I don't think it was pirated software. Older gentleman in a job shop who was not that proficient with a PC.

Where would that file be? Also, could could there be a button along the top that corresponds to the dxf conversion?

Strange. Maybe it has been so long that I just wasn't looking in the right place. I know that V9 won't just open the file like X will. Seems like I have to tell it to specifically go through the converter option.

I ran into an old pc (windows XP) running V9 the other day that did not have the dxf option under the converters list. It has been a long time since I've run version 9 or 9.1, but I remember there being a dxf option in there. I was just curious if this was something that should have been added at installation or if it is some sort of option.

A friend of mine experienced in surfacing was telling me that 2 flute endmills are the only ones that really cut all the way down to the center. I was looking at some 3 and 4 flute ball endmills, and sure enough, I see the relief. Can a 3 or 4 flute be used in the rough surfacing (or any op for that matter) at all, and how do I know the limits for speeds and feeds because of the small section of flute that is essentially not cutting?

Can you elaborate on what exactly radial chip thinning is?

I don't know much about 3d surfacing, or optimizing feeds at the moment. I'm still trying to learn. Please excuse my ignorance. I have used two online speed calculators, and trying to decide how to go further on them. I use FSwizard for the most part because it is free, but I have downloaded the trial of Gwizard. Gwizard seems to give a lot faster feed. I just redid my toolpaths by double checking all my inputs. I am not exactly sure why I was getting such a low number, but I suspect it could have been the input of length. I thought that meant the length of the whole entire tool, not just the stickout from the holder. That changes things considerably. Now I am getting this at 100% on FSWizard: S10K F27.5 for roughing - max axial .067", stepover (radial) .012" S10k F30.38 for finishing. max axial .003", Stepover .006"

The new feeds at 100% are S10K F5.7 for roughing - max axial .067", stepover (radial) .012" S10k F17 for finishing. max axial .003", Stepover .006"

I'm running at 70% on speeds and feeds. Maybe should kick it up to 100%. changing to 100% knocked of another hour or so. Down to 1hr 33min.

It is just a test, but the way the cut works is it initially starts off taking 0(zero) in the Z. It then progressively works down to a final depth of about .067". That would mean that the most axial engagement the tool will see is .067", but the radial will never exceed the max stepover - currently .006" I am cutting aluminum at the moment for the test, and the way I have my speeds figured are at S8350 / F4.2 on the rough pass, and S10K F12. on the finish. 10K is all I have at spindle. If I double the rough stepover, that makes the axial cut .012", and the speeds I'm getting for that are S8350 / F3.3 --Changing from .006" to .012" brought my machining time down from 3hr 31min to 2hr 28min.

Doing more surfacing stuff. Let's say I'm using a 1/8" ball to rough. I was wondering what stepover would be about the max I can leave that a finish pass won't choke on. Initially I was going to use a 1/16" ball to finish, but if I can do it with that same (size) 1/8", I feel like i can push it faster and it would eliminate a tool change. Assuming I do just use one size of tool (1/8"), the way I have it programmed now is to do a .006" stepover and leave .003 on the drive surface for the rough pass. The finish pass is programmed with the same .006" stepover, but no zero material left on the drive surface. Should I open up the stepover on the rough pass?

Ok points taken. I actually have a half inch ball to use as well, and this might be better for the roughing. As far as the bull, I don't really have any endmills that have corner radius at the moment, but I'm just thinking of how the compensation would work. Would I run on left or right cutter comp vs Center or off? I was using the .125" tool because I have a feature that needs it, but it amounts to about 5% of the overall surface operation. I may split that off into its own little surface, and then use the .125" tool there. I need a .065" internal radius and that's why I'm using that tool. I had it finishing the whole op though, and that was taking forty forevers with a .002" stepover. I may go back with the same .25" ball tool that I did the roughing with, and try to make a finish pass with it on the 95% of the surface that remains.

I had a thread here a few months about trying to understand the 3D surfacing side of X9 if I was on mill level one. I have gotten all that straightened out now and have my bearings. It turns out, level one will do surfacing, but only on one surface at a time. That is perfectly fine for what I am doing at the moment. I am able to use the feature just fine and have already created a few tool paths. I have never done any 3D surfacing stuff, and the first thing that stands out is the machining time, especially with small stepover. The only thing I can figure on this is that since the stepover is so small, the tool should be able to withstand significantly faster speeds and feeds. Is this something that the typical speed and feed calculators have provisions for? I have never looked at that side before. Also, I guess that larger stepover is ok for roughing type operations, and then save the small stepover for final finish passes. What I'm doing will be roughing with a .25" ball, and then finishing with a .125" ball. I have a 10K spindle.

I guess I'll just have to wait. My reseller is working on another project at the moment. Appreciate you all's help.

Ok, I have a solid model open in x9. It is a Solidworks file, and I assume it is now a Mastercam file. Where would I start on doing this? For what it is worth, if there is a video or a tutorial somewhere, I'd be glad to go there instead of pester you all. lol I can send the file and also talk with someone on the phone if need be as well.