Mastercam 2017 Mill Advanced Training Tutorial SAMPLE

IMPERIAL

TRAINING TUTORIAL SERIES

MILL

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Mastercam 2017Mill Advanced Training Tutorial

Copyright: 1998 - 2017 In-House Solutions Inc. All rights reserved Software: Mastercam 2017

Author: Mariana Lendel ISBN: 978-1-77146-528-1 Date: June 29, 2016

Notice

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

Disclaimer Of All Warranties And Liability

In-House Solutions Inc. makes no warranties, either express or implied, with respect to this manual or with respect to the software described in this manual, its quality, performance, merchantability, or fitness for any particular purpose. In-House Solutions Inc. manual is sold or licensed "as is." The entire risk as to its quality and performance is with the buyer. Should the manual prove defective following its purchase, the buyer (and not In-House Solutions Inc., its distributer, or its retailer) assumes the entire cost of all necessary servicing, repair, of correction and any incidental or consequential damages. In no event will In-House Solutions Inc. be liable for direct, indirect, or consequential damages resulting from any defect in the manual, even if In-House Solutions Inc. has been advised of the possibility of such damages. Some jurisdictions do not allow the exclusion or limitation of implied warranties or liability for incidental or consequential damages, so the above limitation or exclusion may not apply to you.

Copyrights

This manual is protected under International copyright laws. All rights are reserved. This document may not, in whole or part, be copied, photographed, reproduced, translated or reduced to any electronic medium or machine readable form without prior consent, in writing, from In-House Solutions Inc.

Trademarks

Mastercam is a registered trademark of CNC Software, Inc.

Microsoft, the Microsoft logo, MS, and MS-DOS are registered trademarks of Microsoft Corporation; Windows 7 and Windows 8 are registered trademarks of Microsoft Corporation.

MASTERCAM SHORTCUTS

_{MASTERCAM QUICK REFERENCE CARD}

MASTERCAM SHORTCUTS

Function Keyboard

Shortcut Function Keyboard Shortcut

Analyze entities F4 Mastercam version, SIM serial number Alt+V

AutoSave Alt+A Motion controller rotation point Alt+F12

C-Hook or user app Alt+C Pan Arrow keys

Configure Mastercam Alt+F8 Paste from clipboard Ctrl+V

Copy to clipboard Ctrl+C Redo an event that has been undone Ctrl+Y

Cut to clipboard Ctrl+X Repaint F3

Delete entities F5 Rotate Alt+Arrow keys

Drafting global options Alt+D Select all Ctrl+A

Exit Mastercam Alt+F4 Selection grid parameters Alt+G

Fit geometry to screen Alt+F1 Shading on/off Alt+S

Gview–Back Alt+3 Show/hide all axes (WCS, Cplane, Tplane) Alt+F9

Gview–Bottom Alt+4 Show/hide coordinate axes F9

Gview–Front Alt+2 Show/hide displayed toolpaths Alt+T

Gview–Isometric Alt+7 Show/hide Toolpaths Manager panel Alt+O

Gview–Left Alt+6 Undo the last creation or event Ctrl+U, Ctrl+Z

Previous Plane Alt+P Unzoom to 80% of original Alt+F2

Gview–Right Alt+5 Unzoom to previous or 50% of original F2

Gview–Top Alt+1 Zoom around target point Ctrl+F1

Help Alt+H Zoom with window selection F1

Hide entities Alt+E Zoom/unzoom by 5% Page Up/Page

Down

Level Manager Alt+Z

CUSTOMIZE MASTERCAM

MASTERCAM QUICK REFERENCE CARD

CUSTOMIZE MASTERCAM

WAYS TO GET THE MOST FROM MASTERCAM

Mastercam Training

In-House Solutions offers unsurpassed industrial training for Mastercam and Octopuz. We have training facilities in a number of cities across Canada and some of our courses can also be offered onsite, depending on trainer availability. Learn more at eMastercam.com/store.

Our library of Mastercam Training Solutions consists of several product lines that cater to any learning style. Learn Mastercam at your own pace with our Training Tutorials, teach your students with the help of our

Instructor Kits, learn the theory behind Mastercam with our Handbooks, get projects à-la-carte with our Single Projects, let our instructors show you best practices with our Video Training or go digital with our eBooks. Mastercam Community

eMastercam is the one-stop web resource for Mastercam users. People from all over the world visit the site

whether they are teaching, learning or working with Mastercam daily. Members can post questions, comments or share projects and success stories. Visit eMastercam.com and sign up for your free account today!

For downloaded pdf please visit

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Create Your Own Keyboard Shortcuts

Customize the Ribbon

 Right mouse click in the Ribbon.  Customize the Ribbon.

 Keyboard shortcuts, select the Customize button.  Select the Category.

 Select a command and under Press new shortcut

key enter the key combinations you want to assign

to it.

 Right mouse click in the Ribbon.  Select Customize the Ribbon.  Select a Mastercam command.  Select a Tab or create a New Tab.  Press Add button.

Customize the right click menu

 Right mouse click in the Ribbon.  Select Customize the Ribbon.  Select Context Menu.

 Select the Category and then the command that you want to add.

 Once you click on the Add button the function will be added to the Right mouse button menu.

Customize Quick Access Toolbar

 Right mouse click on a command in the Ribbon.  Select Add to Quick Access Toolbar.

Mill Advanced Training Tutorial

MILL ADVANCED TRAINING TUTORIAL PROJECTS

Tutorial

Geometry Functions

Surface and Toolpath Creation

#1

Solid Extrude Create Body Solid Extrude Cut Body Solid Extrude Add Body Solid Fillet

Surface Rough Pocket High Speed Surface Scallop High Speed Surface Scallop With Trim to Stock

#2

Revolved Surface Transform Project Arc Trim To Curve

Net Surface Fillet Surface

Flat Boundary Surface

High Speed Surface OptiRough High Speed Surface Raster High Speed Surface Pencil

#3

Swept Surface Solid Extrude

Solid Trim To Surface Solid Boolean Add Use Levels

High Speed Surface Area Roughing Rest Material High Speed Surface Radial Surface Finish Blend

Mill Advanced Training Tutorial

MILL ADVANCED TRAINING TUTORIAL PROJECTS

Tutorial

Geometry Functions

Surface and Toolpath Creation

#4

Wireframe for Solid Solid Extrude Solid Revolved Swept Surface Solid Trim to Face Solid Fillet Solid Draft Face Boolean Remove Boolean Add

High Speed Surface Dynamic OptiRough

High Speed Surface Dynamic OptiRough with Rest Material High Speed Surface Hybrid Edit Projection

#5

Revolved Surface

Project Curve Onto Surface Ruled Surface

Draft Surface

Curve At Intersection Trim Surface To Curves Surface Fillet

Fillet Blend Surface

High Speed Surface Area Roughing High Speed Surface Spiral

High Speed Surface Scallop Transform-Rotate

High Speed Surface Waterline

#6

Draft Surface Swept Surface Fillet Surface

Rectangle with Surface Flat Boundary Surface

High Speed Surface Dynamic OptiRough

High Speed Surface Horizontal High Speed Surface Waterline High Speed Surface Raster High Speed Surface Pencil

Mill Advanced Training Tutorial

MILL ADVANCED TRAINING TUTORIAL PROJECTS

Tutorial

Geometry Functions

Surface and Toolpath Creation

#7

Lofted Surface

Net Surface (Window Selection)

Surface Net (Chain Selection) Fillet Surface

Ruled Surface Offset Surface

Trim Surface To Curves Flat Boundary Surface Silhouette Boundary

High Speed Surface Dynamic OptiRough

Surface High Speed Area Roughing with Rest Material

Surface High Speed Scallop Surface High Speed Scallop with Trim to Stock

Pocket Standard

Mill Advanced Training Tutorial

Mill Advanced Training Tutorial

TABLE OF CONTENTS

GETTING STARTED

Getting Started ... 1

Tutorials:

Tutorial #1

- Surface Rough Pocket & Surface High Speed Scallop

...11

Tutorial #2

- Surface High Speed Dynamic OptiRough, Raster & Pencil

...99

Tutorial #3

- Stock Model, Surface HS Area Roughing - Rest Material & Radial &

Surface Finish Blend

...185

Tutorial #4

- Surface HS Dynamic OptiRough, Surface HS OptiRough - Rest Material, Stock

Model & Surface HS Hybrid

...303

Tutorial #5

- Surface HS Area Roughing, Scallop, Spiral & Waterline

...429

Tutorial #6

- Surface HS Dynamic OptiRough, Horizontal, Waterline, Raster & Pencil

...611

Tutorial #7

- Surface HS Dynamic OptiRough, Area Roughing - Rest Material, Surface HS Scallop, & Surface Rough Project

...697

Quiz Answers ... 831

Mill Advanced Training Tutorial

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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:

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

 Solid creation commands such as Extrude Create Body, Extrude Cut Body, Extrude Add Boss and Fillet 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 High Speed Scallop toolpath will be created to machine the floors.

 A Surface High Speed Scallop toolpath with Trim to Stock options will be created to machine the fillets.

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.

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Mill Advanced Training Tutorial

TUTORIAL #1

1

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. In this step you will learn how to hide the manager panels to gain more space in the graphics window.

 Use the Auto Hide icon to hide all Manager panels as shown.

 The panels will be hidden to the left of the graphics window.

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CREATE RECTANGLES

_{TUTORIAL #1}

₁

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

WIREFRAME

 From the Shapes group, select Rectangle.

 Enter the Width, the Height and enable Anchor to center as shown. Make sure that Create surface is not selected.

N

OTE

:

Anchor to center sets the base point of the rectangle

to its center and draws the rectangle outward from the center.

Create surface creates a surface inside of the rectangle. 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 a surface at this time.

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TUTORIAL #1

1

CREATE RECTANGLES

 Press Enter after typing the values to see a preview of the rectangle.  [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 OK and Create New Operation button to stay in the same command.

 To fit the drawing to the screen, press Alt + F1.

N

OTE

:

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

_{TUTORIAL #1}

₁

2.2 Create the 4.0" by 4.0" rectangle

 Enter the Width, the Height and leave Anchor to center enabled as shown.

 Make sure that the Create surface button is not selected (not highlighted).  [Select position of base point]: Select the Origin as shown in Figure: 2.1.1.  The drawing should look as shown below.

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Mill Advanced Training Tutorial

TUTORIAL #1

1

CREATE RECTANGLES

2.3 Create the 2.5" by 2.5"rectangle

 Select the HOME tab and set the construction mode to 3D as shown.

 Enter the Width and the Height as shown.

 Press Enter.

 Press the Space bar and enter the coordinates for the Rectangle as shown.

N

OTE

:

The construction mode can be toggled between 2D and 3D.

In 2D mode, all the geometry is created parallel to the current construction plane and at the current Z depth setting. However, you can override the Z depth setting by typing coordinate values that include a Z depth value different from the current Z depth setting.

In 3D mode, the X, Y, and Z coordinates are all read from AutoCursor when sketching dynamically. The Z depth setting in the HOME ribbon is not used. When working in a 3D environment, you can create entities whose points lie in different planes, or create entities (such as arcs or 2D splines) in planes other than the predefined planes.

N

OTE

:

When you enter the coordinates of a point in Mastercam, the first value is the X coordinate value followed by a comma. The second value is the Y coordinate value followed by a comma and the third value is the Z coordinate value. If you enter the values in this order you do not need to enter the coordinates labels (X, Y or Z) in front of the values.

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CREATE FILLETS FOR THE TWO RECTANGLES

_{TUTORIAL #1}

₁

 Select the OK button to exit the Rectangle command.

 Right mouse click in the graphics window and set the graphics view to Isometric.

 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 the Fillet chain command.

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Mill Advanced Training Tutorial

TUTORIAL #1

1

CREATE FILLETS FOR THE TWO RECTANGLES

WIREFRAME

 From the Modify area, select the drop down arrow next to Fillet Entities and select Fillet Chains as shown.

 Right mouse click in the graphics window and change the graphics view to the Top.

 Press Alt + F1 if needed to fit the geometry to the graphics window.

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CREATE FILLETS FOR THE TWO RECTANGLES

_{TUTORIAL #1}

₁

 [Select chain 1]: Select the rectangle as shown inFigure: 3.0.1.

Figure: 3.0.1

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

 Change the Radius to 1.0 and make sure the rest of the parameters are set as shown (press Enter).

 Select the OK and Create New Operation button to stay within the command.

N

OTE

:

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.

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Mill Advanced Training Tutorial

TUTORIAL #1

1

SUGGESTED FIXTURE:

TOOLPATH CREATION

SUGGESTED FIXTURE:

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SELECT THE MACHINE AND SET UP THE STOCK

_{TUTORIAL #1}

₁

STEP 14: 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:

 Press Alt + F1 to fit the drawing to the screen.

14.1 Unhide the Toolpaths Manager and lock it

 The Toolpaths Manager will be hidden to the left of the graphics window as shown.

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Mill Advanced Training Tutorial

TUTORIAL #1

1

SELECT THE MACHINE AND SET UP THE STOCK

 To lock it, click on the Toolpaths tab and then click on the Auto Hide icon a shown.

 The Manager panels will be translated to the lower left corner of the graphics window.

MACHINE

 From the Machine Type group, select the drop down arrow below Mill.  Select Default.

N

OTE

:

If a Machine Group already exist in the Toolpaths

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SELECT THE MACHINE AND SET UP THE STOCK

_{TUTORIAL #1}

₁

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

 Select Tool settings to set the tool parameters.

 Change the parameters to matchFigure: 14.1.1.

Figure: 14.1.1

Program # is used to enter a number

if your machine 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 to From tool

uses the feed rate, plunge rate, retract rate and spindle speed from the tool definition.

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TUTORIAL #1

1

SELECT THE MACHINE AND SET UP THE STOCK  Select the Stock Setup tab to define the stock.

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

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SELECT THE MACHINE AND SET UP THE STOCK

_{TUTORIAL #1}

₁

 Round the values if needed and change the Z value for the stock to 1.5 as shown inFigure: 14.1.2.

Figure: 14.1.2

 Select the OK button to exit the Machine Group Properties dialog box.  Press Alt + F1 to fit the drawing to the screen.

N

OTE

:

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 an 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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Mill Advanced Training Tutorial

TUTORIAL #1

1

ROUGH OUT THE PART USING SURFACE ROUGH POCKET  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.

STEP 15: 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:

N

OTE

:

Remember that the stock is not geometry and thus cannot be selected.

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ROUGH OUT THE PART USING SURFACE ROUGH POCKET

_{TUTORIAL #1}

₁

15.1 Surfaces and Containment selections

TOOLPATHS

 From the 3D group, select the Pocket icon.

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

 [Select Drive Surfaces]: Select the solid as shown.

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Mill Advanced Training Tutorial

TUTORIAL #1

1

ROUGH OUT THE PART USING SURFACE ROUGH POCKET

 To limit the tool motion inside of the boundary, in the Toolpath/surface selection dialog box, click on the

Select button to select a Containment as shown.

 From the Chaining dialog box, click on the Solids button as shown.

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ROUGH OUT THE PART USING SURFACE ROUGH POCKET

_{TUTORIAL #1}

₁

 [Select faces, edges, and /or loops]: Select the edge as shown.

 The chain selected should look as shown.

 The Pick Reference Face dialog box will appear on your screen as shown.

 Select the OK button to exit the Pick Reference Face dialog box.  Select the OK button to exit the Chaining dialog box.

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TUTORIAL #1

1

ROUGH OUT THE PART USING SURFACE ROUGH POCKET

15.2 Set 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 the Select library tool button as shown.

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839

INDEX

Numerics

2D / 3D Construction ... 6

A

Analyze A Spline ... 544

Assign tool numbers sequentially... 56

B

Backplot The Toolpath ... 72

Backplotting... 72

Boolean Remove...410

,

424 Bounding Box ... 57

Break the fillet at the midpoint ... 571

C

Change The Main Level... 30

Clearance ... 68

Color ... 6

Constant Radius ... 435

Control Definition ... 53

Create A Net Surface ... 157

Create Arc Endpoints ... 383

Create Circle Center Point ... 27

Create Circle Center point ... 27

Create Curve At Intersection ... 576

Create Fillets ... 23

Create Fillets For The Two Rectangles... 23

Create Parallel Lines ... 110

Create Polar Lines ... 116

Create Rectangles ... 19

Create Revolved Surfaces ... 135

Create Silhouette Boundary ... 441

Create The Draft Surfaces... 30

Create The Fillet Surface... 558

Create The obround rectangular shape ... 135

Create The Parallel Lines ... 110

Create The Pocket Floor Surface ... 552

Create The Revolved Surface... 135

D

Delete Entities ... 382 Display ... 58 Divide ... 310 Draft Surfaces ... 30

,

34

,

36

,

43

,

46 Drive surfaces ... 68

E

Extrusion Operation...32

,

399

F

Feed Calculation set From tool ... 56

Feed plane ... 68

G

Graphic Area ... 3

GUI - Graphical User Interface... 3

L

Level... 6

M

Machine Definition ... 53 Material Mode ... 291 Maximum step-down ... 69 Mirror ... 352

Mirror about a line ... 568

Mirror the profile about the Y axis ... 534

Mitered Corners ... 435

N

Net Surface ... 157

O

Offset Contour ... 370 Offset Surface ... 802

Override defaults with modal values... 56

P

Pocket parameters page... 71

Post Process The File ... 98

Post Processing ... 98

Post Processor ... 53

Program # ... 56

Project ... 138

Propagate Along Tangencies ... 435

R

Reorganizing The Toolbars ... 4

Retract ... 68

Rotate - Copy The Surfaces... 606

Rough parameters page ... 69

S

Scale... 3

Select The Machine And Set Up The Stock ... 53

Setting Mastercam To Metric ... 10

Setup the stock model ... 274

Shaded ... 244

Simulate the toolpath in Verify ... 74

Solid Revolve ... 400

Steep/shallow ... 288

Stock Models ... 274

Stock Origin ... 58

Stock to leave on drive ... 68

Surface Finish Blend ... 305

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840

Mill Advanced Training Tutorial

INDEX

Surface Finish Parallel ... 191

Surface Finish Pencil ... 200

Surface Finish Scallop ... 869

Surface High Speed Scallop ...77

,

632 Surface High Speed Core Roughing ...277

,

616 Surface High Speed Finish Horizontal ... 740

Surface High Speed Finish Spiral... 655

Surface High Speed Hybrid ... 482

Surface High Speed OptiArea ...180

,

448

,

847 Surface High Speed OptiCore ... 725

Surface High Speed Pencil ... 762

Surface High Speed Radial ... 294

Surface High Speed Raster... 755

Surface High Speed Rest Roughing ... 858

Surface High Speed Restmill ... 463

Surface High Speed Waterline ... 668

Surface Rough Pocket ... 59

Surface Rough Project ... 892

Swept Surface ...233

,

387

T

Toolpath parameters page ... 63

Toolpaths/Solid Manager ... 3 Total tolerance ... 69 Transform Toolpaths ... 319 Transitions ... 287 Trim 1 Entity ... 116

,

348

,

357

,

377 Trim 2 Entities ... 116

Trim the draft surfaces to the curve ... 578

Trim The Geometry ... 116

Trim The Surfaces ... 576

V

Variable Radius ... 435

View Port XYZ Axes ... 4

W

Warn of duplicate tool numbers ... 56

Wireframe ...58

,

244

Z

Z Depth ... 6