Mill Level 1 Training Tutorial Metric

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Mastercam X5 Mill Level 1 Training Tutorial Metric Copyright: 1998 - 2011 In-House Solutions Inc. All rights reserved Software: Mastercam X5 Author: Mariana Lendel ISBN: 978-1-926566-96-2 Revision Date: March 31, 2011 Notice In-House Solutions Inc. reserves the right to make improvements to this manual at any time and without notice. Disclaimer Of All Warranties And Liability In-House Solutions Inc. makes no warranties, either express or implied, with respect to this manual or with respect to the software described in this manual, its quality, performance, merchantability, or fitness for any particular purpose. In-House Solutions Inc. manual is sold or licensed "as is." The entire risk as to its quality and performance is with the buyer. Should the manual prove defective following its purchase, the buyer (and not In-House Solutions Inc., its distributer, or its retailer) assumes the entire cost of all necessary servicing, repair, of correction and any incidental or consequential damages. In no event will In-House Solutions Inc. be liable for direct, indirect, or consequential damages resulting from any defect in the manual, even if In-House Solutions Inc. has been advised of the possibility of such damages. Some jurisdictions do not allow the exclusion or limitation of implied warranties or liability for incidental or consequential damages, so the above limitation or exclusion may not apply to you. Copyrights This manual is protected under International copyright laws. All rights are reserved. This document may not, in whole or part, be copied, photographed, reproduced, translated or reduced to any electronic medium or machine readable form without prior consent, in writing, from In-House Solutions Inc. Trademarks Mastercam is a registered trademark of CNC Software, Inc. Microsoft, the Microsoft logo, MS, and MS-DOS are registered trademarks of Microsoft Corporation; NSee is a registered trademark of Microcompatibles, Inc.; Windows, Windows XP, Windows Vista and Windows NT are registered trademarks of Microsoft Corporation.

Mill Level 1 Training Tutorial Contents

Getting Started ...................................................................................................A-1 Tutorials
Tutorial #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 Tutorial #8 ......................................................................................................................... 8-1 Tutorial #9 ......................................................................................................................... 9-1 Tutorial #10 ..................................................................................................................... 10-1

Creating/Editing Tools ......................................................................................... C-1 Quiz Answers ......................................................................................................D-1

The following pages outline the geometry functions and toolpaths covered within each tutorial. Two discs are attached to the back of this book; their contents are summarized below. Mastercam X5 Home Learning Edition DVD The Mastercam X5 Home Learning Edition is a demo that provides a fully functional* version of Mastercam that can be installed on your home PC. The software must be re-installed after 6 months and expires completely October 31st, 2012. *All Mastercam modules are available; however, there are a few limitations such as no support for C-Hooks and limitations around post processing. Mill Level 1 Training CD The Mill Level 1 Training CD is an excellent resource for beginners and experienced users alike. For new users, we have created a video called "Mastercam Worksapce" which serves as an introduction to the Mastercam user interface. Video training exercises complement the book by teaching the fundamentals of 2D geometry creation. These are interactive exercises where we provide .MCX-5 files so you can do each exercise with video instruction. We recommend that beginners complete the training exercises prior to starting the book. We have included an additional chapter called "General Notes" that provides useful tools, shortcuts and toolpath parameter descriptions in a PDF file. In addition, there are complete step-by-step videos for each of the tutorials in the book.

Mill Level 1 Training Tutorial

Mill Level 1 Training Tutorial

TUTORIAL #31

TUTORIAL #3
Objectives:
The Student will design a 2-dimensional drawing by: Create arcs polar knowing the diameter, location, start and end angles. Create parallel lines, by defining the offset direction and distance. Create fillets knowing the radius size. Create lines on an angle knowing the starting point and angle. Mirror the part to create the other 1/2 of the part. The Student will create toolpaths consisting of two setups: An open pocket toolpath to remove the material in the open area. Contour remachining toolpath to cut the material which the open pocket left. A circle mill toolpath to remove the material in the arc. Three drill toolpaths to, spot drill, drill and tap the holes. A contour toolpath to remove the material at the parts exterior. The contour toolpath will be part of setup #2. The Student will simulate the toolpaths using Mastercam's Verify and Backplot by: Defining a 3-dimensional rectangular block the size of the workpiece. Running the Backplot to see the path the tool takes to cut the part. Running the Verify to simulate the tool cutting from a solid model. This tutorial takes approximately one hour to complete.

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SETTING UP THE GRAPHIC USER INTERFACE

TUTORIAL #31

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 2D 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. Repeat this command to make it visible again.

Figure: 1.0.1

NOTE: We will create 1/2 of the geometry.

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TUTORIAL #31 STEP 2:

CREATE ARCS POLAR

CREATE ARCS POLAR

In this step you will learn how to create arcs polar. To create arcs polar you need to define center point, radius, start point or angle and end point or angle.

Step Preview:

2.1 Create the 38.0mm diameter arc

Create Arc. Arc Polar. [Enter the center point]: Select the Origin as shown in Figure: 2.1.1. Figure: 2.1.1

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

Input a Diameter

of 38.0mm, hit Tab and enter a Start Angle

of 0.0 degrees and an

End Angle of 180.0 degrees. Press Enter to see the arc.

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CREATE ARCS POLAR

TUTORIAL #31

The drawing will appear as shown.

Choose the Apply button to continue in the same command.

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 To delete unwanted geometry, select it

undo a step by mistake, just use the Redo icon. first and then press Delete from the keyboard.

[Enter the center point]: Select the Fast Point icon from the Auto Cursor ribbon bar. Input the value 31, 0 and hit Enter to place the arc center point.

Enter a Diameter

of 6.0mm, hit Tab and enter a Start Angle of 180.0 degrees. Press Enter.

of 0.0 degrees and hit

Tab again and enter an End Angle Choose the Apply button to continue. The drawing will appear as shown.

[Enter the center point]: Select the Origin for the arc center point. Enter a Radius of 38.0mm, hit Tab twice and enter a Start Angle of 180.0 degrees. Press Enter. of 90.0 degrees and

hit Tab again and enter an End Angle

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

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TUTORIAL #31

CREATE HORIZONTAL LINES

The drawing will appear as shown.

Select the OK button to exit the Arc Polar command. Select the Unzoom Previous icon.

STEP 3:

CREATE HORIZONTAL LINES

In this step you will learn how to create horizontal lines.

Step Preview:

Create Line. Endpoint.

Select the Horizontal icon.

NOTE: Once this icon has been selected you will only be able to create horizontal lines.
[Specify the first endpoint]: Select a point to the left of the large arc. [Specify the second endpoint]: Select another point to the right of the small arc to create a horizontal line as shown in Figure: 3.0.1.

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CREATE HORIZONTAL LINES

TUTORIAL #31

Figure: 3.0.1

Enter a value to offset that line in the Y-Axis direction of 31.0.

Select the Apply button to continue. Use the Fit icon to fit the drawing to the screen. Repeat this same step creating a line offset in the Y-Axis direction of 19.0. Your drawing will appear as shown up to this point.

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TUTORIAL #31 STEP 4:

CREATE VERTICAL LINES

CREATE VERTICAL LINES

In this step you will learn how to create vertical lines.

Step Preview:

Create Line. Endpoint.

Select the Vertical icon.

NOTE: Once this icon has been selected you will only be able to create vertical lines.
[Specify the first endpoint]: Select a point to the right of the small arc. [Specify the second endpoint]: Select another point above the original selected point to create a vertical line as shown in Figure: 4.0.1. Figure: 4.0.1

Enter a value to offset that line in the X-Axis direction of 44.0. Choose the Apply button to continue.

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Mill Level 1 Training Tutorial

TRIM TWO ENTITIES

TUTORIAL #31

Repeat this same step creating a line offset in the X-Axis direction of 75.0. Select the OK button once complete. Pick the Fit icon to view all of the entities. Your drawing will appear as shown.

STEP 5:

TRIM TWO ENTITIES

In this step you will learn how to trim two entities to each other.

Step Preview:

Edit Trim/Break. Trim/Break/Extend.

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TUTORIAL #31

TRIM TWO ENTITIES

Select the Trim 2 Entities icon and ensure the Trim icon is enabled. Select the two lines as shown in Figure: 5.0.1. Figure: 5.0.1

NOTE: When selecting the second line you will notice the lines change to a hidden line style.
This is a preview of what is going to be trimmed and lets you select another entity if necessary. Repeat the step selecting the lines as shown in Figure: 5.0.2. Figure: 5.0.2

The drawing should look as shown.

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TRIM A LINE TO A POINT

TUTORIAL #31

STEP 6:

TRIM A LINE TO A POINT

Trim to point trims an entity to a point or any defined position in the graphics window. If the point that you enter does not lie on the selected entity, Mastercam calculates the closest position on the entity and trims the entity to that.

Step Preview:

Edit Trim/Break. Trim/Break/Extend.

Select the Trim to Point icon and ensure the option to Trim is enabled. [Select entity to trim]: Select the line as shown. [Indicate the trim/extend location]: Select the Origin as the point to trim to as shown in Figure: 6.0.1. Figure: 6.0.1

Select the OK button to exit the trim command.

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TUTORIAL #31 STEP 7:

CREATE LINE ENDPOINT

CREATE LINE ENDPOINT

Create Line Endpoint lets you create lines from a selected endpoint or intersection to a selected point at a given angle.

Step Preview:

Create Line. Endpoint. [Specify the first endpoint]: Select the Intersection point for the first endpoint as shown in Figure: 7.0.1.

NOTE: Ensure the vertical or horizontal is not enabled.

Figure: 7.0.1

[Specify the second endpoint]: Pick the second point roughly in the area as shown in Figure: 7.0.2. Figure: 7.0.2

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CREATE LINE ENDPOINT

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Change the line Length to 75.0 and Angle to 5.0.

Choose the Apply button once the values have been input. [Specify the first endpoint]: Pick the Intersection point for another line as shown in Figure: 7.0.3. Figure: 7.0.3

[Specify the second endpoint]: Pick the second point roughly in the area as shown in Figure: 7.0.4. Figure: 7.0.4

Change the line Length to 75.0 and Angle to 175.0.

Select the OK button once the values have been input. Your drawing will appear as shown up to this point.

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TUTORIAL #31 STEP 8:

CREATE FILLETS

CREATE FILLETS
Fillets are used to round sharp corners.

Step Preview:

Create Fillet. Entities. Enter a fillet Radius of 6.0. Ensure the fillet Style is set to Normal and Trim is enabled.

Select the Arc and Line as shown in Figure: 8.0.1. Figure: 8.0.1

Select the two angled lines as shown in Figure: 8.0.2.

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CREATE FILLETS

TUTORIAL #31

Figure: 8.0.2

Pick the angled line and the vertical line as shown in Figure: 8.0.3. Figure: 8.0.3

Select the Apply button. Input a Fillet Radius of 3.0 in the Ribbon bar.

Select the two lines as shown in Figure: 8.0.4. Figure: 8.0.4

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TUTORIAL #31

DELETE THE CONSTRUCTION LINE

The drawing will appear as shown.

Select the OK button to exit the Create Fillet command.

STEP 9:

DELETE THE CONSTRUCTION LINE

Delete the construction line to remove it from the graphics user interface.

Select the line as shown in Figure: 9.0.1. Figure: 9.0.1

Pick the Delete icon to remove the line.

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Mill Level 1 Training Tutorial

XFORM MIRROR

TUTORIAL #31

STEP 10:

XFORM MIRROR
Mirror entities by reflecting them symmetrically with respect to a defined axis or point.

Step Preview:

Xform Mirror. [Mirror: select entities to mirror]: Create a box around the part. Left click and hold the mouse down, drag the mouse down to the lower left area of the part and left click again as shown in Figure: 10.0.1. Figure: 10.0.1

Select the End Selection button. When the Mirror dialog box appears enable Copy and choose the option to mirror about the X-Axis as shown in Figure: 10.0.2.

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XFORM MIRROR

Figure: 10.0.2

Select the OK button to exit the Mirror dialog box. Pick the Clear Color icon to re-set the drawing colors to the original system color. Your drawing will appear as shown.

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Mill Level 1 Training Tutorial

JOIN ENTITIES

TUTORIAL #31

STEP 11:

JOIN ENTITIES
Join entities is used to join collinear lines, arcs that have the same center and radius.

NOTE: There is no step preview for this step because the drawing will appear the same.
Edit Join Entities. Select the entities as shown in Figure: 11.0.1. Figure: 11.0.1

Once those entities have all been selected pick the End Selection button.

NOTE: If you move your mouse over those entities now they should appear as one solid
entity.

STEP 12:

SAVE THE FILE

File Save As. File name: "Your Name_3". Select the OK button to save your file.

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TUTORIAL #31

SUGGESTED FIXTURE:

TOOLPATH CREATION

SUGGESTED FIXTURE:

NOTE: In order to machine this part we will have 2 setups and output 2 NC files. To view the second setup see page 72.

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SETUP SHEET:

TUTORIAL #31

SETUP SHEET:

Mill Level 1 Training Tutorial

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TUTORIAL #31

SETUP SHEET:

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Mill Level 1 Training Tutorial

SELECT THE MACHINE AND SET UP THE STOCK

TUTORIAL #31

STEP 13:

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 machines capabilities and features. It acts like a template for setting up your machine. The machine definition ties together three main components. The schematic model of your machines components. The control definition that models your control capabilities and the post processor that will generate the required machine code (G-code). For a Mill Level 1 exercise (2D toolpaths) we need just a basic machine definition.

NOTE: For the purpose of this tutorial, we will be using the Default milling machine.
To display the Operations Manager press Alt + O. Use the Fit icon to fit the drawing to the screen. Machine type Mill. Default.

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

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TUTORIAL #31

SELECT THE MACHINE AND SET UP THE STOCK

Select Tool Settings to set the tool parameters.

Change the parameters to match the screen shot as shown in Figure: 13.0.1. Figure: 13.0.1

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.

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SELECT THE MACHINE AND SET UP THE STOCK

TUTORIAL #31

Select the Stock setup tab to define the stock. Select the Bounding Box button as shown in Figure: 13.0.2. Figure: 13.0.2

In the Expand dialog boxes enter 3.0 as shown. This will add 3.0mm of stock on each side of your model as shown in Figure: 13.0.3. Figure: 13.0.3

Select the OK button to exit the Bounding Box.

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TUTORIAL #31

SELECT THE MACHINE AND SET UP THE STOCK

Input the overall Depth of your stock model as shown in Figure: 13.0.4. Figure: 13.0.4

The Stock Origin values adjust the positioning of the stock, ensuring that you have equal amount of extra stock around the finished part. Display options allow you to set the stock as Wireframe and to fit the stock to the screen (Fit Screen).

NOTE: The stock model that you create can be displayed with the part geometry when
viewing the file or the toolpaths, during backplot, or while verifying toolpaths. In the graphics, the plus shows you where the stock origin is. The default position is the middle of the stock. Click on the corner of the part to set it as the stock origin. Select the OK button to exit Machine Group Properties. Select the Isometric view from the graphics view toolbar to see the stock. Use the Fit icon to fit the drawing to the screen.

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Mill Level 1 Training Tutorial

OPEN POCKET

TUTORIAL #31

The stock model will appear as shown.

NOTE: The stock is not geometry and can not be selected.

Select the Top view from the view toolbar to see the part from the top.

NOTE: There will not be facing toolpath because the stock is already to size.

STEP 14:

OPEN POCKET
Open Pocket toolpath automatically enters and exits the pocket through the opening.

Toolpath Preview:

Toolpaths Pocket.

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TUTORIAL #31

OPEN POCKET

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

When the Chaining dialog box appears, choose Partial as the chaining method.

Select the first entity as shown in Figure: 14.0.1. Figure: 14.0.1

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OPEN POCKET

TUTORIAL #31

Select the second entity as shown in Figure: 14.0.2. Figure: 14.0.2

Choose the OK button to exit the Chaining dialog box. In the Toolpath Type page, the Pocket icon will be selected.

NOTE: Mastercam updates the pages as you modify them and then marks them, in the Tree
view list, with a green check mark. Pages that are not changed are marked with a red circle and slash.

14.1 Select a 12.0mm Flat Endmill

Select a 12.0mm Flat Endmill from the library and set the Tool parameters. Select Tool from the Tree view list. Click on Select library tool button. Select the Filter button.

Select the None button and then under Tool Types choose the Flat Endmill Icon.

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TUTORIAL #31

OPEN POCKET

Under tool diameter pick Equal and input a value 12.0 as shown in Figure: 14.1.1. Figure: 14.1.1

Select the OK button to exit the Tool List Filter. In the Tool Selection dialog box you should only see a 12.0mm Flat Endmill.

Select the 12.0mm Flat Endmill in the Tool Selection page and then select the OK button to exit.

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OPEN POCKET

TUTORIAL #31

Make all the necessary changes as shown in Figure: 14.1.2. Figure: 14.1.2

The Feed rate, Plunge rate, Retract rate and Spindle speed are roughly based on the part material Aluminum and HSS tooling. You may change these values as per your part material and tools. In the Comment field enter a comment to help identify the toolpath in the Toolpaths/Operations Manager such as the one shown above.

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TUTORIAL #31

OPEN POCKET

14.2 Cut Parameters

Select Cut Parameters and make the necessary changes as shown in Figure: 14.2.1. Figure: 14.2.1

Pocket Type lets you select from a list several pocket types which are based on your pocket geometry. Open Pocket toolpath automatically enters and exits the pocket through the opening. Open pocket cutting method starts the toolpath at the open end of the pocket and cuts from the inside to the outside.

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OPEN POCKET

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14.3 Roughing
Select Roughing and make the necessary changes as shown in Figure: 14.3.1. Figure: 14.3.1

Cutting Method determines the cutting method. When using open pocket the cutting method is set to Open. Stepover percentage/Stepover distance sets the distance between cutting passes in the X and Y Axes as a percentage of the tool diameter. Changing this value automatically adjusts the stepover distance.

14.4 Entry Motion

Select Entry Motion and pick Off as shown in Figure: 14.4.1. We do not need an entry motion because you will be plunging the tool off the material.

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TUTORIAL #31

OPEN POCKET

Figure: 14.4.1

Off turns off any entry helix or ramp moves for the pocket toolpaths roughing passes. Mastercam plunges the tool to the pocket depth at the start of the toolpath.

NOTE: We are using Off because the tool will plunge off the material. This way we will not waste any time waiting for the tool to get to its cut depth. 14.5 Finishing
Select Finishing and make the necessary changes as shown in Figure: 14.5.1. Figure: 14.5.1

For more information regarding these parameters please see page 34 in Tutorial #2.

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OPEN POCKET

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14.6 Lead In/Out

Select Lead In/Out and disable this option as shown in Figure: 14.6.1. Figure: 14.6.1

14.7 Depth Cuts

Choose Depth Cuts and enable this option. Input a Max rough step of 5.0. Enable the option Keep tool down as shown in Figure: 14.7.1. Figure: 14.7.1

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TUTORIAL #31

OPEN POCKET

14.8 Break Through

Pick Break Through from the Tree view list. Enable this option and input a Break through amount of 2.0 as shown in Figure: 14.8.1. Figure: 14.8.1

Break Through allows you to specify an amount that the tool will completely cut through the material by. This values is always a positive number.

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Mill Level 1 Training Tutorial

BACKPLOT THE TOOLPATHS

TUTORIAL #31

14.9 Linking Parameters

Pick Linking Parameters and make the necessary changes as shown in Figure: 14.9.1. Figure: 14.9.1

Select the OK button to exit the Pocket parameters.

STEP 15:

BACKPLOT THE TOOLPATHS

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 toolpaths are selected (signified by the green check mark on the folder icon). If the operation is not selected choose the Select all operations icon. Select the Backplot selected operations button.

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BACKPLOT THE TOOLPATHS

Make sure that you have the following buttons turned on (they will appear pushed down) to see the tool and the rapid moves.

Select the Isometric view from the View toolbar to see the stock. Select the Fit button. 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. The toolpath should look as shown.

Select the OK button to exit Backplot.

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Mill Level 1 Training Tutorial

VERIFY THE TOOLPATH

TUTORIAL #31

STEP 16:

VERIFY THE TOOLPATH

Verify allows you to use a solid model to simulate the machining of a part. The model created by verification represents the surface finish, and shows collisions, if any exist.

In the Operations Manager both operations are selected. If the operation is not selected choose the Select all operations icon. Choose the Verify selected operations icon from the Operations Manager. Set the Verify speed by moving the slider bar in the speed control bar as shown. Select the Play button to start simulation.

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TUTORIAL #31

REMACHINE THE POCKET CORNERS

The part should look as shown.

STEP 17:

REMACHINE THE POCKET CORNERS

In this step you will create a Contour Remachine toolpath. This toolpath removes the material where the previous tool couldnt fit.

Toolpath Preview:

17.1 Chain selection

Toolpaths Contour.

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REMACHINE THE POCKET CORNERS

TUTORIAL #31

Enable the Last button in the Chaining dialog box. This will reselect the geometry we chained in the previous toolpath.

Select the OK button to exit Chaining. In the Toolpath Type page, the Contour icon will be selected.

NOTE: Mastercam updates the pages as you modify them and then marks them, in the Tree
view list, with a green check mark. Pages that are not changed are marked with a red circle and slash.

17.2 Select a 3.0mm Flat Endmill from the library and set the Tool parameters
Select Tool from the Tree view list. Click on Select library tool button. Select the Filter button as shown.

Select the None button and then under Tool Types choose the Flat Endmill icon. Under tool diameter pick Equal and input a value of 3.0 as shown in Figure: 17.2.1.

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TUTORIAL #31

REMACHINE THE POCKET CORNERS

Figure: 17.2.1

Select the OK button to exit the Tool List Filter. In the Tool Selection dialog box you should only see a 3.0mm Flat Endmill as shown in Figure: 17.2.2. Figure: 17.2.2

Select the 3.0mm Flat Endmill in the Tool Selection page and then select the OK button to exit.

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REMACHINE THE POCKET CORNERS

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Make all the necessary changes as shown in Figure: 17.2.3. Figure: 17.2.3

17.3 Cut Parameters

From the Tree view list, select Cut Parameters and ensure the settings appear as shown in Figure: 17.3.1. Figure: 17.3.1

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REMACHINE THE POCKET CORNERS

For more information regarding these parameters please see page 43 in Tutorial #2.

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REMACHINE THE POCKET CORNERS

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17.4 Depth Cuts

From the Tree view list, select the Depth Cuts Parameters. Enable Depth cuts and input a Max rough step of 1.0 as well enable the option to Keep tool down as shown in Figure: 17.4.1. Figure: 17.4.1

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TUTORIAL #31

REMACHINE THE POCKET CORNERS

17.5 Lead In/Out

Select Lead In/Out from the Tree view list. Disable the option to Enter/exit at midpoint in closed contours as shown in Figure: 17.5.1. Enter an Arc radius value of 0.0. Enable the option to Adjust start of contour. Input a Length of 100.0 and choose the option Extend. Select the Copy button to copy the parameters from the Entry to the Exit options. Figure: 17.5.1

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REMACHINE THE POCKET CORNERS

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17.6 Break Through

From the Tree view list, select Break Through and make the necessary changes as shown in Figure: 17.6.1. Figure: 17.6.1

17.7 Linking Parameters

Select Linking Parameters and input the Depth as shown in Figure: 17.7.1.

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REMACHINE THE POCKET CORNERS

Figure: 17.7.1

Once complete pick the OK button to generate the toolpath. To Backplot and Verify the toolpath see page 37 to review these procedures.

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CIRCLE MILL THE LARGE HOLE

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STEP 18:

CIRCLE MILL THE LARGE HOLE

Circle mill toolpath is used to mill circular pockets based on a single point. Mastercam will pocket out a circular area of the diameter and to the depth that you specify. After milling the center of the circle, Mastercam calculates an entry arc before approaching the perimeter and then a similar exit arc. You can add enhancements such as multiple passes, multiple depth cuts and helical plunge moves as well fine tuning the entry and exit arcs.

Toolpath Preview:

Toolpaths Circle Paths. Circle Mill.

18.1 Select the Geometry

When the Drill Point Selection dialog box appears choose Entities.

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CIRCLE MILL THE LARGE HOLE

Select the arc as shown in Figure: 18.1.1. Figure: 18.1.1

Choose the OK button once the arc has been selected. On the Toolpath Type page Circle Mill will be picked.

18.2 Select the 12.0mm Tool

From the Tool page, select the 12.0mm Flat Endmill as shown in previous step. Make any other changes as shown in Figure: 18.2.1.

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Figure: 18.2.1

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18.3 Cut Parameters

From the Tree view list select Cut Parameters to ensure the parameters appear the same as shown in Figure: 18.3.1. Figure: 18.3.1

Start Angle sets the angle where the helix bore toolpath begins.

18.4 Roughing
Enable Roughing and ensure your parameters appear as shown in Figure: 18.4.1. Figure: 18.4.1

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Roughing select to activate roughing passes and apply a step-over amount and helical entry move to your circle mill toolpath. Helical entry creates a helix at the center of the circle to begin the roughing motion. Output arc moves writes the entry helix to the NCI file as arcs. Use this option to create shorter NC files. If this option is off the helix is turned into linear segments.

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18.5 Depth Cuts

Choose Depth Cuts from the Tree view list. Input a Max rough step of 6.0 and enable Keep tool down. The depth cuts will only be applied to the roughing portion of the toolpath as shown in Figure: 18.5.1. Figure: 18.5.1

18.6 Break Through

Select Break Through from the Tree view list and enable the option. Input a Break through amount of 2.0 as shown in Figure: 18.6.1.

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Figure: 18.6.1

18.7 Linking Parameters

Select Linking Parameters from the Tree view list. Set the Depth to -19.0 as shown in Figure: 18.7.1. Figure: 18.7.1

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SPOT DRILL THE HOLE

Select the OK button to exit the Circle Mill Parameters. To Backplot and Verify your toolpath see page 37 to review these procedures.

STEP 19:

SPOT DRILL THE HOLE

Spot Drilling the holes allows you to start the hole. In this operation we will use the spot drill to chamfer the hole before drilling it.

Toolpath Preview:

Toolpaths Drill. In the Drill Point Selection dialog box choose the option Entities.

Select the small arc as shown in Figure: 19.0.1.

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Figure: 19.0.1

Select the OK button in the Drill Point Selection dialog box once you have picked the arc. In the Toolpath Type page, the Drill toolpath will be selected.

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SPOT DRILL THE HOLE

19.1 Select a 15.0mm Spot Drill from the library and set the Tool parameters
Select Tool from the Tree view list. Click on Select library tool button. To be able to see just the spot drill select the Filter button.

Under Tool Types select the None button and then choose the Spot Drill icon as shown in Figure: 19.1.1. Figure: 19.1.1

Select OK button to exit the Tool List Filter dialog box. At this point you should only see Spot Drills. From that list select the 15.0mm Spot Drill.

Select the tool in the Tool Selection page and then select the OK button to exit.

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Make the necessary changes to the Tool page as shown in Figure: 19.1.2. Figure: 19.1.2

19.2 Cut Parameters

Select Cut Parameters and make the necessary changes as shown in Figure: 19.2.1. Figure: 19.2.1

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SPOT DRILL THE HOLE

Drill/Counterbore recommended for drilling holes with depths of less than three times the tools diameter. Dwell sets the amount of time in seconds that the tool remains at the bottom of a drilled hole.

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19.3 Linking Parameters

Choose Linking Parameters, ensure Clearance is enabled and set the Top of stock to zero. To input the Depth select the Calculator icon. Input the following equation in the Finish diameter area, 6+1, and hit Enter to calculate the Depth as shown in Figure: 19.3.1. Figure: 19.3.1

Select the OK button to exit the Depth Calculator. You will now see the depth we calculated for the spot drilling operation set in the Depth field as shown in Figure: 19.3.2. Figure: 19.3.2

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DRILL THE HOLE

Select the OK button to exit the Drill/Counterbore parameters. To Backplot and Verify your toolpath see page 37 to review these procedures.

STEP 20:

DRILL THE HOLE

Drilling the holes in this example we will drill the holes to a specified depth.

Toolpath Preview:

Toolpaths Drill. In the Drill Point Selection dialog box choose the option Last.

NOTE: This option will automatically select the hole for you based off the selection from the
previous drill operation.

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Select the OK button in the Drill Point Selection dialog box to accept the drill point. In the Toolpath Type page, the Drill toolpath will be selected.

20.1 Select a 5.0mm Drill from the library and set the Tool parameters
Select Tool from the Tree view list. Click on Select library tool button. To be able to see just the drill select the Filter button.

Under Tool Types select the None button and then choose the Drill Icon. For the Tool Diameter select Ignore as shown in Figure: 20.1.1. Figure: 20.1.1

Select OK button to exit the Tool List Filter dialog box. At this point you should see a list of drills.

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DRILL THE HOLE

From that list, select the 5.0mm Drill as shown.

Select the tool in the Tool Selection page and then choose the OK button to exit. Make the necessary changes to the Tool page as shown in Figure: 20.1.2. Figure: 20.1.2

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20.2 Cut Parameters

Select Cut Parameters, change the drill Cycle to Chip Break and input a 1st peck value of 3.0 as shown in Figure: 20.2.1. Figure: 20.2.1

Chip Break drills holes with depths of more than three times the tool diameter. Retracts partially out of the drilled hole to break material chips. 1st peck sets the depth for the first peck move which plunges in and out of the material to clear and break chips.

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DRILL THE HOLE

20.3 Linking Parameters

Choose Linking Parameters and input a Depth value of -19.0 as shown in Figure: 20.3.1. Figure: 20.3.1

20.4 Tip Comp

Pick Tip Comp and enable this option. Input a Break through amount of 2.0 as shown in Figure: 20.4.1.

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Figure: 20.4.1

Select the OK button to exit the Drill/Counterbore parameters. To Backplot and Verify your toolpath see page 37 to review these procedures.

STEP 21:

TAP THE HOLE

Tap cycle taps right or left internal threaded holes.

Toolpath Preview:

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TAP THE HOLE

Toolpaths Drill. In the Drill Point Selection dialog box choose the option Last.

This option will automatically select the hole for you based off the selection from the previous drill operation. Select the OK button in the Drill Point Selection dialog box to accept the drill point. In the Toolpath Type page, the Drill toolpath will be selected.

21.1 Select a M6 - 1 RH Tap from the library and set the Tool parameters
Select Tool from the Tree view list. Click on Select library tool button. To be able to see just the tap RH select the Filter button.

Under Tool Types select the None button and then choose the Tap RH icon as shown in Figure: 21.1.1. Under Tool Diameter select Ignore.

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Figure: 21.1.1

Select OK button to exit the Tool List Filter dialog box. At this point you should see a list full of taps. From that list select the 6.0-1.0 Tap RH as shown in Figure: 21.1.2. Figure: 21.1.2

Select the tool in the Tool Selection page and then choose the OK button to exit. Make the necessary changes to the Tool page as shown in Figure: 21.1.3.

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Figure: 21.1.3

21.2 Cut Parameters

Select Cut Parameters, change the drill Cycle to Tap as shown in Figure: 21.2.1. Figure: 21.2.1

Tap Cycle taps right or left internal threaded holes.

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21.3 Linking Parameters

Choose Linking Parameters and input a Depth value of -19.0 as shown in Figure: 21.3.1. Figure: 21.3.1

21.4 Tip Comp

Pick Tip Comp and enable this option. Input a Break through amount of 2.0 as shown in Figure: 21.4.1. Figure: 21.4.1

Select the OK button to exit the Drill/Counterbore parameters. To Backplot and Verify your toolpath see page 37 to review these procedures.

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SUGGESTED FIXTURE:

TOOLPATH CREATION

SUGGESTED FIXTURE:

NOTE: In order to machine this part we will have 2 setups and output 2 NC files.

SETUP SHEET:

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STEP 22:

CREATING AND RENAMING TOOLPATH GROUPS

To machine the part in two different setups, we will need to have two separate programs. To be able to post process separately the operations of each setup, we will create them under different toolpath groups with different NC names.

22.1 Rename the current Toolpath Group - 1 and NC file

Click two times on the Toolpath Group - 1 to highlight it and rename it "Setup #1" as shown in Figure: 22.1.1. Figure: 22.1.1

Right mouse click on the toolpath group and select Edit selected operations and then, select Change NC file name as shown in Figure: 22.1.2. Figure: 22.1.2

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CREATING AND RENAMING TOOLPATH GROUPS

Enter the new NC name: "Setup #1".

Select the OK button to accept the new NC name. Create a new Toolpath Group. Right mouse click on the Setup #1 and hold the mouse button down. Drag the cursor below the insert arrow and select Copy After. This will create a new toolpath group and copy the toolpaths below. At this time with the toolpaths selected press Delete on your keyboard. A message will pop up asking you if you want to delete the toolpaths. Select Yes from this message. Rename the toolpath group "Setup #2".

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STEP 23:

CONTOUR TOOLPATH
Contour toolpath removes material along a path defined by a chain of curves. A Contour toolpath only follows a chain, it does not clean out an enclosed area.

Toolpath Preview:

Toolpaths Contour. Leave the default settings in the Chaining dialog box as shown.

Select the chain and ensure the chaining direction is the same as shown in Figure: 23.0.1.

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CONTOUR TOOLPATH

Figure: 23.0.1

Select the OK button to exit the Chaining dialog box. In the Toolpath Type page, the Contour toolpath will be selected.

23.1 Pick a 25.0mm Flat Endmill from the library and set the Tool parameters
Select Tool from the Tree view list. Click on Select library tool button. To be able to see all the tools from the library disable Filter Active.

Scroll down and select the 25.0mm Flat Endmill as shown in Figure: 23.1.1. Figure: 23.1.1

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Select the tool in the Tool Selection page and then select the OK button to exit. Make all the necessary changes as shown in Figure: 23.1.2. Figure: 23.1.2

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CONTOUR TOOLPATH

23.2 Cut Parameters

Select the Cut Parameters page and make the necessary changes. Figure: 23.2.1

Roll cutter around corners inserts arc moves around corners in the toolpath. None guarantees all sharp corners. Sharp rolls the tool around sharp corners (135 degrees or less). All rolls the tool around all corners and creates smooth tool movement.

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23.3 Depth Cuts

Select Depth Cuts and enable it. Input a Max rough step of 12.0 and enable Keep tool down as shown in Figure: 23.3.1. Figure: 23.3.1

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CONTOUR TOOLPATH

23.4 Lead In/Out

Choose the option Lead In/Out and input an Overlap value of 1.0. Make any other necessary changes as shown in Figure: 23.4.1. Figure: 23.4.1

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23.5 Multi Passes

Select Multi Passes, enable the option. Set the Number of Rough passes to 1 with Spacing of 2.0 and Number of Finish passes to 1 with Spacing of 0.5. This will have the system make a rough pass and then proceed with a 0.5mm finish pass. Enable the option to Machine finish passes at the Final depth as shown in Figure: 23.5.1. Figure: 23.5.1

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CONTOUR TOOLPATH

23.6 Linking Parameters

Select the Linking Parameters from the Tree view list. Set the Depth to -19.0 as shown in Figure: 23.6.1. Figure: 23.6.1

Select OK exit the Contour parameters. To Backplot and Verify your toolpath see page 37 to review these procedures.

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STEP 24:

RENAME NC FILE
The contour operation in Setup #2 kept the NC name from Setup #1. We need to rename this operation.

Right click on Operation #7, choose the option Edit selected operations and then pick Change NC file name as shown in Figure: 24.0.1. Figure: 24.0.1

When the Enter new NC name dialog box appears select "Setup #2" as shown in Figure: 24.0.2. Figure: 24.0.2

Select the OK button apply the changed NC name to Operation #7. The result you should see Setup #2.NC in the last item of text for Operation #7 as shown in Figure: 24.0.3.

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POST THE FILE

Figure: 24.0.3

STEP 25:

POST THE FILE

Ensure all operations are selected, if they are not use the button Select all operations the Operations Manager. Select the Post selected operations button from the Operations Manager. In the Post processing window make the necessary changes as shown in Figure: 25.0.1. Figure: 25.0.1 in

NC File enabled allows you to keep the NC file and to assign the same name as the MCX file. Edit enabled allows you to automatically launch the default editor.

Select the OK button to continue. Select the OK button to save Setup #1 NC file.

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Select the OK button to save Setup #2 NC file. A window with both NC programs will appear as shown in Figure: 25.0.2. Figure: 25.0.2

To view the two files as shown in the graphic above select Window and pick Tile Horizontal.

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.

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SAVE THE UPDATED MCX FILE

REVIEW EXERCISE - STUDENT PRACTICE

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CREATE THE GEOMETRY FOR TUTORIAL #3 EXERCISE

Use these commands to create the geometry. Create 1/2 of the geometry. Create circle center point. Fast Point to locate arcs. Create Vertical and Horizontal lines. Create Tangent Lines. Edit Trim/Break Two Pieces. Create Line Parallel. Create fillet entities.

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CREATE THE TOOLPATHS FOR TUTORIAL #3 EXERCISE

CREATE THE TOOLPATHS FOR TUTORIAL #3 EXERCISE

Create the Toolpaths for Tutorial #3 Exercise as per the instructions below.

Set the machine properties including the stock setup. Remove the material in the open pocket. Use a 12.0mm Flat Endmill. Set the Pocket type to Open. The cutting method will be set to Open. Entry Motion set to Off. Enable finishing and set the necessary parameters. Disable Lead In/Out. Use Depth Cuts. Enable Break through. Set the Depth according to the drawing.

Drill the 19mm Hole. Choose a 19.0mm Drill. Set the Cycle to Drill/Counterbore. Input a Depth according to the drawing. Enable Tip Comp.

Machine the Pocket. Use a 6.0mm Flat Endmill. Set the Pocket type to Standard. Choose a cutting method. Entry Motion set to Off. Enable finishing and set the necessary parameters. Disable Lead In/Out. Use Depth Cuts. Disable Break through. Set the Depth according to the drawing.

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Setup on 2nd Fixture. Remove the Material around the part (Contour 2D). Select the 12.0mm Flat Endmill from the Tool page. Set your compensation direction according to your chaining direction to ensure your tool is cutting on the correct side of the part. Enable Depth cuts. Enable and set the Lead In/Out parameters. Set a Break through amount. Enable Multi Passes and set Parameters. Set the Depth according to the drawing.

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NOTES:

NOTES:

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TUTORIAL #3 QUIZ
What does Open Pocket cutting method do?

What does Contour Remachine do?

What does the Open Pocket cutting method do?

What is the process used to be able to post different operations as different programs?

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