Sample Mastercam X5 Mill Level 3 Training Tutorial

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Mill Level 3 Training Tutorial

Mastercam X5 Mill Level 3 Training Tutorial Training Tutorial

Copyright: 1998 -2010 In-House Solutions Inc. All rights reserved

Software: Mastercam X5

Author: Mariana Lendel

ISBN: 978-1-926566-79-5

Revision Date: October 21, 2010

Notice

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Mill Level 3 Training Tutorial

Mill Level 3 Training Tutorial Contents

Getting Started ...................................................................................................A-1

TutorialsTutorial #1 .........................................................................................................................1-1

Tutorial #2 .........................................................................................................................2-1

Tutorial #3 .........................................................................................................................3-1

Tutorial #4 .........................................................................................................................4-1

Tutorial #5 .........................................................................................................................5-1

Tutorial #6 .........................................................................................................................6-1

Tutorial #7 .........................................................................................................................7-1

General Notes .....................................................................................................B-1

Quiz Answers ...................................................................................................... C-1

Mill Level 3 Training Tutorial Page|4-1

TUTORIAL #41

TUTORIAL #4

Objectives:

The Student will design a 3-dimensional drawing by:

!Creating the 2D wireframe for the revolved surface.

!Creating the revolved surface.

!Creating the wireframe for the draft surfaces.

!Creating the draft surfaces at 3 degree angle

!Creating 2D wireframe for the swept surface.

!Creating the swept surface

!Creating the 2D wireframe for the flat surfaces.

!Creating the wireframe for the draft surfaces.

!Creating the curve at one edge.

!Trimming surface to curves.

!Creating the fillet surfaces.

!Creating the flat surface.

The Student will create surface toolpaths consisting of:

!Surface High Speed - Area Roughing to rough out the part.

!Surface Restmill to clean areas that the previous tool can not.

!Surface High Speed - Hybrid to finish the part.

!Surface Finish Leftover to clean out the part.

The Student will simulate the toolpaths using Mastercam's Verify and Backplot by:

!Defining a 3-dimensional rectangular block the size of the work piece.

!Running the Backplot to see the path the tool takes to cut the part.

!Running the Verify to simulate the tool cutting from the solid model.

This tutorial takes approximately one hour and half to complete.

Page |4-2 Mill Level 3 Training Tutorial


SETTING UP THE GRAPHIC USER INTERFACE TUTORIAL #41

GEOMETRY CREATION

STEP 1: SETTING UP THE GRAPHIC USER INTERFACE

Before starting the geometry creation we should customize the toolbars to see the toolbars

required to create the geometry and machine a 3D part. See Getting started page A-4 for

details.

Make sure that the Grid is enabled. It will show you where the part origin is. See Getting

started page A-6 for further information.

The Operations Manager to the left of the screen can be hidden to gain more space in the

graphic area for design. From the keyboard, press Alt + O keys simultaneously to hide it.

See Figure: 1.0.1.

Repeat this command to make it visible again.

Figure: 1.0.1

Make sure that in the Status bar the 3D mode is enabled.


TUTORIAL #41 CREATE THE RECTANGLE

STEP 2: CREATE THE RECTANGLE

In this step you will learn how to create a rectangle knowing the width, the height and the anchor

position.

Step Preview:

2.1 Create the 9.0" by 6.5" rectangle

Create

Rectangle

Enter the Width and the Height and disable if needed, Anchor to center and

Create surface buttons as shown below.

Press Enter after typing the values to see a preview of the rectangle.

[Select position of first corner]: Select the Origin as shown in Figure: 2.1.1.

Figure: 2.1.1


CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE TUTORIAL #41

Make sure that when selecting the origin, the visual cue of the cursor changes as shown.

Use the Fit icon to fit the drawing to the screen.

Select the OK button to exit the Rectangle command.

STEP 3: CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE

In this step you will learn how to create different types of lines and fillets. You will also use trimming

options to clean up the geometry. To create a revolved surface you need the 2D profile and the axis of

rotation.

Step Preview:

3.1 Create the axis of rotation

Sub Step Preview:

Create

Line

Parallel

Enter the Distance 5.75 in the Ribbon bar.

NOTE: During the geometry creation of this tutorial, if you make a mistake you can undo the

last step using the Undo icon. You can undo as many steps as needed. If you delete or

undo a step by mistake, just use the Redo icon. To delete unwanted geometry, select it

first and then press Delete from the keyboard.


TUTORIAL #41 CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE

[Select a line]: Select the line as shown.

[Indicate the offset direction]: Select a point to the right side of the line.

Select the Apply button to continue in the same command.

The geometry should look as shown.



3.2 Create the lines parallel with the center line

Sub Step Preview:


[Select a line]: Select the center line as shown.



Select the Apply button.

[Select a line]: Select the same center line as shown before.














3.3 Create the line parallel with the lower horizontal line

Sub Step Preview:





[Indicate the offset direction]: Select a point above the line.

3.4 Create the lines parallel with the new horizontal line

Sub Step Preview:








[Select a line]: Select the same line as shown before.










[Select a line]: Select the last created line as shown.




Select the OK button to exit the command.



3.5 Create lines knowing the endpoints

Sub Step Preview:

Create

Line

Endpoint

[Specify the first endpoint]: Select the Intersection point 1 as shown.



[Specify the second endpoint]: Select the Intersection point 2 as shown.

[Specify the first endpoint]: Select the Intersection point 1 as shown.



[Specify the second endpoint]: Select the Intersection point 2 as shown.


3.6 Create lines knowing one endpoint, the length and the angle

Sub Step Preview:

Create

Line

Endpoint



[Specify the first endpoint]: Select the Endpoint point as shown.

[Specify the second endpoint]: Select an approximate point as shown.

In the Ribbon bar, change the Angle to 45 as shown.




[Specify the first endpoint]: Select the Endpoint point as shown.

[Specify the second endpoint]: Select an approximate point as shown.

In the Ribbon bar, change the Angle to 100 as shown.




3.7 Create the 0.125 radius fillets and the 0.0625 radius fillet

Sub Step Preview:

Create

Fillet

Entities

Enter the Radius 0.125 and make sure that the rest of the buttons in the Ribbon Bar are

set as shown.

[Select an entity]: Select Entity A as shown in the figure below.

[Select another entity]: Select Entity B as shown in the same figure.

[Select an entity]: Select Entity B as shown in the figure below.

[Select another entity]: Select Entity C as shown in the figure below.




Enter the Radius 0.0625 and make sure that the rest of the buttons in the Ribbon Bar

are set as shown.

[Select an entity]: Select Entity C as shown in the figure below.

[Select another entity]: Select Entity D as shown in the same figure.





3.8 Create the line parallel with the upper horizontal line

Sub Step Preview:

Create

Line

Parallel



[Indicate the offset direction]: Select a point below the line.




3.9 Delete the construction lines

Sub Step Preview:

Select the lines as shown.

Select Delete Entities icon.



3.10 Trim the geometry using trim 1 entity command

Sub Step Preview:

Edit

Trim/Break

Trim/Break/Extend

Select the Trim 1 entity button.

[Select the entity to trim/extend]: Select Entity A as shown in Figure: 3.10.1.

[Select the entity to trim/extend to]: Select Entity B.

Figure: 3.10.1



[Select the entity to trim/extend]: Select Entity C as shown in Figure: 3.10.2.

[Select the entity to trim/extend to]: Select Entity D.

Figure: 3.10.2

[Select the entity to trim/extend]: Select Entity C again as shown in Figure: 3.10.2.

[Select the entity to trim/extend to]: Select Entity E.




CREATE THE WIREFRAME FOR THE SWEPT SURFACE TUTORIAL #41

3.11 Delete the construction lines

Sub Step Preview:

Select the lines as shown.


STEP 4: CREATE THE WIREFRAME FOR THE SWEPT SURFACE

NOTE: The current geometry allows us to create the revolved surface. We are continuing by

creating the wireframe required to generate the swept surface.


TUTORIAL #41 CREATE THE WIREFRAME FOR THE SWEPT SURFACE

In this step you will learn how to create different types of arcs and fillets. You will also use offset

contour to offset the geometry with a given distance. To create the swept surface you need the across

contour and two along contours as shown in the Step Preview.

Step Preview:

4.1 Mirror the profile about a line

Sub Step Preview:

Xform

Mirror



[Mirror: select entities to mirror]: Hold down the Shift key and select one entity of the profile

as shown.

Press Enter to continue.

In the Mirror dialog box make sure that Copy is selected and then select the Select line

button as shown.

NOTE: The entire profile is selected.

NOTE: The select line button will bring you back into the graphics window where you can

select the line about which to mirror.



[Select line about which to mirror]: Select the line as shown.

The preview should look as shown.

Select the OK button to exit the Mirror dialog box.

Screen

Clear Colors



4.2 Create the circles that we know the center point and the radius

Sub Step Preview:

Create

Arc

Circle Center Point

Enter the Radius value 2.5 (Enter).

[Enter the center point]: Select the Fast Point icon, and in the empty field enter the val-

ues as shown.

Select the Apply button to continue.

Enter the Radius value 5.5 (Enter).

[Enter the center point]: Select the Fast Point icon, and in the enter the values as shown.




4.3 Create the line parallel with the upper horizontal line

Sub Step Preview:

Create

Line

Parallel



[Indicate the offset direction]: Select a point below the line.




4.4 Create the 0.25 radius fillets

Sub Step Preview:

Create

Fillet

Entities


set as shown.



[Select an entity]: Select Entity A again as shown in the figure below.






4.5 Trim the geometry using trim 1 entity command

Sub Step Preview:

Edit

Trim/Break

Trim/Break/Extend

Select the Trim 1 entity button.





Figure: 4.5.1


4.6 Create a point (0.75, -6.0)

Sub Step Preview:

Create

Point

Position

[Sketch a point]: Select Fast Point icon and enter the coordinates as shown.

Press Enter.




4.7 Create an arc tangent through a point

Sub Step Preview:

Create

Arc

Arc Tangent

From the Ribbon Bar, select Tangent Point icon as shown, and change the Radius to

9.675.

[Select the entity that the arc is to be tangent to]: Select the arc as shown.



[Specify the thru point]: Select the point.

[Select an arc]: Select the arc as shown.


NOTE: The command gives you all the possible results.




4.8 Trim the geometry using trim 2 entities command

Sub Step Preview:

Edit

Trim/Break

Trim/Break/Extend

From the Ribbon Bar, select the Trim 2 entities button and make sure that the rest of the

icons are set as shown.





Figure: 4.8.1


4.9 Offset the profile

Sub Step Preview:

Xform

Offset Contour



[Offset: select chain 1]: Leave the chaining dialog box settings as they are and select the chain

as shown.

Press OK button to exit Chaining dialog box.

In the Offset Contour dialog box make sure that Copy is selected, the # is set to 1 and the

Distance is set to 0.4 as shown.

NOTE: If your chain direction was as shown in the picture above, you need to click on the

Reverse button. The resulting chain (magenta color) has to be located to the right of

the original chain as shown in Figure: 4.9.1.



Select the Reverse button if needed.

Figure: 4.9.1

[Select the OK button to exit Offset Contour dialog box.

Screen

Clear Colors



4.10 Delete the point

Sub Step Preview:

To select the point, from the Quick Mask toolbar, select QM Points.


NOTE: The two contours that we created represent the two along contours needed to

generate the swept surface. Next we will create the arc that represents the across contour.



4.11 Create the 0.25" radius fillets

Sub Step Preview:

Create

Fillet

Entities


set as shown.



Select an entity]: Select Entity A again as shown in the figure below.






4.12 Create the arc in the Right side plane, knowing the endpoints and the radius

Sub Step Preview:

Select the Isometric graphic view.

From the Status Bar, select the Planes button.

From the drop down list select Right plane.

Create

Arc

Endpoints

In the Ribbon Bar enter the Radius value 0.2 (Enter).



[Enter the first point]: Select the Endpoint A as shown.

[Enter the second point]: Select the Endpoint B as shown.

NOTE: Mastercam gives you two choices: two half circles, as shown in the next figure.



[Select an arc]: Select the bottom arc as shown.


Select the Fit icon to fit the geometry to the screen.



CREATE A SWEPT SURFACE TUTORIAL #41

STEP 5: CREATE A SWEPT SURFACE

A Swept Surface is a surface generated by translating or rotating one or more contours (across curves)

along one or two other contours (along curves). In our case we will generate the surface from one

across contour and two along contours.

Step Preview:

5.1 Change the main color to red

From the Status Bar, select the Planes button and choose the Top plane.

From the Status Bar, select the current color field.

From the Colors dialog box, select the red color, no 12.

Select the OK button to exit Color dialog box.

NOTE: It is a good practice to generate the surfaces in different colors. This will make the

further selection of a group of surfaces easier.


TUTORIAL #41 CREATE A SWEPT SURFACE

5.2 Create the Swept Surface

Create

Surface

Swept

From the Ribbon Bar enable Two rails.

From the Chaining dialog box enable the Single button.

[Swept surface: define the across contour(s)]: Select the arc as shown.

NOTE: The green color arrow shows the start of the chain and the red color arrow shows the

end of the chain. Select the arc as shown (CCW).


CREATE A SWEPT SURFACE TUTORIAL #41

Select the OK button in the Chaining dialog box to finish the across contours selection and

continue.

Make sure that Partial button is enabled in the Chaining dialog box.

[Swept surface: define the along contour(s)]: Select first Entity A of the contour as shown.

[Select the last entity]: Select Entity B.

[Swept surface: define the along contour 2]: Select first Entity C of the contour as shown.

NOTE: If needed, select the Reverse direction button.


TUTORIAL #41 CREATE A SWEPT SURFACE

[Select the last entity]: Select Entity D.

Select the OK button to finish the selection.

Select the OK button to finish the Swept Surface command.

The surface should look as shown in Figure: 5.2.1.

Figure: 5.2.1

NOTE: Press Alt +S any time you need to shade or un shade the surfaces


CREATE THE REVOLVED SURFACE TUTORIAL #41

STEP 6: CREATE THE REVOLVED SURFACE

This command allows you to create revolved surfaces, surfaces that are circular in one direction. You

will be prompted to chain an entity that the revolved surface will use as a profile and then, to choose a

line to use as the axis of rotation.

Step Preview:

6.1 Change the main color to dark green no 2

From the Status Bar, select the current color field as shown in previous step.

From the Colors dialog box, select the green color, no 2.

Select the OK button to exit the Color dialog box.

6.2 Create the revolved surface

Create

Surface

Revolved


TUTORIAL #41 CREATE THE REVOLVED SURFACE

From the Chaining dialog box, make sure that Chain (default) button is selected, and the rest

of the dialog box looks as shown.

[Select profile curve(s)]: Select the chain as shown.

Select the OK button to exit the Chaining dialog box.


CREATE THE REVOLVED SURFACE TUTORIAL #41

[Select the axis of rotation]: Select the line as shown.

In the Ribbon Bar, change the End Angle to 180 and press Enter.

The surface should be created below the original geometry as shown in the Figure: 6.2.1.


Figure: 6.2.1

NOTE: If the surface is generated above the original geometry, select the Reverse

button to fix it.


TUTORIAL #41 CREATE THE FILLET SURFACE WITH THE 0.1"RADIUS

STEP 7: CREATE THE FILLET SURFACE WITH THE 0.1"RADIUS

A Fillet surface is a surface generated by creating fillets (radii) that are tangent to two original surfaces.

You can also create a fillet surface between a surface and a plane, and between a surface and a curve.

Step Preview:

7.1 Change the main color to violet no 151

As shown in previous steps, from the Status Bar, select the current color field.

From the Colors dialog box, select the violet color, no. 151.


7.2 Create the Fillet surface with the 0.10 radius

Create

Surface

Fillet

To Surfaces


CREATE THE FILLET SURFACE WITH THE 0.1"RADIUS TUTORIAL #41

[Select first set of surfaces and press Enter to continue]: Select the swept surface as shown.


[Select second set of surfaces and press Enter to continue]: Select the surfaces as shown.

Press Enter to finish the selection.



In the Fillet Surf to Surf dialog box, change the Fillet radius to 0.1 and enable Trim to trim

both original sets of surfaces.

With the mouse wheel, select a point close to the center of the fillet surfaces and spin the

mouse wheel in the upper direction to zoom in from the point

Figure: 7.2.1

NOTE: Some of the fillet surfaces are generated in the wrong direction.

To generate a proper fillet surface you have to have the original surface normals orientated

towards the center of the resulting fillet surfaces. In our case, both sets of surfaces have to

have the normals orientated inwards. As you can see in Figure: 7.2.1 one of the revolved

surfaces is oriented wrong.



Select the Flip Normal button as shown.

Click on the surface shown in Figure: 7.2.1 to reverse its normal.

Press Enter to finish the selection and to return to the dialog box.

The fillet surface preview should look as shown.

Fillet Surf to Surf dialog box, select the Options button.

NOTE: The fillet surfaces are generated correctly but the swept surface is not trimmed.


TUTORIAL #41 CREATE A FLAT BOUNDARY SURFACE

Enable Extend Surfaces.

Select the OK button to exit the Fillet _Surface Options dialog box.

Select the OK button to exit the Fillet Surf to Surf dialog box.

The fillet surfaces should look as shown.


STEP 8: CREATE A FLAT BOUNDARY SURFACE

NOTE: Extend surfaces will extend the fillet surfaces to make the trimming of both surfaces

possible.


CREATE A FLAT BOUNDARY SURFACE TUTORIAL #41

In this step you will learn how to create a flat surface inside of a closed boundary. We will have to

create a curve at the open edge of the swept surface and create a line to close the boundary.

Step Preview:

8.1 Create the curve at the edge

Sub Step Preview:

Create

Curve

Curve on One Edge

[Select a surface]: Select the swept surface.



[Move arrow to Desired Edge of Surface]: Move the arrow to the open edge of the surface as

shown and click to select it.


8.2 Create the line to close the boundary

Sub Step Preview:

With the mouse wheel, select a point close to the middle of the curve and spin the mouse

wheel in the upper direction to zoom in.

Create

Line

Endpoint

[Specify the first endpoint]: Select the Endpoint A as shown.

NOTE: Select the endpoints from the edge curve.



[Specify the second endpoint]: Select the Endpoint B as shown.


8.3 Create the flat surface

Sub Step Preview:

Create

Surface

Flat Boundary



[Select chains to define flat boundary1]: Select the chain as shown.






STEP 9: CREATE THE FILLET SURFACE WITH THE 0.0625"RADIUS

In this step you will create a fillet surface with the radius of 0.0625" between the swept surface and the

flat boundary surface.

Step Preview:

Create

Surface

Fillet

To Surfaces

[Select first set of surfaces and press Enter to continue]: Select the swept surface as shown.


[Select second set of surfaces and press Enter to continue]: Select the flat surface as shown.




The warning "No fillets found" will appear on the screen.

Select the OK button to continue.

In the Fillet Surf to Surf dialog box, change the Fillet radius to 0.0625 and enable

Trim to trim both original sets of surfaces.

Select the OK button again to continue, and then select the Flip Normal button as shown.

NOTE: Both normals, as shown in Figure: 9.0.1, need to be reversed.



Figure: 9.0.1

Click on both surfaces to reverse their normals as shown.


Select the OK button to exit Fillet Surf to Surf dialog box dialog box.


TUTORIAL #41 CREATE THE TWO DRAFT SURFACES

The fillet surface should look as shown.


STEP 10: CREATE THE TWO DRAFT SURFACES

This step shows you how to create the two draft surfaces knowing the length and draft angle. Draft

surfaces are surfaces generated by extruding one or more contours, along a line defined by an angle

and a length. In our case we will create two draft surfaces with the draft angle 3 degrees that are

closing the revolved surfaces open areas. To generate the surfaces we will need two lines.

Step Preview:

10.1 Change the main color to magenta no. 13

From the Status Bar, select the current color field as shown in previous steps.


CREATE THE TWO DRAFT SURFACES TUTORIAL #41

From the Colors dialog box, select the magenta color, no. 13.

Select the OK button to exit Color dialog box.

Change the graphic view to Top.

10.2 Create the top polar line

Sub Step Preview:

Create

Line

Endpoint



[Specify the first endpoint]: Select the Endpoint A as shown.

[Specify the second endpoint]: Sketch the second endpoint as shown.

In the Ribbon bar, change the length and the angle as shown.




10.3 Extend the line 0.2" using trim/break/extend command

Sub Step Preview:

Edit

Trim/Break

Trim/Break/Extend

Enable the Extension button, and enter 0.2.

[Select the entity to trim/extend]: Select the line as shown.





10.4 Create the Draft surface with the 3 degrees angle

Sub Step Preview:

Change the graphic view to Isometric.


Create

Surface

Draft



[Select line, arc, or spline 1]: Leave the settings in the Chaining dialog box as they are and

select the line as shown.


In the Draft Surface dialog box, make sure that the Length is enabled and change it to

3.0"and the angle to 3 degrees as shown.

NOTE: The surface is created above the line. Use the Flip button next to the length to

change the direction as shown in Figure: 10.4.1.



Figure: 10.4.1

Hold down the mouse wheel, click in the center of the draft surface and then slightly move

the mouse to the right to check if the draft angle is inwards as shown.

Select the OK button to exit the Draft Surface dialog box.

Change the graphic view to Top.


NOTE: To rotate the part first click and hold in the middle of the part with the mouse wheel

to select a point. Hold the mouse wheel down, then slightly move the mouse around the

rotation point. Release when the part is in the desired position.

Another way of rotating the geometry is to hold down the Alt key and to click on the

keyboard arrows.



10.5 Create the horizontal line

Sub Step Preview:

Create

Line

Endpoint

From the Ribbon Bar, enable the Horizontal icon.

[Specify the first endpoint]: Sketch the first endpoint as shown.

[Specify the second endpoint]: Sketch the second endpoint as shown.

[Enter the Y value]: as shown.

NOTE: Make sure that the line is extended over the edges of the revolved surface on both

ends.





10.6 Create the Draft surface with the 3 degrees angle

Sub Step Preview:



Create

Surface

Draft



[Select line, arc, or spline 1]: Leave the settings in the Chaining dialog box as they are and

select the line as shown.


In the Draft Surface dialog box, make sure that the Length is enabled and change it to 3.0 and

the angle to 3 degrees as shown.

NOTE: The surface is created above the line. Use the Flip button next to the length to

change the direction as shown in Figure: 10.6.1.



Figure: 10.6.1

Hold down the mouse wheel, click in the center of the draft surface and then slightly move

the mouse to the right to check if the draft angle is inwards as shown.

Select the OK button to exit the Draft Surface dialog box.


CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS TUTORIAL #41

STEP 11: CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS

In this step you will create two fillet surfaces with the radius of 0.0625" between the revolved surface

and the draft surfaces.

Step Preview:

11.1 Create the fillet surface between the upper draft surface and the revolved surface

As shown in previous steps, from the Status Bar, select the current color field.

From the Colors dialog box, select the violet color, no 151.


Create

Surface

Fillet

To Surfaces


TUTORIAL #41 CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS

[Select first set of surfaces and press Enter to continue]: Select the revolved surface as

shown.


[Select second set of surfaces and press Enter to continue]: Select the draft surface as shown.




In the Fillet Surf to Surf dialog box, change the Fillet radius to 0.0625 and enable Trim to trim

both original sets of surfaces.

Figure: 11.1.1

Select the OK button to exit the Fillet Surf to Surf dialog box.

NOTE: The fillet surface is created on the wrong side as shown in. Figure: 11.1.1.



From the Fillet Surf to Surf, select the Options button and check if the Trim Surface options

are set as shown, and the Extend Surfaces is enabled.

Select the Flip Normal button.

Figure: 11.1.2






Select the OK button to exit Fillet Surf to Surf dialog box dialog box.


NOTE: Although the trim options were set for both surfaces and the extend surface was also

enabled to correct any problems, the draft surface is not trimmed. To correct this we will

create the edge curve at the intersection between the fillet surface and the draft. Then we

will trim the surface to this curve.




Sub Step Preview:

From the Status Bar, select the current color field as shown in the previous step.

From the Colors dialog box, select the green color, no 2.


Create

Curve

Curve on One Edge

[Select a surface]: Select the fillet surface.



[Move arrow to Desired Edge of Surface]: Move the arrow to the edge of the surface close to

the draft surface as shown and click to select it.



NOTE: To ensure a proper trimming, next we will need to extend the curve end beyond the

draft surface edges.



11.3 Extend the curve both ends with 0.2" using trim/break/extend command

Sub Step Preview:



Edit

Trim/Break

Trim/Break/Extend


[Select the entity to trim/extend]: Select the curve as shown.



11.4 Trim the draft surface to the curve

Sub Step Preview:

Create

Surface

Trim

To Curves

[Select surfaces and press Enter to continue]: Select the surface as shown below.

Press Enter to finish the surface selection.



From the Chaining dialog box, make sure that Chain (default) button is selected, and the rest

of the dialog box looks as shown.

[Select profile curve(s)]: Select the curve as shown.


Make sure that the only buttons in the Ribbon bar that are selected are the ones shown.



[Indicate area to keep- select a surface to be trimmed]: Click twice on the surface area that

we want to keep after trimming as shown below.

Press Alt + S to shade the surface.

The preview should look as shown in Figure: 11.4.1.

NOTE: By selecting the Delete button the original (base) surface will be deleted, the

Normal button projects the curve normal to the surface in the specified distance (0.1")

and the Keep multiple regions button allows multiple regions to be created after while

trimming.

NOTE: The area outside of the curves was removed because we select the area to keep after

trimming inside the curve.



Figure: 11.4.1


11.5 Create the fillet surface between the lower draft surface and the revolved surface

Sub Step Preview:

As shown in previous steps, change the color to the violet color, no. 151.

Create

Surface

Fillet

To Surfaces

NOTE: The following Sub steps are similar with the Sub steps 11.1 to 11.5. As a challenge

you could create the surface on your own.



Holding down the mouse wheel, select a point close to the center of the geometry and

slightly move the mouse to rotate the part as shown.

[Select first set of surfaces and press Enter to continue]: Select the revolved surface as

shown.




[Select second set of surfaces and press Enter to continue]: Select the draft surface as shown.


In the Fillet Surf to Surf dialog box, make sure that the Fillet radius is set to 0.0625 and Trim

is enabled to trim both original sets of surfaces.

NOTE: The fillet surface is created on the wrong side and the surfaces are trimmed as shown

in Figure: 11.5.1.



Figure: 11.5.1

To be able to select the surfaces to change the normals, from the Fillet Surf to Surf, disable

Trim.

Select the Flip Normal button.

Figure: 11.5.2


NOTE: To change the normal directions click on the surfaces not on the arrows. If you have

problems selecting the revolved surface, change the draft surface normal only, press Enter

to exit and then reselect Flip normal button and select only the revolved surface.





Enable the Trim option again.

Select the OK button to exit the Fillet Surf to Surf dialog box dialog box.





Sub Step Preview:

From the Status Bar, select the current color field as shown in previous step and select the

green color, no. 2.

Create

Curve

Curve on One Edge

[Select a surface]: Select the fillet surface.

NOTE: Although the trim options were set for both surfaces and the extend surface was also

enabled to correct any problems, the draft surface is not trimmed. To correct this we will

create the edge curve at the intersection between the fillet surface and the draft. Then we

will trim the surface to this curve.



[Move arrow to Desired Edge of Surface]: Move the arrow to the edge of the surface close to

the draft surface as shown and click to select it.



NOTE: To ensure a proper trimming, next we will need to extend the curve end beyond the

draft surface edges.



11.7 Extend the curve both ends with 0.2" using trim/break/extend command

Sub Step Preview:



Edit

Trim/Break

Trim/Break/Extend





11.8 Trim the draft surface to the curve

Sub Step Preview:

Create

Surface

Trim

To Curves

[Select surfaces and press Enter to continue]: Select the surface as shown below.

Press Enter to finish the surface selection.



From the Chaining dialog box, make sure that the Chain (default) button is selected, and the

rest of the dialog box looks as shown.

[Select profile curve(s)]: Select the curve as shown.


Make sure that the only buttons in the Ribbon bar that are selected are the ones shown.


TUTORIAL #41 CHANGE AND MOVE SOME ENTITIES ON A NEW LEVEL

[Indicate area to keep- select a surface to be trimmed]: Click twice on the surface area that

we want to keep after trimming as shown below.

Press Alt + S to shade the surface.

The geometry should look as shown Figure: 11.8.1.

Figure: 11.8.1


STEP 12: CHANGE AND MOVE SOME ENTITIES ON A NEW LEVEL


CHANGE AND MOVE SOME ENTITIES ON A NEW LEVEL TUTORIAL #41

In this step you will learn how to work with levels. By organizing your files into levels, you can more

easily control which areas of the drawing are visible at any time and which parts are selectable so that

you do not inadvertently make changes to areas of the drawing you do not want to change.

12.1 Change the main level to level 2

From the Status bar, select Level.

Change the Main Level Name to Wireframe geometry as shown.



Change the Number of the Main Level to 2 and enter in the Name field Toolpath geometry.

Select the OK button to exit Level Manager dialog box.

12.2 Move the outside rectangle and all surfaces to Level 2

To select all surfaces, from the Quick Mask toolbar, select QM Surfaces as shown.

NOTE: The current level number changes to Level 2. Any new entities that we will create will

be saved on this level. The Status bar will be updated as shown.


CHANGE AND MOVE SOME ENTITIES ON A NEW LEVEL TUTORIAL #41

To select the rectangle, hold down the Shift key and select one of the rectangle lines as

shown.

From the Status bar, right-mouse click on the Level as shown.

Leave the Change Levels dialog box settings as shown.

Select the OK button to exit Change Levels dialog box.

12.3 Make Level 1 invisible

From the Status bar, select Level.



In the Level Manger, Visible column, click on the X next to Number 1 to remove it as shown.

Select the OK button to exit the Level Manager dialog box.

NOTE: All the wireframe entities that we used to generate the surfaces are gone. To

machine the part we only need the surfaces and the tool containment boundary. The

rectangle will be used to establish the stock.


CREATE SILHOUETTE BOUNDARY TUTORIAL #41

STEP 13: CREATE SILHOUETTE BOUNDARY

In this step you will learn how to create a boundary curve around a set of surfaces. The command will

create a 2D curve which represents the projection of the selected geometry onto the construction

plane. It will be created at the current Z-depth. This curve is typically used as a tool containment

boundary for toolpathing.

Step Preview:

From the Status Bar, select the current color field as shown in previous steps and change it to

the blue color, no. 9.

Create

Silhouette Boundary

[Select solids, solid faces, or surfaces]: Select the QM surfaces icon to select all surfaces.




Leave the default settings in the Silhouette Boundary dialog box.

Select the OK button to exit the Silhouette Boundary dialog box.


STEP 14: CREATE A FLAT BOUNDARY SURFACE



In this step you will create a flat surface between the rectangle and the silhouette boundary.

Step Preview:

From the Status Bar, select the current color field as shown in previous step and select the

orange color, no. 138.

Create

Surface

Flat Boundary

Leave the same settings in the Chaining dialog box.

[Select chains to define flat boundary1]: Select the rectangle and the boundary as shown.



TUTORIAL #41 SAVE THE FILE


STEP 15: SAVE THE FILE

File

Save As

File name: "Your Name_4"

Select the OK button.

NOTE: You have finished the first part of the tutorial which is the geometry creation.


SUGGESTED FIXTURE: TUTORIAL #41

TOOLPATH CREATION

SUGGESTED FIXTURE:

SETUP SHEET:

STEP 16: SELECT THE MACHINE AND SET UP THE STOCK.


TUTORIAL #41 SELECT THE MACHINE AND SET UP THE STOCK.

In Mastercam, you select a Machine Definition before creating any toolpaths. The Machine Definition

is a model of your machine tool's capabilities and features and acts like a template for setting up

machining jobs. The machine definition ties together three main components: the schematic model of

your machine tool’s components, the control definition that models your control unit’s capabilities and

the post processor that will generate the required machine code (G-code). For a Mill Level 3 exercise

(3D toolpaths) we need just a basic machine definition.

Step Preview:

To display the Operations Manager press Alt + O.

Use the Fit icon to fit the drawing to the screen.

Machine type

Mill

Default

NOTE: For the purpose of this tutorial, we will be using the Default mill machine.

NOTE: If you already have the default machine in the Toolpaths Operations Manager, do not

select another machine.

NOTE: To be able to define the stock the construction mode has to be 3D.


SELECT THE MACHINE AND SET UP THE STOCK. TUTORIAL #41

Select the plus sign in front of Properties in the Toolpaths Manager to expand the Toolpaths

Group Properties.

Select the Tool Settings to set the tool parameters.

Change the parameters to match Figure: 16.0.1.

Figure: 16.0.1

Program # is used to enter a number if your

machine tool requires a number for a program

name.

Assign tool numbers sequentially allows you to

overwrite the tool number from the library with

the next available tool number. (First operation

tool number 1; Second operation tool number 2,

etc.)

Warn of duplicate tool numbers allows you to get

a warning if you enter two tools with the same

number.

Override defaults with modal values enables the

system to keep the values that you enter.

Feed Calculation set From tool uses feed rate,

plunge rate, retract rate and spindle speed from

the tool definition.


TUTORIAL #41 SELECT THE MACHINE AND SET UP THE STOCK.

Select the Stock setup tab to define the stock.

Click on the Bounding box button.

In the Bounding box leave the settings as shown.

Select the OK button to exit Bounding Box dialog box.


SELECT THE MACHINE AND SET UP THE STOCK. TUTORIAL #41

Change the Z value for the stock thickness to 2.75 as shown.

Select the OK button to exit Machine Group Properties.

The stock should look as shown.


TUTORIAL #41 ROUGH OUT THE PART USING SURFACE HIGH SPEED - AREA CLEARANCE

STEP 17: ROUGH OUT THE PART USING SURFACE HIGH SPEED - AREA CLEARANCE

Surface High Speed Area Clearance Roughing toolpath is designed for machining pockets providing a

smooth clean fluid motion. Smoothness settings help create an extremely efficient toolpath, avoiding

sharp corners and direction changes.

Toolpath Preview:

17.1 Surfaces and Containment selections

Toolpaths

Surface High Speed

If a prompt appears to Enter new NC name, select the OK button to

accept the default.

[Select Drive Surfaces]: From the Quick Mask toolbar select QM Surfaces

icon.



ROUGH OUT THE PART USING SURFACE HIGH SPEED - AREA CLEARANCE TUTORIAL #41

From the Toolpath/surface selection in the Containment area click on the Select button.

Leave the default Chaining settings.

[Chain 2D tool containment boundary # 1]: Select the boundary as shown.

Select the OK button to exit from the Chaining dialog box.

Select the OK button to exit from the Toolpath/surface selection.

17.2 Setting the Toolpath Type

Toolpath Type page allows you to change the existing toolpath to a different type. Mastercam updates

the parameter pages so that you only see settings for the toolpath type that you selected. You can also

change or reselect the drive surfaces, check surfaces, and the tool containment boundaries.

NOTE: The High Speed toolpaths have three distinct areas: Tree view, Page and Quick View

Settings as shown in Figure: 17.2.1.



Figure: 17.2.1

From the Toolpath Type select Roughing and then Area Clearance as shown.

17.3 Setting the Tool page

Tool page allows you to select the tool and enter feeds and speeds and configure automatic tool

inspection.

From the Tree View Area, select Tool.



To select the tool, click on Select library tool button.

To search for a specific tool within the default tool library, click on the Filter button.

From the Tool List Filter, select the Endmill Bull icon, and in the Tool Diameter area select

Equal and enter 1/2" as shown.

Make sure that all the other settings are as shown in the screenshot above, and then select

the OK button to exit.

From the Tool Selection list select the 1/2" Bull Endmill with the corner radius of 0.0625".



Select the OK button to exit from the Tool Selection dialog box.

Right mouse click on the tool in the tool display window, and select Feed and speed

calculator.

Select the OK button to accept the default settings.

NOTE: The feeds and spindle speed are based on the tool definition. You can overwrite them

with the feeds and speed that you want to use. You can also let Mastercam calculate the

feeds and speed using the Feed speed calculator as shown next.

NOTE: You can edit the parameters until you get the desired results and then you can save

them to create a new material or tool definition.



Add a comment in the Comment area to identify the toolpath in the Toolpath Manager and

also in the NC file.

The Tool page should look as shown in Figure: 17.3.1.

Figure: 17.3.1

17.4 Set the parameters in the Cut parameters page

In this page you can set the Cutting method, configure the Z spacing (Stepdown) and the XY spacing (XY

stepover) and the Smoothing. You can also set the tool containment options.

From the Tree View Area, select the Cut parameters page and change the parameters as

shown in Figure: 17.4.1.

NOTE: If you click on the tool from the list the feedrates and the spindle speed will be

updated to the original values. You can lock them in the Settings, Configuration, Toolpaths

page by enabling Lock Feedrates.



Figure: 17.4.1

17.5 Set the Transitions page

Transitions page allows you to configure the entry move that the tool will make as it transitions to new

Z levels. You can choose to create either a ramp entry, or helical entry move. If the profile is too small

to create a helix of this size, Mastercam will create a ramp move instead.

Stepdown value sets a constant Z spacing between cutting passes.

Add cuts feature allows you to insert additional cutting passes in areas of your part where the profile is

close to flat. Mastercam will add new cuts to maintain the maximum profile stepover, while spacing them

each by at least as much as the minimum step-down.

Stepdown options allows you to configure how Mastercam spaces the cuts in Z. Mastercam can maintain a

constant Stepdown between passes, or you can choose the Add cuts option to configure adaptive

stepdown strategies.

Corner rounding replaces sharp corners with arcs for faster and smoother tool movements. This lets the

machine tool maintain a higher feed rate and reduces wear on the cutter.

Stock to leave on drive surfaces lets you enter separate values for the wall and floor surfaces. Note that

the stock to leave on walls must be greater than or equal to the stock left on the floor. For surfaces that are

not exactly horizontal or vertical, Mastercam will interpolate between the wall and floor values.

Keep tool down prevents the tool from retracting if the distance between the end of one pass and the start

of the next pass is less than the specified settings.



From the Tree View Area, select the Transitions page and change the parameters as shown

in Figure: 17.5.1.

Figure: 17.5.1

17.6 Set the Linking Parameters page

The Linking Parameters page options allow you to configure how Mastercam links air moves when the

tool is not in contact with the part.

From the Tree View Area, select the Linking Parameters page.

Change the parameters as shown in Figure: 17.6.1.

Radius value sets the radius of the helix as an absolute

value.

Plunge rate sets the helix feedrate to the plunge rate.

Output 3D arc moves instructs the system to output

circular movements instead of linear movements.


TUTORIAL #41 BACKPLOT THE TOOLPATH

Figure: 17.6.1

Select the OK button to exit the Surface High Speed Toolpaths - Area Clearance parameters.

Press Alt + T to remove the toolpath display.

STEP 18: BACKPLOT THE TOOLPATH

Backplotting shows the path the tools take to cut the part. This display lets you spot errors in the

program before you machine the part. As you backplot toolpaths, Mastercam displays the current X, Y,

and Z coordinates in the lower left corner of the screen.

Make sure that the toolpath is selected (signified by the green check mark on the folder

icon).

Select the Backplot selected operations button.

Minimum vertical retract is a vertical

retract and constant-Z move at the Part

clearance height.

Leads fields set the tool moves onto and off

of the part at the start and end of each

cutting pass. These moves are applied to

each pass no matter which cutting pass is

selected.

Fitting settings allow you to choose how the

entry and exit arcs fit to the ends of the

cutting passes.

Minimize trimming sets the path to retract

to be as close to the surface as possible,

maintaining a minimum distance from the

surface to fit the arc.

Max trimming distance parameter limits the

amount of trimming applied to non-

horizontal passes.


VERIFY THE TOOLPATH TUTORIAL #41

Make sure that you have the following buttons turned on (they will

appear pushed down) to see the tool and the rapid moves.

You can adjust the speed of the backplot.

You can step through the Backplot by using the Step forward or Step back buttons.

Select the Play button in the VCR bar to run Backplot.

The toolpath should look as shown.

Select the OK button to exit Backplot.

STEP 19: VERIFY THE TOOLPATH

Verify simulates the machining of a part from a solid stock model display. The stock dimensions are

based on the values that we specified in the Stock Setup

Select the Verify selected operations button.


TUTORIAL #41 VERIFY THE TOOLPATH

From the Verify dialog box select the Options button.

Make the changes in the Verify Options as shown Figure: 19.0.1.

Figure: 19.0.1

Select the OK button to exit Verify Options.

Set the Verify speed by moving the slider bar in the speed control bar.

Select the Fast Forward button to start simulation.

Stock Shape is automatically set to Solid.

Use True Solid allows you, after verifying the part,

to rotate and magnify it to more closely check

features, surface finish, or scallops.

Cutter comp in control allows Verify to use the

information regarding the tool diameter and to

simulate the cutter compensation. Not used in

surface toolpaths.

Change tool/color allows you to change the color

of the cut stock to indicated tool changes in the

toolpath.


CLEAN THE REMAINING AREAS USING SURFACE ROUGH RESTMILL TUTORIAL #41

The part, after the roughing operation, should look as shown.

STEP 20: CLEAN THE REMAINING AREAS USING SURFACE ROUGH RESTMILL

NOTE: Some areas of the part can not be machined as the 1/2" Bull Endmill tool was too big.

To clean just the areas that were not machined we will use the Surface Rough Restmill and a

1/4" Bull Endmill.


TUTORIAL #41 CLEAN THE REMAINING AREAS USING SURFACE ROUGH RESTMILL

Surface Rough Restmill toolpath allows Mastercam to calculate the cutting passes on only the stock

left over from one or more previous roughing operations, instead of the entire drive surfaces. This

toolpath uses the area clearance machining strategies.

Toolpath Preview:

Toolpaths

Surface Rough

Restmill

From the Quick Mask toolbar select QM Surfaces icon.




From the Toolpath/surface selection in the Containment area click on the Select button.

Leave the default Chaining settings.

[Chain 2D tool containment boundary # 1]: Select the boundary as shown.

Select the OK button to exit from the Chaining dialog box.

Select the OK button to exit from the Toolpath/surface selection.

20.1 Setting the Toolpath parameters page

Toolpath parameters page allows you to select a tool, set the feeds and speeds, enter a comment

about the operation, and set other general toolpath parameters.

NOTE: The toolpath does require the tool containment boundary.



Using the same steps shown in previous toolpaths, select the 1/4" Bull Endmill with the cor-

ner radius 0.0625".

Use the Feed speed calculator as shown in the first toolpath, to establish the feed rates and

spindle speed.



The Toolpath Parameters page should look as shown in Figure: 20.1.1.

Figure: 20.1.1

20.2 Set the parameters in the Surface parameters page

In this page you can set the Clearance, the Retract and the Feed plane heights. You can reselect the

drive surfaces and boundaries required by the toolpath and also leave stock on drive surfaces and to

leave stock on check surfaces too. The Surface parameters page is the same for all surface toolpaths.

Check the previous toolpath for more info on the parameters.

Select the Surface parameters page and change the parameters as shown in Figure: 20.2.1.



Figure: 20.2.1

20.3 Set the Restmill parameters page

Restmill parameters page allows you to set the total tolerance for machining, the Maximum stepover,

the cutting method and the options that control area to be machined.

Select the Restmill parameters page and change the parameters as shown in Figure: 20.3.1.



Figure: 20.3.1

20.4 Set the Rest material parameters page

Rest material parameters page is used to calculate the amount of stock left on the part using the

roughing tool dimensions. You can also calculate remaining stock by using one or more source

operations or use an STL file as the source for calculating leftover stock.

Select the Rest material parameters page and change the parameters as shown in

Figure: 20.4.1.

Maximum stepdown sets the distance between

adjacent passes in the Z axis.

Stepover sets the distance between adjacent

passes in the XY plane.

Transition set to Broken moves the tool up and

over, or over and down, between areas smaller

than the gap size.

Optimize cut order keeps the tool in one area to

completely machine it to minimize the retract

motions.



Figure: 20.4.1

Select the OK button to exit Surface Restmill parameters.


20.5 Backplot the Surface Restmill toolpath

Make sure that only the Surface Restmill toolpath is selected in the Toolpaths Operations

Manager (signified by the green check mark on the folder icon).



Roughing tool diameter/ Corner radius enables

Mastercam to calculate the remaining stock

based on the previous operation tool size.

Adjustments to remaining stock set to Use

remaining stock as computed makes no

adjustments to the calculated stock.


TUTORIAL #41 SAVE THE STOCK AFTER ROUGHING AS AN STL FILE



STEP 21: SAVE THE STOCK AFTER ROUGHING AS AN STL FILE

Mastercam saves the part model (stock shape) as an STL (a 3D model) file. The STL file can be used as a

stock model in a subsequent verification. The Save stock file option is only available in TrueSolid mode

in Mastercam Mill and Router.

21.1 Verify both roughing toolpaths

Click on the Select all operations icon to make sure that all toolpaths are selected in the

Toolpaths Operations Manager.


Select the Fast Forward button to simulate the toolpath.


SAVE THE STOCK AFTER ROUGHING AS AN STL FILE TUTORIAL #41

The part, after the roughing operations, should look as shown.

21.2 Save the stock shape as an STL file

From the Verify dialog box, select Save stock as a file button as shown.

Select the OK if you want to keep the same name as the tutorial name.


TUTORIAL #41 FINISH THE PART USING SURFACE HIGH SPEED - HYBRID

Select the OK button to exit Verify.

STEP 22: FINISH THE PART USING SURFACE HIGH SPEED - HYBRID

Surface High Speed Hybrid toolpath addresses steep and shallow areas utilizing both scallop and

constant Z approaches in a single toolpath. The toolpath switches seamlessly between both methods

and cuts in a logical, optimized order.

Toolpath Preview:

22.1 Copy the first operation only

From the Toolpaths Operations Manager, select the first High Speed (Area Clearance).

Below the existing operations, right-mouse click and select Copy.

Right-mouse click again and select Paste.

In the third operation select Parameters as shown.

NOTE: We can copy the existing operation and change the toolpath type to Finishing and

Hybrid. We will save time as the same surfaces and boundary is required.


FINISH THE PART USING SURFACE HIGH SPEED - HYBRID TUTORIAL #41

22.2 Setting the Toolpath Type

Toolpath Type page allows you to change the existing toolpath to a different type. Mastercam updates

the parameter pages so that you only see settings for the toolpath type that you selected. You can also

change or reselect the drive surfaces, check surfaces, and the tool containment boundaries.

From the Tree View Area, select the Toolpath Type, select Finishing and then Hybrid as

shown.

22.3 Setting the Tool page

Tool page allows you to select the tool and enter feeds and speeds and configure automatic tool

inspection.

From the Tree View Area, select Tool.

To select the tool, click on Select library tool button.

Using the Filter options as shown in the previous step, select the 1/4" Ball Endmill.

From the Tool Selection list select the 1/4" Ball Endmill.



Select the OK button to exit from the Tool Selection dialog box.

Add a comment in the Comment area.

The Tool page should look as shown in Figure: 22.3.1.

Figure: 22.3.1

22.4 Set the parameters in the Cut parameters page

In this page you can set the Cutting method, configure the passes (Stepover) and the machining area.

From the Tree View Area, select the Cut parameters page and change the parameters as

shown in Figure: 22.4.1.

NOTE: The feeds and spindle speed are based on the tool definition. You can overwrite them

with the feeds and speed that you want to use. You can also let Mastercam calculate the

feeds and speed using the Feed speed calculator as shown in the previous step.



Figure: 22.4.1

22.5 Set the Transitions page

Transitions page allows you to configure the type of transition between the passes. Select Smooth to

create high speed arc moves between each pass.

From the Tree View Area, select the Transitions page and change the parameters as shown

in Figure: 22.5.1.

Cutting method is set to Climb to create cuts with the tool rotating opposite the direction of travel along

the cutting side of the tool.

Steep stepdown defines the constant Z distance between adjacent stepdowns. Mastercam first slices the

entire model into sections defined by the Steep Stepdown distance. It then analyzes the drive surface's

slope transition between each stepdown along the specified Limiting Angle. If the drive surface's slope

transition within the stepdown distance is less than the limiting angle, the hybrid toolpath considers it

steep and a single 2D waterline cutting pass is generated.

Shallow stepover defines the spacing between 3D scallop-style cutting passes in shallow stepdowns.

Tool containment compensate to Inside keeps the entire tool inside the containment boundary.

Stock to leave on drive surfaces lets you enter separate values for the wall and floor surfaces. They should

be zero.

Keep tool down prevents the tool from retracting if the distance between the end of one pass and the start

of the next pass is less than the specified settings.



Figure: 22.5.1

22.6 Set the Linking Parameters page

The Linking Parameters page options allow you to configure how Mastercam links air moves when the

tool is not in contact with the part.

From the Tree View Area, select the Linking Parameters page.

Select the OK button to exit the Surface High Speed Toolpaths - Hybrid parameters.

To update the toolpath, from the Toolpaths Operations Manager, select Regenerate all

selected operations.

Tangential ramp to create a true high speed transition

between the cutting passes. Mastercam inserts arcs at

the beginning and end of the ramp for the smoothest

tool motion into and out of the move.




22.7 Backplot the Surface High Speed Hybrid toolpath

Make sure that only Surface High Speed Hybrid toolpath is selected in the Toolpaths

Operations Manager.





22.8 Verify both rough and finish toolpaths




From the Verify, select the Options button.

From the Verify Options, in the Stock Shape enable File and click on the Select Stock file

button.

Select the file from where you save it, and then the OK button to exit.

Select the OK button to exit Verify Options.


FINISH THE AREA USING SURFACE FINISH LEFTOVER TUTORIAL #41

The stock should look as shown.

Select the Fast Forward button to simulate the toolpath.

The part, after the finish operation, should look as shown.


STEP 23: FINISH THE AREA USING SURFACE FINISH LEFTOVER

NOTE: We still need to machine the fillet surfaces with the radius 0.0625 which can not be

machined with the 1/4" Ball Endmill. We are going to clean that area with a Surface Finish

leftover toolpath and a smaller tool.


TUTORIAL #41 FINISH THE AREA USING SURFACE FINISH LEFTOVER

Surface Finish Leftover toolpath removes small amounts of material left by a larger tool in a previous

operation. Finish leftover makes a single pass through the leftover material. You can create multiple

leftover toolpaths using a smaller tool for each toolpath.

Toolpath Preview:

Toolpaths

Surface Finish

Leftover

From the Quick Mask toolbar select QM Surfaces icon.




Select the OK button in the Toolpath/surface selection to continue.

23.1 Setting the Toolpath parameters page

Toolpath parameters page allows you to select a tool, set the feeds and speeds, enter a comment

about the operation, and set other general toolpath parameters.

Using the same steps shown in previous toolpaths, select the 1/8" Ball Endmill.

Use the Feed speed calculator as shown in the first toolpath, to establish the feed rates and

spindle speed.



The Toolpath Parameters page should look as shown in Figure: 23.1.1.

NOTE: The toolpath does not require any tool containment boundary. We are going to

machine all the remaining areas.



Figure: 23.1.1

23.2 Set the parameters in the Surface parameters page

In this page you can set the Clearance, the Retract and the Feed plane heights. You can reselect the

drive surfaces and boundaries required by the toolpath and also leave stock on drive surfaces and to

leave stock on check surfaces too. The Surface parameters page is the same for all surface toolpaths.

Check the previous toolpath for more info on the parameters.

Select the Surface parameters page and change the parameters as shown in Figure: 23.2.1.



Figure: 23.2.1

23.3 Set the Finish leftover parameters page

Finish leftover parameters page allows you to set the total tolerance for machining, the Maximum

stepover, the cutting method and the options that control area to be machined.

Select the Finish leftover parameters page and change the parameters as shown in

Figure: 23.3.1.



Figure: 23.3.1

23.4 Set the Leftover material parameters page

Leftover material parameters page is used to calculate the amount of stock left on the part using the

roughing tool dimensions.

Select the Leftover material parameters page and change the parameters as shown

in Figure: 23.4.1.

Figure: 23.4.1

Max. stepover sets the distance between

adjacent passes.

Cutting method is set to 3D Collapse to create a

boundary around the cutting area and then step

in to create each pass by offsetting the outer

boundary by the maximum stepover.

From slope angle sets the minimum slope angle

of the surface to determine the steep areas of

the part.

To slope angle sets the maximum slope angle of

the surface to determine the steep areas of the

part.

Only areas between the From slope angle and

To slope angle are machined

Roughing tool diameter is the diameter of the

previous operation tool that machines the area.

Roughing tool radius is the radius of the

previous operation tool that machines the area.

Overlap distance is an additional offset applied

to the previous tool shape. This value causes the

leftover material to be calculated as if it had

been cut by a larger tool.



Select the OK button to exit Surface Finish Leftover parameters.

23.5 Backplot the Surface Finish Leftover toolpath

Make sure that only Surface Finish Leftover toolpath is selected in the Toolpaths Operations

Manager (signified by the green check mark on the folder icon).





23.6 Verify only the finish toolpaths

From the Toolpaths Operations Manager, click on Surface High Speed (Hybrid) and hold-

down the Ctrl key and select the Surface Finish Leftover.


To speed the simulation, select the Turbo button.

Select the Fast forward button to simulate the toolpaths.


TUTORIAL #41 USE CHECK HOLDER TO FIND THE MINIMUM TOOL LENGTH REQUIRED

The part, after the finish operation, should look as shown.


STEP 24: USE CHECK HOLDER TO FIND THE MINIMUM TOOL LENGTH REQUIRED

FOR THE 1/8 INCH BALL END ENDMILL

Check Holder C-Hook is used to check an operation's tool holder for interference with the part. It

calculates areas where there is interference and tells you the minimum tool length required to avoid it.

24.1 Check the current tool length

From Toolpaths Operations Manager, click on the 1/8" Endmill Bull in the Surface Finish

Leftover operation.

NOTE: In this operation we are machining a deep pocket. To ensure that the tool holder

does not interfere with the part, in the next step we will use the CheckHolder C-Hook.

NOTE: If you have only the Home Learning Edition of Mastercam you will not be able to do this

step.


USE CHECK HOLDER TO FIND THE MINIMUM TOOL LENGTH REQUIRED TUTORIAL #41

Note the Overall value of 2.25".

Select the OK button to exit.

If the Tool definition about to be updated dialog box appears, leave the default setting and

select the OK button.

Enter Alt + C to open the C-hook directory.

Select CheckHolder.dll from the list.


Enable Find minimum tool length and enter the Holder clearance of 0.05".

Keep the other settings as shown.

Select the Perform test button as shown in the figure above.


TUTORIAL #41 USE CHECK HOLDER TO FIND THE MINIMUM TOOL LENGTH REQUIRED

Note the value that the system found.

Select Modify source operation as shown in the above figure.

Enable Modify tool and the tool length will be updated in all the operations where it is used.

Select the OK button to exit.

The Warning "Tool has been modified" appears.


Select the OK button to exit the Check holder dialog box.

NOTE: The test result was some interference and the Minimum tool length value is bigger

than the tool length.


POST PROCESS THE FILE TUTORIAL #41

From the Toolpaths Operations Manager select again the 1/8 Endmill Sphere to check if the

tool Overall distance was updated.

Select the OK button to exit Tool definition dialog box.

STEP 25: POST PROCESS THE FILE

Post processing, or posting, refers to the process by which the toolpaths in Mastercam part files are

converted to a format (NC file) that can be understood by your machine tool's control such as G-codes.

The Post's role is to read the NCI data, read the control definition settings, initiate postblock calls, read

the parameters and output the NC code. Producing the right NC code for your machine and application

depends on properly configuring the machine definition, control definition and the post processor.

Click on Select all operations icon to make sure that all toolpaths are selected in the

Toolpaths Operations Manager.

Select the Post selected operations button from Toolpaths Operations Manager.

In the Post processing window, if needed, make any necessary changes as shown below.


TUTORIAL #41 SAVE THE UPDATED MCX FILE


Enter the same name as the geometry name in the NC File name field.

Select the OK button to save the NC file.

The NC file will appear on the screen as shown in Figure: 25.0.1.

Figure: 25.0.1

Select the red X box at the upper right corner to exit the Editor.

STEP 26: SAVE THE UPDATED MCX FILE

Select the Save icon.

NOTE: How the program is sent to the machine depends on the shop setup.


SAVE THE UPDATED MCX FILE TUTORIAL #41

REVIEW EXERCISE -STUDENT PRACTICE


TUTORIAL #41 CREATE THE GEOMETRY FOR TUTORIAL #4 EXERCISE

CREATE THE GEOMETRY FOR TUTORIAL #4 EXERCISE

Create the Geometry for Tutorial #4 Exercise as per the instructions below.

Create the wireframe for the revolved surface.

Create the wireframe for the swept surface.

Create the Revolved surface.

Select the profile and then the axis of

rotation.

Set the End angle to 180 and use Flip button

if needed to get the proper side of the

surface.


CREATE THE GEOMETRY FOR TUTORIAL #4 EXERCISE TUTORIAL #41

Swept surface.

Enable 2 Rails button in the Ribbon bar.

Using Single selection in the Chaining dialog

box, select the 0.2 radius arc as the across

contour.

Using Partial selection in the Chaining dialog

box, select the 2 contours.

Create the Fillet Surface with the 0.1 radius.

Select the revolved surface as the first set of

surfaces.

Select the swept surface as the second set of

surfaces.

Enter the Fillet radius = 0.1".

Use the Flip normals button to set the

surface normals for both surfaces pointing

inwards.

Enable extend surfaces in options.

Enable Trim in the dialog box.

Create the Draft Surfaces.

Create the two lines as the necessary

wireframe.

Create each draft surface with the Length =

3.0 and the Draft angle =3.

Use the Flip buttons if needed to create the

surfaces in the proper orientation.

Create the upper side Fillet Surfaces with the

0.0625" radius.

Select all the revolved surfaces (there are

two) as the first set of surfaces.

Select the draft surface as the second set of

surfaces.

Disable Trim.

Enter the Fillet radius = 0.0625".

Use the Flip normals button to set the

surface normals for the revolved surfaces

pointing upwards and for the draft surface

towards the center of the part.

In the Options enable Extend surfaces.

Enable Trim in the dialog box.


TUTORIAL #41 CREATE THE GEOMETRY FOR TUTORIAL #4 EXERCISE

Create the lower side fillet surface with the 0.0625" radius.

Follow the same steps as instructed for the upper side fillet.

.

Create the Flat Boundary surface at the open edge of the swept surface.

Create a line between the endpoints of the

arc.

Create the flat boundary surface.

Create a Fillet surface between swept and the flat boundary with the radius 0.0325".

Flip the surface normal if needed.

Organize the geometry on different levels.

Move all surfaces and the outside rectangle on level 2.

Make visible only level 2.


CREATE THE GEOMETRY FOR TUTORIAL #4 EXERCISE TUTORIAL #41

Create the Silhouette boundary.

Create the flat boundary surface between the

rectangle and the silhouette boundary.

Select both the rectangle and the silhouette

boundary.

Save the geometry.


TUTORIAL #41 CREATE THE TOOLPATHS FOR TUTORIAL #4 EXERCISE

CREATE THE TOOLPATHS FOR TUTORIAL #4 EXERCISE

Create the Toolpaths for Tutorial #4 Exercise as per the instructions below.

Set the machine properties including the stock.

Establish the stock using bounding box.

Change the Z thickness to 2.75".

Rough out the part using Surface High Speed -

Area clearance toolpath.

Select all surfaces and as containment

boundaries select the silhouette boundary.

Use the 1/2"Bull Endmill with 0.0625 "corner

radius.

Stepdown= 0.050".

Enable Add cuts and Corner rounding same

as in the tutorial.

XY Stepover percentage of diameter = 45.

Stock to leave on walls/floors = 0.02".

Tool Containment compensate Inside

Transitions = Entry-Helix.

Linking parameters set to Minimum Vertical

Retract and the default settings.

Total tolerance = 0.001".


CREATE THE TOOLPATHS FOR TUTORIAL #4 EXERCISE TUTORIAL #41

Clean up the areas that the previous tool can not using Surface Restmill toolpath.



Stock to leave on drive surfaces only 0.02".

Set up appropriate Clearance, Retract and

Feed plane (see the tutorial).

Use the 1/4"Bull Endmill with 0.0625 "corner

radius.


Maximum Stepdown= 0.050".

Stepover = 0.05".

Transitions = Broken.

Enable Optimize cut order.

Compute the remaining stock from the

Roughing tool diameter.

Use remaining stock as computing.

Simulate the roughing operation in Verify and save the stock as an stl file.

Finish the cavity areas using Surface High Speed Hybrid toolpath.



Use the 1/4"Ball Endmill.

Stepdown= 0.020".

Limiting angle = 45.

Shallow stepover = 0.02".

Stock to leave on walls/floors = 0.0".

Tool Containment compensate Inside

Transitions = Tangential ramp.

Linking parameters set to Minimum Vertical

Retract and the default settings.


Use the stl file as stock when verify the finish

operation.

Finish the remaining areas using Surface

Finish Leftover toolpath.

Use the 1/16"Ball Endmill.

Stock to leave on drive surface = 0.0".


Maximum stepover = 0.02".

Cutting method = 3D Collapse.

From slope angle = 0.0".

To slope angle = 90.0".


TUTORIAL #41 NOTES:

NOTES:


TUTORIAL #4 QUIZ TUTORIAL #41

TUTORIAL #4 QUIZ

What is a swept surface?

How do you create an arc tangent through a point?

What command should you use if you want to trim a surface to wireframe geometry?

When can you use Surface High Speed Area Clearance toolpaths?

When can you use Surface High Speed Hybrid toolpaths?

When shall you use Surface Restmill toolpath instead of Surface Leftover toolpath?


TUTORIAL #41 TUTORIAL #4 QUIZ

Sample Mastercam X5 Mill Level 3 Training Tutorial

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Transcript of Sample Mastercam X5 Mill Level 3 Training Tutorial