How do I create a new tool in FreeCAD path?

To create a new tool in FreeCAD's Path Workbench, you'll define a new Tool Bit within a Tool Controller, typically managed through the Tool Manager. This process allows you to specify its geometry and cutting parameters for your CNC operations.

Understanding FreeCAD Path Tools

In FreeCAD's Path Workbench, a "tool" is specifically referred to as a "Tool Bit" which is contained within a "Tool Controller." Tool Controllers hold the physical characteristics and operational parameters (like feed rates and spindle speeds) for a specific tool. Creating a new tool involves defining these aspects to ensure accurate path generation.

Step-by-Step Guide to Creating a New Tool

Follow these steps to add a custom tool to your FreeCAD Path setup:

1. Open FreeCAD and Switch to Path Workbench:

   • Launch FreeCAD.
   • From the Workbench selector (usually a dropdown menu at the top), choose "Path".

2. Access the Path Tool Manager:

   • Go to the menu bar and select Path -> Path Tool Manager.
   • Alternatively, you can click the Path Tool Manager icon in the toolbar (it often looks like a milling cutter).
   • The Path Tool Manager dialog will open, showing your current tool libraries and available tools.

3. Choose a Tool Library or Create a New One:

   • You can add tools to an existing library (e.g., Default Tool Library) or create a new library for custom tools by right-clicking in the Libraries section and selecting New Library. This helps organize your tools.

4. Initiate New Tool Creation:

   • Select the library where you want to add the new tool.
   • Click the "Add Tool" button (often represented by a green plus sign icon) within the Tool Manager. This action will prompt you to define the new tool bit.

5. Define the Tool Bit Type:

   • A dialog will appear, allowing you to select the type of tool bit you want to create (e.g., End Mill, Ball End, V-Carve, Center Drill). This step is crucial as it sets the basic geometry template for your tool.
   • Select the appropriate tool type that matches your physical cutting tool.

6. Configure Tool Bit Parameters:

   • After selecting the tool type, a detailed configuration dialog will open. In this dialog, a thumbnail of the selected tool shape should appear along with a list of parameters.
   • Set the Bit Parameters as desired. These parameters define the precise dimensions and characteristics of your tool. Key parameters often include:
     • Diameter: The cutting diameter of the tool.
     • Cutting Edge Height: The length of the cutting flutes.
     • Flute Length: Similar to cutting edge height, specifies the effective cutting length.
     • Shank Diameter: The diameter of the non-cutting part of the tool that fits into the collet.
     • Corner Radius (for specific tools): The radius of the cutting edge corner.
     • Tip Diameter (for V-Carve/engraving): The diameter at the very tip of the tool.
     • Angle (for V-Carve): The included angle of a V-bit.
   • You can also specify Default Feed Rates (e.g., Horizontal Feed, Vertical Feed) and Spindle Speeds here, which will be pre-filled when you use this tool in an operation.

7. Save the New Tool Bit:

   • Once all parameters are correctly entered, click "OK" or "Apply" to save the new tool bit.
   • The new Tool Bit will appear in the FreeCAD object tree (specifically within the Path Job or the active Tool Library in the Tool Manager).

Practical Insights and Tips

• Accurate Measurements: Always measure your physical tools precisely with calipers to ensure the parameters in FreeCAD match reality. Inaccurate tool definitions can lead to incorrect path generation, collisions, or poor cut quality.
• Tool Libraries: Organize your tools into logical libraries (e.g., "Wood Milling," "Metal Engraving," "Custom Bits") for easy access and management.
• Default Parameters: Setting default feed and speed rates for your tools can save time during operation setup, but always review and adjust them based on the material, machine, and specific operation.
• Duplicating Existing Tools: If you have multiple tools that are similar (e.g., different diameter end mills), you can often duplicate an existing tool and then modify its parameters, which can be faster than creating from scratch.
• Tool Number: Pay attention to the tool number assigned. While FreeCAD assigns one automatically, some CNC machines require specific tool numbers to match their magazine slots. You can usually edit this in the Tool Controller properties.

By following these steps, you can effectively create and manage your custom cutting tools within FreeCAD's Path Workbench, streamlining your CNC programming workflow. For more in-depth information, you can refer to the FreeCAD Path Workbench documentation.