Mastercam2023 Mill2d Advanced ProfessionalCourseware

IHS Mill 2D Advanced User
Mastercam 2023 Professional Courseware - IHS Mill 2D Advanced User
Copyright: 1998 - 2023 In-House Solutions Inc. All rights reserved
Software: Mastercam 2023
Date: July 22, 2022
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Table Of Contents
IHS Mill 2D Advanced User 1
Getting Started 20
Mastercam® User Interface: 22
Setting The Grid 23
Conventions Used In This Book: 23
Installing MPMASTER Post 24
Customize Ribbon Bars 25
Introduction 26
Create A New Tab 27
Configuration Backup & Restore 33
Introduction 34
Setup Mastercam Interface 35
Customize Right Mouse Menu 44
Introduction 45
Customize The Right Mouse Button Menu 46
Add Analyze Functions To The Right Mouse Button Menu 46
Toolpath Defaults 51
Introduction 52
Instructor Demonstration: 53
Step 1: Open The File 54
Step 2: Set The Default Tool 54
Step 3: Set The Cut Parameters Defaults 56
Step 4: Linking Parameters 57
Step 5: Save The Parameters As Defaults 57
Step 6: Backplot The Toolpath 58
Step 7: Reload The Part 58
Step 8: Create The Face Toolpath 58
Step 9: Check The Cut Parameters Defaults 59
Step 10: Check The Linking Parameters 60

3
Setup Sheets 61
Introduction 62
Step 2: Setup Sheet 64
Multiple WCS 71
Introduction 72
Dynamic Transform Reference Information 74
Step 2: Dynamic Align The Pocket Top Face To The Top Plane 75
Step 3: Create A Viewsheet 80
Step 4: Select A Machine And Set The Stock 81
Step 5: Machine The Pocket Using Dynamic Mill 86
Step 6: Export The Toolpath For Later Use 90
Step 7: Define A Plane Using The Gnomon 91
Step 8: Circle Mill The 1" Diameter Holes 97
Step 9: Using Toolpath Groups 101
Step 10: Define A New Plane Using Plane Manager 104
Step 11: Import The Operation To The New Plane 108
Step 12: Face And Drill The 3/8" Holes Of The Beveled Face 112
Step 13: Machine The Third Pocket 115
Step 14: Face And Drill The 1/4" Holes Of The Beveled Face 117
Step 15: Change The NC File Names 119
Step 16: Post Process The Toolpaths To Generate The G-Code 120
Step 17: Save Your File 122
Exercise 123
Plane Creation & Indexing 125
Introduction 126
4
Step 2: Set The Origin At The Center Bottom Of The Part 128
Step 3: Define A Plane From Geometry 132
Step 4: Select A Machine 138
Step 5: Circle Mill The Hole 140
Step 6: Create A Plane Using From Entity Normal 143
Step 7: Drill The Hole 146
Exercise 152
Levels & Viewsheets 153
Introduction 154
Instructor Demonstration Preview: 156
Step 2: Working With Levels 157
Step 3: Working With Viewsheets 168
Step 4: Save Your Mastercam File 181
Exercise 182
Advanced Drilling Toolpath 184
Introduction 185
Step 2: Advanced Drilling For Deep Holes 187
Step 3: Advanced Drill For Holes With Air Region 196
Dynamic Toolpaths 205
Introduction 206
Step 1: Dynamic Mill Radial Chip Thinning (RCT) 206
Step 2: Dynamic Motion Power Cutting 207
5
2D High Speed Toolpaths (HST) Information 208
2D High Speed Part 1 - Instructor Demonstration: 209
Step 3: Prepare And Orient Model For Machining 210
Step 4: Using The Classic Tool Manager To Create The Tools 210
Step 5: Create The Job Setup 219
Step 6: Use Dynamic Mill With RCT 220
Step 7: Dynamic Mill Power Cutting 229
Step 8: Machine The Left Side Step Using Blend Mill 231
Step 9: Dynamic Mill Using Air Regions 236
Step 10: Machine The Open Pocket Using Automatic Regions 242
Step 11: Machine The Slot Using Slot Mill Toolpath 245
Step 12: Dynamic Mill The Open Step 249
Step 13: Machine The Circular Boss 255
Step 14: Dynamic Mill The Closed Pocket With The Island 259
Step 15: Dynamic Rest Mill The Inside Corners 265
Step 16: Finish The Open Pocket Walls Using Contour 271
Step 17: Finish The Closed Chain Walls Using Contour 276
2D High Speed Part 2 - Instructor Demonstration 281
Step 20: Set The Stock In The Stock Setup: 282
Step 21: Machine Half Of The Outside Profile 282
Step 22: Machine The Top Of The Outside Profile 285
Step 23: Machine The Right Side Open Step 285
Step 24: Machine The Left Side Open Step 286
Step 25: Machine The Top Open Step 286
Step 26: Machine The Open Step At An Angle 287
Step 27: Machine The Pocket With The Island 288
Step 28: Machine The Walls 289
Step 29: Backplot And Verify The Toolpaths 289
6
2D HST Toolpaths 290
Introduction 291
Part Drawing 293
2D High Speed Toolpaths (HST) Information 294
Step 1: Create The Stock Using Bounding Box 295
Step 2: Create A Point At The Top Center Of The Part 297
Step 3: Save The Part 298
Step 4: Open The Vise And Merge The Part 298
Step 5: Move The Origin To The Point 304
Step 8: Facing Toolpath 307
Step 9: Dynamic Mill To Machine The Outside 310
Step 10: Dynamic Mill To Remove The Inside Material 319
Step 11: Dynamic Mill The Closed Pocket 324
Step 12: Peel Mill To Machine The Inside Center Boss 328
Step 13: Dynamic Rest Mill The Inside Corners 334
Step 14: Finish The Walls Using Contour 340
Step 15: Chamfer The Sharp Edges - Model Chamfer 345
Exercise #1 353
353
Horizontal Machining 354
Introduction 355
Instructor Demonstration 357
Step 1: Setup Multiple Stock Using Stock Model 358
Step 2: Set The Stock In The Stock Model 358
Step 3: Setup The Machining Plane At B0 362
7
Step 4: Rough Out The Part Using High Speed Dynamic Mill 364
Step 5: Chamfer Drill & Drill The 3/8" Diameter Holes 368
Step 6: Circle Mill The Large Diameter Hole 370
Step 7: Contour The 0.0625 Radius Channel 372
Step 9: Chamfer Drill & Drill The 31/64" Diameter Hole 375
Step 11: Spot Drill & Drill The 31/64" Diameter Hole 378
Step 12: Machine The Rest Of The Parts - Transform Rotate 383
Step 13: Post Process The Toolpaths 386
Step 14: Save The Mastercam File 389
Exercise #1 390
4 Axis - Axis Substitution 391
Introduction 392
4 Axis -Axis Substitution - Instructor Demonstration: 396
Step 2: Dynamic Mill - Axis Substitution 397
Step 3: Create Another Toolpath Group 405
Step 4: Finish The Teeth - Rolldie Toolpath 406
Step 5: Create Another Toolpath Group 411
Step 6: Drill The Holes 412
Step 7: Define A New Tool Plane To Machine One Slot 419
Step 8: Machine The Slot In The New Plane 424
Step 9: Transform - Rotate To Machine The Other Slots 431
Step 10: Contour The Letters 436
Step 11: Post The File To Generate The NC Code 441
Step 12: Save The Updated MCAM File 441
Surface Machining 442
Introduction 443
Mastercam® Surface Toolpath Work Flow: 445
8
Toolpath Descriptions 450
Instructor Demonstration 453
Geometry Creation Tips 454
Part 1 - Single Surface Machining 455
Step 1: Plane Settings 455
Step 2: Spline From Curves 455
Step 3: Revolved Surface 456
Step 4: Move The Wireframe On Level 100 458
Step 5: Prepare The Part For Machining 458
Step 6: Setup The Stock 461
Step 7: Surface Rough Pocket 462
Step 8: Finish The Part Using Surface Finish Scallop 467
Part 2 - Multiple Surface Model 470
Step 9: Setup The Stock 471
Step 10: Surface Rough Pocket 472
Step 11: Surface Finish Parallel 477
Step 12: Create A Loft/Ruled Surface 480
Step 13: Finish The Surface Using Finish Flowline 484
Step 14: Create A Sweep Surface 488
Step 15: Finish The Sweep Surface - Finish Flowline 495
OptiRough Toolpath 501
Introduction 502
Part Drawing 504
Toolpath Information 505
Step 2: Stock Model 507
Step 3: Dynamic OptiRough Toolpath 508
Step 4: 2D HS Area Mill Automatic Regions 515
Step 5: Finish The Walls Using Contour 518
9
Step 7: Save Your File. 522
Exercise #1 523
Exercise #2 524
Trim Toolpath 525
Introduction 526
Step 2: Make Level 2 Invisible 528
Step 3: Set The Stock 528
Step 4: Machine The Open Pocket Using Facing 531
Step 5: Trim Toolpath 535
Wireframe Toolpaths 539
Introduction 540
Step 1: Create The 2D Swept Wireframe 542
Step 2: Wireframe Toolpath - 2D Swept 546
Step 3: Backplot The 2D Swept Toolpath 550
Step 4: Verify The 2D Swept Toolpath 550
Step 7: Create The Ruled Wireframe 552
Step 8: Wireframe Toolpath - Ruled 555
Solids Model Prep 565
Introduction: 566
Solids Model Prep Drawing 568
10
Step 1: Open The Solid 569
Step 2: Save The File 569
Step 3: Removing The Solid History 570
Step 4: Analyze The Ear Height 571
Step 5: Split The Solid Faces 572
Step 6: Re-size The Bolt Hole Ear Heights - Push/Pull 578
Step 7: Use Move Command To Space The Bolt Hole Ears 582
Step 8: Align The Openings With The Bolt Holes 589
Step 9: Split The Inner Face Of The Cylindrical Shape 595
Step 10: Add An Inner Shoulder Using The Push/Pull Command 597
Step 11: Create A Boss Using The Push/Pull Command 600
Step 12: Use Push/Pull To Change Small Hole Diameter 606
Step 13: Fillet The Top Of The Ears - Push/Pull 610
Step 14: Fillet The Tops Of The Outer & Inner Bosses 614
Step 15: Fillet The Boss Floors 617
Summary: 619
Solid Model Prep - Exercise 620
Align To Plane & To Face 625
Introduction: 626
Step 3: Create A New Plane 629
Step 4: Align To Plane 631
Step 7: Align To Face Parallel 635
Step 8: Align To Face Coincident 640
Step 9: Merge A File 640
11
Toolpaths Manager 643
Introduction 644
Using Toolpaths Manager 657
Step 1: Modify And Update An Operation 657
Step 2: Reorder Operations 659
Step 3: Edit Common Parameters 660
Step 4: Renumber Tools 661
Step 5: Change NC File Name 663
Import Toolpaths 665
Step 6: Check The Part That Has The Toolpaths Completed 665
Step 7: Prepare And Orient Model For Machining 667
Step 8: Import Toolpaths 669
Step 9: Adding The Geometry To The Toolpaths 671
Step 10: Export Toolpaths To A Library 681
Step 11: Import The Library 684
Undercut & Custom Tool 690
Introduction 691
Step 1: Open The Part 693
Step 2: Creating A Custom T - Slot Cutter 693
Step 3: Undercut Machining -Contour Toolpath 694
Step 4: Create A Tool Library 702
Step 5: Find The Tool In The New Library 705
Step 6: Undercut Machining -Contour Toolpath 705
12
Mill 2D Advanced User Projects
Getting Started Topics Covered
n Mastercam User Interface.

n Setting the Grid.
n Installing MPMaster Post.
Exercise 1: Customize Ribbon Bars Topics Covered

n You will create a new Tab and a
new Group.
n You will rename both the Tab and
the Group.
n You will add the utilities functions to
the new Group.
Exercise 2: Config Backup & Restore Topics Covered
n You will learn how to backup and

restore the config file.
n You will learn how to backup and
restore the workspace file.
.
13
Exercise 3: Customize Right Mouse
Topics Covered
Menu
n Using Context Menu to add functions to the

Right Mouse Menu.
Exercise 4: Toolpath Defaults Topics Covered
n Creating a Face Mill toolpath and set the

default values and parameters.
n Saving the toolpath defaults while creating a
toolpath.
Exercise 5: Setup Sheets Topics Covered
n Using the Mill Default SET file, create a

Setup Sheet.
14
Exercise 6: Multiple WCS Topics Covered
n Using Dynamic Transform to move the
coordinate system to the part.
n Using the gnomon from the graphics window
to define a new WCS, Cplane, Tplane and
the Origin .
n Using Planes Manager to define a new WCS,
Cplane and Tplane using Solid Face.
n Create Viewsheets to be able to switch
between the part views.
n Create Toolpath Groups to organize the
toolpaths based on the setups.
n Rename the NC Files to generate separate
programs for each setup.
n Setup Sheets and Tool list.
Exercise 7: Plane Creation & Indexing Topics Covered

n Import a STEP file.
n Use Transform Rotate to rotate the part to be
able to index it around the X-Axis.
n Use Model Prep and Hole axis to create
wireframe from a solid.
n Use Planes Manager to define a new, Cplane
and Tplane using From geometry.
n Machine the hole.
and Tplane using From entity normal.
n Machine the hole.
Exercise 8: Levels & Viewsheets Topics Covered
n How to create and use Levels to better

organize the file geometry.
n How to create and save Viewsheets.
15
Exercise 9: Advanced Drilling Toolpath Topics Covered
n Advanced Drilling toolpath to machine holes

with air segments between.
n Advanced Drilling toolpath to machine deep
holes using a gun drilling process.
Exercise 10: Dynamic Toolpaths Topics Covered

n Using the Classic Tool Manager to create
new tools and save them in a new library.
n 2D HST Dynamic Geometry / boundary
selection rules.
n Setting the 2D HST cut parameters.
n Dynamic Milling Radial Chip Thinning versus
Dynamic Milling Power Cutting toolpaths.
n Blend Milling.
n Slot Milling.
n Peel Milling.
n Dynamic Rest Mill toolpaths.
Exercise 11: 2D HST Toolpaths Topics Covered
n Using imported solid model.

n 2D HST Geometry / boundary selection
rules.
n Dynamic Milling toolpaths.
n Area Milling toolpaths.
n Model Chamfer toolpath.
16
Exercise 12: Horizontal Machining Topics Covered
n Setup multiple stocks using Stock Model

Toolpath
n Setup machining planes to program the part
on a HMC
n Machine the part using HS Dynamic and
Drilling Toolpaths
n Transform - Rotate Toolpath
Exercise 13: Axis Substitution Topics Covered
n 2D HS Dynamic Mill with Axis Substitution.

n Contour with Axis Substitution.
n Swarf Milling.
n Drill the Holes -4 Axis output.
n Setup a new plane.
n 2D HS Dynamic Mill using Index about X-
axis.
n Transform - Rotate.
n Setup a new plane.
n Contour Indexing using Planes.
n Transform - Rotate.
Exercise 14: Surface Machining Topics Covered

n Know common 3D machining definitions.
n Understand the importance of surface data
integrity.
n Know how to prepare a surface model for
machining, including the use of tool
containment boundaries.
n Know how to generate one surface, when
possible using splines as wireframe.
n Be able to successfully select and use all
Mastercam Legacy Surface Roughing and
Finishing functions.
17
Exercise 15: OptiRough Toolpath Topics Covered
n 3D High Speed Dynamic OptiRough

parameter settings options.
n 2D High Speed Area Mill and Advanced
Regions selection.
Exercise 16: Trim Toolpath Topics Covered
n Trimming a Face toolpath, used to machine

a rectangular shape out of a cylinder, using
a circle created in a different plane.
Exercise 17: Wireframe Toolpaths Topics Covered

n Create Curves at All Edges of a surface.
n Create a Curve Constant Parameter.
n Creating a Swept 2D Toolpath to
machine a fillet.
n Create a Stock model with additional
offset.
n Create a Ruled Toolpath to machine a
shape defined by two chains.
Exercise 18: Solids Model Prep Topics Covered
n Remove History.
n Split Solid Faces.
n Move.
n Push-Pull.
18
Exercise 19: Align to Plane & To Face Topics Covered
n Align To Plane.
n Align To Face.
Exercise 20: Toolpaths Manager Topics Covered
n Understanding Toolpaths Manager

Controllers.
n Quick changes in the Toolpaths Manager
such as update a toolpath, change order of
operation, renumber tools, change NC file
name.
n Import toolpaths from an existing job.
n Export operations to a library.
n Import operations from a library.
Exercise 21: Undercut & Custom Tool Topics Covered
n Create a Custom tool.

n 2D Contour toolpath to machine an undercut.
n Using the Classic Tool Manager to create
new tools and save them in a new library.
19
Getting Started
20
Getting Started
WHO THIS BOOK IS FOR:

This book is the third book in the three part series designed to help you to prepare for the Professional Level
Mastercam Certification test.
Advanced Mill 2D is dedicated to the power user. You will learn how to machine an imported solid model
using the WCS for multiple setups. To better organize the parts, you will master how to use levels and view
sheets.
You will practice indexing a 4-axis part using the tool planes defined in the Plane Manager. Fixtures will be
used and the part will be align to their faces. You will learn how to save operations to a library and how to
import them for different parts.
You will learn how to use the Classic Tool Manager to create new tools and save them into a new library.
You will also create tools by importing their STEP geometry from a tool manufacturer.
The difference between the two types of Dynamic High Speed Machining: Dynamic Mill Radial Chip
Thinning (RCT) and Dynamic Motion Power Cutting with be explained in detail.
You will learn how to program Horizontal centers which are better suited for larger, boxy workpieces.
Mastercam uses the planes to machine a part on a Horizontal Machining Center and to determine the table
indexing angles.
A brief introduction to the basic 3D machining that can be used in a Mill product will be also covered. You will
learn how to alter the wireframe to generate one surface using Revolve and Loft/Ruled surfaces.
Solids manipulations using Model Prep functions is also covered. You will use Split Solid Faces command to
split a solid face using Project and Flowlines options. The student will learn how to use Push/Pull command
to change the height of the split areas. You will be using Move command to rotate parts of the solid.
You will also learn how to add an inner shoulder using Push/Pull command. The student will also use
Push/Pull command to create fillets.
You will learn how to set a solid body, that represents the part to be machined, into the fixtures using Align to
Plane and Align to Face.
An introduction to Nesting in Mastercam that allows you to fit parts onto a sheet of material for best yield will
also be provided. You will learn how to apply the nesting options on geometry or toolpaths.
A more in depth description of the Toolpaths Manager panel is provided in this book. A detailed explanation
of the Toolpath Manager Control dialog box and of its right mouse menu is also included.
PROGRAMMING TECHNIQUES USED IN EXAMPLES:

The example exercises in this book can be programmed in an infinite number of ways. In fact, any two
programmers would likely approach each part a different way and probably use different tools or toolpaths.
For the exercises in this book, we used settings that were the personal preference or that came from the
experience of multiple Mastercam authorized instructors. All of the examples and exercises have options
that can be set or changed to suit your experiences or company standards.
We chose one method rather than clutter the book with all of the possible options and disrupting the
workflow of the exercises. Utilize the Mastercam Help that is accessible from most dialog boxes whenever
you need more information about options.
21
Getting Started Mastercam® User Interface:
MASTERCAM® USER INTERFACE:

Mastercam is a completely graphic programming interface that includes built in CAD tools. You will find the
interface to be very streamlined and easy to access all of the toolpath generating commands. There are
several places you need to know to access all of the Mastercam commands. The locations for the Mastercam
commands and tools are shown in the screen display below.
Quick Access Toolbar (QAT) allows you to quickly access the most
Quick Access Toolbar
commonly used functions.
Ribbon Tabs Access to all Mastercam commands, features and functions.
Expanded Gallery and Tooltips Additional icons to start toolpaths and hints on the toolpath.
General Selection Bar Used to access AutoCursor settings and selection options.
Mini Toolbar Quick access to attributes.
Quick access to commands relevant to the graphics view and analyze
Right Mouse Click Menu
commands.
Quick Mask Toolbar Used to control entity masking for easier selection.
This is where all toolpath operations you create are stored. They can be
Mastercam Toolpaths Manager accessed here for editing the Parameters, Tools, and the Geometry of the
toolpaths.
Toolpaths Manager Right
Special commands for working with the operations you have created.
Mouse Click Menu
Managers Tabs Tabs to control which panel is displayed in the Manager panel.
Displays the current WCS, Tool and Construction plane info and current
Status bar
cursor location and also displays the Section View.
22
Getting Started Setting The Grid
SETTING THE GRID

Before starting the geometry enable the Grid. It will show you where the origin of the part is.
File
n Configuration.
n Select Screen from the configuration
Topics.
n Select the plus sign (+) beside screen as
shown.
n Spacing
n X = 0.25.
n Y = 0.25.
n Origin
n X = 0.0.
n Y = 0.0.
n Size = 1.0.
n Select the OK button to exit.
n Select the Yes button to save the settings
in the System Configuration.
n To see the Grid in the graphics window,

from the View ribbon enable Show Grid
as shown.
CONVENTIONS USED IN THIS BOOK:

We have attempted to make this manual as uncluttered as possible and provide you with reference
information when it is appropriate. It is not intended to be a Reference Guide or all-encompassing user
manual.
The text styles used are the followings:
Bold Text - Represents menu commands, dialog box settings or other similar items from the screen
Standard Text - Represents normal wording needed to provide you the instruction.
STEP 1: STEP TITLES

1.1 Sub step titles
Information about the current step or terms or parameter definitions describing the parameters and
description.
Note: Represents information about the process step that is important or may require an explanation.
n Bulleted text is step by step instructions that have to be followed.
23
Getting Started Installing MPMASTER Post
TUTORIALS FILES:
The training files are available for download at http://www.emastercam.com/files/.
INSTALLING MPMASTER POST

In this book you are going to use Mpmaster which is based on CNC Software's master mill post - Mpfan - but
offers additional features. This is a 4-axis G-code post that contains Rotary settings that are configured in the
Machine Definition.
Download the following files from emastercam.com/files
n MPMASTER_VERTICAL.mcam-mmd
n MPMASTER_HORIZONTAL.mcam-mmd
n MPMASTER.mcam-control
n MPMASTER.pst
Save the files at a preferred location such as Desktop.
Copy MPMASTER_VERTICAL.mcam-mmd, MPMASTER_HORIZONTAL.mcam-mmd and

MPMASTER.mcam-control to this location on your computer:
C:\Users\Public\Public Documents\Shared Mcam2023\CNC_MACHINES
Copy MPMASTER.pst to this location on your computer:
C:\Users\Public\Public Documents\Shared Mcam2023\mill\Posts
24
Customize Ribbon Bars
25
Customize Ribbon Bars Introduction
INTRODUCTION
Mastercam allows you to customize the Quick Access Toolbar, Ribbon tabs, drop-down menus, and RMB
menus using the Customize Ribbon and the Context Menu dialog boxes. You can Add and Remove
functions from the toolbar or you can Reset the toolbar to the original functions that the Mastercam
installation provides. The ability to customize Mastercam is a powerful tool for improving productivity. For
example, you can customize the workspace for different machine tools so only options relevant to that
machine are displayed.
In this lesson you will learn how to create a Support ribbon that contains utilities that help you gathering and
sending the information to the technical support team.
The new Support Ribbon tab will be added after the View tab and will contain the following utilities:
n Open User Folder which contains the configuration files.

n Open Shared Folder which contains the machine definition and the post .
n Zip2Go which allows you to zip the Mastercam file currently open as well as the
machine groups in your current file. It also captures certain information such as your
Mastercam configuration, machine definition, post files, tool and material libraries, etc.
To summarize:
n You will create a new Tab and a new Group.

n You will rename both the Tab and the Group.
n You will add the utilities functions to the new Group.
26
Customize Ribbon Bars Create A New Tab
CREATE A NEW TAB

Creating a new tab allows you to add new commands to the Ribbon bars. In this step you will learn how to create a
Support ribbon that contains utilities functions useful to send information to Mastercam tech support.
To access the Options dialog box you can either select:
File
n Options.
n From the Options dialog box, select Customize Ribbon.
0r
n Right mouse click in the tabs area and select Customize the Ribbon.
27
n Click on the View to

select the location to
add the new tab.
n Select New Tab
button.
n A New tab and a New

group will be created
after the View tab as
shown.
28
n Select the Rename button.

n Type "Support" as shown.
n Select the OK button to
continue.
n Click on the New Tab

(Custom) to select it.
n Select the Rename button
and enter Support.
continue.
n The rename tab and group should look as shown.
29
n In the Choose commands from scroll down and select Open Share Folder.
n Select the Support (Custom) group in the Main Tabs. Click on the Add button as shown.
30
n The Open Share Folder will be added as shown.
n Following the same procedure add Open User Folder.
n The Support (Custom) group should look as shown.
31
n In the Choose commands

from, click on the drop
arrow and select File Tab
from the list.
n Scroll down and select
Zip2Go as shown.
n Select the Add button to
add the utility to the Support
(Custom) group.
n The Support (Custom) tab and group should look as shown.

n Select OK to exit the Options dialog box.
n In Mastercam interface the new tab should appear after the View tab as shown.
n Click on the Support tab to see all the utilities functions that were added to it.
n If you want to create another group that contains, for example, the toolpaths that you often use, follow
the same method and create a new group by selecting New Group.
SUMMARY:
In this lesson, you learned how to use Customize Ribbon to create a new ribbon with functions that are
important to you.
After completing this tutorial you should be able to create a new ribbon by:
n Creating a new Tab and a new Group.

n Renaming both the Tab and the Group.
n Adding utilities functions to the new Group.
32
Configuration Backup & Restore
33
Configuration Backup & Restore Introduction
INTRODUCTION
In this lesson you will learn how to backup the System Configuration files that contain all the information
about your Mastercam Attributes such as Colors and Line width, as well as the interface Background color
that you want to use. In the System Configuration dialog box, you can also review and set Mastercam
start up default values.
Mastercam settings are stored in a configuration file (*.config), which typically resides in a CONFIG
directory under the main Mastercam directory. When you restart Mastercam or initialize operations (for
example, open a new file), Mastercam restores the default settings that have been saved in the Mastercam
configuration file.
There are two standard configuration files one for inch and one for metric units.
Another important file that needs to be backed up is the Workspace file, Mastercam.Workspace, which
contains all the information about the interface such as your custom Ribbon bars. You can have multiple
configuration files but only one Workspace file. The keymap information about your shortcuts key to navigate
Mastercam is also stored here.
To summarize:
n You will learn how to backup and restore the config file.
n You will learn how to backup and restore the workspace file.
34
Configuration Backup & Restore Setup Mastercam Interface
SETUP MASTERCAM INTERFACE

In this step you will use the interface with the new Support ribbon that contains utilities functions useful to send
information to Mastercam tech support. You will also change the background color to white and set the wireframe
line thickness to the third one from the top.
1. Set the Background color in the System Configuration

File
n From the Backstage list, select Configuration as shown.
35
n In the System Configuration dialog box, select Colors and Background (gradient start).
n Change the color to white as

shown.
2. Set the Grid
n In Grid Settings, change the Spacing to X = 0.25 and Y = 0.25.

n Set the Size to 1.0.
n Select the OK button to exit the System Configuration.
36
n Select the Yes button to save all the current

setting to configuration file.
n To see the Grid in the

graphics window, from the
View tab, enable Show
Grid as shown.
3. Custom new Ribbon

The interface should have the custom Support ribbon, that you created in a previous lesson.
4. Set New Attributes
n In the Home ribbon, Attributes group, change the Line

thickness to the third one from the top as shown.
n In the Home ribbon, Attributes group, change the Wireframe color

to blue as shown.
37
Mastercam interface should look as shown.
5. Copy the files to back them up
n To quick open the Config folder that contains the four files that you need to backup, in the Support
ribbon, select Open User Folder as shown.
38
n The Mastercam
folder will be open
as shown.
n Double click on the
CONFIG folder to
open it.
n Close Mastercam.
39
n The three files are listed as shown. The path to the files if you want to find them from Windows Explorer
is:
C:\Users\Your Name\Documents\My Mastercam 2023\Mastercam\CONFIG
n Hold down the Ctr key select the three files as shown.
n Press Ctrl + X to cut them. You can paste the files in a Config Backup folder that you created
anywhere you want.
n For our example, create a New Folder on the Desktop and name it Config Backup.
n Open the folder and Ctrl +V to paste the files.
n The files should be listed in the Config Backup folder as shown.
40
6. Open Mastercam
n Relaunch Mastercam 2023.

n The interface should look as the installation Mastercam version as shown.
Note: The Support Custom ribbon is gone, the Background color is back to the standard, the Attributes
are also back to the original installation attributes. If you open the CONFIG folder again the files deleted
are created again. They were created when you open Mastercam.
7. Close Mastercam again
n Close Mastercam.
41
8. Copy the files from the Desktop back into the CONFIG folder.
n Open Config Backup folder

from the C:\Users\Your
Name\Documents\My
Mastercam
2023\Mastercam\CONFIG.
n Highlight and press Ctrl +C to
copy the files.
n Open CONFIG folder from the Desktop.

n Highlight and press Ctrl +V to paste the files.
n Select Replace the files in the destination.
n Open again Mastercam.

n The interface will have all the settings restore to your customized background, ribbon and attributes.
42
SUMMARY:
In this lesson, you learned how to use Backup the Configuration files and Workspace and how to
restore it.
After completing this tutorial you should be able to:
n Setup Mastercam Interface using the System Configuration.

n Copy the files to back them up.
n Restart Mastercam to restore the original configuration.
n Restore your configuration files and Workspace if a new Mastercam installation was performed.
43
Customize Right Mouse Menu
44
Customize Right Mouse Menu Introduction
INTRODUCTION
In this lesson you will learn how add functions to the Right Mouse Menu. The default contains Analyze
Distance and Analyze Entity as shown.
The following Analyze functions will be added to the Right Mouse Menu:
n Analyze Angle
n Analyze Dynamic
n Analyze Chain
n Draft Angle
45
Customize Right Mouse Menu Customize The Right Mouse Button Menu
CUSTOMIZE THE RIGHT MOUSE BUTTON MENU

Customizing the right mouse button menu allows you to add, remove and rearrange commands.
Note: Adding or removing drop down menu functions is associative. All references to the modified
menus are updated (for example the modified drop down menu is used as a submenu in other drop down
menu). When you add or remove functions from drop down menus and submenus, you immediately see
the results in the current Mastercam session.
ADD ANALYZE FUNCTIONS TO THE RIGHT MOUSE BUTTON MENU
n The default Right mouse button menu appears

as shown.
n Right mouse click above the Ribbon bar and select the Customize the Ribbon as shown.
46
Customize Right Mouse Menu Add Analyze Functions To The Right Mouse Button Menu
n Select the Context Menu tab.

n Pick the plus (+) next to Right mouse button menu to expand it if needed.
n In the Choose commands from, select All Commands as shown.
n Scroll down until you see all the Analyze commands.
47
n Select the Analyze Entity button in the Context Menu list.

n In the Choose commands from, select Angle to highlight it.
n Click on Add.
n (Analyze) Angle will be added in the Context Menu list as
shown.
48
n Use the same process to add Chain, Draft Angle and Dynamic.
n The Context Menu list should look as shown.
n Select the OK button to exit the Options dialog box.
49
n Right mouse click in the graphics

window to check the new menu.
SUMMARY:
In this lesson, you learned how to use Context Menu to add function to the Right Mouse button.
After completing this tutorial you should be able to customize the Right Mouse Menu by adding your most
commonly used functions.
50
Toolpath Defaults
51
Toolpath Defaults Introduction
INTRODUCTION
In this tutorial you will learn how to set Toolpath defaults while creating a toolpath.
When you create a new toolpath or other operation, Mastercam populates the fields on each tab or
properties page with default values. These values are stored in a file with a .mcam-defaults extension.
These defaults are specific for each type of operation.
The first time you create an operation of a specific type in a Mastercam session, the default values are read
from the defaults file.
Then, each time you create another operation of the same type, Mastercam uses the values from the
previous operation.
Once you set the parameters and the values for a toolpath as you want, you can save them as the defaults.
NEW CONCEPTS COVERED IN THIS TUTORIAL:

n Creating a Face Mill toolpath and set the default values and parameters.
n Saving the toolpath defaults while creating a toolpath.
52
Toolpath Defaults Instructor Demonstration:
INSTRUCTOR DEMONSTRATION:
Topics:
n Set the default tool for the Face Mill toolpath

as well as the tool Feedrates and Spindle
speed default values.
n Creating a Face Mill toolpath and set the
default values and parameters.
n Saving the toolpath defaults.
NOTES:
53
Toolpath Defaults Step 1: Open The File
STEP 1: OPEN THE FILE

Resources - Download the file from www.EMASTERCAM.COM/TRAININGFILES/
n Find and open the part Toolpath_

Default_Facing.
STEP 2: SET THE DEFAULT TOOL
In this step you will learn how to set the 2.5" Face Mill tool as the default tool for the Face Mill toolpath. You will also
change the Feed rates and the SFM default values and save them as the new defaults.
Step Preview:
Toolpaths
n From the 2D group,

select the Face icon.
54
Toolpath Defaults Step 2: Set The Default Tool
n The Wireframe Chaining dialog box

appears as shown.
Note: In the Stock setup, the extra stock

of 0.05 at the top of the part has been
already set. You do not need to select any
chain for the facing as Mastercam will pick
the information from the Stock setup.
n In the Wireframe Chaining dialog box

select the OK button to continue.
2.1 Set the default Tool
n In the Tool page the 2" Face

Mill is displayed as the
default. If no other tool is
selected, this tool will be used
to generate the toolpath.
n Click on the Select library

tool button and using the
Filter select the 1 1/2 Face
Mill.
n Change the Tool #, the
Length and Diameter
offsets to 1.
n Change the SFM, FPT and
Plunge rate as shown.
55
Toolpath Defaults Step 3: Set The Cut Parameters Defaults
2.2 Save the tool as the default
n To save this parameters as defaults, click on the Save

parameters to defaults file button.
n A message stating that the Library was updated successfully will appear on
the screen.
n Select the OK button to continue.
Note: Next time you create a Face Mill toolpath the default tool and the SFM
and feeds will be the same.
STEP 3: SET THE CUT PARAMETERS DEFAULTS
n In the Cut Parameters,

change the Cutting
method to Zigzag, Stock
to leave on floors to 0.0.
n Move between cuts set
to High speed loops and
disable Even number of
passes to create constant
stepover passes.
56
Toolpath Defaults Step 4: Linking Parameters
STEP 4: LINKING PARAMETERS
n In the Linking
Parameters page ,
enable Clearance and
Use clearance only at
the start and end of
operation.
n Feed plane = 0.125
(Incremental).
n Top of stock = 0.05
(Absolute).
n Depth = 0.0 (Absolute).
STEP 5: SAVE THE PARAMETERS AS DEFAULTS
n To save this parameters as defaults, click on the Save

parameters to defaults file button.
Note: Next time you create a Face Mill toolpath the

default Cut Parameters and Linking Parameters
should be as set.
n Select the OK button to generate the toolpath.
57
Toolpath Defaults Step 6: Backplot The Toolpath
STEP 6: BACKPLOT THE TOOLPATH
n The toolpath should look as

shown.
STEP 7: RELOAD THE PART
n Find and re-open the part Toolpath_

Default_Facing.
n Do Not Save the current file.
STEP 8: CREATE THE FACE TOOLPATH
Toolpaths
n From the 2D group,

select the Face icon.
n In the Wireframe Chaining dialog box select the OK button to continue.
58
Toolpath Defaults Step 9: Check The Cut Parameters Defaults
8.1 Check the Tool page
n The Tool page should look as

shown.
Note: The tool page default

parameters and the default tool
are as you set before.
STEP 9: CHECK THE CUT PARAMETERS DEFAULTS
n The Cut Parameters

defaults should look as
shown.
Note: The defaults for the

Cutting method, Even
number of passes, Move
between cuts and Stock
to leave on floors are as
you set before.
59
Toolpath Defaults Step 10: Check The Linking Parameters
STEP 10: CHECK THE LINKING PARAMETERS
n In the Linking
Parameters
page all the
defaults are as
set before.
n Select the OK button to generate the toolpath.
SUMMARY:
In this lesson you learn how to set a default tool and default parameters for a toolpath while creating it.
After completing this lesson you should be able to:
n Save the default parameters for any toolpath in Mastercam.
60
Setup Sheets
61
Setup Sheets Introduction
INTRODUCTION
In this tutorial you will learn how to generate a Setup Sheet which provides custom information in a
printable format about a selected machine group or NCI file. This information can include: details on
operations, tool references, total programming time and programming comments.
Mastercam provides two customizable setup sheet programs: ActiveReports and SET file.
An ActiveReports setup sheet uses XML data to create a report from a selected machine group's operations
in the current Mastercam file. The setup sheet created this way is a run-time based report that supports
graphics, drafting notes, and barcodes. You can print and export to a variety of formats including PDF,
HTML, RTF, and XLS.
The setup sheets you create using the .SET File program are automatically generated by the Setup Sheet
function. They are based on a .SET file associated with the active machine group's control definition. In this
lesson you will use the default rpx Setup Sheet for Mill.
Once you generate the Setup sheet the The ActiveReports Viewer opens automatically.

n Creating a Setup Sheet.
62
Setup Sheets Instructor Demonstration:
Topics:
n Using the Mill Default SET file, create a Setup

Sheet.
NOTES:
63
Setup Sheets Step 1: Open The File

n Find and open the part

SetupSheet.mcam.
STEP 2: SETUP SHEET
In this step you will learn how to generate a Setup Sheet from a Mastercam default template. The setup
sheet will be launched in the Active Report window. General information about the project name and
location as well as information about the operations used to program the part will be displayed. A tool list
information will be also generated.
64
Setup Sheets Step 2: Setup Sheet
n In the Toolpaths Manager, make

sure that all the operations are all
selected.
n Right mouse click in the Toolpaths
Manager and select Setup sheet
as shown.
65
2.1 Setup Sheet General Information and Selection

In the Setup Sheet dialog box you can enter useful general information such as the project name, the
customer name, programmer name, drawing, revision and notes. You can instruct Mastercam to
generate Images using different views to display them. You can also reassign a different setup sheet.
n Fill the information in the General

Information section as needed.
n The Mill Default setup sheet is
automatically loaded.
Note: If you have a different setup sheet you

need to save all the files in the
C:\Users\Public\Documents\Shared
Mastercam(version)\common\report\SST

n The Active Report Viewer will be automatically launched.
66
2.2 The General Information will look as shown.
67
2.3 Information about the stock size will be displayed next.
68
2.4 Total Cycle Time and Operation List

In this section you can check the total cycle time necessary to machine the part.
The list of operations is displayed with all the information regarding toolpath type, cycle time, spindle speed
and feeds as well as clearance, retract, feed planes and depth. Stock to leave, compensation type and
work offsets information is also provided. The tool information is also available in this section.
69
2.5 Tool List

This section contains the list of tools used to program the part. Each tool has listed all the necessary
information.
2.6 Save the Report

You can save the report as a RDF, PDF, HTML, RTF, TXT, TIF or XLS file.
SUMMARY:
In this lesson you learn how to generate a Setup Sheet.
70
Multiple WCS
71
Multiple WCS Introduction
INTRODUCTION
This tutorial reviews useful functions that will make your 2D toolpath programming more efficient. In this
lesson you will review how to define new planes and how to use the Work Coordinate System to machine
multiple faces of a part on a 3-Axis Vertical Machining Center.
Views, Planes, and Work Coordinate System
The Work Coordinate System (WCS) is the active coordinate system and contains the orientation of the X-
Y-Z axes plus the location of the zero point (the Origin). The plane which you set as the WCS is the Top, or
XY, plane of the part. The WCS tells the software how your part is positioned or oriented in the machine
tool.
Gviews, Cplanes, and Tplanes are all oriented relative to the WCS.
System Defined Cplanes
Construction planes (Cplanes) are required to define certain entities, such as 2D Splines and Arcs. They
also make drawing in 3D easier by creating a flat, two-dimensional workspace wherever you want it.
Mastercam predefines the most commonly used Cplanes those aligned with the coordinate system XYZ
axes. These can be selected from the Planes, Named option on the Status Bar or from the Planes
Manager.
Mastercam allows you to create new Cplanes.

For example, you may need to draw an arc or machine a hole on a beveled face of the part. You can create
new planes using the Planes Manager. The following options to create a new plane are available in
Mastercam:
n From Geometry
n From Solid Face
n From Gview
n From Entity Normal
n Dynamic
The Tool plane (Tplane) is the plane normal to the tool axis, while the construction plane is the plane in
which the tool movements are created. For most applications, these planes will be the same.
A typical use of the WCS would be to machine a part which might be created or imported at an angle, and
located some distance from the origin. Instead of transforming the part geometry, you can use the WCS to
move the coordinate system to the part. Once you define the new WCS you can machine the features in the
Top plane.
Another common application for the WCS is for parts that require multiple setups to be machined.
The difference between using Tplanes and WCS to orient your toolpath is that, typically, changing the
Tplane produces a rotary motion code when you post your toolpath so that the tool axis or fixture will move
to properly position the part. You should use Tplanes when you are indexing the part on a 4 -Axis or on a
Horizontal CNC machine. In contrast, changing the WCS typically does not produce any rotary or other
code; its effect is apparent inside Mastercam, before you post the part.
72
Multiple WCS Instructor Demonstration:

n Using Dynamic Transform to move the coordinate system to the part.
n Using the gnomon from the graphics window to define a new WCS, Cplane, Tplane and the Origin .
n Using Planes Manager to define a new WCS, Cplane and Tplane using Solid Face.
n Create Viewsheets to be able to switch between the part views.

n Create Toolpath Groups to organize the toolpaths based on the setups.
n Rename the NC Files to generate separate programs for each setup.
Topics:
n Use Transform Dynamic to move the part to

align it to the WCS.
n Machine the pocket.
n Use the gnomon from the graphics window
to define a new WCS, Cplane, Tplane and
Origin .
n Machine the 0.375" holes.
n Using Planes Manager to define a new
WCS, Cplane and Tplane using Solid Face.
n Machine the inside pocket.
n Create Viewsheets for each plane in which
you are machining the part.
n Organize the toolpaths in groups.
n Change the NC file names.
n Post processing operations to multiple NC
files.
NOTES:
73
Multiple WCS Dynamic Transform Reference Information
DYNAMIC TRANSFORM REFERENCE INFORMATION

Purpose: To relocate and reorient a 3D model. Usually done to align a model with CNC machine axis and
Origin.
The Dynamic Gnomon helps manipulate

geometry orientation and location interactively. The
Gnomon consists of 3 axes connected at the origin,
with selection areas that allow different types of
transforms.
(See Mastercam Help for more information) .
Goal Start with this Dynamic Transform to this
In this step you will open the file and check the part orientation and origin.
n Find and open the part WCS_Review.mcam.

n Change to the Isometric view and display the axes (F9 and
Alt+F9) to determine the model orientation.
Note: The part is not oriented as needed to machine the

pocket feature. You will rotate it to the correct side.
You will use Mastercam's Dynamic Transform to move the
geometry to align it with the Coordinate system. It is important
to follow the steps in the correct order as follows.
74
Multiple WCS Step 2: Dynamic Align The Pocket Top Face To The Top Plane
STEP 2: DYNAMIC ALIGN THE POCKET TOP FACE TO THE TOP PLANE
Step Preview:
n Rotate the model so you can see the desired pockets and turn off
the axis display (F9 or Alt-F9).
Transform
n From the Position group, select the Dynamic icon.

n Window select the entire solid and select End
Selection button.
75
n Click on the corner of the model as shown to locate

the Origin and position the gnomon.
n Click on the Geometry Manipulation button

to Axis Manipulation icon as shown.
Note: This allows you to align the Gnomon axis

using the geometry.
n Click on the X-Axis rotation arc handle as shown so

we can rotate Gnomon to line up correctly with the
desired X Axis of the part.
n Rotate the axis with the mouse until you

highlight the Vertex shown and select it
so the X Axis is aligned with the edge.
76
n Click on the “Gnomon Axis” icon to switch to Geometry

Manipulation mode.
(This will make the model move to match our axis options).
n From the Dynamic panel, in the Origin area, select

World to move the geometry from our newly located
origin to the Mastercam WCS.
n Press Alt + F1 to fit the geometry to the screen.
n The geometry will be move as shown.
77
n From the Dynamic panel, in the Axes area, select World to

move the geometry and align the X, Y, and Z axes from our
Gnomon axes to the Mastercam WCS.
n The geometry will be rotated to align the axis to

Mastercam WCS.
n Select the OK icon to accept the Dynamic Transform settings.
(For more information on Dynamic Transform, see Mastercam Help).
78
n Right mouse click in the graphics window and select

the Isometric view and confirm the correct model face
now faces the Top as shown.
Fit to fit the geometry to the screen. (Alt +F1)
n Right mouse click and select Clear Colors.
Note: Select Clear Colors to return model color to

normal if needed. Alt-F9 and F9 were used to show
Mastercam WCS. Press F9 to remove the axes
display.
2.1 Analyze Dynamic
Note: Using Analyze Dynamic allows us to confirm

if the top face is flat.
Home
n From the Analyze group, select the Dynamic icon.
n In the General Selection toolbar enable

Face Selection if needed.
n Click somewhere on the face and drag

the cursor on the face.
n In the Analyze Dynamic dialog box,
you should see the Angle set to 90
degrees as shown.
n Click somewhere on the pocket wall and you

should see the Angle set to 0 degrees.
n Select the OK button to exit Analyze
Dynamic dialog box.
79
Multiple WCS Step 3: Create A Viewsheet
STEP 3: CREATE A VIEWSHEET
In this step you will learn how to create and use Viewsheets to be able to quickly switch between the
different WCS planes that you will create during this book. The different part views and planes will each
have their own tab.
View
n In the Viewsheets
group, click on the
On/Off button to activate
it if needed.
n In the Viewsheets group, click on the Viewsheets Settings icon as

shown.
n Click on the Enable All button

and enable Automatically
restore bookmark settings
as shown.
n Select the OK button.

n Select Yes button to save the current settings to configuration file.
View
n From the
Viewsheets
group, click on
On/Off to activate
it.
n Click on the New
icon as shown.
80
Multiple WCS Step 4: Select A Machine And Set The Stock
n A new Viewsheet will be added at the bottom left below the graphics
window.
n Rename it "Top Plane" as shown. Press Enter.
Note: You can right mouse click on it at any moment and select
Rename.
View
n From the Viewsheets group, click on the Save Bookmark

icon to save the part's current view, scaling, and level
settings as a bookmark.
STEP 4: SELECT A MACHINE AND SET THE STOCK

4.1 Load the MPMASTER_VERTICAL
Resources - Download the file from here: MPMaster
Note: For info on how to instal MPMASTER Post, check Getting Started.
Machine
n From the Machine Type

group, select Mill and
Manage list.
n In the Current Machine

Definition Directory,
select MPMASTER_
VERTICAL.mcam-mmd.
n Click on Add button.
81
n The machine should now be

listed in the Machine
Definition Menu Items as
shown.
n From Machine ribbon, click on the Mill and

select the MPMASTER_VERTICAL.mcam-
mmd.
4.2 Set the Tool Settings defaults
n Click on the Toolpaths tab to open Toolpaths

Manager.
n Expand the Properties and select the Files icon.
82
n Click on the Libraries expand arrow.

n Click in the Operation Defaults area on the
Options icon.
83
n Scroll all the way up and expand Properties.

n Select Tool settings.
n Change the highlighted parameters as shown.
Note:These settings will be the defaults. Similar

you can set the defaults for any operation listed in
the Edit Operation Defaults dialog box.
n Select the OK button twice to exit Edit

Operation defaults.
84
n Select the Stock Setup tab.

n Click on the Add from a bounding box button to get
the size of the required stock.
n Enable All shown to select

the solid.
n Click the OK button to
accept and close the
Machine Group Setup.
n To display the stock enable Stock Display as

shown.
Note: In the next steps, you will first, machine the top pocket. Then, you will learn how to save the
operation to a library. You will import the toolpath saved in the future.
85
Multiple WCS Step 5: Machine The Pocket Using Dynamic Mill
STEP 5: MACHINE THE POCKET USING DYNAMIC MILL
2D High Speed Dynamic toolpaths utilize the entire flute length of their cutting tools to achieve efficiency in
milling. They are designed to maximize material removal while minimizing tool wear.
The dynamic mill toolpaths are all designed to simplify the programming of complex pocket and core shapes.
Benefits include:
n Tool burial avoidance

n Minimum heat buildup
n Better chip evacuation
The toolpath machines cores or pockets using the entire flute length. The toolpath supports many powerful entry
methods, including a customized entry method. Entry methods and micro lifts support custom feeds and speeds to
optimize and generate safe tool motion. The toolpath depends on the Machining strategy that you choose in the
Chain Options. If the strategy chosen is From outside, the toolpath starts at the outmost chain and works its way
in, taking on the final shape of the part as it approaches the final pass. You can also machine pockets, in which case
the strategy selected is Start inside, which keeps the tool inside the machining regions.
Step Preview:
Note: The purpose of this tutorial is to teach you how to use the World Coordinate System and the
Construction and Tool planes to generate the toolpath. For more info on the Dynamic Mill toolpath
please see Mastercam Professional Certification Part 1 - Mill 2D.
Toolpaths
n From the 2D group, select the Dynamic

Mill icon.
n The Chain Options appears as shown.

n Make sure that the Machining region strategy is set to Stay inside.
n In the Machining regions click on the Select button.
86
n In the Solids Chaining dialog box enable Face

button is enabled.
n Select the bottom of the pocket.
n Exit from the Chaining dialog box.
n The 2D Toolpaths - Dynamic Mill

dialog box appears on the screen
as shown.
Note: In the following steps you will be setting the parameters to generate the Dynamic Mill toolpath.
87
5.1 Tool
n In the Tool page , select

the 1/2" Flat Endmill.
5.2 Cut Parameters
n Leave the default settings in the

Cut Parameters page.
n Set the Stock to leave on walls
/ floors to 0.0.
88
5.3 Linking
n In the Linking Parameters page set the values

as shown:
n Clearance = 2.0 (Absolute).
n Retract = 0.25 (Absolute).
n Feed plane = 0.1 (Incremental).
n Top of stock = 0.0 (Absolute).
n Depth = 0.0 (Incremental).
5.4 Entry Motion
n Make sure Helix only is enabled.

n Helix radius = 0.225.
5.5 Preview Toolpath
n Select the Apply button.

n Move the dialog box to see the preview or select Hide dialog
button.
n The toolpath preview should look as shown.
n Press Esc to exit the preview.
5.6 Backplot the toolpath
n Select the Backplot selected operations button.
n Select the Play button to run Backplot.
n The toolpath should look as shown.

n From the Backplot dialog box, select the OK button to exit
Backplot.
n Alt + T to remove the toolpath display.
89
Multiple WCS Step 6: Export The Toolpath For Later Use
STEP 6: EXPORT THE TOOLPATH FOR LATER USE
Mastercam allows saving operations that are unique or that you may want to use multiple times at your
company. You will save the Dynamic Mill operation we just created to a library so we can use it again.
n In the Toolpaths Manager, make sure that the Dynamic

Mill is selected.
n Right mouse click on the operation and choose Export as

shown.
n Confirm that the operation is selected in the Export Toolpath

Operations dialog box.
n Enter a name for new group and click OK. ( “My Dynamic Mill” is
the group created in this example.)
n Click the Export operation button to export.
n The Export toolpath operations message appears on the screen as shown.

n After confirmation of export, click the OK button.
n Click the Done button (red X button) to end the import procedure.
90
Multiple WCS Step 7: Define A Plane Using The Gnomon
STEP 7: DEFINE A PLANE USING THE GNOMON
This part has 2 holes in the Front plane that need to be machined. You will assume that the part will be re-
positioned in the vice to be able to machine the two holes.
In this case we cannot rotate the part using Transform Dynamic as this will affect the first toolpath. You
will create a new plane and set it as the new WCS using the gnomon from the graphics window. The new
plane will became the new Top plane in which we can machine the holes.
At the machine, you will have to flip the part and set it in the fixtures to machine the holes.
Step Preview:
7.1 Create the new plane
n Rotate the part roughly as shown.

n From the graphics view, select the gnomon as
shown.
n Drag the gnomon to the corner and click to position it at the

Endpoint as shown.
91
n Click on the Y-Axis rotation arc handle as shown so we can rotate

Gnomon to line up correctly with the desire Y Axis of the part.
n Rotate the axis with the mouse until you highlight the Vertex
shown and select it so the Y Axis is aligned with the edge.
The value of 90 degrees should appear.
Note: To ensure a proper setup at the machine you should keep the Origin
in the same corner.
n Click on the Y axis to translate the origin along the y-axis. The scale will
appear as shown.
92
n Select the Origin as shown.
n In the New Plane panel, enter the Name "1.0 Holes Plane" as
shown.
n In the Work Offset area enable Manual and set it to 1.
Note: Your post processor should be configured to output the

proper codes when you post the operation. For example for
Fanuc controls, 0=G54, 1=G55, 2=G56, etc., while in Fadal
controls 0=E1, 1=E2, and 2=E3. The NCI file will contain the
generic codes.
n In the Set As enable WCS. Make sure that Tplane and Cplane
are also enabled as shown.
n Select the OK button to exit New Plane.
93
n Right mouse click in the graphics window and select the Isometric
view.
n The part should look as shown.
n Select the Planes tab and open Planes Manager.

n The new plane "1.0 Holes Plane" should be listed as
shown.
n In the Planes panel, click on the Show

gnomons if you want to see the gnomon at all
times.
94
n The gnomon should look as shown.
n To remove the gnomon display, in the Planes

panel, click on the Show gnomons icon to
disable it.
7.2 Create a new Viewsheet
n Click on the + icon next to the Top Plane viewsheet as

shown.
n A new Viewsheet will be added at the bottom left below the

graphics window.
n Rename it "1.0 Holes Plane" as shown. Press Enter.
n Right mouse click on the 1.0 Holes Planes

Viewsheet and from the fly out menu select Save
Bookmark as shown.
95
n To switch to the Top plane you need to click on the

Top Plane Viewsheet.
n The part will look as shown.
n In the Planes Manager the WCS, Cplane and Tplane

will be set to the Top plane as shown.
n Click on the 1.0 Holes Plane Viewsheet and the part view
should be updated as shown.
96
Multiple WCS Step 8: Circle Mill The 1" Diameter Holes
STEP 8: CIRCLE MILL THE 1" DIAMETER HOLES
Circle mill toolpath allows you to machine large holes using a milling type toolpath. You will machine the
large 1” center hole using a 1/2” Flat Endmill.
In this step you will Circle Mill the 1.0" diameter holes.
Step Preview:
n In the Toolpaths Manger, select Toggle

display on selected operations to remove the
toolpath display if needed. (Alt +T)
Toolpaths
n In the 2D group, select the drop down arrow and

select the Circle Mill from the Hole making gallery.
97
Note: Hole locations can be selected using the center points or by picking the edge of the hole to be
drilled. You can also select the inside face of the hole. By holding the Ctrl key while selecting the inside
face of one of the holes, the other hole that has the same diameter will be automatically selected. No
Sorting or other options need to be selected.
n Hold down the Ctrl key

and select the inside of
the hole as shown.
n In the Toolpath Hole
Definition select the
OK button.
8.1 Tool
n In the Tool page ,

select the 1/2" Flat
Endmill.
98
8.2 Cut Parameters
n Leave the default settings in the

Cut Parameters page.
n Set the Stock to leave on walls /
floors to 0.0.
8.3 Roughing
n Enable Roughing and set the parameters as shown.
8.4 Finishing disabled

8.5 Tool Axis Control
n Make sure that the Output format is set to 3

axis.
99
8.6 Linking Parameters
n Clearance = 2.0
(Absolute).
n Feed Plane = 0.1

(Incremental).
n Top of Stock = 0.0
(Incremental).
8.7 Repeat the Toolpath preview procedure
n Press Ctrl + T to see the toolpath display.

100
Multiple WCS Step 9: Using Toolpath Groups
8.8 Verify all the toolpaths
n From the Toolpaths Manager, click on the Select

all operations icon as shown.
n From the Toolpaths Manager, select Verify

selected operations icon as shown.
n Select the Play button to run Verify.
n Rotate the part as needed.

n The part should appear as shown.
STEP 9: USING TOOLPATH GROUPS
In this tutorial you will learn how to create Toolpath Groups for each new plane. These groups provide not
only a way to logically organize your operations, but also allow quick selection of toolpaths: selecting a
toolpath group automatically selects all operations within the group. Toolpath Groups will allow you to
organize toolpaths based on the part setups required at the machine.
By default when you post process the toolpath operations, all of the selected operations create one
program. You could carefully select the operations each time before posting, but it is easier to make a
physical change to the output name so you don’t accidentally post the wrong operations to the wrong
output file.
n In the Toolpaths Manager, click on the Toolpath

Group1 and rename it "Top Plane".
101
9.1 Create the 1.0" Hole Plane Group
n In the Toolpaths Manager, right mouse

click on the Machine Group 1 and select
Groups and then New Toolpath group
as shown.
n Rename the Toolpath Group "1.0" Hole Plane".
n Right mouse click on the Circle Mill and drag the

toolpath in the "1.0 Holes Plane" group.
102
n Release the cursor and select Move after.
n Drag the Insert arrow below the toolpath.
9.2 Create the Pocket OP3 Group
n In the Toolpaths Managers, right mouse

click on the Machine Group 1 and select
Groups and then New Toolpath group as
shown.
n Rename the Toolpath Group "Pocket OP3".
103
Multiple WCS Step 10: Define A New Plane Using Plane Manager
STEP 10: DEFINE A NEW PLANE USING PLANE MANAGER
In this step you will define the plane to machine the left side pocket using the Planes Manager and From a
Solid Face option. This is another option that you can use when need to create a new plane.
Step Preview:
n Rotate the part to see the left side pocket as

shown.
n Open Planes Manager and click on the Create

new plane icon.
n Select From solid face as shown.
104
n Select the solid face as shown.
n Select the Next button until the axes are orientated as

shown.
n In the Select Plane dialog box select the OK button to
accept it.
n In the New Plane panel, enter in the Name " Pocket

OP3".
n Click on the Reselect button in the Origin area.
105
n Select the Endpoint at the upper left corner.

n Select the Yes button to Associate plane
origin to new geometry.
n In the Work Offset area, enable Manual and set the

value to 2.
n Make sure the WCS and the Cplane are enabled as
shown.
n Select the OK button to exit Edit Plane.
n Open the Planes Manager.

n The new plane should be listed as
shown.
106
view.
10.1 Create a the Viewsheet
n Click on the + icon next to the 1.0 Holes Plane

viewsheet.
n A new Viewsheet will be added at the bottom
left below the graphics window.
n Rename it "Pocket OP3" as shown. Press
Enter.
n Right mouse click on the Pocket OP3

Viewsheet and from the fly out menu
select Save Bookmark as shown.
107
Multiple WCS Step 11: Import The Operation To The New Plane
STEP 11: IMPORT THE OPERATION TO THE NEW PLANE
You will now retrieve the operation that was saved earlier to use on the pocket.
Step Preview:
n Select the Toolpaths tab.

n Right mouse click and select Import as shown.
108
n In the Import Toolpath Operations dialog box,

scroll to find the saved operation and click on it to
select it as shown.
n Enable Assign current system tool and
construction planes. We need this option to
move the operation to the new front face
construction plane we have set.
n Click on the Import Operations button.
n A message that "1 operation imported successfully" appears on the

screen as shown.
n Click OK to confirm the operation was imported successfully.
n Click the Done button (red X button) to end the import procedure.
Note: The operation has been copied with parameters set as we saved it. However, there is no
geometry associated with the operation. You need to select the geometry to define this now.
109
11.1 Select the Geometry for the toolpath
n In the Toolpaths Manager, click the Geometry in the

third operation as shown.
n The Chain Options dialog box appears as shown.

n In the Machining regions, click on the Select button.
n Unzoom the model as needed for viewing.

n In the Chaining dialog box enable Face button.
n Select the bottom of the pocket as shown.
n Select the OK button to exit Chaining dialog box.
n In the Chain Options enable Stay inside as shown.

n Select the OK button to exit the Chain Options dialog box.
110
n Click on the Regenerate all dirty operations

icon as shown.
11.2 Repeat the Backplot procedure
11.3 Repeat the Solid Verify procedure
n From the Toolpaths Manager, click on

the drop arrow next to the Verify
n Select Add to current verification.
n The part after being verified in Mastercam Simulator should

look as shown.
n When finished verifying, minimize Mastercam Simulator.
Note: Exporting commonly used operations to a library will save considerable time in setting and
confirming parameters the way you like them. Once your standards are established, you will be
able to program shapes very quickly.
111
Multiple WCS Step 12: Face And Drill The 3/8" Holes Of The Beveled Face
STUDENT PRACTICE
Student completes the rest of the toolpaths using the following instructions.
STEP 12: FACE AND DRILL THE 3/8" HOLES OF THE BEVELED FACE
In this step you will create a new plane and machine the third pocket using the same method as previously
shown in Step 8 and Step 9. You will face and then drill the 3/8" holes.
Step Preview:
12.1 Create a new plane using From solid face
n In the Planes Manager use Create new plane

using From solid face.
n Make sure that the axes are oriented as shown.
n Enter in the Name "0.375 Holes Plane".

n Reselect the Origin.
n Set the Work Offset to Manual and 3.
n Select the Yes button to Associate plane origin to new
geometry.
n The plane should look as shown.
112
n Click on the plus next to Pocket OP3 Viewsheet.

n Rename the Viewsheet "0.375 Holes Plane".
n Right mouse click on the 0.375 Holes Plane
Viewsheet and select Save Viewsheet
Bookmark.
12.3 Create a new Toolpath Group
n Right mouse click on the Machine Group and select

Groups and then New Toolpath group.
n Rename the Toolpath Group "0.375 Holes Plane".
12.4 Face the beveled face
n From Toolpaths, 2D group, select Face.

n In the Solid Selection, enable only
Loop.
n Select the edges as shown.
113
n Select a 1.0" Flat Endmill.

n In the Style enable One pass.
n Stock to leave on floors = 0.0.
n Depth cuts enabled. Max rough step =
0.1.
n Feed Plane = 0.1 (Incremental).
n Top of Stock = 0.0 (Absolute).
n The toolpath preview should look as
shown.
12.5 Drill the Holes
n Select the holes by holding down the Ctrl key

and selecting the inside face of one hole. Zoom
in as needed.
n Select 3/8" Drill.
n Set the Cycle to G83 - Peck/Drill.
n First peck = 0.1.
n Subsequent peck = 0.1.
n Peck clearance = 0.1.
n Retract amount = 0.1.
n Enable Calculate incremental values from
holes/lines.
n Enable Use clearance only at the start and
end of operation.
n Retract = 0.1 (Incremental).
n Top of stock = 0.0 (Incremental).
n To sort the holes to be machined in the proper order, in the Toolpath manager, Drill toolpath, select
Geometry.
114
Multiple WCS Step 13: Machine The Third Pocket
n In the Toolpath Hole Definition panel, Sort, select Point to

Point option.
n Pick the hole that you want to start the drilling with.
n Regenerate the toolpath.
n Verify all operations.
STEP 13: MACHINE THE THIRD POCKET
shown in Step 8 and Step 9.
n In the Planes Manager use Create new plane

using From solid face.
n Make sure that the axes are oriented as shown.
115
Multiple WCS Step 13: Machine The Third Pocket
n Enter the Name "Pocket OP6".

n Select the Yes button to Associate
plane origin to new geometry.
n Make sure WCS , Cplane and Tplane
are selected.
view.
n The geometry should look as shown.
n Click on the plus next to 0.375 Holes Plane

Viewsheet.
n Rename the Viewsheet "Pocket OP6 ".
n Right mouse click on the Pocket OP6 Viewsheet
and select Save Viewsheet Bookmark.
n Right mouse click on the Machine Group and select Groups and
then New Toolpath group.
n Rename the Toolpath Group "Pocket OP6".
13.4 Import the toolpath
n Right mouse click in the Toolpaths Manager and select

Import.
n Select the exported toolpath.
n In the Toolpaths Manager, select the last operation
Geometry.
n In the Machining regions , select the bottom of the
pocket.
116
STEP 14: FACE AND DRILL THE 1/4" HOLES OF THE BEVELED FACE
shown in Step 7 and Step 8. You will face and then drill the 1/4" holes.
n Rotate the part as shown

n In the Planes Manager use Create
new plane using From solid face.
n Make sure that the axes are oriented
as shown.
n Enter the Name "0.25 Holes Plane".

n Select the Yes button to Associate plane
origin to new geometry.
n Select the Isometric view.

117
n Click on the plus next to Pocket OP6 Viewsheet.

n Rename the Viewsheet " 0.25 Holes Plane".
n Right mouse click on the 0.25 Holes Plane Viewsheet
and select Save Viewsheet Bookmark.
n Right mouse click on the Machine Group and select

Groups and then New Toolpath group.
n Rename the Toolpath Group "0.25 Holes plane".
14.4 Face the beveled face
n Use solid selection and enable Loop in the Solid Selection.

n Select the 1.0" Flat Endmill.
n In the Style enable Zigzag.
n Depth cuts enabled. Max rough step = 0.1.
Note: To change the cutting direction, select parameters in the

Toolpath Manager and in the Cut Parameters enable Auto
angle.
14.5 Drill the Holes
n Select the holes.

n Select 1/4" Drill.
n Set the Cycle to G83 - Peck/Drill.
n First peck = 0.1.
n Subsequent peck = 0.1.
n Peck clearance = 0.1.
n Retract amount = 0.1.
n Enable Calculate incremental values from holes/lines.
n Enable Use clearance only at the start and end of operation.
118
Multiple WCS Step 15: Change The NC File Names
n Sort the holes if needed.
n Verify all operations.
STEP 15: CHANGE THE NC FILE NAMES
With this part example, there is machining to be done on 6 separate faces. In situations like this where the
part must be rotated and refixtured on the NC machine, you would need to create 6 separate programs.
The procedures that follow will show an example of how this can be achieved.
n From the Toolpaths

Manager, click on the Top
Plane group to select only the
first toolpath.
n Right mouse click on the group
and select Edit selected
operations and Change
NC file name.
n Change the default NC name to a name indicating it is a different

file. (“WCS_Review_Top Plane” used in this example)
n Select the OK button to accept it.
119
Multiple WCS Step 16: Post Process The Toolpaths To Generate The G-Code
n Click on the 1.0 Holes

Plane Group toolpath to
select only the operation
inside this group.
n Right mouse click and
select Edit selected
operations and Change
NC file name.
n Change the default NC name to a name indicating it is a

different file.
(“WCS_Review_1.0 Holes Plane” used in this example)
n Select the OK button to accept it.
Repeat The Steps For All The Other Toolpath Groups
Note: Change the name by adding the plane names. By clicking first on the toolpath group you are
selecting all the operations that are inside of the group. Make sure that both operations inside of the
0.375 Holes Plane and 0.25 Holes Plane will have the same NC file name.
STEP 16: POST PROCESS THE TOOLPATHS TO GENERATE THE G-CODE
We now will take the toolpath information we have created and convert it to a language that the machine
tool can read. This process is called Post Processing.
n Click on the Select all operations icon.

n Select the Post selected operations icon from the Toolpaths Manager as shown.
Note: The HLE/Demo version of Mastercam does not support post processing. The G1 button does not
work and no G-code can be created in the HLE/Demo version.
120
Multiple WCS Step 16: Post Process The Toolpaths To Generate The G-Code
n In the Post processing window, make necessary changes as

shown.
n When prompted for the first file

name, select Save button to accept
it.
(WCS_Review_Top.nc is used in this
example.)
n When prompted for the second file name, select Save button to accept it.
(WCS_Review_1.0 Hole Plane.nc is used in this example.)

Save All The Other NC Files
n Mastercam Code
Expert window will be
launched and the two
programs will be
generated as shown.
n Close Mastercam
Code Expert window.
121
Multiple WCS Step 17: Save Your File
n Click on the WCS_Review_

Top Plane tab to open the
first program.
n In line 14 you can see that
the first Work Offset G54 is
used.
n Check the rest of the
programs and you should
see they will have a different
Work Offset. G55 to G59
will be used.
STEP 17: SAVE YOUR FILE

n Your file will be saved with the Mastercam toolpath data stored inside the file.
SUMMARY:
In this lesson you reviewed how to define new planes and how to use the Work Coordinate System to
machine multiple faces of a part on a 3-Axis Vertical Machining Center. You learned the different options
that Mastercam allows you to define a new WCS and planes. You learned how to generate different work
offsets for each setup.
After completing this lesson and the practice exercise that follow you should be able to:
n Define a new plane and set it as the current WCS, Cplane and Tplane.
n Machine the part features in the current WCS that has it's own work offset.
n Create Viewsheets for each new WCS that later allows you to quickly reset the part to the desired
plane.
n Export and import operations.
n Create toolpath groups to organize the toolpaths based on the planes.
n Rename the toolpaths to allow you to generate separate NC .
122
Multiple WCS Exercise
EXERCISE
Open Multiple-Settings.mcam.
Job Description:
The exercise expands your knowledge on how to program a part with multiple setups.
n Setup the stock : 10 by 8 by 6.
Machine the part in different planes as following:
Top Plane
n Contour one of the slots with a full radius tool.

n Use a 1/2" Ball Endmill.
n Depth = -0.25" (Absolute).
n Copy the operation to the other slots using Transform - Translate.
n Source set to NCI.
n Work offset number set to Maintain source operation's.
n Method Rectangular X 2.0, Y0.0.
n Instances; X = 5 Y = 1.
n Machine the pocket using 2D HS Area Mill.
n In the Machining regions, select the top of the pocket.

n Use a 1/2 Bull Nose corner radius 0.125.
n XY Stepover = 45%.
n Stock to leave on walls and floors = 0.0.
n Depth cuts; Max rough step = 0.25; one finish step of 0.03.
n Helix entry; Radius = 0.35.
n Depth = -0.75 (Absolute).
n Export the operation to a library.

n In the Toolpath Manager, right mouse click on the operation and choose Export.
n Save the library in the Group as My Saved OPS.
123
Multiple WCS Exercise
Create a new plane From solid face
n Select the Front face.

n Name the plane "FRONT FACE 2D PLANE".
n Set the Origin to the lower left corner of the face.
n Set the Cplane Tplane and WCS to the new plane.
FRONT FACE 2D PLANE
n Import the operation.

n Right mouse click in the Toolpath Manager and select Import.
n Find the saved operation and select it.
n Click on the Import Operation button.
n Select the toolpath geometry.
n In the Toolpaths Manager, click on the operation Geometry.
n In the Machining regions, select the top of the pocket.
n Change the Depth to -1.5.
n Create the Letters
n Use Create Letters command.
n Font Style set to OLF SimpleSansCJK OC (TrueType).
n Enter MASTERCAM.
n Height = 0.5.
n Spacing = 0.2.
n Alignment set to Horizontal.
n Engrave the Letters using Contour toolpath
n Select the letters using Window selection.
n Select the 1/8 INCH Engraver Tool 30 DEGREE X .005 TIP.
n Compensation type set to Off.
n Depth cuts Max rough step = 0.003.
n Lead In/Out disabled.
n Change the NC file names.
n Select only the last two operations.
n Righ mouse click in the Toolpaths Manager.
n Select Edit selected operations and then Change NC file name.
n Enter the name Multiple-Settings - Op 2.
n Post process the operations to separate NC files.
124
Plane Creation & Indexing
125
Plane Creation & Indexing Introduction
INTRODUCTION
In this lesson you will learn how to define and change Tplanes to produce a rotary motion code when you
post the toolpath so that the tool axis or fixture will move to properly position the part. You should use
Tplanes when you are indexing the part on a 4-Axis or on Horizontal CNC machine. In contrast, changing
the WCS typically does not produce any rotary code; its effect is apparent inside Mastercam, before you
post the part. In this lesson you will maintain the same WCS and Origin allowing the part to rotate around the
X-axis.

n Using Tplanes to index the part on a 4-Axis Rotary mounted on a vertical Machining center.
n Using Planes Manager to define a new Cplane and Tplane using From geometry.
n Using Planes Manager to define a new Cplane and Tplane using From entity normal.
Note: The purpose of this lesson is to learn other options available to define planes when machining the
two holes that are at an angle on a 4-Axis Vertical machine. The rest of the toolpaths will not be created
in this lesson.
This tutorial covers Mastercam's 4-Axis toolpath functionality. To apply these toolpaths to a 4-Axis machine
tool, a customized post processor for your machine is required.
There are no default 4-Axis post processors included with Mastercam due to the variation in multi-axis
machine configurations. Contact your Mastercam reseller to request post processor services such as multi-
axis post development.
Your post processor may require certain additional programming information not covered in this tutorial. For
instance:
n You may be required to position your stock in machine space rather than at Mastercam's origin.
n You may be required to use the Misc Values box.
n Your post may also prompt for tool gauge lengths.
The nature of the additional information required depends largely on your machine's configuration. Contact
the developer of your post processor for details.
126
Plane Creation & Indexing Instructor Demonstration:
Topics:
n Import a STEP file.

n Use Transform Rotate to rotate the part to be
able to index it around the X-Axis.
n Use Model Prep and Hole axis to create
wireframe from a solid.
and Tplane using From geometry.
n Machine the hole.
and Tplane using From entity normal.
n Machine the hole.
n Post processing the toolpaths.
NOTES:
127
Plane Creation & Indexing Step 1: Open The File
n Find and open the part Planes.stp.
Note: Make sure that you set the file type to STEP
Files(*stp,*step)
n Change to the Isometric view and display the axes

(F9 and Alt+F9) to determine the model
orientation.
Note: The part is not oriented as needed to machine

the bigger holes on a 4-Axis Rotary. You will rotate
the part to be able to machine the holes in one
setup, rotating the part around the X-axis.
STEP 2: SET THE ORIGIN AT THE CENTER BOTTOM OF THE PART

Step Preview:
2.1 Rotate the part
Transform
n From the Position group, select the Rotate

icon.
n Window select the entire solid and select
End Selection button.
128
Plane Creation & Indexing Step 2: Set The Origin At The Center Bottom Of The Part
n Change the Gview to Top.

n In the Rotate panel enable Move and set the
Angle to 90 degrees.
n You can also use the dial as shown.
n Select the OK button to exit the Rotate panel.
2.2 Using Bounding Box to establish the center of the part.
Wireframe
n From the Shapes group, select

Bounding Box.
n Select the Isometric view.
n Window select the entire solid and
select End Selection button.
n In the Bounding Box panel,
enable Lines and arcs.
n Select the OK button to exit
Bounding Box panel.
129
2.3 Move To Origin
n Rotate the part to see the bottom of the part.
Transform
n From the Position group, select Move to Origin

icon.
n Hover the cursor above the opposite corners of the bottom

rectangle until the temporary points appear.
n Select the center point.
n Press F9 to see the axis.

130
2.4 Delete the wireframe
n Right mouse click in the graphics window and select the

Isometric view.
n From the Quick Mask toolbar, click on the Select all
wireframe entities button.

n Click on the Delete button from the keyboard.
n Right mouse click in the graphics window and select Fit
to fit the geometry to the screen. (Alt +F1)
Note: Right mouse click in the graphics window and

select the Clear Colors icon to return model color to
normal if needed.
Alt + F9 and F9 were used to show Mastercam WCS.

Press F9 to remove the axes display.
131
Plane Creation & Indexing Step 3: Define A Plane From Geometry
STEP 3: DEFINE A PLANE FROM GEOMETRY
This part has 2 holes at an angle that need to be machined on a 4-Axis rotary.
In this step you will use Hole Axis command to create the wireframe needed to define the planes.
You will use From geometry to create a new plane.
To define a plane you can select two intersecting lines, three points or a flat entity such as an arc, a flat surface or a
solid face.
Step Preview:
3.1 Set the wireframe thickness
n Right mouse click in the graphics window and in the Mini

toolbar, select the third line thickness.
3.2 Create the Wireframe using Hole Axis command
Model Prep
n From the Create group,

select Hole Axis icon.
132
n In the Hole Axis panel, make sure that the Hole is

enabled and the Vector length is set to 1.0.
n Axis Lines is enabled.
n Circles is enabled and set to Both.
n Select the inside face of the hole.
133
n If the arrow direction does not point upwards as shown,

in the Direction click on the Opposite.
n Rotate the part as needed and select the inside of the

opposite hole face.
n The arrows should point as

shown.
134
n In the Hole Axis panel, enable Axis Lines.

n Leave Circles enabled and set the Location to
Both.
n Select the OK button to exit Hole Axis panel.
n Press Alt + S to unshade the geometry as

shown.
n Press Alt + S to shade the part.
3.3 Create the new plane

a new plane icon.
n Click on the From geometry.
135
n Select the circle as shown.
n The axis should be orientated as shown.

n Select the OK button in the Select plane dialog box.
n In the New Plane enter the Name "Hole 1".

n Click on the Reselect button to change the plane origin.
136
n From the General Selection toolbar,

select the Origin as shown.
Note: You might need to select the Origin

from the graphics window.
n The origin should be set back to the WCS origin as

shown.
Note: In this exercise the new planes Origins should

not be changed.
n In the New Plane panel, in the Work Offset area, enable

Manual and set it to 0.
Note: the Work Offset set to Manual and 0 will generate a

G54 code. This part should only have one Work Offset.
n Disable WCS as shown.

n Make sure that the Tplane and Cplane are enabled.
n Select the OK button to exit New Plane panel.
137
Plane Creation & Indexing Step 4: Select A Machine
n Select the Planes tab and open Planes

Manager.
n The new plane " Hole 1" should be listed as
shown.
Note: The WCS should be set to the Top

plane. The new plane is set to the Cplane
and Tplane which will generate an indexing
motion in the G-code.
STEP 4: SELECT A MACHINE

4.1 Load the MPMASTER_VERTICAL
Machine
n Click on the drop down arrow below the Mill and

select the MPMASTER_VERTICAL.mcam-mmd
4.2 Set the Tool settings

Manager.
n Expand the Properties and select the Files icon.
138
Plane Creation & Indexing Step 4: Select A Machine
Note: Enter the Default Program Number. The rest of

the settings should be already set. No stock will be defined
in this lesson.
139
Plane Creation & Indexing Step 5: Circle Mill The Hole
STEP 5: CIRCLE MILL THE HOLE
Circle mill toolpath allows you to machine large holes using a milling type toolpath. You will machine the
hole using a 1/4” Flat Endmill.
Step Preview:
Toolpaths
n In the 2D group, select the Expand gallery drop down arrow and select
the Circle Mill from the Hole making gallery.
n Select the inside face of the hole as shown.
Note: Hole locations can be selected using the center points or by

picking the edge of the hole to be drilled. You can also select the
inside face of the hole or the center line. Since we are going to Circle
mill the hole you will need to know the hole diameter. You should
select either the circular edge (making sure that the center point is
also selected) or select the inside face of the hole. These selections
allow Mastercam to extract the diameter value of the hole. No
Sorting or other options need to be selected.
n Make sure the arrow points upwards as shown. Otherwise, click on the
arrow to reverse its direction.
n In the Feature list you should see Solid Feature 1 0.369.

n In the Toolpath Hole Definition panel, select the OK
button.
140
5.1 Tool
n In the Tool
page , select the
1/4" Flat
Endmill.
5.2 Cut Parameters
n Leave the
default
settings in the
Cut
Parameters
page.
n Set the Stock
to leave on
walls / floors
to 0.0.
141
5.3 Roughing
n Enable Roughing and set the parameters as shown.
5.4 Finishing disabled

n Enable Calculate incremental values

from holes/lines.
n Clearance = 2.0 (Incremental).
n Top of Stock = 0.0 (Incremental).
n Select the OK button to exit 2D
Toolpaths - Circle Mill.
Note: With the Calculate incremental values from holes/lines enabled, the values set to
Incremental for the Retract, Feed plane, and the Top of stock are measured from the top of the hole
that was selected.
142
Plane Creation & Indexing Step 6: Create A Plane Using From Entity Normal
n Press Ctrl + T to see the solid

translucent.
STEP 6: CREATE A PLANE USING FROM ENTITY NORMAL
Plane From entity normal allows you to set a plane perpendicular to a line. You will use the hole axis line
that you created in a previous step.
Step Preview:

a new plane icon.
n Click on the From entity normal.
143
n Select the line close to the end as shown.
n Click on the Next plane button until the axis are

orientated as shown.
n Select the OK button in the Select plane dialog box.
n In the New Plane enter the Name "Hole 2".

n Click on the Reselect button to change the plane origin.
144
n From the General Selection toolbar, select the

Origin as shown.
Note: You might need to select the Origin from

the graphics window.
n The origin should be set back to the WCS

origin as shown.
Note: In this exercise the new planes

Origins should not be changed.
n In the Work Offset enable Manual and set it to 0.

n In the New Plane panel, make sure the WCS is
disabled as shown.
n The Hole 2 plane should be displayed as shown.
145
Plane Creation & Indexing Step 7: Drill The Hole
STEP 7: DRILL THE HOLE
In this step you will drill the 0.75 hole.
Step Preview:
Toolpaths
n In the 2D group, select

the Drill icon.
n Select the inside of the hole as

shown.
n The arrow should point upwards.

n Select the OK button to exit Toolpath Hole Definition.
146
7.1 Tool
n Use the Filter to

select the 3/4" Drill
as shown.
n Enter in the
Comment area "Drill
the hole".
7.2 Cut Parameters
n Set the Cycle to

Drill/Counterbore as
shown.
n The rest of the
parameters will not be
used to define this cycle
and can be left as they
are.
147
n Set the values as shown making sure

that both the Top of stock and the
Depth are set to 0.0 and
Incremental. Make sure that Use
clearance only at the start and
end of operation is not enabled as
shown.
Note: The tool has to retract to

clearance height between each hole to
ensure there is not a collision with the
standing boss.
7.4 Tip Comp enabled
n Enable Tip Comp and set the Breakthrough

amount to 0.0.
n Select the OK button to exit 2D Toolpaths -
Drill/Circles Simple drill - no peck.
148
Plane Creation & Indexing Step 8: Post Process The Toolpaths To Generate The G-Code
n Backplot the toolpath.
We now will take the toolpath information we have created and convert it to a language that the machine
tool can read. This process is called Post Processing.

n In the Post processing window, make necessary changes as

shown.
149
Plane Creation & Indexing Step 9: Save Your File
n When prompted for the first file

name, select Save button to accept
it.
(Planes.nc is used in this example.)
n Mastercam Code Expert

window will be launched and the
two programs will be generated
as shown.
n Close Mastercam Code
Expert window.
n In the line 18 you can see that the first

Work Offset G54 is used.
n The X-axis rotation is A38.
n In the line 159 you can see that the

Work Offset G54 is used.
n The X-axis rotation is A-52.

150
Plane Creation & Indexing Step 9: Save Your File
SUMMARY:
In this lesson you learned how to define new planes and how to use them to machine a 4-Axis Vertical
Machining Center. You learned how to maintain the unique work offset for all the toolpaths.
After completing this lesson and the practice exercise that follows you should be able to:
n Define a new plane using From geometry and set it as the current Cplane and Tplane.
n Circle mill the hole.
n Create a new plane using From entity normal and set it as the current Cplane and Tplane.
n Create the drill toolpath.
n Generate the G-code with one Work Offset.
151
Plane Creation & Indexing Exercise
EXERCISE
Job Description:
The part is a casting part and only several features need to be machined.
Program the part above Planes_Exercise.stp with the following requirements:
n Use Move to Origin command to locate the origin at the left sharp corner.
n Rename the Toolpath Group "Top Plane".
n Use High Speed Dynamic Mill and machine the pocket.
n Circle mill the 1.5" diameter hole.
n Drill the two 0.375" holes.
n Contour the channel with a 1/8" Ball Endmill.
n Use Hole Axis command to create the circles and the axis for the two 31/64 diameter holes.
n Create a new plane using From geometry option and named In Plane.
n Set the Origin at the top center of the hole.
n Create a new Toolpath Group and rename it "In Plane".
n Drill the 31/64 hole.
n Create a new plane using From entity normal option and named Out Plane.
n Create a new Toolpath Group and rename it "Out Plane".
n Set the Origin at the top center of the hole.
n Drill the 31/64 hole.
n Create a new plane using From solid face option and named Back Counterbore.
n Create a new Toolpath Group and rename it "Back Counterbore".
n Set the Origin at the top center of one of the holes.
n Circle Mill the 0.625 hole.
n Run Backplot and Solid Verify to confirm results.

n Change the NC file names for each toolpath group.
n Create G-code for NC machine.
152
Levels & Viewsheets
153
Levels & Viewsheets Introduction
INTRODUCTION
The purpose of this lesson is to emphasize how to better organize the geometry using levels in Mastercam.
By organizing your files into levels, you can more easily control which areas of the drawing are visible at any
time and which parts are selectable so that you do not inadvertently make changes to areas of the drawing
you do not want to change.
In this lesson you will also review how to create and save Viewsheets.
This helps you to define and quickly retrieve a specific view or plane as well as a attributes associated with
the view.
The file used in this example is for Horizontal Machining Center (HMC) and contains a tombstone with vises
mounted on each face of the block. On each vise, an identical part is fixed. The scope of this lesson is not to
demonstrate how to machine the part, you can use Mastercam 2020 Professional Certification Part 1 - Mill
2D to review the toolpaths.
A typical HMC axis orientation should look as shown.
Note: Keep in mind this general rule: program whatever the machine can get to in one setup with one
WCS. If you have to manually change the part orientation in the machine, use a different WCS.
If you are machining a block on the B axis of an HMC, set the Tplane equal to the Front (B0), Right
(B90), Back (B180) and Left (B270) views with respect to the WCS to work your way around the block
for each toolpath—for example, from the Planes Manager, choose Front. If you want to have a
different work offset, for each plane, you will need to create a new plane with a new Origin for each face
of the block.
154
Levels & Viewsheets Introduction
Example of horizontal machining center (tombstone) and axis orientation.
Example of the G-code (Fanuc controller).
OVERVIEW OF EXERCISE:
In this lesson you will move the tombstone, vises and the parts on different levels.
You will create and save Viewsheets for each face of the tombstone, after setting up the corresponding
Cplane/Tplane and its origin.
CONCEPTS COVERED IN THIS LESSON:

n How to create and use Levels to better organize the file geometry.
n How to create and save Viewsheets.
155
Levels & Viewsheets Instructor Demonstration Preview:
INSTRUCTOR DEMONSTRATION PREVIEW:

Topics:
n Use Change level command and move the

tombstone on Level 1500.
n Name Level 1500 "Tombstone".
n Use Change level command and move the parts
on Level 2501, 2502, 2503 and 2504.
n Name the part levels "Part B0", "Part B90", "Part
B180" and "Part B270".
n Use Change level command and move the vises
on Level 5010, 5020, 5030 and 5040.
n Create a new Viewsheet B0 and create a new
plane using Dynamic Plane B0.
n Save Viewsheet Bookmark B0.
n Repeat the steps for the other 4 faces.
NOTES:
156
Levels & Viewsheets Step 1: Open The File

n Find and open the part Levels and Viewsheets.mcam.
n Change to the Isometric view and display the axes (F9 and
Alt+F9) to determine the model orientation.
Note: The parts are fixed in the vices mounted on a

tombstone and are oriented as needed to machine them on a
Horizontal Machine Center.
In this example the WCS is set to the Top plane and the Origin
is set at the center of the table bottom of the tombstone. The
indexing around the B axis will be shown in the G-code by
setting the Tool planes as needed.
STEP 2: WORKING WITH LEVELS

Step Preview:
2.1 Statistic
n Select the Statistics icon from the Home tab.

n In the dialog box you should see 89 Solids as shown.
157
Levels & Viewsheets Step 2: Working With Levels
2.2 Open and lock Levels Manager
LEVEL MANAGER REFERENCE INFORMATION

Levels are a primary organizational tool in Mastercam. By organizing your files into levels, you can more
easily control which areas of the drawing are visible at any time and which parts are selectable so that you
do not inadvertently make changes to areas of the drawing you do not want to change.
You are always drawing on the main level. You can create and name up to 2 billion levels and set any one to be the
main level. You use the Levels Manager to create and edit levels and to set the main level. You can configure
Mastercam to always display the name of the level.
In our case, you will move the tombstone, the vises and the parts on different levels. This will allow us to
make only the vise and the part we currently work on visible.
n To open Levels Manager, click on the Levels tab located

to the left of the graphics window. If you cannot see the
Level tab, in the View tab, under the Managers group,
click on Levels.
n In the Levels Manager, click on the Hide icon to lock it as
shown.
2.3 Move the Tombstone on Level 1500
n Select the tombstone as shown.
158
n Right mouse click and from the Mini Toolbar, select

Change Level icon as shown.
n In the Change Levels dialog box, make sure Move is

enabled and disable Use Active Level.
n In the Number field enter 1500 as shown.
n In the Name enter "Tombstone".
n Enable Force visibility and Off to make the tombstone
invisible.
n Select the OK button to exit Change Levels dialog box.
n In the graphics window the tombstone disappeared as

shown.
n In the Levels manager you should see 1 entity on

Level 1500 .
Note: Because the vises are made from multiple solids, we will first move the parts on different
levels.
159
2.4 Move the part located at B0 on Level 2501
n Select the part as shown.
n Right mouse click and from the Mini Toolbar, select Change
Level icon as shown.

enabled and disable Use Active Level.
n In the Name enter "Part B0".
n To make the part invisible make sure that Force visibility
and Off are enabled .
n In the graphics window the part disappeared as

shown.
160

Level 2501 .
n Select the part as shown.
n Right mouse click and from the Mini Toolbar, select Change
Level icon as shown.

161

Level 2502 .
n Rotate the geometry and select the part at

180 degree.

Change Level icon.
n In the Number field enter 2503.

162
n Rotate the geometry and select the

part at 270 degree.

Change Level icon.

n The Levels Manager panel should look as shown.
163
n Right mouse click in the graphics window and

select the Isometric view.
n You should only see the vises in the graphics
window.
2.8 Move the vise located at B0 on Level 5010
n Right mouse click in the graphics window and select the Top
view.
n Window select the vise at B0 as shown.
164

Change Level icon.

n In the Name enter "Vise B0".
n The Levels Manager panel should look as shown.
n Window select the vise at B90 as

shown.
165

Change Level icon.

n Click on the Number 5020 to make it the Main Level.

n The Levels Manager panel should look as

shown.
n Follow the same steps and move the vise at B180

on Level 5030.
166
n Follow the same steps and move the vise at

B270 on Level 5040.
n Make sure that Level 1 is set as the Main

level and make all levels visible by selecting
Turn all levels on icon.
n All the solids are visible as shown in the Isometric

view.
167
Levels & Viewsheets Step 3: Working With Viewsheets
STEP 3: WORKING WITH VIEWSHEETS
Use Viewsheets to create different part views and planes, each on its own tab. When you save your part file,
Mastercam stores the Viewsheet settings along with the part.
With a viewsheet you can:
Define a specific view or plane orientation and scale, including a section view
Store modified level settings
Use a bookmark to define a restorable viewsheet state
Step Preview:
View
n From the
Viewsheets
group, select
On/Off icon as
shown.
3.1 Check the Viewsheets settings
n In the Viewsheets group, select the

Viewsheets Settings icon as shown.
168
n In the Viewsheet dialog box,

click on the Enable All button
to save all the items available
to the viewsheets. Make sure
that Automatically restore
bookmark settings is
enabled.
the command.
n Select the Yes button to
accept to save the changes to
the System Configuration.
n Right mouse click in the

graphics window and select
Fit. (or press Alt + F1)
n The geometry should look as

shown.
3.2 Rename and save the Viewsheet Iso Tombstone
n Right mouse click on the generic Viewsheet # 1, and select

Rename Viewsheet.
169
n Type "Iso Tombstone" as shown and press Enter.
n To save the view, right mouse click on it again and select Save
Viewsheet Bookmark.
Note: Once you saved the viewsheet as a bookmark, a
bookmark indicator appears on the tab.
3.3 Make visible only Part B0 and Vise B0
n In the Levels Manager , click on the

Turn all levels off icon to make all levels
invisible.
n Click in the Visible column next to Part
B0 and Vise B0 to make them visible as
shown.
170
n Press Alt + F1 to fit the geometry to the graphics

window as shown.
3.4 Create a New Plane B0
n Rotate the part and zoom in to see

the part as shown.
n In the View ribbon make sure that Planes are enabled.

n Open Planes Manager and select Create a new plane icon.
n Select from the list, From solid face.
171
n Select the face as shown.
n Select the OK button to accept the

plane when the axes are orientated
as shown.
n In the New Plane panel, name the plane

"Plane B0".
n In the Origin area click on the Reselect
button and pick the corner of the vise as
shown.
Note: Hide the Levels and the Planes

Managers as needed to have more space in
the graphics window.
172
n Disable WCS if needed and leave Cplane

enabled.
n Open Planes Manager if needed.

n The new plane should be listed as shown.
Note: Make sure that only C (Construction plane) and

T (Tool plane) are selected for this plane. WCS
should be set to the Top plane as shown.
n Click in the G column of the new plane to set

the graphic view to the same plane.
173
n Make sure the geometry looks as

shown.
3.5 Create a New Viewsheet "B0"
n Click on the + sign next to create a new Viewsheet.
n Name it "B0" and press Enter to finish.
n To save the view, right mouse click on it

again and select Save Viewsheet
Bookmark.
174
n Click on the Iso Tombstone

viewsheet.
n The part and the Planes manager
should look as shown.
Note:WCS (Work Coordinate System), C (Construction plane) & T (Tool plane) are all set to the Top
plane, while G (Graphic view) is set to Iso.
n Click on the B0
viewsheet.
n The part should look as
shown.
175
3.6 Make only Part B90 and Vise B90 visible
n In the Levels Manager , click on the Turn

all levels off icon to make all levels
invisible.
n Click in the Visible column next to Part
B90 and vise B90 to make them visible as
shown.

Isometric view.
n Press Alt + F1 to fit the geometry to the graphics window as
shown.
n Rotate the part and zoom in to see the part as

shown.
176
n Select the gnomon from the graphics

window.
n Drag the gnomon to the corner of the vise

and click to position it.
n Click on the X-axis arc segment to rotate the X- axis

as shown.
177
n Rotate the axis and

select the endpoint of
the edge as shown.
n A 90 degrees angle
should appear on the
screen to align the X-
axis with the edge.
n Pick the red arc segment of the Z-axis and rotate it as

shown.
Note: You can type 90 and press Enter if you have

difficulties to reach the value while rotating.
n In the New Plane panel, Name field, enter "Plane B90".


n Click in the G column of the new plane to set the
graphic view to the same plane.
178
n Zoom in as much as you want the viewsheet to

be saved as.
3.8 Create a New Viewsheet "B90"
n Click on the + sign next to create a new Viewsheet.
n Name it "B90" and press Enter to finish.
n To save the view, right mouse click on

it again and select Save Viewsheet
Bookmark.
179
3.9 Create the Viewsheet for B180
n Use the same steps to create the B180 viewsheet as

shown before:
n Make only Part B180 and Vise B180 visible.
n Create a New Plane "B180". (Use From solid face or
select the gnomon).
n Create a New Viewsheet "B180".
3.10 Create the Viewsheet for B270
n Use the same steps to create the B270 viewsheet as

shown before:
n Make only Part B270 and Vise B270 visible.
n Create a New Plane "B270". (Use From solid face
or select the gnomon).
n Create a New Viewsheet "B270".
Note: To check the Viewsheets click

on each of them and then check the
Planes Manager to see if the
Cplane and Tplane are set as
needed.
n Click on the Viewsheet B90.

n Open the Planes Manager.
n The Plane B90 should be already
selected and the view should look as
shown.
Note: The purpose of this lesson is not to demonstrate how to machine the part, you can use Mastercam
2023 and Mill 2D Professional Courseware to review the toolpaths.
180
Levels & Viewsheets Step 4: Save Your Mastercam File
STEP 4: SAVE YOUR MASTERCAM FILE

n Your file will be saved with the viewsheets and the levels data stored inside the file.
SUMMARY:
In this lesson you learned how to better organize your geometry by moving parts of the geometry on different
levels. You also reviewed and learned how to define planes for a tombstone application when different Work
offsets are required for each plane. You learned how to save the planes and other options on different
viewsheets.
After completing this lesson and the practice exercise that follows you should be able to:
n Move geometry on different levels.

n Create new planes.
n Create new viewsheet that contains the plane information.
181
Levels & Viewsheets Exercise
EXERCISE
Open Levels and Viewsheets_Exercise.mcam
Job Description:
Organize the geometry on different levels and set viewsheets for each face of the tombstone for the
LEVELS AND VIEWSHEETS_EXERCISE.MCAM as following:
n Use Change level command and move the tombstone on Level 1500.
n Name Level 1500 "Tombstone".
n Use Change level command and move the parts on Level 2501, 2502, 2503 and 2504.
n Name the part levels "Part B0", "Part B90", "Part B180" and "Part B270".
n Use Change level command and move the vises on Level 5010, 5020, 5030 and 5040.
n Name the part levels "Vise B0", "Vise B90", "Vise B180" and "Vise B270".
n Use Change level command and move the stock wireframe on Level 10.
n Name Level 10 "Stock Wireframe".
182
Levels & Viewsheets Exercise
n Make all levels visible and rename the viewsheet "Iso Tombstone" and save it as a Bookmark.
n Make only Level 2501 (Part B0) and 5010 (Vise B0) visible.
n Create a new plane by selecting the top face of the part and the origin at the center of the large hole.
n Name the Plane "B0-G54".
n Set the G, C and T planes to the new plane.
n Create a new Viewsheet "B0".
n Save Viewsheet Bookmark B0.
n Repeat the steps for the other 4 faces.

n Name the rest of the planes "B90-G55", "B180-G56", "B270-G57".
n Name the rest of the viewsheets "B90", "B180", "B270".
n Make all Levels visible. and save the file.
183
Advanced Drilling Toolpath
184
Advanced Drilling Toolpath Introduction
INTRODUCTION
This tutorial demonstrates the Advanced Drilling toolpath allows you to create customized drill operations for
specialized applications. Advanced Drill lets you define each hole into multiple segments and customize the
machining action for each segment. This differs from conventional peck drilling because of the amount of
control you have over each segment.
For holes that includes a large air region between two material zones, Advanced Drill lets you divide the hole
into three segments to drill through the holes and rapid between them. Other applications include spot
drilling, deep hole drilling, and back spot facing.
For each segment, you can customize any or all of the following conditions:
n Define individual pecks within the segment, including retracts to simulate a chip break cycle.
n Set the feed rate or choose rapid motion.
n Change the spindle speed and direction.
n Turn coolant options on or off.
n Add manual entry comments or code.
n Fine-tune the order in which the commands are output.

n Advanced Drilling toolpath to machine holes with air segments between.
n Advanced Drilling toolpath to machine deep holes using a gun drilling process.
185
Advanced Drilling Toolpath Instructor Demonstration:
Topics:
n Advanced Drilling toolpath to machine holes

with air segments between.
n Advanced Drilling toolpath to machine deep
holes using a gun drilling process.
NOTES:
186
Advanced Drilling Toolpath Step 1: Open The File
n Find and open the part Advanced Drill.mcam
STEP 2: ADVANCED DRILLING FOR DEEP HOLES
Advanced Drilling toolpaths allows you to create customized drill operations for specialized applications. You will
machine the four 1/4" deep holes using a gun drill process. In this case, the deep hole is divided into three
segments. The first segment is machined with a simple drill cycle, follow up by a chip break cycle and the last
segment is machined using a peck drill cycle. For each segment you will define the feed rate, the spindle speed and
the coolant you want to use. You will also learn how to make comments for each segment that will be displayed in
the g-code.
Step Preview:
187
Advanced Drilling Toolpath Step 2: Advanced Drilling For Deep Holes
n From Toolpaths, 2D group, click on the expand gallery

arrow and select Advanced Drill.
Note: To make it easier to select the holes, the holes that needed to be machined have
the inside faces a different color. To change a solid face color you can use Change Face
command, from the Model Prep ribbon.
n In the Quick Mask Toolbar, select the left side of the Quick Mask Color.
n Select the red color as shown.

188
n The four 1/4" holes are automatically

selected as shown.
Note: You can sort the holes if you

want. We will keep the order as it is
for this example.
2.1 Tool
n In the Tool page, using

the Filter options select a
1/4" Drill.
n Right mouse click on the
tool and select Edit tool.
189
n Overall length =
6.0.
n Cutting length =
4.0.
n Shoulder length =
4.25.
n Select the Finish
button.
n Enter a
comment as
shown.
190
2.2 Holder
n In the Holder dialog box select

the B2C3 holder as shown.
n Change the Tool Projection to
4.5.
2.3 Cut Parameters
In the Cut Parameters you will define the three segments needed to machine the deep hole.
First segment set to: Simple drilling cycle with a Depth of -1.0, Feed set 10in/min., RPM 2800 and Coolant
set to Flood.
n Depth = -1.0 (Click

once in the value to
highlight it).
n Feed = 10.0.
n RPM = 2800.0.
n Coolant set to Flood.
n Segment peck Type
set to None.
n In the Comment area
enter "Simple Drill
Segment".
n Press Enter.
Note: The Depth is

always set to Absolute.
191
n In the Segment modification order area click

on the Comment and click on the Up button as
needed to move the Comment at the top.
n The order should look as shown.
Second segment set to: Chip Break drilling cycle with a Depth of -1.5, Feed set 8in/min., RPM 2200 and
Coolant set to Flood.
n Click on the Retract segment to highlight it

and then click on the + button to define the
new segment
n The new segment should look as

shown.
192
n Depth = -1.5.
n Feed = 8.0.
n RPM = 2200.0.
n Segment peck Type
set to Chip Break.
n First peck = 0.1.
n Nominal peck = 0.1.
n Minimum peck =
0.1.
n Retract amount 1.0.
enter "Chip Break
Segment".
n Press Enter.
n Click on the Up button
twice to move the
Comment at the top.
Third segment set to: Peck drilling cycle with a Depth of -4.37, Feed set 6in/min., RPM 1800 and Coolant set
to Flood.
n Click on the Retract segment to highlight it and then click on the + button to define the new segment.
n Depth = -4.37.
n Feed = 6.0.
n RPM = 1800.0.
n Segment peck Type set
to Full Segment (Peck
Drill).
n Enable Tip
compensation and set
Extend depth to -0.05.
n First peck = 0.1.
n Minimum peck = 0.1.
enter "Peck Drill
Segment".
n Press Enter.
twice to move the
Comment at the top.
193
Retract segment set to: Feed 200, RPM 1800, Coolant Off.
n Change the Retract

segment as shown.
n Clearance = 5.0
(Incremental).
(Absolute).
Toolpaths - Advanced Drill.
194
n The toolpath should look

as shown.
Note: The toolpath drilling

cycles.
2.6 Verify the toolpath
n Verify the toolpath.

n Set the Stock in the
Visibility group to
translucent by clicking once
on the square in front of it.
195
Advanced Drilling Toolpath Step 3: Advanced Drill For Holes With Air Region
STEP 3: ADVANCED DRILL FOR HOLES WITH AIR REGION
In this step you will use Advanced Drilling toolpath to machine the holes with air regions. You will be able to
set three segments and use the middle segment to set a rapid move while the tool is passing through the
air region.
Step Preview:
n From Toolpaths, 2D group, click on the expand gallery

arrow and select Advanced Drill.
n In the Quick Mask Toolbar, select the left side of the Quick Mask Color.
n Select the blue color as shown.
Note: You only need to select the top of the holes.
196
n The two 1/4" holes are

automatically selected as shown.
Note: You can sort the holes if you

want. We will keep the order as it is
for this example.
3.1 Tool
n Select the
existing 1/4"
Drill.
n Enter a
comment.
197
3.2 Cut Parameters
In the Cut Parameters you will define the three segments needed to machine the deep hole.
First segment set to: Peck drilling cycle with a Depth of -1.38798, Feed set 10in/min., RPM 2800 and
Coolant set to Flood.
n Click on the Depth value to highlight it.

n Right mouse click on the value and select Z = Z
coordinate of a point as shown.
Note: Using the shortkeys you can return to the graphic

window and select points (in our case) from the
geometry. Based on your selection you can also select
radius or diameter of an arc, length of an entity, distance
between 2 points, etc.
n Select the bottom of the first segment of the hole as

shown.
198
n Depth = -1.38798.
n Feed = 18.0.
n RPM = 2800.0.
n Enable Tip
compensation.
n Extend depth = -0.05.
n Segment peck Type
set to Full Segment
(Peck drilling).
n First peck = 0.1.
n Minimum peck = 0.1.
enter "Peck Drill
Segment".
n Press Enter.
n In the Segment
modification order
area click on the
Comment and click on
the Up button twice to
move the Comment at
the top.
199
Second segment set to: None with a Depth of -2.875, Feed set 250in/min., RPM 2800 and Coolant set to
Off.
n Click on the Retract segment to highlight it and then click on the + button to define the new
segment
n The new segment

n Depth = -2.875.
n Feed = 250.0.
n RPM = 2800.0.
n Coolant set to Off.
n Segment peck
Type set to None.
n In the Comment
area enter "Air
Region Segment".
n Press Enter.
n Click on the Up
button twice to move
the Comment at the
top.
200
Third segment set to: Peck drilling cycle with a Depth of -4.37, Feed set 15in/min., RPM 2500 and Coolant
set to Flood.
n Click on the Retract segment to highlight it and then click on the + button to define the new segment.
n Depth = -4.37.
n Feed = 15.0.
n RPM = 2500.0.
n Enable Tip
compensation.
n Extend depth = -0.05.
n Segment peck Type
set to Full Segment.
enter "Peck Drill
Segment 2".
n Press Enter.
twice to move the
Comment at the top.
Retract segment set to: Feed 250, RPM 2500, Coolant Off.
n Change the
Retract segment
as shown.
201

Toolpaths -Advanced Drill.
Note: The toolpath drilling cycles.
202
Advanced Drilling Toolpath Step 4: Save Your File
3.5 Verify the toolpaths

n Set the Stock in the Visibility group to
translucent by clicking once on the
square in front of it.


n In the Post processing window, make necessary changes as shown.
203
Advanced Drilling Toolpath Step 5: Post Process The Toolpaths To Generate The G-Code
n When prompted, select Save button to accept the NC file name.
n Mastercam Code
Expert window will be
launched and the two
programs will be
generated as shown.
Note: The Chip Break

and the Peck Drill
NC code format is
Longhand. No Peck Drill
(G83) or Chip Break
(G73) is outputted.
n Close Mastercam
Code Expert window.
SUMMARY:
In this lesson you learned how to use the Advanced Drilling toolpath to set a customized cycle to machine
deep holes and holes with air regions.
n Create customized Drilling cycles using the Advanced Drilling toolpath.
204
Dynamic Toolpaths
205
Dynamic Toolpaths Introduction
INTRODUCTION
Mastercam high speed toolpaths are specially designed to produce the smoothest, high efficiency tool
motions, optimized for high speed and hard milling. These high speed toolpaths can help make the
processes we have learned so far more efficient and automated, minimizing programming and cycle times.
Dynamic Mill Toolpath machines pockets, material that other toolpaths left behind, and standing bosses
or cores using the entire flute length. The toolpath supports many powerful entry methods, including a
custom entry method. Entry methods and micro lifts support custom feeds and speeds to optimize and
generate safe tool motion. Considerations for chip thinning and feed rate adjustment are used so that each
cutting edge of a tool takes a consistent chip thickness with each rotation. Utilizing the entire available length
of cut allows tool wear to be spread over a greater area, prolonging tool life and lowering production costs.
The toolpath depends on the Machining strategy that you choose in the Chain Options. If the strategy
chosen is From outside, the toolpath starts at the outmost chain and works its way in taking on the final
shape of the part as it approaches the final pass. You can also machine pockets in which case the strategy
selected is Stay inside which keeps the tool inside of the machining regions.
STEP 1: DYNAMIC MILL RADIAL CHIP THINNING (RCT)

Radial Chip Thinning (RCT) occurs when the stepover is less than 50% of the tool diameter and relates to
chip thickness and feed per tooth. When your step-over is less than 50%, it causes the chip being cut to
“thin.”
Keeping the feed rate and spindle speed the same with a smaller step-over, excess heat builds, overheating
the tool and shortening its life. In order to maintain the optimum chip load of the tool, the feed rate has to
increase.
When you refer to tool catalogs, tool manufacturers will give you recommended cut parameters, but they are
based on a 50% step over. The Feed (or Advance) per Tooth applies here. So, when there’s a condition
where the chips are thinner than the recommended Feed per Tooth, you actually need to increase your feed
rate to get back up to the recommended chip thickness the tool was designed to achieve. And, if you can
maintain that target chip thickness, yet do so at a higher feed rate, you can improve your cutting efficiency.
206
Dynamic Toolpaths Step 2: Dynamic Motion Power Cutting
STEP 2: DYNAMIC MOTION POWER CUTTING

Dynamic Motion Power Cutting encompasses a technique that results in higher material remover while
using a much different approach to depth of cut and speeds and feeds. Aggressive step-over amounts, much
lighter depths of cut but deeper than the traditional toolpaths paired with traditional feed rates and spindle
speeds. Power cutting can only be used with cutting tools (typically solid carbide) engineered for full slotting
applications and requires high horsepower, high torque machines . Under the right circumstances, Power
Cutting gives the greatest material removal rates over even radial chip thinning.
Power cutting still uses Dynamic Motion to ease in and out of material while maintaining a consistent chip
thickness no matter where you are in the part.
ABOUT CLASSIC TOOL MANAGER

The Classic Tool Manager allows you to view and manage tool libraries, the tools in your part file, and tool
definitions.
You will learn:
n The difference between the tools stored in a tool library or in a machine group.
n How to create new tools and store them in a machine group.
n How to copy a tool form a tool library into a machine group.
n How to edit a tool in a machine group.
n How to create a new tool library.
n You will copy tools from a machine group, to the new tool library.

n Using the Classic Tool Manager to create new tools and save them in a new library.
n 2D HST Dynamic Geometry / boundary selection rules.
n Dynamic Milling Radial Chip Thinning versus Dynamic Milling Power Cutting toolpaths.
n Blend Milling.
n Slot Milling.
n Peel Milling.
207
Dynamic Toolpaths 2D High Speed Toolpaths (HST) Information
2D HIGH SPEED TOOLPATHS (HST) INFORMATION

Benefits include:

Dynamic Mill - Stay Inside Strategy machines pockets using one

or more chains to drive the toolpath.
Dynamic Mill - From Outside Strategy machines open pockets or

standing core shapes using the outmost chain as the stock boundary.
The toolpath starts from the outside and works its way towards the
inner boundary.
Dynamic Contour - Efficient milling of material off walls. Supports

both closed or open chains.
2D High Speed Area Mill toolpaths machine pockets using a smooth

clean motion. Helical entries and tangent stepovers create efficient
motion for tools. Cut parameters allow controlling smoothing to avoid
sharp corners or direction changes.
2D HST Peel Mill toolpath generates an efficient climb mill cut

between two selected contours or along a single contour. It uses a
dynamic style motion with accelerated “back” feed moves when the
tool is not engaged in material. For single chains, user defines the
width of cut, otherwise the width is defined by the area between the 2
boundary chains.
208
Dynamic Toolpaths 2D High Speed Part 1 - Instructor Demonstration:
2D HST Blend Mill toolpaths morph smoothly between two open

boundary chains. The toolpath supports the full depth of the cutting
tool, utilizing more of the cutter’s flute length resulting in less cycle time
and wear.
2D HIGH SPEED PART 1 - INSTRUCTOR DEMONSTRATION:

Topics:
n Job Setup
n Blend Mill Toolpath
n Dynamic Mill From
Outside Toolpath
n Slot Mill Toolpath
n Peel Mill Toolpath
n Dynamic Mill From Inside
Toolpath
n Rest Mill Toolpaths
n Contour Toolpath
NOTES:
209
Dynamic Toolpaths Step 3: Prepare And Orient Model For Machining
STEP 3: PREPARE AND ORIENT MODEL FOR MACHINING
In this step you will open a parasolid file and make sure that it is properly orientated in space for
machining.
n Find and open the part HS Dynamic Part1.mcam
n Change to the Isometric view and display the axes

(F9 and Alt+F9) to determine the model
orientation.
n Press F9 to remove the axes display.
STEP 4: USING THE CLASSIC TOOL MANAGER TO CREATE THE TOOLS
In this step you will learn how to create a new tool library that will contain the tools needed to machine this
part. You will learn how to create a new tool by importing it from ISCAR. You will import the STEP files for
a 1/2" Chatterfree Endmill and 3/8" Chatterfree Endmill.
Resources - Download the STEP files from www.EMASTERCAM.COM/TRAININGFILES or click here:
5666928 - ECI-H4M 500-1.0W500CFE3.5 - Basic-inch.stp
5667924 - ECI-H4M 375-750W375CFE3. - Basic-inch.stp
Toolpaths
n From the
Utilities
group,
select
Tool
Manager.
210
Dynamic Toolpaths Step 4: Using The Classic Tool Manager To Create The Tools
4.1 Create a 1/2" SolidMill ChatterFree by importing the STEP file from the ISCAR Catalog
Family Designation: ECI-H4M-CF-E 4 flute Endmill with different helix (35° & 37°) and variable pitch for
chatter dampening. Used for very high material removal rates roughing and finishing operations. Full slot
milling up to 2XD.
n Right mouse
click in the Part
library window
and select
Create tool.
n In the Select
Tool Type page
select the Flat
Endmill as
shown.
n Select the Next
button.
211
n In the Define Tool

Geometry click on
the Import custom
geometry from a file.
n Find and select the
5666928 - ECI-H4M
500-1.0W500CFE3.5
- Basic-inch.stp

shown.
n Change Cutting length to 1.5.

n Shoulder Length = 1.75.
n Select the Next button.
212
n In the Finalize
Properties set the
Feed rate, Plunge
rate, Retract rate
and the Spindle
speed.
n Change the tool
Name, Manufacturer
name and
Manufacturer's tool
code as shown.
n Select the Finish
button.
Note: These recommended feeds and speeds are for a AISI 1018 Steel a mild low carbon steel that
offers a good balance of toughness, strength and ductility. Provided with higher mechanical properties,
AISI 1018 hot rolled steel also includes improved machining characteristics and Brinell hardness.
4.2 Create a 3/8" SolidMill ChatterFree by importing the STEP file from the ISCAR Catalog
n Right mouse click in

the Part library
window and select
Create tool.
n In the Select Tool Type

page select the Flat
Endmill as shown.
213
n In the Define
Tool Geometry
click on the
Import custom
geometry from a
file.
n Find and select
the 5667924 -
ECI-H4M 375-
750W375CFE3.
- Basic-inch.stp
n The geometry should look

as shown.
n Cutting Lenght = 1.125.

n Shoulder Lenght = 1.375.
214
n In the Finalize
Properties set the
Feed rate, Plunge
rate, Retract rate
and the Spindle
speed.
n Change the tool
Name, Manufacturer
name and
Manufacturer's tool
code as shown.
n Select the Finish
button.
4.3 Add the 1/2" Flat Endmill from Mastercam default library to the part library
n In the Library
window, click on the
Tools tab to see all
the tools in the
default library.
n Click on the Type to
order the tools based
on their type.
n Find the 1/2" Flat
Endmill (290).
215
n To move the tool in

the current Part
window, click on
the Up arrow.
4.4 Edit the tool parameters
n Double click on the

1/2 Flat Endmill to
edit it.
n In the Finalize
Properties, change
the Tool number,
Length offset and
Diameter offset.
n Set the feeds and
speed as shown.
n Select the Finish
button.
Note: When you create or work on a tool in the part window, you are working on a copy of the tool
definition that is stored in the machine group. That means if you edit a tool from the part window, you are
only changing the definition in the machine group and not in the tool library. If you create a new tool, you
need to save it or copy it to the tool library window to make it available to other Mastercam files.
216
4.5 Create a new tool library that contains the current part tools
n Click on the Create new

tool library icon.
n Name the library

"Dynamic library".
n Click on the Save
button.
217
n The new
empty
library will
appear as
shown.
n In the Part window, holding down the Ctrl key select all the tools.
n In the Library window click on the Assemblies tab and then click on the Down arrow to move them in
the new library.
n Select the OK button to exit the Tool Manager dialog.

n Click on the Yes button to save the changes to your current library.
218
Dynamic Toolpaths Step 5: Create The Job Setup
STEP 5: CREATE THE JOB SETUP
In this step you will supply Mastercam with information about tool settings and stock size before starting to
create the toolpaths.
n Click on the Toolpaths tab to open Toolpaths Manager.

n Expand the Properties and select the Stock Setup tab.
n Click on the Add from a bounding box button.
Note: Mastercam creates an image of the stock envelope. This can be saved as geometry and re-sized
as needed. See the Mastercam Help for more information.
n Set the Bounding

Box parameters:
n Enable All shown.
n Shape set to
Rectangular.
n Size X = 24.2.
n Size Y = 14.2.
n Size Z = 1.75.
n No geometry
creation.
n Select the OK button
to exit Bounding
Box panel.
Note: This will create the stock we will use as boundaries for some of the HST toolpaths. We expanded
the stock in X and Y-axis. User can also expand the size of the stock dynamically with Push Pull options.
219
Dynamic Toolpaths Step 6: Use Dynamic Mill With RCT
n Click the OK button to accept and close the Machine

Group Setup.
n Click on the Stock Display icon.
n The stock should look as shown.
Note: The axes displays can be turned off/on.
STEP 6: USE DYNAMIC MILL WITH RCT
Dynamic Mill toolpath machines cores or pockets using the entire flute length. The toolpath supports many
powerful entry methods, including a customized entry method. Entry methods and micro lifts support custom feeds
and speeds to optimize and generate safe tool motion. The toolpath depends on the Machining strategy that you
choose in the Chain Options. If the strategy chosen is From outside, the toolpath starts at the outmost chain and
works its way in, taking on the final shape of the part as it approaches the final pass. You can also machine
pockets, in which case the strategy selected is Start inside, which keeps the tool inside the machining regions.
Radial Chip Thinning (RCT) increases the material removal rate, improves efficiency and tool life. Occurs when
the stepover is less than 50%. For the depth cuts to maintain the constant chip load you need to increase feed rate.
Utilizing the entire available length of cut allows tool wear to be spread over a greater area, prolonging tool life and
lowering production costs.
Toolpath Preview:
Toolpaths
n From the 2D group, select the Dynamic Mill icon.
220
2D HST CHAIN REFERENCE INFORMATION

For further information on settings, see the Mastercam Help file.
Automatic regions: Automatically create Machining, Air, or Avoidance regions

based on the selected solid geometry.
You can mix and match Automatic regions with other region selection types;
you do not have to use one or the other.
Machining regions: Allows selecting areas where the tool will remove material.
If no machining region is selected, the area to be machined defaults to the stock
size defined in Stock Setup.
Machining region Strategy:
Stay inside: keeps the toolpath inside the selected machining region.
From outside: Causes the toolpath to start from outside and work toward the
machining region.
Open chain extension to stock: defines the option to cut open chains to the
stock defined in stock setup.
Avoidance regions: defines areas to be avoided during machining.
Air regions: allows defining areas where there is no material so tool can travel
through it when machining.
Containment regions: defines an area where the tool cannot travel outside of.
Entry chain: defines a chain of geometry or point where the tool enters the part to
begin machining.

n For our toolpath, no Machining regions need to be selected.
Note: When no geometry is selected, the area to be machined defaults

to the Stock Size from the Stock Setup that we completed previously.
n In the Avoidance Regions, click on the Select button.
221
n In the Solid Chaining dialog box,

enable Cplane and leave the
Loop button selected.
n Click on the edge of the bottom of
the part to select the outside
profile.
n Select the OK button to exit Solid
Chaining.
Note: There will be no chains under Machining Regions and one under
Avoidance Regions. With this type of toolpath, we do not need to set
Direction since the machining occurs between the two boundaries
selected.
n Enable From outside.
n Click on the Preview chains button to check your

selection.
n Select the OK button to exit the Chain Options dialog
box.
222
Note: The Avoidance region shows as (1).

Changes to any of the chaining areas can be modified
from this dialog box.
6.1 Tool
In the following steps you will use the1/2” Chatterfree Flat Endmill that you created.
n In the Tool list window, click on

the 1/2" Chatterfree Flat
Endmill.
n The feeds and spindle speed
will be automatically updated.
Note: the feeds and speed was

set in the tool definition based
on power mill cut. After you set
the cut parameters you can
update them for RCT dynamic
cut, by enabling RCTF.
n Comment: “Use Dynamic mill

to remove outside material”.
Note: In this toolpath you are first using Dynamic Radial Chip Thinning with a smaller stepover
amount and bigger depth of cuts.
223
6.2 Cut Parameters
n In the Toolpaths Manager click on

the Parameters.
n Cutting method set to Climb.
n Select the Cut Parameters and
change the Stepover to 10%.
n Back feedrate = 300.0.

n Stock to leave on walls = 0.02.
n Stock to leave on floor = 0.0.
n (Set the rest of settings as desired
or leave as default.)
Stepover Distance sets the distance between cutting passes in the X and Y axes.
Stepover Angle sets the distance between cutting passes in the X and Y axes using an angle.
Approach distance adds the specified absolute distance to the beginning of the toolpath’s first cut.
First pass offset offsets out the machining region with a user defined distance for the tool to safely engage
from the outside of the material.
First pass feed reduction allows you to slow the feed for the first pass on machining region material
approached from the outside.
Min toolpath radius reduces sharp corner motion between cut passes.
Micro lift distance enters the distance the tool lifts off the part on the back moves. Microlifts are slight lifts
that help clear chips and minimize excessive tool heating.
Back feedrate controls the speed of the backfeed movement of the tool.
Motion > Gap size, retract controls retracts in the toolpath when making a non-cutting move within an area
where the tool can be kept down or microlifted.
n Reselect the Tool page and enable RCTF.

n The feedrate increases as shown.
6.3 Depth Cuts disabled
In the Dynamic Mill RTC cutting toolpath the recommended depth is up to two times the tool diameter. In
this example, the depth cuts should be disabled.
224
6.4 Break Through
n From the Tree View List, select the Break Through

and enable it.
n Set the Break through amount to 0.05 as shown.
Linking Parameters page allows you to define the Clearance, Retract, Feed plane, Top of stock and
Depth heights.
n Clearance = 2.0
(Absolute).
n Retract = 0.25
(Absolute).
n Feed Plane = 0.1
(Incremental).
(Absolute).
n Depth = -1.75
(Absolute).
Note: The Depth can be

extracted by selecting the
Depth button and selecting
a vertex at the bottom of the
solid model. It has to be set
to Absolute and the value
shown because this
toolpath is also calculated
from the top of the stock
which is the Machining
area. Incremental and 0.0
will not machine the part.
6.6 Entry Motion
Note: These settings will have no impact on outside core machining.
225
6.7 Coolant
n Select Coolant and turn the Flood

on as shown.
6.8 Preview the toolpath
n Click on the Apply icon as shown.
Note: It might take several seconds as the part is big and the
stepover is quite small.
n Click on the Hide dialog icon as shown to hide the toolpath

parameters.

n Press Esc button when done.
High Speed Toolpaths -
Dynamic Mill.
n In the Toolpaths Manager, the toolpath size

should be as shown.
226
6.9 Arc Filter / Tolerance
This page allows you to control toolpath tolerances.

Line / Arc Filtering allows Mastercam to replace very small moves within the defined line/arc filter tolerance with
larger ones wherever possible and significantly reduces the number of NC blocks in the post. Older controls, may
become very sluggish and respond better with arc-filtered code. With that said, newer, high performance
CNC machines can handle unfiltered code without issues and more lines of code is preferred.
Although the Dynamic toolpaths are automatically filtered they can be filtered more.
n In the Toolpaths Manager, click on the Parameters.
n Select the Arc Filter / Tolerance.

n Change the Total tolerance = 0.003 as
this is a roughing toolpath.
n Enable Line/Arc Filtering Settings.
n Set the Line/Arc tolerance to 70%.
n Output 3D arc enabled.
Note: Select Output 3D arc option to have

Mastercam create the helix with arc (G2/G3)
moves. Otherwise, the helix will be rendered
with many small linear moves. Some
machines might not support the helical arcs
and others might work better using small
linear moves.
n Make sure Generate toolpath is enabled to

automatically regenerate the toolpath.
Note: To generate the toolpath it will take a longer time.
n The toolpath size should be 15 times smaller as shown.
227
n Select the Backplot selected operations

button.
n Select the Play button to run

Backplot.

n From the Backplot dialog box,
select the OK button to exit
Backplot.


n When finished verifying, Minimize the
Mastercam Simulator Window to leave it open
or move it on a separate monitor.
228
Dynamic Toolpaths Step 7: Dynamic Mill Power Cutting
STEP 7: DYNAMIC MILL POWER CUTTING
Mill Dynamic Power Cutting occurs when the stepover is bigger than 50% which results in a higher material
removal while using a much different approach to depth of cut and speeds and feeds. Aggressive stepover amounts,
much lighter depths of cuts but deeper than the traditional toolpaths paired with traditional feed rates and spindle
speeds.
Toolpath Preview:
7.1 Copy the toolpath
n From the Toolpaths Manager, right mouse click on the toolpath and select Copy.
n Right mouse click again in the Toolpaths Manager and select Paste.
n Select the Parameters of the second operation as shown.
7.2 Tool
n Disable RCTF and the feeds and

speed are back to the values set in
the tool definition.
Note: In this toolpath you are first

using Dynamic Motion Power
Cutting with a bigger stepover
amount and much lighter depths of cut
but deeper than the traditional
toolpaths, paired with traditional feed
rates and spindle speeds.
229
Dynamic Toolpaths Step 7: Dynamic Mill Power Cutting
7.3 Cut Parameters

Cut Parameters page allows you to set the Dynamic Mill parameters such as Cutting method and
Stepover.
n Stepover = 70 %.
7.4 Depth Cuts
n Enable Depth Cuts, and set the Max

rough step to 0.5.
n Click on the Apply button as shown.

parameters.
230
Dynamic Toolpaths Step 8: Machine The Left Side Step Using Blend Mill

shown.
Dynamic Mill.
STEP 8: MACHINE THE LEFT SIDE STEP USING BLEND MILL
2D High Speed Blend Mill toolpaths morph smoothly between two open chains. You can create the
toolpath along or across the selected chains, generating the best motion for the application. The toolpath
uses dynamic motion with accelerated back feed moves when the tool is not engaged in material. This
machining strategy supports the full depth of the cutting tool, utilizing more of the cutter's flute length and
resulting in less cycle time and tool wear.
Toolpath Preview:
n Before starting the next operation, turn off the toolpath

display.
231
Toolpaths
n From the 2D group, select the Blend Mill icon.
n Click on the Options button.
n Set the Synch mode to None.
Note: Synch mode allows you to set a method to align

the chains.
None synchronizes the chains by dividing them each into
an even number of points.
n Zoom in on the left side step.

n Make sure 3D is enabled.
n In the Chaining dialog box enable only
Edges button.
n Select the edge as shown.
n Select the End chain button.
232
n In the Solid Chaining dialog

box, enable only Outer shared
edge button.
Note: Make sure you select the edge in the

same direction as the first one. Or select the
Reverse buton.
n Select the OK button to exit the Chaining

dialog box.
8.1 Tool
n Select the existing

1/2" Chatterfree Flat
Endmill tool as
shown.
enter "Machine the
step using Blend Mill".
233
8.2 Cut Parameters
n Leave the Cutting method set

to Zigzag.
n Comp direction = Left.
n Max.stepover = 50%.
n Enable Along.
n Set the Distance to 100%.
n Extend Entry = 0.3.
n Extend Exit = 0.3.
n Stock to leave on floors =
0.0.
8.3 Depth Cuts
n Enable Depth Cuts, and set the Max

rough step to 0.5.
8.4 Finish Passes
n Enable Finish pass.

n Number of passes = 1
n Spacing = 0.05.
n Cutting method = Climb.
8.5 Break Through disabled
234

n From the Tree View List, select Linking Parameters and set the values as shown.

n Feed Plane = 0.1
(Incremental).
(Absolute).
n Select the OK button to exit 2D High

Speed Toolpaths - Blend Mill.
235
Dynamic Toolpaths Step 9: Dynamic Mill Using Air Regions
STEP 9: DYNAMIC MILL USING AIR REGIONS
In this step you will machine the first open pocket using Dynamic Mill Power Cutting method with Air
regions.
Air regions allows you to select an area where there is no material. This allows the tool to travel through it
when machining.
You can have multiple open air region chains per machining region chain.
You can select a segment of a closed machining region chain to allow the tool to approach from the
outside of the selected segment.
n Before starting the next operation, turn off the toolpath display.
n From the Toolpaths ribbon, in the 2D group, select the

Dynamic Mill icon.

n Make sure the Machining region strategy is set to From outside.
n In the Chaining dialog box enable

only Face button.
n Select the open pocket face.
236
n In the Air regions, click on the Select button.
n In the Chaining
dialog box, change to
the Outer open
edges button and
select the face as
shown.
Note: Once you click

on the face,
Mastercam
automatically finds the
open edge. Using Air
regions allows the tool
to approach from the
outside of the open
edge.

to exit the Chaining
dialog box.
237
n Make sure From

outside is enabled.
n Click on the Preview
chains button to check
your selection.

exit the Chain Options
dialog box.
9.1 Toolpath type
n The 2D Toolpaths
- Dynamic Mill
dialog box appears
on the screen as
shown.
238
9.2 Tool
n Select the existing 1/2"

Chatterfree Flat Endmill
tool from the library.
n In the Comment area enter
"Machine the first open
pocket".
9.3 Cut Parameters
n Use the same settings as in

the previous toolpath.
n Stepover = 60.

239


Note: In Dynamic Mill, the Depth value is automatically picked from the selected face of the
Machining regions. In this example the Absolute value of the depth of the large machining region area
is -0.75.

n Click on the Hide dialog icon as shown to hide
the toolpath parameters.

n Select the OK button to exit 2D High Speed
Toolpaths - Dynamic Mill.
240
n From the Toolpaths Manager, click on the Select all

operations icon.
n Using Ctrl key unselect the second toolpath.
n From the Toolpaths Manager, select Verify selected

operations icon as shown.

Mastercam Simulator Window.
241
Dynamic Toolpaths Step 10: Machine The Open Pocket Using Automatic Regions
STEP 10: MACHINE THE OPEN POCKET USING AUTOMATIC REGIONS
In this step you will machine the second open pocket using Dynamic Mill toolpath with two air regions.
You will copy the last toolpath and reselect the geometry using Automatic Regions option.
The Automatic Regions selection creates the Machining, Air, or Avoidance Regions based on the
selected solid face. Using this option will require less selections.
Toolpath Preview:
n In the Toolpaths Manager, select only the last toolpath.

Copy.
n Right mouse click again and select Paste.
n Select the Geometry of the last toolpath.
242
n In the Machining regions, click on the Remove selected

machining chains button.
n In the Air regions, click on the Remove selected air chains button.
n In the Automatic regions, click on the Select machining chains

button.

Face button.
243
n Click on the Preview chains

button.
n The preview should look as
shown.
Chain Options.
10.1 Regenerate the toolpath
n In the Toolpaths Manager, click on the Regenerate

all selected operations button.
n From the Toolpaths Manager, click on the Select

all operations icon. (Unselect the second operation
to not waste time and cut in the air).
244
Dynamic Toolpaths Step 11: Machine The Slot Using Slot Mill Toolpath
n From the Toolpaths Manager, select Verify selected

STEP 11: MACHINE THE SLOT USING SLOT MILL TOOLPATH
Slot Mill toolpath allows you to efficiently machine obround slots. The slots must be closed and include two
parallel, straight sides.
Toolpath Preview:
n Before starting the next operation, turn off the

toolpath display by pressing Alt + T.
Toolpaths
n From the 2D group, click on the Expand

Gallery arrow and select the Slot Mill icon.
245

Cavities button.
n Select the top face as shown. Mastercam
automatically finds the cavity inside of the face
and chains it in the CCW direction.
n Select the OK button to exit the Chaining
dialog box.
11.1 Tool
n Select the
existing
1/2" Flat
Endmill
tool from
the library.
n In the
Comment
area enter
"Machine
the through
cut slot".
246
11.2 Cut Parameters
n Compensation type = Wear.

n Compensation direction = Left.
n Entry / exit arc sweep = 180.
n Enable Perpendicular entry to
have the first tool move
perpendicular.
n Stock to leave on floors = 0.0
11.3 Rough/Finish
n Plunge angle = 2.0.

n Enable Output helixes as arcs.
n Stepover = 50%.
n Finishing passes Number = 1.
n Spacing = 0.05
n Enable Keep tool down.
247
11.4 Break Through
n Enable Break through.

n Break through amount = 0.05.

n Feed Plane = 0.1
(Incremental).

n Select the OK button to exit 2D Toolpaths
- Slot Mill.
248
Dynamic Toolpaths Step 12: Dynamic Mill The Open Step
STEP 12: DYNAMIC MILL THE OPEN STEP
Machine using Dynamic Mill toolpath the open step avoiding the cut through slot.
Toolpath Preview:

toolpath display.
Toolpaths
249


Face button.
n Select the face.
n In the Avoidance regions, click on the Select button.
250
n In the Chaining dialog

box enable only Face
button.
n Select the face.
n In the Air regions, click on the Select button.
n In the Chaining dialog box, change

to the Outer open edges button
and select the face as shown.
251
n In the Solid Chaining dialog box,

change to the Loop button and select
the edge as shown.
n Accept the face . The chains should
look as shown.
n Select the OK button to exit the
Chaining dialog box.
n Make sure From outside is enabled.

n Click on the Preview chains button to
check your selection.
n Select the OK button to exit the Chain
Options dialog box.
252
12.1 Tool
n Select the existing 1/2"

Chatterfree Flat
Endmill.
enter "Machine the step
with the slot".
12.2 Cut Parameters
n Use the same settings as in

the previous toolpath.
n Enable When avoiding a
boundary.
Motion > Gap size, retract set to When avoiding a boundary, adds retracts to avoid intersecting
boundaries. The types of boundaries that Mastercam detects and avoids include chained geometry, part
features, and stock.
253
12.3 Corner Pretreatment disabled


n Feed Plane = 0.1
(Incremental).
(Absolute).
n Press Ctrl + T to remove the translucent

mode.
Speed Toolpaths - Dynamic Mill.
254
Dynamic Toolpaths Step 13: Machine The Circular Boss
STEP 13: MACHINE THE CIRCULAR BOSS
Machine the circular boss using Dynamic Mill.
Toolpath Preview:
n Before starting the next operation, turn off the toolpath

display.

Dynamic Mill icon.
255

n In the Chaining dialog box

enable only Face button.
n Select the faces.
n In the Avoidance regions, click on the Select button.
256
n In the Chaining dialog box enable only Face

button.
n Select the face.

button to check your selection.
Chain Options dialog box.
13.1 Tool

1/2" Flat Endmill.
n Set the Feed rate,
Plunge rate and
Spindle speed as
shown.
enter "Machine the
circular boss".
257
13.2 Cut Parameters
n Change the Stepover to 75%.

n The Motion > Gap size, retract
set to Never.


n Feed Plane = 0.1
(Incremental).
258
Dynamic Toolpaths Step 14: Dynamic Mill The Closed Pocket With The Island
n Press Ctrl + T to remove the translucent

mode if needed.
STEP 14: DYNAMIC MILL THE CLOSED POCKET WITH THE ISLAND
In this operation you will machine the closed pocket with an island using Dynamic Mill toolpath with Stay
inside option enabled to keep the tool inside of the pocket. The top of the island is not flush with the top of
the pocket. You will learn how to face the island in the same toolpath.
Toolpath Preview:
Toolpaths
259

n In the Automatic regions, click on the Select button.
n In the Chaining dialog box

enable only Face button.
n Select the pocket bottom face.
the Chaining dialog box.

n Click on the Preview chains button to check your

selection.
n Select the OK button to exit the Chain Options
dialog box.
260
14.1 Tool
n Select the 1/2" Chatterfree

Flat Endmill from the tool
library as shown.
"Machine the pocket with the
island. Face the island to the
proper height."
14.2 Cut Parameters
n Change the Stepover to 40%.

n Change the Min toolpath radius
to 5%.
261
14.3 Depth Cuts
n Enable Depth Cuts.

n Max rough step = 0.75.
n Enable Use island depths.
n Enable Island facing.
n Overlap = 60%.


n Top of Stock = -0.25 (Absolute).
262
14.6 Entry Motion
n Entry method set to Helix only.

n Helix radius = 0.1875. (Any
value less than tool radius).

Note: With the Automatic regions the software did

not pick the island top. To machine the island top you
will have to add the face in the Avoidance regions.
263
14.8 Avoidance regions
n In the Toolpath Type, Avoidance

regions, click on the Select button.
n Select the top face of the island as shown.

n Select the OK button to exit 2D High Speed
Toolpaths - Dynamic Mill.
Note: With the Automatic regions the

software did not pick the island top. To machine
the island top you will have to add the face in the
Avoidance regions.
Note: The part is completely cut except for the

inside corners. We need to use a smaller tool to
remove the corner material.
Due to the custom tool you can see a lot of
"noise" on the part.
264
Dynamic Toolpaths Step 15: Dynamic Rest Mill The Inside Corners
STEP 15: DYNAMIC REST MILL THE INSIDE CORNERS
In this operation we will use a smaller tool to remove only the small amount of stock that is leftover from the
previous Dynamic Mill toolpaths.
Toolpath Preview:
n Before starting the next operation, turn off the toolpath display for the operation you just completed.
Press Alt + T.
n In the Toolpaths Manager, select only the last Dynamic

Mill toolpath as shown.
265
15.1 Copy the last Dynamic Mill toolpath
n Right mouse click on the selected Dynamic Mill toolpath,

holding down the mouse drag the cursor below the last
toolpath as shown.
n Release the mouse wheel and select Copy after as

shown.
n Make sure that the insert arrow is below the last toolpath.
n Select the Parameters in the last Dynamic Mill toolpath

as shown.
266
15.2 Tool
In the following steps you will select the 3/8” Chatterfree Flat Endmill. The 3/16" radius of the Flat Endmill
will fit inside of the 1/2" corner radii of the inside pocket corners.
n Select the 3/8" Chatterfree Flat

Endmill from the library as shown.
“Remachine the pocket with the
island”.
Note: The Feeds and speed were

not selected from the tool definition.
You need to re-initialize them.
n Select the 0.375

Chatterfree Flat Endmill.
n Right mouse click on it and
select Re-initialize feeds
& speeds.
267
n The feeds and speed should be

changed based on the tool
definition as shown.
15.3 Stock
High Speed Dynamic Mill toolpath with Rest material options enabled, targets material left behind by the
previous toolpaths.
n Enable Rest material.

n Enable All previous
operations as shown.
n Enable Ignore small
cusps.
n Distance = 0.005.
The Rest material page allows you to set how Mastercam calculates the remaining stock.
All previous operations calculates the remaining stock from all operations.
Roughing tool calculates the remaining stock from the tool diameter of the previous operation that machined the
area.
Ignore small cusp allows you to set the adjustment distance to reduce the stock model. Mastercam outputs cuts
that engage large amounts of material. With this setting you will avoid machining all the pocket walls. The tool will
machine only the areas that need to be remachined.
268
15.4 Cut Parameters
n In the Motion > Gap size, retract enable

When avoiding a boundary.
15.5 Depth cuts disabled with the Island facing disabled

n The rest of the parameters can be left as they are.
n Select the OK button to exit 2D High Speed Toolpaths - Dynamic Mill.
269
n From the Toolpaths Manager, click on the

Select all operations icon as shown.
n The part after being verified in Mastercam

Simulator should look as shown.
n When finished verifying, minimize Mastercam
Simulator.
Note: The Dynamic Mill toolpath does not have options to finish the walls in the same operation. In the
next steps you will finish the walls removing the extra 0.02 stock left on them. Blend Mill, Slot Mill and
Peel Mill have a finish incorporated in the toolpath that you used to finish the walls.
270
Dynamic Toolpaths Step 16: Finish The Open Pocket Walls Using Contour
STEP 16: FINISH THE OPEN POCKET WALLS USING CONTOUR
In this operation we will use a smaller tool to finish the walls that still have 0.02 stock using the Contour
toolpath.
Press Alt + T.
Step Preview:
n From the
Toolpaths tab,
select the Contour
icon as shown.
n In the Chaining dialog box enable Outer

shared edges button.
n Make sure the correct direction is shown.
Note: Confirm that the arrows are pointing

correctly to do a “Climb Mill” cut.
271
n Select the face as shown, making sure the

correct direction is as shown.
n Rotate the part and select the face as

shown.
n Select the OK button to exit Chaining.
272
16.1 Tool
n Select the 1/2" Flat

Endmill.
n Enable Rapid Retract
and set the feeds and
spindle speed as shown.
n In the Comment area,
enter “Finish the walls” as
shown.
16.2 Cut Parameters
n Set the Compensation type

to Wear as shown.
n The rest of the settings should
match the default values as
shown.
273
16.3 Lead In/Out
n Enable Lead In/Out.

n Length = 100%.
n Arc Radius = 0.0.

16.5 Multi Passes disabled
n From the Tree View List,

select Linking Parameters
and set the values as shown.
274
16.7 Coolant
n From the Tree View List, select Coolant and turn the Flood on.
n Select the OK button to exit 2D Toolpaths - Contour.

shown.
16.9 Repeat the Verify procedure
n From the Toolpaths Manager, click on the Select all operations icon.
n Unselect the second toolpath.
n The part after being verified in

Mastercam Simulator should look
as shown.
275
Dynamic Toolpaths Step 17: Finish The Closed Chain Walls Using Contour
STEP 17: FINISH THE CLOSED CHAIN WALLS USING CONTOUR
In this operation we will use a smaller tool to finish the walls using the Contour toolpath. You will use the
closed curves that you created at the edges of the walls that still have 0.02 stock.
Press Alt + T.
Step Preview:
17.1 Copy the last Contour toolpath
n Make sure that only the Contour toolpath is

selected.
n Right mouse click on the selected Contour
toolpath, holding down the mouse drag the cursor
below the last toolpath as shown.
276
n Release the mouse wheel and select Copy after as

shown.
n Make sure that the insert arrow is below the last

toolpath.
n Click on the Geometry.
n Right mouse click in the Chain Manager and select Rechain all.
n Enable Loop in the Solid

n Select the chains in the
correct directions as shown.
Note: Confirm arrows are

pointing correctly to do a
“Climb Mill” cut. Click on the
Display all selection
arrows button to see the
chaining directions.
277
n Select the bottom of the outside

profile in CCW direction to
ensure Climb Milling.
Chaining.
Chain Manager.
n The direction of the chains should
look as shown.
n Select the Parameters in the last Contour toolpath as

shown.
17.2 Tool
n Select the 0.375 Chatterfree Flat Endmill
17.3 Lead In/Out
n In the Lead In/Out enable Entry

and Exit parameters.
n Length = 55%.
n Radius = 30%.
n Sweep = 90%.
n Make sure that Generate toolpath
is enabled before exit the toolpath.
278
Dynamic Toolpaths Step 18: Save Your File

shown.
n The part
should
look as
shown.

279
Dynamic Toolpaths Step 18: Save Your File
SUMMARY:
In this lesson, you were increasing your knowledge to the newest Mastercam 2D toolpath technologies that
utilize the high speed capabilities and are specially designed to produce the smoothest, most efficient tool
motions. As you should have noticed, the cut styles are more efficient, but are similar to other toolpaths such
as the standard pockets. These high speed toolpaths can help make the processes we have learned so far
more efficient and automated, minimizing programming and cycle times.
After completing this tutorial and the practice exercises that follow you should be able to:
n Use Stock Setup and Bounding box to create a stock to be used in toolpaths and Verify.
n Know how and when to use Dynamic Mill with Radial Chip Thinning technology versus Power Cutting
technology.
n Understand the 2D HST boundary selection rules and be able to select the appropriate boundary for
each toolpath type.
n Effectively set the 2D HST cut parameters.
n Generate Dynamic Milling toolpaths to machine cores or bosses.
n Generate Dynamic Milling toolpaths to machine pockets.
n Change an existing Dynamic Milling toolpaths to a new type.
n Generate Blend Mill toolpath.
n Generate Slot Mill toolpaths
n Generate Rest Mill toolpaths.
280
Dynamic Toolpaths 2D High Speed Part 2 - Instructor Demonstration
2D HIGH SPEED PART 2 - INSTRUCTOR DEMONSTRATION

Topics:
n Job Setup
n Dynamic Mill From Outside Toolpath
n Open chain extension to stock
n Contour Toolpath
NOTES:
281
Dynamic Toolpaths Step 19: Open The File
In this step you will open the file and make sure that it is properly orientated in space for machining.
n Find and open the part HS Dynamic Part2.mcam.

n Change to the Isometric view and display the axes (F9
and Alt+F9) to determine the model orientation.
STEP 20: SET THE STOCK IN THE STOCK SETUP:
n From the Machine Group Properties, in the Stock Setup click on

All Entities button and change the sizes to:
n X = 15.25.
n Y = 13.0.
n Z = 1.0.
STEP 21: MACHINE HALF OF THE OUTSIDE PROFILE
In this step you will learn how to machine a partial profile using the Open chain extension to stock options.
Toolpath Preview:
n From the Toolpaths ribbon, in the 2D group, select the Dynamic

Mill icon.
282
Dynamic Toolpaths Step 21: Machine Half Of The Outside Profile
21.1 Toolpath Selections

n In the Machining Regions, click on the Select button.
Note: It is important to have the stock previously defined in the Stock

Setup.

box enable the Partial
Loop button.
n Click on the edge of the
bottom of the part to
select the outside profile.
n Select an edge to specify the end of the

loop.
n Select the OK button exit Chaining
dialog box.
283
Dynamic Toolpaths Step 21: Machine Half Of The Outside Profile
n Set the Open chain

extension to stock to
Tangent.
chains button to check your
selection.
Note: By extending the open

chain to the stock, the area
to be machined is
automatically defined. The
Tangent option in this case
is not the best as it extends
the area to be machined on
the sides of the part too.
n Set the Open chain extension to stock

to Shortest distance.
n Click on the Preview chains button to
Options dialog box.
21.2 Parameters
n Use Dynamic Mill (Radial Chip

Thinning method).
n Select the 1/2" Flat Endmill.
n Stepover = 10%.
n Min toolpath radius = 5%.
n Break through amount = 0.01.
284
Dynamic Toolpaths Step 22: Machine The Top Of The Outside Profile
STEP 22: MACHINE THE TOP OF THE OUTSIDE PROFILE
n Copy the toolpath.

n Rechain the geometry.
n Use the same settings and
parameters.
STEP 23: MACHINE THE RIGHT SIDE OPEN STEP
n Use Dynamic Mill (Power Cutting

method).
n Automatic Regions:
n Select the face.
n Use the 1/2" Flat Endmill.
n Stepover = 60%.
n Break Through disabled.
285
Dynamic Toolpaths Step 24: Machine The Left Side Open Step
STEP 24: MACHINE THE LEFT SIDE OPEN STEP
n Copy the last toolpath.

n Select the Automatic regions.
n Use Dynamic Mill (Power Cutting method).
n Use the same settings and parameters.
STEP 25: MACHINE THE TOP OPEN STEP
n Copy the last toolpath.

n Select the Automatic regions.
n Use the same settings and parameters.
286
Dynamic Toolpaths Step 26: Machine The Open Step At An Angle
STEP 26: MACHINE THE OPEN STEP AT AN ANGLE

n Machining regions:
n Enable the Loop button and chain the geometry.
n Air regions:
n Enable the Outer open edges button and select the
face.
Note: The same result will be generated if instead of

Machining regions and Air regions you use Automatic
regions.

n Stepover = 60%.
287
Dynamic Toolpaths Step 27: Machine The Pocket With The Island
STEP 27: MACHINE THE POCKET WITH THE ISLAND

n Machining regions:
n Use Loop and chain the pocket geometry.
n Avoidance regions:
n Use Loop and chain the top of the island.
n Air regions:
n Use Open edge and select the face .
Note: You can use Automatic regions for this

toolpath selection, combined with the Avoidance
regions to ensure that the top of the island will be
machined too.

n Stepover = 60%.
n Depth Cuts enabled.
n Enable Island facing.
n Overlap = 30%.
288
Dynamic Toolpaths Step 28: Machine The Walls
STEP 28: MACHINE THE WALLS
n Use Contour toolpath.

n While chaining use Outer shared edges and
Loop selection options.
Note: You can also create edge curves and use

them to chain the geometry.
n Chain all the walls to ensure Climb Milling.

n Compensation type = Wear.
n Lead In/Out set to Tangent Line.
n Length = 60%.
n Radius = 60%.
STEP 29: BACKPLOT AND VERIFY THE TOOLPATHS
289
2D HST Toolpaths
290
2D HST Toolpaths Introduction
INTRODUCTION
Mastercam high speed toolpaths are specially designed to produce the smoothest, most
efficient tool motions, optimized for high speed and hard milling. These high speed toolpaths can help make
the processes we have learned so far more efficient and automated, minimizing programming and cycle
times.
Dynamic Mill Toolpath machines pockets, material that other toolpaths left behind, and standing bosses
or cores using the entire flute length. The toolpath supports many powerful entry methods, including a
custom entry method. Entry methods and micro lifts support custom feeds and speeds to optimize and
generate safe tool motion.
The toolpath depends on the Machining strategy that you choose in the Chain Options. If the strategy
chosen is From outside, the toolpath starts at the outmost chain and works its way in taking on the final
shape of the part as it approaches the final pass. You can also machine pockets in which case the strategy
selected is Stay inside which keeps the tool inside of the machining regions. The main difference between
the Dynamic Mill and Area Mill is that the cutting method of the first one allows you to use the entire flute of
the tool while with Area Mill, small depth of cuts are recommended.

n Using imported solid model.
n 2D HST Geometry / boundary selection rules.
n Dynamic Milling toolpaths.
n Area Milling toolpaths.
n Model Chamfer toolpath.
291
2D HST Toolpaths Instructor Demonstration:
Topics:
n Import a Parasolid with saved Coordinate

system
n Create the stock
n Open the vise and merge and align the
part
n Job Setup
n Dynamic Mill From Outside Toolpath
n Dynamic Mill From Inside Toolpath
n Rest Mill Toolpaths
n Peel Mill Toolpath
n Model Chamfer
NOTES:
292
2D HST Toolpaths Part Drawing
PART DRAWING
293
2D HST Toolpaths 2D High Speed Toolpaths (HST) Information
2D HIGH SPEED TOOLPATHS (HST) INFORMATION

Benefits include:

Dynamic Mill - Stay Inside Strategy machines pockets using one or

more chains to drive the toolpath.
Dynamic Mill - From Outside Strategy machines open pockets or

standing core shapes using the outmost chain as the stock boundary.
The toolpath starts from the outside and works its way towards the
inner boundary.
Dynamic Contour - Efficient milling of material off walls. Supports

both closed or open chains.
2D High Speed Area Mill toolpaths machine pockets using a smooth

clean motion. Helical entries and tangent stepovers create efficient
motion for tools. Cut parameters allow controlled smoothing to avoid
sharp corners or direction changes.
2D HST Peel Mill toolpath generates an efficient climb mill cut

between two selected contours or along a single contour. It uses a
dynamic style motion with accelerated “back” feed moves when the tool
is not engaged in material. For single chains, user defines the width of
cut, otherwise the width is defined by the area between the 2 boundary
chains.
2D HST Blend Mill toolpath morphs smoothly between two open

boundary chains. The toolpath supports the full depth of the cutting tool,
utilizing more of the cutter’s flute length resulting in less cycle time and
wear.
294
2D HST Toolpaths Step 1: Create The Stock Using Bounding Box
STEP 1: CREATE THE STOCK USING BOUNDING BOX
In this step you will use Bounding Box command to create the stock necessary to machine part.
Find and open the part 2DHST.x_t
n Press F9 and Alt + F9 to remove the axes

display.
n Change to the Isometric View and display the

axes (F9 and Alt+F9) to determine the model
orientation.
n From the Status bar, to set the mode to display the solid, select the Outline Shaded icon.
n Make sure that the construction mode is set to 3D as shown.
n Select the Bounding Box icon from the

Wireframe tab.
n Select the entire solid and select End
Selection button.
295
2D HST Toolpaths Step 1: Create The Stock Using Bounding Box
n To ensure that we have an extra 0.125 at the

bottom of the stock, change the Origin location as
shown.
n Change the X to 10.25.
n Y = 9.25.
n Add to the current Z value 0.125.
n The rest of the stock in Z will be added at the top of

the part.
n Change the Origin and set Z to 1.0.
n In the Create Geometry enable Lines

and arcs only.
296
2D HST Toolpaths Step 2: Create A Point At The Top Center Of The Part
STEP 2: CREATE A POINT AT THE TOP CENTER OF THE PART
In this step you will use Temporary points to create a point at the top center of the part.
n From the Wireframe tab select Point

Position.
n Hover the cursor above the midpoint of the
edge until the temporary green point appears.
Note: Make sure that you do not click to select

the point.
n Hover the cursor above the midpoint of the

edge until the temporary green point
appears.
n Select the red point located at the midpoint
between the two green temporary points.
n Select the OK button to exit the command.
297
2D HST Toolpaths Step 3: Save The Part
STEP 3: SAVE THE PART
n From the QAT select the Save As button and save the file to a desired location.
STEP 4: OPEN THE VISE AND MERGE THE PART
In this step you will learn how to merge and align the part in the vise using the wireframe stock you created.
4.1 Open the Vise
n From the QAT select the Open button and find

the Vise.MCAM file.
4.2 Merge/open the part
File
n From the Backstage select

Merge.
n Find the 2DHST.MCAM
298
2D HST Toolpaths Step 4: Open The Vise And Merge The Part
n Alt + F1 to fit the screen.
Note: You will use Dynamic option

to align the part in vise. It is
important to follow the steps in the
correct order as follows.
4.3 Align the part
n From the Merge Pattern panel, select Dynamic

button.
n Place the gnomon at the left bottom

corner of the box as shown. Make sure
the Endpoint is selected.
Note: In the next steps you will use the

axes to align the stock in the vise.
299
n In the Dynamic panel the Method should be set t

Move.
n Type = Single.
4.4 Move the part along Y axis

n Click on the Y axis and drag the cursor until the ruler appears on the screen.
n Move cursor and select the Endpoint on the vise where the stock should be aligned on Y axis.
300
4.5 Move the part along Z axis

n Click on the Z axis and drag the cursor until the ruler appears on the screen.
n Move cursor and select the Endpoint on the vise where the stock should be aligned on Z axis.
301
4.6 Move the part along X axis

n Right mouse click in the graphics window and select Top.
n Click on the X axis and drag the cursor until the ruler appears on the screen.
n Move cursor to -2.0in as shown.
n Right mouse click in the graphics window and select the Right view.
n In the Dynamic panel, select the OK and Create New Operation button to continue in the same command.
302
4.7 Move the movable jaw to fixture the part.
n Select the movable jaw.

n Press Enter to finish the
selection.
n Locate the gnomon at the Endpoint as shown.
n Click on the Y axis and drag the cursor to align the jaw with the left side of the stock as shown.
n Select the OK button to exit Dynamic.

n Select the OK button to exit Merge Pattern command.
303
2D HST Toolpaths Step 5: Move The Origin To The Point
Note: Zoom in at the corner and notice that the part is above the top highest part of the movable jaw.
When you created the stock box, you gave 0.125 extra stock at the bottom. The movable jaw step height
is 0.1. There is an extra 0.025 stock that allows you to completely machine the outside profile. After you
machine all the features in this setup, you will have to flip the part and face it removing the extra 0.125.
n Right mouse click in the graphics window

and select Isometric.
n The part inside the fixture should look as
shown.
STEP 5: MOVE THE ORIGIN TO THE POINT
In this step you will use Move to Origin command to set the part origin at the top center of the finish part.
You will use the point created with the Bounding Box command.
n From Transform ribbon select the

Move to Origin icon.
n Select the point as shown.

Clear Colors icon.
304
2D HST Toolpaths Step 6: Save Your File
5.1 Use Levels Manager to make invisible the vise
n Open Levels Manager and make the Active Level,

Level 1.
n Make invisible the vise levels by removing the Xs in
the Visible column as shown.
Note: Removing the vise from display makes it easier

to select the geometry required to generate the
toolpaths .

shown.
7.1 Change the construction mode to 3D
7.2 Load the Mill Default if needed
n From the Machine tab, select Mill and Default.
n Click on the Toolpaths tab to open Toolpaths Manager.

n Expand the Properties and select the Tool settings icon.
n Change the parameters as needed.
305
2D HST Toolpaths Step 7: Create The Job Setup
n Select the Stock Setup.

n Enable Show wireframe entities.
n Click on Add from bounding box icon.
n Enable All shown.

n Click the OK button to accept and close the
Machine Group Properties.
Note: The axes displays have been turned off.
Note: You will generate several separate operations to machine the part in this lesson. These operations
will include the latest technology from Mastercam. The operations include: Facing, Dynamic Mill - From
Outside, Dynamic Mill to remove inner material, 2D HST Peel Mill and Dynamic Rest Mill.
306
2D HST Toolpaths Step 8: Facing Toolpath
STEP 8: FACING TOOLPATH
A Facingtoolpath quickly removes material from the top of the part to create an even surface and prepare
for subsequent operations.
n In the
Toolpaths tab,
from the 2D
group, select the
Facing icon as
shown.
n The Chaining dialog box appears on the screen.

n To use the defined stock select the OK button.
Note: This is an option for Face operations.
n The 2D Toolpaths - Facing dialog box appears on the screen.
Note: In the following steps you will be setting the parameters to generate the Facing toolpath.
8.1 Toolpath Type
n The Facing icon is already selected. No chains are

selected in the Chain geometry area.
307
8.2 Tool
n Click on the Select

library tool button
and using the Filter
options select a 2.0"
Face Mill as shown.
n Enable Rapid Retract

to force the tool to
retract from the part at
the rapid feed rate set
at the machine.
n In the Comment area,
enter a description of
what the toolpath does
as shown.
8.3 Cut Parameters
n Set the Style to Zigzag.

n Across Overlap = 25%.
n Along Overlap = 110%.
n Approach distance = 0.
n Exit Distance = 0.
n Max stepover = 75%.
n Move between cuts to High
speed loops.
n Set the Stock to leave on
floors to 0.0 .
308

n Feed Plane = 0.1
(Incremental).
(Absolute).

shown.
309
2D HST Toolpaths Step 9: Dynamic Mill To Machine The Outside
STEP 9: DYNAMIC MILL TO MACHINE THE OUTSIDE
Dynamic Mill toolpath machines cores or pockets using the entire flute length. The toolpath supports many
powerful entry methods, including a customized entry method. Entry methods and micro lifts support custom feeds
and speeds to optimize and generate safe tool motion. The toolpath depends on the Machining strategy that you
choose in the Chain Options. If the strategy chosen is From outside, the toolpath starts at the outmost chain and
works its way in, taking on the final shape of the part as it approaches the final pass. You can also machine pockets,
in which case the strategy selected is Start inside, which keeps the tool inside the machining regions.

Mill icon.
2D HST CHAIN REFERENCE INFORMATION

For further information on settings, see the Mastercam Help file.
Automatic regions: Automatically creates Machining, Air, or Avoidance

regions based on the selected solid geometry.
Machining regions: Allows selecting areas where the tool will remove
material. If no machining region is selected, the area to be machined defaults to
the stock size defined in Stock Setup.
Machining region Strategy:
Stay inside: keeps the toolpath inside the selected machining region.
From outside: Causes the toolpath to start from outside and work toward the
machining region.
Open chain extension to stock: defines the option to cut open chains to the
stock defined in stock setup.
Avoidance regions: defines areas to be avoided during machining.
Air regions: allows defining areas where there is no material so tool can travel
through it when machining.
Containment regions: defines an area where the tool cannot travel outside of.
Entry chain: defines a chain of geometry or point where the tool enters the part
to begin machining.
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n For our toolpath, no Machining regions need to be selected.
Note: When no geometry is selected, the area to be machined defaults

to the Stock Size from the Stock Setup that we completed previously.
n In the Avoidance Regions, click on the Select button.
n In the Chaining dialog box leave the

Loop button selected.
n Click on the edge of the bottom of the part
to select the outside profile.
n Select the OK button to accept.
Note: There will be no chains under Machining Regions and one under
Avoidance Regions. With this type of toolpath, we do not need to set
Direction since the machining occurs between the two boundaries
selected.

n Click on the Preview chains button to check your selection.
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n Click again on the Preview chains
button to remove the display.
Options dialog box.
n The 2D Toolpaths - Dynamic Mill

dialog box appears on the screen as
shown.
Note: The Avoidance regions

selected shows as (1).
Changes to any of the chaining areas
can be made from this dialog box.
Note: In the following steps you will be setting the parameters to generate the Dynamic Mill toolpath.
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9.1 Tool
In the following steps you will choose a 3/4” Flat Endmill from the tool library provided by Mastercam. You
will use the Filter option to search through the tool library for a specific tool type which makes it easier and
quicker to find the desired tool. The model drawing indicates that the smallest inside radius on the outer
contour is 2.00 which can be machined with the 3/4" Flat Endmill.

library tool button and
using the Filter options
Endmill.
n Rapid Retract enabled.
n Comment: “Use Dynamic
mill to remove the outside
material”.
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9.2 Cut Parameters
Cut Parameters page allows you to set the Dynamic Mill parameters such as Cutting method and
Stepover.
n Cutting method set to

Climb.
n Stepover = 15%.
n Stock to leave on walls =
0.01.
n Stock to leave on floor =
0.0.
n (Set the rest of settings as
desired or leave as default.)
Stepover sets the distance between cutting passes in the X and Y axes.
Approach distance adds the specified absolute distance to the beginning of the toolpath’s first cut.
First pass offset offsets out the machining region with a user defined distance for the tool to safely engage
from the outside of the material.
First pass feed reduction allows you to slow the feed for the first pass on machining region material
approached from the outside.
Min toolpath radius reduces sharp corner motion between cut passes.
Micro lift distance enters the distance the tool lifts off the part on the back moves. Microlifts are slight lifts
that help clear chips and minimize excessive tool heating.
Back feedrate controls the speed of the backfeed movement of the tool.
Motion > Gap size, retract controls retracts in the toolpath when making a non-cutting move within an area
where the tool can be kept down or microlifted.
9.3 Corner Pretreatment

Corner pretreatment page sets machining parameters for corners in the selected Machining regions before
machining the rest of the part for a Dynamic Mill toolpath. No need for this shape.

In the Dynamic Mill toolpath the recommended depth is two times to three times the tool diameter. In this
example, the depth cuts should be disabled.
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Linking Parameters page allows you to define the Clearance, Retract, Feed plane, Top of stock and
Depth heights.
n Clearance = 2.0
(Absolute).
n Retract = 0.25
(Absolute).
n Feed Plane = 0.1
(Incremental).
(Absolute).
Note: The Depth can be extracted by selecting the Depth button and selecting a vertex at the bottom of
the solid model.
9.7 Entry Motion
Note: These settings will have no impact when machining from outside. You can enable Plunge only.
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9.8 Arc Filter/Tolerance
n In the Arc Filter Tolerance

enable Line/Arc Filtering
Settings.
n Set the Cut tolerance to 30.0%.
n Enable Output 3D arc entry
motion.
9.9 Coolant
n Select Coolant and turn the

Flood on as shown.
316

parameters.


Backplot.
9.12 Enable Fixtures in Simulator Options.
n In the Toolpaths Manager, select the Simulator

Options icon.
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n In the Simulator Options

dialog box, enable Fixtures
and Level 100, 101 and 102.
n From the Toolpaths Manager, click on the

Select all operations icon as shown.


Verify.
n The part should appear as

shown.
n When finished verifying,
Minimize the Mastercam
Simulator window to leave it
open or move it on a separate
monitor.
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2D HST Toolpaths Step 10: Dynamic Mill To Remove The Inside Material
STEP 10: DYNAMIC MILL TO REMOVE THE INSIDE MATERIAL
In this step you will machine the inside area that has one standing island.

Dynamic Mill icon.

n In the Automatic regions, click on the Select button.

box enable only Face
button.
n Select the large face.
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10.1 Convert Automatic Regions
Note: You can convert the Automatic regions selection to see all
the regions that was automatically generated.
n In the Automatic regions, click on the Convert automatic

regions button.
n The result of the

conversion is as
shown: Machining
regions -1 chain;
Avoidance regions -2
chains and Air regions
-2 chains.
chains button to
n Press Esc button
when done.
n Click again on the
Preview chains
button to remove the
display.
to exit the Chain
Options dialog box.
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10.2 Tool
n Select the
existing 3/4" tool
as shown.
n In the Comment
area enter
"Remove the
inside material".
10.3 Cut Parameters
n Use the same settings

as in the previous
toolpath.
n Ensure that the Gap
size is set to % of tool
diameter = 100.
n In the Motion > Gap
size, retract set to
When avoiding a
boundary.
Note: The gap setting

and the retract will
allow the tool to retract
at the avoidance
regions.
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10.4 Corner Pretreatment disabled

10.6 Entry Motion not needed

n Feed Plane = 0.1
(Incremental).
(Absolute).
Note: In Dynamic Mill, the Depth value is set from the value of the chained edges of the Machining
regions. In this example the Absolute value of the depth of the large machining region area is -0.7.

parameters.
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Dynamic Mill.
10.10 Verify the last toolpath
n From the Toolpaths Manager, select

Add to current verification icon as
shown.
n Open Mastercam simulator window.

n When finished verifying, Minimize Mastercam
Simulator window.
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2D HST Toolpaths Step 11: Dynamic Mill The Closed Pocket
STEP 11: DYNAMIC MILL THE CLOSED POCKET
In this operation you will machine the closed pocket using Dynamic Mill toolpath with Stay inside option
enabled to keep the tool inside of the pocket.
n Before starting the next operation, turn off the toolpath display by
pressing Alt + T.
Mill icon.

n In the Chaining dialog box enable

only Face button.
n Select the pocket bottom face.

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11.1 Tool

3/4" tool as shown.
n In the Comment
area enter
"Machine the
closed pocket".
11.2 Cut Parameters
n Use the same settings

as in the previous
toolpath.
n Set the Motion > Gap
size, retract to Never
to keep the tool down.
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Note: In Dynamic Mill, the Depth

value is set from the value of the
chained edges of the Machining
regions. In this example the
Absolute value of the depth of the
large machining region area is -0.7.
11.6 Entry Motion
n Entry method set to Helix only.

n Helix radius = 0.3375. (Any value less
than tool diameter).
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n Click on the Hide dialog icon as shown

to hide the toolpath parameters.

n From the Toolpaths Manager, select Add

to current verification icon as shown.
n Open Mastercam simulator window.

Mastercam Simulator window.
327
2D HST Toolpaths Step 12: Peel Mill To Machine The Inside Center Boss
STEP 12: PEEL MILL TO MACHINE THE INSIDE CENTER BOSS
In this step you will remove the material inside the slot in the center boss.
n In the Toolpaths ribbon, 2D group, select the Expand gallery arrow

and select the Peel Mill icon as shown.
n Click on the Translucency icon to make the solid transparent.
n In the Chaining dialog box,

enable 3D mode and only the
Edges button.
n Select the 2 individual edges as
shown. Make sure that both
chains are in the same direction
as shown, otherwise select the
Reverse button.
n Enable Display all selection
arrows button to see both chain
arrows.
select the OK button to accept
the chain and continue.
Note: For Peel Mill toolpaths to be defined, the two chains must point in the same direction, so they must
be selected near the same endpoints. The chain direction also determines lead in side.
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12.1 Toolpath type
n In the Toolpath Type you should

have the parameters set as
shown.
12.2 Tool

library tool button
and using the
Filter options
Endmill.
n In the Comment
area enter
“Machine the slot
inside of the boss”.
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12.3 Cut Parameters
n Cutting style set to

Dynamic peel.
Climb.
n Tip comp set to Tip.
n Approach distance = 0.25.
n Stepover = 50%.
n Min toolpath radius = 5%.
n Back feederate = 300.
n No Stock to leave.
REFERENCE INFORMATION
Stepover sets the distance between adjacent cuts of the toolpath.

Min toolpath radius defines the radius of the arc that the tool follows along its semi-circular path. This value must
be greater than the stepover amount.
Micro lift distance is the distance the tool lifts off of the part on back moves. Micro lifts are slight lifts that help clear
chips and minimize excessive tool heating.
Back feedrate controls the speed (inches per minute or millimeters per minute) of the backfeed movement of the
tool. This allows 3D arcs between cuts to have a different feed rate than the rest of the toolpath, which can help
reduce cycle time.
Extend Entry/Exit allows you to adjust the initial and final tool engagement with the material.

12.5 Finish Passes
n Enable the Finish Passes as shown.

n Number of passes = 1.
n Spacing = 0.01.
n Cutting method set to Climb.
n Compensation type set to
Computer.
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12.6 Lead In/Out
n Enable Entry.
n Line set to Tangent.
n Length = 100%.
n Radius = 0.0.
n Click on the double arrow
to set the Lead Out too.

n Clearance = 2.0 (Absolute)

n Retract = 0.25 (Absolute)
n Feed plane = 0.1 (Incremental)
n Top of Stock = 0.0 (Absolute)

n Depth = 0.0 (Incremental)
(Depth is extracted from the Z
value of the selected edges.)
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n Total tolerance = 0.001

n Cut tolerance = 30.0%
n Line/Arc Filtering Settings
enabled.
n Create arcs in XY enabled.
n Output 3D arc entry motion
enabled.
Note: This page is used to control toolpath tolerances. Since this toolpath will have several arc
moves, we want to ensure that arcs are created instead of a large number of linear moves. For
more detailed information on these options, see Mastercam Help.
n Select the OK button to exit 2D High Speed Toolpaths - Peel Mill.
332
n Click on the Apply icon as shown.
n Click on the Hide dialog icon as shown to

hide the toolpath parameters.
n Click on the Translucency icon to

remove the transparency.

Speed Toolpaths - Peel Mill.
n Select the last operation.

n The part after running the
simulation should appear as shown.
n When finished verifying, minimize

Mastercam Simulator window.
Note: As we can see from this verify, the part is completely cut except for the inside corners. We need to
use a smaller tool to remove the corner material.
333
2D HST Toolpaths Step 13: Dynamic Rest Mill The Inside Corners
STEP 13: DYNAMIC REST MILL THE INSIDE CORNERS
In this operation we will use a smaller tool to remove only the small amount of stock that is leftover from the
previous Dynamic Mill toolpaths.
n Before starting the next operation, turn off the toolpath display for the Peel Mill operation you just
completed. Press Alt + T.
13.1 Copy the second Dynamic Mill toolpath
n In the Toolpaths Manager, select only the third Dynamic Mill

toolpath as shown.
n Right mouse click on the selected Dynamic Mill toolpath,

holding down the mouse drag the cursor below the last
toolpath as shown.
334
n Release the mouse wheel and select Copy after as shown.
n Make sure that the insert arrow is below the

last toolpath.
335
n Left click on the Geometry of the Operation 4 and

drag it above the Operation 6 Geometry to copy
the geometry of the closed pocket.
n Release the mouse.

n You should have 6 chains in the Operation 6
geometry.
n Select the Parameters in the last Dynamic Mill

toolpath as shown.
336
13.2 Toolpath Type
n In the Toolpath
Type, enable Stay
inside as shown to
ensure the tools
machine only the
inside corners.
n In the Avoidance
regions, click on the
Remove selected
avoidance chains
button to remove the
chain from the
toolpath geometry.
n In the Avoidance regions, enable Cplane

and reselect the island using the Loop
button.
337
13.3 Tool
In the following steps you will select the 3/16” Flat Endmill. The 1/8" radius of the Flat Endmill will fit inside
of the 1/8" corner radii of the inside pocket and 3/8" corner radii from the larger pocket corners.
n Select the 3/16"

Flat Endmill from
the library as shown.
n In the Comment
area enter
“Remachine the
corners”.
13.4 Stock
High Speed Dynamic Mill toolpath with Rest material options enabled, targets material left behind by the
previous toolpaths.
n Enable Rest material.

n Enable Roughing Tool and set the
Diameter to 0.75.
The Rest material page allows you to set how Mastercam calculates the remaining stock.
All previous operations calculates the remaining stock from all operations.
Roughing tool calculates the remaining stock from the tool diameter of the previous operation that machined the
area.
338
13.5 Cut Parameters
n In the Cut Parameters

page, change the Gap
size to 500%.
n Set the Motion > Gap
size, retract to When
avoiding a boundary
OR exceeding a
distance.
13.6 Depth Cuts
n Enable Depth cuts.

n The rest of the parameters can be left as they are.

n Select the OK button to exit 2D High Speed Toolpaths - Dynamic Mill.
339
2D HST Toolpaths Step 14: Finish The Walls Using Contour
n The part after being verified in

Mastercam Simulator should
look as shown.
minimize Mastercam Simulator.
STEP 14: FINISH THE WALLS USING CONTOUR
In this operation we will use a smaller tool to finish the walls using the Contour toolpath to remove the 0.01
stock.
Press Alt + T.
14.1 Select the Contour toolpath

n From the
Toolpaths
tab, select
the
Contour
icon as
shown.
340
n In the Chaining dialog box, enable

Solid selection.
n Make sure that only the Loop button
is enabled.
n Select the outside profile at the
bottom in CW direction as shown.
Chaining.
n Select the two chains in

the directions shown.
Note: Confirm arrows

are pointing correctly to
do a “Climb Mill” cut.
n Enable Outer shared edges

button as shown.
n Select the face as shown and
make sure the chains direction
is CCW as shown.
341
14.2 Tool
n Select the 3/16" Flat

Endmill.
n Enable Rapid
Retract.
n In the Comment
area, enter “Finish the
walls” as shown.
14.3 Cut Parameters
n Set the
Compensation
type to Wear as
shown.
n The rest of the
settings should
match the default
values as shown.
342
14.4 Lead In/Out
n Length = 30%.
n Radius = 30%.
n Sweep = 90.

n From the Tree View List,

select Linking
Parameters and set the
values as shown.
343
14.8 Coolant
n From the Tree View List, select Coolant and turn the Flood on.
n Select the OK button to exit 2D Toolpaths - Contour.

shown.
n The part after being verified

in Mastercam Simulator
Simulator Window to leave
it open or move it on a
separate monitor.
344
2D HST Toolpaths Step 15: Chamfer The Sharp Edges - Model Chamfer
STEP 15: CHAMFER THE SHARP EDGES - MODEL CHAMFER
In this operation you will machine all the sharp edges using Model Chamfer toolpath and a Chamfer mill
tool.
Model Chamfer toolpath allows you to machine safe horizontal chamfers on solid models. This toolpath
allows you to enter a side clearance to further protect your part.
Step Preview:

toolpath display by pressing Alt + T.
Toolpaths
n From the 2D group, click on the Expand

Gallery arrow and select the Model Chamfer
icon.
n In the Toolpath Type page, in the Chain geometry, click on the

Select button.
345
n In the Chaining Enable only Outer

open edges button.
n Select the faces as shown.
Note: Only the outer edges of

the faces were selected. The
chain is automatically selected in
the CW direction to ensure climb
milling.
n In the Solid Chaining

dialog box, enable Open
edges button and select
the faces as shown.
n Rotate the part as
needed.
Note: Once you

click on a face only
the open edges will
be automatically
selected. The
chaining direction
will be CW to
ensure climb
milling.
346

dialog box, enable
Cavities button and
select the face as shown.
Note: Once you

click on a face only
the pocket will be
automatically
selected. The
chaining direction
will be CCW to
ensure climb
milling.
n Move the start point back

one entity.
exit Solid Chaining
dialog box.
15.1 Tool
n Select the
existing 1/2"
Chamfer Mill
as shown.
n In the
Comment area
enter "Chamfer
the sharp
edges."
347
15.2 Cut Parameters
n Compensation type set to

Computer.
n Chamfer width = 0.03.
n Bottom offset = 0.03.
n Make sure that the rest of the
parameters are set as shown.

15.4 Lead In/Out
n Make sure that just the Arc is

enabled.
n Enable Enter /exit at midpoint in
closed contours.
n Radius = 30%.
n Fitting distance = 0.3.
(smaller sized tool will gouge at
the open edge walls).
Fitting distance allows you to enter a distance to trim the Model Chamfer back to avoid gouging.
348
n Clearance = 2.0.
n Retract = 0.25.
n Feed Plane = 0.1.
Toolpaths - Model Chamfer.
Note: The Clearance, Retract

and Feed Plane values are
measured from the selected chains.
15.7 Backplot the last toolpath

shown.
349
2D HST Toolpaths Step 16: Post Process The Toolpaths To Generate The G-Code
n From the Toolpaths Manager,

select Add to current verification
icon.

shown.
Simulator Window.
n Select all operations.
n Select the Post selected operations

icon from the Toolpaths Manager as
shown.
350
n In the Post processing window, make necessary changes

as shown.

n Give the program a name. (2DHST-1.NC is used in this
example.)
n Select Save button to continue.
n Mastercam Code Expert

window will be launched
and the G-code should look
as shown.
n Close Mastercam Code
Expert window.

351
SUMMARY:
In this lesson, you were introduced to the newest Mastercam 2D toolpath technologies that utilize the high
speed capabilities and are specially designed to produce the smoothest, most efficient tool motions. As you
should have noticed, the cut styles are more efficient, but are similar to other toolpaths such as the standard
pockets. These high speed toolpaths can help make the processes we have learned so far more efficient and
automated, minimizing programming and cycle times.
n Use Stock Setup and Bounding box to create a stock to be used in toolpaths and Verify.
n Understand the 2D HST boundary selection rules and be able to select the appropriate boundary for
each toolpath type.
n Effectively set the 2D HST cut parameters.
n Generate Dynamic Milling toolpaths to machine cores or bosses.
n Generate Dynamic Milling toolpaths to machine pockets.
n Change an existing Dynamic Milling toolpath to a new type.
n Generate Peel Mill toolpaths.
n Generate Rest Mill toolpaths.
n Machine the sharp edges using Model Chamfer toolpath.
352
2D HST Toolpaths Exercise #1
EXERCISE #1
Job Description:
Program the part above 2D HST Exercise-1.x_t with the following requirements:
n Setup the machining plane and locate the origin. Create a point at the Origin.
n Create a bounding box for the stock and add 0.125 extra stock on both top and bottom of the part.
n Open the vise and merge the part.
n Use Move to Origin to set the origin at the point.
n Face the top.
n Use 2D HST Dynamic Mill toolpath to remove the material outside the island.
n Use 2D HST Dynamic to remove the inside pocket area.
n Use 2D HST Dynamic to remachine the inside pocket area.
n Use Contour to finish the walls.
n Use Model chamfer to chamfer the sharp edges.
353
Horizontal Machining
354
Horizontal Machining Introduction
INTRODUCTION
A Horizontal Machining Center (HMC) operates with its spindle in a horizontal position instead of a Vertical
position like a VMC. The CNC horizontal milling machine model allows constant loading and unloading of
production work with 2 or more pallets.
Horizontal centers with their horizontal spindles are better suited to larger, boxy workpieces. With a
horizontal spindle, a wider variety of workpiece shapes are easier to mount and chips fall out of the way
better. Like vertical machining centers, horizontal centers have multiple-axis table movements.
Typically, the horizontal center’s table rotates to present all four sides of a workpiece to the tooling.
This tutorial explains how Mastercam uses the planes to machine a part on a Horizontal Machining Center
and determine the table indexing angles.
In a vertical machining center, the X- and Y-axes reside in the Top plane while the Z-axis is perpendicular to
it. In a horizontal machining center, the Z-axis and Y-axis are reversed. The Front plane axis orientation is
the plane that matches the axis orientation on a Horizontal Machining Center. The other planes, when the
part is rotated about the B axis, have to match the front plane axis orientation. See the diagram below:
Horizontal machining center (tombstone) and

axis orientation.
Sample G-Code and the B angles for the Right Side
and Back planes.
Stock models are created in the Toolpaths Manager in the same manner as other types of toolpath
operations. This includes using the toolpath display option to turn the display on and off. To generate a stock
model, you have to first define the stock to use for the operation and then you have to choose the source
operation to process on the defined stock.
Stock models are used to:
n Verify stock
n Define stock for rest machining
n Visualize stock
n Generate stock model compares
355
Horizontal Machining Introduction
In this lesson you will learn how to set and use multiple stocks. The parts to be machined are mounted on
vices located on a tombstone. In the stock setup you can only set one stock. Using stock Model toolpath
allows you to set multiple stocks that can be used when verifying the part.
You will machine the part located on the B0 vice using 2D HS toolpaths and drilling operations. You will
review how to create and set the machining planes. You will machine the rest of the parts using Transform -
Rotate toolpath.
CONCEPTS COVERED IN THIS TUTORIAL:

n Setup multiple stocks using Stock Model Toolpath
n Setup machining planes to program the part on a HMC
n Machine the part using HS Dynamic and Drilling Toolpaths
356
Horizontal Machining Instructor Demonstration
INSTRUCTOR DEMONSTRATION
Topics:
n Setup multiple stocks using Stock Model

n Setup machining planes to program the part on a HMC
n Machine the part using HS Dynamic and Drilling Toolpaths
NOTES:
357
Horizontal Machining Step 1: Setup Multiple Stock Using Stock Model
STEP 1: SETUP MULTIPLE STOCK USING STOCK MODEL
In this step you will learn how to create multiple stocks using Stock Model toolpath.
Stock Models are created in the Toolpaths Manager in the same manner as other types of toolpath operations.
This includes using the toolpath display option to turn the display on and off. The stock model will be used in Verify to
check the toolpaths.
n Find and open the part Horizontal Indexing.mcam.
STEP 2: SET THE STOCK IN THE STOCK MODEL

2.1 Make only Level 4000 visible
n Open Levels Manager and make all levels invisible except Level
4000 as shown.
n The four pieces of stock should look as shown.
358
Horizontal Machining Step 2: Set The Stock In The Stock Model
2.2 Create the Stock Model
n From the Toolpaths ribbon, in the

Stock click on Stock Model ribbon.
n In the Stock
Definition, enter
Stock in the Name
field.
n Enable Model and click
on the Select button.
n Press Ctrl + A to select all four

solids.
n Press Enter to finish the selection.
n Select the OK button to exit the Stock

model parameters.
Note: In this case you only need to

define the stock from existing geometry.
No source operation is required.
359
n In the Levels Manager, make all levels visible except

Level 4000 as shown.
n In the graphics window the geometry

looks as shown.
Note: The stocks are still displayed.

Remember that the Stock model is a
toolpath. To remove the toolpath display
you need to press Alt + T or select the
Toggle display on selected
operations.
n The toolpath will be added in the Toolpaths Manager as

shown.
n Press Alt + T to remove the toolpath display.

360
2.3 Make only Level 2501 and Level 5010 visible
n In the Levels Manager, make only Level 2501

(Part B0) and Level 5010 (Vise B0) visible.
361
Horizontal Machining Step 3: Setup The Machining Plane At B0
STEP 3: SETUP THE MACHINING PLANE AT B0
In this step, you will review how to create a new plane From solid face.
n Rotate the part and zoom in to see the part as shown.
n In the View make sure that Planes are enabled.

362
n Select the OK button to accept the plane as the axes are

orientated as needed.
n The Origin is automatically set to the center of the large hole.
n In the New Plane panel, name the plane "Plane B0".

Note: Hide the Levels and the Planes Managers as needed

to have more space in the graphics window.

Note: For the horizontal machining you have to set the

Cplane and Tplane to the plane in which you are
machining the part. The WCS plane should be always
set to the Top plane. In this example, you will machine
the pocket and the holes that are in the Plane B0.
363
Horizontal Machining Step 4: Rough Out The Part Using High Speed Dynamic Mill
3.2 Follow Rules Settings In the Plane manager
REFERENCE INFORMATION:
Cplane/Tplane follows WCS always aligns the construction plane and tool plane to match the WCS.
Gview follows WCS always aligns the graphics view to match the WCS.
Cplane follows Gview always aligns the construction plane to match the graphics view. If the Tplane and the
Cplane are set to the same plane, the Tplane will also follow the Gview.
Tplane follows Cplane aligns the Tplane with the Cplane when the construction plane has been changed by the
user, or as the result of another follow rule. The Tplane can still be changed independent of Cplane.Cplane = Top
in Iso Gview aligns the construction plane to the Top plane when the graphics view has been set to Isometric.
n In the Planes Manager, click on the Follow rules

icon as shown.
n To ensure that when you select the Isometric view, the Cplane
does not change to Top and remains in the current plane, click on
the Cplane = Top in Isometric Gview to disable it.
STEP 4: ROUGH OUT THE PART USING HIGH SPEED DYNAMIC MILL
In this step you will machine the inside pocket using Dynamic Mill toolpath. For more information on the
toolpath selection options and parameters please check the Dynamic Toolpaths chapter.
Step Preview:
Note: Before starting the toolpath, make sure that the Cplane and Tplane are set to Plane B0. The
WCS should be set to the Top plane. To check this, you can either open the Planes Manager or check
the Status bar.
364
n From the Toolpaths tab, in the 2D group, select the Dynamic

Mill icon as shown.
4.1 Toolpath Selections
n Enable Stay inside.

n In the Machining Regions, click on the Select button.
n In the Chaining dialog box enable the Outer shared

edges button.
n Click on the bottom face of the pocket to select the
pocket.
n Select the OK button to exit Chaining.
365
n Leave the Open chain extension

to stock set to None.
button to check your selection.
Chain Options dialog box.
4.2 Parameters
n Use Dynamic Mill (Radial Chip

Thinning method).
n Stepover = 10%.
n Entry motion = Helix only.
4.3 Simulator Options
n To be able to see the stock from the Stock model toolpath in

Verify, in the Toolpaths Manager, select the Simulator
Options icon as shown.
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n In the Components enable Stock

model and make sure that the "Stock" is
selected as shown.
n Enable Fixture and select all the levels that contain

the tombstone and the vises as shown.
Note: Make sure that you do not select the parts and
stock levels.
n Select the OK button to exit Simulator Options.
4.4 Verify the Toolpath
n The stocks with the fixtures and tombstone

n The part after being verified should look as
shown.
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Horizontal Machining Step 5: Chamfer Drill & Drill The 3/8" Diameter Holes
STEP 5: CHAMFER DRILL & DRILL THE 3/8" DIAMETER HOLES
In the following step you will chamfer and drill the 3/8" diameter holes. For more information on drilling
selection and parameters please check Mastercam Help.
Chamfer Drill toolpath creates chamfered edges around the holes. The advantage of the Chamfer Drill
toolpath is that you can select holes of different diameter size or that lie in different planes and machine
them in a single operation with a single tool.
Toolpath Preview:
5.1 Chamfer Drill
n From the Toolpaths tab, in the 2D group, click on the

Expand Gallery arrow.
n Select the Chamfer Drill icon as shown.
n To select both holes, hold down

the Ctrl key and select the
inside face of one of the holes.
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Horizontal Machining Step 5: Chamfer Drill & Drill The 3/8" Diameter Holes
n All holes with the same diameter

with be automatically selected.
n Select the 3/4 Spot Drill.

n In the Cut Parameters, set the Width to 0.03.
n Tool Axis Control Output format = 3 axis.
n Top of stock = 0.0.
5.2 Drilling
n Select the Drill icon.

n Hold down the Ctrl key and select the inside face
of one of the holes.
n Select a 3/8 Drill.
n Cycle = Peck Drill.
n First /Subsequent /Minimum peck = 0.1.
holes/lines.
n Disable Calculate depth from top of
line/hole.
n Enable Tip Comp and set the Break through to
0.01.
n Make sure that Generate toolpath is enbled,
otherwise click on the Regenerate all dirty
operations in the Toolpaths Manager.
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Horizontal Machining Step 6: Circle Mill The Large Diameter Hole
STEP 6: CIRCLE MILL THE LARGE DIAMETER HOLE
In the following step you will circle mill the 1.5" diameter hole.
Toolpath Preview:
n From the Toolpaths tab, in the 2D group, select the Circle

Mill icon as shown.
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Horizontal Machining Step 6: Circle Mill The Large Diameter Hole
n Select the inside face of the hole and make sure the arrow
points outwards.
n Use the 1/2 Flat Endmill.
n Compensation type = Computer.
n Roughing enabled.
n Stepover = 50%.
n Helical Entry enabled.
n Minimum radius = 10%.
n Maximum radius = 45%.
n XY clearance = 0.01.
n Z clearance = 0.1.
n Enable Finishing.
n Enable Finish.
n Number = 1.
n Spacing = 0.05.
n Enable Calculate incremental values from holes/lines.
n Make sure that Calculate depth from top of line/hole is
disabled. This will allow Mastercam to automatically
determine the depth based on the selected geometry.
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Horizontal Machining Step 7: Contour The 0.0625 Radius Channel
STEP 7: CONTOUR THE 0.0625 RADIUS CHANNEL
In the following step you will use Contour toolpath with a 1/8"Ball Endmill to machine the channel. The
depth is only 0.03125. For more information on Contour toolpath selection and parameters please check
Professional Certification Part 1 - Mill 2D.
Toolpath Preview:
n From the Toolpaths tab, in the 2D group, select the Contour icon.
n In the Selection Method enable Loop.

n Select the edge in the CW direction.
n Use a 1/8 Ball Endmill.

n Compensation type = Computer.
n Stock to leave on walls = -0.00837.
n Lead In/Out disabled.
n Retract = 0.25 (Incremental). Note: The stock to leave is based on this calculation.
n Depth = -0.03125 (Incremental).
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In this step, you will review how to create a new plane to machine the 31/64" diameter hole of the In port
valve.

373
n Select the OK button to accept

the plane as the axes are
orientated as needed.
n The Origin is automatically set to
the center of the hole.

Note: Hide the Levels and the Planes Managers as

needed to have more space in the graphics window.
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Horizontal Machining Step 9: Chamfer Drill & Drill The 31/64" Diameter Hole

Note: The WCS plane should be set to the Top plane.

In this example, you will machine the In port hole that is
in Plane B90.
STEP 9: CHAMFER DRILL & DRILL THE 31/64" DIAMETER HOLE
In the following step you will chamfer drill and drill the 31/64" diameter hole.
Toolpath Preview:
9.1 Spot Drill

n From the Toolpaths tab, in the 2D group, click on the Expand Gallery arrow and select the Chamfer
Drill icon.

n Make sure the arrow points outwards.
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n Use the 3/4 Spot Drill.

n In the Cut Parameters, set the Width to 0.03.
n Tool Axis Control Output format = 3 axis.
n Top of stock = 0.0.
9.2 Drilling
n Select the Drill icon.

n Select the hole again.
n Use a 31/64 Drill.
n Cycle = Peck Drill.
holes/lines.
n Disable Calculate depth from top of line/hole.
n Disable Tip Comp.
Note: To get the flat hole you can copy the last operation and use a 31/64 " Flat Endmill and set the Cycle
to Drill/Counterbore and leaving the rest of the parameters the same.
In this step, you will review how to create a new plane to machine the 31/64" diameter hole of the Out port
valve.
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n In the Select plane dialog box, click on the Next

button until the axis are orientated as shown.
n Select the OK button to accept the plane as the
axes are orientated as needed.
n The Origin is automatically set to the center of the
hole.

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Horizontal Machining Step 11: Spot Drill & Drill The 31/64" Diameter Hole

Note: The WCS plane should be set to the Top plane.

In this example, you will machine the Out port hole that
is in Plane B270.
STEP 11: SPOT DRILL & DRILL THE 31/64" DIAMETER HOLE
In the following step you will spot drill and drill the 31/64" diameter hole.
Toolpath Preview:
11.1 Copy the last two drilling operations
n Holding down the Shift key, select the last two drilling
toolpaths.
Copy.
Paste.
n Make sure that the last two operations are selected as
shown.
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11.2 Set the Planes in the both operations

Manager and select Edit selected
operations.
n Select Edit common parameters as
shown.
n In the Edit Common

Parameters (Mill/Router),
click to enable Planes.
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n Click on the plane

selection button.
n In the Plane Selection dialog box, select Plane

B270.
n Click on the Copy to

construction plane button to set
the Cplane to the same plane.
n Leave the Working coordinate
system set to Top as shown.
Toolpath Coordinate System.
n Select the OK button to exit Edit Common Parameters (Mill/Router).
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11.3 Select the drilling geometry
n In the Toolpaths Manager, click on the Geometry of

the second last spot drill operation.
n In the Features click on the Solid Feature 1

Diameter 0.484 and then press Delete from the
keyboard.

n Select the OK button to exit Toolpath Hole Definition panel.
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11.4 Copy the Geometry point in the last toolpath
n In the Toolpaths Manager, right mouse click on the

Geometry of the second last toolpath and holding
down drag it about the last Geometry.
n Release the right mouse button and select Replace.
11.5 Regenerate the toolpaths
n In the Toolpaths Manager, select the

Regenerate all dirty operations icon.
n The toolpaths should look as shown.
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Horizontal Machining Step 12: Machine The Rest Of The Parts - Transform Rotate
STEP 12: MACHINE THE REST OF THE PARTS - TRANSFORM ROTATE
The Toolpath Transform function creates copies of operations in different orientations. You can use this
function to translate operations into multiple copies arranged in a matrix, or a vertical, horizontal, or
diagonal row. The arrangement of the copies is determined by the method you use to translate the
operations. Transform also supports a Rotate option, which allows you to select a point of rotation, the
angle, and the number of copies to create for the operation.
Toolpath Preview:
n In the Levels Manager, make all the levels

visible.
n Make Level 4000 "Stock" invisible.
n From the
Toolpaths tab, in the
Utilities group, select
Toolpath Transform
icon.
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12.1 Type and Methods
n Type = Rotate.
n Method set to Tool
plane.
n Include origin enabled.
n In the Source operations
select all operations.
n Source = NCI.
n Group NCI output by
Operation type.
n Enable Copy source
operations.
n Make sure that Disable
posting in selected
source operations is
enabled.
Rotate runs the operations at an angle to the original operation. You can choose to rotate the operation in
the same plane as the original operation, or through a different plane.
Tool plane Method transforms the selected operations in a different orientation than the original and
transforms the tool axis with the operation. An operation's tool plane contains both an origin and a plane.
The Tool plane option also activates the Work offset numbering parameters so that you can output a
different work offset with each new tool plane.
Include origin enabled transforms the operation's tool plane and its origin.
Work offset numbering set to Automatic automatically assigns a matching work offset number (if one
exists), or the next available number if no matching work offset number is found.
Operation type groups the transformed operations by the operation type. In our case you selected 2D
Dynamic and drilling operations, all transformations of the 2D Dynamic operation are executed together,
as are all transformations of the drilling operations. This ensures less tool changes.
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12.2 Rotate
n In the Instances area

enable Angle between.
n #=3
n Initial angle = 90.
n Incremental Angle = 90.
n Enable Rotation plane and
make sure is set to Top.
Instances enter the number of copies to create, and define how they are distributed in the specified
angle.
Rotation plane allows you to select the Rotation plane. If you do not select a different plane, Mastercam
creates the copies in the same plane as the original operation. The axis of rotation remains normal to the
tool plane. If you choose a different rotation plane, the axis of rotation is normal to the selected plane.
n Select only the Transform/Rotate

toolpath.
n From the Backplot panel, select
the OK button to exit Backplot.
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Horizontal Machining Step 13: Post Process The Toolpaths
n From the Toolpaths

Manager, select only the
Transform/Rotate
toolpath.
n The part after being
verified in Mastercam
Simulator should look as
shown.
n When finished verifying, Close the Mastercam Simulator Window to leave it open or
move it on a separate monitor.
STEP 13: POST PROCESS THE TOOLPATHS
In this step you will post process the toolpath using MPMaster for Horizontal machining which can be
downloaded from emastercam.
In this post, the Z-axis is retracting to home before each indexing movement.
The maximum indexing on B axis is set to 360 degrees. This will force the B axis to unwind when reaching
360 degrees. In the code you will see B0 instead of B360. To customize your post you should call your
Mastercam reseller.
Note: Because you enabled Copy source operations you only need to select the Transform operation
which contains all the operations done for the first part. Because you enabled Disable posting in
selected source operations all the other operations will not be posted. All the other operations have
the Post off icon.
386
n In the Post processing dialog box, make sure that the

Active post is set to MPMASTER.PST.
n In Mastercam Code Expert window, the toolpaths are performed in the following order:
n First to be machined are the pockets

with the HS 2D Dynamic. The
indexing Angles and the Work
offsets will appear as shown.
Note: In the Mastercam 2023

Code Expert, Home ribbon, select
Find icon and enter B90 to check for
the G55. Repeat the procedure to
check the rest of the work offsets.
387
n The Spot drilling toolpath for the 3/8" holes is

performed after the pockets are all machined.
Note: The tool retracts along Z to home

before each indexing.
The first spot drilling starts at B0 which will be
achieved by rewinding B-axis.
n The Drilling toolpath for the 3/8" holes

is performed after the pockets are all
machined.
388
Horizontal Machining Step 14: Save The Mastercam File
n The Circle Mill toolpath is next performed on all four vises.

n Contour toolpath is performed on all four vises.
n The Spot drilling for the 31/64 diameter hole in the In port.
n The last toolpath performed is the Drilling for the 31/64 diameter hole in the In port.
n The Spot drilling for the 31/64 diameter hole in the Out port.
n The last toolpath performed is the Drilling for the 31/64 diameter hole in the Out port.
Note: The settings in the Transform toolpath ensure the least amount of tool change possible.
Your post processor dictates how the offsets are outputted.
n Close Mastercam Code Expert window.
STEP 14: SAVE THE MASTERCAM FILE
SUMMARY:
In this tutorial, you learned how to program four identical parts on a Horizontal Machining Center using
multiple stocks that are mounted on four vices on a tombstone. After completing this tutorial and the practice
exercises that follow you should be able to:
n Set multiple stocks using Stock model toolpath.

n Use the Simulator options to set what will be shown in Verify such as tombstone, vises and stocks.
n Create new planes necessary to machine one of the parts.
n Create the toolpaths in the proper planes.
n Use Transform Rotate command to machine the other three parts.
n Setup the Transform toolpath to machine the part with the less possible change of tools.
n Verify using Backplot and Solid Verify.
n Create the NC code to be sent to the machine.
389
Horizontal Machining Exercise #1
EXERCISE #1
Job Description:
Program the part above Horizontal Indexing Exercise.mcam with the following requirements:
n Setup multiple stocks using Stock Model Toolpath

n Setup the machining planes to program the part at B0 on a HMC
n Machine the part using Facing, HS Dynamic, Model Chamfer and Drilling Toolpaths
n Use Transform - Rotate Toolpath to machine the rest of the parts.
390
4 Axis - Axis Substitution
391
4 Axis - Axis Substitution Introduction
INTRODUCTION
The exercise deals only with simultaneous toolpaths where the center of the tool mostly points to the center
of axis rotation. Shapes that require simultaneous rotary motion where the tool moves off-center require
Mastercam Multiaxis.
Adding a rotary axis to a CNC machine can greatly increase machining capability and efficiency. Some
parts, such as cam slots, require a 4th axis. Other parts benefit from using a 4th axis to position the part,
reducing the number of setups required.
Rotary devices are mounted parallel to one of the machine linear XYZ axis. They require a controller card
and wiring. If your machine does not have these, they must be added to control the rotary axis.
There are two types of rotary tables: indexers and servo rotary tables.
Indexers are used to position the part, allowing different sides to be machined with a single setup. Not only
does this save setups and time, in some cases it can improve dimensional accuracy compared with moving
and flipping the part using vise setups. Indexers have an internal brake that releases during rotary motion
and locks when the programmed angle is reached. Some indexers require unlock codes before the indexing
move, and a lock code after the move.
Indexing rotary heads are not capable of continuous rotary motion. Using an indexing-only head for
simultaneous machining can damage the internal mechanism. Be sure to check the manufacturer's
documentation included with the rotary axis to determine whether it is capable of simultaneous rotary motion
before using it in this mode.
Servo rotary heads are capable of continuous rotary motion while machining as shown. These are used to
machine shapes that cannot be machined without rotary motion.
392
VMC Setups
Most VMC's mount the rotary table parallel

to the X-axis. The table is usually mounted
on the right side of the table to provide
clearance for the tool changer as shown.
HMC Setups
Some Horizontal Machining Centers

(HMC's) have a rotary table mounted
parallel to the Y-axis.
393
Axes Designation
Axes are designated based on how the rotary axis is mounted on the
machine. The Figure shows the axis designation for a typical rotary table
mounted parallel to the X-axis on a Vertical Machining Center (VMC).
Axis Label Definition

A Rotary axis mounted parallel to X-axis.
B Rotary axis mounted parallel to Y-axis.
C Rotary axis mounted parallel to Z-axis.
Centerline Vs Off-center Machining
Axis substitution toolpaths always locate the centerline of the

tool so that it passes through the centerline of the rotational axis
as shown.
Shapes that require the tool to move off center during rotary motion
cannot be machined using axis substitution toolpaths as shown. Off-
center rotary machining is a more complex motion that requires Multiaxis
toolpaths such as Swarf and 5-axis curve machining.
394
PROGRAMMING TECHNIQUES USED IN THIS EXAMPLE:

The example exercise in this book can be programmed in different ways. In fact, any two programmers
would likely approach each part a different way and probably use different tools or toolpaths.
We chose one method rather than clutter the book with all of the possible options and disrupting the workflow
of the exercise. Utilize the Mastercam Help that is accessible from most dialog boxes whenever you need
more information about options.

n The student will set up the stock based on a solid saved on a different level.
n Create a 2D High Speed Dynamic Mill with Axis Substitution to rough the teeth.
n Finish the teeth using a Rolldie toolpath.
n Create a Drill toolpath to drill the 3/8" holes.
n Setup the plane and machine one slot using 2D High Speed Dynamic Mill toolpath.
n Machine the rest of the slots using Transform - Rotate toolpath.
n Engrave the letters using Contour with Axis Substitution.
395
4 Axis - Axis Substitution 4 Axis -Axis Substitution - Instructor Demonstration:
4 AXIS -AXIS SUBSTITUTION - INSTRUCTOR DEMONSTRATION:

Topics:
n Job Setup
n 2D HS Dynamic Mill with Axis
Substitution
n Rolldie Toolpath (C-Hook)
n Drill Toolpath
n 2D HS Dynamic Mill Toolpath
n Transform Rotate Toolpath
n Engrave the letters using Contour
with Axis Substitution
NOTES:
396
4 Axis - Axis Substitution Step 1: Create The Job Setup
Find and open the part 4 Axis.mcam.
n Change to the Isometric view and display the axes (F9

and Alt+F9) to determine the model orientation.
STEP 2: DYNAMIC MILL - AXIS SUBSTITUTION
In this step you will rough out the teeth using a 2D High Speed Dynamic Mill. To machine the teeth with
a 4 Axis toolpath, you need to use a flat geometry to create the toolpath and then enable in the Rotary
Axis Control Axis Substitution on Y axis.
Toolpath Preview:
2.1 Rename the Toolpath Group
n In the Toolpaths Manager, click on the Toolpath Group-1

and rename it Axis Sub Un-Rolled - Rough Teeth.
397
4 Axis - Axis Substitution Step 2: Dynamic Mill - Axis Substitution
2.2 Make visible only Level 4
n In the Levels Manager, make visible only

Level 4 as shown.
2.3 Dynamic Mill to rough out the teeth
Toolpaths
n From the 2D group, select the Dynamic Mill

icon.
n In the Machining regions click on the Select button.
398
n In the Wireframe Chaining dialog box, make sure that the

Chain button is enabled and select the chain as shown.
n To start the toolpath from the outside, in the Machining region

strategy, make sure that From outside is enabled.
n In the Air regions, click on the Select air chains button as shown.
399
n In the Wireframe Chaining enable the Single button

as shown.
n [Select 2D HST air chain 1]: Select the line as
shown.
n Select the Preview chains button.
n The Preview chains should look as shown.
Note: The Machining region default colors are red for the background and
black for the crosshatch.
The Air region color is dark blue.
400
2.4 Tool
In the following steps you will use the1/4” Flat Endmill that you created.
n Click on Select
library tool and
using the Filter, select
the 1/4" Flat
Endmill.
n The feeds and spindle
speed will be
automatically
updated.
2.5 Cut Parameters
n In the Toolpaths
Manager click on the
Parameters.
n Cutting method set
to Climb.
n Select the Cut
Parameters and
change the Stepover
to 10%.
n Back feedrate =
290.0.
n Stock to leave on
walls = 0.01.
n Stock to leave on
floor = 0.0.
n (Set the rest of
settings as desired or
leave as default.)
401
In the Dynamic Mill RTC cutting toolpath the recommended depth is up to two times the tool diameter. In
this example, the depth cuts should be disabled.


n Feed Plane = 0.125
(Incremental).
(Incremental).
n Depth = -0.025 (Incremental).
2.9 Entry Motion
Note: These settings will have no impact on outside core machining.
402
Note: It might take several seconds as the part is big and the
stepover is quite small.

parameters.

403
n Enable Axis substitution.

n Enable Substitute Y-axis.
n Enable CW and set the Rotary
diameter to 2.0.
n Make sure Generate toolpath is
enabled to automatically
regenerate the toolpath.
Dynamic Mill.

n Select the Backplot selected operations

button.
n Select the Play button to run Backplot.

n From the Backplot dialog box, select the OK button
to exit Backplot.
Note: The Backplot is broken in Mastercam 2023.
404
4 Axis - Axis Substitution Step 3: Create Another Toolpath Group


Mastercam Simulator Window to leave it
open or move it on a separate monitor.
STEP 3: CREATE ANOTHER TOOLPATH GROUP
In this step you will learn how to create another toolpath group under which you are going to create the
finish teeth toolpath.
n In the Toolpaths
Manager, right
mouse click on
the Machine
Group -1.
n Select Groups
and then New
Toolpathgroup.
405
4 Axis - Axis Substitution Step 4: Finish The Teeth - Rolldie Toolpath
n Rename the Toolpath Group, Axis Sub

Rolldie - Finish Teeth.
STEP 4: FINISH THE TEETH - ROLLDIE TOOLPATH
Note: You need to have Mastercam license version to run a C-Hook. You can not use Mastercam Home
Learning Edition to generate this toolpath.
The Rolldie add-in creates toolpaths around a rotary axis. The toolpath can be rounded or squared on
outside sharp corners. When a tapered tool is used, the tool can run up and down the crease formed at
the intersection of two walls at an inside sharp corner.
The chained entities selected to create the toolpath can be flat or already rolled. In this step you will finish
the walls using Rolldie C-hook.
4.1 Make Level 3 Visible
n Select the Levels tab.
n Click in the Visible column of Level 3 as

shown.
406
4.2 Finish the walls using a Rolldie Toolpath with Axis Substitution
Toolpath Preview:
n Hold-down Alt key and enter C.

n Select Rolldie from the C-Hook
directory.
n In the Wireframe Chaining, enable

Wireframe as Mode.
n Enable Chain button and select the chain in
the CCW direction as shown.
n Use the Reverse button if needed to maintain the same CCW direction.
n Select the OK button to exit the Chaining dialog box.
407
4.3 Set the Tool page parameters

n From the Tree View list, select the Tool page.
n Select the 1/4" Flat Endmill

as shown.
n Add a comment in the
Comment area to identify the
toolpath in the Toolpaths
Manager and also in the NC
file.
n The Tool page should look
as shown.
4.4 Set the Cut Parameters
n From the Tree

View list, select
the Cut
Parameters page
and make sure
the parameters
are set as
shown.
408
4.5 Lead In/Out

Lead In/Outs are not supported in Rolldie .
4.6 Set the Linking Parameters
n Select the Linking Parameters page

and make the parameters are set as
shown.
Note: The absolute values are

measured from the 2.0" diameter
cylinder, set up in the Rotary Axis
Control page. The incremental values
are measured from the chained
geometry.
4.7 Set the Rotary Axis Control page
n Select the Rotary Axis Control page and

change the parameters as shown.
409
n Change the Chordal

Deviation to 0.0001.
n Enable Prerolled
about X as you
selected the already
rolled geometry.
exit the toolpath.
n For a better display of the tool

axis orientation you can enable
in the Backplot Options,
Display Vectors and set the
Length to 0.5.
410
4 Axis - Axis Substitution Step 5: Create Another Toolpath Group


Mastercam Simulator Window to leave it
open or move it on a separate monitor.
STEP 5: CREATE ANOTHER TOOLPATH GROUP
drilling toolpath.
n In the Toolpaths Manager,

right mouse click on the
Machine Group -1.
n Select Groups and then
New Toolpathgroup.
411
4 Axis - Axis Substitution Step 6: Drill The Holes
n Rename the Toolpath Group, Rotary Axis

Positioning.
STEP 6: DRILL THE HOLES

In this step you will drill the 3/8" diameter holes using Rotary Axis Positioning.
Toolpath Preview:
6.1 Drill the 3/8" diameter holes

Toolpaths
n From the 2D group, select the Drill icon.
412
n Hold down the Ctrl key and select the inside face of one
of the holes as shown.
Note: The arrows should point outwards. To change the

arrows orientation click on them
n Click on the arrows which direction need to be

changed.
n The arrows should pointing as shown.
Note: You can also enable, in the Toolpath Hole

Definition, Advanced tab, Axis before selecting the
holes.
413
n In the Toolpath Hole Definition panel, set the Depth Filters to

Off.
n Select the OK button to exit the Toolpath Hole Definition dialog
box.
6.2 Sort the order of the holes
n Click on the Selected Order and select Point to

point.
414
n Select the starting hole.
6.3 Set the Tool page parameters

n Click on the Select library tool button and using the Filter options, select the 3/8" Drill.
n Make the changes to the

Tool page as shown.
415
n From the Tree View list, select the Cut

Parameters page and make sure that Cycle
is set to Drill/Counterbore as shown.
n Select the Linking

Parameters page and
make the following
changes as shown.
Note: Calculate incremental values from holes/lines calculates the Retract, Feed plane, and Top
of stock values from the top of the hole or line. When not selected, Mastercam uses the Retract, Feed
plane, and Top of stock values specified in the fields.
416
n From the Tree View list, select the

Tip Comp page and enable Tip
Comp as shown.
6.6 Rotary Axis Control
Rotary axis positioning indexes the part about the selected rotary axis to a tool plane and remains in
that tool plane. The tool then moves in 3 axes (XYZ) through the toolpath.
n Enable Rotary axis positioning.

n Enable Rotate about X axis.
n Select the OK button to exit the Drill toolpath.
417
6.7 Backplot the Toolpath
n Select the Options button

and disable Display
vectors.

n Select the OK button to exit Backplot.
6.8 Create Another Toolpath Group

toolpaths to machine the slots.
n In the Toolpaths Manager,

right mouse click on the
Machine Group -1.
n Select Groups and then
New Toolpathgroup.
418
4 Axis - Axis Substitution Step 7: Define A New Tool Plane To Machine One Slot
n Rename the Toolpath Group, Slots.
STEP 7: DEFINE A NEW TOOL PLANE TO MACHINE ONE SLOT
In this step you will use the Dynamic option from the Plane Manager to define a new plane. This option will
index the top plane of the part at the desired angle.
Toolpath Preview:
7.1 Define the Tool Plane using the Rotate Planes Option
n Select the Planes tab.
419
n Make sure the current WCS, Cplane, and

Tplane are set to Top as shown.
n Click on the Create a new plane icon and select

Dynamic as shown.
n [Pick new origin position]: Select the Center Point as

shown.
420
n To rotate the Z axis, select the arc as shown.
n Rotate the axis in the CCW direction and enter 45.0 to set the angle as
shown.
Note: If rotating to 45 degrees if difficult, start typing the value and the
rotation will be automatically reached.
n Press Enter to accept the value.
n In the graphics window, you should see the axes of the plane oriented
as shown.
421
n Name the plane "Plane 45 degrees" as shown.

n In the Origin set the X to 0.0.
n Enable Cplane.
Note: The WCS should be disabled as shown.
n Select the OK button to exit the New Plane panel.
n In the Status bar, below the graphics window, you should see the C/T planes set to Plane 45 degrees as
shown.
422
n The Planes Manager should look as

shown.
n Select the Toolpaths tab to open the

ToolpathsManager.
423
4 Axis - Axis Substitution Step 8: Machine The Slot In The New Plane
STEP 8: MACHINE THE SLOT IN THE NEW PLANE
In this step you will machine the slot rotated at 45 degrees from the top plane. You will set both Cplane
and Tplane to the new create plane and using 2D High Speed Dynamic Mill toolpath you will machine the
slot.
Toolpath Preview:
8.1 Machine the slot using the Dynamic Mill toolpath in the Top Tool Plane
Toolpaths
n From the 2D group, select the Dynamic Mill

icon as shown.
n In the Chain Options dialog box, Machining regions click on the

Select machining chains button as shown.
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n Select the Solid Chaining

Mode as shown.
n In the Solid Chaining dialog
box, make sure that the Loop
button is the only one
enabled and select the chain
as shown.
the Solid Chaining dialog
box.
n To keep the tool inside of the slot, in the Machining region strategy,
make sure that Stay inside is enabled.
8.2 Preview Chains
n Select the Preview chains button as shown.
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n The Preview chains should look as shown.
8.3 Select the 1/4" Flat Endmill and set the Tool parameters
n From the Tree View list,

select the Tool page.
n Select the 1/4 Flat Endmill
as shown.
n Make all the necessary
changes as shown.
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select Cut Parameters.
n Set the Stock to leave
on walls to 0.0.
n Select Linking Parameters.

n Enable Clearance and set
it to 2.0 and Incremental.
n Set Retract to 0.5 and
Incremental.
n Set Top to 0.25 and
Incremental.
Note: The incremental

values are measured from
the chained geometry.
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8.6 Entry Motion
n In the Entry Motion page, set the Entry

method to Helix only.
n Z clearance = 0.025.
8.7 Preview the Toolpath
n To quickly check how the toolpath will be generated, select the Apply
icon as shown.
n Select the Hide dialog icon.

n Press Esc when done.
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n Select the Rotary Axis Control

page and change the Rotation type
to No rotation as shown.
n Select the OK button to exit the 2D High Speed Toolpaths - Dynamic Mill dialog box.
8.9 Backplot only the last toolpath
n Select the Backplot selected operations icon.
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8.10 Verify all toolpaths
n From the Toolpaths Manager, click on Select

all operations icon to make sure that all
toolpaths are selected as shown.
n Select the Verify selected operations icon as

shown.
n To go back to the Mastercam window, minimize Mastercam Simulator as shown.

n Press Alt + T to remove the toolpath display if needed.
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4 Axis - Axis Substitution Step 9: Transform - Rotate To Machine The Other Slots
STEP 9: TRANSFORM - ROTATE TO MACHINE THE OTHER SLOTS
In this step you will learn how to use Transform Toolpath to machine the rest of the slots. You will use the
Rotate option which allows you to select a plane, a point of rotation, the angle, and the number of copies to
create for the operation.
Toolpath Preview:
9.1 Use the Transform Rotate Toolpath to machine the other three slots
Toolpaths
n From the Utilities

group, select the
Toolpath Transform
icon.
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n In the Type area enable Rotate.

n If a warning appears, select Yes to continue.
n From the Method area, enable Toolplane which creates a new tool plane for the transformed toolpath.
n Make sure that only the fifth operation is selected in the list.
n The Source is set to NCI as we are rotating the toolpath and not the geometry.
n Group NCIoutput by Operation type (In this case, how we group the output does not matter as we only
rotate one operation).
n Enable Copy source operations and ensure Disable posting in selected source operations is enabled as
well, as shown.
Note:Group NCI output by Operation type groups the transformed operations by the operation type. For
example, if you selected a pocket and a contour operation, all transformations of the pocket operation
would be executed together, as would all transformations of the contour operation (pocket, pocket,
contour, contour, etc.). In this case, how we group the output does not matter as we only rotate one
operation.
Copy source operations creates a duplicate operation directly on top of the source operation. This
operation allows you to quickly modify the transform toolpath if needed. The source operation should not
be posted as it is a duplicate operation.
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9.2 Rotate
n Select the Rotate

tab.
n Enable Origin as the
Rotate point.
n Instances # set to 3
as we have 3 slots
left.
n Enable
Anglebetween.
n Start angle = 90.0.
n Rotation angle =
90.0.
n Enable
Rotationplane as
shown.
n Click the Select plane button.
n Select Right side from the list as shown.
n Select the OK button to exit the Plane Selection dialog box.
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n The Rotate page should look as

shown.

Transform Operation Parameters
dialog box.
9.3 Backplot the Toolpath
n Select the Backplot selected operations icon.
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9.4 Verify all toolpaths
n From the Toolpaths Manager, click on Select all

operations icon to make sure that all toolpaths
are selected as shown.
n Press the Ctrl key and select the fifth toolpath to unselect it
Note: The first slot is included in the transform toolpath.
n Select the Verify selected operations icon as

shown.
n To go back to the Mastercam window, minimize

Mastercam Simulator as shown.
n Press Alt + T to remove the toolpath display if
needed.
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4 Axis - Axis Substitution Step 10: Contour The Letters
9.5 Create Another Toolpath Group

engrave toolpath.
n In the Toolpaths Manager, right mouse click on the Machine Group -1.
n Select Groups and then New Toolpathgroup.
n Rename the Toolpath Group, Axis Sub Pre-Rolled -

Engrave.
STEP 10: CONTOUR THE LETTERS
In this step you will engrave the pre -rolled letters using the Contour toolpath wit Axis Substitution.
Toolpaths
n From the 2D
group, select
the Contour
icon as
shown.
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n Change the Graphic View

to Top.
n Change the Cplane and
Tplane to Top.
n In the Wireframe Chaining
enable Window.
n Make a window around the
letters.
n Sketch approximate start point by

selecting the Endpoint of the letter
M as shown.
The letters will be selected as shown.
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n Select the 1/16" Ball

Endmill as shown.
n The Tool page should

look as shown.

select the Cut Parameters
page.
n Set the Compensation
type to Off.
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10.2 Lead In/Out disabled
n Select the Linking Parameters page

and make the parameters are set as
shown.
n Select the Rotary Axis Control page

and change the parameters as shown.
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n From the Toolpaths Manager, select

Add to current verification icon as
shown.

shown.
Simulator Window to
leave it open or move it on a
separate monitor.
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4 Axis - Axis Substitution Step 11: Post The File To Generate The NC Code
STEP 11: POST THE FILE TO GENERATE THE NC CODE
n Select the Select all operations icon as

shown.
n Select the Post selected operations icon from

Toolpaths Manager as shown.
n Save the NC file.
n Select the "X" box at the upper right corner to exit the Editor.
STEP 12: SAVE THE UPDATED MCAM FILE
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Surface Machining
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Surface Machining Introduction
INTRODUCTION
This lesson introduces the 3D Milling Toolpaths.Mastercam surface rough and surface finish toolpaths
drive the tool over surface or solid geometry or a CAD file. Surface rough and finish toolpaths are available
to Mastercam Mill and Router users, as well as to Lathe users with Mill-Turn capabilities.
Surface Roughing Toolpaths
Surface roughing toolpaths use larger tools, multiple stepovers, and multiple step downs to quickly
remove larger volumes of stock and leave an even amount of stock for finishing. The roughing toolpaths you
choose for the part depend on the shape of the part, shape of the stock, and machining situation.
Surface Finishing
Surface finishing toolpaths finish a part down to the drive geometry (or to the stock to leave amount if one is
specified). Mastercam provides several finishing strategies.
The surface toolpaths in your installation of Mastercam depend on which product level you are running, and
the capabilities of the current machine and control definitions. With Mastercam Mill product you can
machine a single surface or a single solid face using Legacy surface toolpaths.
MULTIPLE SURFACE MACHINING

Mastercam Mill has a limited functionality to machine multi surface/solid faces.
To rough out multiple surfaces/faces you can only use:
n Surface Rough Pocket toolpath.

n 3D High Speed Dynamic OptiRough toolpath.
To finish a part with multiple surfaces/faces you can only use:
n Surface Finish Parallel toolpath.
SINGLE SURFACE MACHINING

To rough out one surface/solid face at a time you can use the following Legacy surface toolpaths.
n Surface Rough Parallel

n Surface Rough Radial
n Surface Rough Project
n Surface Rough Flowline
To finish one surface or one face of a solid you can use the following Legacy surface toolpaths:
n Surface Finish Parallel

n Surface Finish Radial
n Surface Finish Project
n Surface Finish Flowline
n Surface Finish Contour
n Surface Finish Shallow
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Surface Machining Introduction
n Surface Finish Scallop

n Surface Finish Blend
n Surface Finish Pencil
OVERVIEW
In this lesson you will see how you can modify your model to generate single surfaces.
First you will learn how to transform a chain of entities into a spline using Spline From Curves command.
You will learn how to create one Revolve surface using a spline and the axis of rotation. You will also learn
how to create a Loft surface using two splines. Sweep surface can also be used to generate a fillet shape
surface.
You will rough out the parts using Surface Rough Pocket and learn how to create a Silhouette
boundary.
You will finish the parts using Surface Finish Scallop, Parallel and Flowline.

n Know common 3D machining definitions.
n Understand the importance of surface data integrity.
n Know how to prepare a surface model for machining, including the use of tool containment boundaries.
n Know how to generate one surface, when possible using splines as wireframe.
n Be able to successfully select and use all Mastercam Legacy Surface Roughing and Finishing functions.
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Surface Machining Mastercam® Surface Toolpath Work Flow:
MASTERCAM® SURFACE TOOLPATH WORK FLOW:

The process to generate a surface toolpath is simple and straightforward once you have programmed a few
parts. Following is an outline of the process we will follow to create programs:
GEOMETRY
With Mastercam Mill product you can machine surfaces or solid faces. STL files are not supported in this
product.
1. Create new geometry or Open an existing

Mastercam file. You can also import a CAD
file. Select the Machine if it is different than
Default
2. Create boundaries if needed to limit the toolpath inside of

them. You can use Curve One Edge, Curve All Edges or
Silhouette boundary command.
SETUP THE STOCK
n Use Stock Setup to establish and set the stock.
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SURFACE ROUGHING TOOLPATH PROCESS
For multiple surfaces or solid faces, you can only use Surface Rough Pocket and 3D High Speed Dynamic
Optirough. To rough out a single surface or a face of a solid you can use Surface Parallel, Surface Radial,
Surface Project, Surface Flowline or Surface Contour.
1. Select a Surface Rough toolpath.

Toolpaths Manager.
n Select Mill toolpaths.
n Surface rough.
n Click on the toolpath you want to
use.
3. Select the solid faces or surfaces (Drive surfaces) to be

machined.
n Usually all surfaces.
n Press Enter or select End Selection button to finish the
selection.
4. Set the parameters in the Toolpath/surface selection dialog box.

n You can unselect the drive surfaces and reselect them if needed.
Drive surfaces are surfaces that are machined in the toolpath.
n You can select the check surfaces if needed.
Check surfaces are surfaces that have to be avoided while machining the part.
Not all of the toolpaths supports them.
n You can select a Containment if needed.
Containment allows you to select a boundary inside of which the tool can
machine the part. Toolpath can be compensated to the inside, centerline, or
outside of the containment boundary.
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4. Toolpath parameters
n Select the tool.
n Setup the Feed rate, Plunge rate
and Spindle speed.
n Add a comment if you want.
5. Surface parameters
n Setup the Clearance, Retract and
Feed plane.
n Stock to leave on drive surfaces
(machining surfaces).
n Stock to leave on check surfaces
(surfaces to be avoided).
n Set how to manage the Tool
containment boundary if used.
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6. Rough parameters
n Set the toolpath Total tolerance.
n Set the Maximum stepdown and
the Cut depths.
n Set the Gap and Advanced
settings.
n Set the Entry options.
7. "Toolpath name" parameters

This page is specific to the toolpath that
you are using to rough the part.
448
8. Backplot the toolpath.
9. Verify the toolpath.
Note: The surface Finish Process is quite similar.
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Surface Machining Toolpath Descriptions
TOOLPATH DESCRIPTIONS
Surface Rough Toolpath Backplot Result
Rough Pocket toolpaths machine pockets and bosses from

selected surfaces or solids. They require a containment
boundary. This is the only roughing toolpath with which you
can machine multiple surfaces.
Rough Parallel toolpaths are used to rough a single boss or

cavity. The resulting toolpaths, when viewed from the top of
the part, form parallel paths.
Rough Project toolpaths create toolpaths by projecting

curves, points, or other toolpaths.
Rough Flowline toolpaths follow the U or V lines of a

surface and maintain a constant scallop on the surface.
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3D High Speed OptiRough Backplot Result

3D High Speed Dynamic OptiRough
toolpaths are designed to machine standing
bosses and cores, cavities and pockets, or
material that other toolpaths left behind. They
minimize the need for helical ramp moves or full-
width cutting.
toolpaths supports cutters capable of machining
very large depths of cut. A single
OptiRoughtoolpath can cut material in two
directions, on step downs (-Z) and step ups (+Z).
As step downs are calculated, the dynamic
roughing motion clears the material in the -Z
direction, avoiding any islands. If you activate
step up cuts in the toolpath Cut Parameters,
Mastercam calculates additional slices in the +Z
direction to remove any material left behind
between the step downs; for example, islands or
large scallops on angled walls.
Surface Finish Toolpath Backplot Result
Finish Parallel toolpaths are used to finish a single

boss or cavity. The resulting toolpaths, when viewed
from the top of the part, form parallel paths. More
suitable for fairly flat surfaces. Allows you to
machine multiple surfaces.
Finish Contour machining works by driving the

cutter around the part at constant Z levels. This path
does not include multiple XY passes. Consider using
Contour for parts with more steep surfaces.
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Finish Project toolpaths create toolpaths by

projecting curves, points, or other toolpaths. No
depth of cut in the finish toolpath.
Finish Flowline toolpaths follow the U or V

contours of a surface and maintain a constant
scallop on the surface.
Finish Scallop toolpaths create consistent scallop

heights over an entire set of surfaces. The toolpath
consistently touches the surfaces and minimizes
retract motion. It is recommended to use a
boundary.
Finish Shallow controls how cuts are handled on

shallow surfaces. Cuts can be added or removed
from these areas. Which surfaces are considered
shallow is controlled by a limiting angle setting.
Finish Blend toolpaths use a set of curves to direct

the toolpath flow. Toolpaths are blended between
these curves and then projected onto the surfaces.
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Surface Machining Instructor Demonstration
Finish Radial toolpaths typically cut outward from a

central point, like the spokes of a wheel.
INSTRUCTOR DEMONSTRATION
Topics:
n Spline From Curves

n Silhouette Boundary
n Revolve Surface
n Loft Surface
n Sweep Surface
n Locate Geometry and Job Setup
n Surface Rough Pocket Toolpath
n Surface Finish Scallop Toolpath
n Surface Finish Parallel Toolpath
n Surface Finish Flowline Toolpath
n Surface Finish Leftover Toolpath
NOTES:
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Surface Machining Geometry Creation Tips
GEOMETRY CREATION TIPS

In the Mastercam Mill product you have just two toolpaths that you can use on multiple surfaces or solid
faces : Surface Rough Pocket and Surface Finish Parallel. It is important to know how you can modify
the model in an acceptable accuracy, and change it to have only one surface.
If your model can be done with a Revolve Surface, knowing how to change the surface profile from a chain
of lines and arcs to a single spline can be useful. To change a chain of lines and arcs into a spline you can use
Spline From Curves command.
Loft/Ruled Surfaces can be also be transformed into one surface by changing the original chains of entities
into one single spline.
Fillet surfaces can also be modified using Sweep Surface command.
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Surface Machining Part 1 - Single Surface Machining
PART 1 - SINGLE SURFACE MACHINING

n Find and open the part Single Surface_Machining.mcam.
STEP 1: PLANE SETTINGS
n Open Planes Manager and select the

arrow next to the Follow rules icon and
make sure Cplane = Top in Isometric
Gview is enabled as shown. Otherwise,
select it.
STEP 2: SPLINE FROM CURVES
Spline From Curves command allows you to create a spline based on the geometry of existing curves.
Step Preview:
n From the Wireframe tab, from

Splines group, select the Spline
From Curves command.
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Surface Machining Step 3: Revolved Surface
n Once you select the command, the Chaining dialog box

appears on the screen.
n Select the Partial button and you can select the chain of
entities as shown.
n In the Spline Curves panel, set the Tolerance.

n Enable Delete curves.
Note: In the Spline Curves panel, you can set the Tolerance and
choose if you want to keep or delete the original curves. You can
also move them to a different level or set them to the Blank level.
STEP 3: REVOLVED SURFACE
The Revolved Surface is a surface generated by rotating a contour around an axis or a line.
Applications: on parts that require arc or circular cross sections.
Step Preview:
n From the Surfaces tab, from Create

group, select the Revolve command.
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Surface Machining Step 3: Revolved Surface
n Enable Single in the

chaining and select the
spline.
exit the Chaining dialog
box.
n Select the axis of rotation.
n In the Surface Revolve, panel

leave the Start Angle set to 0
and the End Angle to 360.
n In the Isometric view the
surface should look as shown.
n Select the OK icon.
457
Surface Machining Step 4: Move The Wireframe On Level 100
STEP 4: MOVE THE WIREFRAME ON LEVEL 100
In this step you will move the wireframe on Level 100 and make it invisible.
n Select the line and the spline.

n Right mouse click in the graphics
window and select Change Level
icon.

enabled.
n Disable Use Active Level.
n Set the Number to 100.
n Enable Force visibility and Off.
STEP 5: PREPARE THE PART FOR MACHINING
In this step you will use Bounding box command to determine the stock size and to create points at the
middle of the faces. Use Move to Origin and set the Origin at the top face center. Delete the points.
Step Preview:
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Surface Machining Step 5: Prepare The Part For Machining
5.1 Create the Bounding box
n In the
Wireframe ribbon,
select the Bounding
Box icon.
n Make sure you are in

the Top Cplane.
n Select the surface.
n Press Enter to finish
the selection.
n In the Bounding Box
panel, make sure that
the Shape is set to
Rectangular.
n Set the Origin point at
the middle top face as
shown.
n Change the Size:
n X = 5.5.
n Y = 5.5.
n Z = 2.0.
n Enable Lines and
arcs.
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Surface Machining Step 5: Prepare The Part For Machining
5.2 Move to Origin

In this step you will set the part Origin at the top center point using Move to Origin command.
n From the Transform

ribbon, select Move to
Origin icon.
n Select the point as
shown.

Clear colors icon.
n Press F9 to check the origin.
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Surface Machining Step 6: Setup The Stock
STEP 6: SETUP THE STOCK
Set the Machine Type to the Default Mill. Set the stock using All Entities button.
n From the Machine ribbon, select the drop down arrow

below Mill and select the Default.
n Expand Properties and select Stock Setup.
n In the Stock Setup click on the Add from a bounding
box button.
n Ctrl + A to select all

entities.
selection.
Machine Group Setup.
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Surface Machining Step 7: Surface Rough Pocket
STEP 7: SURFACE ROUGH POCKET
Surface Rough Pocket 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.
Toolpath Preview:
7.1 Create the Outside Containment Using Curve One Edge Command
Note: Surface Rough Pocket requires a boundary that will restrict the tool movements.
n From the Wireframe ribbon, in the Curves group, select

Curve One Edge icon.
n Select the surface and drag the arrow to the outside edge
as shown.
n Leave the default settings in the Curve On One Edge and
select the OK button.
7.2 Surface Rough Pocket
n From the Toolpaths ribbon, in

the 3D group, select the Pocket
icon.
selection.
462
n In the Toolpath/Surface selection, click on the Select button in the

Containment area.
n Select the boundary.

Wireframe Chaining dialog
box.
Toolpath/Surface selection
and continue.
463
Toolpath Parameters
The Toolpath parameters page 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.

library tool button
and select the 1/2"
Bull Nose Endmill
with 1/16" corner
radius from the
library.
n Set the Feed rate ,
Spindle speed,
Plunge rate and
Retract rate as
needed.
Surface Parameters
The Surface parameters page allows you to establish the heights above which the machine uses rapid
movement (the Clearance & Retract height), from where the tool moves at the feedrate (the Feed plane
height), 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.

n Feed plane = 0.1. (Incremental).
n Stock to leave = 0.02.
n Tool containment set to Center.
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Rough Parameters
The Rough parameters page allows you to establish the Total tolerance in which the toolpath follows the
surfaces, the 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 the cut tolerance.
Maximum stepover sets the maximum distance between adjacent cuts in the surface toolpath.
n Total tolerance = 0.005.

n Maximum stepdown =
0.0625.
n Enable Entry-Helix.
n Click on the Entry - Helix button.

n Setup the Helix parameters as shown.
n Select the OK button to exit Helix
parameters.
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Pocket Parameters
The Pocket parameters page allows you to establish the Cutting method used to rough out the part and the
Stepover percentage or distance to set the distance between rough passes in the XY plane. You can also
set the Finish options to enable finish passes (as a contour cut) around the part shape at each depth of cut.
Stepover distance sets the distance between passes in the active construction plane. It 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.
n Set the Cutting Method to True Spiral.

n Set the Stepover percentage to 55% of
diam = 0.275.
n Leave Finish enabled and Finish
containment boundary.
n Disable Thin wall.
n Select the OK button to exit the toolpath.
Backplot The Toolpath
Verify The Toolpath
n The part should look as shown after being verified.
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Surface Machining Step 8: Finish The Part Using Surface Finish Scallop
STEP 8: FINISH THE PART USING SURFACE FINISH SCALLOP
Surface Finish Scallop toolpaths differ from the other finish toolpaths in that the stepover distance is a 3D
value which is measured along the surface instead of parallel to the tool plane. This ensures a consistent
scallop height across the surface, regardless of the surface direction. If needed, using the Steep / Shallow
options we can restrict the toolpath to machine only shallow areas.
Toolpath Preview:

Toolpaths Manager, select
Mill toolpaths, Surface
finish and then Scallop.
n Select the surface and press Enter to finish the selection.
467

Containment area.

n Select the OK button to exit Chaining dialog
box.
n Select the OK button to exit Toolpath/Surface
selection and continue.
Toolpath Parameters

select the 1/2" Ball
Endmill from the
library.
Spindle speed,
Plunge rate and
Retract rate as
needed.
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Surface Parameters

Finish Scallop Parameters
The Finish scallop parameters page allows you to establish the Total tolerance in which the toolpath follows the
surfaces, the Max stepover , and the Machining direction.
Max. stepover sets the maximum distance between adjacent cuts in the surface toolpath.
Bias angle changes the angle at which Mastercam looks at the geometry as it creates the toolpath. The bias angle
is usually 0 (zero) and 45 degrees.

n Max stepdown = 0.02.
n Bias angle = 0.0.
n Enable Order cuts by minimum
distance.
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Surface Machining Part 2 - Multiple Surface Model
Verify The Toolpath
PART 2 - MULTIPLE SURFACE MODEL

n Find and open the part Multiple Surface_Machining.mcam.
Note: This part has multiple surfaces. To machine it you can only
use Surface Rough Pocket, Dynamic OptiRough and
Surface Finish Parallel. You will learn how to recreate
surfaces to be able to use Surface Finish Flowline toolpath
which will give you a better finish.
Dynamic OptiRough toolpath will be used in another exercise.
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Surface Machining Step 9: Setup The Stock
STEP 9: SETUP THE STOCK
Set the Stock Setup.
n From the Machine ribbon, select the drop down arrow

below Mill and select the Default.
n Expand Properties and select Stock Setup.
n In the Stock Setup click on the Add from a bounding
box button.
n Enable All shown to

select all entities.
to exit Machine
Group Setup.
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STEP 10: SURFACE ROUGH POCKET
You will rough out the part using Surface Rough Pocket which allows you to machine multiple surfaces.
The Surface Pocket toolpath requires a boundary and in this step you will create the containment boundary
using Silhouette boundary command.
Step Preview:
10.1 Change the Z depth to 0.5
n In the Status Bar, click on the Z value and

change it to 0.5.
10.2 Create the boundary
n From the Wireframe tab, from

Shapes group, select the
Silhouette Boundary command.
n Select the surfaces shown.

n In the Silhouette Boundary panel select the OK button to exit.
472
10.3 Rough out the part using Surface Rough Pocket
n From the
Toolpaths ribbon, in the
3D group, select the
Pocket icon.
n Use Quick Mask toolbar
and select all the surfaces.

selection.

Containment area.

n Select the OK button to exit the Chaining dialog
box.
Toolpath/Surface selection and continue.
473
Toolpath Parameters
n Click on the Select library tool

button and select the 1/2" Bull
Nose Endmill with 1/16" corner
radius from the library.
n Set the Feed rate , Spindle
speed, Plunge rate and
Retract rate as needed.
Surface Parameters
n Clearance = 2.0
(Absolute).
n Retract = 0.25
(Absolute).
n Feed plane = 0.1.
(Incremental).
n Tool containment set
to Center.
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Rough Parameters

n Maximum stepdown =
0.0625.
n Disable Entry-Helix.
n Enable Plunge outside
containment boundary.
Pocket Parameters
n Set the Cutting Method to

Parallel Spiral.
n Set the Stepover percentage to
55% of diam.
n Leave Finish enabled and
Finish containment boundary.
n Disable Thin wall.
toolpath.
475
Verify The Toolpath
n The part should look as shown after being

verified.
476
Surface Machining Step 11: Surface Finish Parallel
STEP 11: SURFACE FINISH PARALLEL
Surface Finish Parallel toolpaths cut the drive geometry using linear zigzag or one-way motion. The tool
passes parallel to the cut direction established by the machining angle. Depending on the maximum
stepover and the total tolerance values, the toolpath will be more efficient on fairly flat parts or parts with
vertical walls in one direction.
Toolpath Preview:
n Press Alt +T to remove the

toolpath display any time
you needed.
Toolpaths Manager,
select Mill toolpaths,
Surface finish and then
Parallel.
n Select the surfaces and press Enter to finish the

selection.
n Select the OK button to exit Toolpath/surface
selection and continue.
477
Toolpath Parameters

select the 1/4" Ball Endmill
from the library.
Spindle speed, Plunge
rate and Retract rate as
needed.
Surface Parameters

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Finish Parallel Parameters
The Finish parallel parameters page allows you to establish the Total tolerance in which the toolpath follows the
surfaces, the Max stepover , and the Machining angle.
Machining angle sets the angle for the surface toolpath relative to the X axis of the current construction plane.
Max. stepover sets the maximum distance between adjacent cuts in the surface toolpath.
Cutting method set to Zigzag moves the tool back and forth across the part.

n Max stepdown = 0.02.
n Machining angle = 90.0.
Zigzag.
Note: The Surface Parallel toolpath does a good job in

areas with fairly flat surfaces and not such a good job in
areas with steep walls parallel with the cutting direction. To
improve machining of the part, you will create one surface
and use other toolpaths that are available with a single
surface.
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Surface Machining Step 12: Create A Loft/Ruled Surface
Verify The Toolpath
STEP 12: CREATE A LOFT/RULED SURFACE
In this step you will learn how to create a Loft/Ruled surface using two splines. When you create the surface
between two contours there is no difference in how the surface is generated between Loft and Ruled.
A Ruled Surface is a surface generated by connecting straight lines between two or more open or closed contours.
When creating a ruled surface with three or more curves defining the boundary, Mastercam creates separate
surfaces between each pair of curves rather than one surface with sharp corners and ridges.
A Loft Surface is generated from the same wireframe by connecting with parabolic curves between the curves.
Applications: any time a surface must be fit between two or more open or closed contours.
Step Preview:
12.1 Change the Main Level to 1000
n In the Levels Manager, make Level 1000 the Main

Level.
n Name it "Ruled Surface".
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12.2 Make only the surfaces needed visible
n Pick the surfaces as shown.

n Press Alt + E to hide the rest of the surfaces.
12.3 Create curves using Create Curve All Edges command.
n From Wireframe
ribbon, click on the
Curve All Edges
command.
n Select the surfaces.

n In the Curve On All Edges panel, enable Only Open Edges as

shown.
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n The curves at the edges should look as shown.
n Select the OK icon to exit the command.
n Delete the top and bottom lines.

n Press Alt + E to bring the rest of the surfaces on.
n In the Levels Manager, click

on the Turn all levels off
icon.
shown.
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12.5 Create a Loft/Ruled surface
n From the Surfaces, in the Create group,

select Loft icon.
n Select the two splines in the same

direction.
n Leave the defaults on the Surface
Ruled/Lofted panel.
n The surface should look as shown.
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Surface Machining Step 13: Finish The Surface Using Finish Flowline
STEP 13: FINISH THE SURFACE USING FINISH FLOWLINE
Flowline Finish 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.
Toolpath Preview:

Toolpaths Manager, select Mill
Toolpaths and Surface Finish.
n Click on the Flowline as shown.

n Press Enter to finish the selection and to continue.
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n In the Toolpath/surface selection panel, click on the Flowline button.
n In the Flowline data panel, click on the Cut

direction button and Start button to make sure that
the flowlines are orientated as shown.
n Select the OK button to exit Flowline data.
n Select the OK button to exit Toolpath/surface
selection.
Toolpath Parameters
n Select the 1/4"

Ball Endmill.
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Surface Parameters
n In the Surface parameters,

the Clearance should be
enabled.
n Leave the rest of the
parameters as they are.
Finish Flowline Parameters
The Finish flowline parameters page allows you to establish the Total tolerance in which the toolpath follows the
surfaces, the Stepover control, and the Cutting method.
Check flowline motion for gouge adjust the flowline toolpath if a gouge is imminent. This option applies to tool
motions larger and smaller than the cut tolerance. If the tool motion is larger than the cut tolerance, the retract move
is adjusted to avoid the gouge.
Stepover control :
Distance sets the maximum distance between adjacent cuts in the surface toolpath.
Scallop height adjusts the stepover between cuts to create leftover material at a specific height.
Cutting method set to Zigzag moves the tool back and forth across the part.

n Enable Check flowline
motion for gouge.
n Scallop height = 0.002.
n Cutting method = Zigzag.
the toolpath.
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n Run Backplot to check the last toolpath.
Note: The toolpath shows the tool cutting below the bottom
of the stock. To avoid this, you need a flat surface at the
bottom of the stock that can be used as a check surface to
stop the tool.
13.2 Adding a flat rectangular surface at the bottom
n In the Status bar, set Z to -2.5, and 2D mode.
n Change the graphic view to Top.

n Use create Rectangle command
with Create surface enabled to
create a rectangle bigger than the
stock as shown.
n Enable Create Additional
Geometry and Surface.
n In the Toolpaths Manager, in the

Surface Finish Flowline toolpath, select
Geometry.
n In the Check surface area select the
rectangular surface.
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Surface Machining Step 14: Create A Sweep Surface
n Regenerate the toolpath and accept the

Warning.
Note: The Warning is just to make you

aware that the stock to leave on Drive
and Check surfaces are the same. They
can be left as they are.
n Backplot the toolpath again.

13.3 Verify the Rough Pocket and the Finish Flowline toolpaths
n Use Ctrl key and select the Rough Pocket and the Finish
Flowline toolpaths.
Note: To machine the fillets you will learn how to create a

sweep surface on each side of the ruled surface and use
Finish Flowline toolpath.
STEP 14: CREATE A SWEEP SURFACE
A Sweep Surface is a surface generated by translating or rotating one or more contours (across curves) along one or
two other contours (along curves).
Applications: used when the across section of the surface at any point is constant (when the surface is generated
from one across contour and one along contour). Also used when the across section at any section is not constant
(when the surface is generated from two or more across contours and one along contour). You can have a maximum
of two along contours and just one across contour.
Step Preview:
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14.1 Change the Main Level to 2000, make Level 100 visible and make Level 1000 invisible
n In the Levels Manager, make Level 2000 the Main

Level.
n Name it "Sweep Surface".
14.2 Make only the surfaces needed visible
n Pick the surfaces as shown.

n Press Alt + E to hide the rest
of the surfaces.
14.3 Create curves using Create Curve One Edge command.
n In the Status bar, change the mode to 3D.
n From Wireframe
ribbon, click on the
Curve All Edges
command.
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n Make a window around the surfaces to select

them.
n In the Curves On All Edges panel enable Only Open Edges as

shown.
n The curves at the edges should look as shown.

n Delete the bottom edges.
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14.4 Delete the bottom edge curves

n In the Levels Manager, click

on the Turn all levels off
icon.
shown.
Note: Sweep surface command generates one surface automatically. There is no need to transform the
curves in splines. To ensure a smooth surface creation, fillet the sharp corners of the contours with a
small radius such as 0.001.
14.6 Fillet the Sharp Corners
n From the Wireframe ribbon,

in the Modify group, select
Fillet Entities icon.
n In the Fillet Entities panel, change

the Radius to 0.001.
n Select the entities as shown.
n Select OK to exit the command.
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14.7 Create a Sweep surface
n From the Surfaces, in the

Create group, select Sweep
icon.
n In the Surface Sweep panel enable Two rails.
Select The Across Contour
n Enable Single button in the Chaining

dialog box.
n Select the entity as shown.
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Select The Along Contour 1
n Enable Partial button and select the first

entity as shown.
n Select the last entity as shown.
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n Repeat the steps to select the second along

contour. Make sure that you chain the second
contour in the same direction.
n Select the OK button to exit the Chaining dialog
box.
n The surface should look as shown.

n Click on the OK and Create New Operation icon.
14.8 Create The Second Sweep Surface
n Use the same steps to create the other Sweep surface as

shown.
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Surface Machining Step 15: Finish The Sweep Surface - Finish Flowline
STEP 15: FINISH THE SWEEP SURFACE - FINISH FLOWLINE

Toolpath Preview:
n Make Level 1000 visible.

Toolpaths Manager, select
Mill Toolpaths and Surface
Finish.
n Click on the Flowline as
shown.
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n Press Enter to finish the selection and to
continue.
n In the Toolpath/surface selection panel, click on the Flowline button.
n In the Flowline data panel, click on the

Cut direction button to make sure that
the flowlines are orientated along the
surface as shown.
n Click on the Start button if needed to start
at the top as shown.
n Select the OK button to exit Flowline
data.
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n In the Toolpath/surface
selection panel, click in the
Check area on the Select
button.
n Select the rectangular flat
surface. Press Enter to
finish the selection.
Toolpath/surface
selection.
Toolpath Parameters
n Select the 1/2"

Ball Endmill.
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Surface Parameters
n In the Surface parameters,

the Clearance should be
enabled.
parameters as they are.
Finish Flowline Parameters

n Enable Check flowline
motion for gouge.
n Scallop height = 0.002.
n Cutting method = Zigzag.
toolpath.
n Accept the warning.
n Run Backplot to check the last toolpath.
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15.2 Machine the Other Side using Finish Flowline
n Copy the last Finish Flowline toolpath.

n Select the Geometry and remove the Drive surface.
n Select the right side surface.
15.3 Verify the Rough Pocket and the Finish Flowline toolpaths
n Use Ctrl key and select the Rough Pocket and the Finish
Flowline toolpaths.
Note: The file will be saved with the Mastercam toolpath data stored inside the file.
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SUMMARY:
In this tutorial, you added to your toolpath skill set by learning how to machine basic 3D models from
surfaces. You learned how to modify the model to create single surfaces. You also learned about the
different types of Surface Rough and Finish toolpaths that are available in Mastercam Mill product.
n Create a Spline from a chain of entities.

n Create a single Revolve surface using a spline and an axis of rotation.
n Modify your model by creating a Loft surface from two splines.
n Modify your model by creating a Sweep surface from a cross contour and two along contours.
n Create a Silhouette Boundary to be used as a Containment in the toolpath.
n Locate Geometry and Job Setup.
n Rough out the part with single or multiple surfaces using Surface Rough Pocket Toolpath.
n Finish one surface using Surface Finish Scallop Toolpath.
n Finish multiple surfaces using Surface Finish Parallel Toolpath.
n Finish one surface using Surface Finish Flowline Toolpath.
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OptiRough Toolpath
501
OptiRough Toolpath Introduction
INTRODUCTION
In this exercise you will learn how to rough out the part using 3D High Speed Dynamic OptiRough
toolpath. The toolpath is used to rough out complex 3D model parts, but can also be used to machine
complex 2D parts that can be rough out with one toolpath.
Similar with the Dynamic Mill toolpath, 3D High Speed Dynamic OptiRough machines pockets,
material that other toolpaths left behind, and standing bosses or cores using the entire flute length.
Considerations for chip thinning and feed rate adjustment are used so that each cutting edge of a tool takes
a consistent chip thickness with each rotation. Utilizing the entire available length of cut allows tool wear to
be spread over a greater area, prolonging tool life and lowering production costs.
This exercise uses also the 2D High Speed Area Mill toolpath with the new Advanced Regions
selection to finish the toolpath in one operation.

n 3D High Speed Dynamic OptiRough parameter settings options.
n 2D High Speed Area Mill and Advanced Regions selection.
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OptiRough Toolpath Instructor Demonstration:
Topics:
n Job Setup - Bounding Box

n Stock Model
n 3D High Speed Dynamic OptiRough
parameter settings options.
n 2D High Speed Area Mill and Advanced
regions selection to finish the floors.
n Contour toolpath to finish the walls.
n Generate a Setup Sheet.
NOTES:
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OptiRough Toolpath Part Drawing
PART DRAWING
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OptiRough Toolpath Toolpath Information
TOOLPATH INFORMATION
3D High Speed Rough Toolpath Backplot Result

toolpaths are designed to machine standing
bosses and cores, cavities and pockets, or
material that other toolpaths left behind. They
minimize the need for helical ramp moves or full-
width cutting.
toolpaths supports cutters capable of machining
very large depths of cut. A single
OptiRoughtoolpath can cut material in two
directions, on step downs (-Z) and step ups
(+Z). As step downs are calculated, the dynamic
roughing motion clears the material in the -Z
direction, avoiding any islands. If you activate
step up cuts in the toolpath Cut Parameters,
Mastercam calculates additional slices in the +Z
direction to remove any material left behind
between the step downs; for example, islands or
large scallops on angled walls.
505
OptiRough Toolpath Step 1: Create The Job Setup
1.1 Open the OptiRough_AutomaticRegions.MCAM

1.2 Load the Mill Default if needed
n From the Machine tab, select Mill and Default.
1.3 Set the Machine Group Properties
Note: The Tool settings should be pre-set from the saved Operations defaults we setup in
previous lesson.
n Select the Stock

Setup tab.
n Click on the Add from
a bounding box
button.
n Enable All shown.
n Set the Origin at the
center bottom of the
face.
n Set the Bounding
Box parameters:
n Shape set to
Rectangular.
n Size X = 8.75.
n Size Y = 7.75.
n Size Z = 1.45.
n Enable Lines and
arcs.
exit the Bounding
Box panel.
Note: This will create the stock we will use as boundaries for our HST toolpaths. We expanded stock to
match imported design intent and origin location. User can also expand dynamically with Push Pull
options
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OptiRough Toolpath Step 2: Stock Model
n The stock will look as shown.
STEP 2: STOCK MODEL
In this step you will create a stock model to be used for roughing with a remachining option.
n From Toolpaths ribbon, Stock group,

select the Stock Model icon.
n In the Stock Definition,

enter the name Stock.
n Make sure that in the Initial
stock shape Rectangular is
enabled.
n Click on the Stock Setup
button to establish the stock
model size from the stock
setup as shown.
Stock Model parameters.
507
OptiRough Toolpath Step 3: Dynamic OptiRough Toolpath
n The stock model should look as shown.

n Press Alt +T to remove the toolpath
display.
STEP 3: DYNAMIC OPTIROUGH TOOLPATH

3D High Speed Dynamic OptiRoughtoolpaths are designed to machine standing bosses and cores, cavities and
pockets, or material that other toolpaths left behind. They minimize the need for helical ramp moves or full-width
cutting. 3D High Speed Dynamic OptiRoughtoolpaths supports cutters capable of machining very large depths
of cut. A single OptiRough toolpath can cut material in two directions, on step downs (-Z) and step ups (+Z). As
step downs are calculated, the dynamic roughing motion clears the material in the -Z direction, avoiding any islands.
If you activate step up cuts in the toolpath's Cut Parameters, Mastercam calculates additional slices in the +Z
direction to remove any material left behind between the step downs; for example, islands or large scallops on
angled walls.
n From Toolpaths
ribbon, 3D group,
select the
OptiRough icon.
3.1 Set Model Geometry

The Model Geometry page allows you to select and change the Machiningand Avoidance Geometry. It
also lets you establish the Wall and Floor Stock. The stock to leave on walls must be greater than or equal
to the stock left on the floor. The only exception is for horizontal area finish passes. You can have multiple
Machining Geometry and/or Avoidance Geometrywith different stocks.
n Select the solid as the Machining

Geometry. (You can make a window
around it or triple-click on the solid to
select it).
n In the Machining Geometry set the
Wall Stock = 0.02 and Floor Stock
= 0.01.
Note: The stock to leave on the walls must be greater than or equal to the stock left on the floor.
508
3.2 Set Toolpath Control

The Toolpath Control page allows you to change the Containmentand the Approximate start point. It allows you
to choose between Stay Inside or From Outsideas the toolpath strategy.
Stay Inside keeps the toolpath inside the selected containment boundary. Use this strategy when roughing out
pockets, cavities, or other areas that be most efficiently machined with an inside to outside toolpath.
From Outside allows you to machine from outside the containment boundary moving inward. This strategy is
designed for machining cores, which can be approached from the outside.
You can set how to control the tool's position around a boundary. Selected closed boundaries limit the tool's position
as it machines the surfaces.
n Enable From Outside.

n In the Compensate to enable
Outside.
n Offset = 0.125.
n In the Boundary chains, click on
the Select button.
n In the Wireframe Chaining,

select Wireframe Mode.
n Enable Cplane and Chain button.
n Select the top rectangle as shown.
Wireframe Chaining.
509
3.3 Set Tool
n Select the 3/4" Flat Endmill .

n Leave the default Feed rate and Spindle speed.
n Enter a comment: "Rough out the part using a 3/4" Flat Endmill".
3.4 Stock
n In the Stock, enable

Rest material.
n In the Previous
operation enable
One other
operation and
make sure that the
Stock model is
selected.
510
3.5 Set Cut Parameters

The Cut Parameters page allows you to establish the Cut method, the Stepover to set the passes in XY plane,
the Stepdown for the cuts in the -Z direction, and the Stepup for the cuts in the +Z direction.
Minimum toolpath radius reduces sharp corner motions between cut passes.
Micro lifts raise the tool slightly off of the part on back moves (non-cutting moves) to help clear chips and minimize
excessive tool heating.
n Cut method set to Climb.

n Optimize stepups set to By
depth.
n Optimize stepdowns set to
Material.
n Set the Stepover as a % of
diameter = 15.
n Set the Stepdown as a % of
diameter = 200.
n Enable Stepup = 200%.
n Set the Minimum toolpath
radius as a % of diameter =
15.
511
3.6 Steep / Shallow

Use the Z depth settings to establish the heights of the highest and lowest cutting passes, regardless of
the drive surface geometry. Select Depth limits to set the Minimum and Maximum fields with values from
the selected drive surfaces, and then edit as necessary. Note that Minimum refers to the minimum depth,
in other words, the highest point in your toolpath.
n Enable Adjust for stock to

leave.
n Enable Minimum depth and
set to 0.0.
n Change the Maximum depth to
-1.5 to break the material
through.
3.7 Set Linking Parameters

Linking Parametersset the links between the cutting passes. In general, you can think of linking moves as air
moves when the tool is not in contact with the part.
The Retract method set to Minimum distance inserts high-speed arcs to and from the retract height and maintains
a minimum retract height above the surface for the fastest transitions.
Leads control how the tool moves onto and off of the part at the start and end of each cutting pass. These moves
are applied to each pass no matter which cutting pass is selected.
Fitting controls how the entry and exit arcs will be fit into each pass. Fitting set to Minimize Trimming creates
the path of the retract will be as close to the surface as possible, maintaining a minimum distance from the surface
to fit the arc.
n Set the Retract method to

Full Vertical Retract.
n Clearance = 2.0.
n Linear entry/exit = 0.025.
n Keep tool down within
500%.
n Microlift distance = 0.01.
n Enable Same lead in and
out.
n Type set to Horizontal;
Sweep angle = 90; Radius
= 0.075.
n Ramp angle = 10.
n Secondary Leads.
n Enable Same lead in and
out.
n Vertical; Radius = 0.075.
n Fitting set to Minimize
Trimming.
512
3.8 Set Entry Motion
n Entry method set to Helix.

n Radius = 0.3375.
3.9 Set Arc / Filter Tolerance
Total tolerancedisplays the sum of the filter tolerance and cut tolerance. The Tolerances Distributionfields
display the total tolerance you defined for the toolpath and the formula used. Use the slider between the fields to
allocate fixed percentages of cut, line/arc filtering, and smoothing tolerances in 5% increments or enter the
percentages directly into the fields. If desired, use the Line/Arc Filtering Settings and Smoothing Settings to
further refine the toolpath.
n Set the Cut tolerance to 30%

and the Line/Arc tolerance to
70%.
n Enable Line/Arc Filtering
Settings and Create arcs in
XY plane.
513
514
OptiRough Toolpath Step 4: 2D HS Area Mill Automatic Regions
STEP 4: 2D HS AREA MILL AUTOMATIC REGIONS
n In the 2D Toolpaths select the Area Mill icon.
n Enable Stay inside and click to select the Automatic regions.

n Make sure Stay inside is enabled.
n Select the bottom of the pockets as

shown.
n Click on the Preview chains button to check

the chaining.
n Select OK button to exit Chain Options
dialog box.
4.1 Tool
n Select a 1/2" Flat Endmill.

n Rapid Retract enabled.
n Comment: “Finish the pocket floors”.
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4.2 Cut Parameters
n Cutting method is set to Climb.

n XY stepover percentage of
diameter = 45%.
n Minimum = 0.12375.
n Maximum = 0.225.
n Keep tool down within % of
tool diameter = 100.

4.4 Trochoidal Motion disabled

n Top of Stock = 0.0 (Incremental).
4.7 Entry Motion
n Enable Entry helix.

n Radius = 0.225.
516

The option to Output 3D arcs will create the entry helix move with arc moves when possible.
n From the Tree View List, select

Arc Filter / Tolerance.
n Set the Line/ arc tolerance to 70%
to ensure that the filter will remove
some of the lines and arcs move in
the given tolerance.
n Enable Line/Arc Filtering
Settings and make sure that
Output 3D arc entry motion is
enabled as shown.
n Select the OK button to exit Area Mill.
517
OptiRough Toolpath Step 5: Finish The Walls Using Contour
STEP 5: FINISH THE WALLS USING CONTOUR
In this step you will use Contour toolpath to finish all the walls and remove the 0.02 stock on the walls.
n From the Toolpaths tab, and select the Contour icon.
n Select the pockets as shown.

n The cut direction should be CCW to ensure
climb milling, the side of the cutter should be
inside of the contour and the starting position
should be as shown.
n To see the arrows click on the Display all
selection arrows button.
518
n For the open pocket enable

Outer shared edges button.
n Select the bottom of the open
pocket and make sure the
chains are selected in CCW
direction.
n You can reverse chain direction
if needed and move the starting
location to match the selection
shown.
n Select the outside profile.

n Select the OK button to accept
the Chain settings.
5.1 Tool

n Enter in the Comment: "Finish the walls".
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5.2 Cut Parameters
n Select the 2D as
Contour type and set
the parameters as
shown.
5.3 Depth Cuts
n Enable Max rough step and set to 0.25.
5.4 Lead In/Out
n In the Entry Line enable

Tangent.
n Length = 60%.
n Radius = 60%.
n Sweep = 35.0.
n Set the same parameters
in the Exit.
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n Depth = 0.0. (Incremental).
Toolpaths - Contour.
521
OptiRough Toolpath Step 6: Post Process The Toolpaths
5.7 Verify the Toolpaths

STEP 7: SAVE YOUR FILE.
SUMMARY:
After completing this tutorial and the practice exercises that follow you should be able to know:
n Stock Model
n Surface High Speed Dynamic OptiRough (Rest Material) parameter settings options.
n Area Mill Advanced Regions selection.
n Contour toolpath to finish the walls.
522
OptiRough Toolpath Exercise #1
EXERCISE #1
Job Description:
Program the part above OPTIROUGH EXERCISE-1.mcam with the following requirements:
n Use Job Setup to prepare the part for machining.

n Use High Speed Dynamic OptiRough toolpath to rough out the part.
n In the Toolpath Control enable From outside and Skip pockets and Skip all to not
machine the holes.
n Use 2D High Speed Area Mill toolpaths to finish the floors.
n Use automatic regions.
n Enable Stay inside.
n Use Contour toolpaths to finish the walls.
523
OptiRough Toolpath Exercise #2
EXERCISE #2
Job Description:
Program the part above OPTIROUGH EXERCISE-2.MCAM with the following requirements:
n Use Job Setup to prepare the part for machining. Give extra in X and Y 0 .4" and enable Lines and arcs
to create the wireframe of the stock.
n Use OptiRough Toolpaths to rough out the part.
n In the Toolpath Control, select the top rectangle as Boundary.
n Enable compensate to Outside and Include tool offset.
n Copy the toolpath and use OptiRough - Rest material to remachine areas if needed.
n Skip pockets smaller than 0.5".
n Use Contour Toolpaths to Finish the walls of the inside boss and outside steps. Use a bigger tool to
machine the steps.
n Use Area Mill with Automatic regions selection to finish the floor of the inside pocket.
n Copy the Area Mill and enable Rest Material to remachine the inside pocket.
n Use Contour Toolpaths to Finish the walls of the inside pocket and island.
524
Trim Toolpath
525
Trim Toolpath Introduction
INTRODUCTION
This tutorial demonstrates the Trim toolpath which allows you to trim one or more existing toolpaths to one or
more closed boundaries that you can select. You can select a trimming plane if the trimming geometry is in a
different plane that the toolpath.
You will be prompted to select a bias point to tell Mastercam which portions of the toolpath you want to keep
relative to the boundaries. (This is similar with trimming a surface to a curve).
Trim operations are similar to containment boundaries or check surfaces, but they are more flexible
because:
n They let you select a plane that you can trim relative to.
n You can trim any type of toolpath except multiaxis toolpaths.
n You can trim more than one toolpath with the same trim operation.
The trim operation and source operations are associative with each other, which means you can edit the
parameters for each operation separately and update the other operation by regenerating it. When you post,
you only select the source toolpaths (in this case, the pocket toolpath), you do not post the Trimmed
operation itself.

n Trimming a face toolpath used to machine a rectangular shape out of a cylinder using a circle created in
a different plane.
526
Trim Toolpath Instructor Demonstration:
Topics:
n Face toolpath to machine the rectangle.

n Trim toolpath with a circle created in a
different plane.
NOTES:
527
Trim Toolpath Step 1: Open The File
n Find and open the part Trim Toolpath.mcam.
STEP 2: MAKE LEVEL 2 INVISIBLE
n Select Levels Manager and make Level 2 invisible

as shown.
STEP 3: SET THE STOCK
n In the Toolpaths Manager, expand Properties and select

Stock setup.
528
Trim Toolpath Step 3: Set The Stock
n Select the Add from bounding box icon.

n In the Shape enable Cylindrical and set the Axis to X.
n Enable All Shown.
n Click the OK button to accept and close the Machine

Group Properties.
529
Trim Toolpath Step 3: Set The Stock
3.1 Stretch the rectangle to the left
Note: To be able to overlap the left edge, you will need to stretch the rectangle to the left with the overlap
value.
Transform
n From the Size group select the Stretch icon.

n Change the graphic view to Top and make a window around the
left size as shown.
n In the Stretch panel, make sure that Move is

enabled.
n In the Delta area set the X to -0.1 as shown.
530
Trim Toolpath Step 4: Machine The Open Pocket Using Facing
STEP 4: MACHINE THE OPEN POCKET USING FACING
Facing toolpaths clean the stock from the top of a part, qualify the top of the part, and create an even surface for
future operations. You can base the toolpath on either chained geometry or on the current stock model. In our
example the toolpath is used to quickly machine the rectangular shape out of the cylinder.
Step Preview:
531
n From Toolpaths, 2D group,

select Face.
n In the Wireframe Chaining
dialog box, enable Chain.
n Select the rectangle as
shown.
4.1 Tool
n In the Tool page, select a 2.0" Flat Endmill.
4.2 Cut Parameters
n In the Cutting method

enable Zigzag.
n Stock to leave on
floors = 0.0.
n Across overlap = 0.0.
n Disable Even number
of passes to generate
constant stepovers.
n Auto angle disable;
Roughing angle =
90.0.
n Move between cuts set
to High speed loops.
532
4.3 Depth Cuts
n Depth cuts enabled.


n Feed Plane = 0.125
(Incremental).
n Make sure that Generate toolpath
is enabled.
Toolpaths - Facing.
533
Note: The toolpath cuts a lot in the air. To improve it, you will
use the Trim toolpath and trim the air motions with a circle that
was created by offsetting the edge of the cylinder with the
radius of the tool plus an extra value for safety. In our case the
offset is 1"+0.25".
534
Trim Toolpath Step 5: Trim Toolpath
STEP 5: TRIM TOOLPATH
In this step you will use the Trim toolpath to trim the face toolpath with a circle to avoid machining in the air.
5.1 Copy the toolpath
n Press Alt +T to remove the toolpath display.

n In the Toolpaths Manager, right mouse click on the
toolpath and select Copy.
n Right mouse click again and select Paste.
n The Toolpaths Manager should have two toolpaths as
shown.
5.2 Make Level 2 Visible
n In the Levels Manager, click in the Visible column of Level 2

to make the level visible.
535
5.3 Open Toolpaths Manager

5.4 Change the Cplane and Tplane to Right
n In the Status bar select Cplane and click on the Right.
5.5 Trim Toolpath

Toolpaths
n From the Utilities group,

select the Trim icon.
n Select the outer circle as the trimming

boundary as shown.
n [Enter a point on the side to keep]: Select

a point inside of the circle as shown.
536
n In the Operations to trim window,

select the second toolpath as
shown.
Trimmed dialog box.
n In the Toolpaths Manager, the second Facing toolpath

will display a trimmed icon in front of the Toolpath info.
n The Trim toolpath is also added in the Toolpaths
Manager as shown.
Note: Both operations are associative. If you change any

parameters in the Facing toolpath the Trimmed toolpath will
also need to be regenerated.
5.6 Make Level 2 Invisible
n Open Levels Manager and make invisible Level2

as shown.
537
Trim Toolpath Step 6: Save Your File
5.7 Backplot the second toolpath
n Open Toolpaths Manager and select the second

toolpath.
n Select Backplot selected operations button.
5.8 Verify the second toolpath

SUMMARY:
In this lesson you learned how to trim a toolpath to a closed boundary to minimize the cut moves in the air.
n Create a Trim toolpath.
538
Wireframe Toolpaths
539
Wireframe Toolpaths Introduction
INTRODUCTION
In this tutorial you will learn how to use a Wireframe toolpath to machine a 3D shape using wireframe
geometry. Mastercam includes several types of wireframe toolpaths, similar to the different types of
surfaces:
Ruled Toolpaths create a linear blend on shapes that can be defined between several chains.
Lofted Toolpaths create a smooth, curved blend on shapes that can be defined between several chains.
Revolved Toolpaths create toolpaths on shapes that can be defined by revolving a profile around an axis.
Coons Patch Toolpaths create the toolpaths on shapes that can be defined as patches in a grid of curves
of chains.
Swept Toolpaths create the toolpaths on shapes that can be defined by sweeping a profile or contour
along another curve. You can choose Swept 2D Toolpaths if the along curve lies within a single plane or
Swept 3D Toolpaths, if the along curve does not.
In the first exercise of this lesson, you will learn how to machine a fillet shape using a Swept 2D Toolpath.
The second exercise will demonstrate how to machine a shape that can be defined by two chains that will be
linked with linear moves. When you are chaining the geometry, select the chains in order and make sure that
the chaining direction is consistent for all the chains so that the toolpath doesn't "twist."
Note: All the Wireframe toolpaths are not gouge protected. This is the main disadvantage of the
toolpaths. The surface toolpaths, because you select the surfaces as drive surfaces are all automatically
gouge protected.

n Create Curves at All Edges of a surface.
n Create a Curve Constant Parameter.
n Creating a Swept 2D Toolpath to machine a fillet.
n Create a Stock model with additional offset.
n Create a Ruled Toolpath to machine a shape defined by two chains.
540
Wireframe Toolpaths Instructor Demonstration:
Topics:
n Create the Wireframe required for the toolpath.

n Creating a 2D Swept Toolpath to machine a fillet.
n Create the Wireframe required for the toolpath.

n Create a Stock model with additional offset.
n Creating a Ruled Toolpath between two chains.
NOTES:
541
Wireframe Toolpaths Step 1: Create The 2D Swept Wireframe
STEP 1: CREATE THE 2D SWEPT WIREFRAME
In this step you will learn how to create the wireframe for the toolpath. 2D Swept toolpath requires an
Across chain which in our case will be the arc of the fillet and an Along chain (the top rectangle). The
toolpath will also prompt you to select the intersection point between the two chains. The across chain is in
a plane perpendicular to the along chain and it is swept along the along chain. The along chain is broken at
the endpoint of the across contour.
Step Preview:
1.1 Open The File

n Find and open the part Wireframe Toolpath

Swept.mcam.
1.2 Create the along chain using Curve All Edges command
Wireframe
n From the Curves group,

select the Curve All
Edges icon.
542
n Select the top face as shown.

n The curves will be automatically created.

n Select the OK button to exit Curve On
All Edges panel.

n The curves should look as shown.
1.3 Break one line at the midpoint
Wireframe
n In the Modify group, select Break

Two Pieces icon.
543
n [Select an entity to break]: Select the

line as shown.
n [Indicate the break position]: Select

the Midpoint of the line.
Note: A temporary point will show

the break location. You have to
break the geometry as both
contours have to be chained starting
from their intersection point. You will
create the Across contour starting
from this point.
1.4 Create the Across Curve using Curve Constant Parameter command.
Wireframe
n From the Curves group, click on the drop down arrow

and select Curve Constant Parameter as shown.
544
n [Select a surface]: Select the fillet

surface as shown.
n [Move to the desired location]: Select
the Endpoint as shown.
n In the Curve Constant Parameter panel enable V as

Direction.
545
Wireframe Toolpaths Step 2: Wireframe Toolpath - 2D Swept
STEP 2: WIREFRAME TOOLPATH - 2D SWEPT
In this step you will create a 2D Swept toolpath to machine the fillet surfaces. You will be prompted to
select the Across contour and then the Along contour. As the intersection point you can select the
endpoint on either the line or the arc.
Toolpath Preview:
n From Toolpaths, 2D group, click on the Expand

gallery arrow and select Swept 2D icon.
546
n [Swept: define the across contour]:

Select the arc starting from the
intersection point as shown.
n [Swept: define the along contour]:

Select the rectangle starting at
the intersection point as shown.
n [Enter the intersection point of the across and

along contours]: Select the Endpoint as shown.
547
2.1 Set the Toolpath Parameters

n In the Toolpath Parameters, click on the Select library tool button.
n Using the Filter options select the 1/2" Ball Endmill.
548
2.2 Swept 2D Parameters
n In the Swept 2D
Parameters change
the Across cut
distance to 0.02.
n Set the Rapid depth
(abs) to 0.25.
parameters as they
are.
Across cut distance sets the distance between cuts in the across direction. Stepover is applied to the
longest along boundary.
Stock to leave sets the amount of material to leave on the part model for the finish operation.
Rapid depth (abs) sets the height from which the tool plunges at the rapid speed before it machines the
part at the feed rate.
Sync option lines up the across and along boundaries.
Infinite look ahead prevents the toolpath from crossing itself to protect against gouging.
Across / Along roll cutter around the corners allows you to choose between:
None - no arc moves inserted

Sharp inserts arc moves around corners of 135 degrees or less.
All inserts arc moves around all corners to create a smooth toolpath.
Across / Along cutter comp in computer allows you to choose to compensate to the Right or to the
Left relative to the chaining direction.
n Select the OK button to exit the Swept 2D toolpath parameters.
549
Wireframe Toolpaths Step 3: Backplot The 2D Swept Toolpath
STEP 3: BACKPLOT THE 2D SWEPT TOOLPATH
STEP 4: VERIFY THE 2D SWEPT TOOLPATH
n In the Stock Setup, click on the

All Entities button to set the
stock.
550
Wireframe Toolpaths Step 5: Post Process The Toolpaths

551
Wireframe Toolpaths Step 7: Create The Ruled Wireframe
STEP 7: CREATE THE RULED WIREFRAME
In this step you will learn how to create the wireframe for the toolpath. Ruled toolpath requires at least two chains.
When you are chaining the geometry, select the chains in order and make sure that the chaining direction is
consistent for all the chains so that the toolpath doesn't "twist."
Step Preview:
7.1 Open The File

n Find and open the part Wireframe Toolpath Ruled.mcam.
552
7.2 Create the along chain using Curve All Edges command
Wireframe
n From the Curves group,

select the Curve All
Edges icon.
n Select the right side face as shown.
n Rotate the part and select the opposite face.

n Press Enter.
n The curves will be automatically created.
n Select the OK button to exit Curve On All Edges
panel.
553
n Press Ctrl + T to see the solid translucent.

n The curves should look as shown.
7.3 Delete the extra lines
n Select the lines as shown.

n Press Delete from the keyboard.
n Press Ctrl +T to remove the translucent mode.

554
Wireframe Toolpaths Step 8: Wireframe Toolpath - Ruled
STEP 8: WIREFRAME TOOLPATH - RULED
In this step you will create a stock model to be used to verify the toolpath. You will learn how to create a
Ruled toolpath to machine the 3D shape. You will be prompted to select the two contours. The ruled
toolpath will be generated as a linear blend between the two contours. To generate a proper Ruled
toolpath, both chains have to be selected in the same direction.
Toolpath Preview:
8.1 Create a Stock Model
Toolpaths
n From the Stock group, click

on the Stock Model icon.
n In the Initial stock shape

enable Model and click on the
Select button.
555
n Select the solid by making a Window around it as

shown.
n Change the Name to

"Stock" and in the
Additional offset,
enter 0.05 as shown.
continue.
n The stock model should look as shown.
n To remove the Stock model display select Alt +T.
556
8.2 Ruled Toolpath
n From Toolpaths, 2D group, click on the Expand

gallery arrow and select Ruled icon.
n [Ruled: define chain 1]: Select the

chain as shown.
557
n [Select an entity to start a new

chain (2)]: Select the chain as
shown.
558
8.3 Set the Toolpath Parameters

n In the Toolpath Parameters, click on the Select library tool button.
n Using the Filter options select the 1/2" Ball Endmill.
559
8.4 Ruled Parameters
n In the Ruled Parameters page

change the Across cut distance to
0.02.
n Set the Rapid depth (abs) to 0.25.
Zigzag forces the tool to stay down on the surface at all times and move back and forth across the part.
One way takes a pass, rapids up to the rapid depth, moves back to the beginning of the cut, and takes
another pass in the same direction. All passes are in the same direction.
Circular produces a spiral toolpath. Normally used only in conjunction with constant Z cutting. Circular
should be used only when all boundaries are closed.
5 axis Swarf used for 5-axis (side) cutting. You can add entry and exit curves to a ruled 5-axis Swarf
toolpath using the Entry/exit option on the Multiaxis, Linking page. Angle tilts the ruled 5-axis toolpath for
tapered cutters. Only available if you select the 5-axis Swarf cutting method.
Across cut distance sets the distance between cuts in the across direction. Stepover is applied to the
longest along boundary.
Stock to leave sets the amount of material to leave on the part model for the finish operation.
Rapid depth (abs) sets the height from which the tool plunges at the rapid speed before it machines the
part at the feed rate.
Comp in computer generates a toolpath with compensation for the tool radius, but does not allow for
tool wear adjustment at the control. Left and Right offset the tool by its radius; Off causes the tool to cut
the center line of the geometry.
Sync option lines up the across and along boundaries. By Entity matches the chains by the endpoints of
each entity. Requires both chains to have the same number of entities.
Trimming plane 1 / 2 prevents the tool from cutting past the specified coordinate. Select the plane in
which you want the toolpath to be trimmed, and enter a coordinate value in the Value field. The toolpath
trims to the trimming plane but the actual surface remains unchanged.
Off (Constant Z cutting) allows the tool to change Z depth during each cut. Select this option when you
set the cutting method to 5 Axis.
On (Constant Z cutting) keeps the tool at a constant Z depth for each cut. Cuts are relative to the
current tool plane (if you define a tool plane) or the XY plane (if you do not define a tool plane). The system
ignores the Gouge check setting if you enable Constant Z cutting.
n Leave the rest of the parameters as they are.
560
n Select the OK button to exit the Ruled toolpath parameters.
n A warning appears on the screen that there are

undercuts.
8.5 Backplot the Ruled toolpath
n Press Ctrl + T to see the solid translucent.

Note: The tool cuts inside of the solid. All

movements are undercuts.
8.6 Modify the Ruled toolpath
n In the Toolpaths Manager, select the

Parameters in the Ruled toolpath.
561
n Change the Comp in

computer to Right.
8.7 Backplot the Ruled Toolpath
562
8.8 Verify the Ruled Toolpath
n In the Toolpaths Manager, select

Simulator Options icon as shown.
n In the Simulator
Options, enable
Stock model as
shown.
n Open Mastercam Simulator.

n In the Verify the stock model should look as shown.
563
Wireframe Toolpaths Step 9: Post Process The Toolpaths
n Run Verify.

SUMMARY:
In this lesson you learn how to set a default tool and default parameters for a toolpath while creating it.
n To create a Stock model with additional offset.

n To create a Ruled Wireframe Toolpath to machine a 3D shape that can be created using a Ruled
surface, from two or more chains.
564
Solids Model Prep
565
Solids Model Prep Introduction:
INTRODUCTION:
This lesson will introduce Solids Model Prep options.
Model Prep allows you to edit an existing solid by using options such as move faces or edges, move or copy
existing features, split solid faces, modify or remove features or fillets, create hole axis, simplify and remove
all history, and modify solid face color or set feature colors.
In this lesson you will open an existing solid and remove its original history to be able to modify it using
functions from the Model Prep ribbon. You will use Split Solid Faces command to split the solid face using
Project option. The student will learn how to use Push/Pull command to change the height of the ears.
The Move command will be used to rotate the two smaller ears. You will align one opening with the smaller
ears and split the solid face using Split Solid Faces command with the Flowlines option.
The student will also learn how to add an inner shoulder using Push/Pull command. You will split the inner
shoulder face using Project option and then create a boss using Push/Pull command.
The student will also use Push/Pull command to create fillets.
NEW CONCEPTS COVERED IN THIS LESSON:

n Remove History.
n Move.
n Push-Pull.
566
Solids Model Prep Instructor Demonstration:
Topics:
n Remove History.
n Move.
n Push-Pull.
NOTES:
567
Solids Model Prep Solids Model Prep Drawing
SOLIDS MODEL PREP DRAWING
568
Solids Model Prep Step 1: Open The Solid
STEP 1: OPEN THE SOLID

Resources - Download the files from www.EMASTERCAM.COM/TRAININGFILES/
1.1 Open SOLID MODEL PREP.MCAM

n From the QAT, select the Open icon.
n Select SOLID MODEL PREP.MCAM.
STEP 2: SAVE THE FILE
To avoid modifying the original solid, to be able to use it again if needed, save the file with a different name.
n Click on the Save As icon from the Quick Access Toolbar at

the upper left corner to save the file.
n Find a location on the computer to save your file.
n File name: "Solid Model Prep_1".
Note: The functions that we are going to use to modify the solid can only be applied on a solid without
history. In the Solids Manager history tree, you should have only a Body as shown. This will be done in
the next step.
569
Solids Model Prep Step 3: Removing The Solid History
STEP 3: REMOVING THE SOLID HISTORY
Note: The Undo button works only in the Solid Manager. Make sure that you save your file after each
function shown in case you need to redo some of the functions.
The Model Prep functions that are shown in this tutorial only work on solids without history. If you are
importing a file from a different CAD software, the solids will be imported without history unless otherwise
specified. In this tutorial you are opening an existing Mastercam file and you have to first eliminate the solid
operations as shown in this step.
Step Preview:
n Open the Solids Manager by selecting the tab on the bottom left
corner or to the left of the graphics window.
Note: The solid has the operations listed in the Solids Manager.
Model Prep
n From the Modify group, select Remove

History as shown.
n The solid should be automatically selected as

shown.
n Hit Enter to finish the command.
570
Solids Model Prep Step 4: Analyze The Ear Height
n In the Solids Manager, you should see just the Solid Body
without any history as shown.
Note: In the following steps, you will learn how to change

the heights of the six ears. To be able to modify the heights, you
will need to first split the faces of the ears. Next you will use the
Push/Pull command to change the heights.
STEP 4: ANALYZE THE EAR HEIGHT
The Analyze Entity Properties command allows you to view entity properties and edit some or all of the
data, based on the entity type. You can analyze all entity types, including lines, arcs, points, splines,
surfaces, solids and solid edges. Properties of a selected solid edge are view-only.
Home
n From the Analyze group, select Analyze

Entity as shown.
n [Select entities to analyze]: Select the

edge of the solid as shown.
571
Solids Model Prep Step 5: Split The Solid Faces
n The Linear Edge Properties dialog box will appear on the screen. The
height of the ear is 0.25" as shown.
STEP 5: SPLIT THE SOLID FACES
In this step you will split the top faces that connect the bolt hole ears to the rest of the solid. The Split Solid
Faces command divides a solid face into multiple faces based on specified geometry, flowlines, or the UV
of the face. You will create a circle first to be used to divide the solid.
Step Preview:
5.1 Set the Construction Mode to 2D and change the Z Depth to 2.0"
n From the Mini Toolbar, set the construction

mode to 2D and the Z Depth to 2.0 as shown.
572
5.2 Create a circle
Wireframe
n From the Arcs group, select

Circle Center Point as shown.
n Right mouse click in the graphics window and select the Top
(WCS) icon as shown.
n [Enter the center point]: Select the Origin as

shown.
n Drag the cursor to the edge of the solid

and select the endpoint as shown.
573
n In the Circle Center Point panel, you should have the

Diameter set to 4.5 as shown.

Isometric (WCS) icon as shown.
5.3 Split the top face by projecting the circle to the face
Model Prep
n From the Direct Editing

group, select Split Solid
Faces as shown.
574
n In the Split Solid Face panel, enable Wireframe and

Project using construction plane as shown.
n [Select geometry and face to split]: Select

the face as shown.
n Then select a position where the split will
occur. Select the circle as shown.
Note: The face will turn yellow when you

are selecting it, but will disappear once
selected.
n You should see the split arc with dashed

lines on the face as shown.
n In the Split Solid Face panel, select the
OK and Create New Operation icon.
575
5.4 Split the bottom face by projecting the circle to the face
n [Select geometry and face to split]: Hold down

the mouse wheel and rotate the part to see the
bottom and then select the face as shown.
n Then select a position where the split will
n In the Split Solid Face panel, select the OK
button as shown.
576
5.5 Delete the circle

n Click on the circle to select it.

n Select the Delete key on the
keyboard.
577
Solids Model Prep Step 6: Re-size The Bolt Hole Ear Heights - Push/Pull
STEP 6: RE-SIZE THE BOLT HOLE EAR HEIGHTS - PUSH/PULL
In this step you will change the bolt hole ear heights to 0.1875" using the Push/Pull command.
Use Push/Pull command to extend bosses or produce cuts based on selected faces or features. You can also use
Push/Pull to create fillets from edges or remove fillets. The results you get depend on how you select the geometry
and the direction you drag the control arrow.
Step Preview:
n Right mouse click in the graphics window and select the Top (WCS)
icon as shown.
n Press Alt + F1 to see the geometry inside of the graphics window.
6.1 Modify the height of the bolt hole ears at the top
Model Prep
n From the Direct Editing group, select

Push/Pull as shown.
n The Push-Pull panel will appear. Leave the defaults as

shown.
578
n [Select faces or edges to be moved]:

Select the faces as shown.
Note: The red arrow will be located at

the last face you are selecting.

n Hover the cursor above the arrow

until the scale appears as shown.
579
n Drag the arrow down to activate the

scale as shown.
n Type in the distance -0.0625 to

override the value resulted from
dragging the cursor as shown.
Note: The value that you type will

override the value that the system
gives. You do not need to click in the
value field. Just start typing the
value.
n Press Enter until the value field

disappears

n To exit the command from the Push-Pull
panel, select the OK button as shown.
580
6.2 Analyze the ear height
Home
n From the Analyze group, select Analyze Entity

as shown.
n Move the cursor over the edge that

you previously analyzed and scroll up
the mouse wheel to zoom in as
shown.

edge of the solid as shown.
n The Linear Edge Properties dialog box will appear on the screen. The
height of the ear is now 0.1875 as shown.
581
Solids Model Prep Step 7: Use Move Command To Space The Bolt Hole Ears
STEP 7: USE MOVE COMMAND TO SPACE THE BOLT HOLE EARS
In this step you will move the two smaller ears 15 degrees each to have all the ears equally spaced
around the circle. Move command allows you to move, rotate, or copy solid features or faces.
Step Preview:
7.1 Move the right side bolt hole ear
Model Prep

Move as shown.
n Make sure that in the Move panel, you have the Snap to
AutoCursor positions and the rest of the options
enabled as shown.
582

Top (WCS) icon as shown.
n [Select features to be moved or copied]: Make a

window around the ear as shown. Ensure that all of
the ear faces are selected. No other faces should be
selected.
Note: Make sure that no other faces are selected

besides the ear faces as shown. You might need to
switch to Isometric view to check. If other surfaces
are selected, click on them to unselect them.
n The gnomon will appear on the screen.

n Right mouse click and select the Top view.
n To move the gnomon to the Origin, toggle the Gnomon Switch to Gnomon Axis mode.
Once switched, the toggle will appear to have a picture of an axis on it .
583
n Select the gnomon and drag it to the

center.
n When you see the cue tip of the Origin,
click to position the gnomon there as
shown.
n Click on the toggle button again to go

back to Geometry Manipulation
mode.
n Select the arc segment of the gnomon to

rotate the ear as shown.
n Rotate the X axis of the gnomon 15.0

degrees as shown.
n Click to accept the value.
Note: If you have difficulties reaching the

15 degrees, type the value in and it will
override the existing value. This operates
the same as when you used the Push/Pull
function.
584
n The bolt hole ear will look as shown.

n From the Move panel, select the OK and Create
New Operation icon.
7.2 Move the left side bolt hole ear
n Make a window around the other ear as shown.
Note: Make sure that no other faces are selected

besides the ear faces. You might need to switch to
Isometric view to check. If other surfaces are
selected, click on them to unselect them.

n To move the gnomon to the Origin, toggle the
Gnomon Switch to Gnomon Axis mode
.Once switched, the toggle will appear to have
a picture of an axis on it .
n Select the gnomon and drag it to the center.

n When you see the cue tip of the Origin, click to
position the gnomon there as shown.
585
n Click on the toggle button again to go

back to Geometry Manipulation mode.
n Select the arc segment of the gnomon to

rotate the ear as shown.
n Rotate the X axis of the gnomon -15.0 degrees as

shown.
Note: If you have difficulties reaching the -15

degrees, type the value in and it will override
the existing value. This operates the same as
when you use the Push/Pull function.
n The bolt hole ear will look as shown.

n To exit the command from the Move panel, select the OK
button as shown.
586
7.3 Analyze the angle of the right ear using 3 points
Home
n From the Analyze group, select Angle as

shown.
n In the Analyze Angle dialog box, enable 3 Points as shown.
587
n [Select point 1]: Select the center of the hole as

shown.
Note: To select the center of the hole, the cursor

has to be above the hole edge instead of the
center of the hole.
n [Select intersection point]: Select the Origin as

shown.
n [Select point 3]: Select the center of the hole as

shown.
588
Solids Model Prep Step 8: Align The Openings With The Bolt Holes
n In the Analyze Angle dialog box, the angle will be displayed as

shown.
7.4 Repeat the same steps to check the angle for the left ear
STEP 8: ALIGN THE OPENINGS WITH THE BOLT HOLES
In this step you will align the openings with the new locations of the bolt holes. You will use Move
command, to move the opening faces.
Step Preview:
8.1 Use the Move command to align the right side opening
Model Prep

Move as shown.
589
n [Select features to be
moved or copied]:
Zoom in to see the gap
better and select the
right side face as
shown.
n Select the opposite

face as shown.
n Press Alt + F1 to see

the entire part in the
graphics window.

n To move the gnomon to the Origin, click on
the Gnomon Switch . Once switched,
the toggle will appear to have a picture of an
axis on it .
n Change the graphic view to Top and select

the Origin as shown before.
590
n Click on the toggle button again

to go back to Geometry
Manipulation mode.
n Pick the arc segment as shown.
n Rotate the X axis of the gnomon

15.0 degrees as shown.

n From the Move panel, select the
OK icon.
n The opening should look as shown.
591
8.2 Use Move command to align the left side opening
Model Prep

group, select Move as shown.
n [Select features to be
moved or copied]: Zoom in
to see the gap better and
select the right side face as
shown.
n Select the opposite face as

shown.
592
n Press Alt + F1 to see the entire part in the graphics

window.
n To move the gnomon to the Origin, toggle the
Gnomon Switch to Gnomon Axis mode. Once
switched, the toggle will appear to have a picture of
an axis on it .
n Right mouse click and select the Top view.

n Select the gnomon and drag it to the center.
n Select the Origin as shown.

n Click on the toggle button again to
switch to Geometry Manipulation
mode.
n Pick the arc segment as shown.
n Rotate the X axis of the gnomon -15.0

degrees as shown.

n From the Move panel, select the OK
icon.
593
n The opening should look as

shown.

Note: In the next steps, you will learn how to add

an inner shoulder using the Push/Pull
command. You will have to split the larger inner
cylindrical face using the Flowlines option in the
Split Solid Faces command.
594
Solids Model Prep Step 9: Split The Inner Face Of The Cylindrical Shape
STEP 9: SPLIT THE INNER FACE OF THE CYLINDRICAL SHAPE
In this step you will learn how to split the solid using Flowlines option.
Step Preview:

Model Prep
n From the Direct Editing group,

select Split Solid Faces as
shown.
595
Solids Model Prep Step 9: Split The Inner Face Of The Cylindrical Shape
n In the Split Solid Face panel, enable Flowlines and V

as shown.
n [Select face to be split]: Select the

face as shown.
n Then select the position where

the split will occur. Select the
endpoint of the edge as shown.
command.
596
Solids Model Prep Step 10: Add An Inner Shoulder Using The Push/Pull Command

shown.
STEP 10: ADD AN INNER SHOULDER USING THE PUSH/PULL COMMAND
In this step, you will use the Push/Pull command to add the inner shoulder with a diameter of 1.5".
Step Preview:
Model Prep

group, select Push/Pull as
shown.
597
n The Push-Pull panel will appear. Leave the defaults

as shown.
n [Select faces or edges to be moved]: Select

the face as shown.
n Hover the cursor above the arrow until the scale

appears as shown.
598
n Drag the arrow inside of the hole to activate

the scale as shown.
n Type the distance 0.75 to override

the value resulted from dragging
the cursor as shown.
Note: The value that you

type will
override the value that the
system gives. You do not
need to click in the value
field. You can just start
typing the value.
n Press Enter until the value field

and the scale disappear.

599
Solids Model Prep Step 11: Create A Boss Using The Push/Pull Command
STEP 11: CREATE A BOSS USING THE PUSH/PULL COMMAND
In this step, you will use the Push/Pull command to create a boss with a diameter of 2.0". You will have to
first create a circle with a diameter of 2.0" using the Offset command. Then, using the Split Solid Faces
command, you will then split the face by projecting the circle.
Step Preview:
11.1 Create a 2.0" diameter circle using the Offset command
Transform
n From the Offset group, select

Entity as shown.
n In the Offset Entity panel, make sure that Copy is

enabled and the distance should be set to 0.25 as
shown.
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n [Select the line, arc, spline or curve to

offset]: Select the edge of the inner hole
as shown.
n [Indicate the offset direction]: Click
outside of the part as shown.
n Select the OK button to exit Offset
Entity panel box.
n Select Clear Colors icon from the Mini

Toolbar.
n The circle should look as

shown.
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11.2 Split the face by projecting the circle
Model Prep

select Split Solid Faces as
shown.
n In the Split Solid Face panel, enable Wireframe and

Project using construction plane as shown.
n [Select geometry and face to split]: Slightly

rotate the part using the mouse wheel and
select the face as shown.
n Then select the position where the split will
n From the Split Solid Face panel, select the
OK icon.
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11.3 Delete the circle
n Select the circle as shown.
n Press the Delete key from the keyboard.

11.4 Create the boss using Push/Pull command

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Model Prep

shown.
n The Push-Pull panel will appear. Leave the defaults

as shown.
n [Select faces or edges to be moved]: Slightly

rotate the part and select the face as shown.
604
n Hover the cursor above the arrow until the

scale appears as shown.
n Drag the arrow upwards by moving the

cursor on the scale until 0.25in appears on
the scale as shown.
Note: If you have a hard time setting the

value to 0.25, type the value as explained
before.

605
Solids Model Prep Step 12: Use Push/Pull To Change Small Hole Diameter
STEP 12: USE PUSH/PULL TO CHANGE SMALL HOLE DIAMETER
In this step you will use the Push/Pull command to change the diameter of the holes in the small ears
from 0.375" to 0.25".
Step Preview:
12.1 Analyze the hole diameter
Home

Entity as shown.
n [Select entities to analyze]: Select the edge of the

hole as shown.
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n The Arc Edge Properties dialog box will appear on the screen.
The diameter of the bolt hole is 0.375 as shown.
n Select the OK button to exit the dialog box.
Model Prep

select Push/Pull as shown.

shown.
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n [Select faces or edges to be moved]: Using the mouse

wheel, zoom in as shown.
n To select all the holes with the same diameter, hold
down Ctrl key and select the face as shown.
Note: All three holes of the smaller ears are selected.
n Hover the cursor above the arrow

until the scale appears as shown.
n Drag the arrow inside of the

hole to activate the scale and
move the cursor on the scale
until 0.125in is reached as
shown.
Note: The value you enter is

the radius of the hole.
608

12.2 Analyze the hole diameter again
Home

Entity as shown.

edge of the hole as shown.
609
Solids Model Prep Step 13: Fillet The Top Of The Ears - Push/Pull
n The Arc Edge Properties dialog box will appear on the screen. The
diameter of the bolt hole is 0.25 " as shown.
n Select the OK button to exit the dialog box.
STEP 13: FILLET THE TOP OF THE EARS - PUSH/PULL
Using Push/Pull command, in this step you will fillet the edges of the ears with a 0.05" radius.
Step Preview:
Model Prep

610

shown.
n Hold down the mouse wheel and rotate the part

approximately as shown.
611
n [Select faces or edges to be moved]: To select

tangent edges, hold down Shift key and select
the edges as shown.
Note: All the edges of the ears should be

selected. The red arrow will be located at the
last edge you selected.
n Hover the cursor above the arrow until the

scale appears as shown.
n Drag the arrow inward and you will see a fillet

created at all the selected edges as shown.
612
n Type 0.05 and the current value will be

overridden as shown.
n Press Enter several times until the scale and
the value field disappear.
613
Solids Model Prep Step 14: Fillet The Tops Of The Outer & Inner Bosses
STEP 14: FILLET THE TOPS OF THE OUTER & INNER BOSSES
Using Push/Pull command, in this step you will fillet the edges of the outer and inner bosses with a 0.0625"
radius.
Step Preview:
Model Prep


shown.
614
n [Select faces or edges to be moved]: Select

the edges as shown.

appears as shown.
615
n Drag the arrow inward and you will see a fillet created
at all the selected edges as shown.
n Type 0.0625 and the current value will be

overridden as shown.
n Press Enter several times until the scale and the
value field disappear.
n To exit the command from the Push-Pull panel,
select the OK button as shown.
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Solids Model Prep Step 15: Fillet The Boss Floors
STEP 15: FILLET THE BOSS FLOORS
Using Push/Pull command, in this step you will fillet the edges of the outer and inner bosses with a 0.125"
radius.
Step Preview:
Model Prep

shown.
n Leave the defaults in the Push-Pull panel.
n [Select faces or edges to be moved]: Rotate

the part as needed and select the edges
shown.
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Solids Model Prep Step 15: Fillet The Boss Floors

appears as shown.
n Drag the arrow outward and you will see a fillet

created at all the selected edges as shown.
n Zoom in to see a finer scale.
n Move the cursor along the scale until 0.125in
appears in the value field as shown.
n Left click to accept the value.
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Solids Model Prep Step 16: Save The File
n From the QAT select the Save icon.
SUMMARY:
After completing this lesson and the practice exercise that follows you should be able to modify a solid using
the following commands from the Model Prep tab:
n Remove History.
n Move.
n Push-Pull.
619
Solids Model Prep Solid Model Prep - Exercise
SOLID MODEL PREP - EXERCISE
620
Job Description:
Open SOLID MODEL PREP

EXERCISE.MCAM
n Select SOLID MODEL PREP

EXERCISE.MCAM.
Make Level 2 Invisible.
n Use Levels Manager and make sure Level 1 is Active

Level.
n Remove the X next to Level 2 to make it invisible if
needed.
Remove the Solid History.
n Use the Remove History command to remove the

solid history.
Use Split Solid Faces command to split the

ear.
n Make sure the construction mode is set to 2D

and the Z Depth is set to 2.0.
n Create a 3.5 diameter circle to be used as
geometry for the split.
n Use the Split Solid Faces command from
the Model Prep ribbon and split the left and
right solid faces at both the top and at the
bottom of the solid.
n Enable Wireframe and Project using
construction plane.
n Delete the circle.
621
Use Move command to rotate the left

ear.
n Use the Move command from the

Model Prep ribbon.
n Select all the solid faces that need to be
rotated (do not forget the back or the
hole faces).
n Enable Axis Manipulation and
move the gnomon to the Origin.
n Enable Geometry Manipulation
and rotate the X axis -30 degrees.
Use Move command to align the

opening with the left ear.
n Use the Move command from the

Model Prep ribbon.
n Select the two faces from the
opening.
n Enable Axis Manipulation
and move the gnomon to the
Origin.
n Enable Geometry Manipulation
and rotate the X axis -30
degrees.
n Delete the construction line.
Use Split Solid Faces command to split the two

faces with circles.
n Create two circles with diameter 1.5 to be used

to split the two faces.
n Use the Split command from the Model Prep
ribbon.
n Select the two faces.
n Enable Project using construction plane.
n Delete the circles.
622
Create two bosses using Push/Pull command.
n Use the Push/Pull command from the Model

Prep ribbon to create the bosses at a 0.125"
height.
Use Split Solid Faces command to split the

inner hole face with Flowlines option.
n Use Split Solid Faces command from the Model

Prep ribbon to split the face.
n Enable Flowlines and V.
n Select the face and pick the endpoint of the gap.
Use Push/Pull command to create a shoulder.
n Select both faces.

Prep ribbon to create the shoulder with radius
1.0".
623
Use Push/Pull command to create the

0.05" radius fillets.
n Select the edges. (The left boss has two

edges).
n Use the Push/Pull command from the
Model Prep ribbon to create the fillets.
Use Push/Pull command to create the 0.0625"

radius fillet.
n Select the edges holding down Shift key.

Prep ribbon to create the fillets.
Save the exercise file.
624
Align To Plane & To Face
625
Align to Plane & To Face Introduction:
INTRODUCTION:
This lesson explains how to set a solid body that represents the part to be machined into the fixtures.
To quickly prepare the part for machining on a mill, Model Prep allows you to use two functions; Align to
Plane and Align to Face. From Model Prep or the Turning ribbon you can also use Align to Z to quickly
orient a solid body for a lathe application.
Align to Plane command aligns a solid body with a new WCS or an existing construction plane. You can
align an edge of the solid to the X axis of the plane or WCS, and then select a point on the solid that will
match the origin of the WCS or plane.
Align to Face command uses the dynamic gnomon to control orientation when mating solid faces. You can
work in three modes:
n Coincident
n Perpendicular
n Parallel
In this lesson you will open a file that contains the fixture and the part as solids. You will use Align to Plane
command to properly position and align the part on the fixture. You will be prompted to select the top face
and an edge on the solid to be aligned. After that, in the Align to Plane panel, you will select the plane and
the origin on the fixture used.
In the second file you will learn how to use Align to Face to move and orient the part to the proper position for
machining by mating faces of the two solids. In our case you will mate a face from the part solid with a face
from the fixture.
NEW CONCEPTS COVERED IN THIS LESSON:

n Align To Plane.
n Align To Face.
626
Align to Plane & To Face Instructor Demonstration:
Topics:
n Create a New Plane.

n Remove History
n Align to Plane.
n Align To Face.
NOTES:
627
Align to Plane & To Face Step 1: Open The File
ALIGN TO PLANE
1.1 Open Align To Plane.MCAM

n Select Align To Plane.MCAM.
Model Prep function does not allow you to undo. To avoid modifying the original solid to be able to use it
again if needed, save the file with a different name.
n Open Levels Manager and make sure that

Level 100 is visible as shown.
n Leave only Level 1000 invisible.
n Fit the screen if needed.

n The fixture and the part should look as shown.

n File name: "Align to Plane_1".
628
Align to Plane & To Face Step 3: Create A New Plane
STEP 3: CREATE A NEW PLANE
In this step you will create a new plane based on the Top plane with a different Z depth than the default top
plane.
Step Preview:
3.1 Create a new plane
n Open Planes Manager, right mouse click on the Top

and select Duplicate.
n Right mouse click on the new plane and select Rename.
629
Align to Plane & To Face Step 3: Create A New Plane
n Rename the plane "Machining Plane" as

shown.
n The plane will be set as shown. We need to set

the plane origin.
Note: The plane origin values in X and Y axis

should be left to 0.0. You need to move Z zero to
the face you will place the part on.
n In the Z Origin field type z as shown and

press Enter. This will allow you to pick a point
from the geometry in the graphics window.
n Pick the Endpoint as shown.
n The Origin values should look as shown.
630
Align to Plane & To Face Step 4: Align To Plane
STEP 4: ALIGN TO PLANE
In this step you will align the part to the Machining Plane. You will select, from the solid part, the top face
and an edge at the bottom of the part that will be set parallel with the X-axis of the plane.
Step Preview:
Model Prep
n From the Layout group, select Align

to Plane as shown.
n Select the top face of the part as

shown.
631
n Select the solid edge that will be parallel to X-axis

as shown.
n In the Align to plane , enable Transform to

plane.
Note: The part is rotated in the Top default

plane position. You still need to select the correct
plane and set the Origin.
n Click on the Select destination plane icon.

n Select the Machining Plane as shown.
632
n In the Origin select the bottom middle point

as shown.

n The geometry should

look as shown.
633
Align to Plane & To Face Step 5: Open The File
ALIGN TO FACE
5.1 Open Align To Face.MCAM

n Select Align To Face.MCAM.

n File name: "Align to Face_1".
n The fixture and the part should look as

shown.
634
Align to Plane & To Face Step 7: Align To Face Parallel
STEP 7: ALIGN TO FACE PARALLEL
In this step you will align a face of the part to a face on the fixture. You will select, from the solid part, the
face, an edge and the reference point at the bottom of the part that will be set parallel with the X-axis of the
plane. You will make similar steps to select the face, edge and the reference point on the fixture face.
Step Preview:
Model Prep
n From the Layout

group, select Align
to Face as shown.
n In the Align to Face enable Move and

Parallel.
635
n Select the face from the part as

shown.
n Select the solid edge

that will be parallel to
X-axis as shown.
636
n Click on the gnomon origin to

modify the original reference
point.
n Select the Middle point of the
edge that you selected as
shown.
n Rotate the geometry to see the

fixture face that you want to use.
637
n Select the edge

as shown.
n Select the
middle point
from the
selected edge as
shown.
Note: The gnomon axis orientation on the part that does not match the gnomon axis orientation on the
fixture face. This rotates the part automatically. To fix this you can rotate the Y axis about the Z axis 180
degrees.
638
n If the part is rotated, click on the

arc next to Y axis and rotate it
180 degrees as shown.
n In the Align to Face panel, select
OK button to exit the command.
639
Align to Plane & To Face Step 8: Align To Face Coincident
STEP 8: ALIGN TO FACE COINCIDENT
In this step you will align a face of the part to a face on the fixture using coincident option to mate the faces.
Step Preview:
STEP 9: MERGE A FILE

File
n From the Backstage, select Merge.

n Select Align to Face_Part.MCAM.
n Select the Open button.

n File name: "Align to Face_2".
Model Prep
n From the Layout

group, select Align to
Face as shown.
640
Align to Plane & To Face Step 10: Save The File
n In the Align to Face enable Move and

Coincident.
n Zoom in on the part and select the

inside of the hole face as shown.
n Make sure the reference

point is at the bottom
center of the hole as
shown.
n Rotate the geometry to see the fixture face

that you want to use.
n Select the pin face as shown.
641
Align to Plane & To Face Step 10: Save The File
n The preview should look as shown.
n In the Align to Face panel, select the

OK button to exit the command.
642
Toolpaths Manager
643
Toolpaths Manager Introduction
INTRODUCTION
In this lesson you will learn how to use Toolpaths Manger panel.
The Toolpaths Manager lists all operations in the current job. Use this panel to sort, edit, regenerate, verify
and post any operations. You can enter this panel by selecting the Toolpaths tab or from the View ribbon if
you click in the Managers group on the Toolpaths .
After you create a toolpath in Mastercam, the Operation Folder will be listed in the Toolpaths Manager.
The organization of the Toolpaths Manager is easier to understand if the Group properties and
Operation Folders are not expanded.
To summarize:
n Each job belongs to a Machine Group that tells Mastercam which machine/controller is used.
n Toolpaths belong to a Toolpath Group.
n Toolpaths are stored in individual Operation Folders.
644
The following rules apply to the Toolpaths Manager:
n You only have to make a new Machine Group if you move the part from one machine to another (for
example, from a Lathe to a Mill).
n You can have as many Toolpath Groups as you want.
n Each toolpath you create results in a new Operation Folder being added to your list of operations.
Toolpaths Manager Customization Options
You can change the Background color, the Line color and the Font type and size by clicking on the drop
down arrow located in the upper right corner.
645
The Toolpath Manager Control dialog box is shown below:
646
The following table gives a short description of the toolpath controls. Many of these controls are familiar to
you.
Item Definition
Selects all operations in the list. Selected operations have a green check
mark over their folder. Toggle individual folders on/off by holding down the
Select all operations
Ctrl key and clicking on the folder. Select a series of folders by holding down
the Shift key and clicking on the first and last folders in the series.
Dirty operations are operations where the toolpath must be regenerated, or
Select all dirty operations recalculated, due to a change in geometry, tool, or certain parameters like cut
depths. Dirty operations are indicated with a red X over the Toolpath icon.
Regenerate all selected operations To regenerate all selected operations.
Regenerate all dirty operations To regenerate only dirty operations.
Dependencies Toggle on to automatically select or regenerate dependent operations.
To simulate machining operations using wireframe Backplot. Only selected
operations are backplotted.
Backplot selected operations
Tip: Backplot a single operation by clicking on the Toolpath icon in that
operations folder. Verify a toolpath by right clicking on this icon.
Verify selected operations To simulate machining operations using Solid Modeling technology.
Allows you to change the Backplot/Verify options. You can Add to current
Simulator Options
verification or Verify selected machine group.
Post selected operations To create a G-code file for the selected operations.
To execute the Mastercam High feed function to optimize program feed
High Feed rates. This requires special setup and machine tests, and should be used by
experienced users only.
Permanently deletes your operations, groups, and tools. Warning: Undo
Delete ops, groups, and tools
does NOT work for this function.
Lock operation Locks the operation so that the toolpath will not be regenerated.
Toggle wireframe toolpath display on or off for the selected operation. This
Toggle toolpath display on selected helps reduce screen clutter and graphic redraw time, particularly when
toolpaths working on complex or large files.
Tip: [Alt+T] or T toggles the toolpath display for all operations.
Toggle posting on selected toolpaths When the toolpath has this activated, posting this toolpath will be ignored.
The red insert arrow shows where the next toolpath operation will be inserted
Move insert arrow down
in the list. This function moves the arrow down one folder.
Position insert arrow after selected
Moves the arrow below the last selected operation or group.
operations or group
Scroll window so insert arrow is Scrolls the operations list so that insert arrow appears at the bottom of the
visible screen.
Only display selected toolpaths Displays only the highlighted toolpaths.
Displays geometry in the graphics area only if it is used to create the

selected toolpaths.
Only display associative geometry Tip: This is a great function that reduces screen clutter making it easy to
isolate and manipulate only the geometry affecting the operation of interest.
It is highly recommended that you learn and use this function.
Advanced Display Allows you to select the set of motions and features that will be
647
Item Definition
displayed.from the selected toolpath.
Opens the Tool Setup Manager dialog box to establish the physical
Set up tools on the machine
orientation and positioning of tools used in the active machine group.
Opens the Machine Reference Position Manager dialog box allowing you to
Edit reference positions
edit the location of the reference positions.
An exercise is provided for additional practice in using the Toolpaths Manager controls.
In Mastercam, is very important to note that the order in which you create the toolpaths is the same order
they will be machined. If you forgot to create one operation, let's say that you forgot to create the Facing
operation at the beginning of your toolpaths, you can simply move the insert arrow where you want to create
the toolpath and then start the toolpath.
You can do this by using one of the following controls:
To move an operation, you will need to select it and using the right mouse button, drag it to the desired
location. Release the button and choose Move before or Move after.
648
TOOLPATHS MANAGER RIGHT MOUSE MENU

Right mouse click in the Toolpaths Manager list area and it opens an extensive menu of commands.
Mill Toolpaths
Mill toolpaths displays a list with all

operations available in Mastercam. You
can start to create an operation from
here. For example by selecting Mill
Toolpaths, Contour the Chaining
dialog will appear on the screen and the
system will prompt you to chain the
geometry to be machined.
Note: The toolpaths that were

removed from the Toolpath Gallery
can be accessed here.
649
Edit Selected Operations
Edit common parameters allows you to edit the common parameters of all the operations inside of a
toolpath group. For example you can change the Feed plane value for all the operations inside the
group. Make sure that you have previously selected all operations.
Change NC file name - allows you to rename the

selected operations with a different NCI file name.
Change Program # - allows you to change the
NC program number.
Renumber tools - allows you to renumber the
tools by giving the first tool number and the
increment number.
Renumber work offsets - allows you to
renumber the work offsets when using more than
one offset (tombstone application).
Reverse toolpath - allows you to reverse the
chaining direction to change the cutting direction.
Recalculate feeds/speeds allows you to adjust
the feed rate, plunge rate, retract rate, and spindle
speed for multiple toolpaths based on a new stock
material. This procedure requires that the feed
calculation in Tool Settings be set to Material.
650
Groups
Groups allows you to organize operations.

Operation groups are handy for quick selection of
toolpaths. Selecting a group automatically selects
all operations within the group.
New Machine group - instructs the system to
add a new machine group.
New Toolpath group - instructs the system to
add a new toolpath group.
Rename - allows you to change the group name.
Delete - instructs the system to delete a selected
group.
Delete all empty - instructs the system to delete
all groups that have no operations.
Cut, Copy, Paste, Delete & Undelete
Cut, Copy/Paste - allows you to reorder the operations.

Delete/Undelete - allows you to delete selected operations or recover
them using undelete.
Expand & Collapse
Expand - expands all the operations and the groups inside of the
toolpaths manager.
Collapse - collapses all the operations and groups inside of the
toolpath manager.
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Reports
Reports - creates a text file that lists all of

the groups, operations, tools, geometry
and NCI destinations that are in the
toolpath manager. You can also create a
text file containing the operation
dependencies.
Operations list
652
Dependencies
653
Sort
Sort - allows you to reorganize operations.
Import, Export & Batch
Import - allows you to import saved operations from a library.

Export - allows you to export operations to a library.
Display Options, Setup Sheet And Tool List
Display options - sets the Toolpath Manager display options.

Setup Sheet - provides information about the work piece, including the
operations, tool reference, total machining time and comments added
during programming in a printable format.
Tool list - allows you to create a list of all the tools used in the existing file.
The Tool list will be opened in the Active Report Viewer.
Toolpath Editor - allows you to modify an existing toolpath. You can:
n Edit tool motion at specific point positions in the toolpath.

n Add points to increase tool motion.
n Move points to adjust tool motion.
n Delete selected points, passes, cuts and sections of a toolpath.
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IMPORTING AN ENTIRE JOB

In the lesson you will also learn how you can import the toolpath from another job that you already
completed.
Mastercam allows you to import all or some of the toolpaths that you created in a previous job into a current
job that can use the same toolpaths and tools. All you will need to do is to select the geometry for the
toolpaths from the current part. This process saves you a lot of time as you are using toolpaths that were
already checked in a part that you machined. You do not need to worry about the tool sizes, feeds and
speeds or about the cut parameters as you already proofed them in a previous job. While importing the
toolpath you can instruct Mastercam to use the current part plane and attributes such as levels.
EXPORT OPERATIONS TO A LIBRARY AND IMPORT THEM INTO A DIFFERENT JOB

Mastercam also allows you to export operations from an existing job and use them to machine different parts.
For example you can export to a library the operations that allow you to machine an 1/2 - 20 Tap hole. You
can save to a library the spot drill, the drill and the tap toolpaths. You can import these toolpaths in another
job that has 1/2 -20 Tap holes and select the part center points of these tap holes.

n Understanding Toolpaths Manager Controllers.
n Quick changes in the Toolpaths Manager such as update a toolpath, change order of operation,
renumber tools, change NC file name.
n Import toolpaths from an existing job.
n Export operations to a library.
n Import operations from a library.
655
Toolpaths Manager Instructor Demonstration:
Topics:
n Update toolpath
n Change operation order
n Renumber tools
n Change NC file name
n Import toolpaths from an existing job
n Export toolpaths to a library
n Import toolpaths from a library
NOTES:
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Toolpaths Manager Using Toolpaths Manager
USING TOOLPATHS MANAGER
Note: The Toolpaths Manager controls are self explanatory and easy to figure out. Hover the cursor
above one of the icons and the name should appear as shown.
In this lesson you will learn about some of them that are not as commonly used.
n Find and open the part Toolpaths Manager.mcam.
STEP 1: MODIFY AND UPDATE AN OPERATION
In this step you will modify operation 2 by transforming the toolpath from a RCT style Dynamic toolpath
with small stepovers to a Power Cutting style Dynamic toolpath with larger stepovers.
The following Toolpaths Manager controls will be used: Select all operations, Toggle display on selected
operations, Only display selected toolpaths and Regenerate all dirty operations.
n In the Toolpaths Manager, click on the Select all

operations icon to select all the toolpaths.
n Click on the Toggle display on selected

operations icon until all the toolpaths are
displayed as shown.
n You can also use Alt +T or just T to toggle
the display on/off.
n Use the Toggle display on selected
operations icon to remove the toolpath
display.
657
Toolpaths Manager Step 1: Modify And Update An Operation
n Click on the second toolpath to select it.

n In the Toolpaths Manager enable Only
display selected toolpaths icon as shown.
Note: This setting allows you to quickly check the existing toolpaths by selecting one operation at a time
and see only this operation toolpath displayed.
n The toolpath has a smaller stepover and creates a

lot of passes as shown.
n Click on the Parameters

of the second toolpath and
in the Cut parameters
change the Stepover to
60% to make this toolpath
a Dynamic Power
Cutting toolpath.
exit the toolpaths.
n Click on the Regenerate all dirty

operations icon to update the toolpath.
Note: You can also enable Generate

toolpaths which will automatically
update the toolpath.
658
Toolpaths Manager Step 2: Reorder Operations
Note: You can remove the change if you Right mouse click in
the Toolpaths Manager and select Undo. A list with the date
and times when you modified the toolpath will appear too. This
list will disappear once you save the file. Mastercam opens the
Cut parameters page and the value is automatically changed.
STEP 2: REORDER OPERATIONS
In this step you will move the second operation above the drilling operation. This insures a better rigidity of the part
as all of the inside pocketing and drilling operations are perform before machining the outside profile.
n Select the second operation and make sure that no other operation
is selected.
n Right mouse click on it and holding down the mouse button drag
the operation to the desired location after the Pocket operation.
n Release the button and choose Move after.
n The operation should be located as shown.
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Toolpaths Manager Step 3: Edit Common Parameters
STEP 3: EDIT COMMON PARAMETERS
Using Edit common parameters, in this step you will change the Clearance for all the toolpaths to 3.0".
n Click on the Select all

operations icon.
Toolpaths Manager and
select Edit selected
operations.
n From the fly out list, select
Edit common
parameters.
n Enable Clearance and set

it to 3.0.
Edit Common
Parameters.
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Toolpaths Manager Step 4: Renumber Tools
n Click on the Regenerate all dirty operations to

update the toolpaths.
n Check the Linking Parameters of any

of the toolpaths.
n The Clearance should be 3.0.
STEP 4: RENUMBER TOOLS
In this step you will create a Facing toopath and you will renumber the tools afterwards.
n Drag the Insert arrow to the

beginning of the operation list.
n Use Face toolpath and a 2" Face
Mill to remove the stock material
above the part.
n Set the Style to Zigzag.
n Top of stock = 0.125
(Absolute).
Note: The tool in the Facing operation is # 5. In the next

step you will learn how to use the Right mouse option that
allows you to Edit selected operations and Renumber
the tools.
n Click on Select all the operations.
661
Toolpaths Manager Step 4: Renumber Tools

Manager, and select Edit selected
operations and Renumber tools.
n Leave the defaults as shown.

n The tool numbers should look as shown.
662
Toolpaths Manager Step 5: Change NC File Name
STEP 5: CHANGE NC FILE NAME
In this step you will learn how to change the NC file name of the group of toolpaths that requires a different
program.
n Click on the Setup #2 group to

select all the operations inside
of the group.
Toolpaths Manager and
select Change NC file name.
n Change the name as needed.
663
Toolpaths Manager Step 5: Change NC File Name
The result should look as shown.
664
Toolpaths Manager Import Toolpaths
IMPORT TOOLPATHS
STEP 6: CHECK THE PART THAT HAS THE TOOLPATHS COMPLETED
In this step you will check the part that has all the toolpaths that will be imported in the new part.
Make sure that the toolpaths all have a description in the Comment area as that will help you when you are
importing them in a different part.
n Find and open the part Toolpath

Export.mcam.
n Enable Only display selected toolpaths icon.
n Select only the first operation.

This toolpath is a 2D High Speed Dynamic Mill and it is
used to rough the outside profile with a 1" Flat Endmill.
n Select only the second operation.

This toolpath is a 2D High Speed Dynamic Mill and it is
used to rough the pocket with the island and two open
edges. The toolpath uses a 1" Flat Endmill.
665
Toolpaths Manager Step 6: Check The Part That Has The Toolpaths Completed
n Select only the third operation.

This toolpath is a 2D High Speed Dynamic Mill and it is used to
rough the inside pocket with a 1" Flat Endmill.
n Select only the fourth operation.

This toolpath is a 2D High Speed Peel Mill and it is used to
machine the open channel with a 1/2" Flat Endmill.
n Select only the fifth operation.

This toolpath is a 2D High Speed Dynamic Mill with Rest Mill
and it is used to clean the areas that could not be machined
by the previous toolpaths (the pocket with the island and the
inside pocket) with a 3/16" Flat Endmill.
n Select only the sixth operation.

This toolpath is a 2D Contour and it is used to finish the walls
with a 3/16" Flat Endmill.
Note: You can close the file or you can keep the file open and open another Mastercam session.
666
Toolpaths Manager Step 7: Prepare And Orient Model For Machining
STEP 7: PREPARE AND ORIENT MODEL FOR MACHINING
In this step you will open the file and make sure that it is properly orientated in space for machining. You
still need to set the Stock size as this is a new part.
n Find and open the part Toolpath Import.mcam.

n Change to the Isometric View and display the axes
(F9 and Alt + F9) to determine the model orientation.
n Press F9 to remove the axis.

Manager.
n Expand the Properties and select the Tool settings
icon.
667
Toolpaths Manager Step 7: Prepare And Orient Model For Machining
668
Toolpaths Manager Step 8: Import Toolpaths
7.2 Check the Stock
n In the Stock Setup, click on the Add from

a bounding box icon.
n In the Bounding box panel, enable All
shown to automatically select the solid.
n Change X = 10.25.
n Change Y = 8.125.
n Click the OK button twice to accept and
close the Machine Group Properties.
STEP 8: IMPORT TOOLPATHS
In this step you will import the toolpaths from an already machined part. Some toolpaths might not be required such
as the third operation which machines the inside pocket, as the current part does not have an inside pocket.
You did not need to change anything in the parameters because in the original part toolpaths, in the Linking
Parameters, all the Depths were set to Incremental. Incremental Depth is based on the depth of the chained
geometry used in the toolpath. All the toolpath geometries were selected at the final depth.
n In the Toolpaths Manager, right mouse click and select

Import as shown.
n In the Import Toolpath Operation dialog box, click

on the Select Operations File as shown.
669
Toolpaths Manager Step 8: Import Toolpaths
n Change the File extension to Mastercam Files

(*.mcam; *.mcx-9; *mcx-8; *.mcx-7; *mcx-6; *mcx-
5; *.mcx).
n Find the Toolpath Export.mcam file.

n Select the Open button.
n In the Import Toolpath Operations dialog box, and enable

Assign current system tool and construction planes.
n Hold down the Ctrl key and select all the operations except
Operation 3 as shown.
n The message that 5 operations imported successfully should

appear on the screen.
n Click on the Cancel button to finish the import.
670
Toolpaths Manager Step 9: Adding The Geometry To The Toolpaths
Note: All the operations are "dirty" and all are missing the
geometry.
STEP 9: ADDING THE GEOMETRY TO THE TOOLPATHS
In this step you will add the necessary geometry to each toolpath.
9.1 Add the geometry to rough out the outside profile
n Click on the first operation Geometry.
671
n For this toolpath you need to use the stock as the Machining regions
(no chain to be selected).
n Select the Avoidance regions.
n In the Solid Chaining enable Loop and

select the bottom of the solid as shown.
n Select the OK button to exit the Solid

chains to check the
toolpath machining
area.
exit the Chain Options
dialog box.
672
n In the Toolpaths Manager, click on the Regenerate all

selected operations icon to generate the toolpath selected.

n Press Alt + T to remove the toolpath
display.
9.2 Add the geometry to rough out the pocket with the island
n Click on the second operation Geometry.
n Make sure that From outside is enabled.

n Click on the Select button in the Automatic regions.
673
n The Face button should be

enabled as shown.
n Select the face as shown

to check the toolpath
machining area.
the Chain Options dialog
box.


674
9.3 Add the geometry to machine the slot with Peel Milling toolpath
n Click on the third operationParameters and

change the Toolpath Type to Peel Mill.
n Select the 3/16 Flat Endmill.
n Click on the Machining regions.

enable Edge and select
the edges at the bottom
of the slot in the same
direction as shown.
Note: You can make the

solid Translucent if
needed by pressing Ctrl
+T.

exit the Chaining dialog
box.
exit the toolpath.

675

9.4 Add the geometry to remachine the areas that previous tool could not machine
Note: As you are machining the area that was machined in Operation #2 you can Copy the Geometry
from Operation #2 to the Geometry of Operation #4
n To copy the geometry just drag the Geometry from

Operation #2 to the Geometry of Operation #4.
n Release the mouse and select Add as shown.
The Geometry of the Operation #4 should have the 1 chains as

shown.
n In the Toolpaths Manager, select Operation #4

and click on the Regenerate all selected
operations icon to generate the toolpath
selected.
676

9.5 Add the geometry to finish the walls with Contour toolpath
n Click on the fifth operation Geometry.
n Right mouse click in the Chain Manager dialog box, and select
Add.
677
n In the Solid Chaining enable

Outer shared edges and select the
face of the pocket bottom in the
CCW direction as shown.

enable Boss button.
n Select the bottom face and make
sure the direction is CW as
shown.
n Enable Loop button.

n Select the outside profile in CW
direction by picking the edge as
shown.
Chain Manager.
678
n Click on the Display

all selection arrows to
double check the
directions of the
chains.

selected operations icon to generate the toolpath
selected.

Note: The tool in the last toolpath is too small for the outside and for the island contour. You can copy the
last operation and use a bigger tool for these walls, while ensuring that you fix the geometry for each
operation.
679
n From the Toolpath Manager, click on the Select all

n The part after being verified in Mastercam Simulator

The purpose of this lesson is to show you how you can import toolpaths from an existing part and apply them
to a new part geometry. You did not need to change anything in the parameters because in the original part
toolpaths , in the Linking parameters, the Depth was set to Incremental. The only toolpath that does not have
the Depth set to Incremental is the first toolpath used to remove the outside material. The Depth in this
operation had to be set to Absolute because we used the stock as Machining regions. You can adjust the
depth as needed in this current part.
9.7 Save your file

680
Toolpaths Manager Step 10: Export Toolpaths To A Library
STEP 10: EXPORT TOOLPATHS TO A LIBRARY
In this step you will learn how to export toolpaths to an operation library. You will export the toolpaths
required to machine 3/8"- 16 Tap Holes.
10.1 Open the file
n Find and open the part 0.375 Tap Holes Export.mcam.
10.2 Set the planes
n In the Planes Manager, make sure that the WCS,

Cplane and Tplane are set to "0.375 Holes Plane".
10.3 Check the Spot Drill, Drill and Tap toolpaths
n Enable Only display selected toolpaths icon.
681
n In the Toolpaths Manager, find the 0.375 Tap Holes Group.

n Select only the Spot drill operation.
This toolpath is a Spot drill toolpath and it is used to spot drill and
create a 0.03 chamfer with a 3/4" Spot Drill.
n Select only the Drill operation.

This toolpath is a Drill toolpath and it is used to drill the hole with a 3/8
-16 Tap.
n Select only the Tap operation.

This toolpath is a Tap toolpath and it is used to tap the hole with a 5/16"
Drill.
10.4 Check the entire group toolpath in Verify
n Click on the 0.375 Tap Holes Group to select all the

operations inside of it.
n In the Mastercam Simulator make the Stock
translucent and remove the Wireframe display.
n Run Verify.
682
10.5 Export the toolpaths
n In the Toolpaths Manager, 0.375 Tap Holes Plane Group,

select only the Spot Drill, Drill and Tap operations as shown.
n Right mouse click in the Toolpaths Manager and

select Export as shown.
n In the Export Toolpath Operations, name the Group "3/8"-

16 TAP Toolpaths".
n Scroll down to see make sure that only the drilling and tapping
toolpaths are selected as shown.
n Click on the Export Operations button.
683
Toolpaths Manager Step 11: Import The Library
n The message that "3 operations exported successfully" appears on

the screen.
n Click on the Cancel button to finish the

export.
STEP 11: IMPORT THE LIBRARY
In this step you will learn how to import the Operation Library into the new part.
11.1 Open the file
n Find and open the part 0.375 Tap Holes Import.mcam.

Isometric view.
11.2 Check the planes
n In the Planes Manager, make sure that the WCS, Cplane

and Tplane are set to "2D Machining Plane".
684
11.3 Import the Spot Drill, Drill and Tap toolpaths from the library

Import.
n In the Import Toolpath Operations, enable Assign

current system tool and construction planes.
n Enable Import operation groups.
n Scroll down and find the "3/8" - 16 TAP Toolpaths" and
click on the Group to select all the toolpaths as shown.
n The message "3 operations imported successfully" should appear on the

screen.
n Click on the Cancel button to finish the import.
685
n The toolpath should be dirty and listed in the Toolpaths

Manager as shown.
Note: All the "dirty" operations are missing the

geometry.
11.4 Add the geometry to the Spot Drill operation
n Click on the sixth operation Geometry.
n The Toolpath Hole Definition panel appears on the

screen.
n Select the center point of the top holes that are 3/8" in
diameter.
686
n Make sure that you

select the center
points as shown.
n Select the OK
button to exit
Toolpath Hole
Definition panel.
n In the Toolpaths Manager, click on the Regenerate all selected

operations icon to generate the toolpath selected.
11.5 Add the geometry to the Drill operation
n In the Toolpaths Manager, using the right mouse button,

select the Geometry of the spot drill and drag it over the
Geometry of the drill.
n Select Add.
687
n In the Peck Drill operation, select the Parameters and in the Linking parameters page,
change the Depth to -1.0.
n In the Toolpaths Manager, select the operation

and click on the Regenerate all selected
operations icon to generate the toolpath
selected.
11.6 Add the geometry to the Tap operation
Repeat the process and copy the Geometry from the drilling operation to the tap operation. Leave the
existing Depth -0.75.
11.7 Check the entire group toolpath in Verify
n Click on the 0.375-16 Tap Toolpaths Group to select

all the operations inside of it.
n In the Mastercam Simulator make the Stock
translucent and remove the Wireframe display.
n Run Verify.
688
SUMMARY:
In this lesson, you learned how to use Toolpaths Manager controllers and the Right mouse menu.
n Update toolpath
n Change operation order
n Renumber tools
n Change NC file name
n Import toolpaths from an existing job
n Export toolpaths to a library
n Import toolpaths from a library
689
Undercut & Custom Tool
690
Undercut & Custom Tool Introduction
INTRODUCTION
In this lesson you will learn how to machine an undercut. You will learn how to create in Mastercam a Slot
Mill tool from a STP file that was downloaded from www.machiningcloud.com. You will save the custom tool
as an assembly in a new tool library created in the Classic Tool Manager.
The Classic Tool Manager allows you to view and manage tool libraries, the tools in your part file, and tool
definitions.
You will learn:
n How to create a new custom tool from a STP file.

n How to machine an undercut using a Custom Slot Mill tool.
n How to create a new tool library.

n Using the Classic Tool Manager to create new tools and save them in a new library.
691
Undercut & Custom Tool Instructor Demonstration:
Topics:

n Using the Classic Tool Manager to create a new
library.
NOTES:
692
Undercut & Custom Tool Step 1: Open The Part
STEP 1: OPEN THE PART

n Find and open the Undercut.mcam file.
STEP 2: CREATING A CUSTOM T - SLOT CUTTER
In this step you will learn how to create a custom T - Slot Cutter using a Step file downloaded from
machiningcloud.com
Resources - Download the STEP files from www.EMASTERCAM.COM/TRAININGFILES/
Note: The tool is Slot Mill (STP) from the Grooving and Slitting Cutters.
The Step file in Mastercam should look as shown.
693
Undercut & Custom Tool Step 3: Undercut Machining -Contour Toolpath
STEP 3: UNDERCUT MACHINING -CONTOUR TOOLPATH
Toolpaths
n From the 2D group, select Contour.
n Select the edge as shown.
3.1 Create a T Slot Mill by importing a STEP file from the Machine Cloud Catalog
n Right mouse click in the Tool

window and select Create tool.
694
n In the Select Tool Type page select the Slot mill as shown.
n In the Define Tool

Geometry click on the
Import custom
geometry from a file.
n Find and select the Slot
Mill.stp
695
n The
Render
Imported
Tool
geometry
should look
as shown.
Note: You can display the

Render Imported Tool used for
Backplot or the Render
Mastercam Tool that will be used
to calculate the toolpath.
You can Zoom in and Zoom out to
check the tool geometry in either
state.
696
n Change the
thickness to
0.25 as shown.
n Select the Next
button.
n In the Finalize
Properties set the
SFM to 100 and
press Enter.
n The Feed rate,
Plunge rate, Retract
rate should be
changed as needed.
n Select the Finish
button.
Note: These are just suggested feeds and speeds. They depend on the machine, tool material and part
material. Change them as needed.
697
3.2 Cut Parameters
n In the Cut
Parameters,
change the
Compensation
type to Wear.
3.3 Depth Cuts

n Set the Max rough
step to 0.125 as
shown.
698
3.4 Lead In/Out
n Set the Lead

In/Out parameters
as shown.
3.5 Linking
n Set the parameters as

shown.
699
n Select the OK button to exit 2D Toolpath - Contour.
n The toolpath
should look as
shown.

700
3.8 Compare
n In the Verify
tab, click on
the Compare
icon.
n Click on the Refresh button to run the compare.
701
Undercut & Custom Tool Step 4: Create A Tool Library
STEP 4: CREATE A TOOL LIBRARY

4.1 Tool Manager
Toolpaths
n In the Utilities
group, select the
Tool Manager as
shown.
n The Slot Mill will be listed in the part section as shown.
702
n To create a new library, in the Library section, select Create a new library button as shown.
n Enter the library

name
MyCustomTool and
select the Save
button.
703
n To add the tool to the new library, select it first and then click on the down arrow as shown.
Note: The tool is added under the Assemblies tab. Any other tool that you add from Mastercam existing
libraries will be listed under Tools.
n Select the OK button and Yes to Save changes to your current library.
704
Undercut & Custom Tool Step 5: Find The Tool In The New Library
STEP 5: FIND THE TOOL IN THE NEW LIBRARY

5.1 Open the Part
n Find and open the UndercutExercise.mcam file.
STEP 6: UNDERCUT MACHINING -CONTOUR TOOLPATH
Toolpaths
n From the 2D group, select Contour.
n In the Solid Chaining, select the

Edges button as shown.
n Hold down the Shift key and select the
edge on the solid as shown.
n Select the OK button to finish the
selection.
705
6.1 Tool
n Click on the Select library

tool button.
n Select the New

Library button to open
the MyCustomTool.
n Find MyCustomTool.TOOLDB and select the Open button.
706
n Disable
Filter
Active and
make sure
that in the
Display
mode Both
is enabled.
n Select the
tool as
shown.
n Select the
OK button to
continue.
6.2 Tool
n The Tool page

parameters should
look as shown.
707
6.3 Cut Parameters
n In the Cut
Parameters,
change the
Compensation
type to Wear.
6.4 Depth Cuts

n Set the Max rough
step to 0.125 as
shown.
708
6.5 Lead In/Out
n Set the Lead

In/Out parameters
as shown.
6.6 Linking
n Set the parameters as

shown.
709
Undercut & Custom Tool Step 7: Save Your File
n Select the OK button to exit 2D Toolpath - Contour.


shown.

SUMMARY:
In this lesson, you learn how to machine an undercut .You will learn how to create in Mastercam a Slot Mill
tool from a STP file that was downloaded from www.machiningcloud.com. You will save the custom tool as
an assembly in a new tool library created in the Classic Tool Manager.
n Create an undercut toolpath using Contour toolpath.

n Create a custom tool from a STP file.
n Save the tool into a new library.
n Find the tool from the new library and use it for another part.
710

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IHS Mill 2D Advanced User

Mastercam 2023 Professional Courseware - IHS Mill 2D Advanced User

Copyright: 1998 - 2023 In-House Solutions Inc. All rights reserved

Software: Mastercam 2023

Date: July 22, 2022

IHS Mill 2D Advanced User 1

Mastercam® User Interface: 22

Setting The Grid 23

Conventions Used In This Book: 23

Installing MPMASTER Post 24

Customize Ribbon Bars 25

Create A New Tab 27

Configuration Backup & Restore 33

Setup Mastercam Interface 35

Customize Right Mouse Menu 44

Customize The Right Mouse Button Menu 46

Add Analyze Functions To The Right Mouse Button Menu 46

Step 1: Open The File 54

Step 2: Set The Default Tool 54

Step 3: Set The Cut Parameters Defaults 56

Step 4: Linking Parameters 57

Step 5: Save The Parameters As Defaults 57

Step 6: Backplot The Toolpath 58

Step 7: Reload The Part 58

Step 8: Create The Face Toolpath 58

Step 9: Check The Cut Parameters Defaults 59

Step 10: Check The Linking Parameters 60

Step 1: Open The File 64

Step 2: Setup Sheet 64

Dynamic Transform Reference Information 74

Step 1: Open The File 74

Step 3: Create A Viewsheet 80

Step 4: Select A Machine And Set The Stock 81

Step 5: Machine The Pocket Using Dynamic Mill 86

Step 6: Export The Toolpath For Later Use 90

Step 7: Define A Plane Using The Gnomon 91

Step 8: Circle Mill The 1" Diameter Holes 97

Step 9: Using Toolpath Groups 101

Step 10: Define A New Plane Using Plane Manager 104

Step 11: Import The Operation To The New Plane 108

Step 13: Machine The Third Pocket 115

Step 15: Change The NC File Names 119

Step 17: Save Your File 122

Plane Creation & Indexing 125

Instructor Demonstration: 127

Step 3: Define A Plane From Geometry 132

Step 4: Select A Machine 138

Step 5: Circle Mill The Hole 140

Step 6: Create A Plane Using From Entity Normal 143

Step 7: Drill The Hole 146

Step 8: Post Process The Toolpaths To Generate The G-Code 149

Step 9: Save Your File 150

Levels & Viewsheets 153

Instructor Demonstration Preview: 156

Step 1: Open The File 157

Step 2: Working With Levels 157

Step 3: Working With Viewsheets 168

Step 4: Save Your Mastercam File 181

Advanced Drilling Toolpath 184

Instructor Demonstration: 186

Step 1: Open The File 187

Step 2: Advanced Drilling For Deep Holes 187

Step 3: Advanced Drill For Holes With Air Region 196