PROJECT 12 VERSION 9

FORMULA 1 BEGINNER TRAINING TUTORIAL

Mill Level 3 – Solids, Surface Machining

Mill V9 STEP 1: CREATE ½ OF THE CAR BODY Open F1 Template File
 MAIN MENU  File / Get  Select the Beginner F1 Template.mc9 file

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[If you cannot find the file ask the teacher where to locate it] [For those with internet access go to www.emastercam.com/files] Download the BeginnerF1Template.zip file and ask your teacher where to copy it to.
 MAIN MENU  File/Save  Name the file accordingly (do not use Beginner F1 Template.mc9)  Save  Click on Level, as shown in the diagram below

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[The Level Manager is displayed as shown below;] [Note that Level 10 is highlighted in Yellow. This indicates that all the geometry created will be on Level 10, therefore your car will be created on level 10] [Note that Level 10 also has a check mark beside it. This indicates that level 10 is visible]
 Click on Used or named[this will show all the levels being used in this drawing]

 Scroll to Level 1 and click in the area under Visible, this will turn level 1 on and a checkmark will be displayed.

[The Level Manager should look as shown below]

 Click OK

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 Change your Gview to Isometric (if it is not already)  MAIN MENU  Select Solids / Extrude / chain  chain your geometry as shown in the diagram below:

 Done

[make sure the arrow is pointing in a Z+ direction (up)]
 Done  Extend by specified distance of Z 2.400" as shown in the picture below:

 OK  The following solid body should be created as shown in the picture below:

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 Hold the ALT key and select the S key to turn the shading on.  Hold the Alt key and select the S key to turn the shading back off.

[You may want to keep the shading turned off in order to see the selection lines that will be opening as you go through this tutorial.]

STEP 2: CREATE THE COCKPIT SHAPE
 Change your Gview to Isometric (if it is not already)  Click on Level  Select levels 2 and turn off level 1  OK  Fit to Screen  Select MAIN MENU / Solids / Extrude / chain  chain the geometry as shown in the picture below:

[the direction of the arrow can point either way]

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 Done  Done  Select; Cut Body / Extend through all / Both directions / as shown in the diagram below;

 OK  Select Alt and S to turn the shading on  Turn shading off

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Mill V9 STEP 3: UNDERBODY
 Click on Level  Select level 3 and turn off level 2  OK  Fit to Screen  Select MAIN MENU / Solids / Extrude / chain

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[now chain the geometry as shown below];

 Done

[the direction of the arrow does not matter]
 Done  Fill out the selections as shown in the diagram below;

 OK  Turn on Shading (Alt S)

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 Moving the part on the screen;

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 Select the Dynamic rotation icon (or right click on your mouse and select Dynamic Spin).  Click on the screen and move the mouse around and the part will spin around.  Select the Isometric icon (or right click on your mouse and select Isometric).

STEP 4: CREATING THE HOOD AND DRIVERS SEAT
 Click on Level  Select level 4 and turn off level 3  OK  Fit the part to the screen  Select MAIN MENU / Solids / Extrude / chain  Chain the geometry as shown below

 Done

[the direction of the arrow does not matter]
 Done  Fill out the selections as shown in the diagram below;

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 OK

STEP 5 CREATE THE FRONT FENDER
 Select Level  Turn off level 4 and turn on level 5  OK  Select MAIN MENU Solids / Extrude / chain  Chain the geometry as shown below;

 Done

[the direction of the arrow should be pointing towards you, if it is not, click on Reverse it]
 Done

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 Fill in the Extrude Chain parameter screen as shown below; be sure to type in Front Fender beside name and enter the distance you want your fender to extrude to [minimum of 0.4" and maximum of 1.4"]

 OK

STEP 6: CREATE THE WHEEL WELL
 Select Level  Turn off level 5 and turn on level 6  OK  Fit to screen  Select MAIN MENU / Solids / Extrude / chain  Chain the geometry as shown below:

 Done

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[the direction of the arrow should be pointing towards you, if it is not, click on Reverse it]
 Done  Fill in the Extrude Chain parameter window as shown below: [type in Wheel Well beside name and enter in the distance you want your wheel well to extrude to minimum of 0.5" and maximum of 1.4"]

 OK

STEP 7: CREATE THE REAR SPOILER
 Select Level  Turn off level 6 and turn on level 7 / OK  Fit to Screen  Select MAIN MENU / Solids / Extrude / chain  Chain the geometry as shown below;

[Note: you may have to dynamically spin the part

to see the geometry to chain]

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 Done

[the arrow should be pointing towards you, if it is not, click on Reverse it]
 Done  Fill in the Extrude Chain parameter screen as shown below;

[type in Rear Spoiler beside name and extrude to the length desired to a maximum of 1.4"]

 OK  Don’t forget that you can always shade the part (Alt S) and move it around good look at your car. to get a

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Mill V9 STEP 8: CREATE THE SIDE AIR DAM
 Select Level  Turn off level 7 and turn on level 8 / OK  Select MAIN MENU / Solids / Loft / chain  Chain the geometry as shown below

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 Done

[do not chain the line that connects the two geometries]
 Done  Fill in the Loft Chain parameter screen as shown below;

 OK

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Mill V9 STEP 9: CREATE HOLES FOR AXLES
 Select Level  Turn off level 8 and turn on level 9 / OK  Select MAIN MENU / Solids / Extrude / chain  Chain the holes as shown below:

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 Done [the direction of the arrows do not matter]  Done  Fill in the Extrude Chain parameter screen as shown below;

 OK  Select Level  Turn off level 9 and enable level 100 / OK  Fit to Screen

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STEP 10: MIRROR THE ½ CAR BODY TO CREATE FULL CAR
 Select MAIN MENU / XForm  Mirror  Select the car body  Done  Line  Select the line as shown below

 Fill in the Mirror parameter screen as shown below;

 OK

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 Your car should look something like the diagrams below;

STEP 11: SAVING YOUR WORK
 Select MAIN MENU  File  Save  Ask your teacher where the file should be saved to

STEP 12: (OPTIONAL) MODIFYING THE CAR

You now have the option to modify your car if you choose. You have the option to modify the front Fender, Wheel Wells and the Rear Spoiler as shown in the diagram below;

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Mill V9 STEP 12A: MODIFY THE FRONT FENDER

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 MAIN MENU  Solids / Solids mgr  Click on the plus sign in front of Solid and Copy of Solid [The solids manager parameter screen is displayed as shown below;]

 Select Copy of Solid  Right click your mouse and select delete  Click on Regen All  OK [one half of the car should disappear] [you may have to fit to screen or repaint to see the change]  MAIN MENU  Solids / Solids Mgr  Click on the + in front of Front Fender and double click the parameters folder  To modify the overall length of the front fender change the number in Distance. [this number has to be a minimum of 0.4" and maximum of 1.4".]

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 Click on OK [note the red x over Solid and Front Fender. This indicates that a change has been made to the parameters and in order to take effect the Regen All Button has to be selected]  Select Regen All

 OK [Note how the Front Fender changes]

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Mill V9 STEP 12B: MODIFY THE WHEEL WELLS

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 MAIN MENU  Solids / Solids mgr  Click on the + in front of Wheel Well and double click the parameters folder  To modify the overall length of the Wheel Well change the number in Distance. [this number has to be a minimum of 0.4" and maximum of 1.4".]

 Click on OK [note the red x over Solid and Wheel Well. This indicates that a change has been made to the parameters and in order to take effect the Regen All Button has to be selected]  Select Regen All  OK [Note how the Wheel Well changes]

STEP 12C: TO MODIFY THE REAR SPOILER
 MAIN MENU  Solids / Solids mgr  Click on the + in front of Rear Spoiler and double click the parameters folder  To modify the overall length of the Rear Spoiler change the number in Distance[extrude to the length desired to a maximum of 1.4"]  Click on OK [note the red x over Solid and Rear Spoiler. This indicates that a change has been made to the parameters and in order to take effect the Regen All Button has to be selected]  Select Regen All  OK [Note how the Rear Spoiler changes]

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 Save your work  Go back to step 10 page 1-15 to Mirror the car

STEP 13 MAKE THE 2 SOLID HALFS ONE SOLID
 MAIN MENU  Solids  Boolean  Add  Make sure Solid is set to Yes (y) and From back is set to No (N)  Click on the car Solid as shown below;

 Click on the other half of the car Solid  Done  Save your work

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Mill V9 TOOLPATH CREATION STEP 14: JOB SETUP

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 Click on Level  Turn on Level 252 Job Setup  OK  MAIN MENU  Toolpaths  Job Setup  The Job Setup Screen will be displayed as shown below;

 Click on the [Select Corners] Button in the Job Setup Screen

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 Select the two corners of the rectangular boundary as shown below;

 Make sure the Display Stock window is checked as shown in the Job Setup Screen above  OK

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Mill V9 STEP 15 CREATE ROUGHT TOOLPATH

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 CPlane  Top  MAIN MENU  Surface  Make sure Contain is set to Y (Yes)  Rough  Pocket  Solids  [Make sure only Solids has a Y beside it. If the other items have a Y displayed click on the item and it will change to an N]  Select the Car Solid with the mouse  Done  Done  The Surface Rough Pocket screen will displayed as shown;  Fill in the Tool parameters as shown. [NOTE if there is no tool displayed in the Tool window follow the Selecting a Tool instructions below.]

Instructions for; Selecting a Tool

1. Right click the mouse cursor in the white box area near the top of the Surface Rough Pocket Screen. 2. Click on Get Tool from library 3. Scroll down and select the ¼ inch ball endmill from the library 4. OK  Click on the Change NCI button;  Replace the name of the file with C:\MCAM9\MILL\NCI\(your name) Rough as shown below;  OK  No [to Update all operations the share the same nci path?

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 Click on the Surface Parameters tab  Make the necessary changes in the Surface Rough Pocket screen as shown;

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 Click on the Pocket Parameters Tab  Click on the checkmark in front of Finish to turn this feature off  OK

 Click OK on the Warning screen.

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[Mastercam will ask you to select a Tool containment boundary]
 Chain  Options  Click on Plane Mask to turn the checkmark on  OK  Click on the line as shown below;

 Done  The screen should look as follows;

 To remove the toolpath display press Alt and T at the same time.

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Mill V9 STEP 16 CREATE THE TOP TOOLPATH
 MAIN MENU  Surface  Make sure Contain is set to Y  Finish  Parallel  Solids  Select the Car Solid  Done  Done  Fill in the parameter screen as shown;  Click on Change NCI button

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 Replace the name of the file with C:\MCAM9\MILL\NCI\(your name) Top as shown below;  No [to Update all operations the share the same nci path?  OK  Select the Surface parameters Tab  Make the changes as shown in the Surface parameters screen;  OK

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 Click on the line as shown below;

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 Done

STEP 17 CREATE THE FRONT TOOLPATH
 Click on Cplane  Select Rotate  Select Y+ Up  Type in 90 and Enter  Save  MAIN MENU  Toolpaths  Surface  Finish  Parallel  Solids  Select the Solid Car  Done  Done  Fill in the parameter screen as shown (if it is not already);  Click on Change NCI

 Replace the name of the file with C:\MCAM9\MILL\NCI\(your name) Front  OK  No [to Update all operations the share the same nci path?  OK

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 Select the line as shown below;

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 Done

STEP 18 CREATE THE BOTTOM TOOLPATH
 Click on Cplane  Select Rotate  Select Y+ Up  Type in 90 and Enter  Save  MAIN MENU  Toolpaths  Surface  Finish  Parallel  Solids  Select the Solid Car  Done  Done

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 Fill in the parameter screen as shown (if it is not already);  Click on Change NCI

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 Replace the name of the file with C:\MCAM9\MILL\NCI\(your name) Bottom  OK  No [to Update all operations the share the same nci path?  OK  Click on the line as shown below;

 Done

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Mill V9 STEP 19 CREATE THE BACK TOOLPATH
 Click on Cplane  Select Rotate  Select Y+ up  Type in 90 and Enter  Save  MAIN MENU  Toolpaths  Surface  Finish  Parallel  Solids  Select the Solid Car  Done  Done  Fill in the parameter screen as shown (if it is not already);  Click on Change NCI

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 Replace the name of the file with C:\MCAM9\MILL\NCI\(your name) Back  OK  No [to Update all operations the share the same nci path?  OK

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 Select the line as shown below;

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 Done

STEP 20 CHECK THE TOOLPATH USING BACKPLOT
 MAIN MENU  Toolpaths  Operations  The Operations Manager screen will displayed as shown;  Click on Select All [this will select all the toolpaths]  Click on Backplot  Make sure Show Tool and Show Path are set to Yes (Y)  Click on Run  The toolpath will be animated and displayed. [Note on the lower left area of the screen, the time will be displayed.  Once the toolpath has finished being displayed you can step through the backplot by clicking on step  Back up

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STEP 21 CHECK THE TOOLPATH USING VERIFY
 Click on the Verify Button  Click on the Play Button as shown;

 The screen should look like the one below;

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Mill V9 STEP 22 CREATING THE NC CODE

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[We will be creating 5 different NC programs. This will allow you change the cars position between programs. It will also help if the program takes longer than the class time allows.]
The 5 different programs will be; 1. (your name) rough.nc 2. (your name) top.nc 3. (your name) front.nc 4. (your name) bottom.nc 5. (your name) back.nc
 Click on Post in the Operations Manager  Click OK  You will prompted to name the NC file. Select the default name (it should be (your name) Rough.NC.  Save  The NC file may be displayed in another window. Close this window.  You will prompted to name the second NC file. Select the default name [it should be (your name) Top.NC.  The NC file may be displayed in another window. Close this window.  You will prompted to name the second NC file. Select the default name [it should be (your name) Front.NC.  The NC file may be displayed in another window. Close this window.  You will prompted to name the second NC file. Select the default name [it should be (your name) Back.NC.  The NC file may be displayed in another window. Close this window.  You will prompted to name the second NC file. Select the default name [it should be (your name) Bottom.NC.  The NC file may be displayed in another window. Close this window  The operations manager should be displayed as shown;  Ok to close the Operations Manager

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Mill V9 STEP 22 SAVE THE FILE
 MAIN MENU  File  Save  Save

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