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Companies that invest in complex machine tools quickly see the advantages of mill-turn machines that perform multiple milling and turning operations on a single machine tool, and often with a single set-up.

What these companies also see is the need for a powerful CAM system to handle the complex programming that factors into the mill-turn equation. Here are six reasons that companies turn to ESPRIT to maximize the productivity of their machine-tool investments.

Program any Machine Tool

The high-performance ESPRIT system offers powerful programming for any CNC machine tool. ESPRIT's full-spectrum functionality includes programming for 2-5 axis milling, 2-22 axis turning, 2-5 axis wire EDM, multitasking mill-turn machining, and B-axis machine tools. Streamline your operations with the powerful and flexible ESPRIT system, valued by CNC programmers for its extensive suite of machining cycles, comprehensive tool control, and capacity to fully support an entire shop.

Machine any Part Geometry

ESPRIT's seamless CAD to CAM interface directly imports any native part model from any source, fully intact, with no need for programmers to edit or rebuild geometry. ESPRIT directly machines from any combination of geometries — solids, surfaces, wireframe, or STL — providing you with complete manufacturing flexibility. Starting with 100%complete and accurate part geometry eliminates nearly all of the difficulty in programming complicated parts and dramatically reduces programming time.

Universal Post Processing

ESPRIT's universal post processor effortlessly creates the high-quality G-code you need to fully exploit your machine tool investment. With ESPRIT you get proven out-of-the-box operation with a complete library of pre-defined post processors. Additional factory-certified posts are available for many of the leading machine tool brands, and ESPRIT's open architecture allows you to easily adjust any post processor to suit your personal preferences and shopfloor requirements. ESPRIT's flawless G-code means you will spend more time cutting parts, giving you maximum machine utilization and optimal part quality at the lowest possible cost.

Dynamic Solid Simulation and Verification

ESPRIT's fast, accurate, and reliable dynamic solid verification eliminates the need for expensive dry runs on the NC machine. Gain complete confidence in your machining process as you compare accurately rendered "as designed " versus "as machined" parts. High-performance, real-time simulation and comprehensive collision detection ensure that even the most complex of parts will be machined correctly the first time. ESPRIT gives you exhaustive verification of the part program simulated within a complete machining environment: machine tool, fixtures, clamps, stock, and workpiece. Minimize downtime, maximize manufacturing efficiency, and cut machining costs while gaining complete confidence in your machining processes with ESPRIT.

Full Synchronization and Verification

Optimize, synchronize, and verify your multitasking machining with ESPRIT's fully integrated solid simulation. ESPRIT readily simulates any combination of mill-turn (2-5 axis) and turning cutting cycles, multiple spindles, multiple turrets — up to 22-axes — in one display. View a combined listing of all your milling and turning operations and their associated cycle times. You will have a realistic verification of how the part is machined eliminating any potential machine crashes along with the ability to move, copy, edit, and synchronize your operations to minimize your cycle times.

Flexible B-axis Programming

Capitalize on the power and flexibility of mill-turn machines with B-axis capability for precise 5-axis simultaneous and 5-axis index milling — on the front and back of any workpiece. ESPRIT's full 5-axis control lets you easily program the non-perpendicular multi-axis tool movements required to machine the intricate features and compound angles of medical components, complex valves, tool holders, oil drilling tools, and the like. ESPRIT provides advanced 5-axis control for its machining cycles including facing, boring, grooving, threading, contouring, pocketing, hole making, and 3D finishing.

Pre-packaged Software Solution

ESPRIT delivers a fresh, out-of-the-box approach to solving the issues that arise with programming complex multitasking machines, such a post processor writing and machine definition. Imagine programming your multitasking machine with a complete, pre-configured solution— developed in cooperation with the machine tool builders and tested extensively at the factory level. ESPRIT's mill-turn prowess is the ultimate result of a collaboration with machine builders and DP's focused software development for this specific class of machine tools. Trust ESPRIT to unlock the potential of your multitasking machine.

Multitasking Efficiency

Multitasking machine tools with mill, turn, and drill capabilities are increasingly popular in metalworking today. These sophisticated machines allow manufacturers to perform simultaneous milling and turning operations, on the front and back of a part, in a single setup. Mill-turn machines represent an enormous potential for profitability, but possess inherent programming challenges due to their complexity. The right CAM system is a key factor for success in the mill-turn equation. It's a critical choice that determines the ultimate productivity of your machine investment.

Comprehensive Multitasking Machining

ESPRIT provides an integrated programming environment specifically designed for multitasking, multi-function CNC machine tools. ESPRIT supports any combination of independent, synchronized, and synchronous milling and turning utilizing any configuration of A, B, C, X, Y, and Z axes. ESPRIT's five levels of functionality for 2–5 axis machining fully support your mill-turn needs, including milling with full, simultaneous 3-axis and 5-axis 3D multi-surface solid machining.

Powerful Programming for All Milling Machines

ESPRIT is easy to use for quick jobs, yet packed with power to handle the most complex production milling work. Whether you are programming 2 1/2-axis parts or 5-axis machining, ESPRIT will give you the programming power you need and the ease-of-use you are looking for.

Production Milling with 5-axis Machines

ESPRIT SolidMill Production adds 5-axis machining capability to ESPRIT's milling cycles. Programmers can use multiple fixture offset with local or global work coordinates to machine any part face, using any ESPRIT machining cycle. ESPRIT's 5-axis indexing supports any combination of rotary tables and tilting heads to orient the part, then machines with 2 1/2 and 3-axis operations using one or more ESPRIT cycles

Roughing and Pocketing

ESPRIT's pocketing cycle provides full tool control and extensive automation for roughing and finishing pockets. ESPRIT can dramatically simplify your programming whether you are machining straight-forward squares or complex pockets with irregular boundaries, multi-level islands, and multiple bosses and sub-pockets. The broad variety of pocket machining and finishing patterns provided by ESPRIT yields virtually unlimited options for your pocket milling needs.

Contouring

CNC programmers find ESPRIT's contour machining cycle a flexible and powerful tool for a variety of machining applications, ideal for profile cutting, roughing, slotting, semi- finishing and finishing straight or tapered walls with constant or variable cutting depths. Simply set your machining parameters and ESPRIT will read the feature properties required to create the toolpath for cutting any geometry. For more comprehensive tool control, ESPRIT will manage individual tool movements while providing you control over individual machining parameters at any point during the cut.

Rest Machining

ESPRIT's intelligent rest machining cutting cycle automatically recognizes the machining operations and cutting tools associated with a given part feature, compares the workpiece 'as machined' to the original part 'as designed', and automatically performs pocketing and contouring of the uncut areas of remaining material. ESPRIT programmers use the rest machining cycle to easily perform roughing and pre-finishing work with optimal cutting tool choices.

Drilling and Hole Making

For drilling and hole making, choose between ESPRIT's machining cycles and your machine tool's canned cycles,or use a combination of both. Cut complex holes that require multiple cycles and tools in a single step with ESPRIT. Using the Process manager, in one step you can spot drill with chamfer, through drill, counter bore, and ream a set of holes. ESPRIT's thread milling machining cycle gives you the ability to machine internal or external right- or left-hand threads, and ESPRIT's spiraling cycle is ideal for milling holes. ESPRIT automatically generates optimized toolpaths, minimizing cycle time.

Machine Complex Free-Form Shapes with Ease

ESPRIT's NURBS-based machining engine handles fabricating difficult free-form shapes with ease. Specifically designed to address the 3D challenges in the mold, die, and toolmaking markets, ESPRIT provides you with a powerful set of tools and machining cycles for free-form roughing, Z-level machining, finishing, and re-machining in 3-axis or 5-axis.

5-axis Free-Form Machining

Machining complex 3D parts in a single setup is easy with the powerful ESPRIT CAM system. ESPRIT streamlines programming and provides dynamic onscreen program verification, eliminating the need for expensive machine-tool dry runs. For 5-axis finishing, ESPRIT gives you a full range of options, including planar, normal, transitional, parametric, and offset styles. Program your 3D 5-axis machine cycles with ESPRIT and benefit from the superior surface quality, part accuracy, and material removal rates provided by today's multi-axis machine tools.

High-Speed Machining

ESPRIT's high-speed machining (HSM) functionality is built into all its machining cycles allowing you to cut hardened materials in minimal time while maintaining constant loads on cutting tools utilizing the smooth, continuous movements so critical in 3D HSM. Your choices include sharp corner smoothing, loop-style bridge movements, ramp and helical entry into material, spiral-style cutting with constant overlaps, tangency entry, and constant Z-level cutting. HSM optimization for NURBS, spline-curve and arc-optimized G-code output is built into ESPRIT's universal post processor.

Z-Level Machining

ESPRIT's Z-level machining cycle automatically maintains constant loads on cutting tools for smooth, continuous high-speed toolpaths. When creating a Z-level finishing operation you have the option to machine the entire part or selectively machine only vertical or horizontal areas. When machining the entire part you can choose to cut the vertical and horizontal areas with different tools and use both roughing and finishing options.

Roughing and Finishing for Complex Parts

Achieve high-quality surfaces with ease with ESPRIT's roughing and finishing cycles, with one- or two-tool options. ESPRIT's 3D roughing cycle performs zigzag, offset and spiral-style rough machining on even the most complex free-form solids and surfaces. Select from nine different semi-finishing and finishing cycles and machine your 3D workpiece to perfection — use one cycle for finishing the entire part, or define containment boundaries and machine zones differently using the most appropriate cycles and cutting styles for each.

Automated Rest Material Re-Machining

Automate re-machining of the uncut areas of your part for maximized part quality and minimized bench work with ESPRIT's rest-material re-machining cycles. ESPRIT monitors the material left over from previous machining operations and uses the information to automatically perform any number of roughing and finishing cycles. Choose from pencil tracing, lace cutting, parallel flowline, and spiral tool-motion patterns, then select a cutter to automatically remove all remaining material.

Machine Regular and Irregular Workpieces

All ESPRIT free-form machining cycles are optimized for machining regular and irregular-shaped stock and workpieces including surface, solid and STL models, and previously machined workpieces. All cutting is identified and contained "limited to the material to be machined for the final part" resulting in optimized machining, reduced cutting time, elimination of air cutting and extended tool life.

Traditional Turning

ESPRIT streamlines and standardizes your lathe machining, with a minimum investment of time and training. ESPRIT offers contour profile cutting for facing and OD or ID turning, a universal machining cycle driving single-point tools for a wide variety of machining tasks. ESPRIT's roughing cycle enables you to work from castings, pre-roughed, irregular-shaped, or bar stock, and has options for controlling every aspect of machine movement — from clearances to differing Z and X stock allowances. For drilling and hole making, choose between ESPRIT's pre-programmed machining cycles and your machine tool's canned cycles, or use a combination of both.

Advanced Machining Cycles

ESPRIT gives you seven grooving cycles with a variety of optional tool movements, including single plunge, multiple plunge, peck grooving, zigzag grooving, and even contouring with grooving tools. For thread machining, ESPRIT offers multiple threading options, including single or multi-point, with straight or tapered threads, and constant or variable leads. ESPRIT automatically calculates the depth and number of cuts, with a manual override option.

Flexible Tooling Options

ESPRIT simplifies the tooling definition process and gives you full tooling support, from standard boring bars to complex custom form tools. Select from a complete ANSI/ISO- tooling library with inserts and holders, or define custom tools in any CAD system, or in ESPRIT, to import into ESPRIT's tooling library. ESPRIT's definition of the complete tool — insert, holder, and turret — ensures highly accurate machining results.

Full Programming for Traditional and Multi-axis Turning

Traditional turning centers are being rapidly supplemented by multi-axis machines with the ability to produce complex parts unattended. Whether you are looking for a CAM system to automate your traditional turning "from roughing and grooving to threading and finishing" for faster, more accurate results, or to maximize your multi-axis machine tool investment, ESPRIT is the right CAM choice.

Multi-Turret, Multi-Spindle Production Turning

Gain full control over your production turning with ESPRIT's program synchronization, dynamic simulation, and accurate collision detection. You'll be empowered to work simultaneously on the front and/or back of the work piece with one, two or more cutting tools. When you use ESPRIT to unlock the potential of your production turning center, your cycle times are dramatically reduced and parts are completed in a single set-up. ESPRIT's comprehensive suite of machining cycles includes all part handling cycles — from initial material bar feeds and stock chucking, through steady rests, and part cut-off and pick-up.

Swiss-Style Machine Programming

Program your multi-axis Swiss-style turning centers with ESPRIT and realize their potential for single set-up, versatile, accurate, unattended machining. ESPRIT accommodates the special demands of your Swiss machines and makes it easy to create programs that take full advantage of Swiss-style capabilities with comprehensive tool path creation, simulation, collision detection, and accurate G-code generation. ESPRIT provides factory-certified programming solutions for Swiss-style machines from the leading builders including: Citizen, Star, and Tsugami.

Synchronization and Optimization

Perform time studies and synchronize your CNC program to readily optimize your G-code and minimize overall cycle time with ESPRIT's sync list. ESPRIT clearly presents the machining timeline in an easy-to-read bar chart organized by turret, spindle, and head. Synchronize and optimize your program using the Windows "drag and drop" technique with quick editing of machining cycles including turrets, spindles, cutting tools, all the individual machining parameters, and synchronization codes.

Accuracy and Predictability

Whether you use your wire EDM machine for small lots of sub-micron precision parts or as a workhorse for production machining, get the most out of your machine tool investment. Dramatically simplify the part-programming process, significantly increase part accuracy, and greatly reduce the length and complexity

of your G-code program with ESPRIT.

Complete Machine Control

ESPRIT provides a universal EDM contouring cycle to machine any contoured mold, die, core, cavity, shape or profile. This versatile machining cycle supports any number of straight or tapered rough and skim cuts while optimizing wire cutting paths. Strategies for all styles of EDM machining such as punch, die, multi-cavity parts, and unattended machining are included. Between cuts ESPRIT automatically handles all the necessary wire-cut and wire-thread instructions, and part-handling functions of the machine: flushing, tank fill, and tank drain.

Advanced Tapering

Easily program the complex tapers common to mold components, forming dies, and cutting tools with the advanced conics capability of ESPRIT's contour cycle. When cutting a radius during tapering, built-in advanced conics allows you to alternate between cylindrical constant radius corners and conical constant taper corners. ESPRIT also provides independent programmable upper and lower radius control. While tapering into sharp corners, ESPRIT offers you the flexibility to maintain sharp corners top and bottom or machine a blended radius on the secondary plane.

4-axis Synchronized Machining

Quickly program parts with extremely complex tapers or completely independent freeform shapes, top and bottom, with ESPRIT's XY (lower), UV (upper) 4-axis contouring cycle. Select any two three-dimensional profiles and the 4-axis cutting process is automatically synchronized; you can add an unlimited number of additional synchronization lines. ESPRIT adds tabs automatically and creates skim cuts for unattended machining. Get 4-axis programming for any geometric shape with any number of elements: 3D, non-planar, UV and XY profiles, and non-planar fixturing.

Efficient No-Core Cutting

Handling slugs efficiently during EDM machining becomes more difficult with decreasing workpiece size. ESPRIT provides a special EDM no-core pocket machining cycle to erode away all the material inside a given cavity without creating a slug. With no-core cutting, a start hole is drilled into the workpiece and ESPRIT recognizes and automatically machines only the slug, preventing wire breakage and minimizing machining time.

Factory-Certified Solutions

ESPRIT's machine-specific EDM KnowledgeBase™ provides you with a full range of cutting features, automation, and factory-certified post processors to maximize performance. Readily access each EDM manufacturer's unique cutting technology and methodologies through machine-specific technology pages.

ESPRIT’s machine-specific EDM KnowledgeBase™ provides you with a full range of cutting features, automation, and factory-certified post processors to maximize performance. Readily access each EDM manufacturer’s unique cutting technology and methodologies through machine-specific technology pages.

Leverage Strategic Assets

KnowledgeBase gives you the power to leverage your shop's most important strategic assets — its best machining practices developed over the years — for maximized productivity and a sharpened competitive edge. ESPRIT's KnowledgeBase™ provides a push-button approach for any programmer or operator to determine the best method to machine a given part or feature by automatically selecting the most appropriate machining cycles, cutting tools, and machining parameters. Free your lead CNC programmers from repetitive parts programming, let them focus on strategic process planning to further improve your best practices — and take your enterprise to a whole new level of production machining.

Streamline Programming

With ESPRIT's KnowledgeBase™ the days of relying on your memory to recall what worked before are gone. In KnowledgeBase™, process-specific information is stored securely and is readily available to any operator or programmer. ESPRIT uses the accumulated "knowledge" of your shop's best practices and preferred methods to automate CNC programming. Streamline your parts programming with ESPRIT's KnowledgeBase™ and achieve an unprecedented degree of automation, quality, and consistency.

Close the Productivity Loop

The multi-user SQL database built into ESPRIT's KnowledgeBase™ closes the loop between CNC programmers and the shop floor by providing a central repository for accumulating shop-wide machining experiences. Refine your best practices using real-world input and apply them automatically for flawless consistency throughout your enterprise.

Sharpen Your Competitive Edge

Your processes are always up to date with KnowledgeBase™ — each time a process in KnowledgeBase™ is used to program a part, the process is automatically retrieved and updated to reflect improved methods, refining your machining in a cycle of continuous evolution. KnowledgeBase™ eliminates guesswork, and shop-wide consistency means unprecedented manufacturing productivity and profitability.

Part-Feature KnowledgeBase

ESPRIT's Automated Feature Recognition is a powerful KnowledgeBase™ component providing CNC programmers with a new level of productivity-enhancing speed and accuracy. Automated Feature Recognition subdivides a given part into features like pockets, slots, shoulders, and holes. Each feature has a set of known physical characteristics including height, thickness, draft, volume, and area. This KnowledgeBase™ component automatically categorizes these features into feature cases based on a shop's standards, terminology, and each feature's characteristics. Examples of feature cases described in KnowledgeBase™ include: Large Open Pocket, M10 x 1.5 Tapped Hole, Thin Wall Part Face, and O-Ring Groove. With KnowledgeBase™ your programming automatically starts with a clear definition of what you are about to machine.

Process KnowledgeBase

The Process KnowledgeBase provides detailed tool control and extensive process automation, automatically choosing the most suitable process to machine a given feature — including machining cycles, cutting tools, speeds and feeds, and all associated machining parameters. When a process is applied, process steps are automatically adjusted to accommodate the feature geometry and other feature characteristics. Programmers can also easily create new processes and update details of existing processes with the Process Manager. All machining parameters are presented in a color-coded display for a clear visual representation of each parameter's source and condition.

Speeds and Feeds KnowledgeBase

A Speeds and Feeds calculator presents the best cutting speeds and feeds for each machining situation based upon the part material class and condition, cutting tool style and material, machining operation, and axial and radial depths of cut. The Speeds and Feeds KnowledgeBase Manager allows programmers to add and update cutting speeds for any given situation, and the optional CUTDATA™ database simplifies programming with over 100,000 speed and feed recommendations.