General Notes Wire9 Mastercam9

TUTORIAL SERIES FOR
VERSION 9
GENERAL NOTES
Wire V9 GENERAL NOTES
MENU NAVIGATION
Menu Cues
More Icons Toolbar
Main Menu
Return to Main Menu Button
Secondary Menu
Prompt
Prompt Area
Area
Toolbar - Can be used instead of Main Menu and Secondary Menu selections.
Menu Cues - Displays selection cues in the space following the Main Menu title area.
Main Menu - Selections used to create geometry and wirepaths.
Secondary Menu - Selections used to work with geometry.
Prompt Area - System displays data and the user inputs data, also prompts the user
for info.
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THE MAIN MENU

When the system first starts, the Mastercam logo screen appears, then the Main and
Secondary Menus are displayed.
Analyze Displays all relevant information about a point, line, arc, spline, surface or
dimension on the screen.
Create: Adds geometry to the system's database and draws it on the screen.
File: Manipulates disk files (saves, retrieves, converts, transmits, receives, etc.).
Modify: Alters screen geometry with the fillet, trim, break, and join commands.
Xform: Transforms geometry with the mirror, rotate, scale, translate, and offset
commands.
Delete: Removes an entity or group of entities from the screen and the system's
database.
Screen: Plots the geometry currently displayed on the screen, changes the current
color or level, displays entity endpoints or changes the way in which geometry is
displayed.
Solids: Creates and modifies solid geometry.
Wirepaths: Programs NC wirepaths (CAM systems only).
NC utils: Manipulates NC wirepaths (CAM systems only).
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THE SECONDARY MENU
Z: Use Z depth only in Mastercam Wire to change the current construction depth. The
construction depth is the depth of the currently defined construction plane. This value
may be entered by selecting an existing point (i.e., endpoint of a line) or by typing Z and
the desired depth, followed by Enter. The construction depth is changed automatically
in most creation functions in the 3D-construction mode.
Color: Assigns a system color. This instructs the system to display any new geometry
created in the selected color (Create | Line, Create | Arc, Backplot | Save geometry,
etc.). It also applies the chosen color to a converted file that does not support colors
(i.e., DXF). Mastercam contains two color palettes from which you can select system
colors, a 16-color and 256-color palette.
Level: Assigns a system level to created/converted geometry. Level stores any new
geometry created in the selected level. It also applies the chosen color to a converted
file that does not support levels (i.e., NFL or ASCII). This feature also controls what
levels are visible. You can set a total of 256 levels in Mastercam. Click the following to
read more about levels: Assigning Levels.
Attributes: Lets you change one or more attributes (color, level, line style, line width,
and point style) for entities that you select, without affecting system default settings.
Groups: Defines a collection of entities as a named group.
Mask: Sets the system's masking level. With the masking level OFF, the system will
recognise any entity in the database; however, if the mask level is set (changed to a
non-zero level number between 1 and 255) the system will then only recognise entities
that are on that level. Mask will affect all functions (delete, group, file conversion, etc.)
except fit, screen statistics, or screen endpoints. To reset the masking level to OFF, the
masking level must be set to 0.
WCS: Allows you to redefine the World Coordinate System, and groups the
functionality of Tool, Construction and Graphic Views. WCS is not supported by
Mastercam Wire.
Tplane: The tool plane (Tplane) is a two dimensional plane that represents a CNC
machine's coordinate system.
Cplane: Defines the plane on which you will create and manipulate geometry. You
have several construction plane (Cplane) options.
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Gview: Alters the way in which you view images through the graphics view (Gview)
feature. Gview allows you to view geometry from several different angles.
GRAPHICS VIEWS
There are 8 standard graphics views in Mastercam.
View 1 = Top
View 2 = Front
View 3 = Back
View 4 = Bottom
View 5 = Right
View 6 = Left
View 7 = Isometric
View 8 = Axonometric
MEASURING ANGLES IN MASTERCAM
Y+
90 DEG
X- ________________________________ X+
180 DEG 0 DEG.
Y-
270 DEG
Page 4
DEFAULT KEY ASSIGNMENTS

The table below lists the default key assignments.
Key(s) Function Description
F1 zoom Activates the zoom-in window. Use the zoom

window to magnify part of your geometry.
F2 unzoom Zooms out from your geometry reducing its

size on your screen.
F3 repaint Redisplays the graphic screen to clean up any

display remnants.
F4 analyze Activates the Analyze menu.
F5 delete Activates the Delete menu.
F6 file Activates the File menu.
F7 modify Activates the Modify menu.
F8 create Activates the Create menu.
F9 display Displays the following:

information *the current system construction, and tool
origins
*the relative positions of all three origins (if an origin is
not defined, then it does not display)
*the current geometry filename, file size, and the date
and time that the file was last saved
*the current NCI filename.
F10 execute Activates the key and button assignment

function window display (shown on the previous page).
Alt+F1 fit geometry Fits the displayed image to the graphic screen
area.
Alt+F2 scale geometry Unzoom by 0.8
Alt+F3 cursor tracking Activates the cursor tracking feature.
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Alt+F4 exit Exits Mastercam.
Alt+F5 delete menu Activates the Delete menu.
Alt+F7 blank Activates the Screen | Blank menu.
Alt+F8 configure Opens the Screen | Configure Window. (You

cannot use this key assignment to access
Allocations, however.)
Alt+F9 draw axes Displays the current graphics view (center),

the current construction plane axis (lower left),
and the current tool plane axis (lower right).
Alt+F10 execute Activates the key and button assignment

function window display (shown on the previous page).
Alt+A autosave Opens the AutoSave Window
Alt+B Toolbar Displays or hides the Toolbar
Alt+C run C-Hooks Lets you run a C-Hook applications program.

The C-Hook's *.DLL file must be in the
directory specified under the
Screen | Configure | Data Paths menu.
Alt+D drafting Opens the Drafting global parameters Window.

parameters (This is the same as clicking PM).
Alt+F menu fonts Opens the Font Window.

selection window
Alt+G Grid Parameters Sets active grid which can be visible or invisible
Alt+H on-line help Opens Mastercam's Help Window for instant

access to on-line help information about
Mastercam and its features.
Alt+I open files Lists files that Mastercam creates for its own
use during a session. This is a diagnostic tool
only. Click the Windows close button to exit
this window.
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Alt+L attributes menu Lets you set the current line style, width, color and
level.
Alt+M memory Lists Mastercam memory allocations. This is a

allocations diagnostic tool only. Click the Windows close
button to exit this window
Alt+N named views Allows saved named views to be quickly accesed
Alt+P prompt area Displays and hides Mastercam's prompt area.

We recommend that you leave the prompt area
visible at all times.
Alt+S shading toggle Activates full time shading
Alt+T draw NC Turns the wirepath display on and off. When

you turn on the wirepath display, the current
NCI file appears in the wirepath color (normally
cyan). After you turn off the wirepath, press F3
to refresh the screen. You can only use this
feature during wirepath creation or until you
select End progrm.
Alt+U undo Lets you undo the last operation that you
performed. You must stay in the last
operation's menu to undo it. After you exit from
the menu of the operation that you want to
undo, this feature is no longer available.
Alt+V Mastercam Displays the software version and serial

version number number of your SIM.
Alt+W set viewport Opens the VIEWPORTS Window. This lets

window you set the viewport configuration. Toggle the
display or enter the viewport number.
Alt+X xform menu Activates the Xform menu.
Alt+Z visible levels Opens the Visible Levels Window.

Alt+0 Cplane (depth) Quick access to changing Z construction depth
Alt+1 color Opens the color dialog box.
Alt+2 levels Opens the Main level dialog box.
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Alt+3 mask level Opens the Mask level dialog box.
Alt+4 toolplane Activates the toolplane menu.
Alt+5 Cplane Activates the Cplane menu.
Alt+6 Gview Activates the Gview menu.
Alt+’ Create|Arc-2pt. cir Activates the Create|Arc|2pt. circle point menu.

Make your selections from the point menu to
create your circle.
Alt+Tab switch between Lets you move between all of the open
open applications applications in Windows. Alt+Shift+Tab lets
you move through open applications in the
reverse order.
Tab /
Shift+Tab navigate in Lets you move between controls in a window
windows (text boxes and radio buttons for example).
Esc system interrupt Press Esc to interrupt some commands

(transform, repaint, etc.) Once a command has
been interrupted, it cannot be restarted from
the point of interruption.
backup key Instead of clicking backup, press Esc to back

up to a previous menu.
Page Up /
Page Down zoom Press Page Up to zoom in on a geometry.
Press Page Down to zoom out.
Cursor pan Lets you pan over geometry. Note that the
Arrows arrows move the geometry window not the
geometry.
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DATA ENTRY SHORTCUTS

Mastercam lets you use several shortcuts to enter information into text boxes when
creating geometry. These shortcuts let you get data from an existing entity and use it
when creating new geometry.
The shortcuts are as follows:
A Use “A” to input an existing angle.

D Use “D” to input an existing diameter.
L Use “L” to input an existing length.
R Use “R” to input an existing radius.
S Use “S” to input the distance between two existing points.
X Use “X” to input an existing X co-ordinate.
Y Use “Y” to input an existing Y co-ordinate.
Z Use “Z” to input an existing Z co-ordinate.
To use a shortcut:
1. Type a letter (from the list above), instead of a value, into the text box.
2. Press Enter. Mastercam prompts you to select the existing entity from
which you want to get the data.
3. Click the entity you want to use.
4. Mastercam displays the data it gets from the existing entity.
5. Press Enter to accept the data or type a different value and press Enter.
6. Mastercam uses the data from the existing entity in creating the new
entity.
Data Entry Shortcut Example
This example uses the “L” data entry shortcut to create a line.
1. Create a line with endpoints at 0,0,0 and 3,0,0.

This will be the existing line from which we get data by using “L.”
2. Click MAIN MENU | Create | Line | Polar.
3. Set 0,0,0 as one endpoint of the polar line.
4. Set 33 degrees as the angle of the line.
5. Type L and press Enter for the line length.
6. Mastercam prompts you to select an existing line.
7. Click the existing line.
8. Mastercam displays the data it gets from the existing line.
9. Press Enter to accept this data.
10. Mastercam creates the new line.
Page 9
ASSIGNING BUTTONS AND KEYS

This Mastercam feature lets you assign a function or C-Hook or macro to a function key
(F1 through F10) or an Alt key (excluding system keys such as Alt+F4) or a button in
Mastercam's Toolbar. You can assign a maximum of 50 keys and a maximum of 99
buttons.
Select the following menu picks:
MAIN MENU
Screen
Configure
Toolbar/ Keys
Funcs/ C-Hooks/ Macros [default]

This allows the user to check all assignments, or filter out the desired
commands. ( Functions, c-hooks, macros, keys, buttons, keys/ buttons).
All [default]
This function allows the user to further filter using the following variables:
Unassigned, assigned, all.
Find Key
This function allows the user to press a button or key, and the function assigned
to it will be filtered out.
Current Assignment
Add This allows the user to add an assignment.

Edit This allows a user to edit an existing assignment.
Remove This allows the user to remove an assignment.
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ASSIGNING A BITMAP TO A BUTTON

Now you have a function assigned to a button. If there is no default bitmap assigned to
the desired function, you can make one, or modify a bitmap from another function.
If this is the case, the button will now look highlighted, but no bitmap is yet assigned.
PROCEDURE
Open the wire9.cfg file, and search for the button number that was just assigned.
( example: search for B92 )
When you have found the appropriate button, record the definition assigned to it.
( this is the word right after assignment )
Create or modify an existing bitmap, and save it in the Mcam9\Common\Icons directory,

using the name of the function found in the .CFG file. Mastercam will automatically
update that button assignment.
ADDING A C’HOOK TO YOUR MENU

Follow these steps to add a frequently used c-hook to the side menu bar.
1) Decide what menu you wish this function to be added to.
2) Open the Wire9.txt file with any text editor.
3) Search for a function that has been previously assigned, which will be before (or
after) the position that you wish to fill.
4) Insert the name of the c’hook within the quotes, in the desired position, immediately
followed by an asterisk * symbol (note to place an underscore on the letter you wish
to use as a shortcut place an ampersand before that letter (letter can only appear
once in any one menu)).
5) The next time you open Mastercam, the menu will be modified.
Definition - C-Hooks
Mastercam C-Hooks are custom-made application programs created in the C programming language. These
application programs are also known as C-Hooks. Anyone, CNC Software, Inc., Mastercam dealers, and our
customers, can develop a C-Hook that runs with Mastercam. C-Hooks use the same graphic and menu functions as
Mastercam.
Page 11
Wirepath Parameters
The following paragraph describes, in alphabetic order, the wirepath parameters that
are used in contour, no core and 4-axis wirepath.
Adding a finish contour operation – Adds a separate contour operation after the no
core operation. When you choose this option, Mastercam Wire opens the contour
parameters dialog box where you can specify all the parameters of a regular contour
operation.
All contours use same subprogram – Available when using Subprograms to create
copies of the same part.
Arc type and radius – Defines the shape of tapered contour when a smooth corner is
encountered in the geometry. See Corner type and radius for more details.
Auto entry – Starts the no core wirepath at the thread point.
Auto exit – Exits the no core wirepath at the cut point.
Auto position cut point – Sets the cut point perpendicular to the end of contour.
Auto start position - Moves the job start point to the thread point of the first contour in
the operation. Disable it to insert a rapid move from the start point to the thread point.
Canned text – Assigns variables from 1 to 99 that can be used to control some specific
machine settings. The post processor has to be customized accordingly.
Change NCI – Allows you to change the current Nci file name to store the wirepath
information.
Comment – Allows you to enter information about the current operation.
Compensation types – Offsets the wire from the geometry. When cutting the part in
the chaining direction, wire compensation can follow the centerline of the geometry or
be offset to the right or the left to compensate for the wire diameter. This offset may be
generated by Mastercam Wire (computer compensation), by the NC control (control
compensation), or a combination of both ("both" and "reverse both" compensation).
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Control: This parameter outputs a command for wire compensation in the CNC system.
You can select “Right,” “Left” or “Auto”. Select “Right” and the system will place the
wire to the right of the part (G42); select “Left” and the system places the wire to the left
of the part (G41). Select “Auto” and the system will automatically place the wire
depending on the location of the thread point. Using this method you are programming
the part edge.
Computer: This parameter builds wire compensation directly into the wirepath. You can
select “Right,” “Left” or “Auto”. Select “Right” and the system will place the wire to the
right of the part; select “Left” and the system places the wire to the left of the part.
Select “Auto” and the system will automatically place the wire depending on the location
of the thread point. Using this method you are programming the center of the tool.
Both: Combines both compensations in computer and in control. It computes the

compensated wirepath and outputs control codes for compensation. Compensation
direction in the computer and control are the same. You can select “Right,” “Left” or
“Auto”.
Reverse both: Combines both compensations in computer and in control. It computes

the compensated wirepath and outputs control codes for compensation. Compensation
direction in the computer and control are opposite each other. You can select “Right,”
“Left” or “Auto”.
Off: Select “Off” and the system will ignore wire compensation within the computer.
Mastercam Wire computes the wirepath with the wire cutting the centerline of geometry.
Contours – Allows you to establish the thread and cut positions in cases where you
have not used point entities.
Thread distance - Allows you to enter a value for the thread distance. Mastercam Wire
activates the contour types for closed and open contours.
For closed contours, specify whether to place the thread point on the inside or outside
of the contour.
For open contours, specify whether to place the thread point to the right or the left of
the contour.
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Corner type and radius – Defines the shape of the tapered contour when a sharp
corner is encountered in the geometry. In the following examples, the geometry is in the
XY plane and the corner and arc types are shown in the UV contour. Also, Roll cutter
around corners is set to None, and each sample wirepath has a 5-degree taper angle.
Conical – Creates a cone shape move around the corner of the part.
Sharp – Creates an angle move around the corner of the part.
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Constant– Keeps the corner or the arc in the contour the same size as the corner or the
arc in the geometry.
Other – Allows you to specify a radius for a custom corner defined in the post
processor. Mastercam Wire draws the corner as it can not anticipate the radius defined
in the post processor.
Fixed – Applies the same radius to all corners. Must be supported by the post
processor.
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Fishtail – Creates a loop at the corners to machine very sharp corners. Must be
supported by the post processor. Fish tail is not supported as an arc corner.
Cutting method – Sets the cutting direction of the contour or 4-axis wirepath.
Reverse - Reverses cutting direction when the wirepath has multiple passes.
One way – Keeps the cutting direction the same direction as the first pass.
Expand Operation – Separates each pass type into a single operation. It is only
available when you first create a wirepath, not on subsequent edits.
Filter – Replaces wirepath moves that lie, within a specified tolerance, in a straight line
with a single tool move. You can also optionally replace multiple linear tool moves with
an arc move of a specified minimum and maximum radius.
Finish – Sets a finish pass to smooth out rough edges left by the no core roughing
pass or to take off additional material as specified by the finish pass spacing.
Number of finish passes - Sets the number of finish passes. The finish passes smooth
out rough edges left by the no core roughing pass. The finish passes follow the
geometry similar to a contour cut.
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Start finish pass at closest entity - Begins the finish pass with the closest endpoint of
the closest entity at the end of the roughing wirepath. When cleared, the finish pass
begins with the first entity in the chain as it was originally selected.
Wire compensation - Sets Wire compensation to computer for the finish pass to offset
the wire as part of the wirepath. Set compensation to control to have the control offset
the wire. The both option applies the offset to the wirepath (computer) but also allows
for additional compensation to be set in the control.
Finish pass spacing - Determines the size of the cut for each finish pass. The roughing
pass leaves stock on the walls of the pocket and on the islands, if the number of finish
passes is greater than zero. The finish passes remove stock left by the roughing pass.
Burn finish passes after roughing all pockets - Used multiple no core wirepaths exist in
a single operation, Mastercam Wire can cut the roughing pass on each no core first.
After completing all the roughing passes, Mastercam Wire then cuts the finish pass on
each no core wirepath.
Format – Controls how the arcs and lines in 4-axis wirepath are handled as data for the
control.
4-axis taper - Outputs only UV/XY linear moves. All circular moves (arcs) are broken
into linear moves based on the linearization tolerance set in the 4-axis parameters
dialog box tab.
Direct 4-axis - Outputs XY/UV linear and circular moves simultaneously. Direct 4-axis
requires that the XY and UV contours have an equal number of entities. In cases where
there aren’t an equal number of entities, branch lines need to be added to the geometry
to connect the entities to a synch point.
General – Controls cutting method, wire EDM machine initial settings and other
parameters. Choose a topic below for more information.
Wire - When checked, wire is present (threaded).
Power - When checked, applies voltage to the wire.
Flush - Sets the initial state for the water settings On, Off, or Other. The "Other" setting
is specific to the control.
Fill tank - Sets the initial state for the fluid tank. "On" fills the tank.
Generate stops – Creates a stop point before each tab.

For first tab cut of each chain - Outputs a stop code before the tab cut for the first tab
cut on each chain. Subsequent tab cuts do not include stop codes.
For first tab cut in the operation - Outputs a stop code before the tab cut for the first tab
cut of the operation. Subsequent tab cuts throughout the operation do not include stop
codes.
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No stops output - Suppresses all stop codes for all tab cuts in the operation.
Infinite look ahead – Examines for wirepath self-intersections along the entire contour
before creating the wirepath. If it finds a wirepath self-intersection, Mastercam Wire
modifies the wirepath so that it does not cut the portion of the part that comes after the
intersection.
Land Height – Sets the height at which the wire pivots to the taper angle.
Lead in – Lets you place a combination of line and or arc at the beginning of a Contour,
Tab cut or/ and Finish cut. The system can add a line or two, of given lengths and an
arc, of given radius and arc sweep to the beginning of each chain. You can set the
following options.
Line only: Lets you add a line at the beginning of each chain.
Line and radius: Lets you add a line and a radius at the beginning of each chain.
2 Lines and radius: Allows you to add two lines and an arc at the beginning of each
chain.
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Lead out – Lets you place a combination of line and or arc at the end of a Contour, Tab
cut or/ and Finish cut. The system can add a line or two, of given lengths and an arc, of
given radius and arc sweep to the end of each chain. You can set the following options.
Line only: Lets you add a line at the end of each chain.
Radius only: Allows the system to add an arc to the end of each chain.
Radius and line: Lets you add an arc and a line at the end of each chain.
Radius and 2 lines: Allows you to add an arc and two lines at the end of each chain.
Entry/Exit Arc : Allows you to define the lead in and lead out arc.
Maximum Lead Out Length: Allows you to determine the distance that the wire travels
toward the cut position on each pass.
Overlap : Lets you set an overlap for the skim cut.
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Also trim final leadout : Moves the final lead out to the Maximum Lead Out Length.
Linearization tolerance – Sets the tolerance to convert 3D arcs and 2D or 3D splines

into lines while creating the wirepath. Smaller linearization tolerance values make more
accurate wirepaths, but may take longer to generate and create a longer NC program.
Misc values button – Sets the values of the miscellaneous integers and reals that can
control some specific machine settings. The post processor has to be customized
accordingly.
Optimize path – Applies an additional check on the no core wirepath that takes
additional time to generate but eliminates material dropout. Not available for Morph or
True Spiral cutting methods.
Output stop code – Sets the types of stop points that can be assigned to a wirepath.
Glue stop - Pauses the wire machine before it cuts the tab only if the "optional" switch
on the wire machine is turned on. If the switch is off, the machine cuts the tab without
stopping. A glue stop (gstop) is also known as an optional stop. Glue stop outputs an
M01 code.
Stop - Pauses the wire machine until the operator restarts the machine. The stop is also
known as a program stop. This stop outputs an M00 code.
Power Settings Library - Contains wire EDM machine-specific settings documented by

the manufacturer for the material you are cutting.
A wire power settings library is organized into 24 "passes." In Mastercam Wire, "pass"
refers to a single path made by the wire around a contour. Pass is synonymous with
"cut". A library can contain up to 24 passes, each with unique power settings needed to
cut a certain material type on a certain wire EDM machine. For example, Pass 1 in the
library may correspond to a rough cut, Pass 2 a tab cut, and Passes 3 – 5 finish cuts
(also known as skim cuts).
Select Library button: - Allows you to choose the power settings library from a list of
existing libraries.
Associate to library: - Allows you to associate the selected library to the operation. If it is
not checked the system allows you to edit each pass of the existing library.
Save Library button: - Allows you to save the changes made in the selected library.
Starting pass: - Sets the first pass to be used by the wirepath.
Offsets: - Sets the wire offset number. Refer to your wire machine documentation.
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Condition code: - Sets a wire machine-specific value that corresponds to a register

number in control. It depends on material, wire type and thickness. Refer to your wire
machine documentation.
Feedrate: - Sets the speed at which the wire cuts the material in inches per minute or
centimetres per minute. Some controllers calculate the feed rate based on material nad
thickness. Other controllers require a value that represents the material and the
thickness. Refer to your wire machine documentation.
Wire diameter: - Sets the width of the wire.
Wire radius: - Sets the radius of the wire automatically when you enter the diameter.
Wire overburn: - Sets the extra material that can be removed by the wire.
Stock to leave: - Sets amount of stock to leave for the finish pass(skim cut).
Total offset: - Displays the sum of the wire diameter, overburn and stock to leave.
Registers1-10: - Values that correspond to the registers in the controller.
Pass comment: - Allows you to enter information about the current pass.
Perform rough cut – Enables the rough cut.

Additional skim cuts (before tab): - Sets the number of skim cuts to be performed before
the tab cut.
Program # – Lets you set the program number for the machines that require a program
name.
Rapid Height – Sets the Z height of the upper wire guide for rapid moves whether or
not the wire is threaded.
Reset pass number on tab cuts – Allows you to use Pass #1 (rough cut) settings
when cutting the tab.
Roll Wire Around Corners - This parameter functions only when you employ the Wire
Compensation - In Computer parameter. You use it primarily for inserting arc moves
around sharp corners in the wirepath. In some cases, the system will fillet sharp corners
(even if the parameter is set to “None”). This is because some objects in the wirepath
do not intersect; in these cases, the computer will automatically add a fillet.
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Rough – Enables the settings for removing almost all of the material in the no core
wirepath.
Cutting method – Sets the patterns Mastercam Wire uses to clean out the no core part.
Zigzag
Constant overlap spiral
Parallel spiral
Parallel spiral clean corner
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Morph spiral
True spiral
Rough angle – Sets the angle of the zigzag pattern.
Seq. inc – Sets the numbering increment for each line of the NC program.
Seq. Start – Lets you set the first line number in the NC program for the machines that
require block numbers.
Stepover percentage - Sets the distance the wire shifts over between XY moves as a
percentage of wire diameter. Changing the stepover percentage automatically adjusts
the stepover distance.
Stepover distance - Sets the distance the wire shifts over between XY moves
Changing the stepover distance automatically changes the stepover percentage.
Sync option – Synchronizes the upper and lower contours using chain synchronization.
When synchronizing the contours, Mastercam Wire breaks each chain into a number of
separate subchains then matches up the chains using the Sync mode selection. The
Sync option provides a choice of methods that Mastercam Wire can use to place points
along the chains, which it matches up when synchronizing the chains.
When Mastercam Wire synchronizes the chains, it aligns the top contour with the
bottom contour by entity, point, branch point, node (if both contours are made up of
splines) or where you tell it (manual, manual/density).
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None: - Synchronizes the chains by dividing them into an even number of segments
using the Step Size option in the 4-axis parameters dialog box tab. The value you enter
for Step Size determines how far apart these points are placed. We recommend that
you keep this value small to retain accuracy in the corners. In many cases, the default
value of .01 is sufficient.
By branch - Requires branch lines to be added to the geometry to create sync points as
shown in the example above.
By entity - Matches the endpoints of each entity and requires both chains to have an
equal number of entities.
By node - Applies only to parametric splines and synchronizes the two chains by nodes
on the splines.
Manual and manual/density - Allow you to manually place the sync points.
Linearization tolerance - Provides a factor that Mastercam Wire uses to place sync
points along chains when using the by branch, by entity, by node, and by point sync
option.
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Suppress all thread flags – No thread flags will be written in the NCI file.
Suppress all cut flags – No cut flags will be written in the NCI file.
Skim cuts after tab – Allows you to program the finish passes.
Together - Sets the number of skim cuts to make before moving to the next contour in
the operation.
Separate - Sets the number of skim cuts to make, with one made on each chain in the
operation separately. Separate is enabled only when you choose Rough, tab, and finish
separately.
Subprogram – Creates subprograms called by the main program each time the
program repeats the same passes in the XY plane. Used to generate a smaller NC
program.
STCW – Sets the start, thread, cut and work origin positions for the current operation.
Start - Is the home position of the operation.
Thread - Is the point where the machine threads the wire, usually a predrilled hole in the
material. The wire cuts from the thread position to the start of the chain based
on the settings for lead ins and lead outs.
Cut - Is the point where the wire machine cuts the wire before moving to
the next thread point.
Work origin - Is a reference point for wirepath creation and is set to the
system origin by default. Changing the work origin offsets the coordinates
for the wirepath.
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Non-vertical thread cut: Sets the UV plane coordinates to allow threading or cutting the
wire on a diagonal.
Tab – Sets an area of uncut material that keeps the part in place until the machine
operator can secure it prior to cutting it free from the rest of the material. Using tabs
prevents the part from falling into the tank and possibly damaging the lower wire guide.
Tab width - Sets the tab size.
Number of tab cuts - Sets the number of passes the wire machine the tab.
Make the tab cutoff move with the skim cut - Make the tab cut at the end of the skim
cut (or rough cut if there is no skim cut).
All cuts together – Allows you to group together all the cuts of a chain (rough, skim cut,
tab). The method is used when you have multiple contours selected in the operation.
Tabs and finish together – Allows you to generate first the roughing cuts on all chains,
and then group together all the tab cuts with the finish cuts of each chain. The method
is used when you have multiple contours selected in the operation.
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Rough, tabs and finish separately – Allows you to generate first the roughing cuts on all
chains, and then the tab cuts for all chains, and at last the skim cuts of each chain. The
method is used when you have multiple contours selected in the operation.
Automatic – Allows you to set the number of tabs to place on each contour in the
operation. Mastercam Wire spaces the tabs equally over the contour.
Manual – Allows you to manually select the tabs positions around the contour, by
selecting Position button.
Use square point for tab position – Automatically places a tab at each location marked
by a square point. You have to previously create points using square style along the
geometry. If you use the square point method, select Start, Midpoint or End to indicate
what square point marks.
Tab Cuts (no dropout method) – Used to eliminate sliver or slug material when using
either the line and radius or (2) lines and radius moves combined with overlap.
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Trimming - Used in a 4-axis wirepath to reference Z values in the wirepath.

In computer - Uses the XY and UV trim planes to reference the Z values for the
wirepath.
In control - Uses the XY and UV height planes (by default, the locations of the XY and
UV geometry) to reference the Z values for the wirepath.
3D tracking - Includes variable Z depths with the XY and UV planes. When supported
by the wire EDM machine and control, 3D tracking allows machining of geometry that
doesn’t lie completely in a single construction plane. With 3D tracking, the wire guides
on the machine follow the nonplanar geometry. When 3D tracking is selected,
Mastercam Wire enables two additional planes: the XY and UV extensions.
UV Extension - Used for geometry with variable depths that not lie completely in a
single plane when 3D tracking is supported by the wire EDM machine. Give a positive
incremental value to lift the extension above the UV height and trim planes.
UV Height – Sets the height of the part, the upper contour of the wirepath. Absolute
locates the UV plane relative to absolute 0,0,0. Incremental locates the plane relative to
the Z depth of the chained geometry.
Page 28
UV Trim Plane – Sets the location of the upper guide that can be required by the
control and is usually set higher than UV Height. When is not required it should be set
to the same height as the UV Height.
XY Extension - Used for geometry with variable depths that not lie completely in a
single plane when 3D tracking is supported by the wire EDM machine. Give a negative
incremental value to locate the extension below the XY height and trim planes.
XY Height – Sets the bottom of the part, the lower contour of the wirepath. Absolute
locates the XY plane relative to absolute 0,0,0. Incremental locates the plane relative to
the Z depth of the chained geometry.
XY Trim Plane – Sets the location of the lower guide that can be required by the control
and is usually set lower than XY Height. When is not required it should be set to the
same height as the XY Height.
Page 29
IGES TRANSLATOR
IGES is a public standard. It is used by many full-scale CAD systems. The IGES
standard is considerably more complex than other file formats. The IGES interface is
three dimensional.
IGES files are written in five sections: the start section (a comment), the global section,
the directory section, the parameter section and the terminate section. The parameters
for the global section cannot be changed. The default delimiter and end of record
(comma and semicolon) are used. A comment is solicited and written in the start
section.
Read File
After you select the file to read, Mastercam displays the Read IGES window. Use this
feature based on the following descriptions.
Trim Surface Handling

Use this setting based on the following descriptions.
Use Preference Flag, XYZ if unspecified

Select this option if you want Mastercam to use the preference flag in the IGES file. If
there is no flag, Mastercam uses XYZ co-ordinates to trim surfaces.
Use Preference Flag, UV if unspecified

Select this option if you want Mastercam to use the preference flag in the IGES file. If
there is no flag, Mastercam uses UV co-ordinates to trim surfaces.
Always Read XYZs

Select this option if you want Mastercam to always use XYZ co-ordinates regardless of
any preference flags.
Always Read UVs

Select this option if you want Mastercam to always use UV co-ordinates regardless of
any preference flags.
Untrimmable Surfaces
Select the Put Untrimmable Surfaces on new level check box if you want to separate
any IGES surfaces that Mastercam cannot trim. Type the level that you want
Mastercam to use in the Level Number text box.
Override with File Values
Page 30
Use this selection to override Mastercam's Tolerance settings with those that the IGES
file is using. This feature scales all Mastercam tolerance settings to meet the converted
file's scale. Select .MC9 Name to replace the current Mastercam file name with the
name of the IGES file.
File is English
This selection lets Mastercam automatically change the Unit System setting in Screen |
Configure | Misc. Settings based on whether the IGES file is U.S. Customary Units or SI
(metric).
Select Scale Data to scale the converted IGES file to the current Mastercam setting.
Select Override Units if you want to reset Mastercam based on whether the IGES file is
U.S. Customary Units or SI (metric).
IGSCAN
Use this feature to scan the IGES file for information. Mastercam displays the
information to the screen.
Masking
This function defines the IGES read/write mask for all supported data types from 100 to
500 (excluding 124 - transformation matrix). Only supported entities may be masked
Mastercam displays the IGES Entity Masking window. Select all the check boxes for
those entities you want to include. Deselect the check boxes for those entities you do
not want to include. Click Done after you select the entities you want to include or
Cancel to quit without masking.
AUTODESK TRANSLATOR
The Autodesk conversion option available with Mastercam Version 9 reads AutoCAD
10 through AutoCAD 2000 DWG, DXF, and Autodesk InventorÔ (IPT) files. It also
writes AutoCAD 13, AutoCAD 14, and AutoCAD 2000 DWG/DXF files.
The DXF (Drawing Interchange File) format is used by AUTOCAD®
The DXF format is three dimensional and supports colors and levels. Splines,
dimensions, leader lines or notes are not supported (use IGES). Commonly used for
shape translation.
The DWG format is the AutoCAD® drawing (*.DWG) file format. The DWG format is
three dimensional and supports colors and levels and splines, dimensions, leader lines
or notes.
Page 31
You can read a single file or an entire directory. A single file becomes the current file. A
scan function is built into the converter to allow you to examine the DWG file before you
convert it. You can also mask entities to selectively convert them.
The Autodesk Inventor file is a 3D solids file created in Autodesk Inventor software. You
must have Autodesk Inventor or Autodesk DesignTracker installed in order to use this
converter. You can install DesignTracker from the Mastercam system CD.
Page 32
OPERATIONS MANAGER
The Operations Manager lists all operations in the current job. Use this dialog box to
sort, edit, regenerate, verify and post any operations. You can enter this dialog box by
choosing Wirepaths, Operations from the Main Menu.
Select All
This button selects all operations listed in the Operations Manager. Selected operations
are represented by a check mark on the folder icon.
Regen Path
The Regen Path button recreates the selected operations after changes have been
made to the operations. This option applies only to associative wirepaths.
Backplot
The Backplot button backplots all selected operations in the order they appear in the
Operations Manager.
Verify
The Verify button opens Mastercam’s wirepath verification program and creates a
model of all selected operations in the order they appear in the Operations Manager.
Post
The Post button creates an ASCII NCI file. The Mastercam post processor uses this
text file for the selected operation according to your default post processor settings. The
Page 33
Post button creates the NC file automatically only if you turn on the default post
processor.
Operation List Area

This area displays the order of operations in the current job. Select the + or – in front of
the file folder icon for an operation to display/ collapse the pieces of that operation,
including parameters, tool definition, geometry, and the NCI file.
Parameters
Select the Parameters icon to edit the wirepath parameters.
Geometry
Select the Geometry icon to edit the chains and points to be machined in that operation.
Right-mouse click in the list area and you can change the followings:
♦ Add a new chain.

♦ Change the side of the cutter compensation.
♦ Rechain all the chains.
♦ Resynchronizing chains.
♦ Analyze all chains.
♦ Delete a chain.
♦ Reverse the chain direction.
♦ Rechain a single chain.
♦ Change the Start point of the chain.
♦ Change at point some of the parameters.
♦ Rename the chain.
♦ Change the thread/cut positions.
♦ Analyze a single chain.
♦ Edit existing tabs.
NCI
NCI is a separate intermediate file that contains all information of the wirepath data.
The post-processor uses the NCI file to create a NC file for your specific
machine/control.
Select NCI icon the system will open the Backplot command.
Right-mouse click on the NCI icon and the Wirepath Editor will be displayed.
Page 34
Wirepath Editor allows you to edit the wirepath. Modify or delete a single move, a
section or an entire pass or depth cut.
About Right-mouse click in Operations Manager list area.

Right-mouse click in Operations Manager list area opens an extensive menu of
commands.
Wirepaths: Displays a list with all operations

available in Mastercam. You can start to create an
operation from here.
For example by selecting Wirepaths, Contour the
system will prompt you, in the graphic mode, to chain
the geometry to be machined.
Wirepaths, New allows you to delete all operations

and tools that were already created.
Wirepaths, Import NCI allows you to import wirepaths

from an existed job.
Page 35
Options: Allows you to:
Edit common parameters allows you to edit the

common parameters of all the operations inside
of a wirepath group. For example you can
change the Feed plane value for all the
operations inside off the group. Make sure that
previously you select all operations.
Filter filters the wirepath.
Change at Point allows you to send special

machine codes at specific points on the
contour. For example you may want to program
a stop code at a given point.
Wirepath Editor allows you to edit the wirepath.

Modify or delete a single move, a section or an
entire pass or depth cut.
Change the NCI destination allows you to change the name of the NCI file.
Renumber the work offsets allows you to renumber the work offsets when using more
than one offset (tombstone application)
Wirepath display can be turned On/Off.
Locking allows you to lock the wirepaths to block the associativity. Can be turned
ON/Off.
Posting allows you to block the post processing option. Can be turned ON/Off.
Select by geometry brings you back in the graphic mode and allows you to select the
geometry used in an exiting operation. It will then, automatically highlight the operation
that used that geometry.
Select by view allows you to see all the operations that use a selected view as their
construction plane (Cplane), tool plane (Tplane), or work coordinate system (WCS).
Select all invalid selects all invalid (dirty) operations at once so they can be regenerated
at the same time.
Page 36
Setup sheet provides information about a workpiece, including operations, tool

reference, total programming time and comments added during programming in a
printable format.
Groups: Allows you to organize operations. Operation groups are handy for quick
selection of wirepaths: selecting a group automatically selects all operations within the
group.
Create new operation group instructs

the system to add a new wirepath
group.
Rename operation group allows you to

change the group name.
Delete operation group instructs the

system to delete a selected group. The
operations within the group are not
going to be deleted.
Set as ACTIVE group places new

wirepaths in the active operation group.
The name of the active operation
group appears in bold type.
Expand all groups displays all the

operations within all groups.
Collapse all groups displays only the group names.
Expand operations within a group expands all the operations within a group.
Collapse operations within a group collapses all the operations within a group.
Cut, Copy/Paste: Allows you to reorder the operations.
Delete/Undelete: Allows you to delete selected operations or recover them using

undelete.
Expand all expands all the operations and the groups inside of the Operations
Manager.
Collapse all collapses all the operations and the groups inside of the Operations
Manager.
Page 37
Doc file creates a text file that lists all the groups, operations, tools, geometry and NCI
destination that are in the Operations Manager.
Sort operations: Allows you to reorganize operations by:
Tool number sorts operations by the

tool number in either ascending or
descending order.
Tool plane sorts operations by the

tool plane number in either
ascending or descending order.
NCI destination sorts operations by

the NCI destination in either
Work offset sorts operations by the

work offset number in either
Creation order chronologically sorts

operations in either ascending or
descending order.
Operation type sorts operations by the type of the operation. For example it will list all
the drilling wirepaths.
Get from library: allows you to import saved operations from a library.
Save to library: allows you to save operations into a library.
Display options: sets the Operations Manager display options.
Job setup: opens Job Setup dialog box.
Page 38

General Notes Wire9 Mastercam9

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TUTORIAL SERIES FOR

More Icons Toolbar

Return to Main Menu Button

Main Menu - Selections used to create geometry and wirepaths.

Secondary Menu - Selections used to work with geometry.

THE MAIN MENU

Solids: Creates and modifies solid geometry.

Wirepaths: Programs NC wirepaths (CAM systems only).

NC utils: Manipulates NC wirepaths (CAM systems only).

THE SECONDARY MENU

Groups: Defines a collection of entities as a named group.

MEASURING ANGLES IN MASTERCAM

DEFAULT KEY ASSIGNMENTS

Key(s) Function Description

F1 zoom Activates the zoom-in window. Use the zoom

F2 unzoom Zooms out from your geometry reducing its

F3 repaint Redisplays the graphic screen to clean up any

F4 analyze Activates the Analyze menu.

F5 delete Activates the Delete menu.

F6 file Activates the File menu.

F7 modify Activates the Modify menu.

F8 create Activates the Create menu.

F9 display Displays the following:

F10 execute Activates the key and button assignment

Alt+F2 scale geometry Unzoom by 0.8

Alt+F3 cursor tracking Activates the cursor tracking feature.

Alt+F4 exit Exits Mastercam.

Alt+F5 delete menu Activates the Delete menu.

Alt+F7 blank Activates the Screen | Blank menu.

Alt+F8 configure Opens the Screen | Configure Window. (You

Alt+F9 draw axes Displays the current graphics view (center),

Alt+F10 execute Activates the key and button assignment

Alt+A autosave Opens the AutoSave Window

Alt+B Toolbar Displays or hides the Toolbar

Alt+C run C-Hooks Lets you run a C-Hook applications program.

Alt+D drafting Opens the Drafting global parameters Window.

Alt+F menu fonts Opens the Font Window.

Alt+H on-line help Opens Mastercam's Help Window for instant

Alt+M memory Lists Mastercam memory allocations. This is a

Alt+P prompt area Displays and hides Mastercam's prompt area.

Alt+S shading toggle Activates full time shading

Alt+T draw NC Turns the wirepath display on and off. When

Alt+V Mastercam Displays the software version and serial

Alt+W set viewport Opens the VIEWPORTS Window. This lets

Alt+X xform menu Activates the Xform menu.

Alt+Z visible levels Opens the Visible Levels Window.

Alt+1 color Opens the color dialog box.

Alt+2 levels Opens the Main level dialog box.

Alt+3 mask level Opens the Mask level dialog box.

Alt+4 toolplane Activates the toolplane menu.

Alt+5 Cplane Activates the Cplane menu.

Alt+6 Gview Activates the Gview menu.

Alt+’ Create|Arc-2pt. cir Activates the Create|Arc|2pt. circle point menu.

Esc system interrupt Press Esc to interrupt some commands

backup key Instead of clicking backup, press Esc to back

DATA ENTRY SHORTCUTS

A Use “A” to input an existing angle.

Data Entry Shortcut Example

1. Create a line with endpoints at 0,0,0 and 3,0,0.

ASSIGNING BUTTONS AND KEYS

Select the following menu picks:

Funcs/ C-Hooks/ Macros [default]

Add This allows the user to add an assignment.