SAMPLE Mastercam_X9_Mill_Advanced Mastercam X9 Mill Advanced Training Tutorial

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Mill Advanced Training Tutorial

Mastercam X9 Mill Advanced Training Tutorial

Copyright: 1998 - 2015 In-House Solutions Inc. All rights reserved Software: Mastercam X9

Author: Mariana Lendel ISBN: 978-1-77146-348-5 Date: May 15, 2015 Notice

In-House Solutions Inc. reserves the right to make improvements to this manual at any time and without notice.

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TABLE OF CONTENTS

GETTING STARTED

Getting Started ... 1

Tutorials

Tutorial #1 - Surface Rough Pocket, Surface Finish Shallow & Surface Finish Contour ...13 Tutorial #2 - Surface Rough Pocket, Surface Finish Parallel & Surface Finish Pencil...101 Tutorial #3 - Stock Model, Surface HS Area Roughing - Rest Material & Radial &

Surface Finish Blend ...183 Tutorial #4 - Surface HS Dynamic OptiRough, Surface HS OptiRough - Rest Material,

Surface HS Hybrid & Surface HS Scallop...307 Tutorial #5 - Surface HS Area Roughing, Scallop, Spiral & Waterline...471 Tutorial #6 - Surface HS Dynamic OptiRough, Horizontal, Waterline, Raster & Pencil ... 645 Tutorial #7 - Surface HS Dynamic OptiRough, Area Roughing - Rest Material, Surface Finish Scallop, Leftover & Project ...735

Quiz Answers ... 867

TUTORIAL #1

1

OVERVIEW OF STEPS TAKEN TO CREATE THE FINAL PART:

OVERVIEW OF STEPS TAKEN TO CREATE THE FINAL PART:

From Drawing to CAD Model:

 The student should examine the drawing on the following page to understand what part is being created in this tutorial.

 From the drawing we can decide how to create the geometry in Mastercam. Create the 3D CAD Model used to generate Toolpaths from:

 The student will create the wireframe needed to create the surfaces.

 Surface creation commands such as Draft Surface, Curve One Edge, Flat Boundary, and Fillet Surfaces will be used.

Create the necessary Toolpaths to machine the part:

 The student will set up the stock size and the clamping method to be used.  A Surface Rough Pocket toolpath will be created to rough out the part.  A Surface Finish Shallow toolpath will be created to machine the floors.  A Surface Finish Contour toolpath will be created to machine the boss walls. Backplot and Verify the file:

 The Backplot will be used to simulate a step-by-step process of the tool’s movements.  The Verify will be used to watch a tool machine the part out of a solid model.

Post Process the file to generate the G-code:

 The student will then post process the file to obtain an NC file containing the necessary code for the machine.

TUTORIAL #1

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SETTING UP THE GRAPHIC USER INTERFACE

GEOMETRY CREATION

STEP 1: SETTING UP THE GRAPHIC USER INTERFACE

Please refer to the Getting Started section to set up the graphical user interface.

STEP 2: CREATE RECTANGLES

In this step you will learn how to create rectangles given the width, the height, and the anchor position.

Step Preview:

2.1 Create the 5.0" by 5.0" rectangle

CREATE

 Rectangle.

 Enter the Width and the Height and enable Anchor to center and disable the Create surface button if needed as shown.

 Press Enter after typing the values to see a preview of the rectangle.

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A surface can be described as the skin on the top of a 3D wireframe. If the surface option is on, instead of the four lines of the rectangle, you will see extra lines which represent the surface display while it is not shaded. You do not need to create the surface at this time.

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 [Select position of base point]: Select the Origin as shown inFigure: 2.1.1.

Figure: 2.1.1

 Make sure that when selecting the origin, the visual cue of the cursor changes as shown.  Select the Apply button to stay in the same command.

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

2.2 Create the 4.0" by 4.0" rectangle

 Enter the Width and the Height and enable Anchor to center as shown.

 Make sure that Create surface button is not selected (not highlighted).

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While creating the geometry for this tutorial, if you make a mistake, you can undo the last step using the Undo icon. You can undo as many steps as needed. If you delete or undo a step by mistake, just use the Redo icon. To delete unwanted geometry, select the geometry first and then press Delete from the keyboard.

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CREATE RECTANGLES

 [Select position of base point]: Select the Origin as shown in Figure: 2.1.1.  The drawing should look as shown below.

 Select the Apply button to stay in the same command.

2.3 Create the 2.5" by 2.5"rectangle Z-.375

 Make sure that in the Status Bar, located at the bottom of the graphics window, the construction mode is set to 3D as shown.

 Enter the Width and the Height and enable Anchor to center as shown.

 Enter the coordinates for the Rectangle as shown.

 Select the OK button to exit the Rectangle command.  Change the Graphic view to Isometric.

CREATE FILLETS FOR THE TWO RECTANGLES

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 The geometry should appear as shown.

STEP 3: CREATE FILLETS FOR THE TWO RECTANGLES

In this step you will learn how to create fillets to all corners of the inside rectangle using Fillet chain command.

Step Preview:

CREATE  Fillet.  Chains.

TUTORIAL #1

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CREATE FILLETS FOR THE TWO RECTANGLES

 Make sure that in the Chaining dialog box, the Chain button is enabled as shown.

 [Select chain 1]: Select the rectangle as shown.

 Select the OK button to exit the Chaining dialog box.

 Change the Radius to 1.0" (press Enter).

 Select the Apply button to stay within the command.

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Mastercam will automatically insert fillets at all four corners with the radius to be the default value or the last value used during this Mastercam session.

CREATE FILLETS FOR THE TWO RECTANGLES

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 The geometry should look as shown.

 [Select chain 2]: Select the rectangle as shown.

 Select the OK button to exit the Chaining dialog box.  Change the Radius to 0.500" (press Enter).

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CREATE CIRCLE CENTER POINT

 The geometry should look as shown.

STEP 4: CREATE CIRCLE CENTER POINT

This step shows you how to create a circle given the diameter and the center point.

Step Preview:

CREATE  Arc.

 Circle Center Point.  Enter the Diameter 0.500".

 Enter the coordinatesX0, Y0, Z-0.25 as shown.

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 Enter the Diameter 1.000".

 Enter the coordinatesX0, Y0, Z-0.5 as shown.

 Select the OK button to exit the command.  The geometry should look as shown.

 Change the graphic view to Isometric to see the preview of the command result.  The geometry should look as shown.

TUTORIAL #1

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CREATE THE DRAFT SURFACES

STEP 5: CREATE THE DRAFT SURFACES

A surface can be described as the skin on the top of a 3D Wireframe. This step shows you how to create the two draft surfaces given the length and draft angle.

Draft surfaces are surfaces generated by extruding one or more contours along a line defined by an angle and a length. The

surface is used to create an angle surface, a tapered wall, or cones and cylinders.

Step Preview:

5.1 Create the Draft surface with a 10 degree angle

CREATE  Surface.  Draft.

 [Select line, arc, or spline 1]: Leave the settings in the Chaining dialog box as they are and select the circle as shown.

CREATE THE DRAFT SURFACES

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 In the Draft Surface dialog box, make sure that the Length is enabled and change it to 0.25" as shown in

Figure: 5.1.1.

 In the same dialog box, change the Angle to 10.0 and press Enter.

Figure: 5.1.1

Figure: 5.1.2

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Mastercam can display the surface in two modes: shaded and unshaded (wireframe display). You can shade the surfaces by holding down the Alt key and enter S. Repeat the step if you would like to unshade the surfaces. The preview of the surface in shaded mode should look as shown inFigure: 5.1.2

TUTORIAL #1

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CREATE THE DRAFT SURFACES

 Press Alt + S to see the surface in the unshaded mode as shown in Figure: 5.1.3.

Figure: 5.1.3

 Select the Apply button to stay in the same command.

 [Select line, arc, or spline 2]: Leave the settings in the Chaining dialog box as they are and select the circle as shown.

CREATE THE DRAFT SURFACES

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 In the Draft Surface dialog box, make sure that the Length is enabled and change it to 0.25" as shown in

Figure: 5.1.4.

Figure: 5.1.4

 The preview of the surface should look as shown inFigure: 5.1.5.

Figure: 5.1.5

TUTORIAL #1

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CREATE THE DRAFT SURFACES

5.2 Create the straight wall draft surface

 [Select line, arc, or spline 1]: Leave the settings in the Chaining dialog box as they are and select the rectangle as shown.

 Select the OK button to exit the Chaining dialog box.

 In the Draft Surface dialog box, make sure that the Length is enabled and change it to 0.375" as shown and press Enter.

CREATE THE DRAFT SURFACES

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 Select the Flip buttons next to the length if needed to have the surface generated as shown in

Figure: 5.2.1.

Figure: 5.2.1

 Select the Apply button to stay within the Draft Surface dialog box.

 [Select line, arc, or spline 2]: Leave the settings in the Chaining dialog box as they are and select the rectangle as shown.

TUTORIAL #1

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CREATE THE DRAFT SURFACES

 In the Draft Surface dialog box, make sure that the Length is enabled and change it to 0.375" as shown and press Enter.

 Select the Flip buttons next to the length if needed to have the surface generated as shown in

Figure: 5.2.2.

Figure: 5.2.2

CREATE A CURVE AT THE EDGE OF THE SURFACE

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STEP 6: CREATE A CURVE AT THE EDGE OF THE SURFACE

In this step you will learn how to create a curve at the open edge of a surface. You need to create curves at the edges of sufaces to use them later to generate other surfaces. The edge of a surface can not be selected or used for any geometry creation or toolpath creation.

Create Curve on One Edge command allows you to create a curve on a single surface edge.

TUTORIAL #1

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CREATE A CURVE AT THE EDGE OF THE SURFACE

6.1 Create the curve

CREATE  Curve.

 Curve on One Edge.

 Press Alt + S to unshade the surfaces as shown in Figure: 6.1.1.

 [Select a surface]: Select the draft surface (with the 10 degree angle) as shown inFigure: 6.1.1.

 [Move arrow to Desired Edge of Surface]: Move the arrow to the lower edge of the surface as shown in

Figure: 6.1.1 and click to select it.

Figure: 6.1.1

 Select the Apply button to stay within the command.

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The curves are not easy to see as they are created on the top of the surface flowlines, which are the graphical representation of the surfaces. Try clicking on the Repaint button to refresh the screen and better see the curves.

CREATE A CURVE AT THE EDGE OF THE SURFACE

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 Hold down the Alt key and click on the down arrow five times to rotate the part as shown in Figure: 6.1.2.  [Select a surface]: Select the draft surface as shown inFigure: 6.1.2.

 [Move arrow to Desired Edge of Surface]: Drag the arrow to the bottom and click to create the edge curve on the bottom as shown inFigure: 6.1.2.

Figure: 6.1.2

TUTORIAL #1

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SUGGESTED FIXTURE:

TOOLPATH CREATION

SUGGESTED FIXTURE:

SELECT THE MACHINE AND SET UP THE STOCK

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STEP 10: SELECT THE MACHINE AND SET UP THE STOCK

In Mastercam, you select a Machine Definition before creating any toolpaths. The Machine Definition is a model of your machine tool's capabilities and features and acts like a template for setting up machining jobs. The machine definition ties together three main components: the schematic model of your machine tool’s components, the control definition that models your control unit’s capabilities, and the post processor that will generate the required machine code (G-code). For a Mill Advanced exercise (3D toolpaths) you need only a basic machine definition.

Step Preview:

 To display the Operations Manager press Alt + O.  Use the Fit icon to fit the drawing to the screen. MACHINE TYPE

 Mill. Default.

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

TUTORIAL #1

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SELECT THE MACHINE AND SET UP THE STOCK

 Select Tool settings to set the tool parameters.

 Change the parameters to match theFigure: 10.0.1.

Figure: 10.0.1

Program # is used to enter a number if your machine tool requires a number for a program name.

Assign tool numbers sequentially allows you to overwrite the tool number from the library with the next available tool number. (First operation tool number 1; Second operation tool number 2, etc.)

Warn of duplicate tool numbers allows you to get a warning if you enter two tools with the same number.

Override defaults with modal values enables the system to keep the values that you enter.

Feed Calculation set From tool uses feed rate, plunge rate, retract rate and spindle speed from the tool definition.

SELECT THE MACHINE AND SET UP THE STOCK

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 Select the Stock setup tab to define the stock.

 Select All Entities button to allow Mastercam to establish the necessary stock based on the existing geometry as shown.

TUTORIAL #1

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SELECT THE MACHINE AND SET UP THE STOCK

 Round the values if needed and change the Z value for the stock to 1.5" as shown in Figure: 10.0.2.

Figure: 10.0.2

 Select the OK button to exit Machine Group Properties.  Use the Fit icon to fit the drawing to the screen.

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The extra 0.5 added to the stock thickness is for fixture purposes.

The Stock Origin values adjust the positioning of the stock, ensuring that you have equal amount of extra stock around the finished part.

Display options allow you to set the

stock as Wireframe and to fit the stock to the screen. (Fit Screen)

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 The stock should look as shown.

This tutorial utilizes a set of legacy surface toolpaths to machine the part. We begin by showing you legacy toolpaths as they still have some value in certain situations and the parameters for these toolpaths are easier to understand for someone just getting started with 3D machining.

That being said, there are more efficient toolpaths that can be used to machine the same part. If you will actually machine this part, we suggest you use the Surface High Speed OptiArea toolpath as your roughing toolpath of choice. Finally, to finish the part, you can use the Surface High Speed Hybrid toolpath which we will describe in Tutorial 4.

STEP 11: ROUGH OUT THE PART USING SURFACE ROUGH POCKET

Surface Rough Pocket toolpath is used to remove a lot of stock quickly by creating a series of planar cuts (constant Z). It is

used to machine both bosses or cavities on surfaces or solid models.

Toolpath Preview:

TUTORIAL #1

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ROUGH OUT THE PART USING SURFACE ROUGH POCKET

11.1 Surfaces and Containment selections

TOOLPATHS  Surface Rough.  Pocket.

 If the New 3D Advanced Toolpath Refinement Feature! appears, enable I’ve tried this feature and want to keep it to use. Do not show me this dialog again.

 Select the OK button to continue.

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

 [Select Drive Surfaces]: From the Quick Mask toolbar select QM Surfaces icon.

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 To limit the tool motion inside of boundary, in the Toolpath/surface selection dialog box, click on the Select button to select a Containment as shown.

 Press Alt + S if needed and leave the default parameters in the Chaining dialog box and select the chain as shown.

TUTORIAL #1

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ROUGH OUT THE PART USING SURFACE ROUGH POCKET

11.2 Setting the Toolpath parameters page

The Toolpath parameters page allows you to select a tool, set the feeds and speeds, enter a comment about the operation, and set other general toolpath parameters.

 To select the tool, click on Select library tool button as shown.

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 Select the OK button to exit from the Tool Selection dialog box. The Surface Rough Pocket dialog box will appear.

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The feeds and spindle speed are based on the tool definition. You can overwrite them with the feeds and speed that you want to use. You can also let Mastercam calculate the feeds and speed using the Feed speed calculator as shown next.

TUTORIAL #1

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ROUGH OUT THE PART USING SURFACE ROUGH POCKET

 Right mouse click in the tool display window, and select Feed and speed calculator as shown.

 Make sure the parameters match the screenshot below.

 Select the OK button to accept the default settings.

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 The Toolpath Parameters page should look as shown inFigure: 11.2.1.

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ROUGH OUT THE PART USING SURFACE ROUGH POCKET

11.3 Set the parameters in the Surface parameters page

In this page you can set the Clearance, the Retract and the Feed plane heights. You can reselect the drive surfaces and boundaries required by the toolpath. You can also leave stock on drive surfaces and for some toolpaths leave stock on check surfaces too. The Surface parameters page is the same for all surface toolpaths.

 Select the Surface parameters tab and change the parameters as shown inFigure: 11.3.1.

Figure: 11.3.1

Clearance sets the height at which the tool moves to and from the part. Retract sets the height at which the tool moves up to before the next pass. Feed plane sets the height the tool rapids before changing to the plunge rate. Drive surfaces are surfaces that are currently machined.

Stock to leave on drive sets the amount of stock left on the drive surface that will be machined by a finish toolpath.

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11.4 Set the Rough parameters page

The Rough parameters page allows you to set the tolerance for machining, the Z stepdown, Z cut depths, the Gap settings, and the Entry options. The total tolerance is set to a higher values as this is a roughing operation.

 Select the Rough parameters page and change the parameters as shown inFigure: 11.4.1.

Figure: 11.4.1

Total tolerance is the sum of the arc filter tolerance and cut tolerance. The cut tolerance determines the accuracy of the surface toolpath using chordal deviation.

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ROUGH OUT THE PART USING SURFACE ROUGH POCKET

 Enable Entry - Helix button and set the parameters for helical entry into the part as shown in Figure: 11.4.2. Figure: 11.4.2

 Select the OK button to exit Entry-Helix.

Minimum/Maximum radius value sets the minimum/maximum radius of the helix as a percentage of the tool diameter or as an absolute value.

Z clearance value sets the distance in the Z-axis above the top of the stock where the helix entry begins. XY clearance sets the minimum distance in the XY axis between the helix and the pocket walls.

Plunge angle sets the helix angle.

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11.5 Set the Pocket parameters page

Pocket parameters page sets up roughing and finishing passes for a surface rough pocket toolpath. It allows you to set the cutting method, the stepover and finish passes that can be performed with this roughing operation.

 Select the Pocket parameters page and change the parameters as shown inFigure: 11.5.1.

Figure: 11.5.1

True spiral creates roughing passes of all tangent arcs. The result provides a smooth motion for the tool, a short NC program, and good clean out.

Stepover percentage sets the distance between cutting passes in the X and Y axes as a percentage of the tool diameter or the tool flat.

Finish option allows you to create finish passes at each z-depth cuts.

TUTORIAL #1

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BACKPLOT THE TOOLPATH

STEP 12: BACKPLOT THE TOOLPATH

Backplotting shows the path the tools take to cut the part. This display lets you spot errors in the program before you

machine the part. As you backplot toolpaths, Mastercam displays additional information such as the X, Y, and Z coordinates, the path length , the minimum and maximum coordinates and the cycle time. It also shows any collisions between the workpiece and the tool.

 Make sure that the toolpath is selected (signified by the green check mark on the folder icon).  Select the Backplot selected operations button.

 Select the Backplot tab and have the following settings enabled as shown.

 Select the Home tab and make sure that you have the following settings on as shown.

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A new window is lunched in which you can choose to check the toopath using either Backplot or Verify. To go back to Mastercam you can either close this window or use the Taskbar and select the Mastercam window.

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 To see the part from an Isometric view right mouse click in the graphics window and select Isometric as shown.

 To fit the workpiece to the screen, right mouse click in the graphics window again and select Fit.

 You can step through the Backplot by using the Step forward or Step back buttons.  You can adjust the speed of the backplot.

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BACKPLOT THE TOOLPATH

 The toolpath should look as shown Figure: 12.0.1.

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STEP 13: SIMULATE THE TOOLPATH IN VERIFY

Material Mode shows the path the tools take to cut the part with material removal. This display lets you spot errors in the

program before you machine the part. As you verify toolpaths, Mastercam displays additional information such as the X, Y, and Z coordinates, the path length , the minimum and maximum coordinates and the cycle time. It also shows any collisions between the workpiece and the tool.

 From Mastercam Backplot Home tab, switch to Verify and leave the settings for the Visibility and Focus as shown in Figure: 13.0.1.

Figure: 13.0.1

 Select the Play button in the VCR bar to run Verify.  The part should look as shown in Figure: 13.0.2.

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SIMULATE THE TOOLPATH IN VERIFY

 Right mouse click in the Simulator window and select Isometric if needed.  To see the entire part, right mouse click again and select Fit.

 To check the part step by step, click first on the Reset simulation icon.  Click on the Step Forward to see the tool moving one step at a time.  The part should look as shown after several steps.

 Click on the Step Forward until the toolpath is completed.

 Minimize Mastercam Simulator window to go back to Mastercam window.

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To rotate the part, move the cursor to the center of the part, click and hold the mouse wheel and slowly move it in one direction.

To Zoom In or Out hold down the mouse wheel and scroll up or down as needed.

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There are a lot of air movements at the beginning of the toolpath. To remove these extra movements we will have to change the settings of the Cut Depths parameters.

INDEX

Numerics

2D / 3D Construction Modes ... 7

3 Fillet Blend Surface ... 559

A

Analyze A Spline ... 505

Arc Tangent ... 342

Attributes... 7

B

Backplot The Toolpath ... 70

Backplotting... 70

Boolean Remove...377

,

389 Bounding Box ... 57

Break the fillet at the midpoint ... 529

Break Two Pieces... 529

C

Color ... 7

Constant Radius ... 402

Control Definition ... 55

Create A Curve At The Edge Of The Surface ... 31

Create A Flat Boundary Surface ... 35

Create A Net Surface ... 134

Create Arc Endpoints ... 349

Create Circle Center Point ... 22

Create Circle Center point ... 22

Create Curve At Intersection ... 534

Create Curve One Edge... 31

Create Fillets ... 19

Create Fillets For The Two Rectangles... 19

Create Parallel Lines ... 106

Create Polar Lines ... 110

Create Rectangles ... 16

Create Revolved Surfaces ... 121

Create Silhouette Boundary ... 407

Create The Draft Surfaces... 24

Create The Fillet Surface... 518

Create The Fillet Surfaces ... 42

Create The obround rectangular shape ... 120

Create The Parallel Lines ... 106

Create The Pocket Floor Surface ... 513

Create The Revolved Surface... 121

F

Fillet Surface ... 42

Finish parallel parameters ... 163

Finish pencil parameters ... 171

Flat boundary surfaces ... 35

Function Prompt ... 4

G

Graphic Area ... 4 Groups ... 8 Gview ... 7

L

Level... 7 Line Style... 7 Line Width ... 7

M

Machine Definition ... 55 Material Mode ... 267 Mirror ... 323

Mirror about a line ... 525

Mirror the profile about the Y axis ... 496

Mitered Corners ... 402 MRU Toolbar... 4

N

Net Surface ... 134

O

Offset Contour ... 338 Offset Surface ... 764 Origin ... 4

P

Planes ... 7

Pocket parameters page... 69

Point Style... 7

Post Process The File ... 92

Post Processing ... 92

Post Processor ... 55

Program # ... 56

Project ... 124

Propagate Along Tangencies ... 402

Q

INDEX

S

Scale... 4

Select The Machine And Set Up The Stock ... 55

Setup the stock model ... 244

Shaded ... 214

Simulate the toolpath in Verify ... 73

Solid Revolve ... 366

Status Bar... 4

Steep/shallow ... 263

Stock Models ... 244

Stock Origin ... 58

Surface Finish Blend ... 282

Surface Finish Leftover ... 833

Surface Finish Parallel ... 159

Surface Finish Pencil ... 167

Surface Finish Scallop ... 824

Surface Finish Shallow ... 76

Surface High Speed Scallop ... 591

Surface High Speed Core Roughing ...250

,

573 Surface High Speed Finish Horizontal ... 695

Surface High Speed Finish Spiral... 608

Surface High Speed Hybrid ... 445

Surface High Speed OptiArea ...415

,

802 Surface High Speed OptiCore ... 679

Surface High Speed Pencil ... 718

Surface High Speed Radial ... 271

Surface High Speed Raster... 710

Surface High Speed Rest Roughing ... 813

Surface High Speed Restmill ... 429

Surface High Speed Waterline ... 622

Surface Rough Pocket...59

,

145 Surface Rough Pocket Toolpath... 145

Surface Rough Project ... 846

Swept Surface ...201

,

352

T

Toolbars ... 4

Toolpath parameters page ... 62

Toolpaths/Solids Operations Manager... 4

Transform Toolpaths ... 293

Transitions ... 262

Trim 1 Entity ... 345

Trim 2 Entities...112

,

117 Trim the draft surfacesto the curve... 536

Trim The Geometry ... 112

Trim The Surfaces ... 534

V

Variable Radius ... 402

View Port XYZ Axes ... 5

W

Wireframe ... 214

Work Coordinate System (WCS) ... 8

Z

Z Depth ... 7