Mill Level 3 Professional Courseware

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Mastercam X6 Mill Level 3 - Professional Courseware
Copyright: 1998 - 2012 In-House Solutions Inc. All rights reserved

Software: Mastercam X6
Author: Mariana Lendel
ISBN: 978-1-926955-49-0
Revision Date: February 16, 2012
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 praticular 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;
N-See is a registered trademark of Microcompatibles, Inc.; Windows, Windows XP, Windows Vista,
Windows NT and Window 7 are registered trademarks of Microsoft Corporation.
 Professional Courseware Contents

3D Geometry .............................................................................................................. 1
3D Wireframe Geometry Creation ............................................................................................................ 2
Set PreDefined Views and Create New Views ........................................................................................... 2
Curve One Edge, Curve All Edges & Curve At Intersection ...................................................................... 32
Surface Geometry Creation ..................................................................................................................... 38
Revolved Surfaces ................................................................................................................................... 38
Draft Surfaces........................................................................................................................................... 44
Flat Boundary Surface .............................................................................................................................. 45
Extruded Surfaces ................................................................................................................................... 48
Primitives ................................................................................................................................................ 49
Free Form Surfaces; Ruled, Loft, Net, Swarf & Fence ............................................................................. 51
Ruled Surface .......................................................................................................................................... 52
Net Surfaces ............................................................................................................................................ 58
Swept Surfaces ........................................................................................................................................ 72
Fence Surfaces ......................................................................................................................................... 91
Derived Surfaces; Offset, Trim, Fillet, Surface Blending & Fillet Blend ................................................... 93
Offset Surfaces ......................................................................................................................................... 93
Trim Surface To Curves ........................................................................................................................... 95
Trim Surface To Surface ........................................................................................................................ 101
Split Surface .......................................................................................................................................... 103
Trim Surface To Plane ...........................................................................................................................105
Fillet Surfaces ........................................................................................................................................ 109
3 Fillet Blend Surface ............................................................................................................................. 117
Surface Toolpaths ................................................................................................... 127
Surface Rough Pocket A Cavity Shape ................................................................................................... 131
Surface Rough Flowline ......................................................................................................................... 138
Finish The Part Using Surface Finish Flowline ........................................................................................ 144
Surface Finish Radial .............................................................................................................................. 147
Surface Finish Blend .............................................................................................................................. 151
Surface Finish Contour .......................................................................................................................... 158
Surface Finish Scallop ............................................................................................................................ 165
Create A Boundary Using Silhouette Boundary .................................................................................... 167
Surface Rough Pocket With Facing Option ........................................................................................... 170
Surface Finish Leftover Toolpath ........................................................................................................... 174
Surface Finish Parallel ........................................................................................................................... 180
Surface Finish Pencil With Limited Passes ............................................................................................ 185
Surface Finish Project Toolpath To Engrave The Letters ....................................................................... 187
Surface Finish Project A Toolpath ......................................................................................................... 189
Surface Rough Restmill .......................................................................................................................... 193
Surface Finish Shallow............................................................................................................................ 198
Surface Rough Restmill From An Stl File ............................................................................................... 202
Surface High Speed Toolpaths ................................................................................. 209
About High Speed Surface Toolpaths .................................................................................................... 210
Surface High Speed Core Rough ............................................................................................................ 212
Stock Model .......................................................................................................................................... 218
Surface High Speed Horizontal Area ..................................................................................................... 219

Mill Level 3 Professional Courseware

 Surface High Speed Scallop Finishing - The Boss Shape Only................................................................. 222
Surface High Speed Scallop (Rest Passes) - Creating A Fillet ................................................................. 224
Surface High Speed Area Clearance ...................................................................................................... 227
Surface High Speed Rest Roughing ....................................................................................................... 231
Surface High Speed Hybrid Finishing ..................................................................................................... 234
Surface High Speed Pencil ..................................................................................................................... 236
Surface High Speed OptiCore ................................................................................................................ 239
Surface High Speed Waterline .............................................................................................................. 242
Surface High Speed Horizontal Area ..................................................................................................... 242
Surface Rough Radial ............................................................................................................................ 247
Surface High Speed Radial ..................................................................................................................... 248
Surface High Speed Spiral ..................................................................................................................... 251
Surface Finish Blend .............................................................................................................................. 254
Appendix: Drawings ................................................................................................ 257

Mill Level 3 Professional Courseware

 SURFACE TOOLPATHS ROUGH POCKET & FLOWLINE, FINISH FLOWLINE, RADIAL & BLEND

EXERCISE: 1ROUGH POCKET & FLOWLINE, FINISH FLOWLINE, RADIAL & BLEND
Resources - Download the file from http://www.emastercam.com/files

File

 Open.
 Select ROUGH POCKET_ FINISH FLOWLINE.MCX-6.

The following toolpaths are covered in this project:

Surface Rough Pocket.
Surface Rough Flowline.
Surface Finish Flowline.
Surface Finish Radial.
Surface Finish Blend.

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 ROUGH POCKET & FLOWLINE, FINISH FLOWLINE, RADIAL & BLEND SURFACE TOOLPATHS

SURFACE ROUGH POCKET A CAVITY SHAPE

Surface Pocket Rough toolpaths machine selected surfaces or solids with different shapes containing pockets and bosses.
It requires a closed boundary inside of which the tool removes the material. To machine the part efficiently you can use
different cutting methods (zig-zag, spiral, etc) depending on the part shape. This rough toolpath also allows you to set a
ramp or a helical entry while machining pockets. You can set the tool to plunge outside of the containment boundary while
machining a boss shape.

1. Set the Tool Settings parameters

The Tool Settings allow you to establish the material type of the part that will be cut. According to the material type and to
the diameter of the tool Mastercam can calculate the feedrates and spindle speeds for each operation.

 From Toolpaths Operations Manager, select and expand the Properties- Generic Mill.
 Select the Tool settings.
 Set the Program # 1.
 Enable Assign tool numbers sequentially and all the Advanced options.
 Enable Feed Calculation From tool.
2. Set the Stock Setup parameters

Stock Setup allows you to establish the stock size that will be used in Verify to simulate the machining process.

 Select the Stock Setup tab.

 Use select corners button to establish the stock.

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 SURFACE TOOLPATHS ROUGH POCKET & FLOWLINE, FINISH FLOWLINE, RADIAL & BLEND

3. Surface Rough Pocket toolpath selections

Toolpath/surface Selection dialog box allows the selection or reselection of any geometry used in a surface toolpath. You
can access the Toolpath/surface Selection by clicking the Geometry icon of a surface toolpath in the Toolpaths Manager.

Toolpaths
 Surface Rough.

 Pocket.

NOTE: The first surface toolpath you select, this New 3D Advanced Toolpath Refinement Feature dialog box
will appear. For the tutorials within this book we will be using this new feature. It is a new way of applying the
tolerances and will be explained when we use them. At this time we will enable the radio button which will
shut off the advertisement yet allow us to use this new feature.

Toolpaths/surface selection definitions:

Drive surfaces are the areas of parts that are machined.
Check surfaces are areas of parts protected from tool movements.
A Tool Containment Boundary is a closed chain that limits the tool movements for a surface toolpath.

 Select all surfaces and the containment boundary (magenta color boundary at the top of the cavity).
4. Toolpath parameters

The Toolpath parameters dialog box allows you to select the tool used in this operation. It also allows you to change the
Spindle speed and the Feed rate. You can insert a comment that will be output in the NC file after running the post
processor.

 Select the 1/2" Bull Nose with the corner Radius of 0.125".
 Leave the default Feed rate and Spindle speed.
 Enable Coolant.
 Enter a comment: "Rough out the part using a 1/2" Bull nose".
5. Surface parameters

The Surface parameters dialog box allows you to establish the heights for rapid movement Clearance & Retract, from
where the tool moves with feedrate Feed plane, and the Top of stock.
You can select surfaces to be protected from machining as check surfaces.
Stock to leave on drive surfaces sets the amount to leave for finish operation as a constant value all the way around the
drive surfaces.

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 ROUGH POCKET & FLOWLINE, FINISH FLOWLINE, RADIAL & BLEND SURFACE TOOLPATHS

 Clearance = 2.0" (Abs).

 Retract = 0.50" (Incr).
 Feed plane = 0.25" (Incr).
 Stock to leave on drive = 0.03".
 Enable Center in the Tool containment.

NOTE: The Tool containment allows you to select the closed contour inside of which the tool will machine the
part. Without it the toolpaths will not be generated.

6. Rough parameters

The Rough parameters dialog box allows you to establish the Total tolerance in which the toolpaths follows the surfaces;
Maximum stepdown to set the depth of cuts and the Entry options (ramp or helix).
Total tolerance is the sum of the filter tolerance and cut tolerance.
Maximum stepdown sets the maximum distance between adjacent cuts in the surface toolpath.
Incremental cut depths are measured from the top to the bottom of the part. You can enter an adjustment amount to the
top and bottom cuts. Mastercam automatically calculates the stock to leave on drive surfaces parameter into the cut
depths, and spaces cut depths equally apart.

 Set the Total tolerance to 0.01".

 Set the Maximum stepdown to 0.1".
 Enable Entry-helix.
 In the Cut depths leave the default settings to incremental.
7. Pocket parameters

The Pocket parameters dialog box allows you to establish the Cutting method used to rough out the part; Stepover
percentage or distance to set the distance between rough passes in XY plane. You can also set the Finish options to enable
finish passes (as contour cut) around the part shape at each depth of cut.
Stepover distance sets the distance between passes in the active construction plane. Can be set as a percentage of the tool
diameter or as a distance.
Finish containment boundary enables the tool to machine contours at each Z depth increment around the closed
boundary selected. This option is mostly used when machining cavity shapes.

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 SURFACE TOOLPATHS BACKPLOT THE TOOLPATH

 Set the Stepover percentage to 55% of diameter = 0.275".

 Leave the Finish and the Finish containment boundary enabled.

BACKPLOT THE TOOLPATH

Backplotting is the process of displaying the path that the tools follow to cut the part. This display lets you spot errors in
the program before you machine the part. When you backplot, the toolpath is displayed in the current graphics view
(Gview) and the x, y, z co-ordinates are displayed in the extend Backplot dialog box.

Button descriptions
Step mode lets you advance the tool along the toolpath entity by entity or with a preset step. Each time you click on Step

forward button the tool advances to the next point in the toolpath.

Play mode advances the tool along the toolpath in one continuous motion without pausing. You can pause it by
selecting Stop button.

Display with color codes will display the toolpaths using different colors.

Display tool will display the tool as a wireframe or shaded based on the choice you make in the Backplot Options.

Display holder will display the tool holder as a wireframe or shaded based on the choice you make in the Backplot
Options.

Display rapid moves will display the rapid moves.

Display Endpoints will display endpoints along the tool path.

Quick Verify shows the tool path shaded based on the tool diameter used.

Option button opens the Backplot Options dialog box and lets you determine general display parameters such as how
the tool moves on the screen (General Settings) and how the tool and the motion looks on the screen (Appearance).

Save as geometry button allows sets whether or not to save the geometry created by the backplot.

 From the Toolpaths Operations Manager, click on the Backplot selected operations icon.

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 VERIFY THE TOOLPATH SURFACE TOOLPATHS

 Select Play.

VERIFY THE TOOLPATH

Verify uses solid models to simulate the machining of a part.

 From the Toolpaths Operations Manager, click on the Verify selected operations icon.

 To be able to see any tool collisions enable Stop on collision.

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 SURFACE TOOLPATHS VERIFY THE TOOLPATH

 Select the configure button and enable Change tool color to see the material that is cut by each tool.

NOTE: The stock shape is a box. Boundaries for the stock size are displayed according to the Job Setup
settings.

 Select OK button to exit Verify Configure dialog box.

 Select the Machine button to run Verify.

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 VERIFY THE TOOLPATH SURFACE TOOLPATHS

The part should look as shown.

 To quick verify the part, instead of using Simulate tool, select the Turbo button.
Surface Rough Pocket Review
Can be used for different shapes containing pockets and bosses.
Requires a closed boundary to generate the toolpath inside of it.
Allows the use of an entry option (helix or ramp for the cavities and plunge outside containment boundary for
bosses).
Quick, optimized toolpath.

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 SURFACE TOOLPATHS VERIFY THE TOOLPATH

SURFACE ROUGH FLOWLINE

Flowline finish and rough toolpaths allow precise control of the scallops left on the part, creating an exact, smooth finish.
You can only use flowline toolpaths on one surface or a row of adjacent drive surfaces.

In this part of the exercise we are comparing the Surface Rough Flowline toolpath with the Surface
Rough Pocket toolpath
 Press Alt + T to remove the toolpath display.

Toolpaths
 Surface Rough.

 Flowline.

1.Toolpath selections

 From the Quick Mask toolbar, select QM Surface icon to select all surfaces and then click on the top
two surfaces to unselect them.

NOTE: Remember that Flowline toolpath only works with surfaces aligned in a row.

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 VERIFY THE TOOLPATH SURFACE TOOLPATHS

 Select Flowline options button.

 The following graphics illustrate different settings available in the Flowline data dialog box and their results.

Offset -Toggles the tool radius offset between the normal and the opposite surface normal as shown.

Cut direction - Toggles the toolpath between along and across direction as shown.

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 SURFACE TOOLPATHS VERIFY THE TOOLPATH

Step direction - Sets the direction of the tool movements as shown.

Start -Sets the starting point at one of the endpoints of the starting flowline as shown.

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 VERIFY THE TOOLPATH SURFACE TOOLPATHS

 Set the Flowline parameters to match this picture.

2. Toolpath Parameters
 Select the existing tool.
3. Surface Parameters
 The Clearance, Retract and Feed planes should remain the same as set in the rough pocket.
 Stock to leave on drive = 0.03".

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 SURFACE TOOLPATHS VERIFY THE TOOLPATH

4. Rough flowline parameters

The Rough flowline parameters dialog box allows you to establish the Total tolerance in which the toolpaths follows the
surfaces; Stepover control and the Maximum stepdown to set the depth of cuts.
Total tolerance is the sum of the filter tolerance and cut tolerance.
Maximum stepdown sets the maximum distance between adjacent cuts in the surface toolpath.
Scallop height can be set either as a stepover distance or as an actual height. When using the scallop height option,
Mastercam automatically adjusts the stepover between cuts, although this amount is not shown in the stepover entry
field.
Plunge control determines the type of Z-axis movement for surface rough toolpaths. It can be used to prevent the tool
from air-cutting through a previously cleared area of the part. Plunge control works well for cavity parts.

 Set the Stepover control as a distance to 0.275".

 Cutting method set to Zigzag.
 Enable Allow multiple plunges along cut.
 Enable both Allow negative/positive Z motion along surface.
5. Backplot the Rough Flowline

 Select Play.

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 VERIFY THE TOOLPATH SURFACE TOOLPATHS

6. Verify the Rough Flowline toolpath

 To quickly verify the part select the Turbo button.

 Select the Machine button to run Verify.

Surface Rough Flowline compared with Surface Rough Pocket

 Can be used only for shapes with one surface or for surfaces in a row.
 Does not allow the use of any entry option; to start outside the part we extend the surfaces.
 Roughly it has 2 times more code which increases the machining time.
 Allows precise control of the scallops left on the part, leaving constant stock for the finish operation.

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 SURFACE TOOLPATHS VERIFY THE TOOLPATH

FINISH THE PART USING SURFACE FINISH FLOWLINE

Flowline Finish toolpath allows precise control of the scallops left on the part, creating an exact, smooth finish. You can
only use flowline toolpaths on one surface or a row of adjacent drive surfaces.

1.Toolpath selections

Toolpaths
 Surface Finish.

 Flowline.
 From the Quick Mask toolbar, select QM Surface icon to select all surfaces and then click on the top
two surfaces to unselect them.

NOTE: Remember that Flowline toolpath only works with surfaces aligned in a row.

 Select Flowline options button and change the settings to match the screenshot below.

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 VERIFY THE TOOLPATH SURFACE TOOLPATHS

2. Toolpath Parameters
 Select the 1/4" Ball Endmill.
 Leave the default Feed rate and Spindle speed.
 Enable Coolant.
 Enter a comment: "Finish the part using a 1/4" Ball Endmill".
3. Surface parameters
 Leave the modal Clearance, Retract and Feed plane.
 Stock to leave on drive surfaces set to 0.0".
4. Finish flowline parameters
 Total tolerance = 0.001".
 Scallop height = 0.002".
 Cutting method set to Zigzag.
5. Backplot the Finish Flowline toolpath

6. Verify the Finish Flowline toolpath

 Hold down the Ctrl key and select both the Surface Rough Pocket toolpath and the Surface Finish Flowline
toolpath.

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 SURFACE TOOLPATHS VERIFY THE TOOLPATH

 Select the Machine button to run Verify.

Surface Finish Flowline Review

 The toolpath can be only used for shapes with one surface or for surfaces in a row.
 It does not allow the use of any entry options; to start outside the part we have to extend the surfaces.
 It does allow precise control of the scallops left on the part, creating an exact, smooth finish.

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 VERIFY THE TOOLPATH SURFACE TOOLPATHS

SURFACE FINISH RADIAL

Surface Finish Radial toolpath is used mainly for rounded shape areas or parts. The toolpath requires a rotation point
(usually at the center of the part) from which the tool moves along the radius. The distance between the passes is
determined by the incremental angle. The part surface will be better finished close to the rotation point and less finish
towards the edges.

1.Toolpath selection

Toolpaths
 Surface Finish.

 Radial.
 Select as Drive surfaces all surfaces.
 Select as Containment boundary the magenta
color boundary.
 Select the Radial point as shown.

2. Toolpath Parameters
 Select the same 1/4" Ball Endmill.

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 SURFACE TOOLPATHS VERIFY THE TOOLPATH

3. Surface parameters
 Leave the modal Clearance, Retract and Feed plane.
 Stock to leave on drive surfaces set to 0.0".
4. Finish radial parameters
 Total tolerance set to 0.001".
 Cutting method set to Zigzag.
 Max angle increment set to 0.5".
 Start angle set to 85.
 Sweep angle set to 100.

5. Backplot the Finish Radial toolpath

NOTE: The tool rolls around the edges. To fix

this problem we need to change the Advance
settings parameters.

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 VERIFY THE TOOLPATH SURFACE TOOLPATHS

6. Change the Advanced Settings to avoid the roll of the tool around the surface edges

Advanced Settings determine the tool motion on the edges of surfaces and solids, and the accuracy (tolerance) of tool
motion on sharp corners. You can also perform checks for hidden solid faces and sharp internal corners on surfaces.
Only between surfaces (solid faces) - rolls the tool between surfaces and/or solid faces only, but not at the extreme edges
of the part (as shown below).
Over all edges - rolls the tool over all edges of the surface and/or solid, both between surface and/or solid faces and at the
extreme edges of the part (as shown below).
Automatically (based on geometry) - allows Mastercam to set tool rolls depending on the presence or absence of a tool
containment boundary, and in some cases, on the geometry itself. If you define a tool containment boundary, the tool rolls
over all surface and/or solid edges, both between surfaces and the extreme edges of the part. If you do not define a tool
containment boundary, the tool rolls only between surfaces and/or solid faces.

 From the Toolpaths Operations Manager, in the Finish Radial toolpath, select the Parameters.
 Select Finish radial parameters page.
 Click on the Advanced settings button, and enable roll tool Only between surfaces.
 From the Toolpaths Operations Manager in the Finish Radial toolpath select the Geometry.
 Select as the Check surfaces the two flat surfaces.
 Regenerate the toolpath.

7. Backplot the Finish Radial toolpath again

NOTE: The retract movements at both ends of

the surfaces. They are the result of the default
gap settings that are set to Broken for a tool
motion that is smaller than the Gap size.

8. Gap Settings

Gap settings control the action (retract or keep tool down) when there is a break of tool motion in a surface toolpath. A
break can occur between two cuts, between drive and check surfaces, or between two drive surfaces.
Gap settings allows you to set the gap size, the action to take when the motion is smaller than the gap size, and whether to
retract when motion is larger than gap size. You can also make selections to insert tangential lines and arcs to create
smooth tool motion in gaps.

 From the Toolpaths Operations Manager, in the Finish Radial toolpath, select the Parameters.
 Select Finish radial parameters page.
 Click on the Gap settings button, and make sure that the Gap size is set to % of tool diameter = 300.
 Select Follow surface(s) for motions that are smaller that the gap size.
 Regenerate the toolpath.

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 SURFACE TOOLPATHS VERIFY THE TOOLPATH

9. Backplot the Finish Radial toolpath again

NOTE: The radial moves are always oriented

towards the radial point. That leaves marks on
the fillet areas shown.

10. Verify the Finish Radial toolpath

Surface Finish Radial Review

 Better results when used on round shapes mainly torus.
 Does not allow the use of any entry option.
 The toolpath requires a rotation point (usually at the center of the part) from which the tool moves along the
radius.
 The distance between the passes is determined by the incremental angle. As a result the part surface will be
better finished close to the rotation point and less finished towards the edges.

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 VERIFY THE TOOLPATH SURFACE TOOLPATHS

SURFACE FINISH BLEND

Surface Finish Blend creates the toolpath on a drive surface in an area defined by two chains of curves. The toolpath is
defined by two splines and is projected onto the selected surfaces.

Toolpaths
 Surface Finish.

 Blend.
 Select all surfaces and unselect the two top flat surfaces.

 Select Blend button and in the Chaining dialog box select the Options button and enable Section angle
to be able to select quick the two contours.

11. Set the Toolpath Parameters

 Select the existing 1/4" Ball Endmill.
12. Set the Surface Parameters
 Leave the modal Clearance, Retract and Feed plane.
 Stock to leave on drive surfaces should be 0.0".

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 SURFACE TOOLPATHS VERIFY THE TOOLPATH

13. Finish Blend Parameters

Finish blend parameters page allows you to set the cutting method to either zigzag, one way, or spiral. The spiral method
makes the most sense if at least one chain is closed.
The Along and Across options control the blend between the chains.

NOTE: The Across method creates 2D cuts in straight lines which may not be parallel to
each other. Across is a good choice for machining across a cavity to leave small cusps for
later hand finishing.

NOTE: The Along method creates cuts that start along the first blend chain then morph
toward the second blend chain. Along is a good choice for flow cutting and creates either
2D or 3D cuts.
Choosing the Blend button when Along is selected provides additional control of the
"mesh" (blend resolution) to support vertical walls.

 Enable Across.
 Set the Max. stepover to 0.035".
 Cutting method set to Zigzag.
14. Backplot the Finish Blend toolpath

NOTE: The tool rolls around the edges. To fix

this problem, in Finish blend parameters page,
in the Advanced settings, enable roll tool Only
between surfaces.

15. Backplot the Finish Blend toolpath again

NOTE: The tool moves, in the area shown, are

not parallel with the surface edges.

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16. Verify the Finish Blend toolpath

Surface Finish Blend Review

 Can be used for cavity or boss shapes where the surfaces are not in a row.
 Does not allow the use of any entry option; to start outside the part we extend the surfaces.
 Does not allow precise control of the scallops left on the part as flowline does but the result is closer.

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