Chapter 4 Toolpaths CO2 Rail Body

Drill Holes - Wheel Cutouts (Pocket/Parallel) - Cut Body (Parallel/Blend)

A. Convert Units to Inches.

Step 1. Click Settings
Menu > Configu-
ration.

Step 2. Click Start/Exit

in the list of con-
figuration topics
on the left, Fig. 1.

Step 3. Set Startup set-

ting Configura-
tion to TECHED
ENGLISH (Eng-
lish), Fig. 1.
Fig. 1
Step 4. Set Current to TECHED ENGLISH (English), Fig. 1 and
click OK.

Step 5. Click Yes to scale part to English, Fig. 2 and Fit .

Fig. 2
B. Convert WCS Origin Units to Inches.
Step 1. Click WCS in the Status Bar
at the bottom of the screen and
View Manager.

Step 2. Click the LEFT CUT view

from the list of views in the
View Manager, Fig. 3.

Step 3. Convert the Y and Z origin

coordinate to inches. To
convert to inches, simply key-
in mm after the inch value and
press tap key, Fig. 3. 38 mm
converts to 1.49606 inches. Fig. 3
Convert both Y and Z coordinate to inches.
Left cut origin

Step 4. Click the Set All button, Fig. 3 and click OK.

Step 5. Change to the Isometric View, use . Check the

origin. Use F9 to show and hide axes. Fig. 4
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C. Machine Type and Stock Setup.
Step 1. Click Machine Type Menu > Mill > MPTECHNO.MMD.

Step 2. If necessary, display Operations Manager. Use Alt-O.

Step 3. Expand Properties (click the +) in the Toolpaths Manager, Fig. 5.

Step 4. Click Stock Setup in the Toolpaths Manager, Fig. 5. Fig. 5

Step 5. Click Bounding box button in the

Stock Setup dialog box, Fig. 6.

Step 6. Set: Check:

All Entities
Stock, Fig. 7
Click OK .

Step 7. Click OK in the Machine

Group Properties, Fig. 6.

D. Drill Toolpath.
Step 1. Zoom-in on the rear axle hole. Use F1
and make a zoom window, Fig. 8.
Fig. 6 Fig. 7
Step 2. Click Toolpaths Menu > Drill Toolpath.

Step 3. Select circle geometry at the hole. You should be Zoom

able to find the circle just inside the solid body.
This should place a point at the center of the hole.
To sure to select only once at hole, Fig. 9.

Step 4. Zoom out, Alt-F1 and zoom-in on the front axle Fig. 8
hole. Use F1 and make a zoom window,
Select circle geometry at the front hole,
Fig. 10.

Fig. 9 Fig. 10

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Step 5. Click OK in the
Drill Point Selec-
tion dialog box,
Fig. 11.

Step 6. Click Select li-

brary tool button,
Fig. 12.

Step 7. Click the Filter

button, Fig. 13.

Step 8. Click All button Fig. 11

under Tool Mate- Fig. 12
rial, Fig. 14.

Step 9. Click None button under

Tool Types, Fig. 14.

Step 10. Click Drill button (forth

button second row), Fig. 14
and click OK. Fig. 13

Step 11. Click 49 Drill 3/32 in.,

Fig. 15 and click OK.

Fig. 14

Fig. 15

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Step 12. Set the Feed rate: 60 Fig. 16.

Step 13. Set the Spindle speed: 20 Fig. 16.

Step 14. Click the Simple drill - no peck tab at

the top of the dialog box, Fig. 16.

Step 15. Set Retract: 0

Step 16. Set Top of Stock: 0

Negative -2.3
Step 17. Set Depth: -2.3

Step 18. Set: Cycle: Peck Drill Fig. 16

1st peck: .5
Subsequent peck: .5
Peck clearance: .05
and click OK . Fig. 17

E. Set-up Toolpath Groups.

Step 1. Rename
Toolpath Group
1 to Axle Holes in
the Ops Manager.
To rename, click
and hold over the
Toolpath Group1
and key-in Axle Fig. 18
Fig. 17
Holes, Fig. 18.

Step 2. Insert another Toolpath

group. To insert group,
right click Machine Group
1 at the very top and click
Groups > New Toolpath
group from the menu, Fig. 19.
Fig. 19 Fig. 20
Step 3. Rename the new Toolpath Group- Left Cut, Fig. 20.

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F. Display Left Cut Level.
Step 1. Change to Isometric View. Use or
Alt-7.

Step 2. Display Level Manager. Use Alt-Z.

Step 3. In the Visible column, click to place a

check in LEFT CUT surface level to
make Level visible. Click OK, Fig. 21.
Fig. 21

H. Left Cut Body Rough Parallel Toolpath.

Step 1. Click Toolpaths Menu > Surface Rough > Rough Parallel Toolpath.

Step 2. Click Boss and OK , Fig. 22.

Step 3. Click the left cut surface, Fig. 23.

Step 4. Click Activate solid selection button in the Solids

selection ribbon bar and click Select body and un- Fig. 22
select others, Fig. 24.

Step 5. Click the body solid, Fig. 23. The solid edges Body solid
will highlight when selected.

Step 6. Press ENTER to accept solid selection and press Left cut surface
ENTER again to accept Drive surfaces.

Fig. 23

Fig. 24

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Step 7. Click Check Select button, Fig. 25.

Step 8. Click Activate solid selection button in

the Solids selection ribbon bar and click Select
body , Fig. 27.
Check
Step 9. Click check block, Fig. 28.
Containment
Step 10. Press ENTER to accept solid selection and
press ENTER again to accept Drive surfaces.

Step 11. Click Containment Select button, Fig. 25. Fig. 25 Fig. 26

Step 12. Click the Wireframe button in the Chain-

ing dialog box, Fig. 26.
Fig. 27
Step 13. Click the C-plane in the Chaining dialog box, Fig. 26. Containment
chain

Step 14. Click the Chain button in the Chaining dia-

log box, Fig. 26.

Step 15. Click a line of the side rectangle bounding box. The
left side rectangle should be selected, Fig. 28. Click
the OK button in the Chaining dialog box. Check block solid

Step 16. Click the OK button in the Toolpath/surface

Fig. 28
selection dialog box.

I. Set Tool and Params.

Step 1. Set the Feed rate: 60 Fig. 29.

Step 2. Click Select library tool button, Fig. 29.

Fig. 29

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Step 3. Click the Filter button,
Fig. 30.

Step 4. Click None button under

Tool Types, Fig. 31.

Step 5. Click Endmill2 Sphere

button (second button top Fig. 30
row), Fig. 31 and click OK.

Step 6. Click 252 Endmill2 Sphere

.25, Fig. 32 and click OK.

Step 7. Click the Surface param-

eters tab at the top of the
dialog box, Fig. 33.

Fig. 31

Fig. 32

Fig. 33

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Step 8. Uncheck Retract, Fig. 34.

Step 9. Set Feed plane: 0 and click Absolute.

Step 10. Set Stock to leave on drive: .04

Step 11. Set Stock to leave on check: .01

Step 12. Click the Rough parameters tab at the

top of the dialog box, Fig. 34.

Step 13. Set Max Stepover: .15 Fig. 35

Step 14. Set Cutting method: Zigzag Fig. 34

Step 15. Set Maximum stepdown: .2

Step 16. Check Allow multiple plunges along cut.

Step 17. Check Allow negative Z motion along

surface.

Step 18. Check Allow positive Z motion along

surface.

Step 19. Click the Total tolerance button, Fig. 35.

Step 20. Set Filter Ratio: 2:1 Fig. 36

Fig. 35
Step 21. Click to place check in
all Create Arcs check-
boxes.

Step 22. Click OK .

Step 23. Click Cut depths but-

ton, Fig. 35.

Step 24. Set Adjustment to top

cut .2 and click OK
. Fig. 37
Fig. 36 Fig. 37

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Step 25. Click Gap settings button. Fig. 38

Step 26. Under Motion, select Follow surfaces,

Fig. 39

Step 27. Check Optimize cut order and click OK

. Fig. 39

Step 28. Click Advanced settings button, Fig. 38.

Step 29. Select Only between surfaces, Fig. 40.

Step 30. Check Skip hidden face test for solid

bodies, Fig. 40 and click OK . Fig. 38

Step 31. Click OK .

J. Finish Blend Toolpath.

Step 1. Use Alt-T to turn off toolpath display.

Step 2. Click Toolpaths Menu > Surface Finish

> Finish Blend Toolpath.

Step 3. Click the Left cut surface, Fig. 41. Fig. 40

Step 4. Click Activate solid selection button

in the Solids selection ribbon bar
Fig. 39
and click Select body and unselect
others, Fig. 42.
Body solid
Step 5. Click the body solid, Fig. 31. The solid edges
will highlight when selected. Left cut surface

Step 6. Press ENTER twice to accept surface and solid

selection as drives surfaces.
Fig. 41

Fig. 42

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Step 7. Click Check Select button, Fig. 43.

Step 8. Click Activate solid selection button in

the Solids selection ribbon bar and click Select
body , Fig. 44.
Check
Step 9. Click check block solid, Fig. 45.

Step 10. Press ENTER twice to accept solid selection as

drives surfaces. Blend

Step 11. Click Blend Select button, Fig. 43. Fig. 43

Step 12. Click the Single button in the

Fig. 44
Chaining dialog box, Fig. 46.
Fig. 46
Step 13. Click Chain 1, top left line on the
Chain 2
bounding box and Chain 2, bottom left
line on the bounding box, Fig. 45. If
Chain 1
the chaining directions arrows are not
pointing in the same direction - click Check block
solid
Reverse .

Step 14. Click OK in the Chaining dia-

log box, Fig. 46.
Fig. 45
Step 15. Click the OK button in the
Toolpath/surface selection dialog box.

Step 16. Set the Feed Rate: 60 Fig. 47

Step 17. Click the Surface parameters tab at the

top of the dialog box.

Fig. 47

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Step 18. Uncheck Clearance, Fig. 48.

Step 19. Uncheck Retract.

Step 20. Set Feed plane: 0 and click Absolute.

Step 21. Set Stock to leave on check: .01

Step 22. Click the Finish blend parameters tab

at the top of the dialog box, Fig. 48.

Step 23. Set Maximum Stepover: .04 Fig. 49.

Step 24. Click the Total tolerance button. Fig. 48

Step 25. Set Filter Ratio: 2:1 Fig. 50

Step 26. Check to place check in all Create Arcs

checkboxes, Fig. 50.

Step 27. Click OK .

Step 28. Click Gap settings button. Fig. 49

Step 29. Under Motion, select Follow surfaces

and click OK . Fig. 51

Step 30. Click Advanced settings button, Fig. 49. Fig. 49

Step 31. Select Only between surfaces, Fig. 52.

Step 32. Check Skip

hidden face
test for solid
bodies and
click OK
, Fig.
52.

Step 33. Click OK

.
Fig. 52
Fig. 50

Fig. 51

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K. Verify Left Cut.
Step 1. In the Toolpaths Manager, click the
Left Cut Toolpath group to select both
toolpaths, Fig. 53.

Step 2. Click Verify in the Toolpaths Man-

ager, Fig. 53.
Fig. 53

Step 3. Click Machine quickly in Verify dialog box, Fig. 54.

Step 4. Turn on (button depressed) Simulate tool .

Step 5. Click the Play in the

Verify dialog box to start
the machining.

Step 6. Click OK to close

Verify dialog box.
Fig. 55 Fig. 54
L. Display Right Cut Level.
Step 1. Display Level Manager. Use Alt-Z.

Step 2. In the Visible column, uncheck LEFT

CUT and check RIGHT CUT levels.
Click OK, Fig. 56.
Fig. 56
M. Change to RIGHT CUT WCS - Convert Origin Units to Inches.
Step 1. Click WCS in the Status Bar at the bottom of the screen and View Manager.

Step 2. Click the RIGHT CUT view from the list of views in the View Manager, Fig. 57.

Step 3. Convert the Y and Z origin

coordinate to inches. To
convert to inches, simply key-
in mm after the inch value
and press tap key, Fig. 100.
38 mm converts to 1.49606
inches. Convert both Y and Z
coordinate to inches.

Step 4. Click the Set All but-

ton, Fig. 100 and click OK.
Fig. 57
Step 5. Change to the Isometric View, use . Check the origin. Use F9 to show and hide axes.
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N. Copy Right Cut Body Toolpaths.
Step 1. Insert another Toolpath
group. To insert group,
right click Machine Group
1 at the very top of the Ops
Manager and click Groups >
New Toolpath group, Fig.
58.
Fig. 58 Fig. 59
Step 2. Rename the new Toolpath
Group- Right Cut, Fig. 59.

Step 3. Right click Left Cut toolpath

group and click Copy from the
menu, Fig. 60.

Step 4. Right click Right Cut toolpath

group and click Paste, Fig. 61.

Step 5. Expand (click +) 4 Surface Rough

Parallel and click Parameters,
Fig. 60
Fig. 62.
Fig. 61
Step 6. Click the Toolpath
parameters tab at
the top of the dia-
log box, Fig. 63.

Step 7. Click Planes but-

ton in the Surface
Rough Parallel
dialog box, Fig.
63.
Fig. 62

Fig. 63

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Step 8. Under Working Coordinate System
System,
click View Selection button
Toolpath Coordinates System dialog box,
Fig. 64.

Step 9. Click RIGHT CUT and click OK

to close View Selection dialog box, Fig.
65.

Step 10. Click the Expand button twice, Fig. 64 Fig. 65

Fig. 66.

Step 11. Uncheck Display relative to WCS,

Fig. 66.

Step 12. Click both Copy Settings Right Copy Right

buttons to copy setting to Tool Plane
and Construction Plane, Fig. 66.
Click OK to close Toolpath
Coordinate System dialog box.
Expand Fig. 66
Step 13. Click OK to close Surface Rough Parallel dialog box.

Step 14. Repeat to set new planes for the Fin-

ish Blend. To set
planes, expand 5
Surface Finish
Blend and click
Parameters, Fig.
67.

Step 15. Click the

Toolpath param-
eters tab at the
top of the dialog
box, Fig. 67. Fig. 67 Fig. 68
Step 16. Click Planes button in the Surface Finish Blend dialog box, Fig. 68.

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Step 17. Under Working Coordinate System
System,
click View Selection button
Toolpath Coordinates System dialog
box, Fig. 69.

Step 18. Click RIGHT CUT and click OK

to close View Selection dialog
box, Fig. 70.

Step 19. Click both Copy Settings Right Fig. 69

buttons to copy setting to Tool Plane and Construction Plane,
Fig. 69. Click OK to close Toolpath Coordinate Sys-
tem dialog box.

Step 20. Click OK to close Surface Finish Blend dialog box.

Step 21. Expand 4 Surface Rough Parallel, expand Geometry and

click Geometry Drive, Fig. 71.

Step 22. Click Deselect All Drive button,

Fig. 72. Fig. 70

Step 23. Click Select Drive button, Fig. 72.

Step 24. Click the right cut surface, Fig. 73.

Step 25. Click Activate solid selection button

in the Solids selection ribbon Fig. 71 Fig. 72
bar and click Select body and
unselect others, Fig. 74. Right cut surface

Step 26. Click the body solid, Fig. 73. The solid edges will
highlight when selected.

Step 27. Press ENTER to accept solid selection and press Body solid
ENTER again to accept Drive surfaces.

Step 28. Click OK to close the Toolpath/ surface

Fig. 73
selection dialog box.

Fig. 74

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Step 29. Repeat and reselect surfaces for the Finish Blend, expand 5 Sur-
face Finish Blend, expand Geometry and click Geometry Drive,
Fig. 75.

Step 30. Click Deselect All Drive button, Fig. 76.

Step 31. Click Select Drive button, Fig. 76.

Step 32. Click the right cut surface, Fig. 77.

Step 33. Click Activate solid selection button in

the Solids selection ribbon bar and click Select Fig. 76
body and unselect others, Fig. 78.

Step 34. Click the body solid, Fig. 77. The solid Fig. 78 Fig. 75
edges will highlight when selected.
Right cut surface
Step 35. Press ENTER to accept solid selection and press
ENTER again to accept Drive surfaces.

Step 36. Click OK to close the Toolpath/surface

selection dialog box. Body solid

O. Verify Right Cut.

Step 1. In the Toolpaths Manager, click Regenerate all Fig. 77
dirty operations , Fig. 79.

Step 2. Click the Right Cut Toolpath group to

select both toolpaths, Fig. 79.

Step 3. Click Verify in the Toolpaths Man-

ager, Fig. 79.

Step 4. Click the Play in the Verify dialog

box to start the machining.

Step 5. Click OK to close Verify dialog

box.
Fig. 79
Step 6. Save your
drawing.
Use Alt-F S.

Fig. 81
Fig. 80
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