How to create a rounded toolpath in Vectric software | Wrapped Rotary Machining

Overview

This tutorial demonstrates how to create a rounding toolpath in Vectric Aspire/VCarve Pro using the Create Rounding Toolpath gadget. It is used to machine a perfectly sized cylindrical blank from square or oversized round stock before rotary machining.

Steps

1. Create a new rotary job
   File → New, set:

   • Job type: Rotary
   • Length: 12 inches
   • Diameter: 3 inches
   • Units: Inches
   • Orientation: Along X axis
   • XY datum: Bottom left
   • Z zero: Center of cylinder
   • Modeling resolution: Very high

2. Open the Create Rounding Toolpath gadget
   Gadgets → Wrapping → Create Rounding Toolpath.

3. Set blank size and shape
   Choose either square stock or round stock. If square, set the target diameter (e.g., 3.25 inches) – slightly larger than the job diameter for finishing.

4. Select machining methodology

   • Radial around cylinder
   • Raster along cylinder
   • Optimized raster along cylinder – recommended for square blanks because it machines off corners first.

5. Set allowance (optional)
   Leave extra material for a semi-finishing pass if needed.

6. Choose a tool
   Click Select, pick an appropriate end mill (example: 1/4“ end mill), and verify speeds/feeds are safe for your machine.

7. Confirm cylinder dimensions and name
   Check length and diameter match the job setup. Change the toolpath name if desired, then click OK.

8. View the toolpath
   Switch to the Toolpath menu and use the 3D view to inspect the generated toolpath and simulated blank.

9. Verify material setup
   Click Set and confirm diameter, XY datum, Z zero position, rapid Z gap, clearance, and plunge values are safe for your machine. If any changes are made, recalculate all toolpaths (dismiss the popup if nothing changed).

10. Preview the toolpath
    Preview the selected toolpath. The software unwraps the cylinder, machines the corners, then wraps the result.

11. Check blank orientation
    Ensure the flat edge of the stock is parallel to the XY plane. If rotated, the tool may cut into free space or remove too much material.

12. Save the toolpath
    Open Save Toolpath, confirm the correct rotary post processor (e.g., gcode wrap Y2A) is selected, name the file (e.g., rounding toolpath), and save.

Key Points / Warnings

• The gadget is useful when starting from square stock or an oversized round blank that must be reduced to an exact diameter.
• Set the rounding diameter slightly above the final cylinder diameter to allow for a finishing pass.
• Optimized raster is only for square blanks; it removes the four corners first to avoid heavy radial cuts.
• The allowance option leaves material for a separate semi-finishing toolpath, especially when using a coarse tool.
• Always verify tool settings, rapid gaps, clearance, and plunge values for your specific machine before running.
• If material setup is changed, all toolpaths must be recalculated.
• The preview mode shows the unwrap → machine → wrap process, confirming the final rounded shape.
• The XY plane must be parallel to the flat side of the stock; any rotation can cause incorrect cutting or air cuts.
• A rotary post processor (e.g., gcode wrap Y2A) is required to convert Y-axis moves into A-axis rotary motion.