Tool compensation / Define as start point - lets you click

directly the positions of the start points of closed compensated paths. If the
tool compensation has a roughing and a finishing path, both must be clicked
separately. The original object trajectory is not modified, only its offset path
changes. If the tool compensation path is recalculated later on, then its start
point returns to the one of the object. Consequently, this operation must be
done last, once the object shape and its tool compensation path have been
definitely validated.

Machining / Tool compensation / Add feed-in segment / … -

allows you to control how the cutter approaches a tool compen-
sated path by defining a horizontal new entry segment, that keeps the same
depth as the previous entry point, thus with a standard drill-in cycle, or uses an
oblique Z slope starting from the top surface of the workpiece. It can also be
chained with the exit point, in which case you click twice on the same object
the feed-in and feed-out segments. Warning: the validity of the new segment is
not checked by the software, especially concerning the fact that it may collide

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with the compensated path trajectory or other neighbouring objects. It is

possible to add successively as many feed-in (or feed-out) segments or arcs as
you like. But if the tool compensation is recalculated (object shape modified,
tool changed, depth changed if the tool is non-cylindrical), then these add-ons
at ends cannot be recalculated and consequently are lost.

Machining / Tool compensation / Add feed-out segment / …

- as above for an exit segment that brings the path away from
the compensation trajectory.

Machining / Tool compensation / Support bridges / Add -

allows you to put, on the tool
compensation paths, bridges of remaining
material which will prevent the cut part from
vibrating when the tool separates it from the
rest of the workpiece, or from flying away if
the path is closed, which is rather usual. The
software asks you to indicate the bridge
width, and if the tool must be completely lifted up at the clearance height or
just leave a small thickness of material, i.e. the cutting depth becomes a bit less
along the bridge, of a given value. Once the machining is completed, material
bridges can be removed manually for freeing the cut shapes. Please note that
these support bridges cannot always be kept when a change in the object shape
requires a recalculation of its tool compensation path. So this operation must
be done last, once the object shape and its tool compensation path have been
definitely validated. The best solution is to set automatic support bridges in the
extended window of tool compensation parameters. Then the calculation
integrates them.

Machining / Tool compensation / Support bridges / Move - lets you

change the position and the parameters of the existing support bridges, to be
pointed in the drawing. In fact, the operation consists of deleting the support
bridge and immediately creating a new one.

Machining / Tool compensation / Support bridges / Delete - allows you

to suppress existing support bridges, to be pointed in the drawing.

Machining / Tool compensation / Support bridges / Change depth - lets

you modify the remaining thickness of the support bridge without having to
point it again.

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Machining / Tool compensation / Support bridges / Delete all -

suppresses all support bridges of the selected objects.

Machining / Tool compensation / Support bridges / Check all - reviews

all support bridges of all tool compensation paths for ensuring that none has a
thickness greater than the machining depth.

Machining / Tool compensation / Internal Sequence / Point the contour

to be machined first - lets you change the machining sequence of the multiple
offset paths for an object. The tool compensation calculation can sometimes
create several pockets or paths if the object shape has narrowings which do not
allow the tool to pass through. This function helps you define the internal
sequence for these multiple paths, without changing the object sequence in the
drawing. The pointing is done directly under the mouse, by clicking the
highlighted path. Warning: if the tool compensation has to be recalculated,
then this change of the internal sequence is reset.

Machining / Tool compensation / Internal Sequence / Point the contour

to be machined last - as above, except that now the tool compensation path
that is clicked becomes last.

Machining / Tool compensation / Flip inside/outside - resets the outer

tool compensation paths to inner tool compensation paths for the selected
objects, and reciprocally.

Machining / Tool compensation / Reverse feed direction - inverts the

machining direction of the tool compensation paths of the selected objects.

Machining / Tool compensation / Select all inner compensations -

selects or adds to the current selection ( key) all objects having a tool
compensated path inside.

Machining / Tool compensation / Select all outer compensations - as

above for all objects having a tool compensation path outside.

Machining / Tool compensation / Filter toolpaths - selects objects

depending on the settings of their tool compensation paths.

Machining / Tool compensation / Advanced parameters - allows you to

control how compensated toolpaths are produced. The angle display threshold

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indicates the minimum angle of the trajectory that will show a circle to
represent the tool. The rolled angle threshold defines the minimum angle that
will trigger an arc around the path point, and the vector stepping. The spacing
percentage smoothes the path before calculations, erasing the points that
appear to be insignificant

Machining / Depths / Summarise - if there are no objects selected, this

displays a summary of all objects and their cut depths, otherwise the list is
limited to the selected objects only. See also the rapid data palettes.

Machining / Depths / Change all - allows the cut depth to be set to the
same value for a group of selected objects.

Machining / Feedrates / Summarise - if there are no objects selected, this

displays a summary of all objects and their feed speeds, otherwise the list is
limited to the selected objects only. See also the rapid data palettes.

Machining / Feedrates / Change all - allows the speed to be set to the

same value for a group of selected objects.

Machining / Duration - calculates the theoretical time required to machine

existing paths, the cleared moves being ignored since they are related to
machining parameters (tool plunge, depth stages, clearance height and
finishing pass) and not considering the kinematical parameters (accelerations
and decelerations) that are necessary for executing the movements.

"Edit" menu

Edit / Undo - successively undoes changes made to the current

drawing from the "Machine", "Edit" and "Design" menus. This only
applies to the drawing process. File, display and parameter functions are not
concerned. The size of the undo stack can be set in the workspace parameters
(up to 50 levels).

Edit / Redo - successively redoes the last undone operations on

the current drawing.

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Edit / Repeat - repeats the last operation performed on the

current drawing from the "Machine", "Edit" and "Design"
menus, using the same parameters. This only applies to the drawing process.

Edit / Restart - undoes the last operation performed on the

current drawing and restarts the function that has been undone,
with new parameters, i.e. again using the dialogue box.

Edit / Delete - deletes the object, point or segment currently selected in

red, i.e. having the focus. Same function as the key.

Edit / Cut - places a copy of the current selection onto the

clipboard then removes the selection from the drawing. See also
"Edit / Copy" and "Edit / Paste" below.

Edit / Copy - places a copy of the current selection onto the clipboard.
This object can then be pasted onto the board or in another drawing
application that accepts vector graphics under EMF format. See also "Edit /
Cut" above and "Edit / Paste" below.

Edit / Paste - places a copy of the objects currently on the clipboard

into the current drawing. This is only supported if it was either copied
from Galaad or from another software package as a vector graphic. See also
"Edit / Copy". You can paste a background bitmap image from the clipboard
using "Display / Background image / Paste".
Please note that a sub-icon "Paste the last but one copy" allows
you to paste the last-but-one object that was copied onto the
clipboard. This icon has no corresponding line in a menu.

Edit / Paste from centre - places a copy of the object currently on the
clipboard into the drawing, positioning its centre instead of its southwest
corner. See comments above.

Edit / Reframe and paste - places a copy of the objects currently on the
clipboard into the current drawing and allows it to be resized at the same time.
See comments above.

Edit / Selection / Select all - selects all objects of the active layer. Tip: the
key selects all across all layers.

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Edit / Selection / Invert selection - deselects the selected objects and

reciprocally selects all objects that were not selected.

Edit / Selection / Select smallest object - is a self-explicit function. Its

major interest is to search for and delete residual micro-objects that cannot be
distinguished because they are too small or they overlap other objects. As
usual, the key lets you add to the current selection, since the objects
already selected are not eligible for that search.

Edit / Selection / Select superimposed clones - searches and selects the

identical paths that overlap each other. It can happen that imported files
include objects that have been duplicated over one another. This is not visible
on the screen or the printer, but the machining makes these objects twice (or
more). The import parameters dialogue box offers an identical option.

Edit / Duplicate / Add one real copy - copies the selected objects and
pastes them at an XY position to be pointed. Machining data (tool,
depth, feedrate) remain unchanged. The original objects and their copies are
independent, unlike the virtual copy (see below).
Edit / Duplicate / Add one virtual copy - copies the selected objects and
places a virtual copy of them at a position to be plotted. The copy remains
linked to the original. In fact it does not exist in the memory or in the file,
which saves space, but it is displayed and machined normally. A virtual copy
follows all modifications of the original.
Note: if you make one or more virtual copies of a set of objects, each series
of copies will be machined immediately after the original. But if your original
objects are associated (see yellow icon of association), then each group of
copies will be fully machined before the next copy. Hence this association
helps to save time when milling. Of course, you may associate objects after
they have been duplicated.

Edit / Duplicate / In line - duplicates the currently selected

objects in a straight line at regular intervals from a position to
be plotted. The parameters for a line duplication are the number of copies, a
possible progressive Z sinking (depths increase for every new copy), and the
ability to make a virtual duplication (ghost copies) or a real duplication (copies
are independent from the original). You must plot the position of the nearest or
the farthest copy.

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Edit / Duplicate / In matrix - duplicates the currently selected

objects in a rectangular matrix at regular intervals to be defined
(number of columns and rows with direction of duplication, intervals between
columns and lines).

Edit / Duplicate / In circle - duplicates the currently selected object at

regular intervals on an arc to be pointed (centre, radius, starting angle). In
addition to the number of copies, you must indicate the angular interval
between two neighbouring copies and the direction of rotation (clockwise or
counter-clockwise), plus an eventual Z
sinking. The rotation around the
centre allows you to make copies
rotate themselves around the
centre of duplication. But then, the
copies being different from the
original, they cannot be virtual copies.

Edit / Duplicate / In kaleidoscope - duplicates the selected object as for a

circular duplication with a rotation about the centre, but welding the intersec-
tions from one copy to the next and deleting parts that
overlap. It is possible to keep either the unions
(intersecting polylines are deleted) or the
intersections (polylines located off intersections are
deleted). This function is for artistic purposes
only, for helping you make repetitive shapes such
as circular arabesques by deleting automatically the
surfaces that overlap each other and welding polylines
between them.

Edit / Duplicate / Mirror / To left, etc. - makes one real copy of the
selected object, mirrored about a vertical (or horizontal) line passing through
the left-most (or right, or above, or below) extremity of the object. Copies are
real and therefore independent from the original. See also "Edit / Clone"
hereafter.

Edit / Duplicate / Mirror / Horizontally (or Vertically), about centre -

duplicates the selected object onto the opposite side of the board about a
central axis of symmetry that can be either vertical or horizontal. Obviously,
the copy is inverted and therefore cannot be virtual.

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Edit / Duplicate / Mirror / About red segment - dupli-

cates the selected object so the copy becomes symmetrical
relative to the segment selected in red. This mirror copy is
obviously inverted compared to the original and therefore
cannot be virtual.

Edit / Duplicate / Mirror / About red point - duplicates

the selected object so the copy becomes symmetrical relative
to the point selected in red (consequently with a double
inversion).

Edit / Duplicate / Mirror / About red cross - as above about red point,
except that here the red cross is used as centre of symmetry.

Edit / Duplicate / Along blue trace -

places copies of the selected object at
regular intervals along the course of a
blue trace, and if necessary moving the
position of the original onto the trace start
point. The Z depth variations of the blue trace can be applied to the copies. It
is possible to rotate every new copy according to the tangent of the blue trace
at the point of duplication.

Edit / Duplicate / On all blue points - places a virtual copy of the selected
object at every point of a group of points selected in blue. Then, for recentring
or adjusting the copies on the points, you just have to move the original and
obviously the virtual copies will follow. The procedure to be followed for
selecting a group of points in blue simply consists of selecting them one by
one or in a Cartesian zone, then click on the yellow icon for inverting red and
blue selections.

Edit / Duplicate / Special - duplicates the selected

object with progressive scaling, rotation, offset and
eventual Z sinking features at every new duplication.
Since copies are different from the original, they are real
and cannot be virtual.

Edit / Duplicate / Trace between points - copies the portion of the

trajectory that is located between a red point and a blue point. Both red and
blue points can be on different objects if these are connected in a single path

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(see "Machining / Toolpath / Connect objects") so Galaad can find its way.
The copy is located on the trajectory itself but can then be repositioned with
the mouse or keyboard.

Edit / Duplicate / At 4 corners of the board / Virtual - makes three

copies of the selected object at the other corners of the board, without
changing its orientation (virtual copies).

Edit / Duplicate / At 4 corners of the board / Symmetrical - makes three

copies of the selected object at the other corners of the board, each of them
being reversed horizontally and vertically.

Edit / Duplicate / Suppress copies - deletes all virtual copies of the

selected object.

Edit / Duplicate / Suppress one copy - deletes one virtual copy of the
selected object by specifying its number (order in which they were created).

Edit / Duplicate / Make copies real - converts all virtual copies of the
selected object into independent real objects. There is no reverse function;
only the immediate undo is possible.

Edit / Duplicate / Make homogeneous copies - this function is used when

two or more objects have virtual copies attached to them and only affects the
virtual copies. The selected object with the largest number of virtual copies is
taken as the datum. All other selected objects with virtual copies are then
modified so that they have the same number of virtual copies with the same
relative offsets in X, Y and Z.

Edit / Clone / Mirror to left, etc. - makes one virtual copy of the selected
object, mirrored about a vertical (or horizontal) line passing through the left-
most (or right, or above, or below) extremity of the object. Only one clone of
an object can exist at a time. The clone is virtual, and is also modified when
the original shape is. But it will be machined like a normal path.

Edit / Clone / Suppress clones - deletes the clones of all selected objects.

Edit / Clone / Make clones real - converts the virtual copy of the selected
object into an independent real object.

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Edit / Libraries / Open - loads an existing library file from the disk and
allows it to be positioned on the drawing, i.e. not whole drawing boards but
only objects. A library object keeps all machining data (tool, depth, feedrate).
The default directory is the last one accessed.

Edit / Libraries / Gallery - displays all objects in a given library and

allows you to select one using a double-click.

Edit / Libraries / Open & rotate - chains the opening of an object in a

library with its positioning in the drawing (about its symmetry centre) and then
automatically calls the rotation function.

Edit / Libraries / Save as - saves the selected objects to the disk, as a

library object, allowing you to give it the name of your choice.

Edit / Libraries / New - creates a new folder within the "Library" folder.

Edit / Library / TrueType symbols - loads a symbol

or a single character from a Windows TrueType font.
A big dialogue box allows you to choose the font and browse all the
symbols it contains. The size (Y height) is settable, and so is the
automatic hatching for filling in the surface of the shape. A double-
click on the symbol selects it.

Edit / Unlock / All - unlocks all locked items in the active layer of the
drawing. Remember that locked items cannot be selected (as objects, but
neither internal segments nor points can be selected).

Edit / Unlock / Mouse select - allows you to unlock the locked object by
clicking on them with the mouse.

Edit / Lock / Lock selected objects - does the same as the yellow icon for
locking, but the fact that it is also in a menu allows you to create a keyboard
shortcut.

Edit / Ungroup / All - ungroups all items in all groups of the active layer,
whether they are selected or not. Bear in mind that the association of objects
makes an automatic selection of the whole group when one of its members is
individually selected.

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Edit / Ungroup / Selected objects - ungroups all items in any groups

selected in red. Note that clicking on the yellow association icon, when
selected objects are already associated, ungroups them if confirmed, without
passing through the menu.

Edit / Ungroup / Mouse select - allows you to extract a single object from
a group by clicking on it with the mouse.

Edit / Ungroup / Mouse selection and associates - allows you to break a

group by clicking on one object with the mouse. All objects in that group are
then ungrouped, even if one only was clicked.

Edit / Ungroup / Select all grouped objects - filters and selects all objects
of the active layer that belong to a group. These objects are not ungrouped but
just selected.

Edit / Ungroup / Group selected objects together - does the same as the
yellow icon for grouping, but the fact that it is also in a menu allows you to
create a keyboard shortcut.

Edit / Unprotect / All - lift the protection from all objects in the active
layer, whether they are selected or not. Remember that protected objects can
just be moved and resized, but neither deleted nor reshaped in any way.

Edit / Unprotect / Selected objects - lifts the protection from the objects
that are selected in red. Note that clicking on the yellow protection icon, when
selected objects are already protected, removes their protection if confirmed,
without passing through the menu.

Edit / Unprotect / Mouse select - allows you to remove the protection of

the objects by clicking on them with the mouse, or select a group of objects by
dragging over them with the mouse.

Edit / Unprotect / Select all protected objects - selects all objects in the
active layer that are protected.

Edit / Unprotect / Protect selected objects - does the same as the yellow
icon for protecting, but the fact that it is also in a menu allows you to create a
keyboard shortcut.

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Edit / Free anchors / All - releases all anchored objects in the active layer.
This applies to both objects anchored in position and objects anchored
together. Bear in mind that absolute anchorage fixes the position of the objects
on the board, and relative anchorage moves simultaneously anchored objects
when one of them is moved in its own.

Edit / Free anchors / Selected objects only - releases all anchored objects
that are selected in red. If anchoring is relative, only the selected objects are
released from the group. Note that clicking on the corresponding yellow
anchorage icon (relative or absolute), when all selected objects are already
anchored in the same mode, releases them if confirmed.

Edit / Free anchors / Selected objects and acolytes - releases all anchors
on objects selected in red and those existing between other objects in an
anchored group of which they are members.

Edit / Free anchors / Mouse select only - allows you to release a single
anchored object by clicking on it with the mouse, or select a group of objects
by dragging over them with the mouse. If anchorage is relative, then only
clicked objects are released from the group.

Edit / Free anchors / Mouse select and acolytes - releases the anchors on
objects selected with the mouse and those existing between other objects in an
anchored group of which they are members.

Edit / Free anchors / Objects located in different layers - releases the

anchors between objects belonging to different layers. Of course, these objects
do not have to be selected.

Edit / Free anchors / Select position-anchored objects - filters and

selects all objects anchored in position. These objects remain anchored. The
function does not free them.

Edit / Free anchors / Select relation-anchored objects - filters and

selects all objects anchored together. These objects remain anchored. The
function does not break the anchoring links.

Edit / Free anchors / Select acolytes of selected objects - selects all

objects that are anchored together with those selected. The function does not
break the anchoring links.

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Edit / Free anchors / Anchor selected objects on position - does the

same as the yellow icon for position anchoring, but the fact that it is also in a
menu allows you to create a keyboard shortcut.

Edit / Free anchors / Anchor selected objects together - does the same
as the yellow icon for relative anchoring, but the fact that it is also in a menu
allows you to create a keyboard shortcut.

"Design" menu

Design / Magnetic grid / Set - sets the step size for the magnetic snap
grid. Leaving a value unset or set to "auto" defines for X or Y inde-
pendently a variable step that always matches the smallest graduation of the
rulers, whatever the zoom is. The angular step applies a polar grid relative to
the previous point when the key is pressed during a line drawing or other
similar pointings. For more details about the magnetic grid, please refer to the
chapter "Learning to draw". No offense meant.

Design / Magnetic grid / Snap to grid - causes the selected object to jump
to the nearest snap point of the grid values currently set. This is useful if the
grid values have changed or if objects were drawn with the grid inactive.

Design / Magnetic grid / Snap and size to grid - as above, but

the object will be also resized so its borders fit between the
nearest snap points.

Design / Align & centre - pops up a window for selecting

among all possible alignments and centring, horizontally,
vertically or both. The palette is wide and should match almost all cases. In
addition, let us remember that, when you move an object with the mouse,
orange lines appear that you can snap for matching neighbouring objects (left
hand side, top side, centre, right hand side, bottom side). The left mouse
button is already pressed at that moment since you are dragging the selection
frame, so snapping orange lines can be done through the bar or in
two stages through and keys.

Design / Object / Change layer / Layer N - moves the selected objects to

'Layer N'. See the zero point of the rulers (bottom left of screen) for the current

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layer number. The rapid data palette, when "Layer" mode is enabled, does the
same without running through the menu, and allows you to jump from one
layer to another. See hereafter the functions at the top of the "Display" menu
to set up the visible layers and the active one.

Design / Object / Duplicate into another layer / Layer N - as above,

except that the object is duplicated into the target layer and the original
remains in the current layer.

Design / Object / Open - opens a closed object by deleting the last point
drawn (and consequently the last segment). If the object is an arc, then it is
transformed into a semi-circle (or half-ellipse), i.e. 180° from the start point,
with the same rotation direction. If it is a curve, then its last sector is deleted,
and its geometrical properties are kept.

Design / Object / Close / By adding a point - closes an open object by

adding an additional point (and consequently another segment). If the object
has geometrical properties (arc or curve), then the object closure is made by
adding a sector of the same nature (arc or curve sector), and its geometrical
properties are kept.

Design / Object / Close / By moving last point - closes an open object by

moving the end point so it coincides with the start point, which does not
change. If the object has geometrical properties (curves only), then the
adjustment is made by moving the last sector and the geometrical properties
are kept.

Design / Object / Close / Through red cross - closes an open object by

adding segments from end point to red cross and from red cross to start point.
If the object has geometrical properties (arc or curve), this function does not
apply. You must first convert the object into a simple polyline.

Design / Object / Degrade - distorts the selected object

according to framed random values that move the XYZ
coordinates. To avoid degrading the depths, just set the Z
variation to 0%. The geometrical properties of the object (arc
or curve) are obviously lost when degrading.

Design / Object / Link - constructs a new object between the end points of
two objects of the same type, one end point having been selected in blue and

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the other in red. The type of the new object will depend on the existing objects
and the depth will, if required, slope to join them.

Design / Object / Weld - is an important function of the drawing,

which lets you assemble independent paths into one single object. If a
point is selected in red, then the function snaps the object that has an end close
to that point, and fuses it with the object that holds the red point. The snapped
object loses its machining data: the resulting object will take its feedrate from
the one containing the red point, which is the master and will retain all of its
properties. This function also applies to a set of selected objects, to weld their
nearest ends together. In the latter case, you are prompted to indicate a
maximum welding distance to avoid snapping objects too far. If the newly
created object is almost closed, it can be closed automatically by adjusting its
outgoing end.
Note that certain objects cannot be welded together, namely those that have
been drawn for use with different tools, protected objects and hatch lines.
Welding objects erases the geometrical properties of each object, except if
they are of the same nature and can be extended, like Bezier curves. See also
the reverse command "Design / Object / Split", just below.

Design / Object / Split - does the opposite of the welding

function by separating the object ‒ if not protected ‒ into two
independent objects, on either side of the point selected in red. Both resulting
parts lose their geometrical properties in the case of a curve. To split a Quadra-
Spline or a Bézier curve at a node whilst keeping its properties, you must edit
its geometry (right mouse click), click on the node so it is given the focus, then
press the key.

Design / Object / Geometry handles - displays the control points used by

Beta-Splines, Quadra-Splines or Bezier curves. Selecting them
with the right mouse button does the same thing, directly or
through a pop-up menu.

Design / Object / Convert to polyline - erases the geometrical properties

of the selected object (arc, curve or text). In the case of text, the function "Text
/ Convert to polylines" does the same but keeps the text block associated in a
single selection group.

Design / Object / Define as hatching - defines the currently selected

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object as hatches. Objects created by hatching or pocketing are automatically

given this flag. Objects defined as such cannot be welded and can be selected
by the filters.

Design / Object / Create framing rectangle - draws a rectangle that

matches the borders of the selection frame.

Design / Object / Create cylindrical projection - stretches the selected

object so that its projection on the cylindrical workpiece corresponds to the
plan view from above, for example for cutting the circle of a welded tube.
Then the wrapped machining does not describe a circle but an oval shape,
stretched in Y directions (angular direction of the wrapping).

Design / Object / Replace each object with a point / At start point -

replaces each selected object by a simple drilling point located at its starting
point.

Design / Object / Replace each object with a point / At centre of

symmetry - as above, except that it sets the newly created point at the object's
symmetry centre.

Design / Object / Surface - calculates the surface covered by the closed

object (or connected toolpath) that is selected. If several closed objects are
selected, the result is the sum of all surfaces, even when they overlap one
another. An open object has a null surface. A toolpath in "8" like a Moebius
tape will have a surface that is partly positive and partly negative, and
consequently a truncated result. Don't ask for too much…

Design / Object / Trace length - displays the total length of all

selected objects and indicates the number of points they contain.
This calculation obviously does not apply to isolated drilling points or groups
of points.

Design / Object / Distance between points -

displays the distance and angle between two XY
coordinates to be plotted on the board, not necessarily on
objects. The result is displayed as a movable strip. After
the second click, a simple mouse movement will make it
disappear so you can loop to the next measurement.

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Design / Object / Adjustment from two points - adjusts (i.e. stretches or

reduces, plus rotates) the selected objects depending on the distance and angle
between two points that can be outside these objects.

Design / Object / Display ISO G-code - displays a simple G-code

programme for the selected objects to assist in checking the coordinates. This
is read-only: trying to modify the code is pointless.

Design / Object / Copy tool-depth-speed - does the same as the green

icon for copying machining data from the selected object. This function is also
in a menu so you can create a quick keyboard shortcut (see "Parameters /
Function keys").

Design / Object / Paste tool-depth-speed - related to the previous

function, does the same as the green icon for pasting the previously copied
machining data into the selected objects.

Design / Object / Visual - does the same as the option "Visual object (will
not be machined)" in the dialogue box for setting the tool, depth and speed,
available from the green icon on the left hand side of the screen. This function
is also in a menu so you can create a quick keyboard shortcut (see "Parameters
/ Function keys").

Design / Polyline / Delete parts where clicking - is a very important

function for drawing, which can help you suppress parts of the objects
very quickly by simply clicking on
them. A part is limited by an end or
an intersection with another path,
which avoids incising and deleting
operations. Warning: the remaining
parts are not connected automatically. You must then proceed with these
connections.

Design / Polyline / Select inner objects - automatically selects all objects

that are entirely contained in already selected objects. As usual, the classical
key allows the addition of new objects to the current selection, conse-
quently including the contour. If an object is open, the function acts as if a
segment was linking its ends.

Design / Polyline / Select overlapping objects - as above, except that it

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filters only the objects that cross the selected ones, namely having a part inside
and a part outside.

Design / Polyline / Select outer objects - as the two above, except that it
filters only the objects that are entirely outside the selected ones.

Design / Polyline / Link vertices - produces a polyline from a group of

selected points, by drawing a series of connected lines between the points, in
the order in which they were originally drawn. The point coordinates remain
unchanged. See also the reverse function, below.

Design / Polyline / Unlink vertices - produces a series of points at the

vertices of a selected polyline by removing the segments
connecting them. See also the reverse function, above.
The major difference with the drawing icon "Points on
trace" is that the selected object is changed in isolated and grouped
points, though the icon adds isolated points without changing anything in the
selected object.

Design / Polyline / Explode into segments - changes the

selected object in as many independent segments.

Design / Polyline / Link objects - is the reverse function of the above,

since it recombines in one single polyline independent segments or isolated
paths, provided that their ends match.

Design / Polyline / Set steps - inserts additional points along the trajectory
of the selected polyline, by linear interpolation based on the maximum
distance between two consecutive points (or maximum length of a vector),
distance to be set by you.

Design / Polyline / Increase steps - inserts additional points along the

trajectory of the selected polyline by linear interpolation based on the multipli-
cation factor, number to be set by you. The difference with the above function
is that each segment of the selected object is concerned, whatever its length.

Design / Polyline / Delete useless points - deletes all intermediate points

along the length of a trajectory that have no effect on the object shape and thus
neither visible nor useful (coordinates are aligned).

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Design / Polyline / Substitute to the closest path - replaces a neighbour-

ing path by the one selected. This function aims to redraw a part of a rough
polyline without needing to split its ends, replace the part and
then weld it back into the original path. For example, you
can replace the jerky part of a path with a Bezier curve,
drawn as closely as possible. The substituting path is a
selected object which does not need to perfectly match the ends of the
part to be replaced.

Design / Polyline / Simplify path - reduces the roughness of a jerky path,

for example after having vectorised a bitmap image, by trying to find
a smoother curve which complies as much as possible with the
significant sharp angles. The path can be a whole selected
object, or the part of an object between the points selected
in red and in blue. Warning: the calculation is heavy and
can be time-consuming.

Design / Polyline / Smooth path - produces a new trajectory from the

selected polyline by generating a Bezier curve that passes through its vertices,
allowing you to specify by how much the curve can deviate from the original
polyline, which is kept.

Design / Polyline / Smooth angles - more or less as above, except that

vertices correspond to attractors of the Bezier curve and node points are the
midpoints of the path segments. It is a smoothing that runs closer to the
original polyline. Warning: this original polyline is not kept.

Design / Polyline / Create equivalent Beta-Spline - produces a new

trajectory from the selected polyline by generating a Beta-Spline that uses the
vertices from the original polyline as its control points. This
is exactly as if you were plotting these vertices one by
one for building the spline. Let us remember that the
maximum number of points in a Beta-Spline is 256,
which gives some space for unleashed creativities.

Design / Polyline / Create equivalent Quadra-

Spline - produces a new Quadra-Spline from the
vertices of the selected polyline.

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Design / Polyline / Create equivalent Bezier

curve - produces a new Bezier curve from the
vertices of the selected polyline.

Design / Point / Select all isolated points - selects as objects all points
that are present in the active layer. This helps you check that there will be no
unexpected drills in the workpiece to be machined, since the points are not
always clearly visible on the screen, especially when they are covered by a
path, a visual dimension or an identifier, or are simply located outside the
zoom window.

Design / Point / Insert a point on a trace - interpolates a new

point on the segment that you point, and selects it in red. Much
faster, the double-click with the mouse right button on
any segment interpolates a point that is immediately
selected in red, so you can handle it at once for
repositioning.

Design / Point / Delete points to be clicked - suppresses the

points or the polyline vertices, or vertices in other traces without
geometrical properties, that you are going to click.

Design / Point / Delete red point - suppresses the vertex selected as red
point. The key does the same when the red point has the focus.

Design / Point / Set a cross mark at given distance - fixes a red or blue
reference cross on the path, at a given distance from the point of
this path that is selected in red. This distance may be negative for
fixing the cross backwards.

Design / Segment / Delete segments to be clicked - suppresses

the segments on which you are going to click, a segment being
understood as going to its end or its intersection with another object. The
green highlighting shows what will be indeed suppressed.

Design / Segment / Delete red segment - suppresses

the segment selected in red and consequently splits the
object path. The key does the same when the red
segment has the focus.

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Design / Segment / Divide red segment - inserts one additional point

along the length of the red selected segment at the position
of your choice, according to a given distance that you
can set absolute or proportional to the vector (default
being half the length).

Design / Arc / Edit - opens a

dialogue box allowing you to edit all
features of the currently selected arc,
including centre point, radius, start and
end angles, etc. which is equivalent to
editing its geometrical properties with
red graphical handles, then press the
key for entering the circular
dimensions and the stepping data.

Design / Arc / Select all arcs

(open, closed, elliptical) - selects the
corresponding arcs in the active layer.

Design / Arc / Select by filtering diameters - selects all arcs from the
active layer depending on their diameter, between a minimum and a maximum
value to be indicated.

Design / Arc / Set the diameter of all selected arcs - applies to the
selected arcs a unique diameter to be indicated.

Design / Arc / Define borings - adds to the selected circles a boring path
that includes the tool compensation and the plunge mode, either helical milling
or basic vertical drilling. The objects are not modified, so if you need to return
to original circles, then you just have to erase the tool compensation paths that
this function adds.

Design / Arc / Replace circles by points - deletes the selected circles and
replaces them by simple drill points at their centres.

Design / Arc / Replace points by circles - deletes the isolated points that
are selected as objects (i.e. not a red point) and replaces them by circles being
given the indicated diameter.

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Design / Arc / Clockwise - sets the direction of the selected or edited arc
as clockwise. Opened or closed, the arc does not change its appearance but
only its direction, starting and ending points being swapped.

Design / Arc / Counter-clockwise - as above, except that the new arc

direction is counter-clockwise.

Design / Arc / Close - closes the selected or edited arc. The starting point
remains unchanged.

Desin / Arc / Complementary - changes the selected or edited arc into its
complementary arc, if open.

Design / Arc / Circular stepping - sets the vector stepping of

arcs and ellipses, namely the angle between two consecutive segments
along the arc. When milling, this stepping is reused for arcs of ellipses, or
even arcs of circles if your machine does not make circular interpolation
(see the machine parameters). Two automatic stepping modes are
available, that reduce the angle step depending on the diameter, so you
need not worry about the stepping whatever the arc size: the
greater the diameter, the smaller the stepping angle becomes, and reciprocally.
The result is rounded to the floor value of the following scale: 0.1° (minimum)
/ 0.2° / 0.5° / 1° / 1.5° / 3° / 5° / 10° / 15° (maximum). The automatic mode
with maximum vector-arc distance is probably the most common in CAD
applications.

Design / Arc / Set a cross mark - places a red or blue cross on the
selected arc at an angle to be entered.

Design / Arc / Reset the arc from the polyline - recovers the geometrical
properties that an arc may have lost after being changed into a polyline. The
arc must more or less correspond to the trace, the tolerance range being short.
Tip: if you import drawings that contain drilling or boring circles but have
not been imported as circles, you can select all and use this function for
restoring circles where they are found. Then you can eventually replace these
circles by simple points (see above) if you just want to drill to the diameter of
the tool. Finally, you can replace the points by circles with a diameter to be
specified, if needed.

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Design / Slot / Add - allows you to place mechanical mounting slots

on cut shapes. The function lets you plot directly on the existing objects:
first you locate the notch point somewhere on a path, then you set the
angular direction of the groove with a second click. Finally, the
software asks you to validate the width, depth and direction angle.

Design / Slot / Delete - suppresses a slot that has been added to a path.
This slot must be pointed directly and will be highlighted in green.

Design / Slot / Change - changes the appearance of a slot to be pointed

directly (width, depth, angle). It is possible to point successively several slots
to be modified.

Design / Slot / Delete all - suppresses all slots that have been added to the
selected objects.

Design / Slot / Change all - changes in one single operation the appear-
ance of all slots that have been added to the selected objects.

Design / Hot-wire connection / Manual, on closed contours - adds a

direct linking line or double-line between two independent objects, by pointing
directly on each, at an accurate position on their
path. The resulting object is unique. The "Hot-
wire connection" functions have been made
especially for cutting polystyrene using a
hot wire, generally on 2 axes where it is not possible to make inactive linking
movements with the tool up: the machining path has only one single point of
entry into the material and one single point of exit. If the points that have been
plotted do not correspond to an end, then the connection makes a round trip.

Design / Hot-wire connection / Automatic, on internal islands - adds

round-trip connections between contouring objects and inner objects, for
example to connect the internal island of a letter A or both internal islands of a
letter B (in the latter case, both islands are connected together and one of them
is connected to the contour path).

Design / Hot-wire connection / Automatic, on selected objects - adds

round-trip connections between all selected objects, contours or internal
islands, by using the nearest points. Once the operation has been completed,
there is just one single object and consequently a unique path of the hot wire

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for cutting the whole set. The function asks you to position the point of
entry/exit of this set, generally at an easy location for engaging the wire.

Design / Hot-wire connection / Check path - allows you to

follow dynamicallly the hot wire motion along the path of the
selected object. The keyboard arrows make the hot
spot move slower or faster, slowing down can even run
backwards if necessary. The key stops the checking
function.

Design / Hot-wire connection / Delete - suppresses a simple or round-trip

connection between two objects, from a direct pointing with the mouse.

Design / Hatching - fills the surface of the selected object or connected

toolpath with hatches to be defined. Please refer to the chapter "Tool-
paths" for more details about hatching and pocketing functions.

Design / Pocketing cycles - fills the surface of the selected

object or connected toolpath with successive contour lines in a
pocketing cycle. Again, please refer to the chapter "Toolpaths" for more
details about pocketing functions.

Design / Overall contour / Convex - constructs a

convex external contouring polyline of the selected objects.
This contour has no inward angles.

Design / Overall contour / Union - constructs an

external contouring polyline of the selected objects. This
contour may be open.

Design / Overall contour / Intersection - constructs an

internal contouring polyline of the selected objects. This can be
calculated only if there is one single solution.

Design / Path Contour - constructs a new object by running a cutter round

both sides of an open shape or the outside of a closed shape.
If the selected object is closed, the contour produces two
paths.

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Design / Transmutation - creates the successive

intermediate shapes between two selected objects,
which must not be connected paths. For example,
from two objects that represent topographic contour
lines, this function will interpolate intermediate curves,
or an object with an internal island will be given successive
pockets that transform one into the other. There must be other
more or less useful applications for that function.

Design / Box & cap - constructs, from closed and selected objects, sets of
boxes and caps, typically for obtaining shop sign letters with internal lightings,
cut in a thick material for the box. The original object path defines
the overall edge and is assigned a classical external tool
compensation for cutting. This path is duplicated inside with
an offset for giving a thickness which will create a vertical
wall. This wall is also assigned a tool
compensation inside for setting a deep
excavation with a low floor. This vertical wall can have,
in its inner side, a small shoulder so a flat cover
can fit in. If the original object integrates an
internal island, then the paths created are
inverted inside/outside for a coherent result.
Finally, the cap itself is optional and its
cutting corresponds to the internal border
of the wall minus a small clearance for
nesting. It is transferred into an alternate layer
since it will probably be machined in a thinner material with
another colour or transparency.

Design / Mask / Inside - splits and eliminates

the parts of non-protected objects that are
located inside the object or connected path,
selected in red. This function corresponds to an
incision (paths are cut with new coordinates
created at the intersections), followed by a deletion of the object parts that are
inside the original selection. The selected object or path can be open, in which
case a virtual segment is added to close it. The cut objects that are partly
deleted lose their geometrical properties (arcs, curves or text). Please
note that one of the delete icons does the same.

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Design / Mask / Outside - as above, except

that it eliminates the parts of non-protected
objects that are located outside the object or
connected path, selected in red, instead of
inside. Please note that one of the delete icons
does the same.

Design / Incise - cuts, at the points of intersection, any objects

not protected that are intersected by the current selection. The
paths of the selected objects becomes a blade for cutting everything it crosses.
Alternatively, if no objects are selected, the mouse can be used to
define where the incision should be made (simple line). The
major difference with the "Design / Object / Split"
function is that the target object can be cut anywhere, not
only at an existing vertex. The incision may be multiple, with
the mouse line or the incision path selected in red. Incised
objects lose their geometrical properties (curves or texts, but not arcs).

Design / Trim / At selected object - cuts, at the point of intersection, any

objects (neither selected nor protected) that are intersected by the selected
trimming objects and deletes the remaining parts. In the case of an open shape
that is intersected only once, the shortest part is deleted. However,
with open shapes that are intersected more than once, or with closed
shapes, the pieces between the end points and the first points of intersection
are removed. The trimming selected objects are not affected. The link/trim
icon in the "Polylines" series appears to be easier in most cases, but this
function allows you to trim several objects in a single operation.

Design / Trim / Selected objects only - as above, except that only the
selected objects are affected, i.e. they are all cut and trimmed. Warning: the
sequence affects the result.

Design / Trim / Blue segment at red segment - cuts a blue segment at the
point where it is intersected by a red segment and removes the shortest part of
the blue segment.

Design / Trim / Red segment at blue segment - cuts a red segment at the
point where it is intersected by a blue segment and removes the shortest part of
the red segment.

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Design / Trim / Red and blue segments at intersection - cuts both a red
and a blue segment at the point of intersection and removes the shortest parts
of both segments.

Design / Chamfer - chamfers the vertex of a polyline to be

clicked (or the point selected in red, if any) or alternatively all the
vertices can be chamfered if the whole object is selected. Several
chamfering methods are available, plus a filtering function for the vertices of
the selected object.

Design / Fillet / Simple, on vertices - as above, in the same

conditions to be defined, inserts a single fillet radius at vertices
instead of a chamfer segment.

Design / Fillet / Complete, for nesting - suppresses all sharp angles of the
selected object and replaces them by fillets
which correspond by default to the diameter
of the cutter used, so it becomes possible to
assign later tool compensations inside and
outside that will be able to perfectly match each other once
the parts are cut. Due to its own diameter, the tool cannot
cut to the deep end an inward angle, and a protruding angle on
a cut edge corresponds to an inward angle on the edge of the other
part that will itself be adjusted. Consequently, all angles are rounded.
You can also add a little clearance to the suggested default diameter. This
function has been made for cutting marquetry polygons. The original object is
kept but switched to visual (not machined).

Design / Fractal - is a function for artistic purpose only. It constructs a

fractal drawing by replacing each segment of an object selected in red with an
object selected in blue, suitably scaled to fit, on the condition that the blue
object is an open shape. Then a
copy of the blue object path replaces
every segment of the red object. This
operation is interesting only if repeated
several times.

Design / Equation / Simple y=f(x) - constructs a simple plane curve based

on a mathematical formula to be entered. The maths fans will immediately and
delightfully be projected into the frozen and sophisticated universe of applied

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geometry, while the others will run away towards the next pages. Based on a
few equations and much phosphorus, you can create a 2D or 3D trajectory as
accurate as a polynomial. Warning: without wanting to state an academic
platitude, let no one ignorant of geometry enter here. Two small examples
using the very basic y=f(x):
On an empty drawing board whose dimensions are about 100  60 mm,
call function "Design / Equation / Simple y = f(x)" and enter the equation
Y = 20*SIN(3,6*X) in the box at the top of the window. Set as origin point
Yo = 30 mm and for definition interval for X from 0 to 100 by steps of 1 mm.
Validate the whole: what comes out of it a
beautiful sinusoid curve on one period, that you
could have drawn much more easily by using the
corresponding icon in the series of polylines and
curves.
Please note that the function SIN() of the syntax analyser uses degrees and
not radians. So the result was a variation of X from 0 up to 100 by steps of 1
and, consequently, a sine argument varying from 0 to 360°. The amplitude is
set by the multiplication factor at left hand side of the sine, here 20 mm, and
the depth is indicated by the box Zo.
Another one just for the fun:
Y = 10*LOG(X) with X varying from 1
to 100 by steps of 1, and Yo = 30 mm.
If you abuse zero for the function LOG(), then a horror message will pop
up to call you to order. It will be the same if you pretend to divide by zero,
extract a negative square root and several other insanities which will make the
real insiders shake their heads, with them is our salvation.
Keep in mind that the functions of the syntax analyser remain available
when entering directly coordinates or any numerical value. For example,
you may enter "Abs(12.34+5.67*CosR(PI/8.9))" instead of a dimension in a
dialogue box, hoping that this big effort on your part will help you reach the
contemplative life. Unfortunately, the calculation is direct and the formula is
lost as soon as the result has been validated.
The functions that are known to Galaad syntax analyser are:
ABS (...) returns the absolute value
ATG (...) returns the arc tangent, in degrees
ATGR (...) returns the arc tangent, in radians
COS (...) returns the cosine, in degrees

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COSR (...) returns the cosine, in radians

CUBE (...) returns the cube
EXP (...) returns the exponential ex
FRAC (...) returns the fractional part
HCOS (...) returns the hyperbolic cosine
HSIN (...) returns the hyperbolic sine
INT (...) returns the integer part
LN (...) returns the natural (Naperian) logarithm
LOG (...) returns the decimal logarithm
RAND (...) returns a randomised value (max argument = 999)
RND (...) returns the value rounded to the nearest whole number
SIN (...) returns the sine, in degrees
SINR (...) returns the sine, in radians
SQR (...) returns the square
SQRT (...) returns the square root
TG (...) returns the tangent, in degrees
TGR (...) returns the tangent, in radians
Known constant: PI, without brackets, no need to introduce.

Design / Equation / Triple (x,y,z)=f,g,h(t) - constructs a curve in the

space from three equations. The available maths functions are the same as
those described above. Example, on a drawing board whose dimensions are
100  60  30 mm, enter the following equations:
X = 20*COS(3,6*T) Y = 20*SIN(3,6*T) Z=1
Now the variable is named T and varies in a definition
domain from 0 to 100 by steps of 1. A cosine on X, a sine on
Y, the whole being developed on 3,6  100 = 360 degrees with
a main amplitude of 20, all this looks very much like the
circumference of a circle with a radius of 20 mm.
Do not forget to set the centre of your board for Xo and Yo. You can have
fun entering the following equations, for a variable T varying from 0 to 1 by
steps of 0.01 with Xo and Yo still at the centre of your drawing board.
Spiral: X = 20*T*SIN(4*360*T)
Y = 20*T*COS(4*360*T)

Cardioid: X = 10*(2*SIN(360*T)-SIN(2*360*T))
Y = 10*(2*COS(360*T)-COS(2*360*T))

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Epicycloid: X = 20*COS(360*T)-2*COS(10*360*T)
Y = 20*SIN(360*T)-2*SIN(10*360*T)

Trochoid: X = 20*COS(360*T)-4*COS(10*360*T)
Y = 20*SIN(360*T)-4*SIN(10*360*T)

Lissajous: X = 30*SIN(2*360*T)
Y = 30*SIN(3*360*(T+0.05))

For the same price, you can find hereafter their general equations, for T
being an angular variable that runs from 0 up to 360 (degrees):
Spiral: X = SIN(N*T)*R*T/360
Y = COS(N*T)*R*T/360
where N is the number of revolutions and R the max radius.
Cardioid: X = R*(2*SIN(T)-SIN(2*T))
Y = R*(2*COS(T)-COS(2*T))
where R is the size of the cardioid.
Epicycloid: X = (R1+R2)*COS(T)-R2*COS(((R1+R2)/R2)*T)
Y = (R1+R2)*SIN(T)-R2*SIN(((R1+R2)/R2)*T)
where R1 and R2 are the radii of the inner and outer circles of
the epicycloid.
Trochoid: X = (R1+R2)*COS(T)-H*COS(((R1+R2)/R2)*T)
Y = (R1+R2)*SIN(T)-H*SIN(((R1+R2)/R2)*T)
where R1 and R2 are the radii of the inner and outer circles of
the trochoid, and H the offset of the mobile point.
Lissajous: X = AX*SIN(FX*T)
Y = AY*SIN(FY*(T+Delta))
where AX and AY are the amplitudes of the Lissajous ellipse, FX
and FY the horizontal and vertical frequencies, and Delta the
small dephasing between both amplitudes.
This awful litany is indeed extensive. In fact, the only limit to creating
'Potatoid' curves is the imagination and perhaps the user's geometric spirit. But
there is more to life than maths.
And, to end on a high note which is going to catapult us into the third
dimension, a small triple equation, T varying from 0 to 600 by steps of 1:
X = 20*COS(3,6*T)
Y = 20*SIN(3,6*T)
Z = T/20

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Note the definition interval from 0 to 600, which will give an angular variation
in the sine and cosine from 0 to 2160°, actually 6 revolutions. Do not forget to
set the centre of the drawing board for Xo and Yo. At first sight, the result is a
stupid circle centred in the middle of the board. Call up the 3D view of the
thing, you will see that it is in fact a helix which sinks down into the board
thickness, and which seems evident considering the linear variation of Z. It is
up to you to play: here, all things are numbers.

Design / 3D mesh / Rectangular - constructs a rectangular 3D mesh with

a cross-sectional profile in the XZ plane, that follows the XY profile of the
selected object or the two selected objects. Two examples can help you
understand:
Draw any curve, for example a Bezier curve, with the trajectory going
from left to right with no overlapping parts, i.e. no two points should have the
same X coordinate. The curve must go continuously from a lateral border
to the opposite and not double-back on itself, but Y coordinates can go up
and down.
Got it? Now select the curve and use "Design / 3D mesh / Rectangular".
This pops up a dialogue box requesting the spacing of the mesh and a few
additional parameters. Complete it without asking more questions and validate.
You will be returned to the drawing board, then asked to define the rectangular
area of the mesh. Use the mouse to drag over a large rectangle that covers
most of the board and is wider than it is tall, (X > Y), but don't worry if it
overlaps with the curve.
Galaad will then generate a wiremesh, the
accurate XY size of the rectangle, and
use the profile of the reference curve
to generate the variations in the Z
depth. The 3D view is automatically
displayed.
Depending on the drawing of your curve and the thickness of your
material, it is possible that you will get an error message stating maximum
depth exceeded. Ignore this for now. With two shapes and three movements,
you have constructed a mesh describing a 3D surface. The rest of the game is
just variations on a theme.
Returning to the XY view, the reference curve is no longer selected, but is
still present on the board and has changed colour. Galaad understands that it is

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an object used to produce the drawing but not to be machined and conse-
quently transforms it into a visual object. Anyway, it has not lost any of its
characteristics and can be modified if you so wish.
Now delete your wiremesh and draw a second curve, for example an arc
with a large radius, then select them both. So you have two different refer-
ences selected. Bring up the rectangular mesh function with
exactly the same parameters. Galaad is going to
construct a new wiremesh that will
make the progressive transition from
one shape to the other. The overall Y
position of each curve determines which
one will be close to each border of the mesh
rectangle.

Design / 3D mesh / crossed - constructs a rectangular 3D mesh following

the XY profiles of the two selected objects having perpendicular general
orientations.
Draw two simple objects, for example again a
Bezier curve and an arc with a large radius. Lay them
out such that one is generally in the X direction and
the other in the Y direction without doubling back, as
illustrated here.
Select them both, use the function and provide the necessary parameters in
the dialogue box. This time, Galaad does not ask you to define a rectangle but
constructs a mesh from the two curves, using the intersection point and their
lengths to define the mesh size and position. It is as though
you had drawn the XZ and YZ lateral sections of
your mesh. It is a bit like if you had drawn
the XZ and YZ lateral profiles of your mesh.
The shape of the Y oriented curve is applied
to the depth first, followed by the X oriented
curve to produce the overall 3D effect.

Design / 3D mesh / Circular - constructs a circular 3D mesh following the

XY profile of the selected object. The path from left to right of the selected
object will be running from the centre to the periphery of the mesh.

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Delete everything from the drawing

board and draw a Bezier curve, similar
to that shown on the left, using the
appropriate drawing icon. As before,
ensure that the curve does not double-
back on itself in the vertical plane.
Select the curve and use the "Design / 3D mesh / Circular" command, then
provide the necessary parameters for the mesh. Finally, you have to draw two
concentric circles with different radii. Make one of them small and the other
large so that a decent sized mesh is produced. Forget the aperture and orienta-
tion angles which do not matter for the moment.
Galaad performs a few calculations, then
displays the results in the form of a
circular or toroidal mesh comprising
concentric and radial mesh lines,
depending on your parameters. The
quad view is then called automatically if
it was not already active, so that you may
admire the results.
Take a cross section along any of the radial mesh
lines, the original reference curve is clearly visible.
The variation in depth of each radius, from the centre
outwards, follows the profile of the curve from left to
right.
Here again, the absolute dimensions of the reference curve do not matter
because they will be adjusted to match the length of the radii, which are
defined by the distance between the inner and outer circle. Each concentric
circle in the mesh is confined to an XY plan (the depth is constant) and
consequently can be machined with a 2½D machine. Alternatively, you can
define the inner construction circle as having a radius of zero, namely a point,
to avoid having a hole in the centre of the mesh. If you have selected two
objects as references, the mesh will follow a progressive transformation
from one to the other (from the starting angle to the ending angle). This
allows you to create partial meshes with limited aperture angles, passing
smoothly from one mesh to another, following the shapes drawn.

Design / 3D mesh / Revolved - constructs a semi-cylindrical 3D mesh on

the board, following the XY profile of the selected object. This type of mesh is

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to the cylinder what the circular mesh is to the disk. Start with something
simple and generate an arc, with a very large radius, by using the icon for an
arc defined by three points. You can equally use any other icon that will allow
you to produce a similar result. Don't worry about being precise, it is not too
important. Select it and position it somewhere towards the top of the board.
Now use the function and quickly move on past the dialogue box that appears.
Position the horizontal axis about half way
up the board and click to set the position.
This will be the axis around which the
shape will be revolved. Once again,
Galaad knows how to manage the
situation itself and will rotate the curve
through half a revolution to produce the
corresponding mesh.
If you are unfortunate enough to trigger an error message telling you that
the thickness of the material has been exceeded, don't worry, just accept it. For
now it is important to understand how the function works, you can always
work out for yourself any questions relating to thickness when you come to
machine the thing.
It goes without saying that you can also do
the same thing with different reference
objects, and they will produce an even
more complex result. As with all the
other types of mesh, avoid any
doubling back as this will produce a
mesh that will be difficult or
impossible to machine.

Design / 3D mesh / Sheaves - constructs a 3D mesh following the profiles

of the two selected objects. This type of mesh reuses the drawing technique for
sheaves between two objects selected in red and in blue. In this case, it is
necessary to first set the 3D profile of each, using the plane inversion func-
tions from XY to XZ or YZ. Galaad will just create sheaves between them, but
will nevertheless add the perpendicular mesh.

Design / 3D mesh / Lofted - constructs a 3D mesh following the succes-

sive XZ profiles of the selected objects, for example the cross sections of a
boat hull or an airplane wing. Granted that it is a bit more complicated, but it

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can be viewed as an extension of the rectangular mesh method. The aim is to

draw, in XY, a series of XZ sections, which will be used as references to
construct the mesh. Select each XY section, one at a time, and use the "Design
/ 3D effects / Flip Y and Z planes" command, which will convert them to XZ
sections. Ensure that you are happy with their positions on the board then
select them all before calling up the function and completing the ensuing
dialogue box.
Viewed from above, the result is similar to the rectangular mesh
method, but this time the area is defined by the outer
extremities of the reference objects, rather than being a
simple rectangle. The width of the result is determined by
the width of the reference objects that were selected, whilst
the height of it is controlled by their position on the board.
What is not so clear from this view is how the depth and
profile of the mesh have been generated, as the original
reference sections can not be distinguished from the rest of
the mesh. The YZ lateral view shows how the mesh changes
at the reference sections.
However, the 3D view shows how this method
of construction works much better. The
successive cross sections, originally
drawn in XY, now provide the controlling
XZ sections and retain their existing
dimensions. Then you can make sure that
the mesh will accurately correspond.
As usual, we will finish on a lighter note. Try
and quickly construct a somewhat
strange and rather artistic shape
instead of something useful, by
using several sections drawn free-
hand. Note that Galaad only uses a
maximum of 32 reference objects.
In addition, note that if two objects
occupy the same Y position, there will be
two different sections at the same spot, which is not possible except to make
an infinite number of transformations. Galaad does not do this and will refuse
to produce the mesh.

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Design / 3D mesh / Extruded - constructs a 3D mesh that extrudes on Z

axis the contours or XY trajectories of the selected objects. The procedure is
quite simple: just draw and select closed
objects which have either their
internal surface or their contour
extruded. These objects are
already positioned and the mesh
will cover them.

Design / 3D mesh / Contour lines - constructs a rectangular 3D mesh

whose wires are given a depth that depends on the selected
objects. Every curve defines an XY horizontal plane that
will remain unchanged until it matches another curve
with a different depth. The whole mesh must be
contained inside the boundaries of the selected curves,
otherwise the horizontal plan beyond the borders
cannot be calculated by Galaad. The
mesh lines can be either 3D (giving
oblique Z variations with stretching of
the intervals between lines) or follow
stages corresponding to average levels by
default or by excess.

Design / 3D mesh / Resection points - constructs a 3D mesh that is

modulated on Z axis by the depths of the dispersed points, all selected
together. These points can come from a topographic file with free XYZ
coordinates. Each of them will attract towards its own depth the mesh which
comes in its neighbourhood, this attraction being modulable according to a
smoothing function.

Design / 3D mesh / Track - constructs a 3D mesh

that reproduces a milling track with a
conical section along the trajectory of
the selected object. The ends are
rounded as if the track was machined by
a tool with a conical profile. The track
width is constant. The variations of depth
modulate the angle of the lateral sides of the conical profile.

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Design / 3D mesh / Airfoil - constructs a 3D mesh

modelising for example a surf fin or an airplane wing.
The airfoil contour and its half-profile must be selected
(objects number 1 & 2 on the sketch here). Half-profile
means that the airfoil is
symmetrical. This half-
profile will be adjusted between the
extreme points of each horizontal section
of the foil contour. It is also possible to
define an extra curve on a vertical axis,
which will define the evolution of the profile
thickness from top to bottom. This curve must then be selected in blue (object
number 3 on the sketch).

Design / 3D mesh / 4-axis wrapping - constructs a Cartesian

mesh whose development in cylindrical milling reproduces the
shape of the selected object, with an axis rotation about the red
cross (so there must be one in the drawing board). This type of
mesh allows you for example to quickly model a cam, perfectly
machinable using a flat end cutter in a 4-axis cycle. Warning: it
is very important that the radius of the cylinder to be
machined corresponds to the distance between the red
cross (rotation axis) and the furthest vertex, minus
the minimum depth that has been entered in the
dialogue box (top of the cam). If this radius is
incorrect, then the machining will distort the profile.

Design / 3D mesh / Background image -

constructs a matrix of points or a line mesh whose
depths vary depending on the background image.
This function can work on an engraving only if
the machining is made with a tool with a conical
profile. The lower the tool plunges in the
material, the larger the hole or the track is. The
result looks very good with pictures.
First, you must have a background image (see
later on the functions "Display / Background
image"). This background image must be
small since every pixel will correspond to a

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machined line or point. If you set an interval of say 1 mm between points, then
an image of 100 pixels height will already give a 100 mm result. So, looking
for megapixels is pointless and a very low resolution picture is quite sufficient.
For setting its size, use "Display / Background image / Frame" function until it
is small enough. A good contrast is highly preferable.
Two options are then available: a matrix
of drilled points with varying depth, or a
mesh of tracks from a horizontal 3D scan.
Obviously, the mesh of tracks is much
faster to mill. Once the matrix or mesh has
been created and selected, you can first
enlarge it and re-position it on the board.
Then, using the dimensioning dialogue box
for the selected object ( key), it is
possible to darken overall the image of the
machined result by increasing the depth Zo,
or increase its contrast by stretching the
depth range Dz. A view of that result can be
displayed via the function "Display / Final
rendering / Trace" or its shortcut icon. Keep
in mind that even an ultra-high resolution screen has a finite accuracy, so the
final rendering will always remain rough compared to the machined reality of
the workpiece. The best is to zoom in deep on important details during the
final rendering (simple click, and right mouse click for zooming back out).
The adjustment of Zo and Dz dimensions using key becomes very
important here.
Tip: you can machine a semi-opaque plastic plate with a flat-end cutter
whilst inverting the machining and using a large depth range. The plate seen
from the non-machined side will let the picture appear by semi-transparency
when you put it in front of a source of light.

Design / 3D mesh / Change / Add perpendicular mesh - creates a

framework of mesh lines perpendicular to the selected mesh, going through
exactly the same coordinates. This function can be applied only onto a
Cartesian wiremesh.

Design / 3D mesh / Change / Make bi-directional - converts a unidirec-

tional mesh into one with alternate directions along adjacent lines.

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Design / 3D mesh / Change / Make unidirectional - converts a bi-

directional mesh into one with the same direction along adjacent mesh lines. It
is also possible to use the function "Machining / Toolpath / Define as start
point / The point which is most at …" on a Cartesian mesh.

Design / 3D mesh / Change / Make continuous - converts individual

mesh lines into a continuous zigzag mesh.

Design / 3D mesh / Change / Make individual - converts a continuous

zigzag mesh into a series of individual mesh lines.

Design / 3D mesh / Change / Reduce stepover - adds new lines to the

selected mesh. This addition is a simple interpolation without recalculating or
smoothing the result.

Design / 3D mesh / Change / Increase stepover - spaces out adjacent

lines of the selected mesh by deleting intermediate lines.

Design / 3D mesh / Change / Delete horizontal plane - suppresses the

lines of the bottom or top surfaces of the mesh, to keep only the useful shape.
A dialogue box lets you define the plan to be deleted, with a tolerance margin
for the Z value.

Design / 3D mesh / Change / Change mesh from background image -

modifies the selected image mesh for resetting its creation data.

Design / 3D effects / Select 3D objects - selects all available objects that

have a variable depth.

Design / 3D effects / Select points from filter - selects in "Range of

points" mode the points or vertices situated in a depth range to be indicated.
This mode corresponds to the yellow icon with the same name.

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Design / 3D effects / Reverse Z trajectory - inverts the relative depth of

the selected objects. On a 3D path, the hollows become bumps and vice-versa.
On a group of 2½D objects having been given different depths, this places at
the top those with the lowest depth, at the bottom those with the highest, and
all intermediates are reversed.

Design / 3D effects / Flip X and Z planes - exchanges the X and Z

coordinates of the selected object vertices.

Design / 3D effects / Flip Y and Z planes - exchanges the Y and Z

coordinates of the selected object vertices. This function is useful for creating
lofted meshes.

Design / 3D effects / Frame Z trajectory - sets a floor and a ceiling limit

on the depths of the selected object. Any
coordinate which is out of the range is
minimised or maximised. Warning: for 3D
objects, long lines are not vectorised; only Z
coordinates change.

Design / 3D effects / Project onto a tilted plane - increases the depths of

vertices or points on the route of the selected
object according to the value of its XY
coordinate. The tilted plane can be either XZ or
YZ. The relative depths of the objects between
them are kept.

Design / 3D effects / Project onto a cylinder - changes the Z coordinates

of the selected objects for projecting them onto a cylinder, parallel to the X
axis, with a diameter to be defined. The objects are
segmented by interpolating new points for a
smooth bending. Warning: the cylinder axis is
always located at the Y centre of the board.

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Design / 3D effects / Project onto a sphere - as

above, except that the projection target is now a
sphere, with a diameter to be defined, and centred
at the middle of the drawing board.

Design / 3D effects / Apply onto background - changes the depths of the

selected objects depending on neighbouring objects, for example to apply text
onto an existing wiremesh. The depths of the selected object are added to the Z
coordinates of their neighbours, using a weight attractor which depends on
their XY distance.

Design / 3D effects / Change depths according to the blue profile -

applies a new range of depths for the selected objects in relation to the curve
that is selected in blue. This functions can for example compress or stretch a
land mesh for enhancing the topography. If the blue selected object is a simple
straight line at 45°, then the Z coordinates will remain unchanged. If this
object is an arc of circle from 180° to 90°, then the low depths will be
stretched and the high depths will be compressed. The blue curve represents
the distribution graph. Its position and dimensions have absolutely no impor-
tance; only its out-of-scale path matters.

Design / 3D effects / Follow a continuous slope - increases regularly the

Z coordinates along the path of the selected object between its point of
departure and its point of arrival. The depth increase for the coordinate of each
vertex is proportional to its distance from the start point, following the path.

Design / 3D effects / Follow blue trace slope / Along its Y trajectory -

increases or decreases the depths of points along the path of the selected
object, following the relative Y coordinates of the line of the object selected in
blue. Once again, the XY path of the blue object is used as a reference to apply
depth variations with Y coordinates becoming Z coordinates. The difference
between this function and the yellow icon "Modify Z depth" is that the slope
runs along the path of the selected object (distance from start point along the
path) and not along its X coordinates only (distance from left hand point).

Design / 3D effects / Follow blue trace slope / Along its Y trajectory -

increases or decreases the depths of points along the path of the selected
object, following the relative Z coordinates of the line of the object selected in
blue. This blue object is therefore supposed to have a 3D path.

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Design / 3D effects / Create a 3D track - builds a 3D polyline of which

the variable depth allows a conical tool to make the route of the two selected
objects flush. These are considered the framing edges of the newly created
object. The result is a 3D carving effect which modulates the depth according
to the width of the track to be rendered. Warning: the two objects near each
other must have open paths.

Design / 3D effect / Apply a 3D carving track effect - Makes the depth of

the selected object path vary, if machined using a conical tool, so it gives a
conical carving effect. The track becomes deeper along the path between its
ends or sharp angles.

Design / 3D effects / Transform using equations - subjects the X, Y and

Z coordinates to three mathematical transformation equations. The coordinates
submitted to the equations are always considered as variables, but relative to
the southwest corner of the object. This means that the overall position on
the drawing board does not change the result. These equations recognise as
variables the labels 'X' and 'Y' which correspond to the points or vertices
constituting the selected object, it being fully understood that, in the case of
multiple equations, the input values are calculated, not the resulting values
after passing through the first equation. The second and third equations have
nothing to do with the result of the first and second equation in their own
analysis. Well, do not worry about it, this is Galaad's internal cooking. But do
not forget to add the input value of the coordinates to each equation, if you do
not wish to obtain a completely flat object.
For example, you must type
Y = Y+20*SIN(4*X) and indeed not
Y = 20*SIN(4*X), unless your tortured
object will have lost all its Y thickness
when coming out of the equation.
A triple equation requires three times more phosphorus
(having fun...):
X = 50+(2+Y+X/10)*COS(4*X)
Y = (2+Y+X/10)*SIN(4*X)
Z = X/10
The following little creation works very well in space, simply open the file
"3D \ MOGULS" to see the results. We will give you the recipe: set the
dimensions of a new board to 100  60  20 mm, and create a network of lines,

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quite closely spaced, covering the surface of the board, this is easiest by
simply duplicating one. Select everything and transform them using equations,
the magic formula being X = X; Y = Y (no changes, indeed, and you can
simply leave these boxes blank, Galaad will understand that coordinates
remain the same), and above all Z = 10+5*SIN(10*X)*SIN(10*Y).

"Display" menu

Display / Active Layer / Layer N - allows you to define the layer number
N as the active layer, namely the layer you are working in. All other layers
remain in the background and objects on them are visible in grey but not
accessible for drawing operations. Unless filtered, objects in inactive layers
can be machined and are greyed or invisible (see next command about visual
layers), but remain unavailable for drawing operations. No selection frame
survives in an inactive layer. Furthermore, it is possible to limit snapping to
the objects of the active layer. This option can be set from the advanced
functions of the workspace parameters. However, in case of an emergency, the
function "Edit / Select all", when key is pressed, selects together all
selectable objects (i.e. not locked) of all layers.

Display / Active Layer / Transfer to active layer / All objects on

layer N - moves to the layer currently active all objects from the chosen layer,
even if they are locked. This layer N is then empty. All transferred objects are
automatically selected (even those locked, one minor exception), to ease
handling or to permit resending them to another layer. If some objects were
already selected, then they are no more.

Display / Visual layers / Layer N - allows any background layers to be

hidden if required. Obviously, the active layer is always visible, otherwise the
job would become a bit difficult.

Display / Visual layers / All layers - makes all background layers visible
(objects in inactive layers are displayed in grey).

Display / Visual layers / Active layer only - hides all background layers
and only displays the active layer. If the active layer is changed, the view will
be updated accordingly.

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Display / Visual layers / Name layers - allows you to give a name and
also a colour to each drawing layer. These layer names are saved with the file
and will remain present in future drawings unless their own layers have also
been named. After opening or initialising a new file, you may restore the last
layer names and colours that have been used, through the buttons "Previous" at
the bottom of the dialogue box. Please see also the options of the function
"Parameters / New file defaults", where you can decide if you wish to keep or
forget the layer names and colours.

Display / Visual layers / Limit direct snapping to active layer - toggles

the option for accepting the suggestions to snap the drawing plotter to
positions related to the objects of the active layer (or, by default, all layers). If
your drawing is heavily loaded, the snapping suggestions are too many and it
can become difficult to choose the right one. This option is also available in
the advanced workspace settings, but rendering it accessible in a menu makes
it programmable from a function key so you can quickly change the mode (see
"Parameters / Function keys").

Display / Trace / Bold - displays all objects on the active layer using bold
lines (or by default thin lines). The objects that are present in other layers
always remain displayed in thin and grey lines.

Display / Trace / Object dependant - displays objects on the active layer

using a line thickness that has been drawn for each object (see the green
drawing icon to define object colours and thickness). Remember that the
thickness of a line on the screen has no relation to the machined result, that
you can see using function "Display / Final rendering / Trace" hereafter.

Display / Trace / Path / Start points - displays a small cross at the start
points of all objects on the active layer whether or not they are part of a larger
connected toolpath. This is supposed to ease the checking of tool plunges.

Display / Trace / Path / Link points - displays a small point at the linking
points of all objects that are part of a larger connected toolpath in the active
layer.

Display / Trace / Path / All points - displays a small point at the vertices
of all objects on the active layer. The drawing may become a bit overloaded,
especially with curves, and the screen display is slower.

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Display / Trace / Tool compensation / Feed-in path -

displays the feed-in path of a compensated toolpath, a circle
represents the diameter of the cutter used and a small arrow
shows the path direction, which helps checking the visual
elements for closed objects.

Display / Trace / Tool compensation / Feed-out path - displays the feed-

out path of a compensated toolpath, a circle to represent the diameter of the
cutter used.

Display / Trace / Tool compensation / Angles (roughing

trajectory) - displays a circle representing the cutter diameter at
all internal angles on the trace of a compensated roughing
toolpath. The threshold angle is set in "Machining / Tool
compensation / Advanced parameters".

Display / Trace / Tool compensation / Angles (finishing trajectory) -

displays a circle representing the cutter diameter at all internal angles on the
trace of a compensated finishing toolpath.

Display / Trace / Protection - displays a small shield at the start point of

all protected objects.

Display / Trace / Position anchors - displays a small anchor at the start

point of all objects anchored to an absolute position.

Display / Trace / Machining pauses - displays a small cross at the start

point of all objects which require a machining pause. A pause is a validation
message that pops up on the screen before machining the object, whilst the
process hangs in mid-air. The pause can be defined in the dialogue box for the
machining data (tool, depth, feedrate).

Display / Trace / Path directions - displays a small arrow at the start

point of all objects, indicating the path direction which is not always
visible for closed and non-compensated objects.

Display / Trace / Identifiers / None - removes the small

identifiers that are displayed at the start points of the objects in
the active layer (see identifiers below).

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Display / Trace / Identifiers / Sequence - adds a small identifier giving

the machining sequence number at the start point of all objects on the active
layer.

Display / Trace / Identifiers / Tools - adds a small identifier giving the

machining tool number at the start point of all objects on the active layer.

Display / Trace / Identifiers / Depths - adds a small identifier giving the

depth (or the depth range for 3D objects) at the start point of all objects on the
active layer.

Display / Trace / Identifiers / Z Changes - displays the depth changes at

the vertices of all 3D objects on the active layer, except if these vertices do not
correspond to a change of the Z coordinate.

Display / Trace / Identifiers / Feedrates - adds a small identifier giving

the machining speed at the start point of all objects on the active layer.

Display / Path colour mode / Monochrome - displays all objects on the

active layer in black, i.e. no distinction is made between different cutters. In
fact, black is the default colour on a white background but can be changed
from the "Parameters / Colours", "Primary paths" entry.

Display / Path colour mode / Layer dependant - displays all objects in

the colour set for their layers. Layer colours are set from "Display / Visual
layer / Name layers".

Display / Path colour mode / Tool dependant - displays all objects in the
active layer in the colour set for the cutter selected. Tool colours are set from
"Parameters / Tools".

Display / Path colour mode / Object dependant - displays all objects in

the active layer in the colour set for each. Objects colours are set from the
green drawing icon for colour and line thickness.

Display / Path colour mode / Default tool - displays in black (actually the
primary path colour, which obviously will not be black if the background
already is) all objects on the active layer using the default tool and the rest in
grey (actually the secondary path colour). This colour mode is probably one of
the most useful.

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Display / Path colour mode / Default depth - displays in black (actually

the primary path colour) all objects on the active layer using the default depth
and the rest in grey (actually the secondary path colour).

Display / Path colour mode / Default speed - displays in black (actually

the primary path colour) all objects in the active layer using the default
feedrate and the rest in grey (actually the secondary path colour).

Display / Path colour mode / Black background - sets the background to

black. Normal lines will appear in bright green. Please note that all display
colours can be set from "Parameters / Colours".

Display / Final rendering / Trace - displays a plan view of the

cutter path using a line of width equal to the cutter diameter,
relative to the current magnification and board dimensions. The
left mouse button allows you to zoom in and the right mouse
button to return to the global view. Only the active layer is
concerned. Furthermore, if objects are selected, they are
displayed alone and the rest is hidden. It is possible to change
trace and background colours from the left side of the screen, in
the mini-zoom box just under the drawing icons. All this
remains valid for other functions of final rendering.

Display / Final rendering / Mesh - displays a 3D wire frame representa-

tion of the cutter path showing both the width and depth of the path relative to
the material dimensions.

Display / Final rendering / Surface - displays

a 3D rendered surface representation of the
cutter path, showing both the width and
depth of the path relative to the material
dimensions. The orientation of this view
reuses the one of the 3D plane view (or quad
view).

Display / Final rendering / Parameters - allows you to set up the few

parameters related to 3D final rendering in mesh mode.

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Display / Permanent final trace - permanently displays the machined

trace of the objects in the active layer, calculated from the tool profile and
diameter. The colour is set in "Parameters / Colours", at the "Dot enhance-
ment" entry, which also corresponds to display enhancement spots
around isolated dots.

Display / Quad view - allows you to split the screen into four different
views of the current drawing, i.e. plan (XY), front (XZ), side (YZ) and
3D view. The basic layout of the split screen can by configured in "Parameters
/ Workspace / General settings". A double-click on the 3D view switches it to
full screen, and back again. The projected paths on the top surface remain
visible in this case. When clicking on the corresponding icon, temporarily
pressing the key displays a quad view with a rotary 3D part.

Display / 3D view / Plane - displays the 3D view at full screen

size, letting you orientate the angle of view (left mouse button)
or shift the plane view (right mouse button) or zoom
(mouse wheel or / keys). This is for
viewing only, no operations can be
carried out on this board. When clicking
on the corresponding icon, pressing the
key temporarily displays a rotating 3D
view that you can interrupt with the key. By the way, if
the workpiece was defined as a cylinder, then the 3D
view displays its diameter and wraps the drawing
around its circumference for showing the result that
will be machined. And talking about cylinders, let us
say again that it is possible to select an object in blue for
defining the external profile of revolution.

Display / Data palette / None - removes the data palettes at the top of the
screen. See the "Rapid data
palettes" section at the end of the "Advanced drawing techniques" chapter for
more details about data palettes. Please remember that the palette title on the
left hand side is reactive to the right mouse click for defining which palettes
must be displayed.

Display / Data palette / Layers - displays a small palette at the top of the
drawing area, showing the layers used in the current drawing to allow rapid
selection of the active layer.

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Display / Data palette / Tools - displays a small palette at the top of the
drawing area, showing the cutters used in the current drawing to allow rapid
selection of them.

Display / Data palette / Machining depths - displays a small palette at the

top of the drawing area, showing the machining depths used in the current
drawing to allow rapid selection of them.

Display / Data palette / Feedrates - displays a small palette at the top of

the drawing area, showing the speeds used in the current drawing to allow
rapid selection of them.

Display / Data palette / Pen colours - displays a small palette at the top of
the drawing area showing the colours used in the current drawing to allow
rapid selection of them.

Display / Data palette / Pen thickness - displays a small palette at the top
of the drawing area, showing the thicknesses used in the current drawing to
allow rapid selection of them.

Display / Margins - places a small margin around the drawing board,

allowing you to check trajectories that have a certain
tendency to escape. A slider helps you set the size of
the margins, relative to the board size, which will
remain memorised. The lateral margins are passive; it is not possible to draw
in them.

Display / Rulers - displays the rulers to the left and at the bottom of the
board, plus the lateral views. Rulers are purely visual; clicking or pointing
on them calls up no functions, except the southwest square that displays
the active layer number: if you click on it with the right mouse button, then
Galaad saves its workspace just like if you were exiting then reopening the
software.

Display / Visual grid / None - removes the background grid from the
work board.

Display / Visual grid / Points - displays a visual grid of points on the

work board.

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Display / Visual grid / Crosses - displays a visual grid of crosses on the

work board.

Display / Visual grid / Dotted - displays a visual grid of dotted lines on

the work board.

Display / Visual grid / Solid - displays a visual grid of solid lines on the
work board.

Display / Visual grid / Matrix - displays a visual grid of millimetric lines

on the work board, which always corresponds to the smallest ruler gradua-
tions, whatever the zoom state is. Probably your best choice.

Display / Visual grid / Set step - allows you to define the distance
between two lines of the visual grid.

Display / Background Image / Enabled - allows you to display or remove

from the board the background image to trace from.

Display / Background Image / Open - loads a background image under

the board to trace from. Zoom functions remain valid until a maximum
enlargement is reached. The background image is of course passive and cannot
be machined. See the "Design / 3D mesh / Background image" function to
create a toolpath from a background image. Please note that tracing is easier
with a light image (or dark in case of a black background). See below the
functions for controlling the light.

Display / Background Image / Paste - puts on the board the background

image copied in Windows clipboard.

Display / Background Image / Invert-Rotate - applies to the background

image Cartesian transformations or a free rotation for adjusting.

Display / Background Image / Frame - allows you to frame the back-

ground image, like a rectangle to be plotted from two diagonal points.

Display / Background Image / Position - allows you to locate the

background image on the board.

Display / Background Image / Dimension - allows the scale of the

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background image to be varied as a percentage of the original. Galaad must

prepare the background image before its display, which can be a long opera-
tion. Consequently, it is recommended not to use big original images if they
have to be reduced here.

Display / Background Image / Scale from two points - adjusts the size of
the background image from two points whose real distance is known. The rest
of the drawing remains unchanged; only the background image is resized. This
is probably the best way to resize the background image accurately on your
board.

Display / Background Image / Black & white - displays the background

image in black & white if the original is in colours.

Display / Background Image / Brightness-contrast - increases or

decreases the overall light of the background
image from two trackbars with almost immediate
application, depending on the calculation delay.

Display / Background Image / Original - returns to the background

image as it was opened the first time, resetting all changes that have been
applied since then.

Display / Background Image / Negative - inverts the light of the pixels of

the background image, so it appears in negative.

Display / Background Image / Saturated - displays the background

image in black or white with no intermediate grey
levels, according to a settable saturation threshold.

Display / Background Image / Engrave - does the same as the function

"Design / 3D mesh / Background image" that has been explained in detail a
few pages back ‒ so to which please refer.

Display / Background Image / Change engraving - does the same as the

function "Design / 3D mesh / Change / Change mesh from background image"
for resetting the interval between lines or the range of engraving depths.

Display / Main comment - determines whether a comment produced with

the "File / Comment" command is visible.

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Display / Visual dimensions / Enabled - displays visual dimensions that

have been added to the current drawing. See also the function "Parameters /
Visual dimensions".

Display / Visual dimensions / Relative to red/blue cross - changes the

displayed positions so they become relative to the fixed cross, red or blue.
Other dimensions (distances, angles, etc.) are not concerned.

Display / Visual dimensions / Recalculate all - recalculates all dynamic

visual dimensions that have been added to the current drawing.

Display / Visual dimensions / Delete all - deletes all visual dimensions

that have been added to the current drawing.

Display / Deselect all - removes all selections (objects, segments, points),

and even selections that do not have the focus. "Remove" does not mean
"delete". The shortcut key is . Changing active layers does the same,
except if you use the rapid data palette.

Display / Set pointer - allows you to set the size and format for the
crosshairs of the drawing cursor.

Display / Calculator - opens the Windows calculator, provided that it is

indeed located in its usual system folder. Remember that, in any dialogue box
of Galaad, it is always possible to enter a maths formula instead of a numerical
value.

Display / Refresh - rebuilds the current drawing. The hotkey for this
function is .

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"Text" menu
Text / Font style - opens the dialogue box for the text style settings
(font, size, spacing, shading, etc.). Note: the automatic kerning controls
the spacing between two adjacent letters taking their shapes and possible
overlapping into account (an "A" followed by a "V", or an "L" followed by a
"T", etc.).
Galaad provides about 50 fonts that are dedicated to engraving, including
centreline fonts, for example a capital 'I' being a single line and not a rectan-
gle. These font names have "G - " header. Other fonts with "TT - " header are
those installed by Windows and we are not going to give details about how
they work. By definition, a TrueType (or OpenType) glyph consists of one or
several closed paths, since the filling is done on the screen or the printer. We
are not supposed to get an infinitely thin line. It is possible to find TrueType
fonts with centreline characters (i.e. without thickness) but they are nonethe-
less made of closed paths, meaning that for example a capital 'I' is made of two
zigzag segments that overlap one another. To avoid useless machining paths,
you may in this case enable the option "Delete superimposed contour lines
(thin fonts)". Then Galaad will keep useful lines only.
When engraving from the bottom in a transparent material, letters can be
filled at a lesser depth than the contours, say 50 %, for a nice visual effect.

Text / Arrange letters - allows the letters to be selected individually and

positioned independently from the rest of the text. Movement from one letter
to the next is done with the help of the (tab) key or with the (shift)
key to reverse direction. This command can also be found in the "Text"
series of drawing icons.

Text / Select internal islands - automatically selects the inner

paths of a previously selected text (which, of course is no more
selected). This function can be used for applying a reversed tool
compensation to internal islands, though the tool
compensation function is supposed to do so for text objects,
or making an internal hatching for an extruded text.

Text / Edit - places a selected block of text into an edit window for
allowing you to both edit the text and change the alignment. This command
can also be found in the "Text" series of drawing icons, or from a
double-click on a block of text.

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Text / Rebuild - completely recreates all the selected text using all its
parameters. If some letters have been moved or modified, unfortunately these
changes are lost.

Text / Convert to polylines - converts the selected text into simple

polylines and curves based on its current style. This is a one-way process and
any text specific properties (style, alignment and the text itself) will no longer
be available. Objects still remain associated.

Text / Split - only works after a single letter has been selected using
"Text / Arrange letters" and splits the text into two distinct blocks at the
currently selected letter.

Text / Merge - merges all the independent blocks of selected text into one
single block. The style and paragraph settings are those of the first block of
text in the sequence. A carriage return / line feed is inserted between each
merged block.

Text / Writing direction - opens a box in which you can change the
primary and secondary direction of texts. This allows some of the more exotic
languages to be used in their correct orientation. This should not be confused
with the direction of the paragraph itself, which can be rotated by 90° when
entering the text.

Text / Increment numbers - increases the first number found in the

selected block of text by one unit. The block of text may be either normal or
auto-incremented.

Text / Decrement numbers - decreases the first number found in the

selected block of text by one unit.

Text / Column of numbers - creates a column of numbers in either

descending or ascending order.

Text / Change all - partner of the previous function, replaces all selected
texts by a new one to be written, in one single operation.

Text / Text file - imports text from an external text file (*.TXT). The text
retains its text format and can be edited by the above commands.

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"Parameters" menu

Parameters / Workspace / General settings - allows you to set the

general workspace parameters. See the chapter on "Workspace parameters"
for details.

Parameters / Workspace / Password - allows you to set up and change

your password in the usual manner. If by chance you have forgotten it, then
please note that the password is stored in the PASSWORD.TXT file in Galaad
installation directory.

Parameters / Workspace / Restrictions / Ignore - allows you to override

all restrictions that have been previously imposed on the workspace, and
therefore come back to full mode (restriction set is not lost).

Parameters / Workspace / Restrictions / Change - lets you define your

own set of restrictions, i.e. customise the Galaad workspace by removing the
icons and the menu functions that you do not need. See the chapter on
"Workspace parameters".

Parameters / Workspace / Restrictions / Level 1-3 - directly loads a set

of predefined restrictions, saved in the files LEVEL-N.CUS that have been
installed with Galaad but that can still be modified.

Parameters / Workspace / Restrictions / Open - directly loads a set of

restrictions that has been previously defined and saved. The files that corre-
spond to restriction sets are located in the "CONFIG" subdirectory.

Parameters / Colours - gives access to display colours of all visual

components of Galaad and its machining module.

Parameters / Function keys - lets you customise the keyboard by

assigning a menu command to each of the function keys from F1 to F12, alone
or associated with . Just click on the corresponding line then select a
command in the top menus. Please note that the F10 key is generally reserved
by Windows and is not customisable.

Parameters / Visual dimensions - sets the style of all visual dimensions

that have been added to the drawing.

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Parameters / Network / User - allows you to configure the current

settings of the workstation on the local network. See the chapter on “Using a
network”.

Parameters / Network / Workgroup - determines which workgroup the

current installation of Galaad is attached to. This does not modify the Galaad
installation but changes the access to central folders on the disk of the master
workstation. See the chapter on “Using a network”.

Parameters / Network / Upgrade workspace - if the PC is either an

independent workstation or a networked "Master", then the current environ-
mental parameters will be saved, or if the PC is a secondary "Slave", new
environmental parameters will be loaded from the master workstation. See the
chapter on "Using a network".

Parameters / Tools - allows you to define the detailed parameters of the

cutters within their own tool library. See the chapter on "Toolpaths".

Parameters / Machine / Basic data - allows you access to the basic data
for the CNC. See the chapter on "Machine parameters".

Parameters / Machine / Full data - allows you access to the full details of
the CNC. See the chapter on "Machine parameters".

Parameters / Machine / I-O test - opens a reduced dialogue window that

helps you control the inputs/outputs of the machine, without any motion. This
function is useful for checking the electrical connections. See also the
"Machining / Manual control" command.

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Parameters / Machine / Calibration - opens a window for a semi-

automatic calibration of your machine (inputs, gear factors, orientation,
kinematics). This function is dedicated to those who have built their own
machine or have integrated an electronic control that is different from the
authenticated one. Galaad will save the calibrated parameters.

The first thing to be done is find the inputs that correspond to the safety
cover, the switches for the machine zero and the tool sensor. If you have none
of these, then this first phase is useless. The method for finding which input a
device is connected to, and using which polarity, is quite simple: click on the
corresponding "Test" button and trigger the contact manually (for the safety
cover and the tool sensor, this is easy, but it can become a bit tricky for zero-
end switches). A sub-window displays and keeps the input that has changed.
The safety cover must be opened when you click on "Test". The tool sensor
must be released, and the axes must be away from their zero point (contacts
must not be triggered).
Finding axis gear factors requires an access to each motor for seeeing it
turn. Stepper motors generally have increments of 1.8°, i.e. 200 full steps per
revolution. Warning: this is not always the case. Anyway, you must find the
right value that corresponds to one motor revolution, taking into account the
microstepping or the encoder increments for a servodrive. Try typical values
like 400, 800, 1600, 3200, etc. by clicking every time on "Test" button until

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the motor makes exactly one revolution. Once your motors have the correct
number of pulses per revolution, then you must measure very accurately the
linear motion that corresponds to one revolution, if possible using a compara-
tor or a calliper. At every new click on the "Test" button, the motor makes one
revolution.
The direction of axes defines the geometry of your machine. You must
indicate the location of the machine zero, i.e. the position of the zero-end
switches for axes X and Y (zero-end switch for Z is always at the top). The
direction of axes can be tested from a movement where you indicate whether
the axis has moved in one direction or its opposite. Galaad will eventually
determine an inversion to be applied to the motor.
At last, the kinematics settings, probably the most complicated to tune up,
suppose that other calibrations have already been made. The first thing to set
up is the maximum speed the axes can afford. Both XY axes work together, so
it is the slower of the two that will be kept. When you click on "Test" button,
the machine starts moving with a weak acceleration until it reaches the
indicated speed. Galaad asks you if a motor stalled. If you click on "Yes", it
will keep the last speed that was validated. If you click on "No", it retries with
a higher speed until the motor stalls. It is up to you to check and answer:
Galaad cannot know if a motor stalled due to a too fast top speed.
Once the maximum speed has been set, you must calibrate the Start/Stop
frequency. This frequency corresponds to the instant speed that is applied to
the motor when still, or reciprocally the final speed just before stopping. A too
low Start/Stop frequency renders accelerations unnecessarily long. On the
other hand, a too high frequency can block a motor which then cannot catch its
acceleration ramp, or simply makes it knock at starting and stopping phases.
The test consists of making the motor turn instantly at the corresponding
frequency, for each axis. Galaad asks you if one motor has knocked (started
too abruptly) or stalled. If you click on "Yes", it returns to the previous value,
otherwise it retries with a doubled value.
Corollary of the Start/Stop frequency: the acceleration ramps. If a motor
accelerates too quickly, it may stall and get blocked, or just lose steps (or raise
a drag-error if it is a servodrive). If it accelerates too slowly, all movements
will be unnecessarily long. The acceleration of an axis must be strong enough
but with no risks of blocking or stalling. This test does the same as the
calibration of the Start/Stop fequency, with the acceleration slope becoming
steeper and steeper. Please note that the Start/Stop frequency and the accelera-
tion must correspond to the most critical axis, namely the one that stalls at the

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lowest value. These settings correspond to inactive movements, when driving

manually or when the tool is above the material in an automatic milling
process.
Though they are the most difficult to set up, the two last kinematical
parameters are important since they determine how the machine will react
when milling with the tool down in the workpiece. The test method is the same
as the one used for the Start/Stop frequency and the acceleration. Please refer
to the chapter dedicated to the machine parameter for understanding exactly
what they are related to.

Parameters / Machine / External driver - allows you to use a milling or

CNC upload programme that is not part of Galaad. See the end of chapter
"Machine parameters".

Parameters / Machine / Save - saves the whole set of machine parameters

to a .CNC file that you can recover using the next command.

Parameters / Machine / Open - loads the whole set of machine parame-

ters that have been saved using the previous command.

Parameters / Machine / Restore point / Create - lets you save a restore

point with the machine parameters, the various settings for positions and
calibrations, the cutting databases (for plasma, laser, water jet, etc.) and the
tool library. This function saves you spending hours searching for a parameter
that you might have modified and cannot remember where it is, which is
changing the behaviour of the machining. The files are located in the
"RESTORE" subdirectory of Galaad installation directory of the hard disk.
Their names are composed of the recording date & time, plus an optional title.
You may request the automatic creating of a restore point at regular intervals.
See the next function.

Parameters / Machine / Restore point / Recover - loads the parameter

files of a restore point that has been previously saved. You can select which
parameters you wish to restore, and a few buttons help you manage the list of
restore points.

Parameters / Machine / Post-processor - defines a file format for export,

for a generic numerical controller or for an external driver that uses a particu-
lar language unknown to Galaad. All usual syntaxes are possible, provided that

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they are based on text format with numerical values which are decimal or
hexadecimal. Some frameworks are predefined for the most common syntaxes,
on which you may embroider your own format. For a description of the syntax
set-up, please refer to the end of chapter "Machine parameters".

Parameters / Auto save - allows you to set the period of time between
every auto-save of the current drawing. The auto-save corresponds to an
automatic command "File / Save". This supposes that the file has already got a
name. Otherwise, it is the whole workspace that is saved.

Parameters / New file defaults - allows you to define the default “new
file” settings (workpiece dimensions, tool, depth, feedrate).

Parameters / Rapid depth changes - allows you to define the change in

depth when using the or hotkeys on the selected objects, for
adjusting coordinates.

Parameters / Automatic feedrates - opens the dialogue box which allows

you to change the settings of the feeding speeds that are calculated automati-
cally. These automatic feedrates mainly concern beginners who are not yet
familiar with milling speeds, to avoid starting their career on a big heap of
broken cutters. They are calculated from the material hardness family (this
classification of the material is used only for this purpose), the tool diameter
and profile, the machining depth and other secondary parameters. In the metal
milling industry, a feedrate is normally calculated from the cutter rotation
speed, its number of teeth and the standard feed length per tooth. For wood or
plastic materials, the situation is different. The feed length per tooth does not
apply to an engraving bit or a ball-end cutter. The automatic feedrate calcu-
lated by Galaad leads to a large under-estimation: the aim being not to
optimise the tool cycle but avoiding the breakage of tools because the speed
was too high. Once you have become familiar with the speeds, probably you
will forget the automatic feedrates, and precisely for saving time.
The automatic speed calculation can be adapted for each family of
material. You can multiply the result for feeding faster or slower.

Parameters / Save parameters - lets you save the current set of parame-
ters (environment, restrictions, machine, tools) under a given name. The
memorised sets of parameters are located in the "CONFIG" subdirectory of
Galaad installation directory on the hard disk.

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Parameters / Load parameters - lets you fully or partially load a set of

parameters that has been previously saved using the above function.

Parameters / Quick transfer / Send parameters - uploads the full set of

parameters currently in use, to a removable disk or network disk, from which
they can be transferred to another workstation.

Parameters / Quick transfer / Receive parameters - downloads all or

part of a set of parameters previously saved onto disk using the above
function.

"Help" menu

Help / User's manual - displays this manual in PDF format, which

supposes that a document viewer such as Adobe reader has been installed on
your computer.

Help / Remote intervention - calls up the integrated function for distant

connection on your screen. This presumes that your computer is connected to
the Internet. When calling this function, a new pop-up window indicates an ID
number and a password. You must communicate these to your contact person,
by telephone or e-mail, so that he or she can connect to your PC and see your
screen to help you out.

Help / Debugging - creates a text file containing some or all of the

parameters currently in use, together with those of the last machining opera-
tion, to assist technical support staff in case of a
software or hardware malfunction. The two
default options are the machine parameters and
the last data flow archive. They are sufficient for
tracking any problems with the machine. The
resulting file GALAAD.BUG, located in Galaad
installation directory, must be sent by e-mail to
the technical support. Very important: unless you have generated this
debugging file, do not restart a manual drive or an I/O test which would
erase and overwrite the last archived data flow between Galaad and the
machine. All exchanges are archived in the text file GALAAD.XON, formatted

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GALAAD 3 —————————————————————————————

as time-tags, commands sent, feedback codes, and many automatic comments

that ease the hunt for bugs. This file is concatenated with the other parameter
files depending on the selected options, to generate the final file
GALAAD.BUG from this debugging function.

Help / Temporary licence - allows you to enter a licence code which is

valid for one month with the key unplugged. This licence can be renewed
three consecutive times maximum, and the current installation of Galaad must
have detected the key at least once during the past three months. The only
purpose of this command is to allow the replacement of a lost or damaged key
and keep on working while awaiting its return. This function cannot unblock
the user's licence of a Galaad installation that has no key. Please note that
the identification number is not fixed and changes every time a new temporary
licence is validated. Unless you have been prompted to do so, do not plug the
licence key in again once this temporary licence has been activated: if the key
is detected, even partially, the temporary licence will immediately be disabled.

Help / About - displays version and copyright information. This dialogue

box also provides information about your installed version for potential
updates, and indicates the status of your licence. The button "Download
update" helps you update your Galaad installation without manipulating files.
This obviously supposes that your computer is connected to the Internet.

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Shortcut icons

A promise made should mean a promise kept, so: here is the list of
available icons in the top bar, with their connections to the menu commands.

File / New

File / Open template

File / Material dimensions

File / Open

File / Import

File / Gallery

File / Quick transfer / Receive drawing

File / Save

File / Save as

File / Export

File / Quick transfer / Send drawing

File / Print

Machine / Standard machining

Machine / Standard simulation

Machine / Multisided machining on 4 axes

Machine / Manual control

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Edit / Undo

Edit / Redo

Edit / Repeat

Edit / Restart

Edit / Copy

Edit / Cut

Edit / Paste

Edit / Paste second-last copy

Edit / Duplicate / Add one real copy

Edit / Duplicate / In line

Edit / Duplicate / In matrix

Machine / Toolpath / Connect objects

Machine / Toolpath / Disconnect objects

Machine / Toolpath / Define as start point / Red point

Machine / Toolpath / Define as start point / Point to click

Design / Object / Weld

Design / Object / Split

Design / Incise

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Design / Polyline / Delete parts where clicking

Design / Segment / Delete segments to be clicked

Design / Point / Delete points to be clicked

Design / Point / Insert a point on a trace

Design / Arc / Replace circles by points

Design / Arc / Replace points by circles

Design / Arc / Set the diameter of all selected arcs

Machine / Sequence / Set as first

Machine / Sequence / Set as last

Machine / Sequence / Mouse select successively

Machine / Tool compensation / Define toolpath

Machine / Tool compensation / Remove toolpath

Machine / Tool compensation / Support bridges / Add

Machine / Tool compensation / Set start point

Machine / Tool compensation / Feed in point / Horizontal

Machine / Tool compensation / Feed out point / Horizontal

Machine / Tool compensation / Feed in & out points

Design / Hatching

Design / Pocketing cycle

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Design / Object / Distance between points

Design / Object / Trace length

Design / Magnetic grid / Set

Design / Magnetic grid / Snap and size to grid

Design / Align & centre

Text / Font style

Edit / Libraries / TrueType Symbols

Display / Quad view

Display / 3D view

Display / Final rendering / Trace

Display / Trace / Identifiers / (on/off)

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12
01100

MACHINE PARAMETERS

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Main parameters

Setting up the parameters of your CNC machine is one of the most

important parts of configuring Galaad and must be done with the greatest care.
Generally, this only needs to be done once and it is unusual to have to reset
these values once the machine is performing correctly. Using incorrect values
is not supposed to harm your machine, except with very special mechanical
configurations. At worst, it will be happy to sulk in a corner and totally ignore
you, at best it will respond a little and make the odd excusable silly move.
Nevertheless, do not leave your fingers in the way, one never knows.

In order to help you configure your very first machine, Galaad provides a
reduced dialogue box giving access to the main parameters only, leaving the
finer details until later. It goes without saying that this only applies to full
standard machines that can be found in the list of models known to Galaad.
Use the menu command "Parameters / Machine / Basic data" to find them.

Without doubt, the most

important parameter is the
model of the machine. Look
through the double-list of
known machines until you
find yours and select it. For
the most part, all other
parameters will be loaded
automatically. Please note
that machines are sometimes
re-badged by importers.

The type of controller is usually governed by the model of the machine.

Moving directly to the frame at the bottom of this window, the physical
characteristics of the machine can be set. These depend on the machine model
but bear in mind that they can, and do, change with time, so check the
technical data supplied with your machine (if any…), and especially the pitch
of the ballscrews. If this value is set incorrectly, then the machine will work
almost normally, but movements will not be of the correct distance and speed.
Too small, a figure increases the values of the coordinates sent to the machine
and consequently the size of all movements. Conversely, too large, a value
reduces the size of all movements. If your machine is not actually fitted with

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ballscrews, nor even basic screws, then this value corresponds to the linear
distance that each axis moves for one revolution of its driver motor.

The communication between Galaad and the machine generally takes place
through a cable, which takes commands from Galaad to the numerical
controller and returns data or acknowledgements back to the software. Most
machines are connected to a USB port or a COM port (RS-232 serial port).
In this case, you plug one end of the cable into the machine or its controller
and the other end into the corresponding port on your computer. Few PCs are
still equipped with COM ports nowadays, but these can still be present on
desktop computers. If your machine requires a serial port and your computer
has none, then you must add a USB/Serial converter module that will set up a
virtual COM port to the PC (generally numbered beyond COM2). Real or
virtual, the available COM ports listed by Galaad have an asterisk after
their numbers. If you do not know which COM port number has been
assigned by Windows to your USB/Serial converter, these asterisks can help
you out. The button "Detect COM port" can also help you find the machine by
trying all available ports until it receives a valid feedback. But this is not fully
garanteed.

If your machine is driven throughout a COM port, then the communication

protocol includes a transmission baudrate. We generally consider that this
speed has been set on the machine controller and the driving software must
adapt itself to the machine rather than the contrary. Do not change the baudrate
needlessly. It is not really with a faster communication that you will save time.

Important: if no machine is connected to your PC, just set the port to

"None".

Remember also that Galaad does not produce Step/Dir signals on the
LPT parallel port for directly driving a power stage. You must interface an
electronic device that is able to produce these signals.

The next pages refer to the complete set of parameters for the machine,
which you can access very logically through "Parameters / Machine / Full
data".

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"Table" page

Do not proceed beyond here until you have read the information given
above which will not be covered again. Check that the necessary connections
have been made to your ports for both the machine and the licence dongle. The
basic machine parameters have been set a fortiori to the full parameters
described below.

As mentioned above, the complete machine parameters are accessed via

the menu command "Parameters / Machine / Full data". This command opens a
multi-page dialogue box,
which contains all the
information relating to the
machine, numerical controller
and spindle. You will find
here the basic parameters, as
already discussed above,
buried in a mass of more
complex data. Do not panic, at
least not yet, as we will go
into the details of this and the
penny should drop. Moving
on from the machine model,
set in the basic parameters, if
yours is not in the displayed
list, the simplest is select "Not
listed". Anyway, if its controller is compatible with Galaad, then all hope is
not lost, it will probably work, but you will have to set up all the parameters of
this beautiful stranger.

We now have to provide some additional information, this time the actual
number of axes. Most machines in the list have 3 axes XYZ, but some specific
configurations can have only 2 axes, and others have a 4th turning axis A or a
double master-slave axis, or even a 5th axis B. All this is described in detail a
further on.

The usable range represents the maximum travel of each axis, the
combination of which defines the maximum working envelope of the machine.
We have seen in the basic parameters the ballscrew pitch and the conse-
quences of using a wrong value. If your machine has axes fitted with differ-

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ently pitched ballscrews, then they must be set here. The motor steps specify
the number of pulses that the CNC must produce for a stepper motor to make
one revolution, or in the case of a servo motor the number of pulses returned
from the encoder. Here again, if a value is wrong, so will be the scaling factor
on the machine, generally by a factor 2 or 4 or 8, etc.

The bottom frame is for defining a fourth axis (and even a fifth), if one is
fitted. A fourth axis can have one of three possible configurations in Galaad: a
rotary axis parallel to the X axis (A axis) for cylindrical milling; a rotary axis
parallel to the Z axis (C axis) for use with a knife blade; and finally as a simple
slave linear axis, allowing there to be two actuators on any of the three main
axes. It can also be an E-axis for extruding on a 3D printer, usable only with
the Kay module. A fifth axis can be an orientation axis for a milling head that
is tilted by the fourth axis (5-axis milling) or a second slave axis for an
existing linear axis. The Galaad drawing module and its associated machining
module can use only 3 axes out of 4, namely an XYZ Cartesian machining or
an XAZ cylindrical machining. However, the manual control lets you jog all
existing axes, even for a workpiece origin before a 3-axis process. Only Kay
and Kynon modules can drive up to 5 axes in an automatic cycle.

Rotary milling on A axis

The current standard wants rotary axes A, B and C turn around parallels to
respectively X, Y and Z axes. So an A axis is parallel to X axis and permits
volume machinings by rotating the horizontal plane, which allows milling
faces that are inaccessible in a classic 3-axis process, or making a simple
cylindrical wrapping of the flat drawing. Please refer to functions "Machin-
ing / Cylindrical machining on 4-axes" or "Machining / Multi-sided machining
on 4-axes" for more information about how a Galaad drawing can be wrapped
around a cylinder or mill different lateral sides of a 3D workpiece. In addition,
the Gawain turning module can use a 4-axis mill fitted with a rotary A axis for
milling a drawn profile, including threadings (faces and external threadings
only, since the cutter cannot reach the inside).

The configuration for a rotary A axis, or "Lathe A axis" is very basic: just
indicate the number of motor increments per chuck revolution (and not per
motor revolution). The maximum rotation speed in °/s must be set in the
"Speeds" tab.

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Steerable blade on C axis

Galaad can drive a motor that

rotates a swivelling blade so it is
always heading in the horizontal
cutting direction. This motor can
be either the third axis (if there is
no Z axis on the machine) or the
fourth axis. Selecting "Orientation
C axis" as extra axis (or re-
selecting it if already active)
opens a sub-dialogue box that gives access to the specific parameters of this
rotary blade. When the machine has no Z axis, then we can suppose that the
blade is driven up and down by an electromagnet or an actuator with mechani-
cal stops that set the high and low positions. The first parameter indicates
which electrical output on the controller triggers this electromagnet or
electrovalve. As a corollary, the corresponding delays must be given for
lowering and raising, to prevent Galaad from starting an early horizontal
motion whilst the blade is not yet back to its low position.

Since a rotary blade generally cannot turn for changing its apex when in
low position in the material, the maximum angle allowed without rising must
be indicated. If the rotation for the next vector is greater than this angle, then
the cutting motion stops, the blade is retracted up, rotated towards the new
cutting direction, then lowered and the motion is resumed. If the rotation is
lesser than or equal to this angle, then the blade is rotated in low position.
Hence, passing the angle is done with a cutting motion, then a rotation, then a
new cutting motion. For keeping a continuous motion in the horizontal path,
the blade can begin to rotate before having reached the turning point, conse-
quently cheating a bit on the orientation apex near the angle. This eases
chaining the cutting vectors with no stop points because Galaad will interpo-
late small vectors just before and after the turning point, that integrate the
blade rotation. In this case, you are requested to give the distance from the
turning point, from which the blade can begin to rotate. If the actual path
vector is shorter, then the blade will be in permanent rotation. Warning: the
blade must rotate about its cutting point. There are no XY compensations if
the blade is off-centre.

The rotation speed (when blade is up) can be set here, and also the
reference angle (parking position). The trigonometrical 0° corresponds to the

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direction X+, or 3 o'clock in the aviation lingo, the direction Y+ corresponding

to 90°. When launching the process, the blade must be set to this reference
angle, and it will return to it when the cycle is completed. If the blade cannot
turn infinitely, for example due to wiring or pipes turning with it, then you
must enable the rewind option. Anytime the blade is lifted up, it is rotated so it
is as close as possible to its reference position. Finally, this blade can be
activated for one single tool only in the drawing, other tools corresponding to
a classical process without the C axis.

Parallel axes

If your machine has a double axis, for example two screws or two cogs at
the pillars of its mobile gantry, then several options are available. The simplest
is to send the same command signals to both motors. But, in this case, if it
happens that one axis drifts away from the other, the gantry will lose its
perpendicularity and it will become difficult to reset it manually. This is why
Galaad offers a function for a differential homing which automatically
readjusts the squareness of the gantry. This supposes that the two motors
are driveable together and separately. When resetting the machine on its zero
point, Galaad moves together both parallel axes until one
of the two end-switches is triggered, then dissociates the
axes, resets the master axis alone, resets the slave axis
alone, and finally reconnects both axes together. For
resetting the gantry accurately perpendicular after a
differential homing, either the end-switches are me-
chanically adjusted, or both clearance values are set in
Galaad parameters.

You may use the 4th axis of the controller by setting it as a slave axis X' or
Y', but then you will lose a channel which, most of the time, will do exactly
the same as the master axis channel. If you have only 3 axes on your control-
ler, or if you need the 4th channel for a rotary axis, then the option "Coupled
axis", at the top of the "Table" page of the machine's full data, offers a simple
solution that requires a small electronic circuit: by making the Step signal (or
Clock or Pulse, it is the same), duplicated for the two parallel axes, pass
through a couple of mini-relays or electronic switches, each being driven by an
on/off output of the controller, Galaad may cut the movement of one motor

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GALAAD 3 —————————————————————————————

and not its twin. The Dir signal, also duplicated, does not need to be cut. The
result is the same, except that, instead of reserving an axis channel of the
controller, this reserves two outputs. Anyway Galaad can deal with both
solutions. In any case, a differential homing requires two end-switches
connected to two different inputs, unless you use the same relay system for
also cutting the link between both contacts and one single input (here, the
switches should be parallel-mounted if normally opened, or serial-mounted if
normally closed).

It may happen that the Step and Dir outputs of the numerical controller are
unable to provide enough current each for two opto-couplers on the power
stages, or that these signals cannot be parallelised downstream. A line driver
integrated circuit may then become necessary.

Additional axes

As above mentioned, only Kay and Kynon modules can manage up to 5

axes in an automatic cycle. The Galaad machining module is limited to 3 axes
among 4, i.e. a process will be made either on XYZ (flat milling) or on XAZ
(wrapped cylindrical milling). 3D machinings that require 4 or 5 axes must be
managed by the Kay module, which is described later on in this manual. If you
have a rotary tilting head for 5-axis machining, then you must indicate the
number of motor increments for a 360° revolution of the head. The 4th and 5th
axes must be set as independant axes A and C (or B and C).

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"Controller" page

The next page allows the CNC to be specified (integrated controller,

racked controller or controller card), and its communication system to be set.
In addition, the position of the machine zero point (also called the datum,
home point or reference point)
has to be indicated along with
details of how and when a
homing should be performed.

The type of the CNC will

normally be set based on the
model of machine, whose
details have already been
entered in the previous page.
However, some types of
unlisted or custom built
machines can use a variety of
different controllers. In this
case, you must specify
yourself what type drives your
axes.

Many controllers integrate a local memory buffer which is able to store

vectors and postpone their execution. This function is very important because
it avoids delays between each movement and therefore provides a continuous,
fast and fluid trajectory. Sending batches of vectors to the controller before it
executes them breaks the synchronism between the software and the machine,
so the coordinates that are displayed on the screen no longer correspond to the
real movements but to the transmission. Then the software is ahead of reality,
which suits it well. Using an asynchronous mode may look confusing but it is
more efficient, especially when the machining path is made up of curves.
Some machines such as Isel have a linear memory, with a transmission time
first, the tool remaining in standby, and then an execution time, the software
being now in standby. Here, it looks like some time is lost compared to the
mode without buffer, which is however not the case since the transmission
delay is diluted among the sendings of vectors. On the other hand, on a
machine with a ring memory buffer, the transmission occurs while the vectors
previously sent are executed, consequently in hidden time. On some control-

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GALAAD 3 —————————————————————————————

lers (AxeMotion, Soprolec), Galaad can read in real-time the position and, in
that case, the monitoring on the screen corresponds to the motion of the axes.

You may choose to disable the local memory buffer and leave the machine
directly connected to the software for supervising every single vector. This
renders the movements continuously interrupted by the data transmission, and
therefore the path becomes jerky. So, if your numerical controller integrates a
local memory buffer, then it is always better to use it. On the other hand, if it
does not, it is useless and not even recommended to make it believe something
else. For sure it will not work any better.

Galaad limits the use of the local memory by re-synchronising with the
machine at every tool bottom right. This makes it follow block by block the
progress of the cycle and enables resuming a machining at the last tool plunge.
However, it is possible to make a unique block for the whole process, pro-
vided that the local memory buffer is circular. For simple drills with or without
plunge cycles, movements are much
simpler and there is no need to re-
synchronise at every tool bottom right.
Anyway it is possible to store a series of
drills in the memory to save this re-
synchronisation time. If the numerical
controller is able to dialogue with the
computer whilst it is executing the
content of the buffer, in particular for
answering a read command about the
status of the inputs or the position, then it is possible to monitor the critical
inputs and synchronise the screen with the machine, depending on the chosen
granulosity.

Your CNC may be a very old model that cannot move three axes simulta-
neously, in which case Galaad offers an alternative of interpolating only the X
& Y axes and stepping the Z axis in stages, but you must then uncheck the
XYZ interpolation. Likewise for the circular interpolation, if your machine
is not able to produce arcs from a specific single command. These features
depend completely on the actual controller and not the mechanics of your
machine. Unless you have a specific reason, stick to the default values that are
pre-programmed in Galaad.

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Communication with the machine is via a port to be specified: USB,

Ethernet, serial, parallel or internal, the choice is wide but each machine
generally offers one single possibility. If your computer is not connected to a
machine, select "None" instead of a port. Galaad will make a simulation of the
process with the parameters of the selected machine.

When using an RS232 serial connection, the COM ports that are available,
real or virtual, are followed by an asterisk in the drop-down list. If you do not
know what COM port number has been assigned by Windows for your
USB/Serial converter, then these asterisks may help you out. The button
"Detect COM port" may also help find the machine by trying all available
ports until it gets a valid echo. Likewise, the button "Device Manager" will
pop up a system window giving access to the list of peripheral devices
connected to USB ports, plus the COM and LPT ports for checking their
validity. On a serial port, it remains necessary to tune up the communication
protocol. The parameters in Galaad have to be set so they match those of the
CNC, rather than the other way round. Refer to the technical data for your
CNC to find the correct settings. Here again, playing about with parameters
brings more pain than pleasure.

The homing frame helps setting the position of the machine zero point.
This information is very important and determines the overall orientation
of your XY axes. It is assumed that, whatever the machine looks like, the Z
axis zero point is always at the top of the travel, i.e. with the tool fully
retracted. Yes, even in the southern hemisphere. But concerning the X and Y
axes, the position of the zero point can be at 4 possible corners. An old and
convenient standard wants the X axis to run from left to right and the Y axis
from front to back, seen from the operator's point of view, which looks quite
clear. Another more recent standard prefers the X axis to be the longest of
both. It is doubtless very masculine but not always so clever for operators who
might then have X and Y axes inverted compared to what they can see on the
screen or what they have drawn. Consequently, it is recommended to define
the X axis as the one that moves from left (west) to right (east) and the Y axis
as the one that moves from front (south) to back (north). If, seen from the
operator, there is an inversion of one of these axes, it is easy to rectify this
inversion (see the "Advanced" page).

On most machines, the X axis has its zero point at west, namely to the left
hand side when seen from the front of the machine. But the Y axis can have its
zero point at north (back) or at south (front), depending on the model. Simply

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power up your machine and give it a home run to see where the datum point is
situated. Warning: the position corresponds to the tool on the table, not the
movement of the table itself. If your machine has a mobile table Y,
then when the table moves to front, it is in fact the tool which is
moving to back, and reciprocally. You must always consider the
virtual motion of the tool on the table, not the real motion of the
table. If your machine has a fixed table and a mobile gantry, then
please forget this detail. The parameter for the position of the zero
point will also be updated automatically when the machine model is
changed, probably not a very common occurrence. If the axis reset
is correctly performed but the manual jogging arrows and the
cursor on the screen are inverted, compared to the reality, then probably
the position of the machine zero that has been indicated is wrong. The tick
box, immediately below, controls whether or not Galaad should warn you
before making a homing reset. For safety reasons, it is always preferable to
have this feature enabled, especially when the machine is open and the homing
motion is fast.

You may want to forget about the machine zero and use only floating
origins. In that case, simple untick the option "Homing / Machine zero". We
are not going to debate here the pros and cons of working in absolute coordi-
nates with a machine zero point. Just consider that, without a machine zero,
you cannot manage fixed positions, therefore no fixed tool sensor, no tool
changer, no memorised clamps. In addition, you will have to set the workpiece
origin at every new process, even if the position did not vary.

When a machine is fitted with stepper motors, it is sometimes necessary for

peace of mind to reset the position of the axes by performing a homing
movement. Galaad does this automatically if the machine loses power as it
then no longer knows the position of its own axes. However you can choose to
home the axes at more frequent intervals if you so wish. In fact, if your
machine is really losing steps, perhaps there are more important things you
should check, and not only in Galaad.

Before we forget it, a discrete but no less important button , situated

to the right hand side of the controller type, gives access to special parameters
related to the numerical controller. Selecting any particular controller brings
up the dialogue box that applies to it. These special parameters are described
hereafter for the most common controllers ‒ those which consequently
generate the most questions.

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Arduino GRBL controllers

Many small machines for amateurs integrate Arduino controllers with

GRBL firmware or more or less compatible. More or less because many
variations exist on this
draft standard, and not
all provide the best
compatibility. GRBL is
a super-set of the ISO
G-code for rendering it
conversational and
sending parameters to
the controller when
opening the dialogue
(the $nn commands).

Important: if a file named GRBL-TOP.TXT exists in the Galaad installation

directory, containing a list of $nn commands with corresponding values, then
this file is sent as is and Galaad uses none of its own parameters. Every
command line of the file must nevertheless be acknowledged by the controller.

With GRBL, no inputs/ouputs can be addressed directly from an identifica-

tion number, but only commands for activating the spindle (you can set your
own custom commands if necessary), for using the zero end-switches when
resetting the axes, and for the tool measurement sensor. These inputs/outputs
are assigned by the firmware and only the function is available. Well, when it
is. However, you may reverse the polarity of the inputs in these parameters.

When the driving window is closed, the serial communication is cut, which
re-initialises most controllers. When opening the next dialogue, the position
counters are consequently reset to zero and it is necessary to perform again a
homing reset. Otherwise the current position becomes the relative zero. If you
wish to avoid this problem, just ask to keep the machining window or mini-
mise it. Calling a new task will wake up the machining module.

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AxeMotion controllers

The parameters described

here are shared by all AxeMo-
tion cards, including "Pulse-
Box" models which are given
an extended page for assigning
signals on the pins of the DB-
25 connector. It is possible to
preset the status of outputs at
boot of the card, even before
Galaad is active. As soon as it
is powered up, the card will
enable them. We will see later
on in this chapter the values
for the Start/Stop frequency
and acceleration, along with
kinematical parameters. An
input can report if the power
stage is active, or assigned to the monitoring of some error signal, for
example a drag error from a servodrive or positive end-switches. If this critical
input is triggered, then the numerical controller stops the axes and Galaad
aborts the process.

A speed potentiometer can be mounted on the analogue input (ADC) of

the "PulseMaker" cards. This potentiometer instantly slows down the feedrate,
to the point where the axes are frozen. This is a very interesting option. The
communication on the USB port is normally set to "Very fast" for old genera-
tion cards, but you may select a slower communication if the machine is
working in a noisy environment with important sources of electrical parasites
which seem to interfere with the transmission. Finally, if your AxeMotion
controller integrates a jogpad on the local I2C port, then you can ask Galaad to
manage it.

Here the homing reset is managed directly by Galaad at low level, so it is

necessary to indicate which inputs are connected to the fast-approach switches
(XY near-ends for large tables) and the zero-end switches, with their logical
states. Warning: a "disabled" input does not mean that it is not used; in
fact, this corresponds to its polarity when the switch is triggered: switch
normally opened  "active (NO)" input / switch normally closed 

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"inactive (NC)" input. It is possible to add a little offset value from the
contact points to set a machine zero that does not tickle the switches. In
addition, the home runs for X and Y axes can be driven simultaneously in a
diagonal motion for saving time, with final movements one by one. An option
can render these inputs critical for the card which will immediately stop the
automatic process when an end-switch is triggered. On a well-tuned machine,
this should not happen.

For the AxeMotion "PulseBox" modules that advantageously replace a

machine driving through LPT parallel port, the window is extended on the
right hand side and there you
may set up the signals that are
generated on the DB-25
connector for the power rack
and, for older versions, on the
auxiliary connector which
provides a few more inputs
and outputs. Some assignment
models for existing racks have
been predefined in Galaad.
Please note that inverting
"Direction" and "Clock" (or
"Pulse" or "Step") signals has
absolutely no bad consequences on your machine. The axes will simply not
move. So you have the right to grope around. Warning, the "PulseBox"
module gets its power supply from the USB port, so the available current is
limited: it cannot provide more than 10 mA per output, with a total of 50 mA
for the whole set.

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Isel-Automation "IMC" controllers

The most recent Isel machines with stepper motors are driven by numerical
controller IMC4-M, IML-4 or IMC-M/P.
These give access to a few specific
parameters, including the possibility to flip
an axis direction or flip the direction of
the homing reset (both options are inde-
pendent). If you select a standard Isel
machine that integrates one of these
controllers, the inversions will be automati-
cally set. But for a machine with an external
rack, you might have to define them
yourself. The parameters for the axis end-
switches are available for using either one
of the available switches as zero point, or
for changing the working polarity of a
contact that is normally opened or normally
closed.

The frequency range indicates which minimum and maximum values for
motion frequency (the increments) can be sent to the motors. It is possible to
set values for the Start/Stop frequency and the acceleration different from
those used by default. Finally, if your machine integrates an electromagnetic
brake on the Z axis, then you should indicate it here.

These machines or numerical controllers have a "Power" button that the

operator must activate manually. Checking the status of the power stage can be
disabled here, since it may not work on all controllers of these types.

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Isel-Automation "CNC-API" controllers

Isel machines with

servodrives use dynamic
link libraries (DLL) and set-
up files (INI) that have been
installed on the driving
console at the factory. They
are driven through these
DLLs which consequently
must be in place and
configured, otherwise the
machine control will be
buggy. "Motion Control" is
the only DLL that is
theoretically required, for
managing the axes, but it is
probable that the DLL
"Inputs/Outputs" will also be necessary, at least for controlling the spindle or
the machining tool. The "Spindle Control" DLL is useful only for a special
spindle with integrated control, not for a standard spindle that can be con-
trolled from a basic binary output or even an analogue output. Likewise, the
"Safety Circuit" DLL is needed only if the machine integrates a particular
safety system. So it is possible to leave those two DLL settings unspecified.

The button "Find DLLs" allows you to start a search for the Isel
factory installation, grab its parameters and apply them here, avoiding a
manual search of the files. Once the DLLs and the INI parameters are vali-
dated, it is possible to check them using the button "Load DLLs" which will
give access to several internal functions reporting the version, initialisation,
diagnostic and control. But it is better not to fiddle around with the DLLs and
their related INI parameters, which are supposed to have been set at the factory
and probably require no operator's action. The purpose of this window is only
for seeking on the hard disk the files that have been installed by Isel techni-
cians, and to validate them (the files, not the technicians, no-one is infallible).

For an Isel machine driven through the control DLLs, the communication
port must be set to "Internal".

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SM-Motion controllers

SM-Motion racks or control cards

require many parameters that will be
used by Galaad only if they have
been enabled. If your machine has
been configurated at the factory or
when installing it in your workshop,
then do not modify them, at least
those related to the most advanced
controls, unless you know exactly
what you are doing. The whole set of
parameters is sent to the machine
only if the option "Send parameters to
the CNC at initialisation" has been
enabled in "Advanced" page (see later
on, same chapter).

If your machine integrates an

overspeed potentiometer, then you
must enable it here, and also the
number of inputs/outputs the controller provides. A maximum of 32 inputs and
32 outputs can be managed by Galaad, which should be sufficient for most
applications. The passing mode G62/G60 of the SM-300/400 allows chaining
vectors with a good fluidity, with the kinematics calculation. Unless you have
big problems when used, it is always better to leave it active. This function is
not relevant when the local memory buffer has been disabled.

The initialisation parameters are generally preset at the factory and do not
require any changes, except parameters A (number of digits after decimal
point, which must be 2 for all axes), B & C (gear factor and conversion of
distance units in increments), and also the parameter K (homing speed). You
should not need to change the others unless you have been requested to do so
by the manufacturer or a qualified technician.

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Soprolec "InterpCNC" controllers

Developed by Soprolec, the

InterpCNC cards are well known to
professionals or hobbyists who build
their own machines. The Interp-
CNC-1 card communicates through
a classical serial port RS232; the
InterpCNC-2 card, able to drive up
to 5 axes, communicates through a
USB port using a driver DLL that is
provided by Soprolec, in charge of
the data exchanges with Galaad.

For the Start/Stop frequency

and the acceleration, please refer to
the section dedicated to kinematics,
later on in this chapter.

Some inputs may be used for monitoring the emergency stop, any error
signal that feeds back from the power stage or positive end-switches, or a
safety system such as a protection door. If this input is activated (or inacti-
vated depending on your settings), then the CNC card immediately stops the
motion and Galaad aborts the machining process. These parameters are all
optional.

The output states at boot-up define which outputs must be activated

when the card is powered on, even before it communicates with the PC.

The InterpCNC cards undertake the homing reset themselves, provided

that you have indicated the inputs that correspond to the zero-end switches,
with their trigger state (normally opened  input set to "enabled" / normally
closed  input set to "disabled"). X and Y runs may be driven simultaneously
in a diagonal line to save time, with a final run one axis at a time.

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K40 controller

The K40 laser engraver has been interfaced with Galaad for a direct drive.
Before going any further, let us mention that all controller cards fitting the
K40 are not compatible. It may
happen that the software cannot
drive your machine. Parameters are
not many and fairly clear. You can
calibrate the position of the
standard XY origin point in the
northwest corner of the machine,
so your workpieces will all be set
there, or define an offset out of the
workpiece with a laser flash for
marking the position.

Generic controllers

Some machines contain a numerical controller that can only receive

commands but do not return usable data to Galaad (for example GravoGraph,
Roland or Suregrave). However, it remains possible to drive it directly in
unidirectional mode for automatic millings. In this case, Galaad cannot
provide manual drive functions since this requires position feedback and
specialised commands. Hence the communication is write-only, from Galaad
to the machine.

But if the machine has a control panel

with local manual drive functions for a
workpiece origin set-up, there is hope yet.
Galaad will prompt you to set the origin
directly from the machine and will then send
the commands that correspond to the milling
process through the cable. The format to be
used can be chosen among the available
command languages, including the customisable post-processor.

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Customised controller

If your machine is fitted with a numerical controller that is not listed in

Galaad but uses a command language in text mode, decimal or hexadecimal,
on a COM or LPT port, then it is possible to set up yourself the syntax of these
commands by choosing the model "Generic / Customised".

The telegrams sent to the machine can be framed by heading and trailing
bytes, indicated in decimal ANSI code. The commands must be given in text,
with variables between < > which will be substituted by the corresponding
values when executing. The acknowledgements returned by the machine for
every command line are defined as a unique byte, given in decimal ANSI
code. The undefined commands will not be used. If you have a CNC on serial
or parallel port that works with a decimal text language, then you should be
fine, provided that you know the available commands of the controller and
their actual syntax.

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"Spindle" page

The next page of machine

parameters lets you define the
model of the spindle that is
used for milling, if any, and its
control system. On a machine
that has been provided by a
manufacturer, generally the
spindle will be the standard
model. But it may be that yours
is a particular model, with an
alternative control that you
must then set up here. If in
doubt, always select the
standard spindle that is
associated with the machine.
Please note that changing the
machine model or the numerical controller model in the previous pages of
parameters automatically resets the spindle to the standard model. Indeed, it is
more than likely that if you change the machine, then the spindle will be
changed too.

If your spindle is actually a laser cutter, plasma cutter, water-jet cutter or

something of the same kind such as a liquid dispensing nose, then you should
only start it when the tool is feeding and switch it off as soon as the tool
should be lifted-up. The drawing interface, in particular the green icon at left
hand side for accessing the tool, depth and feedrate, can adapt itself conse-
quently. Please note that a full chapter is dedicated to the plasma torch cutting
systems, later on in this manual.

Several predefined spindle models are controlled either by one or several

binary outputs of the numerical controller, or by an analogue or PWM output,
or through a separate communication port. You can define here its parameters,
i.e. choose an output and a binary state for switching on and off. It is possible
to indicate several different outputs for one single command, for example
the output number 12-2 for the outputs 12 and 2 triggered one after the other.
You can indicate up to four successive numbers for one digital switching. This
remains valid for all binary outputs.

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A delay can be set for the spindle run-up, that is the time it takes for it to
reach full speed. Galaad likes to use time efficiently and will make good use of
this delay by moving the spindle above the entry point of the first object to be
machined, avoiding sitting idly by. But it will then be happy to wait patiently,
if necessary, for the spindle to finish accelerating before plunging into the
material. If the spindle is activated during the feed phase only (laser cutter,
water jet or liquid dispenser), this delay occurs between cutter switch-on and
feed move. In such a case, the two laser pause values define an extra delay
after enabling (i.e. before starting feed motion) and before disabling (i.e. after
ending motion). The difference with the above mentioned run-up parameter is
that these two delays are not used if the spindle is a classical one that remains
continuously active during the whole process. In this case they are greyed. If
the spindle control system returns a signal indicating that the spindle is now
ready, then you can connect that signal to an input of the controller and
indicate it here. Galaad will wait until this input is triggered for considering
that the spindle has reached the chosen speed.

Tachometric spindles (with speed control)

Galaad can drive the rotation speed of a tachometric spindle if it is

managed by a control system through an analogue data channel or similar.
Several special parameters must be set in this
case.

The spindle rotation speed is normally

predefined for each tool. However, when
starting the spindle in manual or automatic
mode, a dedicated window will pop up to
allow you adjust the speed. The control
system for the speed (analogue, PWM or multi-outputs) and the spin direction
does not override the binary outputs that have been set for power on/off.
Consequently these outputs remain valid with such spindles. If you do not
wish to use them because they are redundant with the rotation control system,
then just delete the corresponding output numbers or set them to zero.

In the case of a spindle with a control system for the rotation speed, you
must indicate in percentage the floor and ceiling values that can be used for the

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signal that will determine the RPM. The floor value corresponds to the motor
starting to turn with a minimum torque. Galaad will consider that the speed
range begins with that value which is not always 0%. The ceiling value
corresponds to the motor at full speed, which can be reached before 100% on a
variator with no feedback loop. Of course you must indicate both speeds that
correspond to these values, and the range between them can be non-linear.
Furthermore, the software can even drive a progressive run-up to avoid
overloading the electrical power supply. This run-up is linear and can be set in
RPM-per-second. It is of course subtracted from the run-up lapse.

A PWM (Pulse Width Modulation) signal uses one single output bit that
works in 0/1 mode, but this square signal is time-sliced according to a given
frequency. The percentage of the high state compared to the total period gives
a relative width for the pulse, from 0% (no high states) to 100% (full-width
high state). A small integrator circuit can convert the pulses into an analogue
signal, doing so with only one output bit.

If your numerical controller has

neither an analogue nor a PWM output
but provides a wide range of binary
outputs, then it is still possible to control
the spindle rotation speed by switching
several outputs that are linked to an
external D/A converter. You can set the
number of bits that will drive the DAC
(1 minimum, but well, do not expect too
much of an analogue signal in that case;
and 12 maximum, which should give a
fine resolution). The corresponding
outputs do not need to follow each other
in a sequenced list. You must assign an
output number for every weighted bit that defines the analogue signal value.
Galaad will then calculate the pattern of all outputs that represent the binary
digits of the digital value, which then produces the required rotation speed.
Instead of a D/A converter, you may also use a staged integrator device.

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Special spindles

Some spindles that require particular parameters can be used with Galaad.
For example, a flip/flop pulse spindle is started by sending a simple activation
signal on one (or several) output(s) and needs
to be rearmed periodically by sending again the
same signal, the stop command being managed
by triggering another output. That rearming
command will be sent only when the tool is up
so the feed process cannot be affected. You
must set the renewing delay consequently. If you select an analogue laser
head engraver, Galaad will modulate the power according to the depth of the
object, i.e. the Z coordinates, including
along a 3D path, the maximum power
of the laser (or any other system for
machining) being set to a given depth
that will not be exceeded. The
modulation goes through the DAC or
PWM output. Finally, it is possible to control a punching or dot-drilling
head that uses the normal outputs for switching on/off the spindle, so with no
specific parameters, except that this
head will be activated at regular
intervals along the paths, these intervals
being set before every new machining
process. Obviously the activation is
intermittent.

Spindle command scripts

Perhaps your spindle or your application is demanding and

cannot be happy with a basic on/off command, even accompanied
by several pauses and rotation speed controls throughout an
analogue or PWM channel. In this case, not all is lost, you may
still programme yourself the sequence of commands for switching
your device on and off. Here, the spindle model should be set to
"Programmed sequence of commands".

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The dialogue box for a specific set-up allows you to write the two control
scripts in a very simple programming language. The software will then
interpret your own
instructions one by one
when starting or
stopping the spindle.
The list of available
commands is displayed
at the bottom of the
window. Most of them
correspond to the inputs
and outputs of the
machine. But you may
also call up a set of
external programmes
and pass them function arguments, for example the rotation speed which is
available as a variable labelled <RPM>, which will be replaced by the actual
speed in revolutions-per-minute, in decimal text (a maths formula can be used
around this variable). You may also indicate a direct command to be sent on
the communication port inside this script, using the command SEND (see also
hereafter).

Talking about commands to be sent directly to the machine, it is possible to

select as spindle model the "Direct commands on port". In this case, you do
not write a sequence of com-
mands that have been defined
and interpreted by Galaad, in a
script language that will call the
corresponding functions of the
machine. Here you must totally
write in the machine command
language every telegram to be
sent, knowing that Galaad will not try to understand what you are doing and
will just expect a standard acknowledgement for every command it sends.
These commands must be written as texts, there are no variables and of course
the machine is supposed to appreciate the sense and subtleties of what it
receives. You are at the helm.

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External control programme

Now, if your spindle is totally unknown to Galaad with absolutely no

control channels available from the numerical controller, but was fortunately
provided with its own driver programme for Windows (even in a DOS-like
console mode), it should still be possible to establish the link between Galaad
and the spindle through this programme.

The three spindle

commands available are
switch-on, change rotation
speed, and switch-off. For
each one, you must
indicate an external
programme with its own
arguments (of course it can
be the same executable
programme). Galaad will
replace the variable
arguments <RPM> and <T> by the actual rotation speed and the tool number,
written in decimal text in the command line. The programme called cannot
access the communication port with the machine, since it is already opened
and reserved by Galaad. Using an external programme supposes that the
spindle is driven by another channel that this programme is able to manage.
Galaad makes these calls and immediately continues. It is up to you to deal
with their execution.

Important: it is possible to define, for each tool, using the button "More" of
its parameters, some special outputs for the spindle when this tool in particular
is called. These special outputs
depending on the tool replace the
default outputs in the "Control"
frame of the spindle parameters. If
you encounter a communication
problem using one tool and not the
others, perhaps you should check
these extensions.

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"Speeds" page

The next page of the machine parameters brings us to the set-up of the
working speeds. These are generally set once for all and are not linked to any
particular job. They affect
neither the feedrates, that you
have defined in your drawing,
nor the plunge or drilling
speed, that you have set in the
tool library.

Your controller is capable

of driving your machine over
a wide range of speeds, but
that range is not infinite. All
the same, limits have to be
imposed for mechanical and
safety reasons and it is
necessary to specify a
minimum and a maximum
speed, so that Galaad can ensure that they are never exceeded. Also a maxi-
mum angular speed must be set if your machine is fitted with rotary axes. If
you do not know your machine limits, then let us say that it is rare that a
feeding speed is less than 0.1 mm/s (6 mm/mn) or moves an axis at more than
100 mm/s (6000 mm/mn) but some large tables can move faster, and even
sometimes much faster. These limits can usually be found in the technical
information provided with your machine, but not always. In some cases,
travelling too fast can result in a loss of the current position (at least with
stepper motors in an open loop) and consequent damages on the machined
workpiece and the cutter. So please do not blame Galaad immediately when
you have tried to push the limits. If the speeds that are sent to the machine are
incorrect, you can always change them overall by adjusting a post-multiplier,
which is normally set to 1.

The central frame on this page sets the speeds of the various automatic
moves that occur during the working cycle when the tool is not actually
cutting the material. The homing speeds are quite simply the speeds, axis by
axis, at which the machine will move to reset its absolute position on the zero
point. For the sake of the limit switches and the mechanical stoppers, please do
not use too fast a speed. The XY rapid motion is the horizontal travelling that

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takes place when the tool is retracted to a safe height above the work (the rapid
plane) and moving between machining operations. The Z rapid motion down
is the one that takes place from the rapid plane down to a point just above the
surface of the workpiece. The tool then slows down to a speed that depends on
the tool being used, before entering the material. Therefore this speed, together
with the feedrate, is set depending on your work and the cutter being used. The
Z rapid motion up covers all movements where the cutter is retracting away
from the material. Finally, there are the tool sensor approach and the
digitiser lowering speeds which, as their names suggest, cover the speed at
which the cutter approaches the tool sensor for measuring its length during the
workpiece origin procedure on Z axis, and the speed at which a digitising
probe approaches the workpiece, if they are fitted to your machine.

The two values for manual control set the initial positions of the speed
control sliders that will be displayed in the machine control windows. Pre-
setting here avoids moving speed sliders anytime you open a manual drive
window, whatever the mode, manual jogging or workpiece origin setting.

If your numerical controller offers a speed override

function (real-time control of the speed), then Galaad
may accelerate motion progressively when an axis is
moved manually. This can be useful to undertake both
long movements and accurate approaches without
having to change the speed slider all the time. Ticking
this progressive acceleration checkbox pops up a small dialogue box that
allows you to set the delay before acceleration (start speed remaining the slider
speed) and the run-up delay (motion accelerates slowly until speed is dou-
bled). Another possibility: the repeated motion in incremental mode (when
the manual jogging is not continuous and unlimited) lets you reproduce the
same movement after a brief delay if the motion key is
maintained pressed. A small beep is emitted for
punctuating the movement. Remember that, whatever
the speed sliders display, you can still move axes
manually at slow speed using the right mouse button,
by pressing the key on the keyboard or by pressing the button #2 on the
joystick (default setting).

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"Advanced" page

Now we come to the spare room that contains a hotchpotch of machine

related parameters that do not have anywhere else to go, which does not make
studying them any easier. It is
now recommended that you get
a compass before venturing
alone into this dark hole. But
there again, that is the purpose
of this manual, so follow the
guide and stick to the path.

Right at the top of this

window are the scaling
factors, whose values will
increase or reduce the magni-
tude of all distance commands
sent to the controller or
returned from it, for each axis.
We have already seen similar
factors for the speeds, but these work in one direction, Galaad  machine,
because these values do not have to be returned as only the software can
change them. These scaling factors are linked very closely to the pitch of the
ballscrews and the resolution of the motors, as set in the "Table" page, and
ultimately all distance values are rounded to the nearest motor step (or half-
step, quarter-step, etc.). Unless you want to correct a micro-error, all scaling
factors should be left at value 1.

Descending further into the cave, you will find on the shelf at the left hand
side the features to reassign the axes, for example for inverting the X or Y
axes if the machine orientation seen from the operator's point of view does not
match the reality (then set X on channel 2 and Y on channel 1). You may also
invert the direction of an axis. Warning: the purpose of inverting an axis is not
to change the position of the machine zero, but just to make the motor turn in
the correct direction. For making the screen match what the machine move-
ments, you must first set the position of the machine zero in the "Controller"
page (see a few pages before in this manual).

Many available options in this page display a text followed by suspension

dots. This means that, if you enable the option, a dialogue box will pop up for

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setting the sub-parameters. If the option is already active, then you must
double-click or simply press while clicking on it. If you validate a sub-
window, you must also validate the parent window.

If your numerical controller receives initialisation parameters, you can

decide whether these parameters must be sent or not. Do not disable this
option unless your machine is fitted with a dashboard giving access to internal
settings.

The XY origin with offset allows you to validate the workpiece origin on
XY axes (using green buttons) at the current position of a pointing device
instead of the tool itself, for example a laser spot for a cutting table with a
plasma torch, or a video camera for a printed circuit engraver. Please see the
chapter "Advanced milling
functions", section "Plotting
the origin with a video
camera" for more information
about the use of a webcam.
Together with Galaad is
provided a small visualisation
module which, unfortunately,
will not work with all
webcams, but you can replace
this with another video display
programme and simply specify
its command line. Laser spot
or webcam, the aim must be
accurately parallel to the Z
axis, and special care must be
taken to the calibration of the
plotter-tool offset, otherwise you will have wrong workpiece origins. Here a
button gives access to the calibration procedure, which consists of these four
stages: marking with the tool end a position on the workpiece or directly the
machine bed, activating the spindle to drill a small hole there; validating this
tool position with the corresponding green button; moving the XY axes so that
the laser spot or video cross accurately match the centre of the hole; and
finally validating the plotter position. Galaad will memorise the XY offset in
its parameters.

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Manual jogging from an external device

If you wish to jog your axes in manual mode from an

external device (a joystick or gamepad, a numerical
keypad, an encoder wheel), which is an excellent idea,
then you must tell Galaad that it must read the data
coming in from that device or keyboard. Of course you
may activate several devices all at once.

If you have a joystick or a gamepad, both being equivalent seen from

Windows, then Galaad is supposed to react to your pushings on the stick. The
device must have at
least two axes for
jogging the machine.
Analogue models are
suitable: the small
sliders help you
calibrate accurately
the thresholds that
trigger the motion of
each axis. The buttons
available on the
joystick can also be
assigned functions to
be chosen in the drop-
down lists.

You may also use an external keypad (or more simply the main keyboard)
and assign a function to each key. The set-up is very basic: click on a button,
free or already occupied, then press a key on the keyboard or the keypad, then
select in the drop-down list the function to be associated. The manual drive
will enable this function when you press the programmed key, provided that it
is usable at that moment. The option for the process control from keyboard
offers a similar window with fewer possibilities. The functions for supervising
the machining cycle are not many since, at that particular moment, while
Galaad is working hard, the operator is away at the canteen.

For an accurate approach of a workpiece origine, the encoder wheel is an

interesting device. Remember that the mouse wheel moves the last axis that
has been jogged by an increment of 0.01 mm (if the resolution is sufficient),

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which is a basic but no less efficient handwheel. Galaad also manages some
control devices that have been developed for the video editing but can be
adapted successfully to the manual
control of a CNC machine. The very
first function of a handwheel consists
of moving the axes by small incre-
ments, for completing the approach to a
workpiece origin. The movement
direction is linked to the wheel rotation
direction, which it is possible to reverse
for each axis. The number of buttons
varies a lot from one handwheel to
another (one single for the PowerMate, fifteen for the ShuttlePro2). The
functions associated with the buttons are not settable. Generally, these
handwheels provide a keyboard emulation and every action virtually corre-
sponds to a key press. The usable models are as follows:
- Contour Design / ShuttleXpress, efficient and cheap, fitted with a handwheel
at its centre for managing the incremental movements of the active axis, with a
fast motion ring to left or to right for the continuous move. If your numerical
controller integrates a real-time control function for the speed (AxeMotion,
SM-Motion, TechLF), then the movement will be modulated according to the
position of the ring. The two buttons beside the centre wheel allow you to
choose the increment (their values are settable here). The three buttons at top
select the active axis among XYZ. The position of the active axis at the bottom
of the screen is framed by a white
rectangle to avoid misunderstandings.
A double-press on one of these buttons validates the workpiece origin as if one
of the green buttons "X/Y/Z - ok" was clicked. With a speed-controlled
spindle, the handwheel and the lateral buttons also adjust the rotation speed,
the three buttons validating the window. When machining, these three buttons
correspond to the step mode, the pause and the stop. The ring then corresponds
to the overspeed and the wheel to the spindle rotation speed.
- Contour Design / ShuttlePro is the big sister of the previous one, much more
richly endowed in buttons. The functions for the wheel, the ring and the lateral
buttons are identical to the ShuttleXpress, but the five buttons above control
five axes XYZAB. The four buttons at the top call the command buttons of the
manual drive, and the four buttons at the bottom emulate the , ,
and keys, also usable in the dialogue boxes. The installation
procedure for the Contour Design handwheels is describes hereafter.

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- DV Keyboard is a video editing keyboard that integrates a handwheel and a

ring, topped by two buttons. These two buttons allow you to choose the
increment between 0.1 mm and 0.01 mm (both values settable). The functions
associated to the wheel and the ring are the same as previsouly described.
- Griffin Technology / PowerMate is a simple handwheel with one single
button. So the increment is set to 0.01 mm, and the selection of the active axis
is done by pressing the button rapidly once, twice, three times, etc.
- Hanwha / GR100 is another keyboard dedicated to the video editing job, but
fitted with eight buttons. The two buttons at top change the increment; the
others change the active axis.

Installation of a ShuttleXpress handwheel

When the ShuttleXpress or the ShuttlePro handwheel is plugged to the PC

and its driver installed, an icon appears at the bottom right of the screen in the
System Tray. Click on it and call the function "Open Control Panel". The
window shown here is opened.
Now click on button "Op-
tions", then on "Import
settings". Then look for a file
named SHUTTLEXPRESS-
LAN.PREF in the hard disk
directory where Galaad has
been installed. Click again on
the button "Options", then on
"Change target application".
Now look for the file
LANCELOT.EXE, again in the
disk directory where Galaad
has been installed. Then close
this window "Contour Shuttle
Device Configuration". For Kay and Kynon modules, if you are using them,
repeat the operation with the files SHUTTLEXPRESS-KAY/KYN.PREF
associated to programmes KAY/KYNON.EXE that have been installed with
Galaad suite.

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To finish looking at the various options, it is possible to automatically

bottom right tool when Z-ok pressed. After you have moved the tool down
so it touches the workpiece top surface or the machine bed, and you click on
the green button "Z - ok" for validating that new Z origin, then the tool will be
lifted up to the new retraction point, which is the workpiece top surface minus
the retraction height. This eases the next operations on axes because you do
not have to lift Z up manually, for example to move XY horizontally towards a
new origin point.

The option for warning before starting last cutting Z stage induces a
machining pause, tool up, when it is going to proceed with the last Z stage that
will free the cut parts. This is not an invitation to put your fingers in the
machine workspace. Better use the support bridges in the drawing, located
among tool compensation functions.

After the machining cycle, you can request sending an e-mail, and even at
different phases of the process. The technical data for accessing the mail
server must be indicated in the sub-window.

At last, for monitoring from afar what happens on the computer, it is

possible not to allow the screen saver while machining, temporarily. The
settings of your Windows screen saver are not affected by this option, but will
simply be disabled as long as the machining cycle is in progress, and conse-
quently that screen saver will not be called. Once the end-of-cycle message
has been validated, the screen saver is restored as it was.

Mechanical corrections

To compensate for a mechanical error caused by the X and Y axes not

being accurately at a right angle to each other, you can use the XY orthogonal
correction factor, after measuring the error. The following example explains
how: use the machine to cut out a large rectangle from any old cheap material,
using a cylindrical cutter. Take a set-square and test the corners, looking for a
gap, or just daylight, between the square and the
material. If you see a gap, then it is because the X and Y
axes on your machine are not strictly perpendicular. In
other words, it machines a parallelogram where you
expected a rectangle. Before grabbing a very big and

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vengeful hammer, please consider the possibility that Galaad might be able to
cure the problem using some alternative medicine.

Accurately measure the gap G, between the square and the material, as
far from the corner as possible, and also the height H, of the rectangle at that
point. It does not matter if you measure H along the board or the square unless
the gap is gigantic, in which case your legal adviser should perhaps write to
the manufacturer. Bring G back to a percentage using the little prorating rule
of three G' = G  100 / H and simply enter the resulting value G' into the text
box marked "XY orthogonality correction". Now machine again the same
rectangle. If the problem has become worse, then the correction has been made
in the wrong direction. Simply reverse the sign of the correction and make it
negative, i.e. enter - G' instead of G'. This time, it should be better. An
alternative method to check for any error involves measuring the two diago-
nals of the rectangle that you have just cut. We will spare you the maths
lesson, as it is slightly more complicated and best left for devotees of applied
trigonometry, we salute them all.

The XA orthogonal correction does exactly the same as above for

rectifying the error of alignment between the linear X axis and the rotary A
axis.

Another great classic of machine tools, the backlash compensation for X

and Y axes is possible with Galaad, though that type of correction does not
make much sense in numerical control since the axis remaining still is not
blocked by a brake and will therefore be free to move inside its mechanical
clearance. Let us also argue that this function does not mix well with the rapid
and fluid machinings of curves where the kinematics calculation helps to
achieve good chaining dynamics for the series of motion vectors. The dynam-
ics will be irretrievably broken by the instant offsets that are needed by the
backlash compensation when an axis is reversing its direction of movement,
which is somewhat frequent. If your machine requires backlash compensation,
then it is up to you to make a quantum choice between speed and positioning
accuracy, knowing that it is always better to fit the machine with quality
transmissions. The clearances to be corrected on X and Y axes are given in
absolute values, and there is no backlash compensation possible for the Z axis.
In addition to the above-mentioned limits, the spindle weight and the plunge
pressure render it even less useful.

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The workpiece flatness correction is an advanced function of Galaad that

allows you to make engravings at constant depth even if the workpiece top
surface is not perfectly flat
or when its thickness
varies, for example a
printed circuit made of
epoxy. Before machining,
Galaad can carry out a set
of Z measures with a probe
for mapping a topographic
matrix of the surface and
then apply field tracking
corrections. Many options
are available at the top of
the sub-dialogue box for
managing the probe. The
simplest device can be a
basic electrical contact
between the tool and the
workpiece, for example a
crocodile clip on the tool,
connected to one of the input plugs, and any type of contact with the work-
piece, connected to the other plug. When the tool touches the top surface, then
the circuit is closed and the input is triggered. This is perfect for engraving a
copper plate or any other electrical conductor. Of course you must make sure
that the circuit cannot be interrupted by something else like losing the clip or
the wire connected to the surface, in which case both the tool and the plate will
need replacements. A sub-option asks you if this probing phase requires an
intervention from the operator, for example to avoid starting the spindle while
the clip is still locked on the tool, which could result in a big tangle. Another
simple probe can be an accurate mechanical switch mounted beside the spindle
on the Z axis, or even inside the chuck instead of the tool. In this case, Galaad
must know, to avoid performing operations with the tool that the sensor might
not appreciate at all. You may also use a retractable sensor with plunge-down
and bottom right commands under software control through an on/off output.
This allows you to chain the probing and the machining phases immediately
with no operator's intervention requested. Finally, the sensor can also be a
virtual tool in the rack of the tool changer, consequently mounted in the
spindle, but automatically.

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If the probing sensor is not mounted in the chuck at the location of the
engraving tool, then the sensor-spindle offset must be calibrated, so Galaad
can probe at the right locations. It is also possible to avoid probing when there
are only cutting paths and no engraving jobs. The measurement itself will
generally be managed by a binary input that is triggered when the sensor is
pressed, or through a laser sensor that directly feeds Galaad with the Z
variation. For a binary sensor, it is possible to set up a safety procedure by
requesting that the probing session is launched only when the sensor is pushed
manually by the operator, which enables checking that the electrical circuit
works and is connected to the right input. This, because a probe that plunges
down without stopping at the workpiece top surface can quickly become a
probe to be replaced.

In the same vein, the machine-

bed flatness correction considers the
whole machine surface defects once
and for all. On a small-sized machine,
surfacing the bed using a flat cutter
with a big diameter is quite enough
for obtaining a very good flatness that
corresponds to X and Y axes.
Machinings on a bed that has been
surfaced by the machine itself should
be no problem concerning the Z
variation. But on a big table, or if the
bed that supports the workpieces
cannot be surfaced for any reasons,
then the software can apply a
calculation for correcting these
variations of the workpiece plane.
This supposes that the part to be
machined follows the variations of
the machine bed. The function is
based upon a matrix of points located at regular intervals on the machine bed,
every point having a measurable Z position. You can indicate the number X
and Y of points to be probed, and the general position of the matrix, i.e. the
lateral margins around it. The software will help you probe the altitude of
every point of the matrix, by positioning itself the probe or the comparator,
taking into account the offset between the probe and the spindle. If your
machine is fitted with a probe sensor, then Galaad can fill up the matrix all

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alone by measuring every point. Otherwise you must mount a comparator and
drive the Z axis manually until the needle returns to the reference position.
Once a measurement has been validated, the software lifts up the Z axis,
moves it to the next XY point and plunges down to the previous position.
Here, you just have to gently move the Z axis up or down so the comparator
needle returns to the reference and Galaad records the relative altitude.

The matrix of flatness points is used for readjusting the Z coordinates of

the machined paths, with a progressive smoothing function so the result is
perfectly adapted to the variations of the bed.

Kinematics post-calculation

The kinematics calculation is an important function that manages fast

machinings. It aims to ensure an optimal motion fluidity at high speeds whilst
avoiding losses of steps of a stepper motor, or drag errors in case of a ser-
vodrive. When this function is enabled, the feedrate is no longer a constraint
that is imposed for every movement, but an objective to be reached as far as
possible, the major requirement being to prevent a motor from overriding its
electromechanical limits. The kinematics calculation can be activated only on
machines that have numerical controllers integrating three functions:
- A local memory buffer (see that parameter) that is able to store the motion
vectors before they are executed. The software then works in asynchronous
mode and tries to maintain a high level of buffer fill-up.
- Corollary of the above, a high bandwidth so the transmission of the vectors
is faster overall than their execution. If the path is completed faster than its
own transmission, then the buffer gets empty and then, at some point, the
machine will be thrown into a fast trajectory, to be brutally interrupted by the
lack of new coordinates not yet transmitted, resulting in knocks or losses of
steps.
- The possibility to execute movements with acceleration ramps and move-
ments at constant speed (see hereafter). Other types of movement exist, that
Galaad uses when they are available, generally on very advanced CNC
systems.

If one of these three functions is lacking, then the kinematics calculation

cannot work. The bandwidth, closely related to the communication port as

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well as the protocol and the command language, often represents the crucial
point of a fast machining. If the number of vectors to be transmitted is high for
a short distance of the path, for example in a curve with a very fine resolution,
then the motion speed may render the transmission time longer than the
execution time for the machine. Conversely, a long straight line requires only
one coordinate to transmit, which is very brief, and much time for executing
that movement, which lets the transmission get ahead of the curve. So, the
local memory buffer is in charge of absorbing the variations of the gap
between the transmission and the execution along the machining path. But,
even with a very large memory buffer, the transmission must be faster overall
than the execution.
The kinematical parameters are split into two main parts, each of them
corresponding to a type of movement that the machining process can perform.
Let us take this opportunity to do some theory about vector dynamics. Sure
you were missing it.
The first type of movement a numerical controller can undertake is the
vector with acceleration ramps. A vector is a basic movement from one point
to another at a given speed (or more accurately the movement from the current
point to a distant target point). For example, in a 3-axis machining, a vector
will have relative distance components X, Y, Z and a velocity component V.
The power of a motor is not infinite. Coupled to an axis, it has an inertia that
thwarts its speed changes. It cannot jump from immobility to a high rotation
speed, nor reciprocally jump from a high rotation speed to immobility.
Consequently, the numerical controller imposes three phases for performing its
movement between two points:
1 - An acceleration phase, enabling achievement of the speed demanded. The
motor does not start from a null-speed but a floor speed named "Start/Stop
Speed". The numerical controller makes the motor jump instantly from
stillness to that start/stop speed and then increases the RPM according to the
acceleration ramp that its power and its inertia can afford.
2 - Once the cruising speed is reached, the RPM remains stable. The motor
does most of the movement to the target point at that speed.
3 - Before arriving at the target point, the controller triggers a braking ramp
that makes the motor slow down and stop softly on the target point. The
deceleration is generally symmetrical to the acceleration.
The closer the points are to each other, the shorter the movement. So if,
furthermore, the cruise speed is high, it can happen that the motor jumps
directly from phase 1 to phase 3, i.e. begins to brake even before having

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completed its acceleration but without reaching the speed. The controller
manages all this. In fact, the speed curve describes a trapeze: a first ascending
slope (acceleration ramp), then a stable flat, and lastly a lowering slope
(braking ramp).

The two parameters of a movement with ramps are then the start/stop speed
and the acceleration slope. The numerical controller generally uses neither the
metric nor the imperial systems, but rather the motor increments. So the speed
is actually a frequency, set in Hertz. We are talking about a "Start/Stop
frequency" which is translated into a speed for each axis. If these have
different gear factors, then the frequency will correspond to the most critical
axis, namely the weakest motor of the heaviest axis having the highest gear
factor. Please put all this in a jar, shake strongly and it will generally output a
frequency of about ½ to 1 revolution per second, at least on a more or less
classical machine. For example, if your motors have a resolution of
1600 pulses/revolution, the start/stop frequency will typically be between 800
and 1600 Hertz.
The start/stop frequency indicates the instant speed for pulling away from
immobility, and also the last speed before stopping the motor. A bad setting
can have important consequences on the behaviour of the machine. If the value
is too low, then the acceleration and braking ramps will be a bit longer and it
will sound like the movements are too soft, which is not very harmful. But if it
is too high, then the motor will have to make too big a jump for catching its
acceleration ramp, and reciprocally it will turn too fast just before stopping. At
best, the machine will knock and, at worst, the motors will lose steps (the
position will drift away gradually) or, for a servodrive, raise a drag error. A
good ear listening to mechanical noises is a significant asset for fine tuning
a start/stop frequency and more generally the kinematics.

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The second parameter of a vector with ramps is the acceleration slope,

namely the time for increasing the speed. Since the deceleration slope is
symmetrical for decreasing the speed at the end of the vector, the acceleration
value is the same for the braking. As for the start/stop frequency, the distance
is encoded in increments. An acceleration in increments per second square is
then quantified in Hz/s and will be common to all axes, like the start/stop
frequency. If the value is too low, then the speed increase and decrease will be
too long, with too soft movements. But if it is too high, then the motor may
fail to follow the the slope and will stall on the way up, resulting in a position
drift or a servodrive error. The acceleration slope is supposed to be calculated
for the working conditions of the most critical axis, therefore the weakest
motor having the heaviest load, taking into consideration the torque curve of
this motor relative to its speed. In other words, this is not simple and, here
again, experience and a fine ear are often more precious than a calculator for
finding the good acceleration value. By the way, Galaad's calibrating function
may help you fine tune these settings.
The vectors with ramps are used for all types of isolated movement
between two points. Isolated means that the speed at each of these points is
slow or null. All driving movements in manual or semi-automatic modes, with
no exceptions, use vectors with ramps, including the probing, the plunge down
to the tool sensor or the tool changer. All these movements are considered
isolated even if they are part of a chained sequence. In automatic machining,
the positioning movement with the tool cleared, the tool lowering down to the
contact with the workpiece top surface, the vertical drilling plunge in the
material, the tool bottom right to clearance height, and the parking are also
isolated movements, consequently using vectors with ramps. Lastly, when the
tool is down in the material and feeding horizontally, if a movement is
performed between two sharp vertices on which the tool passes at slow or null
speed, for example the sides of a rectangle, then here also the software will use
a basic vector with ramps, even if it is not isolated.
Many machines of an old type or having limited speeds can perform only
movements with ramps. Consequently, on a curve trajectory, there will be an
acceleration, a cruise speed and a braking for every small vector that makes up
the curve. This means that the machine spends most of its time accelerating
and braking, and probably never reaches the target speed, except for long
movements. The result is slow and jerky, especially when the cruise speed is
high. Obviously, if the numerical controller integrates a circular interpolation
command, at least the arcs of circles will be performed in one single move-
ment with an acceleration and a braking at the beginning and the end of the arc

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instead of every vector forming that curve. But this supposes on one hand that
the arc itself is isolated, with no direct chaining before and after with the rest
of the path, and on the other hand that resolutions and gear factors of X and Y
axes are strictly identical, otherwise the circular interpolation is ineffective.
Anyway, this type of interpolation is irrelevant for a non-circular curve such as
an ellipse, a spline or a Bezier curve. In fact, the best way for getting a good
path fluidity whatever the curve type and the axis features are, would be
chaining the vectors without slowing down between them, which leads us to
look for something other than the vectors with ramps for moving fast enough
along a continuous trajectory.
The second type of movement Galaad can manage, provided that the
numerical controller accepts it, is the vector at constant speed. Here, there are
no acceleration and braking ramps; the speed remains unchanged from the
beginning to the end of the vector. The advantage is, several vectors can
succeed to one another with no slowdown between them. But this creates new
problems, the first being the fact that, for reaching the cruise speed, the axes
must accelerate along the curve and not forget to brake at the end of the path,
and also a calculation formula must be applied for maintaining an overall
consistency in the speed changes.
The vectors with constant speed do not have main parameters such as the
start/stop frequency and the acceleration, since their speed does not vary. On
the other hand, for managing them correctly, the software needs more complex
parameters since it is no more possible to try them separately in a simple
manual jogging.
Many systems for overall path management are based on the angle between
two consecutive vectors, this angle determining the speed reduction at their
passing point. But this solution, that looks simple and efficient, actually works
only in the most optimal cases. The local angles of a series of consecutive
vectors reveal nothing about the chaining dynamics, which may vary a lot
depending on whether the overall curve is wide or tight. A U-turn performed
along a half-circle made of 180 vectors following one another with an angle of
1° between each of them is obviously not run at the same speed if the arc has a
radius of 100 mm or a radius of 1 mm.
The Galaad function for calculating the kinematics is arithmetical and not
geometrical. It considers every single vector separately. In fact, even if we
have a global view on the path in a motion using several axes, a motor does
not want to know what its dear colleagues are doing in the meantime. The only
important thing to know is whether each motor can deal with the speed change

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it has to face, depending on the power it can provide and the inertial load it
must carry. Above all, the calculation is a search for the discontinuities of the
rotation speeds. There are two kinds of resulting parameters, that look more or
less like a start/stop frequency and an acceleration: first, what speed change
can a motor accept without stalling? Second, how much delay does a motor
require for absorbing a speed change before being able to cope with a new
one? The purpose of the calculation is to replace too high a step, by a series of
small ones that the motor can climb or descend without stumbling on it. A big
change of speed then becomes a succession of affordable little changes, spread
over time. Now we have only to define the height of the small stages (the
maximum speed discontinuity that the motor can deal with) and their width
which, once combined, determine the overall slope of this set of steps. The
more the motor can handle an important speed change, the less there will be
intermediate steps. And the shorter the delay for absorbing a speed discontinu-
ity, the stronger the acceleration will be.

Indeed, adding intermediate mini-vectors greatly increases the number of

coordinates to be transmitted, which is a bandwidth killer. Hence it is tempting
to set a high value for the maximum discontinuity. But the purpose is, above
all, to keep the motors inside their own range of efficient work. The bandwidth
will have to cope with that, otherwise it will become necessary to reduce the
maximum feedrate, considering that the machine cannot follow. Nevertheless,
please note that a motor torque is not constant. Particularly on stepper motors,
there is a brutal stall of the torque with the speed, generally about 10 to 20
revolutions per second, due to the charging time of the coils, which can be
reduced by increasing the voltage. So the parameters for speed discontinuity
and for acceleration capability are not constant, unlike those for start/stop
frequency and acceleration for the vectors with ramps which are applied
around the null speeds when the torque is maximised. It is up to you to find the
best compromise for the usual feedrates of your machinings.

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Setting the kinematical parameters

can be done by activating (or double-
clicking on) the option "kinematics
post-calculation". The underlying
dialogue box offers a possibility for
setting easily from two sliders, one
for the vectors with ramps, that
correspond to the inactive movements
when the tool is up or the manual jogging, and the other for curved paths with
fast vector chainings. The more a slider is on the left hand side, the more the
motion it controls is soft. Conversely, the more the slider is on the right hand
side, the more the motion is hard, until it reaches the risk of losing control and
beyond.
For accessing the fine tuning of
the calculation, click on the button
"Advanced parameters" at bottom,
which displays the complete dialogue
box. Here, you can indicate in the
middle frame the actual start/stop
frequency and acceleration values (for
movements with ramps if you have
understood the demonstration), and in
the lower frame the values for the
maximum speed discontinuity that
the most critical motor can carry out
without stalling, and the continuous
acceleration capabilities along a
path. These two values are to be set
respectively in mm/s and mm/s²
because the calculation applies to
coordinates and real speeds, even if the numerical controller uses increments
and frequencies. The start/stop frequency is sent as a general parameter to the
numerical controller when initialising the dialogue and, thereafter, Galaad
does not want to hear about it anymore. On the other hand, the speed disconti-
nuity and the continuous acceleration capability are used for its own calcula-
tions concerning every new path.
These two values for the "look-ahead" calculation when milling can be
rendered variable with the option that manages a dynamic reduction of the
acceleration with speed. This reduction makes sense with motors that lose

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torque when they are gaining speed, even though this loss of torque is
generally not linear. If that option is enabled, then you should consider that the
acceleration value (and this only) that has been set applies to a feedrate of
about 20 mm/s (1200 mm/mn) and will progressively decrease when the speed
is higher (but the acceleration is not increased when the speed is slower).
The "look-ahead" kinematics calculation dramatically increases the number
of vectors by interpolating new ones that are used as intermediate levels for
overcoming important speed discontinuities. Therefore, it can become
necessary to reduce overall the number of vectors to be transmitted. This may
prevent a traffic jam on the bandwidth, which would result in drying out the
local memory buffer. The anti-overflow optimisation of the bandwidth will
be in charge of filtering mini-vectors that are considered non-significant and
consequently will not be transmitted. A discarded vector actually makes a very
small angle with the previous vector and runs along very short distance, say a
few tenths of millimeter, that distance being adjusted depending on the
feedrate. This aims to lighten the curves with too high a resolution that would
lead to a risk of stalling the transmission capabilities. A saturated bandwidth is
characterised by a machining that suddenly becomes jerky though it was fluid
just before.
As a conclusion about the kinematics calculation, let us say that it is a
rather complex function that requires much more accurate settings than simple
sliders varying between "soft" and "hard". Please keep in mind that the energy
needed for accelerating or slowing down a movement is proportional to
the square of the speed: feeding twice faster requires four times more power;
feeding three times faster requires nine times more power. The kinematics
calculation cannot perform miracles, and the stepper motors are running
against important falls of torque when turning fast. Don't ask your machine for
the impossible, even with Galaad.

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Automatic tool changer

To conclude these pages of advanced parameters, a last button at bottom

right allows you to open the set-up of an automatic tool changer.
A tool changer, whatever it looks like, rack, barrel, or anything else,
always uses a sequence of automatic commands for moving axes, switching
outputs, waiting for inputs to toggle on/off, etc. Galaad offers the ability to
programme for every tool a pick-up sequence, i.e. the process that will load
the tool from where it was parked and mount it on the spindle, and a parking
sequence, i.e. remove it and store it back in the rack. If the positions should be
identical, it is more than probable that the set of input/output commands will
differ. But it is up
to you to set up
these processes
according to the
technical infor-
mation you have.
Manual jog-
ging will help
you find the right
positions, inputs
and outputs. Do
not forget that the
"Refresh" and
"Loop" buttons
allow you to
check the inputs,
and clicking on
the green boxes
of outputs will
change their state.
A good prelimi-
nary manual drive
is worth any
teach-in sessions. On a classic tool changer with a linear rack, the procedure
consists of bringing the XY axes vertically above the tool cone and noting the
accurate position. Then lower the Z axis until the cone is engaged in the
chuck, of course having made previously sure that the jaws are open, and note
the Z position. After having closed the chuck by triggering the output that

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controls it, you can move the X or Y axis horizontally

so the tool is extracted from its clamp with a sufficient
margin, and again the clearance position is noted. Now
you just have to measure the distance between two
neighbouring clamps. By the way, this can be done by simply
jogging the axes. Having done all this, you should have the
absolute XY position of the first clamp, the clearance position
(X or Y depending on the direction of the rack), the offset (X
or Y) between the clamps, and of course the output number
and polarity for triggering the cone clamping jaws, whatever
the mechanical technology is, pneumatic or electric. Once
these informations are recorded, you can easily write the
scripts for picking-up and parking any tool that is present in
the rack. A button for copying these scripts and another one for shifting all
coordinates in one operation should help you out.
For every tool numbered, you must indicate whether it belongs to the
changer by ticking the checkbox "Automatic change". If this checkbox is
active, then only you can access its two scripts. The button "Run live test" will
help you give it a try. Warning: the pauses are sometimes long when there is a
mechanical action, especially with pneumatical items that have some inertia.
And do not forget to insert in your scripts a prior bottom right of the tool
before sending it to a new XY position, just in case there could be some
obstacles in its way. Galaad does not like to impose movements and conse-
quently does not decide them alone. You can also write a script for manually
ejecting a tool off the chuck without moving the machine. But there is often a
button for this beside the spindle.
The linear racks are sometimes topped by a protection cover which
prevents the tool cones from receiving chips or dust. You can integrate the
command for opening this cover, which may also protect the tool sensor, in
which case you must indicate it in the parameters of the tool sensor (see the
page "Inputs/Outputs" hereafter). A linear rack will generally be located on the
table side, with an exclusion zone that forbids Galaad to operate automatic
movements except when executing these scripts. Manual jogging is possible
inside the exclusion zone, but a stop point is set at the borderline. Another
security, the tool measurement sensor can enable checking if one of them is
already present in the chuck. It is a bit time-consuming, but quite efficient. In
the same way, a measurement of the tool at the end of the cycle can help
checking whether it is still alive or a part of it is missing.

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"Inputs/Outputs" page

The last page of machine parameters gives access to a special control of the
inputs and outputs for some applications that use peripheral devices. Galaad
agrees to trigger binary outputs
on demand according to logical
events of the machining
process (an output is consid-
ered binary if it has only two
possible states, on or off, with
no intermediate states such as
an analogue or PWM output).
The software can also react
when a binary input is trig-
gered.

Do not forget that you may

indicate several outputs (4
maximum) and in some cases
several inputs for one single
function. To do so, you must separate their numbers with spaces or hyphens. If
you specify several outputs, then all will be triggered when the corresponding
function is activated. If you specify several inputs, then Galaad considers that
the function is triggered when at least one of them is in the indicated state (a
logical "or" is applied). For one single function, it is not possible to specify
several outputs or several inputs in different logical states.

The top frame allows you to manage standard peripherals such as the
safety devices for the operator, or the tool measurement sensor. If you wish to
modify their underlying parameters, then double-click on them.

According to official standards in force, the mode of operation for a safety

circuit must be fully independent from the software and even from the
computerised numerical controller. Opening the door of a safety enclosure or
pressing an emergency stop button cannot alone notify a programmed process.
Safety circuit action must be immediate and direct by stopping the tool and all
machine movements, the simplest being of course a clean cut-off of their
power supply. The operator should not be confronted with an active spindle
without an intermediate cover or screen, and an axis involved in an automatic
movement is potentially dangerous. The real importance of protective

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equipments can never be overemphasized, including for hobby CNCs. Even a

low power machine can seriously injure an operator. The applicable
regulations are not flexible, but they do not ask for the impossible. Safety is
important. Protect your eyes; protect your hands; protect your
colleagues. Do not shunt the human protection systems, even
though they can sometimes look cumbersome. If your machine
does not require an enclosure, then at least please think about
wearing protective glasses.

It is becoming easier and easier, nowadays, to find class 4 laser sources

that can act as a computerised pyrography device or equivalent. Working
without an efficient eye protection with such a system is dangerous. A simple
diffused reflection on a slightly reflective material can be sufficient
to cause a skin burn and moreover irreversibly damage the retina.
Never work with a laser source unless you have the
appropriate protection equipment!

The fact that the safety system reacts autonomously does not forbid a polite
dialogue with the software that supervises the automatic process. Conse-
quently, that software is supposed to know in which state the protection
equipments are and it can
even talk to active safety
devices. If the protection
cover is open, Galaad will
refuse to switch the spindle
on and to launch the
automatic process. So does it
check this status before
sending a sensitive com-
mand to the machine, and
warns the operator if the
cover remains open. The
safety regulations may allow
a lower safety level when the
supervisor's key is in "Test"
mode, provided that your
machine has one and
assuming that the machine can then just perform harmless calibration and
verification movements. These two states, cover and key, correspond to a

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couple of inputs that you must set: their number and polarity. If there is no
key, then just indicate nothing.

Opening and closing the safety cover can also be controlled by two outputs
and a closing delay before starting the automatic cycle. Some protection
enclosures are also fitted with an electromagnetic or pneumatic safety lock that
Galaad can activate before starting the spindle or the automatic process. The
unlocking will be completed after switching off the spindle, plus a pause delay
that lets the motor stop. That pause delay can integrate a fixed part plus a
variable part that depends on the rotation speed when switching off. Finally,
you may indicate three outputs which correspond to a signalling tower that
reports the general status of the automatic cycle: green light for the machine
being stopped, waiting for a cycle or cycle over; orange light for a cycle in
progress; red light for a stopped cycle. If there is no signalling tower, then
these outputs can be used as well for switching a beacon light, a horn, a cello
suite, it's up to you to decide.

If your machine is fitted with a tool measurement sensor, which is highly

recommended for making life easier, then you must tell Galaad on which input
that sensor is connected, and of course its polarity. Let us remember that here
once again, an "enabled" input is
triggered when the contact is
normally opened (N.O.) and a
"disabled" input is triggered when
the contact is normally closed
(N.C.), "disabled" absolutely not
meaning "unused". If an input is
not linked to a switch but to a
peripheral device that sends a
signal, please conclude nothing from the high or low states and rather use the
function "Parameters / Machine / IO test" to know more about it.

The descent of the tool on the sensor can be continuous, in which case
Galaad sends one single movement command down to the low end of the Z
axis. This movement will be interrupted by the trigger of the sensor. But not
all controllers have such a command. Then Galaad will drive a stepped
descent, each step being followed by a read command for checking the state of
the input, until the sensor is triggered. A dichotomic search of the trigger point
will then be launched for finding quickly the accurate position. You must set
the step length: too short, the descent will be long; longer than the sensor

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stroke, you might become a good client for your provider of cutters. Or for
your provider of tool sensors if your cutters are solid. Do not forget that,
before each descent on the sensor, you can enter a rapid Z movement for pre-
positioning. By the way, before and after having launched a tool measurement
procedure, you can execute command scripts according to your needs.

On machines that are fitted with an automatic tool changer made of a linear
rack, it can happen that the measurement sensor is located under the protection
cover of the changer. Galaad should be informed to avoid doing unfortunate
operations. Of course, you have indicated in the parameters of the tool changer
the output that triggers the opening of the cover, because if it is integrated in
the scripts, Galaad will not find it alone. You may set here an output to be
triggered during the tool measurement procedure. This output can also
correspond to the changer cover or any electrical requirements for operating
the sensor. A security option allows you to manually press (and of course
release) the sensor to start the descent, with a waiting message on the screen. If
the sensor does not work or has been wrongly parametered, then at least the
tool will not smash it. Your cardiologist recommends that option, even though
your manicurist disagrees.

Back to the "Inputs/Outputs" page of the machine parameters, the frame

"Events" helps you trigger outputs correlated to events such as the activation
of axis motors after initialising the machine, with a possible pause just after.
The output will be reset before exiting the machining module. Powering the
motors can also release the Z axis brake, but the parameter is independent
since it can happen that both outputs have opposite polarities. Galaad is often
in a hurry to move axes, so releasing the brake may also require a pause to
temper his ardour for getting to work.

Perhaps your machine is fitted with a tool cooling system, connected to a

binary output which will be activated either continuously from the beginning
to the end of the machining cycle, or only when the tool is down in the
material and interrupted every time it is lifted up, or when you request it, in
which case a message will ask you about it at every new process. But nothing
prevents you from installing a basic switch beyond the output so you can
decide during the cycle whether you want the coolant on or off, it being fully
understood that, if it is on, the output will in any case be switched off at the
end of the process. And also the intermittent mode remains valid then.

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If you have a workpiece clamping system, for example a pneumatic vice,

a vacuum table or any device that can keep the workpiece locked on the
machine bed, then that system will be switched on with no interruptions from
the beginning of the workpiece origin set-up to the end of the last machining
cycle, the workpiece being completely finished (or the cycle aborted). Galaad
can also switch on a lamp for lighting up the table during the manual jogging,
which can ease the approach of the workpiece datum, and this lamp will be
switched off when the machining cycle begins. Please do not overdo this
gadget, a simple switch mounted on the machine is also not too bad. Lastly,
you can set a vacuum cleaner to be switched on during the normal passes and
switched off after, if your ears do not appreciate much a vacuum cleaner that
works continuously with the spindle. It is obvious that the above mentioned
items are purely indicative and of course you may use other more esoteric
devices on the same actions.

The bottom part of the frame allows you to automatically trigger a stop of
the machining cycle if an input changes its state. In this case, Galaad manages
a simple stop with a spindle switch-off and sending the tool to its normal
parking position. But this stop is not always immediate, because the numerical
controller may not consider the input critical, i.e. triggering a rapid braking
procedure. This depends on the capabilities and the specific parameters of the
controller. Some can deal with this, some cannot. Since it is not possible to
overload the machine with repetitive messages permanently asking for the
input statuses, Galaad reads these inputs only before making the tool plunge
down into a new path. If, at that moment, a stop or pause input is triggered,
then only the function shall take effect. There cannot be any reading of that
input when the tool is feeding in the material, and an immediate reaction is
therefore impossible. If your numerical controller integrates a settable critical
input, for example an error signal, then you may reuse this input here to inform
the software that the machining cycle is already stopped and it is now useless
to go on sending motion commands to the machine. If you wish to have a less
programmed stop but more efficient and possibly more abrupt, then you
should integrate a small circuit that powers-off the machine directly. You can
also request a simple machining pause when an input is triggered. In this
case, the machining will not be aborted but will be resumed as soon as the
input returns to its initial state. The operator will not even be bothered by
Galaad popping up a message on the screen. This is just a local pause,
managed locally.

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When the automatic cycle is completed, a last input can be checked for
reiterating the process, for example when the operator is pressing some
"Start" button without having to use the keyboard
or the mouse. When the cycle-end message
appears on the screen, then this input is read in a
loop (actually twice per second so pressing the
button must be a bit long). If it is triggered at this
moment, then Galaad interprets it as the equiva-
lent of a click on the option "Redo" followed by a
validation of the message.

Extended inputs/outputs

Galaad manages more input/output related events than appear on the

standard parameter page. When you click on the "Extended inputs/outputs"
button, a large window appears on the screen:

At the top of the window, you can set up a probe configured especially to
find the Z position of the material to be machined before every tool plunge.

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 ————————————————————————————— GALAAD 3

This can be helpful for milling or drilling workpieces with a top surface that is
not perfectly horizontal. In addition to the classical parameters of the surface
probe, you may indicate a Z offset value from the trigger point, which allows
you to lift the sensor higher above the tool if necessary. The lowering will be
continuous unless you indicate a stepping value or if your machine does not
integrate a function for moving until an input is triggered. The upper margin
determines the Z position (in relation to the workpiece origin Zo) from which
the search for the contact begins. There is no point in entering too high a value
that would slow the process. The lower margin indicates the maximum Z
position for stopping that search if the contact is not found (still in relation to
the workpiece origin Zo). If the top surface was not detected at the workpiece
origin plus this value, then the process is stopped and the operator called up,
who can then decide to continue from the lower Z point, without searching
below, or abort the whole cycle. In brief, in relation to the workpiece origin
point Zo, the search for the top surface is performed between the upper margin
and the lower margin.

The main frame is intended for automation technicians. Its lines display
repetitive events of the machining process, on which you can insert output
triggerings, wait-states related to inputs, or simple pauses. For example, if you
want to activate a coolant system only when the tool is drilling the material
and stop it when it starts the horizontal or 3D feeding, and this coolant is
connected to the output number 2 enabled but the software must wait for a
validation of the coolant system on the input number 4 disabled after an
instability delay of 50 milliseconds, then you should validate the two follow-
ing event lines:
At surface touch, enable outputs #2;
pause 50 ms, wait for inputs #4 disabled (timeout 1000 ms);
enable outputs.
The last argument "enable outputs" means that the output #2 must remain in its
active state at the end of the event. It could be possible to stop it for getting
just a pulse. For stopping that drilling coolant, it would be:
At drilling end, disable outputs #2;
pause 0 ms, wait for inputs #0 disabled (timeout 0 ms);
disable outputs.
An unused input or output gets the number 0 or remains empty. The words
"inputs" and "outputs" are plural when you may indicate several, separated by
hyphens or spaces.

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The two lines "At feeding start" and "At feeding end" add intermediate
triggering points on the path. Their positions will be calculated automatically
depending on the feedrate. This can be used for dispensing glue or paint when
the liquid flow must be stopped some time before reaching the terminal point
of the path.

Local manual drive

If your machine offers a dashboard that is connected to the binary inputs,

then you may assign functions to these inputs and Galaad will permanently
scan inputs when in manual control mode. The usual commands are for
moving the axes and miscellaneous control items for all manual operations.

Once again it is better to begin

with a short trip to the function
"Parameters / Machine / IO Test" so
you can take note of which buttons
correspond to which inputs and which
states. This manual control is available
only on numerical controllers which
can start a movement that will be
stopped when triggering an input
defined as critical, i.e. interrupting any
motion currently in progress. If the
controller does not provide this
function, then no movement can be
linked to an input. Other functions
will remain usable.

This local manual drive is a bit eclipsed by the extended possibilities that a
joystick or an external numeric keypad can offer, since these have buttons or
keys that can also be programmed from Galaad, as mentioned in the previous
pages. But you can nonetheless link these functions to the few buttons that are
sometimes available on a machine or a controller front panel. Finally, if your
machine includes a dashboard with local motion control, Galaad can ask for
the position of the axes at regular interval for keeping the display of the
coordinates coherent with the reality.

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External driver

As you have understood it, Galaad integrates the whole process chain,
from drawing the object with its related toolpaths, to supervising the automatic
machining process, through setting the workpiece origin point. However,
many machines not known to the software cannot be controlled directly by it
in real-time mode. Galaad can still be used for drawing an object ready for
machining, but a different software package will have to be used to download
the machining file, or control the automatic milling process, or both.

To facilitate the connection, Galaad will start the external process directly
from the command "Machining / Standard machining on 3 axes" or the
corresponding icon. In this case, the current drawing is automatically exported
in the format required by the external driver, which is immediately started as a
new Windows task. Please note that this driver programme can equally be an
application running under a Windows console session.

In fact, the two modules Galaad and

Lancelot represent the drawing part
GALAAD
and the driving part of the same
software. You may use Galaad as a
CAD-CAM application with any other machine
CNC driver module which will be
called automatically via the "Machin-
LANCELOT EXT.
ing / Standard machining" command. DRIVER

Alternatively, it is possible to call up the Galaad machining modules

Lancelot (specialised in 2½D processes) and Kay (3D) from another CAD
application, if it permits this. The Lancelot programme just has to be called up
with the mill file name as an argument, and the standard name of the file
format in brackets, if the extension is not significant. Example:
"C:\Galaad\Lancelot.exe" C:\…\MyDrawing.plt
"C:\Galaad\Lancelot.exe" C:\…\MyDrawing.xyz (plt)

Calling up an alternate machine driver is not absolutely direct but goes

through Lancelot as an intermediate module that defines milling parameters
and manages tool cycles. In fact, it is Lancelot and not Galaad itself that will
chain to the external CNC driver once the intermediate file is generated.

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To configure an external driver programme, use the command "Parameters

/ Machine / External driver". The dialogue box offers the choice between the
module Lancelot, internal driver for Galaad, and an external module which can
also be a virtual printer driver.

When you launch a

machining cycle through
an external driver, an
intermediate file will be
created in the format
specified and the external
programme will be called
up with all its arguments
as specified in the
command line text box.
Galaad will then continue
to operate independently
while the external driver
gets on with its work. If
you do not set a command line, the intermediate file will nonetheless be
generated but no external programme will be called to chain the process. If
you do not indicate an intermediate file to be transferred to the external driver,
then you will be prompted to give a name every time you start a new process.
Since this file is automatically generated by Galaad, it is probably not useful to
save it under its own name. Instead, you should overwrite it when starting a
milling process. The important thing is the drawing file, not the intermediate
file for the driver. You may also indicate neither command line nor intermedi-
ate file, in which case no driver will be called up and you will be prompted to
give a file name every time. Please note that the file name (and its complete
path) is automatically added at the end of the command line. Consequently it is
pointless to enter it twice.

The formats for the file to be sent to the external driver are those among
the export functions that are the most usual. It is obvious that you can use the
post-processor whose syntax is entirely definable in Galaad (see that function
hereafter).

The other parameters help you set the coordinate system and the directions
of the axes. It is possible to accelerate the generation of the intermediate file

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by disabling the path displays, which may slow down the process depending
on the performance of your computer.

Post-processor format

If you are happy with none of the available export or external driver
formats, you still have the possibility to define for yourself your own format
from the function "Parameters / Post-processor", which opens a generously
endowed dialogue box.

Here you can find everything needed for describing any format, provided
that it is in text mode and that the encoding of the numerical data is decimal or
hexadecimal. The binary formats, which would raise many problems related to
the data size, are therefore excluded. Fortunately, they are never used for file
transfers, at least in the area of numerical control.

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Even if the standard format remains the ISO G-code, on which you can
graft several variants your machine might need, you can nevertheless create
your own alien encoding with an exotic syntax. By the way, Galaad provides a
few frameworks based on ISO, Isel-NCP or HPGL, that you can pick up and
modify using the button "Open" at the top right. On the other hand, you can
memorise your modified format under your own name, using the button
"Save".

Since the format is based on text, you must indicate the codes of the
constant characters that will be used as line header and line trailer. These
codes are set as decimal values representing an ASCII code, for example 2 for
<STX> (Start Text) and 3 for <ETX> (End Text). However, the most common
remains a line with no header codes (set 0 for no code) and 13 for <CR>
(Carriage Return) then eventually 10 for <LF> (Line Feed) as line trailer.
Every line produced by Galaad will begin and end using these control bytes,
with no exceptions.

It is possible to number the lines. In this case, you must set the line
numbering format, the zero indicating the number. For example, if you set
"N0", the lines will have the heading character 'N' followed by the line number
with just the number of digits needed. If you set "N0000", then the number
will have 4 digits filled with heading zeros, for example "N0012" for the line
number 12. Of course, if the number overruns the size, then it will not be
truncated: the number of zeros set here is a floor, not a ceiling. If you enter
nothing in this box, then there will be no line numbers. Warning: the top of
file and the end of file are not numbered, and these only. In the first one, you
must add your own line numbers (you may set as many lines as necessary,
with a maximum of 1000 characters for the total). This block will be sent
exactly as you have defined it. But the end of file block may eventually
receive normal line numbers that follow the previous ones, see below how.

Very important: the variable data must appear in the form of labels
predefined by Galaad, inserted between symbols < (lesser than) and > (greater
than). For example, for the end-of-file block, the only variable data that
Galaad suggests is the line number <N>. If the line counter is at 123 at that
moment, for producing a line "N123 M02", you must set the parameter <N>
M02 in which the variable <N> will be replaced by the pre-formatted line
number, in this case "N123". This remains valid for all boxes or blocks that
accept variable data. The available data labels are indicated at the right
hand side of each box to be completed. Other example, for a linear motion

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command to a target position, if you indicate "G0 F<V> X<X> Y<Y> Z<Z>",
then Galaad will replace <V> by the velocity value, <X> by the coordinate X,
etc. The spaces that you have set are preserved, even if you enter too many of
them (except those heading or trailing the line). No syntax validity checking
is done. It is your own format, you indicate what you want as you want. The
software does not interpret it.

Almost as important: you may set between square brackets an expression

containing one or several variable data. In this case, the whole expression will
be produced only if at least one value inside the brackets has changed. For
example, if you do not want to repeat the feedrate unless it has changed, then
the line of the previous example becomes "G0 [F<V> ]X<X> Y<Y> Z<Z>". If
the speed has been changing since the previous call to a command using it,
then the expression "F<V> " will be retained with its trailing space. If the
speed did not vary, then Galaad will act as if the line was "G0 X<X> Y<Y>
Z<Z>". The same applies to coordinates.

The available variables are as follows:

- Tool change: <T> for tool number, <D> for tool diameter, <R> for tool
radius, <Name> for tool name.
- Spindle start/stop: <T> for tool number, <RPM> for rotation speed in
revolutions per minute, <RPS> for rotation speed in revolutions per second.
- Pause: <S> for seconds, <dS> for decisecond, <cS> for centisecond, <mS>
for millisecond.
- Enable/Disable output: <N> for output number.
- Speed change: <V> for velocity (see the scaling factor).
- All movements, active or inactive: <X>, <Y>, <Z> for Cartesian coordinates
(absolute or relative depending on the mode that has been chosen in the option
"Relative coordinates" at bottom right), <V> for motion velocity, <R> and <A>
for polar coordinates (absolute or relative).
- Circular interpolation: <Cx> <Cy> for Cartesian coordinates (absolute or
relative) of the arc centre; <X1Cx> <Y1Cy> for coordinates of the centre
relative to the arc start point; <R> for arc radius; <A1> <A2> for the arc start
and end angles (in degrees of angle); <A12> for the arc opening angle (in
degrees); <X1> <Y1> for Cartesian coordinates (absolute or relative) of the arc
start point; <V> for feedrate; <X2> <Y2> for Cartesian coordinates (absolute or
relative) of the arc end point; <X1X2> <Y1Y2> for coordinates of the arc end
point relative to the start point; <Z> for Z coordinate (absolute or relative) of
the arc end point.

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A bit less important, but nevertheless: the scale boxes allow you to
individualise the multipliers to be used for each coordinate or for the speed,
and you may use relative (incremental) coordinates, considering that absolute
coordinates are in fact relative to the workpiece origin point, according to the
corner and the plane that have been defined. The format boxes indicate the
number of digits of the variable data and also the decimal separator for real
numbers.

12 - 316 — Machine parameters ————————————————————

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———————
13
01101

PLASMA TORCH

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GALAAD 3 —————————————————————————————

Many features in Galaad are dedicated to the management of a plasma

cutter table, including additional tools. In the machine parameters, if you select
a plasma torch instead of a classic spindle, then the software changes some
little items of its look here and there: the green icon at left hand side for setting
the tool, depth and speed is then replaced by a simple selection of the
plasma function (cutting or engraving) and a few commands in the top
bar are redrawn.

Here, we are in a pure and simple 2D design. The machining depth no

longer exists; the feedrate is set by the operator when launching the cutting
cycle; the torch is the only tool available, or almost. Almost, because it
remains possible to perform an engraving job with the torch set to a reduced
current or using an engraver pen, pneumatic or piezoelectric. The paths drawn
are either assigned to the cutting job (tool number 1), and then they are
assumed to have a tool compensation attached to them since the cutting kerf
has a given width, or to the engraving job (tools number 2 or 3 depending on
the type of the engraver). The machining window is also going to lose many
features that become pointless.

Constants of use

As we have seen in the previous chapter, each type of milling spindle has
its own set of parameters. In the case of a plasma torch, they can be numerous
and sometimes very complex, depending on the machine and the numerical
controller that fits it. Since the modes of operation may vary, we can consider
three major possibilities:
1- the cutting tables with Soprolec controller;
2- the cutting tables with ThunderCut controller;
3- the other cutting tables with other controllers.

Setting the origin Zo is not managed in the same way as milling with an
approach to the contact with the metal sheet then validation with the green
button "Z-ok". The cutting quality requires a repeated probing along the cycle
because the Z coordinate of the sheet surface may vary. Hence, the machine
must be fitted with a probe for measuring automatically the Z position of
the surface, throughout the duration of the process. The most common is an
assembly of the torch on a vertical slide rail with a stopper at the bottom, the
torch being pushed down to that stopper by a spring but still able to move back

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 ————————————————————————————— GALAAD 3

up until it triggers a sensor. It is all planned in Galaad for calibrating it, we are
going to see this later in this chapter. Another important probing parameter is
the operating range. It is not always useful to probe again the sheet top
surface just a few millimeters away from the previous probing. You may
indicate a range for the last probing done, to avoid losing time. Lastly, for
calculating the cutting compensations, Galaad must know the kerf width that
corresponds to the grooves of material that are removed by the fusion. This
width can be readjusted when launching the cycle, depending on the operator's
settings and the cutting charts.
But the calculation of the basic
compensation is done in the
drawing screen and the software
applies a default offset.

If your machine is fitted with

a numerical controller that does
not provide any functions for
plasma torches, then the set-up
stops here. Thanks for reading.

THC

Among those managed by Galaad, the numerical controllers Soprolec

InterpCNC-2 and ThunderCut PMK3 integrate a Torch Height Control (named
THC in the next pages). This function is an important feature of the plasma
cutting process, that helps keep a torch-sheet distance stable enough, based on
a direct feedback of the field tracking. A correct cutting height is essential
for obtaining quality kerfs. If too high, the torch is going to
scatter the beam, overheat the material around, and the cut
edges will be slanted, narrowed at bottom, with a risk of
extinguishing the stretched electrical arc. If too low, the
torch is going to leave slags and the upper edges will be
narrowed, with a risk of collision. Add to this the fact that a metal
sheet may curl ‒ especially a thin sheet which dilates faster because its caloric
mass is less ‒ and everything is ready for making the cut go wrong. However,
on a thick sheet, hence rather flat, laid down-and-out on the machine with no
raised edges, the THC becomes less significant. We will come back in detail
on the different settings, a bit later on, same chapter.

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GALAAD 3 —————————————————————————————

The field tracking is in fact a simple measurement of the arc voltage: the
more the torch gets close to the sheet, the more the voltage decreases, until it
reaches a null value when both are in contact. Then there is no more arc. Most
torch boxes provide measurement plugs for that voltage, which generally
varies between 80 and 140 V. It is necessary to first isolate galvanically and
divide this voltage for receiving a usable analogue value with no risks of
interference for the numerical controller. A plasma torch is already producing
enough electrical noise, no need to add more. You should use a good quality
isolator-divider, which will divide the voltage by 15 approximately if your
analogue input has a range of 0 to 10 V, or divide by 30 if your analogue input
has a range of 0 to 5 V. Hence, for an arc voltage of 150 V, the ADC input
(Analogue-Digital Converter) of your numerical controller will indicate a
value of 100 % that will be transmitted to the software. Regardless of the
actual resolution of the ADC, what does really matter is the reliability of the
measurement.

It is not Galaad which measures in real-time the arc voltage and manages
the Z axis for rectifying upwards or downwards. The reaction loop is purely
local. The software just activates and frames it. Even with a THC correction
acting on the Z position, we are still in the 2D area, at least in theory. This is
why the controller must integrate a specific function that links the analogue
input to Z movements that are added to the coordinate received. Here, Galaad
can deal with two operating modes:
1- The Soprolec mode uses a typical voltage value, provided by a chart in a
database that is installed with the software and that you may access. The
probing is useful only for triggering the torch at the correct height, but then the
controller will target the analogue value that has been transmitted by the
software. Advantage, the probing accuracy is less significant; drawback, if the
voltage value that has been picked from the database does not or no longer
correspond, then the whole cutting cycle will be affected.
2- The ThunderCut mode considers that the probing gives the correct cutting
height and performs a quick sampling of the arc voltage, measured during the
first millimeters of the horizontal path. The 2 extreme values are rejected and
the controller takes the average of the 32 remaining measurements, which
becomes the target. Advantage, if the nozzle is worn out, the current wrongly
set or anything else, then the sampling remains valid; drawback, if the probing
has been made on a slag or the sampling on a slope, then the cutting height at
the beginning or the average voltage are incorrect for the paths until a new
probing is performed.

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As we will see, Galaad incorporates advanced management of the THC.

The purpose is to follow a varying ground, so we can consider that a path
that covers a small surface does not require a Z correction since it does not
go far away from the probing point. In addition, the cutting job on thin sheets
is often performed with high speeds. But, as we have seen before, speed
induces kinematical constraints, on which we are not going to spend more time
except for arguing that the cutting speed will not be fulfilled everywhere. The
problem is, when the movement is slowed down, the melted metal being
ejected downwards, there is less of it under the torch and the voltage increases,
which the controller will interpret wrongly as a raising distance from the
surface. Then it is going to rectify downwards, with a risk of collision. So it is
necessary to cut the THC when the speed gets under a percentage of the
nominal value. Of course this percentage is settable in the software.

During the cutting job, the parts of the paths where the THC is enabled are
displayed on the screen with a blue halo.

Ignition acknowledgement

When the torch is triggered, there is a little delay before the arc is steady.
Since the movement will begin after that, Galaad will wait until the corre-
sponding input gets the signal. But it is actually a bit more complicated, as we
will see by clicking on the small neighbouring button "More…", which pops
up a new subordinate window for more ignition parameters:

—————————————————————— Plasma torch — 12 - 321

GALAAD 3 —————————————————————————————

If the software waits too long for the start signal, then the arc is going to
dig a big hole at the ignition point, especially if the sheet is thin. But if it does
not wait long enough, the torch may move to the cutting height before the arc
is stabilised, with a risk of extinction. To resolve this dilemma, Galaad suggest
that two cases be managed, discriminated by the thickness of the sheet:
immediate validation or postponed validation. The first case is the simpler:
the torch is triggered, then there is a time lapse to be defined, during which the
acknowledgement is ignored because there can be noisy feedback when the
pilot arc is active, then the input that receives the signal "Arc OK" is read
periodically during a maximum time interval, and eventually the signal is
confirmed. Then only, the Z axis is moved for reaching the cutting height and
the horizontal feeding can begin. For example, if you set the line "check input
after 250 ms and during 1000 ms, every 50 ms, confirming acknowledge 2
times", Galaad is going to trigger the torch, then wait 250 ms, then enter a
reading loop of the acknowledgement input every 50 ms. It must get 1 good
feedback plus 2 confirmations, so 3 times in a row a reading that validates the
ignition. If a reading is negative, then the counter is reset to zero: the first good
reading and the confirmations must follow each other with no change. Finally,
if after 250 + 1000 ms, the acknowledgement has not been validated yet, then
it is a failure. At the bottom of this window, you can decide what the software
should then do. We may simply wait a while because it is possible that the
failure be due to an overheating of the torch that the control box secures, and
repeat the attempt several times, after which the cycle stops and the operator is
warned by an error message on the screen (plus an e-mail if you have set it).

If the sheet is too thin and it is not possible to wait motionless for the
acknowledgement, then we must opt for a postponed validation. In this case,
Galaad will trigger the torch and start moving the axes without waiting more
than the pauses that are present in the database. The validation of the ignition
will then be done while the cutting job has begun. If this validation is not
obtained, then the torch is switched off, sent back to the start point and the
procedure is looped. It can happen that the path is too short so the validation
cannot be done. In this case, it is possible to ignore the acknowledgement and
replace it by a simple set of pauses before and after ignition.

The same line for the immediate acknowledgement is available for the
engraving mode when the current is reduced. The risk for holing the sheet
being very unlikely in this case, only the immediate validation makes sense.

13 - 322 — Plasma torch ——————————————————————

 ————————————————————————————— GALAAD 3

Critical inputs

Trigger the torch, validate the ignition in different conditions then follow
the Z variations using a THC cover most of the needs, but some other prob-
lems may still occur, that we are going to learn by clicking on the small button
"Critical inputs" in the torch parameters. The first problem is the sudden
extinction of the arc, generally when it passes over a hole in the sheet. The
software response is not urgent here. Galaad just needs to be informed before
the end of the path that
it has been interrupted.
So the input can be
monitored with a low
frequency, about one
second, to avoid
overloading the
transmission. As long as
the validation of the
ignition has not been
completed, the input "Arc off" is not checked, because it is usually the same.
This input can require a confirmation, in which case the procedure will be a
first reading then the eventual confirmations, all at once, for considering that
the arc is indeed off and that it was not just some noisy feedback.

The input that corresponds to the surface probe can also be read for
security reasons, when there is no THC. If triggered, it is better not to insist
and stop the process. But there is a chance that the input "Arc off" already
reacted since it does not wait until the torch has moved back up.

In case of a critical input trigger, the software is going to stop the

motion and switch off the torch. You may choose what must be done then:
stop the cycle and send an error message in full and final settlement, or switch
to the mode "VCR-Seek" so the operator can retrieve manually the resuming
point, or also resume alone at the estimated point of interruption, with a
maximum number of times so the software does not enter an infinite loop.
Since the detection of the critical input is not immediate and the machine must
follow a braking ramp, it is possible to go back a little to find the interruption
point. Galaad will convert the time lapse in distance according to the cutting
speed. At last, if this interruption occurs shortly after the starting point, the
resuming can be a simple restarting from zero.

—————————————————————— Plasma torch — 12 - 323

GALAAD 3 —————————————————————————————

Soprolec controller

The numerical controllers InterpCNC-2 are integrated in the cutting tables

of various manufacturers (Air Liquide Welding, JD-Cut, Lincoln Electric,
Phenix Technologie, FabTec) and some handmade machines. The parameters
are many and spread over
several windows and sub-
windows. Once again, do
not forget that you must
validate the stacked
parent-windows for saving
what you have modified in
the offspring.

For the probing, it is

possible to use an ohmic
sensor which has the
advantage of not pressing
the sheet, which can
distort the measurement.
The drawback is that such
sensor is subject to interference from water on the sheet or a variation of the
electrical resistance due to the material and its oxidation state. The software
can manage both the recoil sensor of the torch and the ohmic sensor for more
security. In the latter case, a small fixed value for the Z calibration allows you
to add or subtract to the Z coordinate that the probe defines. Since that ohmic
sensor will probably not appreciate too much the 150 V of the arc, it is safe to
put in an isolator relay, driven by an output during the probing. The option for
confirming the input corresponds to a re-reading after the probing plunge has
stopped: if the input has in fact not been triggered, then Galaad redoes the
probing.

Let us skip the ignition acknowledgement, already seen. An input can be

assigned to a torch-tilt sensor, for stopping any movement if the torch
collided with an obstacle. Since there is a reaction delay, and even more when
it must inform the software, it is better to cut the main power supply to the
machine when the torch is tilted. It is much safer and costs less in case of a
crash. Let us skip also the critical inputs, already seen too.

13 - 324 — Plasma torch ——————————————————————

 ————————————————————————————— GALAAD 3

While calibrating the torch recoil sensor, it is possible to define a rapid Z

plane. When the torch is plunging towards the surface, it can begin with a fast
movement down to a fixed height plus the sheet thickness. The slower probing
starts here. That height can also be reused for locking XY movements when
jogging the axes manually, which could damage the torch due to a collision
after a wrong operation: if the option XY manual jogging prohibited under
Z rapid plane is enabled, then the operator will be allowed to move the XY
axes only when the torch is above this critical height.

The vacuum cleaner for the smoke can be switched on through a simple
binary output, or through a pulse whose duration must be indicated. The torch
clearance height can be set here, in which case the operator will not be
allowed to modify it. If you enter no value, then it can be set classically in the
machining window.

Above the Soprolec torch parameters, several buttons give access to

different functions, the first being the cut settings database, which opens a
sub-window featuring a data chart:

This database is installed along with the software. It contains settings for
cutting jobs depending on the material (steel, inox, aluminium), its thickness,
the current and the nozzle to be used. The operator provides information about
the two first items and Galaad suggests the next on the same line. This

—————————————————————— Plasma torch — 12 - 325

GALAAD 3 —————————————————————————————

database is not frozen. You may modify the values at your convenience for
adapting them to your machine, your torch or your nozzles. However, we
suggest that you save your own settings into a file with an alternate name: if
you need to reinstall the software, you will retrieve the data by default (on the
other hand, updating Galaad does not affect your personal data).

In a few words, the current setting is the value you must set on the torch
box before launching the cycle, unless this setting is under software control
through a DAC or PWM output or an RS-485 port. The nozzle depends on
what consumables you have at your disposal. The kerf width is the resulting
cut groove, whose value will let Galaad rectify the default kerf of the drawing.
The ignition height is set relative to the sheet surface. The drilling height is
used only by Air Liquide Welding and Lincoln Electric machines, which are
fitted with torches that require an intermediate transfer point for managing the
pilot arc. The ignition pause is the time lapse immediately after the torch
ignition, before the acknowledgement procedure begins. The cutting height is
the optimal torch-sheet distance for a quality cutting job. The cutting speed is
the XY feedrate along the paths. The THC voltage is the target value that
Galaad will send to the numerical controller when the THC mode is enabled,
correcting the height by moving the torch up or down so it sticks to that
voltage. The air pressure is the compressed air setting the torch must be
provided with.

Still in torch parameters, the button for THC settings gives you access to
the THC internal functions. You must indicate here which analogue input
receives the arc voltage, isolated and divided, and its validity range. Galaad
will use this for
converting the ADC
value into Volts, and
also reciprocally for
sending the THC
instruction to the
controller. The
activation delay and
the PID proportional
gain are internal data
for the Soprolec card,
which is best not to
modify. These two
settings are given here for granting access to specific applications. If your

13 - 326 — Plasma torch ——————————————————————

 ————————————————————————————— GALAAD 3

machine is fitted with a Z tuning potentiometer for adjusting the cutting

height during the process, then you must indicate here to which analogue input
it is connected, and its variation range, on the basis that the median position
corresponds to a null correction. This potentiometer is supposed to rectify the
deviations of a tired nozzle. Do not forget to wear good welding goggles if
you follow the cutting job close to.

The Z correction floor defines a maximum offset between the cutting

height as measured by the probe, and the lowering that is driven by the THC.
We can consider that this offset cannot increase infinitely downwards. But this
floor is not applicable when the operator chooses a corrugated sheet. The Z
reactivity related to the XY speed sets the reactive power of the THC
correction. On a veiled sheet, and even more on a corrugated sheet, it will be
much more responsive than on a flat sheet, so you can define a field tracking
with a soft or hard reactivity.

The THC may be switched off when the real cutting speed falls below a
minimum percentage of the theorical cruise speed, to prevent the torch from
plunging when it slows down in tight turns, the lack of metal increasing the arc
voltage, which is wrongly interpreted by the controller as a raising distance
from the surface. For managing sharp angles, generally during the tool
compensation overruns, the speed can be reduced and the THC switched off at
some distance away from the angle. This also avoids leaving the THC active,
when the angle overrun in a triangular cusp causes an overlap, with the torch
crossing again the path it has just traced, causing a brief increase of the arc
voltage and an attempt for correcting immediately, which will make the Z axis
plunge uselessly.

Still at the top of the parameters dialogue box concerning the Soprolec
torch, the management of the nozzles by Galaad is detailed later on in this
same chapter.

At the bottom right, a button "Extensions" gives access to related func-

tions, and in particular the engraving devices. Two possibilities: a plasma
engraver directly on the torch, or a pen engraver mounted on an actuator
beside the torch and working independently. The plasma cut always corre-
sponds to the tool number 1 in the drawing. The engraving with the plasma
torch corresponds to the tool number 2. As with the cutting job, a database for
the engraving settings is available for the three usual metals and depending on

—————————————————————— Plasma torch — 12 - 327

GALAAD 3 —————————————————————————————

the nozzles to be used. Switching the torch to engraving mode may require an
additional output, with its own pause delay after ignition.The THC can also be
used in engraving mode. Lastly, you may impose a cooling delay between
paths, to avoid ignition
problems of the pilot arc
due to an overheating.

The pen engraver is a

device to be mounted
beside the torch, with a
vibrating hard tip driven
by a piezoelectrical or
compressed air oscillator.
It corresponds to the tool
number 3 in the drawing.
The pen is lifted up or
lowered by an actuator
that requires a movement delay. It is the Z axis which moves up and down at
every new path, but the actuator is lifted up when the probing must be redone,
depending on the distance from the previous probing and its operating range
(which can be different from the one used for the cutting job). The torch
remaining the reference tool, the XY offset of the pen relative to it must be
calibrated. There are no databases for the pen engraver and the feedrate must
consequently be set here once and for all, and also its own clearance height (if
it is not indicated, then Galaad reuses the one for the cutting job). Finally,
when the path to be engraved is an isolated dot, then the software needs to
know how long it must remain still so the dot is engraved.

At the bottom of this window, the current control allows Galaad to drive
directly the amperage without having to set it manually on the torch control
box. This control can use either a PWM output between 0 and 100 %, with the
current range to be indicated, or a command from an RS-485 port of the PC.

Last button at the bottom right of the parameters dialogue box of the
Soprolec torch, the calibration allows you to measure the offsets between the
torch on one hand, and the additional devices such as the laser spot or the pen
engraver on the other hand. Lower the torch down so it touches the surface,
validate its position, draw a circle around its nozzle, retract it up, bring the
device accurately at the centre of the circle and validate it. That is all.

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When lauching the cycle, the screen displays a window that allows you to
choose the cut settings (or the engraving, or both). You just have to select the
material and
its thickness.
The database
is going to
help Galaad
set all the rest.
But you can
choose also
the current
and the nozzle
to be used, or
change any
resulting value
on the right
hand side. Do not forget to indicate if the metal sheet is flat, veiled, or
corrugated, so the software will consequently apply the corresponding THC
reactivities. The kerf width depends on the nozzle and the current. If it differs
from the default width that has been defined for the drawing, then the compen-
sated paths are rectified using a simple offset, unless you disable the corre-
sponding option at the bottom of the window.

If you modify the cut settings in the right hand column, you can also add
them directly in the database. You may also remove a setting that you
consider pointless.

Among the few cutting options, it is possible to disable the rapid plane for
probing if you think there is a risk of collision, in which case the probing will
start from the top of the Z axis. You may also disable the probing range, and
then it will be performed at every new path. Also, the paths that cover a small
surface can be executed at slow speed relative to the normal cutting speed,
which may induce a THC switch-off.

If there is an engraving job to be performed with the plasma torch, some

similar settings and options will be displayed, either in a reduced window if
there are no cutting paths, or in the same window, just extended.

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GALAAD 3 —————————————————————————————

ThunderCut controller

The ThunderCut cutting tables are fitted with an AxeMotion controller that
integrates the THC function. Here again, the parameters are many and spread
over several windows and sub-windows. Do not forget that you must validate
the stacked parent windows for saving what you have modified in the child
sub-windows.

In addition to the kerf width and the surface probe already seen above, it is
possible that Galaad seeks and deletes the clones. In this case, when validat-
ing the drawing, the software will search for the overlaid copies. Time-
consuming for the CPU, this calculation will be long on loaded drawings. It is
not very useful if you are drawing with Galaad or if you have used the same
filtering function when importing. The option for rebuilding the sequence is
going to put the inner cuts before the outer cuts that surround them, to avoid
letting a part of the workpiece fall out before its islands are made.

The torch clearance height can be set here, in which case the operator
will not be allowed to modify it. If you enter no value, then it may be set
classically in the machining window. An output for switching the vacuuming
can be defined, possibly just for the cylindrical cutting jobs on 4 axes. That
output is triggered at the process start and released at the process end.

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 ————————————————————————————— GALAAD 3

The SmartProbe functions define how the THC is going to be used. When
starting the cycle, the operator must select the type of metal sheet: flat (or
almost) or corrugated. On a flat sheet, it is possible to disable the THC on
paths that cover a reduced surface, since in that case the torch does not go far
away from the probing point. If you indicate no surface value, then the
operator will be allowed to set it. The reactivity, in a range from 1 to 10, gives
the velocity of the Z correction by the THC. Too weak a value induces a soft
reaction, with a risk of extinguishing the arc if it is moving away from the
sheet; too strong a value induces a hard reaction which will make the axis
jump over small slags or wrong measurements. The sampling is performed
just after the feed start, on a brief duration. It is probably better to keep the
default values. On a corrugated sheet, there are no variable cutting heights
picked up from the database, but a fixed value to be set here. The hysteresis
range is then definable, which gives a threshold for activating the THC
correction to avoid oscillations.

In addition to the surface detection by the torch itself, it is possible to use

an ohmic sensor that offers the advantage of not pressing the sheet, which can
distort the measurement. The drawback is that such sensor is subject to
interference from water on the sheet or a variation of the electrical resistance
due to the material and its oxidation state. The software can manage both the
recoil sensor of the torch and the ohmic sensor for more security. In the latter
case, a small fixed value for the Z calibration allows you to add or subtract to
the Z coordinate that the probe defines. Since that ohmic sensor will probably
not appreciate too much the 150 V of the arc, it is safe to put in an isolator
relay, driven by an output during the probing. The option for confirming the
input corresponds to a re-reading after the probing plunge has stopped: if the
input has in fact not been triggered, then Galaad redoes the probing. If the
ohmic sensor is already triggered though the torch is in an upright position,
then we can infer that it is wet and the software will briefly activate the torch,
which will blow a compressed air jet in the nozzle without igniting the arc.

Let us skip the ignition acknowledgement, already seen. An input can be

assigned to a torch-tilt sensor, for stopping any movement if the torch
collided with an obstacle. Since there is a reaction delay, and even more when
it must inform the software, it is better to cut the main power supply to the
machine when the torch is tilted. It is much safer and costs less in case of a
crash. Let us skip also the critical inputs, already seen too.

—————————————————————— Plasma torch — 12 - 331

GALAAD 3 —————————————————————————————

When calibrating the torch recoil probe, it is possible to define a rapid Z

plane. Then the probing procedure begins with a fast motion down to a fixed
height increased by the sheet thickness. The actual probing, slower, then starts
from that height. This height is also usable for locking the XY movements in
manual mode, which might damage the torch if colliding with something
during an improper handling: if the option for prohibiting XY manual
jogging under Z rapid plane is enabled, then the operator will be allowed to
move the XY axes only when the torch is above that critical height. Lastly,
you can define a measurement range for the electrical arc, which values will be
used for displaying the Volts at the bottom of the screen.

Back to the top of the dialgue box, the button for accessing the kerf
calculation table pops up a small chart for correlating the current, the kerf
width and eventually the PWM value if the amperage is under such control. At
last, another button gives access to the cut settings database, which displays a
chart window:

The software can manage up to 10 different materials, but only three are
preset: steel, inox and aluminium. For each of them, you can associate up to 20
chart lines indicating, for different sheet thicknesses, the typical cutting values.
The default database is installed with the software, but these lines are not

13 - 332 — Plasma torch ——————————————————————

 ————————————————————————————— GALAAD 3

frozen: you may modify the values as you like for adapting them to your
machine, your torch or your consumables. However, it is better to save your
changes to your own file: if you need to reinstall the software, you will return
to the data by default (but on the other hand, updating does not alter your
personal data).

In a few words, the current setting is the value you must set on the torch
box before launching the cutting process, unless this setting is under direct
control through a PWM or RS-485 output. The ignition height is set relative
to the sheet surface. The plunge pause is the time lapse after triggering the
torch and before checking its acknowledgement, if any. The plunge speed
corresponds to the movement between the ignition height and the cutting
height. The cutting height is the optimal torch-sheet distance for a quality
cutting. The cutting pause occurs immediately after the plunge, just before
starting the horizontal feed. The cutting speed is the XY feedrate along the
paths. The early torch-off is the distance from the end point for switching the
torch off. The SmartHole surface is the surface covered by a path, under
which the THC will remain disabled unless that surface is indicated in the
general parameters of the parent window. It is assigned a specific SmartHole
speed, that will not consider the normal cutting speed which applies to larger
surfaces. The THC hysteresis gives the THC correction threshold to avoid
oscillations. It does not apply to corrugated sheets which use a unique setting
in the parent window. The cutting and protection gas remembers the
operator about the settings for the gas inputs, if they are part of the process.

The THC may be switched off when the real cutting speed falls below a
minimum percentage of the theorical cruise speed, to prevent the torch from
plunging when it slowers down in tight turns, the lack of metal increasing the
arc voltage, which is wrongly interpreted by the controller as a raising distance
from the surface. For managing sharp angles, generally during the tool
compensation overruns, the speed can be reduced and the THC switched off at
some distance away from the angle. This also avoids leaving the THC active,
when the angle overrun in a triangular cusp causes an overlap, with the torch
crossing again the path it has just traced, causing a brief increase of the arc
voltage and an attempt for correcting immediately, which will make the Z axis
plunge uselessly.

At the top right, a button "Extensions" gives you access to related func-
tions, and particularly the engraving and drilling systems. Two possibilities
exist for engraving: a plasma engraver directly from the torch with reduced

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GALAAD 3 —————————————————————————————

current setting, and a pen engraver, mounted on an actuator beside the torch,
working independently. The plasma cutting always corresponds to the tool
number 1 in the drawing. The plasma engraving corresponds to the tool
number 2 and the pen engraving to the tool number 3. These are constants that
you cannot change. Switching to engraving mode with the torch requires an
additional output, with a specific pause time after ignition, an engraving
height, a speed and a fixed current (no database in this case). The THC
remains available.

The pen engraver is a device to be mounted beside the torch, with a

vibrating hard tip driven by a piezoelectrical or compressed air oscillator. It
corresponds to the tool number 3 in the drawing. The pen is moved vertically
by an actuator which requires a movement delay. It is the Z axis which moves
up and down at
every new path, but
the actuator is lifted
up when the probing
must be redone,
depending on the
distance from the
previous probing
and its operating
range (which can be
different from the
one used for the
cutting job). The
torch remaining the
reference tool, the
XY offset of the pen
relative to it must be
calibrated. There are
no databases for the
pen engraver and
the feedrate must consequently be set here once and for all, and also its own
clearance height (if it is not indicated, then Galaad reuses the one for the
cutting job). Finally, when the path to be engraved is an isolated dot, then the
software needs to know how long it must remain still so the dot is engraved.

At the bottom of that window, the current control allows you to manage
the amperage directly from the software so there is no need for the operator to

13 - 334 — Plasma torch ——————————————————————

 ————————————————————————————— GALAAD 3

set it on the torch box. This control can use: a PWM output between 0 and
100 % with the range of current to be indicated, or the same PWM output
using a mapping table, or a command throughout an RS-485 channel of the
numerical controller, or a direct command from an RS-485 port of the PC.

ThunderCut machines offer as an option a classical drill. Every drill bit

must be accurately defined in Galaad, it being fully understood that the three
first numbers are reserved for the torch, the plasma engraver and the pen
engraver, even if these are not present. Hence the drill bits begin with the tool
number 4. The drill is mounted on an actuator so it can be moved lower than
the torch, using an output for that actuator and another one for activating the
motor, which can be the same for both functions. The probing is undertaken as
for the torch with the drill bit end, the input for the recoil sensor being shared
with the torch. The actuator is not lifted up when probing. On the other hand,
the drill motor is off at that moment, even if the only risk is to drill a hole,
which by the way remains the purpose for that job. The plunge speed is fixed,
to be set here, and also the margin between the sensor trigger and the upper
mechanical stop. So Galaad knows the recoil distance for the drill after the
sensor is triggered and until it presses the upper stop for drilling efficiently.
The plunge depth corresponds to the material thickness.

If your torch is mounted on a tilt & turn head under the control of a
couple of servomotors that are driven by an RS-485 channel of the numerical
controller, then Galaad enables the mode "orientation head" in the drawing,
which allows you to define, for each path, a tilting angle so you get oblique cut
edges towards the inside or outside, still subject to the kerf compensation. The
calculation will be performed internally and dotted lines will be displayed so
you can visualise where the oblique path matches the bottom of the workpiece,
provided that the thickness indicated is correct.

When launching the cycle, Galaad displays a window that allows the
operator to choose the cut settings. You just have to select the material,
indicate its thickness and the type of surface (flat or corrugated). The corre-
sponding parameters are automatically picked from the database and displayed
in the right hand column, because it is the action centre.

—————————————————————— Plasma torch — 12 - 335

GALAAD 3 —————————————————————————————

Nozzle management

Whatever the controller you are using, Soprolec or ThunderCut, Galaad

can assist you in tracking the ageing of your cutting nozzles and other
consumables. When
starting a cutting job,
the software displays
a message asking for
the mounting of one
of your nozzles and
monitoring statistics
such as the duration
of use and the number
of ignitions. That
message shows at the
bottom a button
"Consumables" with
the torch model you
have set. If you click
on that button, then
you get on the screen
its references and
image. Example: you
have indicated as
torch name "PowerMax-45". The button becomes "PowerMax-45 consum-
ables". If you click on it, Galaad will seek, in the subdirectory \CONFIG of the
software, the image POWERMAX-45 REFS.BMP and, if found, displays it on
the screen. Under that button, at the bottom of the message window, you can
also have the images of the nozzles. For example, if you enter as a reference a
nozzle "220930 FineCut", when launching the cutting job, Galaad will seek
the image NOZZLE-220930FINECUT.BMP still in the subdirectory \CONFIG
and, if found, display it at the bottom of the window when the nozzle is
selected. The spaces are ignored in the file name, as well as the case.
For each nozzle, in addition to the reference name, you may indicate a
colour that will be the background of the flashing message to the operator, to
facilitate the selection of the correct nozzle, and a maximum current that will
help pre-selecting it in the cut settings. The coolant pause will stop the torch
after one or several paths to let it cool down if necessary before resuming the
process. The lifetime in number of ignitions and duration is the base for the

13 - 336 — Plasma torch ——————————————————————

 ————————————————————————————— GALAAD 3

statistics that are displayed just before starting the cycle. Galaad points out in
red the overruns but will not prevent the use of a nozzle beyond its lifetime.
Up to you to manage your business.

Still for each nozzle, the height value looks pointless at first sight since the
probing is performed with the torch touching the sheet surface, whatever the
nozzle can be. But in fact, with a pen engraver,
the Z calibration depends on the nozzle that has
been mounted. Galaad considers that the nozzle
number 1 is the reference and therefore it is the
one you must use for calibrating the probe-pen
Z offset. If, later on, you have mounted another
nozzle, when probing before engraving, the
software will use the calibration by adding the height of the current nozzle and
subtracting the height of the nozzle number 1. So, if you are starting an
engraving job with no associated cutting job, then you will be prompted to
indicate which nozzle is mounted under the torch.

—————————————————————— Plasma torch — 12 - 337

GALAAD 3 —————————————————————————————

Calibrations

When mounted on a vertical slide rail, the torch becomes the probe directly
with its nozzle and a recoil sensor. It is obviously necessary that the sensor
should be calibrated, namely measure the Z distance between the contact with
the sheet surface and the trigger point, such as a milling tool sensor. This
calibration is accessible only from the basic manual control (not in the
workpiece origin window). The process is simple: bring the torch down in
contact with any surface, firm enough not to move when the nozzle pushes it.
Be very accurate, for example by trapping a thin paper so you can find the
position where the torch touches the surface without beginning to move back
up in its slide rail.

Now click on the calibration button. If you have configured a pen

engraver or a drill, indicate which one you are currently calibrating.
But let us consider that it is indeed the torch which is being calibrated. A
dialogue box then asks you what the Z
position corresponds to. Click on the
radio-button "the contact with the top
surface" and validate. The software is
going to note the Z position and then
lower the torch until its recoil triggers
the sensor, note the trigger point and
memorise the offset between both
coordinates. From now on, moving the
torch down until its sensor is triggered
and subtracting the offset will be
sufficient for finding the position that would make it gently touch the surface,
and consequently the coordinates for the ignition and the cutting job. In the
same way, you may lower the Z axis down until it reaches an intermediate
position that you can calibrate as being the rapid plunge before probing.
When performing a surface probing, Galaad will move the torch down quickly
to that Z position minus the sheet thickness and will start the probing plunge
from that point. That Z coordinate is reused for forbidding the XY manual
jogging when the Z axis is underneath, provided that you have enabled the
corresponding option in the parameters. Finally, you may lower the torch until
it touches the machine bed and use the third calibration option "maximum
probing distance". The software will set it as a floor and, if a probing goes
underneath, then it will consider that the probing has been made in a hole and
the process will be stopped.

13 - 338 — Plasma torch ——————————————————————

 ————————————————————————————— GALAAD 3

Workpiece origin and related functions

The workpiece origin is simplified when Galaad works in plasma mode.

There are no more tabs at the top of the window and the machining parameters
are all gathered together in a dialogue box which can be accessed
from the first command button at the top left. You can choose the
cycle which is
about to start, if
there are several of
them among the
cutting, engraving
and drilling jobs.
Galaad begins with
the engraving, then
the drilling, and
the cutting is the
last. The classical
options for repea-
ting the cycle are present, and also the parking and maintenance positions. The
Z clearance height of the torch can be set here, but if a value has been
indicated in the parameters, then it is imposed and the operator cannot change
it, the edit box is greyed out. The other parameters for the layout and the
filtering are classical, already seen in the machining advanced functions.

The torch ignition button is at your disposal, but be careful with

this. Even if the software is cautious and pops up a confirmation
message before activating the torch, to prevent an assistant-operator from an
electrical shock. A plasma torch is not a harmless toy; please always think
about your own safety and that of your colleagues, particularly concerning
your eyes, your hands and your lungs.

Important: in the basic manual jogging window (but not in the workpiece
origin window), a function can help you check the proper functioning of your
THC circuit and operate voltage measurements. Click on the torch ignition
button by simultaneously pressing the key on the keyboard: instead of
activating the torch as expected, you get a test window for measuring. From
the current position, just indicate a target XY position with a motion speed, an
ignition height and a cutting height. The torch is going to probe the sheet
surface (we are supposing that the Z calibration has already been done,
otherwise please jump one page back), then will be activated and reach the

—————————————————————— Plasma torch — 12 - 339

GALAAD 3 —————————————————————————————

cutting height, then move along the line whilst making a series of measure-
ments which will be displayed with their average and extreme values. This
function should allow you to check that indeed you get a voltage feedback into
the analogue input of the numerical controller, that the voltage range is correct,
that the conversion that has been set in Galaad matches the results, and
eventually that the arc voltages are correlated with your database, in the case
using a Soprolec controller.

The direct plot button allows you to record XY points on the table
for building a polyline that will then be executed in its entirety with
probing and torch activated. This aims to detach a part of the skeleton of the
workpiece already machined without using a disc cutter nor make a new
drawing.

When in basic manual control, some additional buttons let

you operate the actuator for the engraving pen or switch
the vacuum cleaner on, if they exist.

There is no green button for the workpiece origin in

plasma mode, even if you can still move the Z axis as you like. The workpiece
origin Zo is validated by the probing operation for every path or almost,
depending on the probing range that has been set in the parameters. So you do
not have to worry about it, at least if you have calibrated your probe. You can
also use the restricted or full display mode with the small button at
the top right of the workpiece origin frame. The function for testing the XY
workpiece origin with the cyan button allows you to check
that a cutting job will fit in an already machined workpiece part. The torch will
not be activated and the coordinates used correspond to the laser spot (or the
video camera) to facilitate the tracking. The double-origin X2Y2 remains
valid for a plasma cut and even more useful that the metal sheets thrown on a
table are rarely positioned against Cartesian stops. So you can simply validate
the southwest corner as XY origin, then the southeast corner as secondary
origin for adjusting.

Note: the "VCR-Seek" function is very useful in plasma mode for

resuming an interrupted process due to the loss of the arc or any other incident.
Please refer to the chapter "Advanced milling functions" for more information
about it.

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——————————————————————————————————

———————
14
011 10

SPECIAL APPLICATIONS

——————————————————————————————————
GALAAD 3 —————————————————————————————

Laser engraving and cutting

If you have selected a laser head as spindle model, then Galaad is going to
modify part of the drawing window and a bit more the machining window.
The green icon for choosing the tool, the depth and the feedrate is
changing its look. The
underlying dialogue box also
changes, so that only three modes
become available: marking,
engraving or cutting. You may
associate a colour to each of them
for identifying easily the objects on
the drawboard. The laser power
and the number of passes are related to a type of material for which you can
add or modify the existing data by clicking on the small button "Settings" at
the top right. The maximum power of the laser is assumed to have been
indicated in the "Spindle" page of the machine parameters (beside the model
line). According to this, each mode is assigned a relative power ‒ which will
be converted to a percentage of the maximum power ‒ and a feedrate. To
prevent the material from burning or even catching fire, it is better to operate
successive passes instead of feeding slowly.

The workpiece origin is simplified

when Galaad works in laser mode.
There are no more tabs at
the top of the window and
the machining parameters are all
gathered together in a dialogue box
which can be accessed from the first
command button at top left. The tools
no longer exist, neither therefore the
overall sequence, but Galaad will
always begin with the marking, then
the engraving, and the cutting is the
last. The options for repeating the
cycle remain present.

In the spindle parameters, it is possible to select an analogue laser en-

graver, whose power will be modulated directly by the depth of the objects,
with a fixed maximum value. In this case, the laser mode with its user

14 - 342 — Special applications ————————————————————

 ————————————————————————————— GALAAD 3

interface is not enabled and the classical milling functions remain displayed.
You still set the depths and speeds, even if the tool concept is no longer
significant.

Very important reminder: a laser is dangerous, and even more because its
use looks easy. But a simple reflection of the beam on a surface or even
shimmering dust can cause irreversible damage to the eye by
burning the retina, and as a consequence a black spot for life in the
field of vision. It is very easy to find class 4 laser diode sources
with a power of several Watts, that can be used as pyrography
device or small numerical cutter. Working with a laser supposes that your
machine is fitted with certified protection equipment or that you wear good
quality protective goggles. For testing them, just send the laser on a border
(because they will be damaged there) and check that the beam does not pass
through by putting a paper sheet behind. If the paper is marked, even a little
bit, then you can consider your glasses are an illusory protection.

A waterjet cutting system, seen from Galaad, does not differ from a laser
system. The changes to the user interface and the general operation remain
identical.

Oxycutting

Some specific parameters are available in the software for managing an

oxycutter. As for the
plasma torch, the user
interface of the machine
control is simplified and a
default kerf must be
indicated, which will be
rectified eventually when
launching the cutting
process. The use of an
ignition device is possible,
at a given XYZ position, by
a pulse on an output. A gas
electrovalve and three

———————————————————— Special applications — 14 - 343

GALAAD 3 —————————————————————————————

oxygen valves can be driven. If the numerical controller provides several

analogue inputs, it is possible to plug in potentiometers that give the delays for
heating and for adjusting the cutting height, according to range values to be
defined. Like for the cutting jobs using a basic plasma torch, the operator can
set working heights, feedrates, etc. while building his own database.

Liquid dispensing

If most usual Galaad applications consist of milling a workpiece by

removing material during the paths drawn, the software is nonetheless capable
of controlling a system in charge of adding it at the same locations. It is even
possible to deal with both cases one after the other, for example by engraving
tracks and then injecting ink or paint. Of course, it that particular case, it will
be necessary to have an injection nozzle beside the milling spindle, with an
XYZ offset fully calibrated between them. The extensions of the tool parame-
ters allow you to manage such a situation easily, by assigning different outputs
to the triggers of the spindle and the nozzle. In addition, a script for an
automatic tool change can consider the respective Z heights of both items. It is
also possible to assign differents tools to different injectable tints, still with the
extensions in the tool parameters. Simply, each electrovalve or pump must be
connected to the corresponding output.

But there is no compulsion to perform a milling process before injecting

the liquid. Another similar application with Galaad consists of dispensing glue
or an equivalent in the paths of a drawn workpiece, with no preliminary
machining. The extended inputs/outputs allow you to closely manage the
dispensing cycle, by waiting a little after the opening of the valve or the
injection pump, and shutting off this valve a bit before reaching the final point
of the path, so the remaining liquid can flow out. This is probably not neces-
sary for all liquids; some will be very happy with a classical trigger at the path
start & end points.

14 - 344 — Special applications ————————————————————

 ————————————————————————————— GALAAD 3

Other intermittent tools

We have already seen that, in the machine parameters, "Spindle" page, it is

possible to choose an engraving or cutting system that is activated only when
the machine is moving along the path. That type of machine is often fitted with
two XY axes, the Z coordinate being manual. But who can do more can do
less, and Galaad will be equally happy to drive a machine with 2 axes only. In
addition, the workpiece origins will be easier since the approach on the Z axis
is often the toughest.

The system for activating and stopping the cutter remains a classical
control, generally submitted to the triggering of a binary output (on/off) that
drives downstream a power device. The simple checkbox "only start when tool
is feeding" determines the operating mode, either an activation when launch-
ing the machining cycle with a stop at the end, or an activation at the start
point of every path with a stop at the end of that path, when the classical
milling spindle would move down and up. Anyway, if your machine is fitted
with a Z axis, then it remains possible to make both operating modes live
together, plunge to the contact then to the depth, activation of the cutter,
inactivation before bottom right.

The laser pause parameters are available only for an intermittent cutting
system. It can become necessary that Galaad begins the horizontal feeding
motion along the path after the tool is completely active. If there is a small
inertia, then you must indicate a delay (in milliseconds) in the "on" edit box.
Galaad will trigger the output and then will hold on before starting the feeding
motion. Conversely, the "off" delay sets a pause to be completed at the end of
the path after switching off the tool, before moving the head to a new path or
to the parking location.

If that tool integrates a switch-on control function with a "Ready"

feedback signal returned to the supervisor system, then the best is to connect
that signal to an input of the numerical controller so Galaad can read it. Just set
this input as "Spindle ready signal" in the spindle parameters. In that case,
Galaad will activate the tool, will hold on during the "on" pause, then will wait
until the "spindle ready" signal is triggered, before beginning the cutting or
engraving motion. See the extended inputs/outputs for advanced controls.

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GALAAD 3 —————————————————————————————

3D printing

A frequently asked question about Galaad concerns the control of 3D

printers. Altough the purpose is also to create a mechanical workpiece with a
3-axis Cartesian machine, we are here in a completely different area that does
not have much to do with machining. Anyway, Galaad is not a 3D design
software, even if it can execute a 3D machining.

However, the Kay module, specialised in machining files, is able to open

G-code files for 3D printing with coordinates that correspond to unwinding a
wire on an A or E axis, without making a graphical interpretation of a
workpiece rotation. So is it usable for driving a machine that is fitted with a
printing head, provided that it can talk to its numerical controller. A milling
machine can eventually be adapted for printing, but keep in mind that the
mechanical needs are much different: a mill requires a good resistance against
the cutting force, with a strong body, and on the other hand, a 3D printer just
requires motion speeds that the inertia of a heavy mill cannot afford. Reusing a
mill for printing is tempting, but please be aware that the machine will not be
able to work as fast as a real 3D printer.

14 - 346 — Special applications ————————————————————

——————————————————————————————————

———————
15
0111 1

"LANCELOT"
STANDALONE USE

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GALAAD 3 —————————————————————————————

Galaad and Lancelot

You have doubtlessly noticed that the installation of the Galaad suite added
on your Windows desktop a folder that contains several cousin icons, with
different names, including an icon "Lancelot". You may also have purchased
only the basic "Kay" licence for the machining, without dongle, in which case
the modules Lancelot and Percival remain at your disposal. Anyway, please
double-click on that icon "Lancelot".

This immediately opens the Galaad window that asks for the machining
parameters, but it is covered by a file selection dialogue box which closely
resembles the one used for the imports in the drawing module. If you just have
the "Kay" licence and are opening this user's manual here, then you will
nevertheless need to trek through the chapters "Learning to mill", "Advanced
milling functions" and even "Machine parameters". Please take the time these
chapters need, we will wait for you by the coffee machine.

As you may have understood, Lancelot is the standard machining module

for Galaad and both work closely together. But this is common-law partner-
ship and, just as Galaad can be unfaithful by entrusting the machining process

15 - 348 — "Lancelot", standalone use —————————————————

 ————————————————————————————— GALAAD 3

to a third-party software, Lancelot can also become the recipient for master-
pieces made by another creator. Both programmes are technically independent,
which allows you to launch a machining process and go on drawing another
workpiece, provided that you can bear working with the noise.

So, Lancelot can be used alone. The file is then imported directly for the
machining and you see it in the previews. Now you just have to configure it,
and indeed it is there that the fixed values (especially depth and feedrate) may
become useful. For the rest, namely the workpiece origin and the supervision
of the machining process, you know the music since you have read the
previous chapters.

The main problem with a file import, that we will see again with the Kay
module, is that no formats contain standard information about the raw
dimensions of the workpiece, and particularly its thickness. Nevertheless, the
raw dimensions are essential for setting the workpiece origin, and this is
why you are prompted to indicate them. The dialogue box that sprouts out as
soon as you open the file agrees very fully
with this. You may let Lancelot reframe the
drawing with margins to be entered, or
indicate yourself the raw dimensions,
including the thickness. Please note that the
drawing can also be wrapped around the A
axis for a cylindrical machining, provided
that your machine is fitted with a rotary 4th
axis.

The speed for the plunge into the material

is not in the fixed values, so you may enter it
here. Lastly, the toolset can correspond to the
standard rack in Galaad which is also
accessible from Lancelot, but you can also
indicate in this window a diameter and a rotation speed. The diameter will help
compensate the lateral approach of the X or Y origin, and the default rotation
speed if automatic. These settings remain accessible by clicking on the button
"Workspace" at the bottom right, through the option "Import parameters". The
other options give a direct access to the parameters or to the specific functions
of Lancelot, normally reachable from the Galaad module that perhaps you will
not use, depending on the licence you have.

————————————————— "Lancelot", standalone use — 15 - 349

GALAAD 3 —————————————————————————————

Note that Lancelot can be launched directly by an application other

than Galaad with the automatic opening of a file that is passed as a program-
ming argument, i.e. the actual input expression supplied to a function. The
extension of the file name, if it is standard, gives the information about the
format. Otherwise it is necessary to pass as a next argument the standard
extension between brackets. Examples:
C:\Galaad\Lancelot.exe "C:\My Works\MyFile.plt"
C:\Galaad\Lancelot.exe "C:\My Works\MyFile.xyz" (plt)
The quotation marks are used to integrate in a single block a file name
including spaces, without splitting it into two arguments. Please go to the
chapter "Technical matters" at the end of this manual for more information
about the various possible arguments of the command lines for the different
modules of Galaad suite.

Lancelot and Kay

The Kay module does the same as Lancelot, i.e. driving manually the
workpiece origin and supervising the automatic machining, but with more
specialised formats. Let us just say that the major difference between Lancelot
and Kay is that Lancelot takes only the active part of the machining files
(tool down in the material) and therefore uses the inactive speeds and the
drilling cycles that have been defined in Galaad, with its toolset. On the other
hand, Kay drives the machine with the file as it is without changing anything,
including the inactive movements. Kay is a 3D machine driver for 3 up to 5
axes; Lancelot is a 2½D and 3D driver for 2 or 3 axes (XYZ or XAZ).

15 - 350 — "Lancelot", standalone use —————————————————

——————————————————————————————————

———————
16
10000

"KAY"
3D CNC DRIVER

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GALAAD 3 —————————————————————————————

General

The Kay module is a component of Galaad software that can be used

independently, either with the Galaad standard licence, or with its own limited
licence. Kay is a CNC machine driver, i.e. it simply loads CAM files under
ISO G-code, Isel-NCP or MasterCam NCI format, from which it supervises
the automatic milling process once the workpiece origin has been set using the
same functions as the standard machining module of Galaad.

Kay is specialised in the milling of 3D toolpaths, from 3 to 5 axes. 4th

and 5th axes are presumed to be normalised, i.e. rotary axes A and B according
to the current standard. The manual drive applies to all axes that are available
on the machine.

At start-up, Kay displays a classical manual control window for workpiece

origin set-up, and immediately asks for a file to be machined. If you do not
select a file, it can be used as manual drive module.

The file name can be passed as a programming argument with its

access path, in which case the file will be opened automatically. Hence Kay
can be directly integrated at the end of a CAD-CAM-CNC processing chain. If

16 - 352 — "Kay", 3D CNC driver ———————————————————

 ————————————————————————————— GALAAD 3

you use a software application that can create the toolpath under a format
known to Kay, and this application can call up an external machine driver, as
Galaad does, and give it the name of the file that has been created, Kay will
automatically open this file. The file extension then indicates the format. If this
extension is not known to Kay, just add it as an argument next to the file
name, between brackets. Examples:
 "C:\\Galaad\Kay.exe"
calls Kay without giving it a file to open;
 "C:\ Galaad\Kay.exe" "C:\ CadCam\File.iso"
calls Kay and asks it to directly open the file under ISO format;
 "C:\ Galaad\Kay.exe" "C:\CadCam\File.xyz" (iso)
calls Kay and asks it to open the file, the format being indicated immediately
after the name.

Coordinates and file origin

As soon as the file is loaded, Kay succinctly displays the volume that is
used by the toolpath on XYZ axes with extreme
values, and the speeds for feed and rapid
movements. This is purely indicative informa-
tion, which you cannot change.

It is important to keep in mind that the

formats of the files that Kay reads contain no
data about the dimensions of the raw material,
information which is essential for a milling process with Galaad. These files
provide only vectors and arcs that define the active and inactive toolpath, with
corresponding speeds and tool numbers. It is impossible to determine either
the shape or the dimensions of the raw workpiece from the file data. The
automatic drive will therefore start from an origin point that must be defined
on the machine bed. The origin point that is set with Kay corresponds to
point (0,0,0,…) of the file. This point may even be completely outside the
toolpath, depending on the coordinate system and the offsets that have been
configured by the application that produced the file.

It is common practice to find the zero point XY (0,0) at the southwest

angle of a rectangular workpiece, the zero point Z being generally located

——————————————————— "Kay", 3D CNC driver — 16 - 353

GALAAD 3 —————————————————————————————

either at the top surface of the workpiece or at its bottom surface. You must
set the position of the file zero point yourself from the module that has
been used to create it.

In case of a 4-axis machining job, the standard location of the Y origin

point is always at the centre of rotation of the A axis. This standard applies
to Kay graphical display. If your file did not use this, the display will not
represent the toolpath correctly, nevertheless the machining process will
remain correct, provided that you have set the Y origin at the corresponding
location in the file. In addition, it is possible to indicate the Yo-A axis offset, if
any. Otherwise, Kay's coordinate system complies with the geometrical
standard with ascending values for X from west to east (left to right), for Y
from south to north (front to rear), and for Z from bottom to top.

However, it is still possible to change the file origin point once it has
been opened in Kay. The "File / Dimensions & origin" command opens a
dialogue box in which you
can manually specify the
Cartesian dimensions of your
raw material, and locate the
origin point inside these
dimensions, including a fixed
position at an XY corner of
the rectangle and the Z point
at the top or bottom surface.
This dialogue box can be displayed at every file opening if you so wish. A
checkbox makes that option accessible.

There are more commands available in the "File" menu to manually shift,
reverse or rescale coordinates. You may also filter part of the file by indicat-
ing start and end points of the toolpath. All vectors and arcs located before or
after will be ignored but commands that concern speed, tool change, etc. will
remain active.

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Multiple tools

When opening the file, and if it

contains several successive tool cycles, for
example for roughing and finishing, you
are prompted to define how the tool
changes must be managed. The list of the
tools detected in the file is displayed at the
top of the dialogue box, and several
options are then available:
1 - The tool changes are simply ignored. In this case, Kay will consider that
only one single tool is used to machine the whole path, the one that is mounted
on the spindle when starting the process. The file is then machined in one go
with no interruptions.
2 - Only one tool cycle in the file is to be processed. The code lines that refer
to this tool are the only ones that generate machining motion, and all others are
ignored. It is therefore possible to redo an exclusive cycle.
3 - The tool changes are managed by Kay. Several sub-options are then
possible:
3.1 - The tools are ringed or have all the same length under the spindle.
Mounting a new tool does not require setting a new Z origin. In this case,
Kay stops the machining when it comes to a tool change command in the
file sequence, and prompts the operator to mount the tool that is going to
start. As soon as the message is acknowledged, the cycle is resumed.
3.2 - The tool change requires a new manual set-up of the Z origin. In this
case, the message for mounting the new tool is displayed, and then Kay
returns to the manual jogging window. Clicking on the yellow button for
launching the process resumes the cycle.
3.3 - The tool change requires a new set-up for the Z origin, but this can be
done automatically by the tool sensor. In this case, as soon as the message
for mounting a new tool is acknowledged, Kay operates an automatic tool
measurement which sets the new Z origin, and immediately resumes the
cycle.
3.4 - The machine is fitted with an automatic tool changer that has been
programmed in the parameters. The interruption is then limited to the park-
ing of the tool in its rack, the picking of the new one and eventually its
measurement on the sensor. Then the cycle is resumed.

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Workpiece origin

As soon as the file is loaded and the active range message validated, Kay
starts communicating with the machine and lets you take control of it. Setting
the workpiece origin is operated classically from the manual jogging and
related functions, including the green buttons for validating the current
positions of the axes. The manual control aims to tell Kay where the file zero
point is physically located on the raw workpiece. To do so, just move
manually the tool end to the coordinates of the reference point, axis by axis.
For manual jogging and origin validation functions, please refer to the chapter
"Learning to mill", section "Workpiece origin" which will give you all details
plus a few tips.

You can enter a numerical position to be reached by clicking on the axis

coordinates at the bottom of the screen, or by pressing the X, Y or Z keys.

But the purpose is not only make the machine move along its axes.
Although Kay is supposed to know permanently the position of the tool end, it
does not know any better where the machining path is located in the machine
volume, and this is what you must indicate. Now you are going to approach X
Y and Z one by one or together, validating for each axis the target position.
For example, you set the Z axis at the point on the raw workpiece that
corresponds to the zero of the file, then you click on the green button for
validating the Z position:

With Galaad standard machining, the point of coordinate Zo in the drawing

is always the workpiece top surface, and its thickness is known. With Kay, it is
possible that you cannot move the tool to the point of coordinate Z=0 of the
file, simply because it is located inside the material. If it is at the bottom of the
workpiece, then the simplest is to approach the machine bed or the bottom of
the clamp. But this is not always
possible and the Zo point can also be
somewhere inside the workpiece
thickness, at a known but unreachable
position. Consequently, when validating
"Z-ok", Kay asks you to state if the file
origin Zo is below the point you have approached. The Z coordinate then
jumps to the workpiece origin position.

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Simply follow exactly the same steps for all other axes, including rotary
axes if necessary, by physically approaching the point on the raw workpiece
presumed to correspond to the zero point in the file, and click on the other
green buttons. It is not necessary to move the axes to the origin point before
starting the process. If you have a fixed XY clamp and all your toolpaths refer
to the same coordinate system, i.e. start from this point, then you just have to
set the XY origin once and for all when you prepare your very first workpiece
process. Incidentally, it is possible to memorise origins and recall them later.
The axis positions for the Z axis and for any potential rotary axes can also be
memorised, the last position used remaining valid until it is moved.

Important: if your machine is fitted with a tool sensor, please refer to the
chapter "Advanced milling functions", section "Automatic tool measurement"
for detailed information. The method remains the same here, but using a tool
sensor supposes that your machining files have their Zo origin located
either at the bottom of the workpiece (fixed sensor) or the top surface of
the workpiece (mobile sensor), since Kay cannot know its thickness. It is the
same for an automatic tool changer.

In a 4-axis machining, i.e. if your machine is fitted with a rotary axis and
the current file contains rotary coordinates A, then the validations "Y-ok" and
"Z-ok" can define either the position of the rotary axis on the Y and Z axes,
information that is necessary
for calculating the tangent
speed and a correct display, or
the position of the points of
coordinates Y=0 and Z=0 in
the file, if these are not located
on the rotary axis (this may happen though it should not). When you click on
the green buttons, then Kay asks more about the validated position.

Note that the keyboard space bar stops a display update that is
in progress. This can be useful with very big files on a slow computer, to avoid
unnecessary screen updates.

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GALAAD 3 —————————————————————————————

Parameters

We are not going to repeat here how you can define and set up your
machine. Please refer to the chapter "Machine parameters" if you need
information about it. Setting the machine parameters is exactly the same
from the main module Galaad, and any changes that are made from a
given module apply to all. In Kay, changing one or several CNC parameters
resets the communication as soon as the changes are entered. In the same way,
the "Parameters / Reopen communication" command avoids closing then
restarting Kay in case of a break in communication, for example a machine
temporary switch-off. The initialisation process is then restarted.

The options "upload to CNC memory" and "save to CNC card" concern
only machines that have a local linear memory, able to store the whole
toolpath and execute it locally, either from the buffer memory or from a
memory card. The calibration functions concern the machine tuning and the
tool sensor. Please refer to these functions in the previous pages of this
manual.

It is possible to initiate a system shutdown once the milling process is

achieved. In this case, Kay is automatically closed after it has sent a system
shutdown command to Windows. Depending on its format and its generator
programme, the toolpath file may or may not contain commands that switch a
coolant device on and off. Obviously, Kay switches off the coolant at the end
of the process, whether it is complete or not, even if this switch-off was not
specified in the file. In all cases, the output that corresponds to the coolant
system must have been defined in the machine parameters.

The warm-up moves the machine along a slanted ellipse at fast speed, so
the three axes are heating up to the working temperature. A repeated process
can be defined, so the cycle will be restarted after a given delay, and once the
previous cycle has been completed without errors. The workpiece origin
remains the same. A serial process can also be configured, to get a matrix of
workpieces on the machine. It is necessary to indicate the number of work-
pieces per row and column, and the origin offset from a given workpiece to its
closest XY neighbours. As for the coolant, the spindle command can be
disabled or forced independently from what the file indicates. The counter
allows you to follow the cycles that have been applied to one or several
workpieces to get the overall time spent for machining. Unlike the Galaad
module, Kay provides only one single counter.

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 ————————————————————————————— GALAAD 3

The tool start position is important if your machine is cluttered by various

obstacles such as clamps, a rotary axis, etc. A file produced by a well-
mannered CAM application generally begins with a rapid XY movement to the
start point of the first path. But the coordinates of this file are relative to the
workpiece origin point and not the machine zero. The very first movement is
responsible for ensuring the convergence. And here, we never know if,
between the current position
and the start point of the first
path, the tool is not going to
hit some barricade. Either you
manage things every time so
the tool is close to the start
point when launching the
cycle, to prevent a collision, or you indicate a start point in absolute coordi-
nates which will always be reached before beginning a cycle. That point can
be defined for each type of machining, 3, 4 or 5 axes. If your machine works
in floating origin mode (i.e. no machine zero), then you have read this
paragraph uselessly. Sorry about it.

Conversely, at the end of a cycle, the

machine moves automatically to the tool
change position if another tool must be
mounted manually in the spindle before
resuming the process, or to the parking
position when the workpiece is completed.
You can find here the same settings as
Galaad. An interruption position can also
be indicated, corresponding to what the
machine must do when the milling cycle
has been stopped for any reasons.

The import scales allow you to adjust the scaling factors for all coordi-
nates, plus the speed scales that can be a bit complicated when a linear axis
and a rotary axis are working together, since they do not use the same units.
The ISO inputs/outputs are an add-on for interpreting the G-code so the
on/off outputs can be controlled from M commands, and eventually waiting
loops related to inputs, the standard being what it is. The M0 and M1 codes for
calling the operator can be ignored. The distance and speed units concern the
screen display. It is up to you to set the import scales and calibrate your
machine according to them. Last of all, the assignment of axes indicates, in

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GALAAD 3 —————————————————————————————

order, which coordinates are used when opening a file, the default being
logically XYZAB. For example, for inverting A and B axes in a given format,
just reset it to XYZBA.

Milling process

Like all other driving modules in the Galaad suite, the big yellow button
starts the machining process defined in the file, from the origin point previ-
ously set. When validating the cycle start, you may still decide to leave the
spindle and the coolant off.

Keep in mind that the space bar stops the automatic process, the
same as when you click on the emergency button at the bottom right of the
screen. A bit more civilised, the button at the bottom left of the
screen allows you to interrupt the machining process as soon as the tool is
retracted above the workpiece. In this case, the interruption is not immediate,
and it is still possible to resume the process where it has been interrupted. This
can be useful to clean the tool or workpiece during the machining, with no

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 ————————————————————————————— GALAAD 3

risks of marking the material. However if the whole toolpath is one single
active block, the pause will have no effect since it will correspond to the end
of the complete cycle.

Like the standard machining module Lancelot, Kay displays at the bottom
of the screen some buttons that allow you to adjust the cutter feedrate and
rotation speed of the spindle if it is under control. It is also possible to shift the
Z origin, i.e. change the toolpath depth whilst the machining cycle is in
progress. This offset is valid only for the current tool cycle and will not apply
to any subsequent cycles.

Once the automatic process is complete, all

tools having been called in, the spindle is
switched off, the last tool is sent to its parking
position and a final message warns that the
workpiece machining is finished, even if you
have gone off to lunch.

If you have purchased only the Kay licence, the current chapter may
look succinct or even incomplete. Please remember that this licence also gives
you access to the Lancelot module, which is Galaad's standard machine driver
and has already been described in the chapters "Learning to mill", "Advanced
milling functions" and "Lancelot, standalone use" of this manual. Conse-
quently, it is highly recommended to read these chapters for more details, not
only about Lancelot, but also about the general machining process. Most
functions that are described in these chapters remain valid for the Kay module.

In the same way, the chapter "Machine parameters" remains valid for the
use of the Kay module, even if certain specific parameters only refer to
machining with Lancelot, for example the flatness correction of the extended
inputs/outputs.

It is worth reminding that Lancelot is called up directly by the main 2½D

drawing module Galaad. It can drive only 2 or 3 axes but can still supervise a
3D milling, including with external files. Simply, the rapid movements when
the tool is retracted up are filtered and redefined by Lancelot, which applies
the maximum depth stages that are assigned by Galaad tool parameters.
Furthermore, Lancelot allows you to control extended inputs/outputs for

——————————————————— "Kay", 3D CNC driver — 16 - 361

GALAAD 3 —————————————————————————————

processes related to special peripherals. On the other hand, the Kay module
drives from 3 to 5 axes but drives the machining process with the file as it is,
with no addition of passes, which it is presumed to have already been defined
by the CAM application that generated the file. The kinematics calculation is
the only change that Kay is allowed to operate to the paths, modulating the
feedrates to prevent any off-road trips.

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——————————————————————————————————

———————
17
10001

"GAWAIN"
TURNING CAD-CAM

——————————————————————————————————
GALAAD 3 —————————————————————————————

Drawing module

Turning applications with Gawain closely resemble milling, but are

somewhat simpler, especially for the drawing, and more complicated for the
machining. This module is not as powerful as Galaad, but workpiece drawings
are much less complex, with just a single external profile, typically chess
pawns or chair rods, with in addition the turning of the inner and lateral sides.
The use of the Gawain module assumes you are already familiar with the use
of Galaad, as well for the drawing as for the workpiece origin and the auto-
matic machining. If this is not the case, please go back to chapters "Learning
to draw" and "Advanced drawing techniques", which will tell you more about
the methods and functions. Drawing with Gawain is as intuitive and should not
cause any problems at first sight.

According to the geometrical references of turning standards, "Z" is the

feeding axis and "X" is the diameter axis, which might induce some confu-
sion about positions and dimensions when drawing on an XY Cartesian plane.
Galaad (generally) and Gawain (particularly) comply with the official
standards. If you are familiar with milling applications but not turning, then
you will have to remember that the X and Y axes of the drawing become

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 ————————————————————————————— GALAAD 3

respectively Z and X. But the general use is unchanged, so this should not be
your biggest problem.

The display of the workpiece profile on the drawing screen shows the
turning path at the top, where you draw your lines and curves using drawing
icons like in the Galaad CAD module, and its symmetrical twin at the
bottom, area which remains inactive (no need to click here). The whole
display represents the complete workpiece once machined. So you draw the
half-profile of the workpiece, the opposite side being displayed passively. For
a better overview of the machined result, sharps angles of the profile are
enhanced with dotted lines that link to the symmetrical path. The Z positions
of these sharp angles are displayed near the rotation axis, the default origin
being located on the right hand edge of the workpiece.

You will soon notice that there are much fewer drawing icons in Gawain
than in Galaad. It is obvious that drawing functions that create dots or closed
shapes are useless in a turning application, since the purpose is here to draw
parts of the profile using lines, arcs and curves, the whole drawing being a
single continuous path from one lateral end to the other one. In fact, it is
possible to draw several different profile sub-sets along the feed path, without
connections. Empty spaces between shapes will simply not be machined, so
the workpiece remains raw material at these locations. Therefore you have the
right to make a non-continuous path.

Since there is only one profile, the drawing entities must be connected to
build a single path. Gawain understands that separate shapes whose ends meet
make one path. Galaad contains a connection function which is useless here.
Gawain considers that two entities do not build one path if the distance
between the nearest ends is greater than 1/10th of a millimetre. In this case, the
turning process will retract the cutter to move from one end to the other. Along
the same lines, the drawing sequence has no importance. When machining,
Gawain will ask you to indicate the feeding direction of your choice, i.e. from
left to right or from right to left. Also the speed parameter disappears. One
single feedrate can be set directly in the machining window, for the whole
process (roughing, finishing, threading).

———————————————— "Gawain", turning CAD-CAM — 17 - 365

GALAAD 3 —————————————————————————————

Tools

The concept of tool remains valid in Gawain, even if turning cutters have
little relation with Galaad's machining tools. Turning tools are not drilling,
engraving or milling cutters, but passive blades that erode a turning workpiece,
like potter's hands.

The profile can be machined in successive passes using different tools. So

it is necessary for each object drawn to be assigned a tool whose technical
parameters have already been set. It is possible to define a library of a
maximum of 50 tools, but one single toolrack. And like Galaad, it is necessary
that, first of all, you define the parameters of the tool you are going to use.
Hence, you must call up the
function "Parameters / Tools"
which gives you access to the
technical data of each tool. The
changes you apply to one tool are
memorised when you select a new
number, the whole being saved
definitively when you click on
"OK" button for closing the
window, the "Cancel" button
erasing all the changes you just
made. The tool name is purely
indicative. It will be displayed in
the messages and selections when
machining, but has no incidence on the process. Conversely, the function is
very important: it tells Gawain who does what in the process, and particu-
larly the external, internal or lateral sides (see later on in this chapter).

The cutting profile and its origin offset allow you to use a calibrated tool-
holder and tools accurately measured. The cutter profile can be defined
roughly with two sets of coordinates around its origin point. This point
corresponds to the tool end that touches the workpiece, for example the sharp
angle of an oblique blade. When setting the workpiece origin, it is this point
that will be the reference. Every couple of ZX coordinates defines a new
segment on the tool profile. Consequently, it is not possible to draw a really
complex profile, but basic cutters remain definable very easily. In the case of a
sectioning cutter, only the Z width of the tool can be defined. Such a cutter is
considered to be a simple bar with a flat end, and therefore with a rectangular

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 ————————————————————————————— GALAAD 3

profile. This type of tool is rarely used in a turning profile since it just cuts the
end of the already machined workpiece. When you ask for a
final display of the trace actually machined, Gawain calcu-
lates and shows any conflicts between the originally drawn
path and the application of the cutter profile. As usual with
Galaad, this is purely indicative: you can still decide to
ignore the warning and start a turning cycle regardless of
these overlaps, even if the workpiece profile may therefore be altered. On the
other hand, 3D displays, with wiremesh or
surface rendering, represent the
workpiece as it has been
drawn, regardless of the
tool shape and therefore
without the possible
conflicts. These two views
are printable as they appear
on the screen, like the
normal display.

External, internal and lateral sides

As we have just seen, the function "Parameters / Tools" allows you to

define each tool and link it to an external, internal or lateral job. Hence,
assigning a tool to an object, using the green icon, determines what
type of machining is going to correspond to it. The display also takes
this into acount; an object for the internal profile will not come into conflict
with an object for the external or lateral profile.

When turning, if you have drawn with tools assigned to different sides, the
corresponding functions in the machining menu and their shortcuts in the top
command bar are no longer greyed out. Of course, the approaches differ, and
particularly for retracting and extracting the tool when turning internal sides.
Note that only the profiles for the external side can also be machined using a
4-axis mill.

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GALAAD 3 —————————————————————————————

Threading

With Gawain, it is possible to integrate in the

workpiece design horizontal or conical threadings,
regardless of the fact that your lathe will or will not be
able to execute them. If the chuck motor of your
lathe is not indexed or its speed not under control,
then the turning can produce only workpieces
perfectly symmetrical about the rotation axis, which actually exclude
threadings. Indexing the motor obviously supposes that the numerical
controller that supervises the lathe can operate a movement subject to an
external synchronisation, a function not so common. A typical indexation
consists of mounting on the motor an encoder or an optical disk that returns
the accurate count of the pulses to the controller card, through a frequency
divider or multiplier. Threading without indexation remains possible, provided
that your lathe is fitted with a very accurate spindle variator or integrates its
own closed loop for controlling the rotation speed.

The last icon in the series of lines inserts

a threading object in the drawing. The
double-click or the right mouse click on a
threading summons the editing dialogue box
for its technical data. You may indicate any
screw pitch and any thread depth, even non-
standard. A small button "Auto" will make
the direct conversion from the pitch to the
depth according to the usual calculation
formulas. The rotation speed can be set here
for each threading object, as well as the
spindle direction of rotation, provided that
the motor variator can turn clockwise. You
may also choose the feeding direction which, combined with the direction of
rotation, will determine a screw pitch on the right or on the left.

The profiling tool is the one that will be used during the finishing pass for
setting the workpiece to the correct dimension before threading. Finally, the
pitch depth can be reached after several successive passes, on condition
however, that your lathe also integrates a 0° synchronisation on the motor.

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Lathe parameters

If it can reassure you, the technical data of your turning machine seen from
Gawain are much simpler than the corresponding machine parameters seen
from Galaad. But Gawain can deal with the parameters of a lathe and a 4-axis
mill for machining a profile in a rotary milling, including threads. We will see
later on how that can be done.

The function "Parameters / 2-axis lathe" displays the settings of your

machine. The listed lathes are not so many, compared to mills, but Gawain
can control all numerical controllers already available for milling. This
allows you to reuse the axes of
your mill for turning at low
cost, by mounting on the table
a very basic turntable made of
a motorised chuck and its
opposite mobile tailstock, the
turning tools being fixed on a
clamp on the Z carriage of the
machine. By the way, the set-
up asks you whether the lathe
is eventually fitted with a 3rd
vertical Y axis (the Z axis of a
mill). If yes, then the manual
jogging will help you adjust
the tool height on the rotary
axis.

The mechanical parameters are classical. You must nevertheless indicate

whether the chuck is at left and if the tool is at front (which is the standard),
so the jogging becomes coherent between the screen and the machine. The
parameters in the other pages are identical to those of the mill and have the
same scope. Only a few of them do not appear because they are not relevant
when turning. Consequently, please refer to the chapter "Machine parameters"
for more details. In the "Controller" page, a small discrete option at the top
right says if the lathe controller is able to operate threadings.

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GALAAD 3 —————————————————————————————

Guided tour of the launch pad

Once the workpiece has been drawn, it is time for a test of your lathe in
real conditions, calling up "File / External turning 2-axes".

The turning parameters page is more crowded than the one for milling, but
its content is not so complicated. On the left hand side of the window, the
miscellaneous parameters are general and not related to the current job, except
the dimensions of the raw cylinder that you can change here without modify-
ing the drawing. The part in the chuck defines the Z length of the workpiece
that is sunk in the chuck, accessible in the internal turning mode but not in the
external turning (displayed in pink). The retraction distance indicates how far
the tool must be cleared out for its positioning movements. This distance is
relative to the external diameter of the raw cylinder. If your lathe is fitted with
a speed variator, then the rotation speeds can be either constant or variable
depending on the X position in the material, so the tangent speed is regular. In
the latter case, the rotation speeds that are indicated correspond to the external
circumference of the raw cylinder, and the software accelerates the rotation
when the tool gets closer to the axis. Obviously, the spindle variator must be
under control and its parameters calibrated.

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 ————————————————————————————— GALAAD 3

On the right hand side, the process is split into four stages: roughing,
finishing, threading, slicing, with their own parameters. You must indicate
which one you wish to operate. These stages will be chained with no interrup-
tions if there are no tool changes, which would be a bit surprising.

1 - Roughing:
The tools in the drawing correspond to the finishing pass and the threading
cycles. The drawing does not tell which tool is roughing the workpiece, and
you must select it, together with the roughing parameters. With a classical flat
cutter (basic tool for slicing), then the software automatically calculates the
lateral offset of the tool to avoid
machining the vertical or oblique
sides. Four modes are available for
performing the roughing passes: the
classical Z scan executes simple
horizontal passes in stages on the
feeding axis, with a little variant
which can limit the tool back
retraction whenever possible, for
saving time; the X scan operates
partial slicings vertically on the
diameter axis towards the centre of
the cylinder; the X envelopes
follow the drawn objects and
gradually get closer to the finishing
profile; lastly, the ZX envelopes
calculate for every pass an offset
trajectory relative to the finishing
profile. The two last modes make
both Z and X axes turn together in
oblique movements.

The plunge speed and the feed speed correspond to the movement for
penetrating the material along the X axis, and to the lateral or oblique move-
ment along the defined pass. The option for plunging off material, valid only
for Z scans, tells the software that, for machining the lateral side of the
workpiece, opposite to the chuck, it can make the tool plunge beside the raw
cylinder and then come back laterally in the workpiece, which avoids plunging
in the material. Beware of the collisions with the mobile tailstock.

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GALAAD 3 —————————————————————————————

Once all the passes have been executed, the option for a roughing final
envelope makes a final path that follows the finishing profile, leaving just the
final layer around the profile drawn, so the jagged edges that have been
created by the lateral or vertical passes are removed.

2 - Finishing:
The remaining material thickness to be removed by the finishing pass is
given by the value for the final layer, to be set in the roughing parameters. If
you are roughing with scan passes, the stepping effect will increase that
thickness here and there, unless you have executed a final envelope. The
parameters for the finishing pass are few: you must either select a tool used in
the drawing, that will execute its cycle on the corresponding objects, or ignore
the drawing tools and select one single tool that will machine all objects. This
last option is of course not appropriate if you have feeding directions west-
bound and eastbound, except if you filter the selected objects. On the other
hand, if you are using the same tool for roughing and for finishing, both passes
will be chained automatically, with no recovery of the origin.

3 - Threading:
The threadings can be done only after the drawn profile is completed, with
the finishing pass in charge of dimensioning the external (or internal) side of
the threading. The profiling tool that has been indicated in the drawing
corresponds to the tool which will execute that preparatory work. As for the
finishing pass, you can either select a tool assigned to a threading in the
drawing, which will then execute its cycle on the corresponding objects, or
ignore the threading tools that have been set in the drawing and select a single
tool that will machine all threadings. The rotation speed for each threading can
be overwritten here. The feeding direction is set in the drawing.

4 - Slicing:
In the dimensions of the workpiece, you may have indicated a Z position
for slicing with the corresponding tool. In this case, and if you enable the
option, that will be done, with an eventual chip-breaking cycle and a maxi-
mum X position for overriding the rotation axis. A pause can be set if the
whole cycle is based on automatic tool changes.

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Workpiece origin

Once the operating phase and its parameters have been set, the next page of
the turning window lets you define the workpiece origin for the tool that is
going to start its cycle. As soon as the window is displayed, Gawain opens the
dialogue with the numerical controller, eventually resetting the axes.

The big circular button and the sliders allow you to move Z & X axes at a
given speed. The keyboard arrows obviously correspond, and also the joystick
or any jogging device that you have configured. Like all manual control
modules in Galaad's suite, it is possible to apply a continuous movement
mode, or incremental by steps to be defined. If your machine has a 3rd vertical
Y axis, then you can also set the height of the tool carriage, for aligning it on
the rotary axis. Please refer to the chapters "Learning to mill" and "Advanced
milling functions" for more details on the subtleties of the manual control.

Gawain adds, at the bottom of the screen, some buttons for resetting to
zero, switching to relative coordinates and back to absolute coordinates. You
can mark a position manually and then offset
from an accurate value relative to that position.
The relative coordinates are displayed in yellow instead of green.

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Setting a workpiece origin on a lathe is an operation more complicated

than on a mill. Where the milling is happy with a reference point XY, gener-
ally not varying as long as the workpieces are stuck in a clamp or two
stoppers, plus a Z approach that can be helped by a tool sensor, the turning
requires that you approach a Z or X position at every tool change, these
positions being themselves subject to variation. The art of turning is an art of
the origin recovery. Classically, the operation consists of making the cutter
edge touch a reference position on the workpiece or the chuck, and
validate that position whilst indicating what it stands for.

For the Z axis (feed along the workpiece), we can choose to position the
edge on the right hand edge of the raw cylinder, tailstock side, on the
lateral side of the chuck (i.e. the base of the workpiece if it is correctly
embedded), on the red-marked point in the drawing, or on a point to be
defined, relative to one of the three previous references. Once the tool's lateral
edge is positioned at the chosen origin, click on the button ,
which will make the coordinate of the axis jump to the workpiece origin
position. Do not forget to select in the combo list under the green button which
reference point you have just validated. Important detail: for a slicing or
roughing tool with flat end, you must imperatively approach its left hand edge
(chuck side). It is this left hand edge that
is used as tool reference for the origin and
the automatic process.

For the X axis (diameter of penetration into the

workpiece), you can choose to approach the
rotation axis, assuming that the raw workpiece is
not yet clamped, or the surface of the raw cylinder,
supposing that it is perfectly cylindrical and centered on the rotary axis, which
is not always evident, or the chuck circumference, its diameter giving the
position of the rotary axis, or a red-marked point in the drawing. As for the Z
axis, once the active edge of the tool is positioned at the chosen origin, you
must click on the button for validating the coordinate, without
forgetting to select in the combo list under the green button whose reference
point you have just validated.

Of course you may set Z and X in any order. The last position used is
memorised relatively to the left hand edge of the workpiece (chuck side), and
relatively to the rotary axis, considering the raw dimensions of the workpiece.
So you will have to redo the origin set-up only if you change the tool.

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Semi-automatic commands

Before launching the automatic process, let us make a little detour through
the command buttons at top left of the window.

The first button corresponds to the classic command for resetting

the machine zero point, already seen in the milling mode. This
supposes that your lathe works in absolute coordinates from a fixed position,
defined by axis end-switches.

The second button starts or stops the lathe motor. If there is a

variator set, duly configured, then a window helps you manage the
rotation speed (see chapter "Advanced milling functions", section "Spindle
Start/stop").

The third button allows you to reduce the diameter of the raw
workpiece. This operation
consists of feeding lateral passes
along the Z axis, sinking the tool
step-by-step in the cylinder from the
current position. The indicated data
are used as they are with no validity
checking in relation to the drawn
workpiece or the origin already defined. It is up to you to verify your settings
before proceeding. Note that, once it is started, you can nonetheless stop the
process using the space bar on the keyboard.

The fourth button drives a lateral preparatory work from the

current machine position on the
workpiece, an operation which is somewhat
close to the slicing but allowing a repetitive
cycle. The plunging value may or may not
reach the rotation axis, and even overrun it:
Gawain just moves to the indicated X
position. The plunge can be repeated from a
starting Z position to the current position.

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The fifth button allows you to slice the

workpiece at the current Z position.
You must indicate the maximum X depth for the
penetration, which can overrun the rotation axis at
your own risks, and also the speed for plunging in
the material. Again, keep in mind that there are no
validity checkings here. It is possible to execute a
chip-breaking cycle for this operation. You can
also ask for the slicing to be repeated at regular
intervals.

The sixth and last button offers the possibility to perform a pre-
paratory boring at the end of the workpiece, tailstock side, from
the current position of the axes. You must mount a reaming cutter on the
carriage that support the tools,
oriented towards the chuck with its
leading edge located on the correct
side relative to the rotation direction.
The software will drive a Z- feeding
movement towards the chuck at the
feedrate, and will reiter the cycle
until the X feed is reached, with or without passes. It is possible to smooth
eventual jagged edges appearing at the bottom of the pit by setting a finishing
pass on the X axis.

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Automatic process

Once the turning parameters and workpiece origin have been validated,
you just have to click on the big yellow button that starts the turning process.
The key is the keyboard equivalent. A last message prompts you to
confirm the process launch. It is time to switch on the lathe motor if it is not
automatic. Validating this message starts the cycle immediately.

The tool path corresponds to its leading edge. In the case of a slicing or
roughing cutter with a flat end, remember that the coordinate is the one for its
left hand border, usually chuck side, with an automatic compensation offset on
the opposite border. Hence the software displays a wide cursor that represents
the tool in its full width.

In the end, and if everything went well, a new bishop for your chessboard
is now machined. It might be more complicated for the horses.

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Turning on a 4-axis mill

Although Gawain is dedicated to the turning process only, it gives

access to the mill parameters. If this mill has a 4th rotary A axis, then
the software can ask Galaad's machining module for a small service, that is to
execute the machining of the drawn profile by milling, using the command
"Machining / Cylindrical milling 4-axes". This is the only gateway (one-way)
between turning and milling.

The specific parameters of this cylindrical milling are displayed in a

dialogue box when opening the machining module. In case of need, it can be
recalled with a little double-
click on the preview area at
the bottom left of the
window. The parameters look
like those of the classic
turning, but more concise
because the machining is
going to reuse the tool and
pass settings that are valid for
the cylindrical millings
launched from Galaad's
drawing module. The turning
tools have nothing to do with
milling tools, so the software needs to know which tool is about to be used for
the machining. This tool will generally be a cylindrical flat-end cutter. Gawain
will automatically calculate a lateral compensation offset for fulfilling the
drawn profile. The machining will feed successive XZ passes (these axes
corresponding to a mill) with an incremental rotation of the A axis, the lateral
margin for the plunge allowing the tool to move down out of the material,
tailstock side. A perpendicular finishing pass can be added, milling rotary
slices with XZ being still.

Threading is fully enabled in 4-axis machining since the indexing angle of

the rotary axis is known permanently. As for the turning, the milling path will
complete its job at the accurate dimensions of the drawn profile. Then you will
have to mount an engraving bit with a conical end that corresponds to the
thread gorges.

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——————————————————————————————————

———————
18
100 10

"KYNON"
MOTION PROGRAMMER

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GALAAD 3 —————————————————————————————

Automaton for axis controls

If the main purpose of Galaad software is to perform milling ‒ and possibly

turning ‒ operations, the CNC machine can roughly be defined as a more or
less complicated set of motorised axes plus a numeric controller, able to
communicate with a specialised software application. Hence we have several
linear or rotary axes and input/output signals, the whole set being under the
full tight control of your computer. Consequently, this gives the computer the
ability to drive movements, wait time lapses, react depending on input
signals, and switch connected peripherals on/off, be they electrical or
electromechanical.

In addition, those who become interested in Galaad's extended in-

puts/outputs, for special applications such as glue dispensing or engraving on
a variable Z surface, may have noticed that the application is able to consider
external signals and pauses during automatic machining processes. In such
particular cases, Galaad remains no less focused on creating and driving a 2D
or 3D path, the management of electrical signals being a secondary function
which is closely framed by the fact that this geometric path must be followed.
The main Galaad module cannot deal with all possible cases, and particularly
conditional jumps, loop sequences or interactive messages to the operator.
Even including external controls, Galaad's movements remain a graphical
path with a start point, an end point and a unique sequence with no possible
dynamical redirections.

Most Cartesian machines that have been built for automatic milling can
also become compatible with other types of more exotic applications, with or
without a milling spindle and a cutter tool, such as automatic pick & place
or, more generally, motion that interacts with the workpiece. Furthermore, the
sequence of handling or a similar operation cannot always be displayed as a
path design, but rather as a list of operations that must be performed in a
given order, which may vary during execution. It is for these reasons that the
Kynon module has been added to the set of main functions of the Galaad
software, but here graphics are no longer the main purpose.

The Galaad standard licence grants access to the use of the Kynon module
and all additional programmes, though it is also possible to purchase a
restricted licence for the use of Kynon alone.

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At start up, the Kynon module displays the window shown above. For
experienced Galaad users, the right hand side of the window should not be a
total surprise. Indeed you can find here the classical buttons for manual
motion of axes, with corresponding speed sliders and motion mode selectors,
continuous or stepped. Those who have become familiar with the maze of
functions of the manual control will also recognise the double panel of binary
inputs and outputs. The bottom of the page provides classical control objects
that allow you to set a workpiece origin.

It is not useful to enumerate again and again the subtle functions that
appear at the right hand side of the screen; they have already been much com-
mented in the previous pages. Help us avoid converting too many trees into
paper, this manual is guilty enough in that matter. If you are reading only this
chapter and are not familiar with manual drive from Galaad software, probably
because you have purchased only the Kynon licence, then please jump back to
the previous sections, as follows (if we dare to say):
- Chapter "Advanced milling functions", section "Moving axes", which will
tell you how to jog axes manually at a given speed, in continuous or stepped
mode, with the mouse, keyboard, joystick or a handwheel.

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GALAAD 3 —————————————————————————————

- Chapter "Advanced milling functions" still, now section "Manual drive", to

learn how you can read inputs and switch outputs from a mouse click.
- Chapter "Learning to mill", section "Workpiece origin", which very logically
describes how you can define a workpiece origin for an automatic process.
In fact, Kynon can ignore this origin point if there is no workpiece in classi-
cal terms and that all coordinates are based on the machine zero.
- Chapter "Machine parameters" last of all, which should tell you all the
possible ways to set up your CNC configuration and especially the gear
factors and communication port.

The right hand side of the screen is now presumed to be known and the
machine correctly defined, but you may still play with the parameters. At start-
up, Kynon first opens the dialogue with the machine, possibly resetting the
axes with a homing movement to the machine zero. It then becomes possible
to play with the buttons. It is worth mentioning that you may enable/disable
an output by clicking directly on its corresponding number with the mouse.
This should help you check the reactions of the peripheral devices that you
have connected to the machine. Concerning inputs, no real-time reading
functions are possible, but you can display input states by clicking on the
"Refresh" button, or make a cyclic reading by enabling the "Loop" button
(click again to disable). If you have connected a peripheral that produces a
signal to be monitored and you wish to check the number of the corresponding
input or the correct electrical wiring of the device, this cyclic reading may be
very helpful.

Kynon can drive from 1 to 5 axes depending on the capabilities of your

machine. Classically, XYZ axes are considered linear axes and AB are
considered rotary axes that are presumed to be parallel to XY. It could be the
case that your machine is different and does not match this configuration,
however this should not block your use of the Kynon module. A special set-up
of the machine gear factors may help you solve this problem to obtain
coordinates that correspond to reality, even if the units displayed no longer
make sense.

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Programming technique

The left hand side of the screen displays a zone that is supposed to contain
the sequence of instructions to be executed – in other terms the programme –
and just below, a preview of the path, if any. If anyhow the axes of your
machine are not Cartesian, then you can get rid of this preview thus making
more room for the programme itself, by unticking "Parameters / 3D view".

The body of a Kynon programme may be displayed in capitals or lower

case, colours or monochrome. The top of the "Parameters" menu helps you
select all this. Operators who already have programming language skills, even
the basics, should not have big problems becoming familiar with Kynon. Also,
absolute beginners have not been forgotten: learning this programming
technique is very easy and close to BASIC language, which is the simplest
ever invented and was made for beginners, as its name says ("Beginner's All-
purpose Symbolic Instruction Code"). Therefore you should not encounter
huge problems creating a Kynon programme, and then… well, let us just say
that there are no good programmers, only old programmers. And unfor-
tunately we know what we are talking about.

In classical sequential programming, and Kynon matches this model for the
most part, the sequence begins at the top and instructions are executed one
by one downwards, until the last line of the programme is reached. However,
there are some instructions which let you break that sequence by executing
jumps forward or backward. Kynon also offers the possibility to define blocks
of macro-instructions, over which the sequence will skip regardless of what
they contain, but can be called and recalled at several stages of the process.
This will be described later.

A basic Kynon programme consequently has a beginning point at line #1,

followed by a more or less long series of operations that will be executed one
by one until the last line is reached. Once this end line has been executed, the
process is completed. There are no limits concerning the number of lines.

There are four major groups of instructions in a Kynon programme, which

will be detailed later with the usual examples:

- Motion commands send one or several axes to an absolute position or

perform a relative movement at a given speed. Arc commands are also
available, the circular interpolation being valid only in the XY plane. This

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GALAAD 3 —————————————————————————————

group of instructions also integrates the homing, which resets the machine to
its zero point, or conditional movements which stop when a binary input state
is changed. All motion commands apply to coordinates and therefore to axis
positions. These commands are: SPEED, MOVE TO, MOVE REL, ARC, ARC REL,
HOME, MOVE UNTIL, ORIGIN, SCALE and PASSING.

- Switching and pausing commands change output states or freeze the

programme for a given length of time. Unlike Galaad, which is able to trigger
multiple outputs simultaneously, it is not possible with Kynon to switch a
whole block of outputs with one single command. You must define a
sequence, even if the time between every instruction is limited to the
communication delay with the machine, which is generally very short. These
commands are: OUTPUT, DAC (Digital-to-Analogue Converter), PWM (Pulse
Width Modulation), SPINDLE, PAUSE and WAIT UNTIL.

- Jump commands, fixed or conditional, break the linear process sequence by

skipping instruction lines forwards or backwards. These commands are: GOTO,
GOSUB, LABEL, RETURN, IF / GOTO, IF / SKIP, COUNTER, BLOCK, END BLOCK,
EXEC BLOCK, INCLUDE and REITERATE.

- Management commands allow you to add a neutral comment line, modify

the programme execution mode in the machine, interact with the operator or
call external software. These commands are: REM (remark), BUFFER,
MESSAGE, SEND and RUN.

Kynon programme editor is purely passive: unlike classical text editors,

you do not type the language instructions yourself. The list of available
commands is displayed in the central column of the window, you simply click
on them to pop up a dialogue box that gives access to the corresponding
command parameters. This should at least avoid
syntax errors, which are quite usual with a
classical text editor.

When the active line (displayed in negative colours) is empty, clicking and
validating an instruction will add it at this position in the programme, by
shifting down the following instructions. If the line already contains an
instruction, either the instruction you have clicked on is identical, in which
case it will be a simple change of its parameters (it is even simpler to double-
click directly on the line in the programme), or it is not identical then the new

18 - 384 — "Kynon", motion programmer ————————————————

 ————————————————————————————— GALAAD 3

one will be inserted just before the existing one, which will be shifted down.
Therefore, if you wish to insert a new instruction, which is identical to the
existing one, you must first insert an empty line using the key. Con-
versely, you can delete the active line, whether it is full or empty, using the
key. All consequent instructions are immediately shifted up.

Warning! When you write a programme with Kynon, you are still in
manual drive mode. Keyboard arrows and / (PgUp / PgDn) keys or
/ keys do not move the active line but actually move the axes of the
machine. Moving the active line of the programme can be done only with the
mouse. Consequently, the programme body provides little interactivity, but
this is not a classical development with many changes. Building a Kynon
programme – which is generally short unless you have a rich imagination – is
closer to a line-by-line lesson in that it is related to the manual drive, as we
will see in the next pages.

Motion commands

The main command in this group is the MOVE TO instruction, which moves
the axes to the indicated position. This instruction will generally follow a
SPEED instruction, which defines the corresponding motion speed. The MOVE
TO instruction does not require the coordinates of all axes; one coordinate is
sufficient to define a movement. Obviously, if the position to be reached is the
same as the current position, nothing happens – which is always better than an
accident along the way.

Very important: the position coordinates are always relative to the

origin point of the whole path. If your application does not need an origin
point and is happy with a simple machine absolute origin, then you can simply
set all origin positions to zero. In such case, the machine zero point will be the
actual origin for the path.
Exceptionally, you have
the right to indicate a
negative origin. Kynon
is more permissive than Galaad in that matter, and let us hope that so will be
your machine.

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GALAAD 3 —————————————————————————————

If you have entered a series of motion commands that define a fully correct
path but at a wrong location, do not panic: there is no need to redo everything,
you can simply shift a set of lines using the "File / Shift" command. Block
macro-functions can also help in such cases (see later on).

The question of actual position has no sense with the MOVE REL instruc-
tion, which uses only relative values. The sequence is identical, but then the
origin has no more importance since all movements are driven relative to the
previous point. Keep in mind that Kynon checks the absolute position of the
next point to be reached and will stop if you are trying to escape from the valid
range of an axis.

The ARC and ARC REL instructions describe an arc of circle on the XY
plane, which starts from the current position towards another XY target
position around an IJ-centre. Depending on the instruction you have used,
coordinates are indicated in absolute (i.e. relative to the total path origin point)
or relative coordinates.

The SPEED instruction defines the motion velocity for the linear axes on
the actual path (and not the velocity of the axis that carries the longest
movement like most numerical controllers read). If you move a rotary axis A
or B with a linear axis X, Y or Z, the speed applies to the linear motion and the
rotary axis will obviously be synchronised. If the rotary axis moves on its own,
then the speed becomes a tangential velocity around the rotary axis, unless
you have previously indicated a fixed angular speed in °/s. Consequently, the
speed will be greater when the position is closer to the axis centre. For an A
axis, the arc radius is the YZ distance from the current position to the origin
point; for a B axis, the XZ distance applies. If you want a rotation of the A or
B axis whilst the current YZ or XZ position is (0,0), then Kynon will not dare
to divide by zero and therefore the speed will be the maximum value the
numerical controller can perform. This particular case should never occur if
your path has been validated.

The MOVE UNTIL command starts a movement to a given position,

movement which is stopped if an input state changes. Kynon immediately
updates its position registers, but it is up to you to execute the following
sequence with absolute or relative movements, depending on your application.

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The HOME instruction allows you to drive an axis to the machine absolute
zero, which will reset its position. Each axis can be driven individually. It is
quite usual to shift the Z axis up first to avoid problems.

The position of the path origin can be changed while running, using the
ORIGIN instruction, which allows you to relocate all subsequent coordinates.
Here, "subsequent" means "executed after" and not "below in the program-
me", especially if there are jump instructions. On the same subject, it is
possible to change the coordinate scaling factors while the programme is being
executed, by using the SCALE command.

Finally, the PASSING instruction, eligible only for certain numerical

controllers, allows you to chain vectors with no deceleration before the end
point and no re-acceleration after the start point. This mode obviously assumes
that you are using the BUFFER command (see next pages) so that there are no
transmission delays between vectors, which would cut the benefit of the
chaining. If your machine does not read this passing mode instruction, it will
simply be ignored.

Switch & pause commands

In addition to axis motion, Kynon can address outputs and check inputs.
The main command in this group is the OUTPUT instruction which sets a given
output in a high (active) or low (inactive) state, the default state being
generally inactive. It is up to you to connect the peripheral devices of your
custom application to the corresponding outputs.

Please note that, unlike Galaad, it is not possible with Kynon to specify
multiple output numbers that could be switched in one single operation. You
must set the switching sequence line by line.

The DAC instruction sets the signal level of the machine analogue output
number 1, if it exists. The resolution is 8 bits, which allows you to set values
between 0 and 255, from 0 to Vmax. On the same topic, the PWM instruction
sets the frequency of the machine PWM signal, again if it exists, and the pulse
width in percentage (i.e. between 0 and 100%). These commands allow you to
drive an analogue device such as a rotation or dispensing control.

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GALAAD 3 —————————————————————————————

Though the purpose of the Kynon module is not focused on milling

processes, the SPINDLE command is available with the same external calling
and speed setting capabilities as in Galaad. The instructions therefore include
rotation speed and direction arguments that may not apply to your machine,
depending on its type.

The PAUSE command allows you to suspend the process during a given
time period. The unit is the second, and you may naturally use a decimal value.
In direct mode, the basic time unit of Kynon is the millisecond and it is not
possible to set a smaller value. In buffer mode (asynchronous upload to local
memory), this depends on the capabilities of your numerical controller.

At last, the WAIT UNTIL instruction suspends the process until an input state
changes (with a possible timeout lapse). The operator can manually jump to
the next instruction without waiting for the input to be triggered, by pressing
the key. In such case, no message is displayed on the screen but the
current instruction line blinks so the operator knows that the process is
suspended.

Jump commands

In any civilised programmable sequence, it must be possible to break the

linearity of the process and skip instructions, imperatively or depending on
certain conditions. Obviously, Kynon provides such possibilities with its
jumping instructions.

Before we go further, please keep in mind that it is always better to use the
LABEL instruction to define a landing line for a jump in the programme.
Nevertheless Kynon accepts to jump directly to a line whose number is
known, and is even courteous enough to shift the winning number when new
instructions are inserted above this line, but there are at least two serious
reasons to use labels: firstly, reading the programme is much easier; secondly,
you do not need to check the changes of line numbers to keep your jumps
correctly targeted. You define a label, i.e. a line name, then you can add a
jump to this line whatever its number is and however it evolves. It is obvious
that the label line is neutral, i.e. nothing happens when it is executed, such
lines are just fixed references in the programme sequence.

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Jump instructions can be either imperative, i.e. Kynon executes the jump
whatever, or conditional, which can become much more interesting. The two
imperative jump instructions are GOTO and GOSUB, that probably most BASIC
programmers know. The first makes a one-way jump whereas the second
makes a temporary jump until the programme encounters a RETURN
instruction, which allows you to define round trips to specific sections of the
programme, especially in conditional mode.

In the same way, the conditional jump instructions are IF / GOTO and IF /
GOSUB. The conditions are either an input change from/to low/high state, a
loop counter (see the next pages) with a value that reaches a threshold, an
instruction to be executed by the numerical controller that overruns a
predefined timeout lapse, or a message to the operator which must be
acknowledged by "Yes" or "No" (condition being true when affirmative).

Slight variation, the IF / SKIP instruction allows you to undertake

conditional jumps depending on an input state, but this instruction differs
from the above because it can be uploaded to the local memory of the
machine, depending on the controller type, for example Isel C-10, C-142 and
i-MC. The number of lines to be jumped can be negative (backward jump),
positive (forward jump), or null (conditional wait loop).

Kynon can manage numbered counters, for example when repetitive loops
are created with an internal GOTO instruction that exits the loop. Simply insert
in the programme, if possible before entering the loop, a COUNTER that will be
initialised to a given value, zero or otherwise. Then, in the loop, add an
incrementing or decrementing command for this counter, for example
"Counter #3 + 1" which means that the data in the counter number 3 will
increase by 1 every time the loop is executed. This instruction will obviously
be followed by a conditional jump related to the counter level, if the
corresponding value has overstepped a given threshold. In this case, the
programme will have executed N times the loop before jumping to the next
instruction lines.

Similarly, the REITERATE command allows you to repeat several times the
last N lines of the programme. This looks like a loop with an internal counter,
but that instruction can be stored in the machine local memory, depending on
the controller type (still Isel C-10, C-142 and IMC4). It has little interest if you
do not have such a machine or do not use the upload to the local memory.

———————————————— "Kynon", motion programmer — 18 - 389

GALAAD 3 —————————————————————————————

Macro-commands

To ease reiterations, improve the modularity and consequently the

readability of the programmes, it is possible with Kynon to define programme
blocks, that will be called up from another part of the programme. For
example, you define a given procedure that contains movements, output
switching, etc. and you wish to reuse this procedure without modifying it and
without adding a complicated set of jump instructions.

Kynon can define a sequence of commands that begins with a heading

BLOCK instruction with a block name, and ends with an END BLOCK
instruction. When the process reaches the block header line, it jumps directly
to the end of the block without executing the inner lines. The block is
considered a neutral set when executing, so you can locate it anywhere in the
programme body, before or after a call to this block. To execute the inner
lines, it is necessary to call up the block with an EXEC. BLOCK command.
Furthermore, and here it becomes really interesting, you can assign a
coordinate offset to your call.

For example, you define a series of XY movements which draw a rectangle

with rounded corners, using linear and circular movement instructions, and the
start point of this rectangle is (0,0). All movements are written inside a block
that is named for example ROUNDRECT. Hence ROUNDRECT becomes an
instruction like any other, that you may insert in your code and give it XYZAB
coordinates according to your wishes. If you put the instruction line
ROUNDRECT X10 Y20 Z30 somewhere, Kynon will execute all lines inside the
block named "RECTROND" and will shift its XYZ coordinates by (10,20,30),
i.e. all inner coordinates are added these values. The main purpose is
obviously multiple calls to ROUNDRECT with different coordinates. But this
can also be used to simply make the reading of the programme easier. Please
note that all or part of the position arguments XYZ etc. are optional. If you do
not indicate any, the corresponding coordinates when executing the block lines
will be the actual coordinates of the inner lines with a null-offset.

To close this section, it is worth mentioning that a block can contain an

inner call to another block and so on, to define more and more elaborated
macro-blocks. In the same way, a block can call to itself, but it is better to
avoid this unless it contains a conditional jump to the block end line, so you do
not have an infinite recursive loop (in fact, Kynon is able to stack a maximum
of 256 successive calls, this maximum value also applies to all IF / GOSUB

18 - 390 — "Kynon", motion programmer ————————————————

 ————————————————————————————— GALAAD 3

instructions, which still leaves a rather comfortable margin for most

applications).

And finally, the INCLUDE instruction allows you to call up an external file
which can either be another Kynon programme, and this would define a super-
block, or a 2D or 3D vector path file. In the same way, a coordinate offset
applies to this external file to relocate it. This can be interesting for integrating
a whole path without having to encode the sequence of movements.

Programme management commands

Some not so easily classified instructions can help supervise several

process steps, hereafter and helter-skelter:

The REM (Remark) instruction, known to well brought up programmers,

allows you to add a comment into the sequence for the next generation who
will have to decrypt the programme and try to understand how it works – if it
does. Obviously, this instruction is neutral and consequently has no effect
when executing.

On the other hand, a message can be sent to the operator during the process
execution, using the MESSAGE instruction which opens a window and displays
the attached text. The operator can then either acknowledge it by pressing the
key (or clicking on "OK"), or abort the process with (or clicking on
"Cancel"). As long as the message remains unacknowledged by the operator,
the process is hanging.

With certain numerical controllers, it is possible to send instructions to

the local memory for execution later on. Either the machine starts executing
already loaded instructions whilst receiving the next ones (ring buffer), or the
machine first receives all the instructions then executes them (linear buffer).
This depends on the machine you are using. Kynon provides an "Upload"
mode in its menus that uses the local buffer if it exists. But this does not
prevents the use of buffer management commands inside the programme itself.
Hence you can execute locally some sequences, for example the chained
movements in passing mode (mentioned above in the motion command
section).

———————————————— "Kynon", motion programmer — 18 - 391

GALAAD 3 —————————————————————————————

Since certain numerical controllers may integrate some instructions that are
unknown to Kynon, you still have the possibility to handle them yourself using
the SEND command which will simply transmit the corresponding telegram on
the communication port without trying to understand it. Kynon will
nevertheless add data frame codes according to the machine dialogue protocol.

Finally, you may execute external software, even in console mode, using
the RUN instruction which will call up this executable programme and either
skip to the next line or wait until its execution is terminated before resuming
the current process.

Manual drive teach-in

A major feature of Kynon module is the fact that you can directly drive the
main functions of the machine (linear or rotary movements, output switching,
input checking) to build up a programmed path step-by-step. So the process
looks like the manual digitising function of Galaad, except that here you can
access the supplementary commands of the machine, and that up to five axes
are available. On the other hand, the origin point becomes important.

Two concrete cases may occur, depending on your application: either your
process handles a workpiece or a restricted volume which is located some-
where in the available machine space (operations on workpieces), or it applies
to a general space with no local reference point (pick & place handling).

In the first case, it is important to first define the origin point of the
programmed path. Classically, you just have to move the axes to the
corresponding position and validate them with the "XYZ… - OK" green
buttons. Then all coordinates indicated in the programme body for absolute
movements MOVE TO, ARC, MOVE UNTIL and calls to programmed macro-
blocks or external files to INCLUDE will be considered relative to this origin
point. In extenso, position (0,0,0,…) will correspond to the origin point,
which can be readjusted later so you do not have to shift the programmed
coordinates. If you have skipped this step and have already begun to encode
movements, simply position or reposition this origin (it is not too late) then
call up the "File / Shift" function to change all programmed coordinates in one

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 ————————————————————————————— GALAAD 3

operation. The offset value for each axis will obviously be the position of the
new origin point minus the position of the old one.

Concerning the second case (no path reference point), it is necessary to

validate the point (0,0,0,…) as the path origin. Hence programming
movements will be made in absolute coordinates from the machine zero
point, which is set by the homing reset. If you notice that this machine zero
point has drifted away, which should never occur, either you need to readjust
all programmed coordinates with the "File / Shift" function, or you can
indicate a path origin point that is not (0,0,0,…).

The instructions for relative movement MOVE REL and ARC REL are
obviously not concerned by these considerations about the path origin point.

A manual path teach-in can be done very easily, once the

origin point has been correctly validated. Simply move the
axes directly to the target position, using the manual drive
buttons, then click on the blue buttons at the top centre of the
Kynon window.

For example, you move the three axes XYZ to a given position that you
wish to reach in two steps, then you click successively on "Pos. XY" and
"Pos. Z": the programme will memorise a movement to the XY position, then
a Z movement to the actual point. These buttons automatically insert the
corresponding instructions at the active line of the programme.

Important: remember that the Galaad module allows you to export

drawing paths to Kynon programme format. This can be very helpful when
creating paths based on full graphics.

Last of all, you can enable/disable all outputs under control by clicking
their numbered rectangles, and use the "Refresh" button or the "Loop" button
(cyclic refreshing) to check input state changes.

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GALAAD 3 —————————————————————————————

User-defined buttons

In addition to numbered outputs, it is possible to define custom buttons

that correspond to your peripheral devices. These buttons are displayed at
the bottom left of the Kynon window. The "Parameter / User buttons" function
pops up a dialogue box in which you can give each button a title, active and
inactive colours. Clicking directly on a user-defined button will enable you to
disable one or several outputs that are classically defined, or will make a
system call to an external executable programme.

18 - 394 — "Kynon", motion programmer ————————————————

——————————————————————————————————

———————
19
100 11

"PERCIVAL"
PRINTED-CIRCUIT ENGRAVER

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GALAAD 3 —————————————————————————————

General features

The Percival module has been added to the Galaad suite for allowing the
owners of a CNC machine to transform Gerber and Excellon files, produced
by electronic CAD software, to drilling and engraving paths that isolate copper
tracks. This prototyping module is fully integrated into Galaad, sharing the
tool library and the CNC parameters. In addition, and still in the philosophy of
Galaad, it can directly call up the milling module without requiring heavy
manipulations of intermediate CAM files.

Percival is not an electronic router, and not even a manual printed-circuit

CAD system. Its capabilities are few compared to Galaad; it provides no
drawing functions, and consequently focuses simply on the preparatory works
on the isolation engraving and the drilling of a circuit that has already been
designed.

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Gerber files

The standard file format concerning electronic CAD is the GBR format (or
GRB, or many other possible extensions depending on the software that
produces them). This format was intended for Gerber Scientific Instruments
photo-plotters. Photoengraving circuits using light-printing techniques leads to
specific considerations that appear in the format. Light-printing is performed
by an optical head that focuses the light beam on the circuit after travelling
through a diaphragm, at the locations where the copper should be preserved.
The diaphragms generally have predefined size and shape, the simplest being a
basic circular disc. The pads may have more exotic shapes, but the tracks are
printed using simple circular diaphragms of given diameters along the
connecting path.

A Gerber file therefore contains aperture numbers that are either

predefined in the optical library of the photoplotter, or referenced in the file
itself. Light-printing instructions are very simple: the flash head can be
moved, with the diaphragm shut, to a given XY position (movement without
light-printing), or with the diaphragm opened (light-printed track), or even
be sent to a position and the diaphragm being opened then shut to light-print
a fixed point (pad). This makes a total of three positioning instructions, plus
the number of the aperture that is currently used. The Gerber RS274-X format
offers more geometrical data about the diaphragms used, the macros, the
polygonal surfaces, and sometimes the drills.

Excellon files

Another file format concerns the drilling process of pads in a printed

circuit, this format has been elaborated for Excellon Automation multi-drills.
Like Gerber files, Excellon files contain XY drilling coordinates and tool
numbers whose diameters correspond to the holes. These DRL (or EXL) files
unfortunately do not always contain the drilling diameters, so it is necessary to
fetch them in attached files that are not standard, or indicate them manually
once the file has been loaded. An Excellon file cannot represent a printed
circuit, not even its pads, but only the drills.

Furthermore, there are actually different Excellon formats, one using real
coordinates (XY numerical values are formatted and indicated in immediately

—————————————— "Percival", printed-circuit engraver — 19 - 397

GALAAD 3 —————————————————————————————

usable units), the other in coordinates with no trailing zeros on the right hand
side, which may generate position errors if the file does not contain header
information about the numeric framing format. To avoid this problem, Percival
lets you select both formats under two distinct entries, which allows you to
directly choose the correct numerical model. If your file looks wrong, load it
again using the other available Excellon format, and all being well things
should look better.

Tools

The very first thing you should do after installing the software is to define
the tools that will be used for drilling, engraving and cutting the circuits. The
tool library is shared with the Galaad drawing module. It is accessible in
Percival from "Parameters / Tool library" (see chapter "Toolpaths", section
"Tool parameters"). This allows you to define all available tools but, for
indicating which ones among the whole set will be used for machining the
circuits, you must then call up the function "Parameters / Selected tools".

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 ————————————————————————————— GALAAD 3

The tools are assigned to five types of tasks, the first of them being the
isolation engraving for the circuit pads and tracks. It is obvious that the
engraving depth must be at least equal to the copper layer so the tool reaches
the underlying epoxy. The software will calculate the toolpath by offsetting it
outside the circuit border, of a distance that corresponds to the appearing
radius, measured at the engraving depth. The margin allows you to add
something to the calculated offset. It can be negative for getting closer to the
circuit if necessary. The same tool, or another tool, can be assigned to
hatching areas that must be completely cleared of the useless copper. The
hatches will be spaced by the tool radius, for a recovery of 50%, plus the
eventual margin.

The cutout of the card will probably be done using a special cutter for
milling the epoxy, a material whose dust is very abrasive. It is necessary to
indicate the cutting depth, assumed to correspond to the card thickness. Setting
the thickness from the function "File / Dimensions" updates the value that is
set here.

The centering drills and bores the holes that allow you to put in fixing pins
when the card is reversed for engraving the opposite side. The depth of these
holes will be the card thickness, plus an eventual overdepth for driving the
pins into the bed.

Things get a bit more complicated with the drilling which offers two
possibilities: either you are using one single tool for all drills and this will
reduce your round trips to the machine for changing the tool, or you set up a
list of available drill bits so Percival will choose, for each series of holes, the
tool whose diameter is the closest by default, adding a small boring, or by
excess without boring (which in fact gives us three possibilities). The small
buttons let you eject a tool out of the list. Since the drill bits are generally
not made for feeding horizontally, and particularly in the epoxy, you can limit
the circular boring that finishes the hole only from a minimum diameter. As
for the cutting job, the drilling depth is assumed to correspond to the card
thickness, plus an eventual opening margin.

—————————————— "Percival", printed-circuit engraver — 19 - 399

GALAAD 3 —————————————————————————————

Automatic functions

When opening a Gerber file, Percival searches in the new circuit or the
new layer for the track nets that are connected to no pads at all. These nets can
represent a cutting contour, a ground plane, a text, a reference point, etc. If the
net found is completely closed and surrounds the whole circuit, pads and
tracks, then the software considers that it must be a trimming path for
cutting the card, since the cutouts do not have a specific definition in the
Gerber format. Percival then asks you to confirm that the red-displayed path
indeed defines a trimming path. If yes, the path will be transferred into the
layer #6, containing cutouts. The inner trims are not detectable automatically,
but you can filter them manually, as we will see later on.

If you have left enabled the function "Machining / Copper planes / Detect
when opening file", then the software is going to seek all track nets that are
connected to no pads, and neutralise them. Neutralise means that tracks appear
in brown and will be considered when calculating the isolation contours.
Percival will make no differences between a real copper-plane made of a
hatching of thin tracks, and a network that draws text or position crosshairs. It
just filters all sets of tracks that are connected together and that touch no pads.
The copper-planes are neutralised simply because the copper will be removed
only around the active circuit, saving the rest of the surface. If you leave a
copper-plane made of thin hatch tracks, then the calculation for the isolation
might be much longer, every track of the plane being fully isolated and then
submitted to a search for all possible collisions. Such a copper-plane defined
by a thin hatching can requires hours of calculation, even on a high-
performance computer. It is recommended to use G36/G37 polygonal
surfaces of the Gerber RS274-X format, whose isolation calculation takes
only a few milliseconds. For the texts and crosshairs, a function allows you to
engrave them at centreline instead of making isolation contours. The function
"Edition / Re-enable" undoes the neutralisation, and also the right mouse click
on a neutralised track followed by "Re-enable track net". You can neutralise
yourself parts of the circuit; several functions are available for that.

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 ————————————————————————————— GALAAD 3

Adjusting layers

It can happen that successive circuit layers do not match, depending on

how the Gerber files have been produced. It is even more common with a drill
file because Gerber and Excellon are independent. You may invert or rotate
the current layer with the functions "File / Flip" or "File / Rotate 90°" and their
shortcut icons. If the active layer is the layer #1, then all layers are
inverted or rotated at the same time. For other layers, including drills and
cutouts, only the active one will be concerned. This allows you to apply
overall or limited operations.

When two layers do not match one another, you

can plot a pad with "File / Reference pad / Define"
(or right mouse click on the pad and corresponding
command). Then jump to the other layer, call up "File
/ Reference pad / Adjust" and plot the pad or drill that
should match the reference pad but does not (or right
mouse click on that pad and corresponding com-
mand). The active layer will be automatically
relocated so both items match each other.

Isolation contours

Isolating active pads and tracks requires a preliminary offset calculation,

depending on the diameter of the engraving tool head, and managing the
collisions when the paths are close to one another. "Machining / Contours /
Calculate contours" (or the correspond-
ing shortcut icon) is Percival's main
function. From the geometrical data in
the file, it is going to create the isolation
paths. The distance from the toolpath to
the border of the pad or track depends on
the selected tool, its diameter, its profile
and eventually the engraving depth if the
profile is conical. You can add successive contours to improve the isolation,
around all networks or only around pads.

—————————————— "Percival", printed-circuit engraver — 19 - 401

GALAAD 3 —————————————————————————————

When the offset calculation is completed, Percival displays the circuit with
the toolpaths in thin yellow lines. You may magnify part of the screen using
the mouse wheel or with the zoom icons, the mouse
centre button allowing you to drag the zoomed view. It
is also possible to visualise the isolated circuit as it will
be left after the milling process, via the function
"Display / Final rendering" or the corresponding icon,
the zoom remaining active. This final rendering helps
you check visually that the isolation contours are valid,
especially some networks that might remain in contact because the tool was
too large and could not find its way between close items.

In some particular cases, it may happen that the

calculation of the isolation contour of a pad and track
network remains open. Most of the time, the contour
will actually be made up of two paths that complement
or overlap each other but could not be welded together.
Since an isolation is naturally supposed to be a closed
contour, the software displays in red the paths that
remained open, i.e. whose ends do not match, the purpose being to catch your
attention on these. You can nonetheless disable that function from "Display /
Open contours".

Some manual operations on isolation contours are available. The function

"Machining / Contours / Delete selected contours" allows you to click directly
on a calculated path to be completely removed. The function "Machining /
Contours / Add segments" lets you plot manually new isolation lines that the
calculation might have missed, for example between two neighbouring pads
that were too close to each other and that you wish to trim a bit. Plotting with
the mouse left button snaps automatically the ends of the open contours,
whereas plotting with the mouse right button
remains free. Reverse operation, you can remove
isolation segments by using "Machining / Contours /
Delete selected segments".

Many functions are available from the mouse right button, when a pad, a
track, a drill or a cut path is clicked.

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 ————————————————————————————— GALAAD 3

Limitations

Percival suffers from some limitations that you should keep in mind when
working with this module:
- The isolation of copper networks requires a contour calculation around every
active circuit item (pad, track, surface), then a search for possible collisions
with neighbouring contours, and lastly a re-assembly of the collided items,
removing residual segments. When calculating the overall contour of a copper-
plane made of thin hatch tracks, this process can be extremely long. Let us
insist on this: it is better that the copper-planes are defined by a simple contour
polygon with G36/G37 surface encoding in the Gerber RS274-X standard,
which any electronic CAD software is able to produce nowadays.
- Percival can read pads that have been defined by macros for non-classical
shapes, but it cannot read parametric macros. These macros use redefinable
coordinates that are given as variables $n passed as arguments, instead of
numerical constants. They are rarely used, but it can happen.
- The calculation with floating point real numbers does not have an infinite
accuracy, and the roundings that are used for speeding up the process can lead
to isolation paths that do not close up. The open paths are displayed in red to
catch your attention. Generally, the isolation is completed but the contour is
made of two or more open paths that overlap one another.
- Last of all, when the tool is too large at the engraving depth for being able to
pass between two pads or tracks, there are no mir acles and the isolation is not
made. Reduce the depth or use an engraving tool with a sharper head.

Hatching empty zones

Engraving contours is sufficient to isolate tracks and pads, but you may
want to remove the remaining copper from the card surface. This allows you
to make sure there are no copper chips that have been left, which would create
shortcuts. Furthermore, the printed circuit looks much cleaner when the copper
is totally removed. Since your machine is happy to work while you enjoy a
cup of tea and read your two hundred e-mails, there is nothing wrong with
increasing the number of paths to engrave. The result is always better, even for
a simple circuit prototype.

—————————————— "Percival", printed-circuit engraver — 19 - 403

GALAAD 3 —————————————————————————————

The hatching function can be called up only if the track and pad contours
have already been calculated. This is because hatches are not supposed to
touch the actual border of the active copper
islands but need a contoured path. The
hatching tool is the same as the contouring
tool.

The hatching density can be set in the

selected tool's parameters. It corresponds to
the distance between two consecutive
hatches. The default value is the tool radius
at the engraving depth (for a conical cutter),
which gives an overlapping ratio of 50%.
But you may obviously choose a custom distance according to your needs.
Percival can link hatches together to define a zigzag path whenever possible
without milling a shortcut through a contour. Hatch ends approach the
contours at about 10% of the hatching distance. This leaves a very small
margin to avoid eroding the active copper. Logically, the hatchwork is
performed before the contouring process, to obtain a better finishing of tracks
borders. You may also hatch only the zones where pads are aligned at regular
intervals. The software will detect these alignments.

The hatching is Cartesian, in horizontal or vertical direction. If the option

"optimal" has been selected, then the software calculates both directions and
keeps the one that will give the shortest cycle. So it is longer to calculate but
faster to execute on the machine.

Here again, the final view shows the engraved circuit. If hatchwork has
been defined, only the remaining copper of tracks and pads appears on the
screen, unless your tool diameter was too small compared to the calculated
distances. Please keep in mind that the tool library is common to both
Galaad and Percival, and must correspond to what you actually have in the
tool rack attached to your machine.

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Card cut-out contour

The layer #6 contains the paths for trimming the card. These paths can
have been detected when opening a circuit layer, or plotted manually, and a
tool-compensated path is calculated automatically. The possible operations in
this layer are very few: you can change the offset side (outside or inside),
remove the cutting path, or add support bridges. These functions are available
by pointing the path concerned and clicking on it using the right mouse
button.

The support bridges avoid trimming the card com-

pletely but leave some linking points with the raw
workpiece. You must locate them yourself, directly on the calculated offset
toolpath. Warning: they will be removed if the tool compensation must be re-
calculated (tool or side changed).

Milling

The display on the screen does not represent the ultimate goal, at least not
with Galaad. Now we must do the business, that is wake up the machine for
milling the copper and drill the epoxy.

The command "Machining / Mill" calls up a final dialogue box which

allows you to set the sequence of tasks to be completed, add depth and speed
data, and then send the resulting
work to the machining module,
or to the drawing modules if
you need to add something else.

The data relative to the

sequence, tools, depths and
speeds will be retrieved by Galaad or its machining module Lancelot, which
can also chain to an external driver if this is how you are working. Then you
just have to mill and close Percival.

—————————————— "Percival", printed-circuit engraver — 19 - 405

GALAAD 3 —————————————————————————————

Dispensing weld-paste

Two additional functions may help you weld surface-mounted components,

which require dispensing weld-paste on the pads concerned. The first possibil-
ity consists of milling a simple stencil sheet that will be the template for
dispensing the paste manually with a scraper blade. The function "Machining /
Cut stencil for SMC pads" lets you choose which series of pads on the circuit
will be concerned, with a few cutting parameters (tool,
depth, feedrate). The automatic chaining to the machining
module Lancelot is direct, and it will be very happy to cut
the stencil. Be careful with the choice of the tool, with the
material and its clamping on the machine bed. Milling a
thin plastic or metal sheet require some experience to avoid
tearings.

The other possibility requires an electric or electropneumatic pump for

ejecting the paste directly onto the
printed circuit. Instead of machining,
Lancelot will drive the dispensing
nozzle that is mounted on the Z axis,
and will control the attached pump
through an output that activates a motor
or an electrovalve during a settable duration. You may configure a typical dose
for the paste, proportional to the surface of the pads. But the dose thus
calculated for every series of pads will nonetheless remain under your full
control. The dispensing cycle will just bring the nozzle to the centre of the
pad, lower it down to the contact (depending on your workpiece origin set-up
for the Z axis),
then trigger the
output that drives
the pump for the
given duration, and lastly lift up the nozzle for reaching the next pad. Remem-
ber to avoid dispensing paste at the centre of a drilled pad.

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——————————————————————————————————

———————
20
10 100

"OWEIN"
GRAPHICAL TOOLPATH
BROWSER

——————————————————————————————————
GALAAD 3 —————————————————————————————

Small add-on utility, the Owein module is able to display 3D toolpaths that
are encoded in ISO G-code, Isel-NCP or MasterCam-NCI files. It accepts from
2 to 5 axes, be it fully understood that the 4th axis (A) and the 5th axis (B) are
classical rotary axes respectively parallel to the X axis and the Y axis,
according to the current standard, turning around the linear support axis and
thus defining the zero point. Obviously, XYZ axes are assumed to be linear
and Cartesian axes of a direct orthonormed system.

Owein allows you to directly modify coordinates in the file that is

displayed under ISO or NCP format at the left side of the screen. Just double-
click to edit a line of code. Changes are incorporated into the display, and you
may also save the modified file. Some side functions like general offset,
inversion, and scaling are available, and you may remove all lines of code
before or after the active one. This remains the kind of exercise that should be
reserved for experts who are used to direct programming on a numerical
controller display.

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———————
21
10 101

FIRST AID

——————————————————————————————————
GALAAD 3 —————————————————————————————

This chapter is about the questions and issues usually raised about Galaad's
different modules, with the corresponding answers or remarks.

Drawing

Galaad does not detect the licence key

- First of all, check that the dongle key is plugged into a USB port. If that key
was provided before 2017, then it requires installing a driver so Windows can
communicate with it. Installing Galaad from the CD also installs that driver
silently and you do not have to worry about it. But if you copy a Galaad
installation from one computer to another, the driver is not copied since it is
something linked to Windows, not to Galaad. In that case, you must install
yourself the driver from the software that is provided by the key manufacturer,
also available from the Galaad website. Just validate its successive pages as
they appear.

Impossible to save my parameters or my current drawing

- You must make sure that, in your Windows user's session, Galaad is allowed
to save files in its own installation directory on the hard disk (parameters
files). And also, for drawing files, in the directory where you choose to save
them. If you have installed Galaad somewhere in the tree "C:\Program Files\..."
or "C:\Programs\..." on the hard disk, then bad luck, these directories are write-
locked in a Windows basic user's session, and even worse with Windows 10
which can even lock the access to the administrator. Galaad is more a work-
shop software than an office software and therefore does not comply with
Microsoft's "best practices" for the installation target, so it can be copied easily
between workstations.

I have forgotten the password that protects the restrictions

- Don't panic. Use Windows Explorer and find the file PASSWORD.TXT in
the hard disk directory where Galaad is installed, double-click on it and your
password will appear in clear text in Windows NotePad editor.

A DXF file cannot be imported

- Galaad offers two filters for importing DXF files. The first one makes a
direct interpretation and the second one via an external converter. DXF format
is complex and varies within different AutoCad versions. In such conditions, it

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 ————————————————————————————— GALAAD 3

is difficult to guarantee the accuracy of the reading for older, present and
future versions. The best is to try generating the file from the software that
produced the drawing by using another version of the DXF compatibility. The
binary DXF format, rarely used, is not read by Galaad. Neither are the DXF
3D files that contain facets or surface functions.

A PostScript (EPS or AI) file cannot be imported

- The EPS format can contain three types of graphics: 2D vector coordinates,
bitmap images, and font glyphs. Galaad will not consider the last two. It can
read only vector graphics, namely made of coordinates in relation to segments
and curves. An image is made up of pixels with no geometrical meanings. In
most cases, an EPS file which cannot be imported into Galaad is in fact a file
that contains an image. When importing it into a drawing software that accepts
images and zooming on paths can confirm this by showing the pixels as big
squares.

A G-code ISO file displays unexpected large circles

- Due to a breach in the standard, there are two conventions for the circular
interpolations G2/G3 in ISO G-code, which tarnishes the very notions of
standard. One of these conventions, the most widely used, carried away by
GE-Fanuc and Siemens, considers that I and J coordinates of the centre are
always relative to the arc start point. The other convention, used by NUM,
considers that I and J coordinates are absolute by default, or relative if the
mode has been set to incremental coordinates. Both conventions are incom-
patible and it is very difficult to detect which one has been used by the
software that generated the file. So it is up to you to choose one and try the
other one if it does not give a good result.

Impossible to apply a drawing function onto an object

- Check that your object is indeed in the active layer and has not been
protected (protections are visible with "Display / Trace / Protections").

Impossible to obtain a tool compensation on a path

- It can happen that you have in your contour path some very small recoils of
the trajectory, which may in some cases interfere with the offset calculation.
Zoom in the path for checking that there are no little spines, sharp and useless
and, if yes, remove them.

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Manual control and automatic machining

Galaad does not detect my machine

- The small button "Detect" in the machine parameters, "Controller" page,
helps only for identifying an RS232 serial port, on which the machine has
been connected. This detection does not apply to other types of ports, espe-
cially USB ports which do not need to be identified. In addition, some
machines that communicate through a serial port do not always pass the
detection test. Keep in mind that the COM ports that Windows recognises are
given an asterisk beside their number, in the combo-list of available ports.
Generally, there are only one or two recognised ports that you can try for real.
With a few exceptions, the ports COM1 and COM2 are the physical serial ports
of the motherboard, and the ports COM3 up to COM256 correspond to
USB/Serial converters. So it should be easy to find out.

Galaad cannot drive my machine

- If your machine does not react at all when the software tries to open the
dialogue with it, then we can suppose that either the indicated port is not the
right one, or the communication is failing, or the selected machine is incorrect.
First, check the machine model or the numerical controller model that you
have configured in Galaad. If it looks good, then check that your cable is
indeed plugged in and the machine is powered on. Some RS232 cables have
an end for the PC and an end for the machine, and some machines do not
communicate anymore when their protection door is open. If it is a serial port
transmission, then check the baudrate.

The homing movement goes toward the opposite direction

- If your machine is an Isel with numerical controller IMC or IML, then you
can reverse the direction of the homing (see chapter "Machine parameters",
section "Isel-Automation IMC& IML controllers"). If your machine is fitted
with a CNC card with settable end-switches, either your axis is reversed (see
"Advanced" page of the machine parameters), or you have indicated a wrong
input number for the end-switch of the axis that goes towards the bad direc-
tion, or you have indicated a wrong polarity for the switch ("enabled" instead
of "disabled" or the contrary), so the software tries to offset slowly from the
switch, thinking that it is triggered. You should use the function "Parameters /
Machine / IO test" for checking the input numbers and polarities of your end-
switches.

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The homing movement does not stop

- If you are using a CNC card, then check that you have parametered the right
input number for the corresponding end-switch. Call up the function "Machin-
ing / Manual unblock" for approaching the switch while monitoring the inputs
that trigger after every movement. Otherwise, or if the checking does not say
more, just check the switch itself and its electrical wiring.

The manual jogging is reversed

- The XY position of the machine zero, indicated in the "Controller" page of
the machine parameters, does not correspond to the real position. If you have a
mobile table, do not forget that the movement to be considered is the appearent
movement of the tool on the table, and not the real movement of the table
itself. If the inversion concerns the X and Y axes, then swap the assignment of
the channels in the "Advanced" page of the machine parameters, or swap the
motor connectors. Warning: swapping the motors may require also swapping
the corresponding inputs for the end-switches.

The automatic machining runs above the workpiece

- Check that, when your have set the tool touching the workpiece top surface
and validated the green button "Z-ok", you have indeed selected "Location on
workpiece: upper surface" and not "lower surface" in the combo-list below the
green button. It is a very common mistake, fortunately with no danger. The
opposite situation (touching the machine bed whilst indicating that it is the
workpiece top surface) is more harmful. Take a quick look at the chapter
"Advanced milling functions", section "Defining the workpiece origin". This
cannot hurt you.

The machined result is out of scale

- Several parameters should be checked, and especially the ballscrew pitches
and the motor resolutions. Some machines built in series can have different
screw pitches depending on the year, and unfortunately Galaad cannot list all
possible combinations. Also check that the scaling factors, input and output,
are set to 1.

My machine drifts when milling

- First, try to redo the machining at very slow speed. If the offset persists, then
you might have a mechanical issue, for example the workpiece not properly
clamped, an axis with some backlash or a slippery motor-screw coupling (this
case happens more often that we think). If the offset appears only when the
feedrate is high, then you should reduce your kinematical settings. Please refer

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GALAAD 3 —————————————————————————————

to chapter "Machine parameters", section "Kinematics post-calculation", and

also the chapter "Menu functions", function "Parameters / Machine / Calibra-
tion". Keep in mind that the energy needed increases with the square of the
speed: machining twice as fast requires four times more power. Speed is
indeed a question of money.

The screen and the machine are not synchronous

- When the numerical controller is fitted with a local memory buffer, then
Galaad sends the vectors beforehand and the machine stores them in this
memory before executing them. This workmode produces very fluid motion
dynamics in curves, but it desynchronises the software and the machine. The
screen corresponds to the bursts of vectors sent. The software ignores the
actual position of the axes at that moment.

Printed circuits

The drills do not match the pads

- The drilling files and the circuit files use different formats that talk to
different machines. Percival searches for a minimum correlation between holes
and pads, but if your circuit contains a majority of undrilled pads or tracks that
are used as oblong pads, or macro-pads, it will not find that and you must
operate manually (see below).

The layers do not match

- If your files use different references or orientations, you must rotate or
reverse the added layer and then use the functions for choosing a reference pad
and adjusting on the reference.

The calculation of isolation contours is endless

- You have on your circuit a ground-plane made of thin hatches which require
a very big calculation time for each, and hours will be needed to complete the
result. Percival prefers the ground-planes that are defined by surface polygons.

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———————
22
101 10

TECHNICAL MATTERS

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GALAAD 3 —————————————————————————————

Command-line arguments

A relic from the ages of text consoles, it remains possible with Windows
application software to give a starting programme some specific arguments.
Obviously, no arguments are attached to the default icons associated with
Galaad modules. However, you may add some indications, provided that you
have a special workspace configuration, for example a computer for
CAD/CAM tasks and another one for machining sessions under the operator's
control. These arguments may be passed manually from the "Run" command
of the Windows "Start" menu, or permanently integrated into the properties of
a Galaad shortcut icon, be it an original or a simple copy. An argument is
indicated in the command line after the programme call, with an intermediate
space character. Several arguments may be passed one after another, and their
order has absolutely no impact. If an argument has to contain spaces, you must
put the whole expression between double quotes "… …"; also, all arguments
are read regardless of upper/lower case characters.

All Galaad modules accept specific arguments. Of course the first usable
argument is a file name to be opened as soon as the programme starts. The
automatic links between GAL files and the Galaad module, or between KYN
files and the Kynon module, are based on such arguments. For example,
double-clicking on a GAL file makes Windows run Galaad and give it as
argument the path and name of the file that has been double-clicked. If you do
it manually, just start Galaad with the following command line (this is an
example):
"C:\Galaad\Galaad.exe" "F:\Galaad Files\Drawing.gal"
This is going to start Galaad and ask it to load automatically the file "Draw-
ing.gal" located in directory "Galaad Files" of the disk unit "F". If a drawing
is already opened and not saved, Galaad will display it and will ask you if you
want to save it first.

In addition to the file to be loaded at start-up, the other arguments that are
accepted by the Galaad drawing module are as follows:
- MINIMIZE starts the software in the taskbar (nothing on the screen).
- MAXIMIZE starts the software in full-screen mode.
- RESET removes the current drawing and opens Galaad with an empty board.
This is useful only if the current drawing file has been damaged and blocks
Galaad's normal opening.

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 ————————————————————————————— GALAAD 3

- CUSTOM starts the software in the restricted mode that has been defined.
- CONFIG:xxx starts the software with the parameter set "xxx" that has been
previously saved by the command "Parameters / Save parameters".
- ORIGINX=123.45 directly sets the workpiece origin to the value indicated for
the X axis. The argument is available for each axis.
- AUTOMILL opens Galaad and immediately starts the machining module.
This one takes over, skips the normal stages and does not ask the user for
anything. Machining parameters are the default ones; the workpiece origin is
the last one validated; messages to the operator's attention are not displayed,
except the very last one before the actual launch of automatic process, which
the operator can only confirm or abort, and which allows them to check the
displayed toolpath that is going to begin (see below the AUTOSTART argu-
ment for Lancelot & Kay which is the logical continuation of this AUTOMILL
argument).
- AUTOTEXT instantly modifies the existing text of the current drawing,
whatever its style and mode, in a straight line or written along a curve. This
argument must be followed by two others that indicate which block of text
should be replaced and the text it should be replaced by. For example, if the
drawing contains "Old text" that must be replaced by "New text", the com-
mand line will be: …\Galaad.exe AutoText "Old text" "New text". Here it is
important to take care with the order of the arguments (text to be replaced
immediately after the AUTOTEXT argument, and the new text immediately
after the text to be replaced), and the upper/lower case of characters. If the text
that is found does not exactly match the text that is given as argument, it will
be ignored. You may put several successive "AutoText" arguments for
multiple replacements. Also, if there are several occurrences of the same text
in the drawing, the first found will be replaced, which is one less for conse-
quent replacements.
- AUTOQUIT closes Galaad as soon as other arguments have been applied.
This one is complementary to "AutoMill" or "AutoText".
- AUTOIMPORT> DIM:100x75 TOOL:3 DEPTH:0.5 FEEDRATE:20
MIRROR:X FILE:C:\GALAAD\IMPORTS\TEST.DXF immediately imports an
external file and resets its workpiece dimensions, tool, depth, feedrate, and X,
Y or Z inversions. The values for the tool, depth and feedrate will replace
those of all objects in the file. You may ignore some of the arguments, and the
spaces between them are optional. If you are using the spaces, then you must
set the whole string between quotation marks "…" so the argument "AutoIm-

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GALAAD 3 —————————————————————————————

port>…" is seen as a single block. Do not forget the colons between the labels
and the corresponding values.
- AUTOEXPORT> FORMAT:ISO FILE:C:\GALAAD\IMPORTS\TEST.ISO
immediately exports the current file (which can also be opened just before
using the GAL file argument or the "AutoImport>…" argument), under the
indicated format. See the default extensions for specifying the format.

The machining modules Lancelot and Kay also accept a direct file name,
from allowed import formats. The file extension determines the import filter. If
this extension is not standard, it becomes necessary to add its standard
extension between brackets as the argument immediately after the file name.
Example: …\Kay.exe …\Drawing.nc (iso) to open the file "Drawing.nc"
under the ISO import format. Other arguments that the Lancelot and Kay
modules recognise are as follows, and are also valid for the Kynon pro-
gramming module:
- AUTOSTART skips all intermediate stages without asking the operator
anything, exactly like the "AutoMill" argument of Galaad, above mentioned.
Machining parameters are the default ones; workpiece origin is the last one
used; messages to the operator's attention are not displayed, except the very
last one before the actual launch of the automatic process, which the operator
can only confirm or abort. The module closes as soon as the process end
message has been acknowledged by the operator, or if the process is aborted.
- AUTOSKIP allows you to avoid all intermediate messages for the operator
before starting the process. See also the above argument "AutoStart".
- AUTOUPLOAD starts the machining process exactly like the above men-
tioned "AutoStart" argument, except that the machining path is sent to the
local memory of the machine with no run command ("Upload machining to the
controller memory" mode of the machining options).
- AUTOSTORE does the same as the "AutoStart" argument, except that the
upload goes to the local disk drive of the numerical controller.
- AUTOTOOL makes an automatic measurement of the tool on its sensor as
soon as the initialisation dialogue with the machine is completed. Of course
the tool is supposed to be already mounted on the spindle.
- AUTOPARK1 sends the tool to its parking position as soon as the initialisa-
tion dialogue with the machine is completed. The variant "AutoPark2" sends
to the tool change position.

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 ————————————————————————————— GALAAD 3

- OPERATOR locks the access to the machining parameters. The operator can
only set the workpiece origin and start the automatic process.
- ORIGINX=123.45 sets directly the workpiece origin to the value indicated for
the X axis. The argument is available for each axis.
- MANUALM opens the Lancelot module on its manual jogging window for the
milling machine.
- MANUALT opens the Lancelot module on its manual jogging window for the
lathe.

Integration into an automated chain

Galaad does not need external software from creation of the drawing to the
automatic machining process. Except for the specific case of machines or
spindles that cannot be driven directly and consequently require a call to an
external driver, it is therefore not necessary to include Galaad or part of it in a
heterogeneous processing chain.

However, and once this has been made clear, it is still possible to find
room for Galaad in a wider set, in which case it will do its best to cooperate
with its workspace environment. Obviously, the commands that should be
passed to the software can only be carried through the command line, whose
arguments have been mentioned above. Considering that it is a programme
that starts Galaad at a given moment in an automatic process chain, the four
main things that can be expected from Galaad are as follows:
1 - load a given GAL file name;
2 - modify blocks of text in this file;
3 - start the machining process and skip the operator's dialogue stages;
4 - close itself once the process is completed.

As seen before, there exist some arguments that Galaad can understand
which may help you build that sequence, stages 3 and 4 being merged into one
single argument. Please refer to the arguments above described for more
details. It is obviously not possible to tell Galaad to create or modify pure
graphic items from the command line, which would be very difficult, requiring
too many parameters. It you wish to create a drawing automatically and start
its machining process with no operator interference, then the best way to do it

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GALAAD 3 —————————————————————————————

is to create a file in a standard format that Lancelot or Kay can read, and call
them up with the corres-ponding file name as an argument, followed by an
"AutoStart" argument that will launch the automatic milling process and will
even close the module once the cycle is complete.

If Galaad's machining task is performed by an external driver, it will be

opened automatically, provided that the corresponding arguments have been
passed to the software.

For a more complicated process that requires advanced input/output

controls, pause delays or others, the Kynon module should do the job since it
is also able to load and execute immediately any programme that has been
generated by external software, using the same "AutoStart" argument. The
format of Kynon programme files is text type, and the syntax is not very
complicated, looking very much like the instruction list on the screen. It is
important to use this syntax and particularly the spaces, because bad instruc-
tion lines will be purely ignored.

As a conclusion, anything that can be done by Galaad modules under the

control of an operator can also be done automatically using command line
arguments. These may be a bit difficult to handle by a user from the Windows
desktop, but much easier to integrate in a calling application that encapsulates
Galaad in a superset, including a batch process.

Message-transmitted commands

For programmers, there is another possibility of directly calling up some

machine driving functions, based on Windows inter-applications message
system and limited to Lancelot and Kynon. When these are in manual jogging
mode, they are listening to WM_COPYDATA messages that you can post
through the function SendMessage() of Windows API. The structure
COPYDATASTRUCT encapsulates the data to be transmitted to the module, its
address being given by the argument LPARAM of SendMessage(). In this
structure, the value dwData must be 26912021, the pointer lpData targets the
ANSI string of the command to be executed, and the value cbData gives the
size of the string, including the terminal zero.

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For recovering the handle on the Lancelot or Kynon window, you can use
the API FindWindow(), considering that the module ClassName is the pro-
gramme name with its full path, for example "C:\GALAAD\KYNON.EXE" (all
in upper case). You can also use the window title, but it is subject to varia-
tions. The commands to be transmitted are those you can find in the tool
change scripts. If the calling application has indicated the handle of its own
window in the argument WPARAM of SendMessage(), then Kynon will return
the result as another WM_COPYDATA message, acknowledging the command
once it is executed. The returned data structure is identical, the data buffer
lpData now containing the text "OK" or "ERROR".

The small programme COPYDATA.EXE which is installed along with

Galaad allows you to send commands to the module. The first argument is the
name of the target module, and the second argument (between quotation
marks) is the command to be executed. Example: COPYDATA KYNON
"MOVE TO X12.34 Y56.78 V600"

Interface with Windows

This section is for those users who have a solid understanding of the
control mechanisms within the Windows environment. The various technical
details described below can help when trying to resolve the possible problems
associated with either loading or using Galaad.

Remember that Galaad is a coherent collection of files, comprising

modules created with the Borland C++ 5.02 compiler, and intended exclu-
sively for use on the Win-
dows 32 bit platform in
graphic mode, that is Win-
dows 95, 98, ME, NT-4,
2000, 2003-Server, XP, 2008-
Server, Vista, Seven, 8, 10
and all the successors that
Microsoft will be happy to
endow us with in the future.
These 32-bit modules work
perfectly in the standard

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GALAAD 3 —————————————————————————————

encapsulations of the 64-bit systems (XP-64, Vista-64, Seven, 8 & 10). You
do not need to change or parameter anything. The only restriction is the write-
access in the directory where the software is installed, from the user's current
session.

As already mentioned in the chapter on installation, Galaad does not add

any files to your computer outside its installation directory, with the exception
of a couple of shortcuts placed on the desktop and in the "Start" menu. These
shortcuts, GALAAD.LNK, LANCELOT.LNK, etc., are placed in the usual
subdirectories of C:\WINDOWS or C:\WINNT and are of the classic type,
associated to the executables. Two new keys are added to the Registry, in
HKEY_CLASSES_ROOT\GALAAD and HKEY_LOCAL_MACHINE\GALAAD to
associate *.GAL files with Galaad. Nothing else is done to the registry. Should
you ever remove Galaad and delete its folder, then you can find and remove its
registry keys if you really want to, but Windows will not be bothered if you
forget.

The executable files of Galaad suite are compact and self contained,
created entirely using the Borland Object Windows Library, without the use of
exotic VBX, OCX controls or other adornments. Some DLLs that have been
developed by AxeMotion, Isel-Automation, Soprolec and others are added for
driving their numerical controllers. The core module of Galaad is the pro-
gramme GALAAD.EXE, which manages the drawing and working environ-
ment. For convenience, the machining and manual control module has been
created as a standalone executable programme, LANCELOT.EXE, which is
automatically called up by Galaad, who passes it all necessary arguments and
files. This enables the machining to be run as a background task while Galaad
returns to perform further drawing work, if the noise (which is not always in
the backgound) allows it. The other modules are independent and work
autonomously, except the drawing module for turning GAWAIN.EXE which
also uses the module LANCELOT.EXE for driving the lathe. Shared space.

Windows undertakes all of Galaad file management, including use on a

network, and therefore you can use long file names and any legal Windows
features available in this area. The file extensions of Galaad 3 are *.GAL, the
library objects are *.GLI and the templates are *.GLT. Double-clicking on a
GAL file causes Galaad to be started, and the file opened and displayed.

To prevent worries about portability, communication with the machine

uses the standard stream control functions of the Windows API, (CreateFile(),

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ReadFile(), WriteFile(), etc.), rather than special functions that access the ports
directly. This is to provide compatibility with the latest and future versions of
Windows. However, in the computer area, it may be wise not to predict too
much.

A little reminder: if your machine is fitted with a special spindle, that is

started or stopped with codes other than the default ones built in, Galaad can
substitute codes provided by yourself. It is also possible to use an external
DOS or Windows programme just for the spindle. Please refer to the chapter
"Machine parameters", section "Spindle".

TrueType and Galaad fonts

Galaad 3 uses standard TrueType fonts or compatible fonts having the

Windows flag, TRUETYPE_FONTTYPE. These vector fonts are constructed
from two types of geometrical objects, polylines and Q-Splines. The hatching
or clearing out of the interior is undertaken automatically by Galaad, which
detects the external contours and any islands. Specifying Italics uses the
corresponding TrueType font, however, if there is no italic version available,
you can always incline the characters yourself and specify the angle of
slanting. Alternatively, if the italic version exists, that angle will be added to
the current slanting.

You may find TrueType fonts that have no pen thickness, though
Windows cannot use fonts with simple lines (for example a capital 'I' drawn
from a single line, actually a rectangle with no width but nevertheless a to-and-
fro movement). In such case, Galaad is able to get rid of the overlaid vectors,
which saves time when milling, even if the vectors do not match absolutely.

The old fonts from Galaad 1 & 2 are still available to provide simple line
characters that do not exist as TrueType fonts, or equally fonts where the
hatching is already done. These fonts, approximately fifty of them, are
installed in the FONTS sub-folder. Three extensions are used: GLF for Galaad
Light Font (simple line fonts, very useful), GOF for Galaad Outline Font
(thick contoured fonts and possibly hatched) and GSF for Galaad Special Font
(special fonts such as Braille).

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Parameter files (and other files)

In addition to the executable modules, we can find many files in the

software installation directory. So that you can copy thoses that may be useful
to you, the simplest is to describe what they are used for, in alphabetical order
of their extensions. All these parameter files are text type and so are they
editable with Windows NotePad, but it is better to change their content only if
you know what you are doing…
- GALAAD.CNC (Computerised Numerical Control) contains all machine
parameters.
- GALAAD.CUS (CUStomised workspace) contains the restrictions that you
want to apply to the workspace.
- GALAAD.FLT (FLaTness data) contains the matrix of the Z-plane measures
for the machine bed.
- GALAAD.INI (INItialisation data) contains all workspace parameters (except
the restrictions). Warning, this file also contains the name of the current
drawing and its directory (but not the drawing itself). If you copy it to another
installation that works on another drawing, there will be a confusion. In
addition, the recent file names are stored here.
- GALAAD.IPC contains the plasma torch cutting database for the Soprolec
InterpCNC-2 controller.
- GALAAD.JDC contains the plasma torch cutting database for the JD-Cut
machines.
- GALAAD.LAS contains the cutting and engraving database for laser works.

- GALAAD.MAC (MAChining data) contains the machining parameters

overall: forced values, scales, iterations, 4-axis milling, etc.
- GALAAD.NET (NETwork data) contains the network parameters.

- GALAAD.OBS contains the definitions of roadblocks on the machine bed.

- GALAAD.OXY contains the oxycutter setting database.

- GALAAD.PLC (PLasma Carving) contains the database for simple engraving

using the plasma torch (with reduced current).
- GALAAD.PLS (PLaSma data) contains the plasma torch cutting database for
a basic controller without THC function.

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- GALAAD.PPF (Post-Processor File) contains the syntax and the parameters

for the post-processor.
- GALAAD.PRT (PRinTing) contains the printing settings.

- GALAAD.PTN (Plasma Torch Nozzles) contains the nozzle parameters for

the plasma torches. It does not contain their statistics of use.
- GALAAD.STA (STAtistics) contains the statistics of use for the tools and the
plasma nozzles, plus the main statistics for the machinings.
- GALAAD.THC contains the plasma torch cutting database for the Thunder-
Cut machines.
- GALAAD.TOO (TOOl library) contains the tool parameters.

- GALAAD.UDC (User-Defined Controller) contains the syntax and the

parameters of the customised generic numerical controller.
- GALAAD.XON contains for debugging the exchanges between the software
and the machine of the very last machining or manual control.
- GALAAD.XYZ contains the calibration data (tool sensor, laser pointer, torch
recoil sensor) and the absolute positions on the machine (current origin,
memorised origins, parking) and also the last settings used for the plasma
torch, the laser, the oxycutter or the hot wire.

The modules Gawain, Kay, Kynon, Owein, Percival use these same exten-
sions for the same types of parameters. If these files do not exist for them, it is
simply because they are shared with Galaad, for example the file
GALAAD.CNC which is used for all modules that access the machine parame-
ters. You cannot set up a machine in Galaad and another one in Kynon. In that
case, you must have two different installations which will coexist peacefully
on the same hard disk. You just have to identify clearly the shortcut icons on
Windows desktop.

The current drawing file is GALAAD.CUB (CUrrent Board) and it is a simple

GAL format, which is binary and not documented. If Galaad freezes at start-
up, then possibly that file has been damaged. Yet just delete it manually after
making a copy elsewhere. The file GALAAD.CMB (Current Machining Board)
is the one transmitted for machining and therefore exactly the same as long as
the drawing remains unchanged.

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Downloading updates

Galaad evolves regularly. If bug fixes have become rather rare over time,
some new functions are still being added here and there, at random and in
accordance with suggestions. These developments can be of interest for you,
especially since the update in the same version is free and easy when you have
a direct access to the Internet: call up the
function "Help / About" and click on the
button "Download update". If your Galaad
workstation is not connected but you can
still access the Internet from another
computer, then just grab the update file
GAL-ENG.ZIP (version in English) and
then copy it into the installation directory of the software and restart Galaad. It
will detect the presence of the file and will be in charge of the update.
Updating the software does not affect your parameters nor your current
drawing board.

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23
101 11

A FEW TIPS FOR BEGINNERS

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Reading many Internet forums dedicated to CNC machinery, it appears that

many persons of good will rightly hesitate before embarking on the purchase,
the modification, or even the build-up of a machine, fearing that the conse-
quences of a mistake become expensive because difficult to correct. This
chapter is a bit off-topic in the user's manual of a piece of software that
provides a large number of parameters for calibrating your machine, and will
do its best for compensating possible defects. The purpose of these lines is not
to settle the few items presented as definitive and condescending answers, but
rather make you ask yourself the right questions or, at least, ask yourself some
useful questions.

- Mechanical structure
Before getting excited about a type of machine, think about what you intend to
do with it. The requirements in rigidity are not the same depending on whether
you are going to mill expanded polystyrene or tempered steel. Strong rigidity
means heavy structure, and heavy structure means big inertia. If you want to
machine quickly, choose for preference a light machine with an aluminium
profile frame. If you want to machine metal with greedy passes, you will not
machine quickly and inertia is less important, as long as the assembly is solid.
Obviously, if you want to machine metal at high speed, then you will have to
put a price on it, to have both good rigidity and high driving power. It is
possible to consider machining a material harder than the machine body,
provided that every milling stage removes a small amount of material. But in
general, it is still better to have a more rigid structure than the workpiece to be
machined.

- Bending
The critical point in a machining effort is the tool that feeds in the workpiece.
The resistance of the material strains the elements of the structure in a chain,
which will eventually distort, causing a loss of precision. The first one
concerned is obviously the Z axis. In theory, the longer the stroke, the thicker
the parts can be machined, at least if you have a suitable tool. But the lower
your spindle goes, the further it moves away from its guiding rails that remain
at the top on the gantry, and the more your axis will tilt when the workpiece
resists the toolfeed. Choosing a long Z axis is a miscalculation if you do not
need it. However, you can compensate by using a very thick machine bed to
raise the workpiece so the machining point is brought closer to the gantry.

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- Guiding rails
As long as the machine body does not warp under the power of machining
forces, at least at reasonable feedrates, the quality of an axis can be considered
to depend essentially on its guiding rails. Nature being fundamentally hostile
to any kind of intelligence, a guided carriage will always take maximum
advantage of the small amount of clearance allowed for trying to get some
contorsion. If the rail supports only one skate, the longer the skate is, the less
freedom it has. If there are two skates, the further apart they are from each
other, the more limited the twisting force will be. It should also be noted that
poor parallelism between two guiding rails of the same axis can cause a rapid
wear of the skates. A fine ear, possibly armed with a stethoscope, a dyna-
mometer and foil sheets are the best friends of your rails.

- Transmissions
The only thing requested from a transmission is to have no backlash. There are
still mechanical designs whose guiding quality is partly based on the transmis-
sion, for example a double screw on a wide axis. This is equivalent to admit-
ting that the guiding rails are not optimal or that the body is bending. On a
perfectly rigid structure whose axes cannot twist, the positions of the transmis-
sion points do not matter. Instead, focus your efforts on the rigidity of the
structure and the quality of the rails. Also, if you use V-screws or toothed
belts, do not rely too much on the software for managing a reversed backlash
compensation. A classical manual milling machine can easily accept such a
backlash compensation on one axis, provided that the other axis is blocked by
a mechanical brake. Such blocking does not exist in numerical control. When
a transmission has some backlash, its axis will oscillate by the value of this
backlash when it is supposed to be stationary while other axes are moving,
depending on the forces involved in the machining. This erratic backlash
cannot be compensated. If an axis has some backlash, it is much better to fix it
by a mechanical action.

- Coupling
Aligning perfectly a motor on a screw is mission impossible. You must insert a
flexible system that will absorb the misalignment: either a mounting of the
motor to the chassis on silentblocks, or a cardan or homokinetic joint, or two
pulleys and a toothed belt. In the latter case, keep in mind that the larger the
diameter of the pulleys, the less the angular error caused by the elasticity of
the belt or its backlash on the pulleys results in a linear error on the screw. But
the more the inertia increases.

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- Accuracy
We can sometimes hear promises of 0.01 mm accuracy with a machine made
with a light aluminium structure. Let us not dream too much. At best, you are
actually told about the linear resolution of the motors, which has nothing to do
with mechanical accuracy. Unless you mill polystyrene (and again, given its
elasticity), you can only expect to reach a machining accuracy of 0.01 mm
with a heavy-duty machine, made of cast iron and reinforced on all diagonals,
whose feet are sealed in the concrete slab of the workshop, equipped with
high-end guides and transmissions. Be realistic about mechanical performance.

- Motor resolution
The accuracy of a machine depends solely on its mechanical design. The
movement fineness of the motors does not contribute to the accuracy. If your
transmission has too high a ratio, i.e. one motor revolution produces too long a
linear movement, for example with toothed belts, or racks and pinions, or
cables, then increasing the resolution of the motors is not the solution, since
the torque remains unchanged. On a stepper motor, the torque even tends to
decrease when increasing the microstepping mode. And the torque curve of a
stepper motor is drops sharply above a certain speed. It is therefore appropriate
to stay below this critical speed. A low transmission ratio requires a high
rotation speed, which may exceed the torque drop point. If you want a fast
machine, better use long screw pitches with powerful motors that do not rotate
too fast. Increasing the resolution is mostly used for reducing vibrations,
because the rotation in microstep mode is smoother. However, pushing the
resolution further is generally useless.

- Power electronics
The threshold for the torque drop on a stepper motor is related to the charging
time of its coils. As the rotation speed increases, the coils have less time for
getting charged. If this charge is too slow, then it will be incomplete and the
accumulated energy will be reduced, causing the torque to fall. For making a
coil charge quickly, a high voltage is required. The speed of a stepper motor is
therefore linked to the voltage of its power drive. But be careful then, handling
high voltages is dangerous. Think first about your safety. In the same vein, an
inadequate power supply will inevitably cause losses of steps or drag errors
from a certain speed when several motors need power simultaneously or in
resonance. As far as possible, it is preferable to have a power supply for each
axis, and largely oversized.

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- Control electronics
The performance of a CNC system is not measured in KHz on its output
signals, but in its ability to process the maximum number of vectors in a
minimum of time. In addition to an optimised command language, it is
important to have a high bandwidth so the transmission always runs faster than
the machine. When this is no longer the case, there comes a time when the
machining gets jerky, because the numerical controller has no more motion
vectors in its local memory buffer. A USB port does not always guarantee high
bandwidth; it depends on how it is managed, the exchange protocol and the
transmission mode. In addition, a large buffer size helps to absorb the fluctua-
tions of the gap between the transmission and the execution of the vectors. On
most machines, a small movement and a long movement require as much time
to be transmitted. But the long movement will take time to execute and the
transmission will then be able to take advantage of it for getting far ahead,
provided that the size of the buffer allows it. This will prevent a critical
situation when, on the other hand, a large number of small motion vectors
have to be transmitted, their transmission being slower than their execution on
the machine.

- Motion dynamics
Fast machining requires big technical ‒ and therefore financial ‒ resources.
Keep in mind that, if the energy required to move a given mass increases in
direct proportion to that mass, it also increases with the square of the velocity.
Therefore, driving an axis twice as heavy at the same speed with the same
acceleration certainly requires twice as much power, which must be taken into
account with long ballscrews or those having a large diameter. But, on the
same machine, moving twice as fast requires four times more power; moving
three times faster requires nine times more power, etc. It is easy to move an
isolated axis at a very high speed, as long as you apply accelerations and
braking ramps long enough. In automatic machining, the feedrate is supposed
to be more or less constant. It is therefore out of question to spend most of the
time in endless acceleration and braking phases that will cause the average
speed to drop and make the required cruising speed completely inaccessible
anyway. Festina lente.

- End-switches
If your machine works using absolute coordinates, with an invariable zero
point (sometimes called "machine origin" or "machine zero" as opposed to the
workpiece origin), it is necessary that it can be set with the best accuracy as
possible. A lack of reliability will affect all fixed positions reused by the

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GALAAD 3 —————————————————————————————

machine. Microswitches with tabs such as the Cherry DB1 or Saia-Burgess

XC are fine, provided that they are facing the mobile carriage rather than being
mounted laterally in its path. A reliability of the click point of about 0.01 mm
is then easily achieved with a microswitch of good quality. It goes without
saying that the switch must be protected by a mechanical stop that will prevent
it from being destroyed by crushing if the carriage does not brake fast enough
or if a configuration error prevents it from stopping when the contact is
triggered. If your switches have too short a stroke, simply bend the tab to
increase it and thus avoid knocking on the mechanical stop when the homing
movement is fast. With an almost infinite lifetime, inductive sensors also offer
excellent reliability, but their use does not always allow a braking distance
after the trigger. For the tool sensor, a simple vandal-resistant switch such as
the ITW 76-95 is sufficient for obtaining an excellent reliability.

- Spindle
It would be a pity to have a rigid machine, well-guided and fitted with solid
transmissions, for moving a low-quality spindle. And unfortunately, it is very
easy to find poor spindles whose bearings quickly become loose, in addition to
any weakness they may have already when leaving the factory. A bad spindle
will give bad results and will wear down your tools faster. Do not neglect it in
your budget. Choose spindles with high-quality bearings, such as ceramic, and
if possible including four bearings.

- Cooling
The faster the spindle turns, the more the tool heats up by friction. And the
more the tool heats up, the faster it will wear down. Tools are expensive: if
you mill at high speeds, or if you mill hard materials using deep stages, then
please feel sorry for them and think about fitting your machine with a coolant
device: watering or spraying, venturi chilling system, even a simple flow of
compressed air can be enough to lower the temperature significantly.

- Software
If you are reading this user's manual, then you probably already have a Galaad
licence. Excellent choice, nothing more to say.

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24
11000

GLOSSARY OF TERMS

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The aim of this glossary is to provide a guide to the meaning of certain

words used in this manual, which may not be apparent to an inexperienced
user.

2½D: motion generated by the simultaneous interpolation of any 2 axes with

the third one being stationary (engraving or cutting application).

3D: motion generated by the simultaneous interpolation of 3 axes. A toolpath

whose depth varies is presumed to be 3D.

Arc: circular or elliptical curve, opened or closed.

Axis: motor-actuator assembly enabling either linear or rotary movement of

the spindle or the workpiece.

Axis X: horizontal linear axis, X+ moves from west  east.

Axis Y: horizontal linear axis, Y+ moves from south  north.

Axis Z: vertical linear axis, Z+ moves from low  high.

Axis A: rotary axis parallel to the X axis.

Axis B: rotary axis parallel to the Y axis.

Axis C: rotary axis parallel to the Z axis.

Baudrate: units of speed for serial data communication (bit-per-second).

CAD/CAM: Computer Aided Design / Computer Aided Manufacturing.

Cartesian coordinate: position defined by its linear distance from the origin
along the X, Y and Z axes.

CCW: Counter-Clockwise.

Chip-breaking cycle: drilling operation where the bit drills down to a given
depth stage, then retracts slightly up for breaking the swarf spirals, before
descending and drilling a further step. The cycle is repeated until the required

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final depth is reached.

Chip-clearance cycle: drilling operation where the bit drills down to a given
depth stage, then retracts completely out of the hole for deburring the swarf,
before descending and drilling a further step. The cycle is repeated until the
required depth is reached

Circular interpolation: simultaneous movement of two axes, resulting in a

circular arc.

Clearance height: a safe vertical distance above the surface of the workpiece,
that the tool retracts to before making any rapid lateral moves.

CNC: Computerised Numerical Controller.

Contouring: a compensated toolpath, usually around the inside or outside of a

closed shape, such that the centre line of the tool is at an offset distance of half
the diameter from the trajectory of the shape.

Cut-out: machine an object at a depth equal to or greater than the thickness of

the material.

Cutter: see "Tool"

CW: Clockwise.

Digitise: operation where the points on the surface of an existing object can
automatically be obtained by using a suitable digitising probe.

Drill: operation where the cutter descends into the workpiece to make a hole.
(See also "Plunge").

Encoder: precision measuring device mounted on a servomotor to provide

feedback to the CNC as to the exact position of an axis.

Feed: motion whilst cutting material either horizontally or in 3D.

Feedrate: speed of motion whilst cutting material either horizontally or in 3D.

Finishing: a second machining pass following a roughing operation, to

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remove any residual stock and provide an accurate finish (see "Roughing").

Homing: special movement where the machine resets the position of the axes
to a fixed zero by sending each one, individually, to find the built-in reference
switches.

Inactive movement: any movement when the tool is retracted above the
workpiece, including the one for pulling up.

Initialisation: operation to establish communication with the CNC.

Island: material within a pocket that is to be left intact.

Linear interpolation: simultaneous movement of two or more axes, resulting

in a straight line.

Machine origin: see "Machine zero point ".

Machine zero point: absolute zero position (0,0,0) of the machine, determined
by in-built reference switches.

Manual control: the CNC is controlled directly by Galaad to determine the

position of the workpiece origin.

Override: real-time increase or decrease of the final speed (plunge or feed).

Pass: a single machining operation, (roughing, finishing or cutting out) of the

drawing.

Plunge: the phase where the cutter descends into the workpiece to the required
depth, before making any lateral moves. (See also "Drill").

Pocketing cycle: a series of moves, each at a fixed depth, to clear out material
from a defined area.

Polar coordinate: position defined by its radial distance from the origin and
the angle from the X axis.

Port: port on computer to which the communications cable to the CNC is

attached.

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Post-processor: programme or function that produces a dedicated machining

code for the CNC in the required format.

Profile of a tool: cross sectional view of a cutter (cylindrical, conical,

hemispherical etc.).

Rapid movement: non-cutting motion where the tool is clear of the workpiece,
made at the rapid speed of the machine.

Resolution: the smallest movement the machine can make.

Retraction: vertical movement when the tool is pulled up above the

workpiece.

Roughing: initial course cut to remove the bulk of the material rapidly, whilst
still leaving a small amount of stock material to be cleaned up with a finishing
pass. (See "Finishing").

Snap: a jump to the nearest position meeting the snapping criteria.

Spindle: device for holding and spinning the cutting tools, usually driven
either electrically or pneumatically.

Stage: an intermediate Z pass, repeated by levels until the final depth is

reached, due to the fact that the tool has a limited cutting height.

Stock: material remaining after a roughing pass, which will be removed by the
finishing pass.

Surfacing: operation for cleaning up the top surface of a piece of material so

that it is accurately parallel to the XY plane of the machine.

Tool: any cutter, including slot drill, end mill, router, engraving tool, etc.

Tool centre: vertical axis around which the tool rotates.

Tool cycle: complete machining operation for one tool.

Tool sensor: device for automatically measuring the length of a cutter

mounted in the spindle.

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Tool shank: parallel portion of the tool that does not cut and is held by the
collet in the spindle.

Visual: refers to an object used in the construction of the drawing, but not
machined.

Workpiece origin: reference point on the workpiece to which all positions and
moves are referred.

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