MAN - ISTR Maestro - EN

User manual
Rew. 2 of 28-09-2011
SUMMARY
1. DESCRIPTION OF THE SOFTWARE ..................................................................................................... 6

2. OPERATOR INTERFACE ........................................................................................................................ 7
3. PROJECT MANAGEMENT...................................................................................................................... 8
3.1. PROJECT DEFAULT.............................................................................................................................. 9
3.1.1. Default: "Project name”............................................................................................................ 9
3.1.2. Default “Project folder”............................................................................................................. 9
3.2. NEW PROJECT SETTING..................................................................................................................... 10
3.3. OPEN AN EXISTING PROJECT ............................................................................................................. 10
3.3.1. Open a sub-program ............................................................................................................. 10
3.4. END PROJECT ................................................................................................................................... 11
3.5. SAVE PROJECT................................................................................................................................. 12
3.5.1. Save the sub-program .......................................................................................................... 13
3.6. WORKPIECE ..................................................................................................................................... 15
3.6.1. Rough workpiece................................................................................................................... 15
3.6.2. Finalised workpiece ............................................................................................................... 15
3.6.2.1. Parallelepiped shaped workpiece .................................................................................................... 15
3.6.2.2. Extruded workpieces........................................................................................................................ 16
3.6.3. Import the workpiece ............................................................................................................. 17
3.6.4. workpiece Removal ............................................................................................................... 17
3.7. WORKING PLANES ............................................................................................................................ 18
3.7.1. Standard Faces ..................................................................................................................... 19
3.7.2. Parallel Plane......................................................................................................................... 20
3.7.3. Inclined Plane ........................................................................................................................ 21
3.7.4. Work plane tree ..................................................................................................................... 23
3.7.4.1. Work plane selection........................................................................................................................ 23
3.7.4.2. Properties and plane modification.................................................................................................... 24
3.7.4.3. Plane removal .................................................................................................................................. 24
3.7.4.4. Displaying working processes on planes ......................................................................................... 25
3.8. 2D GEOMETRY ................................................................................................................................. 26
3.8.1. Introduce new geometries ..................................................................................................... 26
3.8.1.1. Type a new point ............................................................................................................................. 27
3.8.1.2. Type an existing point by using the Osnap ...................................................................................... 28
3.8.1.3. Point................................................................................................................................................. 29
3.8.1.4. Line .................................................................................................................................................. 30
3.8.1.5. Arc ................................................................................................................................................... 31
3.8.1.6. Circle................................................................................................................................................ 33
3.8.1.7. Polyline ............................................................................................................................................ 35
3.8.1.8. Rectangle......................................................................................................................................... 36
3.8.1.9. Buttonhole........................................................................................................................................ 37
3.8.1.10. Loop line .......................................................................................................................................... 38
3.8.1.11. Smooth ............................................................................................................................................ 39
3.8.1.12. Offset ............................................................................................................................................... 40
3.8.1.13. Text.................................................................................................................................................. 41
3.8.2. 2D geometry imported from DXF........................................................................................... 42
3.8.3. Geometry selection................................................................................................................ 45
3.8.4. Contextual Menu of graphic area ......................................................................................... 46
3.8.5. Geometry removal ................................................................................................................. 47
3.8.6. Geometry Properties ............................................................................................................. 47
3.8.7. Modifying existing geometries ............................................................................................... 48
3.8.7.1. Cut ................................................................................................................................................... 48
3.8.7.2. Invert................................................................................................................................................ 48
3.8.7.3. Initial point........................................................................................................................................ 49
3.8.7.4. Join .................................................................................................................................................. 49
3.8.7.5. Explode............................................................................................................................................ 49
3.8.8. Move and/or copy the existing geometries............................................................................ 50
3.8.8.1. Move ................................................................................................................................................ 51
3.8.8.2. Rotate .............................................................................................................................................. 52
3.8.8.3. Mirror ............................................................................................................................................... 53
3.8.8.4. Oppose ............................................................................................................................................ 54
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3.8.8.5. Cut ................................................................................................................................................... 55
3.8.8.6. Copy ................................................................................................................................................ 55
3.8.8.7. Paste................................................................................................................................................ 55
3.9. WORKING PROCESSES ...................................................................................................................... 56
3.9.1. Boring .................................................................................................................................... 57
3.9.1.1. Bore position.................................................................................................................................... 57
3.9.1.2. Bore Structure.................................................................................................................................. 58
3.9.1.3. Boring modes................................................................................................................................... 58
3.9.1.4. Boring technology ............................................................................................................................ 59
3.9.2. Milling..................................................................................................................................... 60
3.9.2.1. Miling position .................................................................................................................................. 60
3.9.2.2. Milling form ...................................................................................................................................... 63
3.9.2.3. Milling modes ................................................................................................................................... 64
3.9.2.4. Milling technology ............................................................................................................................ 65
3.9.3. Channel ................................................................................................................................. 66
3.9.3.1. Channel position .............................................................................................................................. 66
3.9.3.2. Channel structure ............................................................................................................................ 67
3.9.3.3. Channel execution mode ................................................................................................................. 67
3.9.3.4. Channel technology ......................................................................................................................... 67
3.9.4. Blade cut................................................................................................................................ 68
3.9.4.1. Cut position...................................................................................................................................... 68
3.9.4.2. Cut structure .................................................................................................................................... 69
3.9.4.3. Cut modes ....................................................................................................................................... 69
3.9.4.4. Cut technology................................................................................................................................. 69
3.9.5. Contouring ............................................................................................................................. 70
3.9.5.1. Contouring position .......................................................................................................................... 70
3.9.5.2. Contouring structure ........................................................................................................................ 71
3.9.5.3. Contouring modes ........................................................................................................................... 71
3.9.5.4. Contouring technology ..................................................................................................................... 71
3.9.6. Emptying................................................................................................................................ 72
3.9.6.1. Emptying position ............................................................................................................................ 72
3.9.6.2. Emptying structure ........................................................................................................................... 72
3.9.6.3. Emptying mode................................................................................................................................ 73
3.9.6.4. Emptying technology........................................................................................................................ 73
3.9.7. Working process tree............................................................................................................. 74
3.9.7.1. Object selection ............................................................................................................................... 74
3.9.7.2. Working process ordering ................................................................................................................ 74
3.9.7.3. Working process display .................................................................................................................. 75
3.9.7.4. Contextual menu.............................................................................................................................. 76
3.9.8. Working process selection..................................................................................................... 77
3.9.9. Contextual menu for working processes ............................................................................... 77
3.9.10. Working process removal ...................................................................................................... 77
3.9.11. Working process properties................................................................................................... 77
3.9.12. Working process modification................................................................................................ 78
3.9.13. Move and/or copy existing working processes...................................................................... 78
3.9.13.1. Select the technology....................................................................................................................... 78
3.9.13.2. Apply technology ............................................................................................................................. 78
3.10. WORKING STEPS .............................................................................................................................. 79
3.10.1. Working step tree .................................................................................................................. 79
3.10.2. Inserting a working step......................................................................................................... 80
3.10.3. Removal of a working step .................................................................................................... 80
3.10.4. Working step properties......................................................................................................... 81
3.10.5. Modifying the workpiece position in one step........................................................................ 81
3.10.6. Moving working processes from one step to another one..................................................... 82
3.10.7. Add workpiece name to working process name.................................................................... 83
3.11. PARAMETERS ................................................................................................................................... 84
3.12. SUB-PROGRAMS ............................................................................................................................... 85
3.13. PROJECT MANAGEMENT FROM "SCRIPT" ............................................................................................ 86
3.14. PROJECT GRAPHIC DISPLAY .............................................................................................................. 87
3.14.1. What you see of the project................................................................................................... 87
3.14.2. Where to see the project ....................................................................................................... 88
3.14.2.1. Zoom................................................................................................................................................ 89
3.14.2.2. Pan .................................................................................................................................................. 89
3.14.2.3. Orbit ................................................................................................................................................. 89
3.14.3. How to see the project........................................................................................................... 90
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3.15. MACHINE WORKPIECE DISPOSAL ........................................................................................................ 92
3.16. PROJECT OPTIMIZATION .................................................................................................................... 93
3.16.1. Guided Optimization .............................................................................................................. 94
3.16.2. Automatic optimization .......................................................................................................... 96
4. NESTING PROJECT MANAGEMENT................................................................................................... 97
4.1. DEFAULTS FOR “NESTING PROJECTS”................................................................................................ 98
4.1.1. Default Folder for “Nesting Projects” ..................................................................................... 98
4.1.2. Default Nesting Parameters .................................................................................................. 99
4.2. CREATING A NEW NESTING PROJECT ............................................................................................... 100
4.2.1. Nesting Parameters............................................................................................................. 100
4.2.1.1. Type of Nesting.............................................................................................................................. 101
Rectangular Nesting..................................................................................................................................... 101
Free Form Nesting ....................................................................................................................................... 101
4.2.1.2. Part sequencing............................................................................................................................. 101
Insertion in sequence by Area...................................................................................................................... 101
Insertion in sequence by Perimeter.............................................................................................................. 101
4.2.1.3. Minimum distance between two nested parts ................................................................................ 102
4.2.1.4. Cutting tool..................................................................................................................................... 102
4.2.1.5. Correction of cutting depth............................................................................................................. 102
4.2.1.6. Spoil board thickness..................................................................................................................... 102
4.2.1.7. Enable cutting outside the sheet.................................................................................................... 102
4.2.2. Nesting Sheets .................................................................................................................... 103
4.2.2.1. Adding a sheet to the list................................................................................................................ 104
4.2.2.2. Deleting a sheet from the list ......................................................................................................... 104
4.2.2.3. Copying sheet data ........................................................................................................................ 104
4.2.2.4. Pasting sheet data ......................................................................................................................... 104
4.2.2.5. Editing sheet data .......................................................................................................................... 104
4.2.2.6. Meanings of sheet data.................................................................................................................. 105
4.2.3. Nesting Parts ....................................................................................................................... 106
4.2.3.1. Adding a workpiece to the list ........................................................................................................ 107
4.2.3.2. Deleting a workpiece from the list .................................................................................................. 107
4.2.3.3. Copying workpiece data................................................................................................................. 107
4.2.3.4. Pasting workpiece data.................................................................................................................. 107
4.2.3.5. Editing workpiece data................................................................................................................... 108
4.2.3.6. Meanings of workpiece data .......................................................................................................... 108
4.3. OPENING AN EXISTING NESTING PROJECT ....................................................................................... 109
4.4. CLOSING A NESTING PROJECT ........................................................................................................ 109
4.5. SAVING A NESTING PROJECT .......................................................................................................... 109
4.6. NESTING PROCESSING.................................................................................................................... 110
4.6.1. Conditions to be complied with in Nesting........................................................................... 110
4.6.2. Recurring strategies in Nesting ........................................................................................... 111
4.6.2.1. Positioning small workpieces at the center .................................................................................... 111
4.6.2.2. Contouring outside the sheet ......................................................................................................... 112
4.7. OPTIMIZING NESTING MACHINING..................................................................................................... 112
5. TOOL DATA-BASE.............................................................................................................................. 113
5.1. DEFAULT FOR TOOL DATA-BASE ...................................................................................................... 114
5.1.1. Default "Name Tool Data-Base " ......................................................................................... 114
5.1.2. Default "Folder for tool Data-Base" ..................................................................................... 114
5.1.3. Default "Folder for Import/Export toll Data-Base"................................................................ 114
5.2. TOOL DATA -BASE CREATION .......................................................................................................... 115
5.3. TOOL DATA-BASE OPENING.............................................................................................................. 115
5.4. CLOSING TOOL DATA-BASE .............................................................................................................. 116
5.5. SAVING TOOL DATA-BASE ................................................................................................................ 117
5.6. TOOL DATA-BASE IMPORT FROM XILOG ............................................................................................ 118
5.7. TOOL DATA-BASE EXPORT TO XILOG ................................................................................................ 119
5.8. ACTIVATE TOOL DATA-BASE ........................................................................................................... 120
5.9. TOOLS ........................................................................................................................................... 121
5.9.1. Tool introduction .................................................................................................................. 121
5.9.1.1. Points............................................................................................................................................. 122
5.9.1.2. Milling cutters ................................................................................................................................. 123
5.9.1.3. Blades............................................................................................................................................ 124
5.9.1.4. Probes ........................................................................................................................................... 125
5.9.1.5. Heads ............................................................................................................................................ 126
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5.9.2. Modifying tolls ...................................................................................................................... 127
5.9.3. Tool removal ........................................................................................................................ 127
6. MACHINE CONFIGURATION.............................................................................................................. 128
7. POST-PROCESSOR ............................................................................................................................ 129
7.1. XILOG INSTALLATION ....................................................................................................................... 129
7.2. POST-PROCESSOR OPTIONS........................................................................................................... 130
7.3. PROJECT TRANSLATION FOR XILOG ................................................................................................. 131
8. APPENDIX............................................................................................................................................ 132
8.1. SIZES USED BY MAESTRO ............................................................................................................... 132
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1. Description of the software
The software described in this manual allows the definition of workpieces and the related
machining operations so that they can be machined on numeric control machining centers.
The setting of all workpieces occurs in a three-dimensional CAD environment very useful
for the user in order to check immediately his schedule.
Working processes are divided in two different steps: firstly, by setting the geometries,
secondly by applying machine tools like in a CAM system.
After setting workpiece and working processes, all of the information will be passed to the
machine, which will carry out the machining.
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2. Operator interface
Maestro interface is structured as follows:
There are six areas:

Menu
Trees
Parameters
Graphics
Current command
Status bar
Following chapters describe all commands included in the menus.
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3. Project management
A "project" is defined as an object that may include the definition of one or more
workpieces with 2D geometries and related working processes.
The "Project" file - with a .pgmx size- must contain at least one workpiece and it might
include - but not necessarily- also working processes.
It is a compressed file including:
tool.tlgx Data Base Tools
progetto.xml Instructions to set the geometry.
progetto.epl Clamp/suction pad definition
A project can be:

Created
Started
Ended
Saved
By using these icons in the Menu area:
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3.1. Project default
You may change project defaults by clicking on the icon "Options" in the folder "Tools".
3.1.1. Default: "Project name”

If you wish to modify the default name of a new project:
Click on the icon "Options"
Fill the field "Project name" .
3.1.2. Default “Project folder”

If you wish to change the name of the folder where projects are started/saved:
Click on the icon "Options"
Fill the field "Project folder".
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3.2. New project setting
If you wish to set up a new project,.click on the icon "Create project"
The name of such new project will be definedas described in paragraph

3.1.1 Default “Project name”
Since a project must include at least one workpiece, whenever you create a new Project,
you activate the option
“Create Workpiece”.
If a project was already been started, following option would automatically start.
“Closing project”
3.3. Open an existing project

If you wish to open an existing project, click on the icon "Open".
The resulting window shows you the list where you may select a pgmx file.
The default folder will be defined as described in paragraph
3.1.2. Default ”Project folder”
Please select a pgmx file and click on "Open".
Or click twice on the pgmx file.
For a project that has already been started, following option would be automatically
performed:
3.3.1. Open a sub-program

If you wish to open an existing sub-program, click on the icon "Open".
The resulting window shows you the list where you may select a pgmx file.
Select "File type" "Sub-program (*xsp)".
Select the folder "Macros".
Select a xsp file and then click on "Open".
Or click twice on the xsp file.
For a project that has already been started, following option would be automatically
performed:
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3.4. End project
If you wish to end a project click on the icon "Close".
If your project is saved, following question will appear:
If your project has not yet been saved, following question will be displayed:
If you click on "Yes”, following option will be automatically performed in order to save your
project: "Automatic Saving"
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3.5. Save Project
If you wish to save an open project, click on the icon "Save"

If the project was already named, no question would be asked.
If the project was already created, the option "Save with name" would be performed.
You can specify the project name in the box "File name".
then click on "Save".
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3.5.1. Save the sub-program
After the project setting, you can save the 2D geometries and the working processes as
sub-program in order to reuse them for further projects.
Subprograms can be performed only for projects with one workpiece.
In order to save a sub-program, use the command

"Save as sub-program" in the menu "Home" "Save".
The resulting window will allow you to save the .xsp subprogram.
The default folder for saving programs is the Maestro set up sub-folder "Macros".
You can also save sub-programs in another folder but if you wish to use them, you must
save them also in the default folder.
After naming the sub-program and clicking on "Save", following window will be showed:
Fields included in "View Properties" serve as indicators for the menu where the sub-
program will be saved.
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If you click on "Forward", on the resulting window - almost like the previous one- you will
be asked to list the names of the bitmap to link with the subprogram. (Optional)
If you click on "Forward", the resulting window will allow you to establish those variables to
be exported.
If you click on "end", the saving process will end.
You can check the saving process :

- in the menu "Operations" (written in the field "Tab Name")
- since the sub-menu "Forme" has been created (written in the field "Group Name").
- and it contains the sub-program "esagono" (field " Macro Name”)
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3.6. Workpiece
Workpieces must be defined as "Finalised workpiece" and optionally also as "Rough

workpiece ". You may insert more workpieces in one project.
3.6.1. Rough workpiece

Option available only in "script " mode (see paragraph 3.11)
3.6.2. Finalised workpiece

The finalised workpiece can have several geometric shapes:
3.6.2.1. Parallelepiped shaped workpiece
If you wish to set a parallelepiped shaped workpiece click on the menu "Create
workpiece".
Introduce the values in the menu on the right.
Name of the
workpiece
Dimensions
Position
You can change your field values after creating the workpiece.
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3.6.2.2. Extruded workpieces
If you wish to set an extruded workpiece - no matter its shape - click on the menu "Crea
workpiece"
Then click on "Extrusion".
Design commands will be activated and the workpiece menu will be showed as follows:
Name of the
workpiece
Select geometry
Height of
extruded
workpiece
Using the menu commands "Draw" (see paragraph 3.8) a closed outline is set up, then
click on the icon "Select geometry" and on the outline.
If you click on "Apply", our "Extruded workpiece" will be created and outlined by a
parallelepiped as a bulk.
You can change your field values after creating the workpiece.
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3.6.3. Import the workpiece
You may also import a workpiece to another project.
To this purpose you can use the command "Import workpiece” of the menu "Home"
"Importa".
The resulting window shows you the list of projects where you can select the workpiece to
be imported.
After clicking on the icon "Open", the list of workpieces in the selected project will be
showed:
You can select one or more workpieces to import and click on the icon "Open".
In the tree of our project the selected workpieces will be added.
3.6.4. workpiece Removal

The workpiece can be removed from the working processes.
(see paragraph3.9.7 )
In order to remove a workpiece:

- select the workpiece to remove from the tree of the working processes.
- click on the command "Remove” in the tree commands or in the context menu of
the workpiece
the workpiece removal implies also that all related workings processes are removed as
well.
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3.7. Working planes
The "working plane" is a plane with Cartesian axis where you can add shapes of plane
geometry like line, arc, circle and so on (see paragraph 3.8)
Working planes can be created in three ways:

- automatically during the creation of a new workpiece (Standard Faces)
- by creating a plane in parallel with an existing plane (Parallel Plane)
- by setting the rotations around axis Z and around axis X (Inclined Plane)
In case of Parallel and Inclined Planes you can also modify - after the creation - any value
in the window - the name of the plane as well.
With regard to all standard faces, all fields remain unvaried.
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3.7.1. Standard Faces
A workpiece has six faces in which six working planes called "Standard Faces" have been
created when a new workpiece is created.
Names and positions of the "Standard Faces" are as follows:
Upper Face Lower Face
Left Face Right face
Front Face Back Face
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3.7.2. Parallel Plane
A parallel plane is a new plane in parallel with an existing plane in the project.
There are two possibilities in order to create a parallel plane:
by using the tree of planes
By clicking - with the right button of the mouse - on the selected face, the resulting menu
allows you to create a "New parallel plane"
by using the menu “Draw” “Inclined Plane” “Parallel Plane”
In both cases a window will be displayed:
By setting following options "Distance from the plane” and "Apply" (apply), a new parallel
Plane will be created.
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3.7.3. Inclined Plane
An inclined plane is a general plane created by the user with origin and inclination.
Two possibilities apply for every plane:
by using the plane tree
By clicking - with the right button of the mouse - on "Workpiece", the heading "New plane”
will appear.
by using the menu "Draw" "Inclined Planes" "Generic"
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In both cases a window will be displayed:
The definition of Inclined Plane starts with the threesome related to the workpiece placed
at the lower corner on the left.
By setting X values as origin, Y origin and Z origin, the origin of the new plane is
established.
By setting the rotating angles of Z-axis and X-axis, you also set the plane direction.
You must also take into account that both rotation angles are sequential, that is to say:
only after the rotation around the Z-axis, the rotation around the new X-axis position will
be performed.
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3.7.4. Work plane tree
The work plane tree collects all planes set for a certain project.
Properties
Display
Switch off
Remove
This tree - a workpiece from displaying existing planes- allows you to:
- activate an existing plane
- display and change the properties of existing planes
- remove a plane
- create parallel planes (see paragraph 3.7.2)
- create an inclined plane (see paragraph 3.7.3)
Buttons with light bulbs (on or off) allow you to display or switch off the working processes
(see paragraph 3.9.7.3)
3.7.4.1. Work plane selection
The work plane selection will identify the active plane, that is to say, the plane where the
two-dimensional geometry will be drawn.
In order to reactivate an existing plane, click - with the left button of your mouse- on the
name of the plane in the tree.
If you wish to know the active plane, check the plane highlighted in light blue.
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3.7.4.2. Properties and plane modification
In order to see or modify the properties of a plane you can activate a plane then click on
the button "Properties” or click with the right button on the name of that plane and on the
heading "Properties" of the plane menu.
On the right side of your screen the menu will show you all current properties of the plane.
If you wish to modify the plane, click on "Apply" in order to change its values.
3.7.4.3. Plane removal
If you wish to remove a plane click with the right button on the plane name, then click on
"Remove" of the plane menu.
You can delete only the Parallel Planes or Inclined Planes.

You are not allowed to delete the Standard Faces.
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3.7.4.4. Displaying working processes on planes
You are free to decide to display -or not- the working processes on the plane tree.
To the left side of every work plane there is the icon which stands for the face type. To the
left of the icon there is the symbol which represents an "eye".
By clicking with the left button on the eye, you change its status from open to closed.
If the eye is open, it means that all plane working processes will be displayed.
If the eye is closed, it means that all working processes will not be displayed.
In this example, you see a project in which the “Upper Face”

is active but all working processes on the same "Upper
Face" have been switched off.
If you wish to switch all working processes off you can:

1) close all eyes to the left of the planes.
2) close the eye to the left of the workpiece
3) or click on the light bulb that is off.
If you wish to display all working processes you can:

1) open all eyes to the left of the planes
2) open the eye to the left of the workpiece
3) or click on the light bulb that is on.
The selection on the tree has an immediate impact on the graphic area.
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3.8. 2D Geometry
The 2D geometry is used in order to set the profile of an extruded workpiece as well as to
set a profile (open or closed) of a working process
Before introducing any two-dimensional geometric element, you must set and activate a
working plane.
3.8.1. Introduce new geometries
The icons about the commands to insert the basic geometries are diplayed in the menu
"Draw" "Geometries"
All commands to create 2D geometry can be interrupted if you select a new command or
click on "Esc key".
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3.8.1.1. Type a new point
Every command aimed at introducing a new geometric shape has to identify one or more
points by the operator.
Firstly, it is important to explain the meaning of "type a new point".
"Type a new point" means that the operator creates a new point or sets an existing one
within the project.
The point can be created with Cartesian Coordinates (X, Y) or with Polar Coordinates
(Lenght, Angle).
If you wish to type a new point with Cartesian Coordinates (X; Y) you can:
- move the mouse (X and Y coordinates are upgraded).
- click with the left button of the mouse or press Enter key.
Or:
- type the value of the X coordinate
- move your mouse (Y coordinate is upgraded)
- press Enter key.
Or:
- type the value of the Y coordinate
- move the mouse (X coordinate is upgraded)
- press Enter key.
Or:
- type the value of the X coordinate
- type the value of the Y coordinate
- press Enter key.
In order to type a new point with Polar Coordinates (Length, Angle) you can:
- move the mouse (values corresponding to Length and Angle are upgraded)
Or:
- type the Length value
- move the mouse (the Angle value is upgraded)
- press Enter key.
Or:
- type the Angle value
- move the mouse (the Length value is upgraded)
- press Enter key.
Or:
- type the Length value
- type the Angle value
- press Enter key.
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3.8.1.2. Type an existing point by using the Osnap
In order to type a point, it is often desirable to use the points of the shapes that are already
on our plane.
To this purpose, the Osnap (Object Snap) in the following menu are a useful support.
For an existing point:

- click on one command Osnap
- move the mouse (a red cross appears on the geometry)
FinalÆ It is linked to the final point of any graphic shape.

In a polyline it is linked to the final point of every entity that is contained in its
structure.
IntersectionÆ It is linked to the intersection of two entities.
MiddleÆ It is linked to the middle point of any entity (also a circle)
CentreÆ It is linked to the centre of arcs and circles.
QuadrantÆ It is linked to the X and Y points of maximum and minimum in the circles.
Perpendicular Æ It is linked to the point perpendicularly projected to a segment.
Tangent Æ It is linked to the tangent point of an arc or a circle.
ParallelÆ It is linked to the point projected on the parallel to a segment.
Point Æ It is linked to an entity "Point”.
Horizontal Æ It keeps the Y coordinate of the previous point.
Vertical Æ It keeps the X coordinate of the previous point.
Near Æ It is linked to the point nearer to the point of the mouse.
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3.8.1.3. Point
It introduces a geometric element: "Point”
In order to introduce a point:

- click on the command "Point"
- type a point
In the graphic area the point is represented with this symbol:
Point properties
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3.8.1.4. Line
It inserts a line
A line can be inserted in two ways:
1) Line for 2 points
2) Length and angle line
In order to introduce a line for 2 points:

- click on the command "Line”
- type the initial point of that line
- type the final point of that line
In order to introduce a Line with a certain length and a certain angle.

- clcik on the command "Line length and angle”
- type the initial point of that line
- type the final point of the line (with Polar Coordinates)
Line properties
30
3.8.1.5. Arc
It inserts an arc.
An arc can be inserted in 5 ways:
1) Arc for 3 points
2) Arc Centre and 2 Points

3) Arc given radius
3) Arc given centre
4) Continous tangent arc
In order to insert an Arc for 3 points:

- click on the command "Arc"
- type the initial point of the arc
- type the intermediate point of the arc
- type the final point of the arc
In order to insert an Arc whose centre radius initial and final angle are known:
- click on the command "Arc Centre and 2 Points"
- type the point of the arc centre
- insert the radius value and press Enter key
- insert the value of the initial angle and press Enter key
or move the mouse (the radius value is upgraded) click on the left button of the
mouse (also the initial angle is captured)
- Insert the angle value at the centre of the arc
or move the mouse (the angle value in the centre is upgraded) click on the left
button of the mouse
This command has two options at disposal:

- Sequence (Single/Multiple)
- Input (radius/Diameter)
that can be changed by the dynamic menu
The multiple sequence allows you to insert a further concentric arc to the previous one.
In order to insert an Arc whose final point and radius are known:
- click on the command "Arc given radius"
or move the mouse (the value of the radius is upgraded) click on the left button of
the mouse

- Direction (clockwise-anticlockwise)
- Arc length (Shorter/Longer)
31
In order to insert an Arc whose centre and final point are known:
- click on the command "Arco dato centro" (arc given centre)
- type the point of the arc centre
This command has following option at disposal:

Direction (clockwise-anticlockwise)
In order to insert a tangent Arc in the previous element in a continuous manner:

- click on the command “Continuous tangent arc”
- select a geometric element
- click on the left button of the mouse
This command has three options:

- Type of feature (Arc/Line)
- Tangency (Direct
Inverse
Shorter length
Longer length)
that can be changed from the dynamic menu

The multiple sequence allows you to make tangent elements with the previous one.
The direct tangency does not create a sharp edge

The inverse tangency creates a sharp edge
The length options create the workpiece of Shorter or Longer arc.
Arc properties
32
3.8.1.6. Circle
It introduces a circle:
A circle can be inserted in 3 ways:
1) Circle for 3 points
2) Circle given radius

3) Circle given diameter
In order to insert a Circle for 3 points:

- click on the command "Circle”
- type the initial point of the circle
- type the intermediate point of the circle
- type the final point of the circle
In order to insert a Circle whose centre and radius are known:

- click on the command "Circle given radius"
- type the point at the centre of the circle
or move the mouse (the value of the radius is upgraded) click on the left button of
the mouse

The multiple sequence allos to insert a further concentric circle to the previous one.
In order to insert a Circle whose centre and diameter are known:

- click on the command "Circle given diameter"
- type the point at the centre of the circle
- insert the value of the diameter and press Enter key
or move the mouse (the value of the diameter is upgraded) click on the left button of
the mouse

The multiple sequence allows to insert a further concentric circle to the previous one.
It is the same command used for the circle given radius, in which the default "Input" has
been turn into "Diameter"
33
Circle properties
34
3.8.1.7. Polyline
It introduces a polyline that is a continuous sequence of arcs and/or open or closed

segments.
It can be drawn using the commands for the input of lines and arcs.
In order to insert a polyline:

- click on the command "Polyline"
- follow the instructions related to the command set in the option "Mode”

- Closed (option that can be ticked off)
- Mode (Line given 2 Points
Arc given 3 Points
Arc given radius
Arc given Centre
Continuous tangent arc
Continuous tangent line)
that can be changed from the dynamic menu
End: it is an option that allows you to make an open or closed polyline
Modus describes the command to use in order to describe the next geometric element.
The six commands in the menu modus have been described in the previous paragraph
about lines and arcs.
Polyline properties are made of several tables that stand for the properties of all elements
in the structure (Lines or Arcs).
You can surf the tables by clicking on the left/right arrows.
If the field "Length” appears, the element described is a Line.
If the field "Radius” appears, the element described is an Arc.
Polyline properties
35
3.8.1.8. Rectangle
It introduces a rectangle that is performed with a closed polyline made of 4 lines.
The rectangle can be inserted in two ways:
1) By inserting 2 vertex:
2) Typing the dimensions
In order to insert a rectangle given 2 vertex:

- click on the command "Rectangle 2 points”
- type the point of the first vertex
- type the point of the second vertex
In order to insert a rectangle by typing the dimensions

- click on the command "Rectangle dimensions”
- type the central point of the rectangle
- Insert the Width value and press Enter key
or move the mouse (the Width value is upgraded) click on the left button of the
mouse.
- Insert the length value and press Enter key
or move the mouse (the Length value is upgraded) click on the left button of the
mouse.
- Insert the Angle value and press Enter key
or move the mouse (the Angle value is upgraded) click on the left button of the
mouse
Rectangle properties
36
3.8.1.9. Buttonhole
It inserts a buttonhole performed with a closed polyline of 4 elements two lines and two
arcs.
Arcs have a diameter like their width and a breadth of 180°.
In order to insert a buttonhole:

- by clicking on "Buttonhole”
- type the central point of the buttonhole
- Please insert the Width value and press Enter key
or move the mouse (the Width value is upgraded) click the left button of the mouse.
- Please insert the length value and press Enter key
or move the mouse (the Length value is upgraded) click on the left button of the
mouse.
- Please insert the Angle value and press Enter key
or move the mouse (the Angle value is upgraded) click on the left button of the
mouse
Buttonhole line
properties
37
3.8.1.10. Loop line
It inserts an arc of circle or a tangent circle to 2 existing entity.
In order to insert a loop line:

- click on the command "Loop line"
- type the radius value
- move with the mouse (a loop line next to the cursor)
Or:
- select the first geometry
Or:
- click on the option "Quadrante" (quadrant)
- select the second geometry

- Cut/Widen (both
First
Second
Nothing)
- Quadrant
- Type (Usual
Inverted
Circle)
Cut/Widen serves as option to widen or cut the selected elements
Quadrant serves to insert the loop line in the third mode (2 geometries and the quadrant)
Type establishes the type of desired loop line.
The properties of the loop line are the same of the Arc.
38
3.8.1.11. Smooth
It inserts a segment that smooths 2 existing entities.

The smooth can be set in 4 modes (see option "Type")
In order to insert a Smooth:

- click on the command "Smooth"
- type the values to set the smooth
- move with the mouse (a smooth will appear next to the cursor)
Or:
- move with the mouse (a smooth will appear net to the cursor)
Or:
- click on the option "Quadrante" (quadrant)
- select the second geometry
- move with the mouse (a smooth will appear net to the cursor)

- Cut/Widen (both
First
Second
Nothing)
- Quadrant
- Type (1 Distance
2 Distances
Length/Angle
Length)
The Cut/Widen option serves as option to widen or cut the selected elements
The Quadrant option aims at introducing the smooth in the third mode (2 geometries and
the quadrant)
The Type option establishes how to insert the data about the loop line
The values inserted in 1 Distance or 2 Distances are measured along the selected
geometries.
The length represents the length of the new smooth segment inserted.
The smooth properties are the same of a Line.
39
3.8.1.12. Offset
It creates one or more geometries that have a steady value compared to an existing
selected geometry.
The new entities will look like the selected ones.

In case of a polyline, the new entities will always be considered as polylines but the
number of elements in their structure can be higher or lower than the elements of the
selected polyline.
In order to creare an Offset geometry:

- click on the command "Offset"
- select one or more geometric elements
- insert your offset value
- set the number of repetitions
- select the reference point to establish where to create the offset

- Repetitions
- Preview
The option "Repetitions" allows you to create one or more offset geometries
The option Preview - if it is marked - allows you to see - in Preview- the geometries that
will be created by moving the mouse.
40
3.8.1.13. Text
It inserts a text made of many polylines (one or more for every character)
The text can be inserted in several fonts and heights.
In order to insert a text:
- click on the command "Text"

- select the reference plane
- selected the desired character
- select the desired style
- insert the text
- type the height
- type a precision
- select the desired alignment
- type the position in X and Y of the text
- Click on the button "Apply"
41
3.8.2. 2D geometry imported from DXF
It is possible to import 2D geometry from an existing DXF file.

To do this, there must be a project with at least one workpiece defined.
To import a DXF file use the “Import dxf” command in the

“Home” “Import” menu.
After selecting the command, the dialogue box appears which allows you to select a “.dxf”
file from the PC disk.
The “DXF program (*.dxf)” filter is already set in the “File type:” box.
42
Once you have selected the file, the
menu shown here appears:
In the menu you can see the name of

the dxf file which is being imported in the
“File Name” field.
You can select:

- the Layers present in the dxf file
- the face on which you want to import
the geometric entities present in the
selected Layers
Use the “Cancel” key to interrupt the

operation.
Use the “Apply” key to begin importing

the dxf file.
At the end of the import

operation this window appears:
(Do you want to see the import report?)
Select “No” to conclude the operation.

Select “Yes” and another window opens,
showing the dxf import operation report.
43
In the report, for each layer you can see how many and which entities were imported and
how many and which entities were not imported and the reason why.
The report file is also saved in the “Maestro/Report/DXF” folder in XML format.
The name with which it is saved has the prefix “DxfImpor” followed by the date and time.
Example: “DxfImport_20110920_085538.xml”.
Note: The following geometries cannot be imported:

1) SPLINE
2) POLYLINE3D
3) ELLIPSE
In Autocad 2004 ellipses can be exported as polylines using the “PELLIPSE” variable. This
would allow it to be imported into the packet.
44
3.8.3. Geometry selection
Once all geometric entities or working processes have been inserted, it is often necessary
to select them in order to carry out several operations
You can select a single entity by clicking with the left button of the mouse on the desired
entity.
The selection is clearly visible because it is red-coloured.
In order to select more than one entity you can press - like for the single selection - "Shift".
In order to make a quicker multiple selection, this is a suitable method:

- press the left button of the mouse
- move the mouse (a rectangle is drawn)
- release the left button of the mouse
At this point all entities included in the rectangle will be selected and red-coloured.
45
3.8.4. Contextual Menu of graphic area
After selecting one or more geometric entities or working processes, if you click with the
right button of the mouse, one of these two menus will appear with the commands related
to the selected geometric elements.
The first menu will appear if you select two or more elements.
The second one if you select one geometric element.
The third if you select only one working process.
It is possible to display "Properties" only for one entity.
If there is no geometric entity among the selected elements, the commands "invert”, "Join”
and "Explode” are inhibited.
In case of one working process, it is possible to display the "Properties" of the working
process or the "Properties" of the geometry concerning the working process.
46
3.8.5. Geometry removal
After selecting one or more geometric entities, you can delete:

- by clicking with the button "Canc"
- or clicking on the command "Remove" of the menu "Home" "Clipboard"
- or on the command "Remove" if the contextual Menu.
3.8.6. Geometry Properties
Every geometric feature has several properties.

In order to display the properties of one element:
- Select the object (red-coloured)
- click on the command "Geometric properties of the contextual menu”
- The resulting table will show you the geometric data.
The tables displayed for every entity have been reported in the paragraphs related to the
geometry inserting commands.
By marking the field "absolute Coordinates”, the data will not refer to the faces on which
the geometry has been built but to the three-dimensional "Zero" of the Project.
By changing the values in the fields of properties it is possible to modify the geometry.
47
3.8.7. Modifying existing geometries
Icons related to commands to modify basic geometries are to be found in the menu "Draw"
"Modify".
All commands of geometry modification are interrupted by selecting a new command or

pressing the button "Esc".
3.8.7.1. Cut
It removes a workpiece of a geometric entity intersected by other entities.

If an entity is not intersected by any line, it will be completely deleted.
In order to remove a workpiece of geometric entity:

- Click on the command "Cut”
- move the mouse (the entity workpiece to delete is green-coloured, in bold)
3.8.7.2. Invert
It inverts the initial point with the final one of any geometric entity.
The command is available in the menu "Draw” “Modify” as well as in the “Contextual
menu).
In order to invert the direction of one or more geometries:

- Select one or more geometric entities
- click on the command "Invert”
The inversion is evident when the symbol linked with the geometric initial point has
changed.
48
3.8.7.3. Initial point
It changes the initial point of a closed geometry (circle or polyline).
In order to modify the initial point of a closed geometry:

- click on the command "Initial point”
- move the mouse
- click with the left button of the mouse (for a new initial point )
The representation of the initial point is performed with an arrow that detects the position
and the direction.
3.8.7.4. Join
It creates a polyline by combining geometric entity with coinciding vertex.

The command is available in the menu "Draw” “Modify” as well as in the "Contextual
menu”.
In order to combine one or more geometries with coinciding vertex:

- Select one or more geometric entities
- click on the command "Join"
One or more polylines can be combined only with the entities that have coinciding vertex.
In case of more entities with coinciding vertex, the entities inserted in the polyline will
follow the selection order.
The direction of the new polylines is casual
3.8.7.5. Explode
A polyline explodes in all basic geometric elements in its structure.

menu”.
In order to explode one or more polylines:

- select one or more polylines
- click on the command "Explode”
The direction of the single entities will be the one inside the polyline.
49
3.8.8. Move and/or copy the existing geometries
The icons on the commands to move, rotate, mirror or copy the existing geometries are to
be found in the menu "Draw” “Modify”
All commands of geometry modification are interrupted by selecting a new command or

pressing the button "Esc".
Further recurring commands are to be found in the menu "Home" "Clipboard".
50
3.8.8.1. Move
Move one or more entities from one point to another one.

menu”.
In order to move one or more entities:

- select one or more entities
- click on the command "Move”
- type the reference point
- type the final point
Or:
- click on the command "Move”
- type the final point

- Create a copy
- Coordinates (Relative/Absolute)
The option "Create a copy” allows you to make a copy out of the source text.
The option Multiple Sequence allows you to keep on moving the element by typing further
final points.
The option "Absolute Coordinates" allows you to stop the select geometries at a certain
level starting from a zero level of the work plane.
51
3.8.8.2. Rotate
Rotate one or more entities.

The command is available in the menu "Draw"”Modify” as well as in the "Contextual
menu”.
In order to rotate one or more entities:

- click on the command "Rotate”
- set an angle (typing the point or inserting the value)
Or:
- click on the command "Rotate”
- set an angle (typing the point or inserting the value)

- Create a copy
The option "Create a copy” allows you to make a copy out of the source text.
The option Multiple Sequence allows you to keep on moving the element by setting other
angles.
52
3.8.8.3. Mirror
It mirrors one or more entities compared to the axis of the centre line in the work face.
The command is available in the menu "Draw" "Modify" as well as in the "Contextual
menu”.
This command works only in case of standard faces.
In order to mirror one or more entities:

- click on the command "Mirror”
- select the mirror mode in the menu
- click on the button "Apply"
This commands has five options:

- Mirror in X
- Mirror in Y
- Mirror in X/Y
- Keep in the source form
- Invert the working process
The option "Mirror in X” mirrors the geometry compared to the Y-axis of the centre line in
the active face.
The option "Mirror in Y” mirrors the geometry compared to the X-axis in the middle of the
active face.
The option "Mirror X/Y" mirrors the geometry compared to the X and Y axis in the middle
of the active face (this mode is like a rotation of 180°)
The option "keep the source geometry" allows you to make a copy out of the source
geometry.
The option "Invert working process” allows you to invert the direction of the working
process if the command "Mirror” is used to mirror a working process.
53
3.8.8.4. Oppose
It copies one or more entities on the standard face opposite to the active one.
The command is available in the menu "Draw" "Modify" as well as in the "Contextual
menu”.
This command works only in case of standard faces.
In order to copy one or more entities on the opposite standard face:

- click on the command "Oppose”

- Keep in the source form
- Invert the working process
The option "keep the source geometry" allows you to make a copy out of the source
geometry).
The option "Invert the working process” allows you to invert the working direction if the
command "Oppose" is used for a working process.
54
3.8.8.5. Cut
It cuts one or more geometric elements or working processes in order to put them in the
buffer for the option "paste”.
The command is available in the menu "Home" "Clipboard" as well as the "Contextual
menu”
and works only for elements of the active face.
In order to cut one or more entities from the active face.

- click on the command "Cut” or press "Ctrl-x"
- type one reference point.
As a result of the geometry of the selected working process it will disappear from the
display.
3.8.8.6. Copy
It copies one or more geometric elements or working processes in order to put them in the
buffer of the option "Paste)
menu"
and works only for the elements of the active face.
In order to copy one or more entities from the active face:

- click on the command "Cut” or press "Ctrl-c".
You do not notice any effect but the previously selected geometry will be available to be
copied through the option "Paste”
3.8.8.7. Paste
It pastes one or more geometric elements or working processes that have previously been
selected from the option "Cut” or "Copy”
menu”
In order to paste one or more entities on the active face:

- click on the command "Paste” or press "Ctrl-v"
55
3.9. Working processes
The commands in order to insert the working processes are to be found in the menu
"Operations”
Every working process must be carried out combining a tool with a 2D geometry.
As a result, it is necessary to activate a Tool- Data-Base (see paragraph 5.8)
In order to set any working process, it is useful to keep this structure in mind:
1) Set the position in which you carry out the working process (Pos)
2) Set the Geometric Shape of the working process (Geo)
3) Set the Work mode (Mode)
4) Set the technology adopted (tool, speed and so on).
56
3.9.1. Boring
In order to bore, you can:

- click on the command "Boring”
- select one or more 2D elements
Or:
- click on the command "Boring”
The selection of 2D elements can be single or multiple as

the option for boring will make bores connecting them with
the points or the circles.
3.9.1.1. Bore position
If, among the selected elements, there are points and/or

circles, the bore position is automatically set.
If no point or circle has been selected, you can set the

position of a new point in this way:
- select the reference face
- fill the field X Coordinate in
- fill the field Y Coordinate in
It is possible to set a set of matrix bores by using the sub-menu "Repetitions”
to this purpose, the nearby menu fields must be filled in.

Rotat. 1 represents the angle to set the lines
Rotat. 2 stands for the angle to set the columns compared to
the lines
By clicking on the button "Preview", you obtain a

representative table that displays the bore position as
described above.
57
3.9.1.2. Bore Structure
In order to set the bore structure, Diameter, Depth and bore Type must be set in the menu.
In field "Depth" you will insert the value corresponding to the

thickness of the workpiece in case the option "Passer-by” is
selected.
If the "boring" operation has been performed by selecting a

circle rather than a point, the field "Bore diameter” will be filled
with the value of the circle diameter.
In this case, if you wish to change the diameter, you can
unmark the heading "Keep circle diameter” and set a new
diameter.
The field "Extra depth is filled with the extent through which the bore must go beyond the
thickness of such workpiece (this heading will appear only if the option "Passer-by" has
been selected")
The type of bore must be specified when it is not linked to a drilling tool and in this case, in
order to choose the tool, you need this information.
3.9.1.3. Boring modes
In order to set how to structure the bore, you use the sub-menu "Strategy”
The bore can be performed in a single or a multiple rub.

In case of multi rubs, you have to set the number of rubs
needed to bore.
58
3.9.1.4. Boring technology
In this step, you set all technical aspects related to tools, spindles and machines at
disposal.
To this purpose, you use following menus:
In the menu "Technical data” you can select the tool, set the
speed and set the spindle rotations.
In the menu "Advanced data”, you can insert a condition

with comment that establishes if the work must or must not
be carried out.
The parameter "Approach” sets the safety distance of the

tool before making the bore.
The parameter “Removal” sets the safety distance of the

tool before making the bore.
Functions in the menu "Machine data” change according to

the machine pattern variation.
In this case, you can choose which Jerk parameters are to

be set.
In the field "Head data” you select the chunk to use in order
to perform the boring.
By choosing "Automatic, the system will automatically set
the chunk to use for this boring.
59
3.9.2. Milling
In order to insert one or more milling operations you can:

- click on the command "Milling”
Or:
- click on the command "Milling”
The selection of 2D elements can be single or multiple

because the function "Milling" will perform milling operations
connecting them with lines, polylines, arcs and circles.
3.9.2.1. Miling position
If there is any line and/or polyline and/or arc and/or circle

among the selected elements, the milling position is
automatically set.
The real position of every milling is affected by the used tool

correction and the super-material.
In the following tables it is possible to understand how the different combination of options
work.
The light blue line stands for the "2D geometry" and the red line represents the tool path in
the tool centre.
By marking "Correction C.N.”, it implies that the coordinates of the 2Dgeometry are passed
and the effective path (red line) will be calculated by the CN.
If you mark "Cad correction”, the coordinates of the red line are directly transferred to the
CN and this latest will not make any correction.
60
Behaviours with left, central and right corrections without any correction in length and
without any super-material.
Behaviours with left, central and right corrections in length and without any super-material.
61
Behaviours with left, central and right correction without any correction in length and with
super-material.
Behaviours with left, central and right corrections in length and with super-material.
62
3.9.2.2. Milling form
In order to set he milling form you have to set Length and Depth in the menu.
The field Width is automatically filled when a tool is

connected with the milling.
thickness of the workpiece in case the option "Passer-by is
selected.
The field "Extra depth" sets the extent of the milling to cross the workpiece. (This heading
will appear only the option "Passer-by" has been selected)
63
3.9.2.3. Milling modes
In order to set how to perform the milling, you use the sub-menus "Strategy" and
"Approach/Removal".
The milling can be performed only in one or more rubs.
In case of "multi-rub", you must choose between One- way

or two- ways strategy.
In the "one-way strategy", you have to establish if the rise

between two rubs must occur:
- at a safety level on the workpiece
- or in the workpiece
The values of these two parameters can be modified in the

menu "Help" "Options" "Working processes" .
For the one-way strategy as well as for the two ways

strategy, the heading "Enable multi-rub” must be marked
and the values "Rub depth” and depth "Last rub.”
Another modification to the milling mode can be set by the

menu "Advanced data" through the parameter "Invert".
By marking this parameter, the working process can be
performed starting from the final point of the selected 2D
geometry.
64
In the menu "Approach/Removal" you set the in-and-out mode from the milling path.
For the entry as well as for the exit, you can choose the line or
arc geometry.
The length of these paths is set by "Radius multipl." that, in
case of a milling cutter of 10 radius and a multiplier of 1.2, a
length line of 12 will be added to our path or a radius ray of 12
with a width of 90° and tangent to the initial/final point or the 2D
geometry.
These additional properties can be performed by the machine:

- in case of security level (on level)
- while the point of approach in reached (in fall)
- while the point of removal is reached (in rise)
The surmount is the workpiece worked along the first object of

the polyline.
if this value is higher than the length of the first polyline
element, the working process would end in the last workpiece
of the element.
3.9.2.4. Milling technology
See paragraph3.9.1.4 (boring technology)
If in the machine configuration the device "Chip conveyor” is

available, it can be activated by using the menu "Machine
data”.
65
3.9.3. Channel
The channel is a milling process with one limit and some added-values compared to the
general milling process.
The limit is due to the fact that the channel can be applied only for a line.
The added-values will be showed in the menu explanation.
In order to insert one or more channels, we can:

- Click on the command "Channel”
Or:
- Click on the command "Channel”
because the function "Channel" will perform milling cutters
associated with the lines.
3.9.3.1. Channel position
if there is any line among the selected elements, the

channel position is automatically set.
If no line has been selected, the position of a new line can

be set in this way:
- select the reference face
- fill the X field initial point
- fill the Y field initial point
- fill the X field final point
- fill the Y field final point
The real position of every milling is affected by the used tool

correction and the super-material.
In the tables in paragraph 3.9.2.1(milling position) it is

possible to understand how the different combinations of
options work.
By marking "Correction C.N.”, it implies that the coordinates

of the 2Dgeometry are passed and the effective path (red
line) will be calculated by the CN.
If you mark "Cad correction”, the coordinated of the red line

are directly transferred to the CN and this won't make any
correction.
66
We can also change the channel position by using the
parameter "Enable edge” in the sub-menu "Advanced data".
By using this function, the selected segment will be stretched
until it crosses the panel edges.
You can also have a channel extension if you activate the

paramters "Extra initial distance” and "Extra final distance”.
3.9.3.2. Channel structure
In order to set the channel structure, Length and Depth

must be set in the menu.
The field Width is automatically filled when a tool is

connected with the channel.
In field "Depth" you will insert the value corresponding to

the thickness of the workpiece in case the option "Passer-
by” is selected.
It si possible to set a "Final Depth (associated with the final

point of the geometry) different from the one associated
with the final point).
3.9.3.3. Channel execution mode
The channel execution mode looks like the milling mode

(see paragraph 3.9.2.3).
3.9.3.4. Channel technology
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3.9.4. Blade cut
In order to insert one or more blade cuts you can:

- click on the command "Blade cut”
Or:
- click on the command "Blade cut”
The selection of 2D elements can be single or multiple because the option "Blade cut" will
performs cuts associated with the lines.
3.9.4.1. Cut position
Blade cuts can be performed only on lines on the upper

face.
If there are lines among the selected elements, the cuts
position is automatically set.
If no line has been selected, the position for a new line can
be set in this way:
- Fill the X field initial point
- Fill the Y field initial point
- Fill the X field final point
- Fill the Y field final point
- fill the Inclination field
The real position of every cut is affected by the used tool

correction and by the super-material.
In the tables in paragraph 3.9.2.1(milling position) it is

possible to understand how the different combinations of
options work.
By marking "Correction C.N.”, it implies that the coordinates

of the 2Dgeometry are passed and the effective path (red
line) will be calculated by the CN.
If you mark "CAD correction”, the coordinated of the red line

are directly transferred to the CN and this won't make any
correction.
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We can modify the cut position using the sub-menu
"Advanced data”
The parameter "Enable edge” extends the selected segment

until the cross of the panel edges.
You can extend it using the parameters "Extra initial dist." and
"Extra final dist."
By using the parameter "Lower reference” the selected

geometry will lie on the lower face.
This working process generates also a work plane on one of

the two surfaces caused by the cut.
The surface will be created on the new external face of the
workpiece, so you must specify the material placement after
the cut using the parameters "To the right of the geometry" "To
the left of the geometry".
3.9.4.2. Cut structure
In order to set the structure of the blade cut, Length and

Extra Depth must be set in the menu.
The field Width is automatically filled when the blade is

associated with the cut.
The Depth (whose field is not present) will correspond to the

thickness of the workpiece.
The field "Extra depth” indicates the extent of the cut

overcoming the thickness of the workpiece.
3.9.4.3. Cut modes
See the use of the parameter “Invert” of the menu Advanced data in the paragraph 3.9.2.3
(Milling mode)
3.9.4.4. Cut technology
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3.9.5. Contouring
The contouring is a milling that can apply the external contour of the workpiece or the
geometries.
In order to perform the contouring to the external

workpiece:
- click on the command "Contouring"
The resulting menu will show you the parameter of the

selected "workpiece".
By inserting the workpiece contouring, a closed polyline will
be created on the upper face, that overlaps with the
external profile of the workpiece.
In order to insert one or more geometric contouring, you

can:
- click on the parameter "Geometry"
Or:

because the contouring will perform millings associated
only with closed polylines or with circles.
3.9.5.1. Contouring position
The contouring position is automatically set by the selected geometry.
If the contouring is set to the geometry, then it is possible to choose the "Eternal" "Internal"
"Side" from the menu where you can set it.
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3.9.5.2. Contouring structure
In order to set the contouring structure, you must set Length and Depth in the menu.
The field Length is automatically filled when you associate a

tool to the contouring.

selected.
The field "Extra depth" sets the contouring extent to go

beyond the workpiece (This heading will appear only if the
option "Passer-by" has been selected)
3.9.5.3. Contouring modes
See the use of the parameter “Invert” of the menu Advanced data in the paragraph 3.9.2.3
(Milling mode)
See the use of menu parameters "Approach/Removal” in paragraph 3.9.2.3 (Milling mode)
3.9.5.4. Contouring technology
See paragraph 3.9.2.4 (Milling technology)
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3.9.6. Emptying
In order to insert one or more empty workpieces you can:

- click on the command "Emptying"
Or:
- click on the command "Emptying"
The selection of 2D elements can be single or multiple since

the option "Emptying" will carry out working processes
associated with closed polylines or with circles.
3.9.6.1. Emptying position
The emptying position is automatically set by the selected geometry.
3.9.6.2. Emptying structure
In order to set the emptying structure, you have to set Length Cut and Depth in the menu.
The field Length cut is automatically filled when you

associate a tool with the emptying.

selected.
The field "Extra depth" indicates the extent of the emptiness

on the workpiece ( This heading will appear only if the option
"Passer-by" has been selected).
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3.9.6.3. Emptying mode
In order to set how to perform the milling, you use the sub-menus "Strategy" and
"Approach/Removal.
The strategy "Parallel to the contour" aims at making a set

of polylines to a certain offset from the selected polyline.
The space among polylines is calculated according to the
tool-diameter and the parameter Overload. (%).
For a multi-rub management, see paragraph 3.9.2.3 (milling

modes)
See the use of menu parameters "Approach/Removal” in paragraph 3.9.2.3 (Milling mode)
3.9.6.4. Emptying technology
See paragraph 3.9.2.4 (Milling technology)
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3.9.7. Working process tree
The working process tree represents the workpiece and all working processes set in a
certain project.
Move on working process Display
Move down the working Switch off

process
Properties Remove
3.9.7.1. Object selection
You can perform the object selection on the tree by clicking with the left button of the
mouse on any displayed element.
It is possible to select the workpiece or a working workpiece and it is not possible to select
more than one object.
When an object is selected, the name is written in white on a blue background.
The selected object in the tree will be marked also in the graphic area.
3.9.7.2. Working process ordering
The working process tree shows us the working processes in our project as well as their
sequence. so you could benefit from ordering the working process sequence.
In order to move a working process in the tree:

- select the working process
- use the command "Move on the working process, arrow upwards”
- or "Arrow downwards”
This option is inhibited by the working process tree when the project has more than one
step (see paragraph 3.10.6 )
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3.9.7.3. Working process display
On the working process tree you can display or not the different working processes.
To the left of every working process name, you can see the icon that represents the type
of working process and to the left of the icon there is the symbol that stands for an eye.
By clicking with the left button on the eye, you change its status from open to closed.
The open eye means that the working process will be displayed.
The closed eye means that the working process will not be displayed.
In this example you can see a project where the Emptying

has been selected and the Milling and the Countouring have
been switched off.
If you wish to switch all working processes off you can:

4) close all eyes to the left of the working processes.
5) close the eye to the left of the workpiece
6) or click on the light bulb that is off.
If you wish to display all working processes you can:

4) open all eyes to the left of the working processes.
5) open the eye to the left of the workpiece
6) or click on the light bulb that is on.
The selection on the tree has an immediate impact on the graphic area.
75
3.9.7.4. Contextual menu
After selecting any object of the tree, by clicking with the right button of the mouse, a
contextual menu will show us what kind of operations we can carry out with the selected
object:
Contextual Menu workpiece
Contextual Menu Working process
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3.9.8. Working process selection
The working process selection in the graphic area occurs in the same way as the
geometry selection (see paragraph 3.8.3)
you can also select a single working process from the working tree (see paragraph 3.9.7.1)
3.9.9. Contextual menu for working processes
The contextual menu for working processes is available:

- In the graphic area (see paragraph3.8.4 )
- and in the working process tree (see paragraph 3.9.7.4 )
3.9.10. Working process removal
After selecting one or more working process you can remove them:
- by clicking with the button "Canc"
- or clicking on the command "Remove" of the menu "Home" "Clipboard"
- or on the command "Remove" if the contextual Menu.
This menu will appear:
You can choose if you wish to:

- remove only the working process
- remove Geometry and Working process
3.9.11. Working process properties
If you wish to know an existing working process properties, the dialogue menu during the
working process inserting will be showed.
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3.9.12. Working process modification
After selecting one working process (on the screen or in the tree) it is possible to modify
the parameter values in the dialogue menu.
3.9.13. Move and/or copy existing working processes
The options used to move or modify working processes are:
- Move
- Rotate
- Mirror
- Oppose
- Cut
- Copy
- Paste
these same options are also used for the geometries (see paragraph 3.8.8)
Apart from the mere copy of the working process, there is also the possibility of copying all
technological information of a working process and apply them to the new 2D geometries.
(it means to copy the whole working process apart from the geometry).
To this purpose, you use following commands "Select technology” and "Apply technology"
in the menu "Operations" "Modify".
3.9.13.1. Select the technology
In order to select a technology to copy on further 2D geometries:

- use the command "Select technology"
- select a working process that already exist in the project.
3.9.13.2. Apply technology
In order to apply a technology to another 2D geometry:

- select a technology
- use the command "Apply technology”
- select one or more 2D geometries compatible with the working processes
previously selected.
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3.10. Working steps
A working step describes the positioning of one or more workpieces and which working
processes must be performed if they are in the positions described.
When you create a new project, the step "Setup" is automatically created.
3.10.1. Working step tree
The working step tree represents all working steps set for a certain project.
Switch off
Move on working process
Remove
Move down the working
process Add
workpiece
Properties
Display
Through this tree it is possible to:

- Insert a working step
- Removete a wokring step
- See the step properties
- Add working processes
- Move the working processes from one step to another one.
- Display or switch off the working processes
- Add the workpiece name to the working process name.
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3.10.2. Inserting a working step
In order to insert a new working step, you use the command "New step” in the contextual
menu of the step tree.
After selecting the command, the menu to the right will show you where you can insert the
name of the "Working step".
3.10.3. Removal of a working step
In order to remove a working step, you use the button with the red cross or the command
"Remove" in the contextual menu of the step tree.
The initial "Setup" cannot be removed.
Remove
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3.10.4. Working step properties
In order to display a working step, you use the button "Properties" or the command
"Property" in the step contextual menu.
After selecting such command, the menu to the right will show you the name of the
"Working step" and the workpiece positioning in that step.
Properties
3.10.5. Modifying the workpiece position in one step
It is possible to modify the workpiece position in a certain

step by using the command "Properties" in the contextual
menu of the step tree.
By clicking on the arrows to the left of the workpiece name,

the menu will show the current position of the machine
workpiece.
You can change the workpiece position in the selected step

by modifying the values to the right of the parameters.
- X origin
- Y origin
- Z origin
By clicking on the button "Apply"
81
3.10.6. Moving working processes from one step to another
one
In order to move the working processes from one step to another one, you use the buttons
with the blue arrows on the tree.
Move up working process
Move down the working

process
In the image above, if you click on the button with the arrow downwards, the Contouring
will be shifted on the Milling but it will remain the same during the step "Setup".
By using the arrow downwards, the Countering will always occur before the boring, but will
shift from "Setup" to "Working step"
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3.10.7. Add workpiece name to working process name
If you look at the step tree, we see what kind of working processes are performed in every
step but we do not know to which workpiece they belong.
In order to obtain this information, you use the button "Add workpiece name".
Project example with 2 workpieces and 2 steps:
Add
workpiece
As you see in the step tree, you cannot understand to which workpieces the working
processes belong. By using the command "Add workpiece name", the step tree will
appear in this way:
The working processes are not modified, but you see only a temporary representation that
can be restored by clicking on "Add workpiece name".
83
3.11. Parameters
If you insert a workpiece in the project, parameters dx1, dy1, dz1 will be available in the
workpiece dimensions.
By inserting a second workpiece in the project, also dx2, dy2, dz2 will be also included.
The list of parameters available in the project is to be found in the interface down on the
left.
By using the command "Create a new variable", it is possible to insert new parameters.
Create a new
variable
Variable
properties
Delete variable
By using the command "Variable Properties", the same window used for the creation will
appear:
By using the command "Delete variable", it will be possible to delete the variables created
by the user but not those which have been automatically created (dx1, dy1, dz1).
All parameters available in the project can be used in every field that accepts a number in
order to create 2D geometries as well as to set working processes.
In order to use a parameter, it is sufficient to write it in place of such number, or you can
also write the formula with more parameters and mathematic operators.
Parameters can also be exported with the sub-program as input data (see paragraph 3.5.1
"Saving the sub-program").
84
3.12. Sub-programs
The sub-programs or "Macro" are used in order to insert 2D geometries or recurring

working processes.
Maestro has a set of sub-programs in the menu "Operations" "Macro"
A workpiece from existing sub-programs, the user can create further programs as
described in paragraph 3.5.1 (Sub-program saving)
In order to use a sub-program:

- click on the command of the chosen sub-program
- fill the important fields of the sub-program
Every program can insert one or more 2D geometries or working processes.

Geometries or working processes can be created on the active plane or on prearranged
planes.
If you wish to know details about variables, geometries or working processes of every
macro route, you need to refer to a dedicated manual.
85
3.13. Project management from "Script"
86
3.14. Project Graphic display
The project is displayed in the mein are at the centre of the screen.
it is a three-dimensional representation.
The operator can choose what, where and how to see interesting project workpieces.
3.14.1. What you see of the project
In order to select the working processes to display among all those included in a sole
project, you can use the commands available:
- In the plane tree (see paragraph 3.7.4.4 )
- in the working process tree (see paragraph 3.9.7.3 )
- in the menu of the step tree:
or use the command "Opaque View" in the menu "Options"
The command "Dim" displays only the working processes of the active plane.
If one or more working processes of the active plane have been switched off with the tree
menu, these will no be displayed.
87
3.14.2. Where to see the project
If you wish to see the project, it is possible to set the point from which you display it.
The main references to this purposes are the "Standard faces".
Immediate commands are available to see the different faces.
In the menu "Home" sub-menu "Views"
Clicking on the commands with the Face names, you will only display the face related to
the seleced view.
In the same menu, you can also see three commands related to three isometric views.
After selecting one out of ten views, you can zoom, size, shift or rotate the project view by
using the menu "Surfing" to the right of the menu "Views".
88
3.14.2.1. Zoom
The main icon of the Zoom displays the whole screen.
The icon "Zoom" allows you to zoom through a rectangle. You can select it by clicking on
the left button of the mouse.
The icon "Zoom +" allows you to size the view whenever you click with the left button of
the mouse.
You can use this option also by rotating the mouse roller forward.
The icon "Zoom" allows you to size the view when you click with the left button of the
mouse.
You can select this option by rotating the roller backwards.
The icon "Dynamic Zoom" allows you to zoom by cliking with the left button of the mouse
on the area to be zoomed and then to move in order to zoom/size the view.
You can select this option by rotating the roller backwards and forwards.
The commands "Zoom +", "Zoom -" and "dynamic Zoom" can be disabled if you click on
the "Esc key".
3.14.2.2. Pan
Pan allows you to shift the view by keeping the left button of the mpuse pressed and then
to shift with the mouse.
You can disable the command with the button "Esc" or by modyfing the command.
The same function is always available if you press the central button of the mouse and
then you move with the mouse.
3.14.2.3. Orbit
This option allows you to rotate the view by keeping the left button pressed and then move
with the mouse.
You can disable the command with the button "Esc" or by modifying the command.
This option is also available if you press the button "Ctrl", the central button of the mouse
while moving the mouse.
89
3.14.3. How to see the project
All project elements can be displayed in different ways.

In order to choose the way to see such elements, the commands of this menu allow you to
produce the different representations that have been shown.
90
The command CAMCAM allows you to display the tool path and the side of correction.
Here you can see a workpiece with a profiling and two tenonings in Shading
representation (25%)
The same workpiece in CAM representation shows you:

- the basic geometries of the profile
- paths in tool centre
- the circle with the arrow that indicates the initial point of the working process and the
direction
The command "Redraw" upgrades the whole graphic area.
91
3.15. Machine workpiece disposal
92
3.16. Project optimization
This option allows you to minimise the number of tool changes and the paths related to the
transfer from one working process to another one.
Starting from a saved project, a new project will be created, with a working processes
structure according to the modes indicated.
The project name will be "NameProjectOriginalOpt.pgmx".
After the process, the source project will be closed and the optimised project will be
opened.
In order to optimise a project, use commands "Guided optimization" or "Automatic

Optimization" in the menu "Machines" "Optimizator".
After applying the optimization modes described in following paragraphs, the file
"NameProjectOriginalOpt.pgmx". will be created.
If the optimised file was already been created, following message would appear:
By choosing "No", the optimization will end without saving any optimised file.
If you choose "Yes", following message will appear:
By choosing "Cancel", the optimization process will end.

By choosing "OK", the source project will be closed and the optimized project will open.
93
3.16.1. Guided Optimization
This mode allows you to restructure the working process ordering in every step before
optimizing the project.
By using "guided Optimization", following menu will open:
You can decide the optimization on one step or all steps by using the area "Working
steps".
This workpiece of the menu will appear only if working processes on almost two steps
exist.
In the area "Working processes", all working processes in the step or in the selected steps
will be displayed. You can change the working process ordering with the arrows.
In the area "Tools", all tools in the selected type of working process will be selected. It is
possible if you change the tool ordering with the arrows.
If you select the check "Sub-programs optimization", all working processes in the sub-
programs will be drawn, following the same structure of the previuos project. In order to
avoid losing the ordering operations, following message will appear:
94
If you select the check "Optimization tool path", apart from tool change minimization, also
the whole tool path is minimised among the different working processes.
After the selection, you can:

- Click on the command "Cancel" to avoid the optimization
- click on the command "Restore"
- Click on the command "Apply"
The command "restore" could restore the working tree as it was in the source project, so
following message would appear:
With the command "Apply", the optimization for the tool change would be carried out
without keeping the technological sequence on all working processes in the selected step.
95
3.16.2. Automatic optimization
By using the command "Automatic Optimization", following menu is open:
If you do not insert any check, the optimization for tool change is carried out on all project
working processes without changing the technological sequence.
If you select the check "Disable technologic sequence", you perform the optimization for
tool change on all working processes without keeping the technological sequence.
If you select the check "Optimization tool path", apart from tool change minimization, also
the whole tool path is minimised among the different working processes.
IIf you select "sub-program optimization", before starting the process, all working
processes in the sub-programs will be drawn. The working tree of the source project will
be modified.
After the selection, you can:

- Click on the command "Cancel" to avoid the optimization
- Click on the command "Apply"
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4. Nesting Project Management
“Nesting” is a technique which allows the best arrangement of workpieces on a panel to be

found, so as to minimize waste when the workpieces are produced.
A “Nesting Project” is a project including the definition of one or more workpieces to be
produced, definition of the rough panel with all of the workpieces positioned, and the
information describing methods for positioning the workpieces on the panel.
Hereinafter the “rough panel” is referred to simply as the “Sheet”.
The “Nesting Project” file has a (.nstx) extension and is a compressed file containing:
pezzo1.pgmx Workpiece 1 design
pezzo2.pgmx Workpiece 2 design
pezzon.pgmx Workpiece n design
foglio1.pgmx Nesting Arrangement on sheet 1
foglio2.pgmx Nesting Arrangement on sheet 2
foglion.pgmx Nesting Arrangement on sheet n
Progetto Nesting.xml information for positioning workpieces on panel
A Nesting Project can be:

Created
Opened
Closed
Saved
Using these icons present in the menu area:
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4.1. Defaults for “Nesting Projects”
It is possible to change the Defaults relating to Nesting Projects by clicking on the

“Options” icon in the “Tools” tab.
4.1.1. Default Folder for “Nesting Projects”
To change the name of the folder in which the Nesting Projects are saved:
Click on the “Options” icon and the following window opens:
In which you can change the “Nesting Projects Folder” field.
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4.1.2. Default Nesting Parameters
To change the value of the Nesting Parameters:

- Click on the “Options” icon and after the “Options” window opens
- Click on “+” to the left of “Parameters”
- Click on the “Nesting” item
The following window opens:
In which you can set:

- the dimensions of the sheet which is normally used
- the thickness of the spoil board
- the Nesting calculation resolution
- the angle of rotation of the parts for fitting them in the Free Form nesting
After setting the values, you can:

- save them by clicking on the “Apply” key
- cancel the changes by clicking on the “Cancel” key
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4.2. Creating a new Nesting Project
To create a new Nesting project, a tool Database must

have been activated (see sec. 5.8), then click on the
“Nesting” icon.
If there is a project already open, the

“Close Project” function is automatically activated.
Select the “Nesting” command and you will be asked for information grouped into three
parts of a dialogue box, in this sequence:
1) Parameters
2) Sheets
3) Parts
4.2.1. Nesting Parameters
Nesting parameters are collected in the following dialogue box:
Use the “Forward” command to go to the “Sheets” dialogue box.

Use the “Close” command to cancel the Nesting operation.
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4.2.1.1. Type of Nesting
There are two possible types of Nesting:

1) Rectangular
2) Free Form
Select one or the other by clicking in the related radio button.
Rectangular Nesting
Rectangular Nesting allows only rectangular workpieces, which may even be rotated anti-
clockwise through 90°, to be positioned on the sheet.
This type of nesting has a relatively low processing time, since it has a lot fewer degrees of
freedom than Free Form Nesting.
Free Form Nesting
Free Form Nesting allows workpieces having any shape and arranged at any angles to be
positioned on the sheet.
This type of nesting has longer processing times than Rectangular Nesting because it
involves many more degrees of freedom.
4.2.1.2. Part sequencing
Part sequencing allows definition of the sequence in which the workpieces must be
arranged on the sheet.
Possible alternatives:
1) By Area
2) By Perimeter
which can be selected from the drop-down menu.
Insertion in sequence by Area
In this mode, the arrangement of the parts on the sheet is done starting with the workpiece
which has the largest area and ending with the workpiece which has the smallest area.
Insertion in sequence by Perimeter
In this mode, the arrangement of the parts on the sheet is done starting with the workpiece
which has the longest perimeter and ending with the workpiece which has the shortest
perimeter.
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4.2.1.3. Minimum distance between two nested parts
This value represents the distance remaining between a workpiece and the tool machining
the adjacent workpiece.
4.2.1.4. Cutting tool
A default tool can be set, which will carry out contouring (separation of the parts) for those
workpieces for which a tool has not been programmed.
4.2.1.5. Correction of cutting depth
It is possible to change the cutting depth of the tool which separates the workpieces in
such a way as to separate them completely or leave them joined to the rough sheet.
Set a positive value and the workpieces will be separated from the sheet.
Set the value 0 and the machining will precisely reach the spoil board.
Set a negative value and the workpieces will not be separated from the sheet.
4.2.1.6. Spoil board thickness
For setting the size of the panel placed beneath the rough sheet to be machined.
4.2.1.7. Enable cutting outside the sheet
Tick this box and separation of the workpieces at the border of the sheet can be carried
out even outside of the sheet.
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4.2.2. Nesting Sheets
In this session you can set the dimensions of the rough sheets to be used for Nesting
machining.
The following dialogue box appears:
The sheet which is shown is that set in “Default Nesting Parameters” (see sec. 4.1.2)
Use the “Back” command to return to the “Parameters” dialogue box

Use the “Forward” command to go to the “Parts” dialogue box
In this context you can:

1) Add a sheet to the list
2) Delete a sheet from the list
3) Copy sheet data
4) Paste sheet data
5) Edit sheet data
Right click with the mouse in the Sheets area and the following
context menu appears:
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4.2.2.1. Adding a sheet to the list
To add another sheet to the list:

- Left click with the mouse on the “Insert” item in the context menu.
- Or select a cell or the line of a sheet and press the “Ins” key
A new sheet immediately appears with the same features set in “Default Nesting
Parameters” (see sec. 4.1.2)
4.2.2.2. Deleting a sheet from the list
To delete a sheet from the list:

- Right click on the number to the left of the sheet you want to delete.
- Left click on the “Del” item in the context menu.
- Or press the “Del” key
4.2.2.3. Copying sheet data
To copy the data from a sheet:

- Highlight the cells of the sheet to be copied
- Left click on the “Copy Ctrl+C” item
- Or simultaneously press the “Ctrl” and “C” keys
The selected data will be placed in a temporary memory so that it can be pasted.
4.2.2.4. Pasting sheet data
To paste the data previously copied from one sheet to another sheet:
- Right click on the number to the left of the sheet you want to paste the data to.
- Left click on the “Paste Ctrl+V” item in the context menu.
- Or simultaneously press the “Ctrl” and “V” keys
4.2.2.5. Editing sheet data
To edit the sheet data:

- Double click with the left mouse button on the data item to be edited
- Enter the new data item
- Press “Enter” or left click on another data item
Note: Some data items have preset values. In this case, the new value must not be typed
in, but selected from a drop-down menu which can be displayed by clicking on the arrow to
the right of the value or on the value itself.
104
4.2.2.6. Meanings of sheet data
Each sheet contains the following data:
- Name Æ Sheet name

- Length Æ Sheet length
- Width Æ Sheet width
- Thickness Æ Sheet thickness
- Material Æ Sheet material
- Quantity Æ Quantity of sheets available
- Vertex Æ Starting position for positioning workpieces
(selectable from menu)
o Top left
o Top right
o Bottom left
o Bottom right
- Direction Æ Direction in which the workpieces will be positioned
o X
o Y
- Grain Æ Direction of the sheet grain
o X
o Y
o None
- Left margin Æ Size of left margin in which workpieces cannot be positioned
- Right margin Æ Size of right margin in which pieces cannot be positioned
- Top margin Æ Size of top margin in which workpieces cannot be positioned
- Bottom margin Æ Size of bottom margin in which workpieces cannot be positioned
- Rotation Æ Sheet rotation through 90° (tick to select)
Notes:
- The Vertex and Direction parameters are only available in Free Form Nesting
- The Rotation parameter is only available in Rectangular Nesting.
105
4.2.3. Nesting Parts
This session is for setting the list of workpieces to be machined.
The following dialogue box appears:
Use the “Back” command to return to the “Sheets” dialogue box

Use the “Finish” command to start processing (active if you added at least one workpiece)
In this context you can:

1) Add a workpiece to the list
2) Delete a workpiece from the list
3) Copy workpiece data
4) Paste workpiece data
5) Edit workpiece data
Right click with the mouse in the Parts area and the following context
menu appears:
106
4.2.3.1. Adding a workpiece to the list
To add a workpiece to the list:

- Left click on the “Insert” item in the context menu.
- Or select a cell or the line of a workpiece and press the “Ins” key
The workpiece is added at the end of the list.

If the workpiece to be added is already present
in the list, this message appears:
(Selected part is already present in the list.)
4.2.3.2. Deleting a workpiece from the list
To delete a workpiece from the list:

- Right click on the number to the left of the workpiece to be deleted.
- Left click on the “Del” item in the context menu.
- Or press the “Del” key.
4.2.3.3. Copying workpiece data
To copy workpiece data:

- Highlight the cells of the workpiece to be copied
- Left click on the “Copy Ctrl+C” item
- Or simultaneously press the “Ctrl” and “C” keys
The selected data will be placed in a temporary memory so that it can be pasted.
4.2.3.4. Pasting workpiece data
To paste the data previously copied from one workpiece to another:

- Right click on the number to the left of the workpiece you want to paste the data to.
- Left click on the “Paste Ctrl+V” item in the context menu.
- Or simultaneously press the “Ctrl” and “V” keys
Note: The following data will not be pasted: File, Name and workpiece dimensions
107
4.2.3.5. Editing workpiece data
To edit workpiece data:

- Double click with the left mouse button on the data item to be edited
- Enter the new data item
- Press “Enter” or left click on another data item
Note :
- Note: Some data items have preset values. In this case, the new value must not be
typed in, but selected from a drop-down menu which can be displayed by clicking
on the arrow to the right of the value or on the value itself.
- Note: the data “File”, “Name” and “workpiece dimensions” cannot be edited.
4.2.3.6. Meanings of workpiece data
Each workpiece contains the following data:
- File Æ Workpiece file name

- Name Æ Workpiece name
- Length Æ Workpiece length
- Width Æ Workpiece width
- Thickness Æ Workpiece thickness
- Material Æ Workpiece material
- Quantity Æ Quantity of workpieces to be machined
- Extra quantity Æ Quantity of workpieces to be machined if space remains on
the sheet after machining the required quantity of workpieces
- Angle Æ The angular increase used for tests when positioning
the workpiece during Nesting processing
- Rotation Æ Workpiece 90° rotation (tick to select)
- Grain Æ Direction of workpiece grain
o X
o Y
o None
- Priority Æ Priority for insertion of workpiece on sheet
(the workpiece with the highest value is inserted first)
- Distance from edge Æ Distance from edges in workpiece positioning
Notes:
- The parameters Angle, Priority and Distance from edge are only available in Free
Form Nesting
- The Rotation parameter is only available in Rectangular Nesting.
108
4.3. Opening an existing Nesting Project
To open an existing Nesting Project, click on the “Open”
icon.
A window appears in which you can select a file.

Change the “File type” (whose default setting is: “Project (*.pgmx) ) to Nesting (*.nstx).
Then select a .nstx file, followed by the “Open” key.
Or double click on the .nstx file.
If there is a project already open, the

“Close Project” function is automatically activated.
4.4. Closing a Nesting Project
Nesting project closing is the same as for a normal project

(see sec. Errore. L'origine riferimento non è stata trovata. )
4.5. Saving a Nesting Project
Nesting project saving is the same as for a normal project

(see sec. Errore. L'origine riferimento non è stata trovata. )
109
4.6. Nesting Processing
Nesting project processing takes place when you click on the “Finish” command in the
“Parts” dialogue box (see sec. 4.2.3 ).
You access the “Parts” dialogue box both when a Nesting project has been created and
when an existing Nesting project is opened, since all of the data entered at the creation
stage was saved in the .nstx file.
After giving the “Finish” command, Nesting

processing beings and it ends with a report message
which summarizes the result:
Click on “OK” and the project graphics appear,

showing all of the workpieces positioned on the sheet.
4.6.1. Conditions to be complied with in Nesting
If the data relating to:

- Thickness
- Material
- Grain
is not compatible between the workpieces and the sheets, Nesting processing is not
successfully completed and the following message appears:
(No parts could be processed because their thickness, material or grain is not compatible
with any of the sheets available. Update the parts or sheets data and run the algorithm).
110
4.6.2. Recurring strategies in Nesting
4.6.2.1. Positioning small workpieces at the center
A recurring technique in Nesting is that of positioning small workpieces at the center of the
panel to overcome hold-down problems.
To do this:
- assign small workpieces a priority value higher than that of larger workpieces
- for the small workpieces set a “Distance from edge” value which places them at the
center.
Example :
The result obtained is as follows:
111
4.6.2.2. Contouring outside the sheet
To increase the number of workpieces which can be obtained from a sheet, you can use
the technique of producing workpiece contours which are on the edges of the sheet
outside of the sheet.
To do this, simple put a tick by the “Enable cutting outside the sheet” parameter (see sec.
4.2.1.7 )
Example :
4.7. Optimizing Nesting machining
After Nesting processing and before the workpieces are machined on the machine, it is a
good idea to optimize the Nesting project produced.
(see sec. Errore. L'origine riferimento non è stata trovata. Optimizing Projects)
112
5. Tool Data-Base
The tool data-base includes all necessary information to choose the tools for the working
processes as it has been established.
In order to manage the tool data-base you use the “ToolManager.exe” , launched by
clicking on hte icon "Tools" of the menu "Machines".
Tool Manager can be also launched from the installation directory by clicking on the file
“ToolManager.exe” .
The Tool Manager Interface is shown as follows:
113
5.1. Default for tool Data-Base
It is possible to change the Data-Base defaults by clicking on the menu "Options" in the
folder "Tools"
5.1.1. Default "Name Tool Data-Base "

In order to modify the default name of a new tool Data-Base:
Click on the icon "Opzioni"
Fill the field "Name of the default tool file".
5.1.2. Default "Folder for tool Data-Base"

In order to modify the folder name where toll data-base are open/saved:
Fill the field "Path of the Tlgx export directory"
5.1.3. Default "Folder for Import/Export toll Data-Base"

In order to modify the default name in which tool Data-Base are imported exported:
Fill the field "Path of the Xilog Bin directory".
114
5.2. Tool Data -Base creation
In order to create a tool data-base, you use the command " in the menu “Home” “File”.
The data-base will be empty but strctured with following categories:
5.3. Tool data-base opening
In order to open a tool data base, click on the icon "Open".

A window will appear where you can select a Tlgx file.
The default folder will be definedas described in paragraph
5.1.2. Default "Folder for tool Data-Base"
Then select a Tlgx file and the button open
Or click twice on the Tlgx file.
If a tool data-base has been already open, the option "Tool data-base closing" would be
automatically performed.
115
5.4. Closing tool data-base
In order to close an open tool data-base, click on the icon "Close".
If the tool data-base has not yet been saved, following question will appear:
By clicking on "Yes", the option "Saving tool data-base" will be automatically performed.
116
5.5. Saving tool data-base
In order to save an open tool data-base, click on the icon "Save"

If the tool data-base had already been named, no question would be made.
If the project was already created, the option "Save con nome" would be performed.
The default folder proposed for the saving is set as described in paragraph 5.1.2.. Default
"Folder for tool Data-Base"
You can specify the data-base name in the folder "File Name".
then click on "Save".
117
5.6. Tool data-base import from Xilog
In order to import a tool data-base from Xilog, use the command "import" in the menu
"Home" "Conversion".
The default folder proposed to import a tlg file is set as in paragraph 5.1.3 Default Folder
Import/Export tool Data-Base.
You can also specify the tool data-base Xilog (tlg) in the fiedl "File name:"
then click on "Open".
118
5.7. Tool data-base export to Xilog
In order to export a tool data-base to Xilog (tlg) in the menu "Home" "Conversion".
select the file. Tlgx to be exported from the dialogue window and click on the button
"Open".
Following message will appear to confirm the export:
119
5.8. Activate Tool Data-Base
In order to insert any working process on a sole project, you have to select a tool data-
base to be activated since the working processes are described by combining a tool and a
2D geometry.
In order to activate a tool data-base, use the menu "Machines" "Tools".

By clicking on the button "Tools"; a list of available data-base will appear in the "default"
folder.
The tool data-base marked on the left is the active one.

In order to activate another one, select it with the left button of the mouse.
You find the information about the tool data-base is to be found also in the lower
workpiece to the right of Maestro interface.
120
5.9. Tools
The tools are the object used for working processes.

In order to use them, you need to know all geometric and technological information of
every tool.
The information collected must be inserted in a toll Data-Base
5.9.1. Tool introduction
In order to insert a new tool in the data-base, you use one of the commands in the
following menu:
After selecting the command about the tool you have to fill the fields in the menu "General
Data".
These data are common for all tools, for every category will be necessary to insert the data
related to the tool type.
121
5.9.1.1. Points
Boring points are divided into following categories:
Lance Point Flared Point Flared Lance Point Flared Plain Point
In order to insert a point in the data-base, click on the command related to the wished
head in the menu "Point s" and fill all fields in order to describe the point shape and use
properties (speed, rotation number and so on)
122
5.9.1.2. Milling cutters
Cutters are divided into following categories:
Cylinder cutter Spheric Cutter Toroidal Cutter
In order to insert a cutter in the data-base, click on the cutter type in the menu"Milling
cutters" and fill all fields to describe the cutter shape and use properties (speed, rotation
number and so on).
123
5.9.1.3. Blades
Blades are all contained in the category "Blades".
In order to insert a blade in the data-base, click on the command "Universals" in the menu
"Blades" and fill all fields to describe the blade shape and use properties (speed, rotation
number and so on)
124
5.9.1.4. Probes
Probes are all included in the field "Tools for contact".
In order to insert a probe in the data-base, click on the command " sphere-shaped" in the
menu "Probes" and fill all fields to describe the probe shape and use properties (speed
and so on).
125
5.9.1.5. Heads
Heads are divided into following categories:
Inclined angle return Multi-spindle angle return
In order to insert a head in the data base, click on the command related to the head type in
the menu "Heads" and fill all fields to describe the head shape and use properties (speed,
rotation number and so on).
If you wish to add a spindle in the multi-spindle head, click with the right button on "User
head", a contextual menu will appear with the command "Add spindle".
Then fill the data about the new spindle.
126
5.9.2. Modifying tolls
In order to modify a tool:

- Search the tool in the type folders:
- choose the tool
- modify the values
- confirm the modification by clicking on the button "Apply"
In order to confirm the tool data-base modification, the tool data-base saving must be
performed (see paragraph 5.5 )
5.9.3. Tool removal
In order to remove a tool data-base:

- Search the tool in the type folders:
- choose the tool
- click with the right button on the tool name
- click on the command "Remove" in the contextual menu
In order to confirm the tool data-base modification, the tool data-base saving must be
performed (see paragraph 5.5 )
127
6. Machine configuration
128
7. Post-Processor
Projects performed with Maestro can be exported in xxl or pgm files as input data for the
interface "Xilog"
7.1. Xilog installation
In order to translate project into files compatible with Xilog (xxl or pgm) it is necessary that
Xilog is installed.
In order to choose the field for Xilog installation, click on the icon "Options" in the field
"Tools"
Write the folder name in the field "Xilog folder"
129
7.2. Post-Processor Options
Post-processor options can be set by clicking on the icon "Options" in the folder "Tools".
If you select the folder "Post", following screen will appear:
The "Output Folder" is the folder where XXL or PGM projects will be written as selected in
"Output Format"
130
7.3. Project translation for Xilog
In order to translate the open project in a file compatible witht Xilog (xxl or pgm) use the
command "Post" in the menu "Machines".
If this message appears:
You have to insert the correct path where Xilog has been inserted (see paragraph 7.1)
If the translation is well performed, following message will appear:
By clicking on "Yes", the program for Xilog will be displayed.
131
8. Appendix
8.1. Sizes used by Maestro

Maestro uses several files with following sizes:
epl Instructions to set clamps/suction pads

lbdx machine elements library
lbsx supports library
nstx Nesting projects
pgmx Projects
tlgx Data-base Tools
xcs Script Files
xml Instructions to set parameters/geometries
xsp Sub-programs
xxl Files exported for Xilog
pgm Files exported for Xilog
132

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User manual

1. DESCRIPTION OF THE SOFTWARE ..................................................................................................... 6

Maestro interface is structured as follows:

There are six areas:

Following chapters describe all commands included in the menus.

A project can be:

By using these icons in the Menu area:

3.1.1. Default: "Project name”

3.1.2. Default “Project folder”

If you wish to set up a new project,.click on the icon "Create project"

The name of such new project will be definedas described in paragraph

3.3. Open an existing project

3.3.1. Open a sub-program

If you wish to end a project click on the icon "Close".

If your project is saved, following question will appear:

If you wish to save an open project, click on the icon "Save"

In order to save a sub-program, use the command

If you click on "end", the saving process will end.

You can check the saving process :

Workpieces must be defined as "Finalised workpiece" and optionally also as "Rough

3.6.1. Rough workpiece

3.6.2. Finalised workpiece

3.6.2.1. Parallelepiped shaped workpiece

3.6.4. workpiece Removal

In order to remove a workpiece:

Working planes can be created in three ways:

Names and positions of the "Standard Faces" are as follows:

Upper Face Lower Face

Left Face Right face

Front Face Back Face

by using the menu “Draw” “Inclined Plane” “Parallel Plane”

In both cases a window will be displayed:

by using the menu "Draw" "Inclined Planes" "Generic"

3.7.4.1. Work plane selection

3.7.4.3. Plane removal

You can delete only the Parallel Planes or Inclined Planes.

In this example, you see a project in which the “Upper Face”

If you wish to switch all working processes off you can:

If you wish to display all working processes you can:

3.8.1. Introduce new geometries

For an existing point:

FinalÆ It is linked to the final point of any graphic shape.

IntersectionÆ It is linked to the intersection of two entities.

MiddleÆ It is linked to the middle point of any entity (also a circle)

CentreÆ It is linked to the centre of arcs and circles.

Perpendicular Æ It is linked to the point perpendicularly projected to a segment.

Tangent Æ It is linked to the tangent point of an arc or a circle.

ParallelÆ It is linked to the point projected on the parallel to a segment.

Point Æ It is linked to an entity "Point”.

Horizontal Æ It keeps the Y coordinate of the previous point.

Vertical Æ It keeps the X coordinate of the previous point.

Near Æ It is linked to the point nearer to the point of the mouse.

It introduces a geometric element: "Point”

In order to introduce a point:

In the graphic area the point is represented with this symbol:

A line can be inserted in two ways:

1) Line for 2 points

2) Length and angle line