MasterCam - X4 - Training Tutorials Mill Level 3 Applications - Tutorial #6

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Author:MarianaLendel ISBN:9781926566238 Notice InHouseSolutionsInc.reservestherighttomakeimprovementstothismanualatanytimeand withoutnotice. DisclaimerofAllWarrantiesandLiability InHouseSolutionsInc.makesnowarranties,eitherexpressorimplied,withrespecttothis manualorwithrespecttothesoftwaredescribedinthismanual,itsquality,performance, merchantability,orfitnessforanyparticularpurpose.InHouseSolutionsInc.manualissoldor licensed"asis."Theentireriskastoitsqualityandperformanceiswiththebuyer.Shouldthe manualprovedefectivefollowingitspurchase,thebuyer(andnotInHouseSolutionsInc.,its distributor,oritsretailer)assumestheentirecostofallnecessaryservicing,repair,or correction,andanyincidentalorconsequentialdamages.InnoeventwillInHouseSolutionsInc. beliablefordirect,indirect,orconsequentialdamagesresultingfromanydefectinthemanual, evenifInHouseSolutionsInc.hasbeenadvisedofthepossibilityofsuchdamages.Some jurisdictionsdonotallowtheexclusionorlimitationofimpliedwarrantiesorliabilityfor incidentalorconsequentialdamages,sotheabovelimitationorexclusionmaynotapplytoyou. Copyrights ThismanualisprotectedunderthecopyrightlawsofCanadaandtheUnitedStates.Allrightsare reserved.Thisdocumentmaynot,inwholeorpart,becopied,photocopied,reproduced, translatedorreducedtoanyelectronicmediumormachinereadableformwithoutprior consent,inwriting,fromInHouseSolutionsInc. Trademarks MastercamisaregisteredtrademarkofCNCSoftware,Inc. Microsoft,theMicrosoftlogo,MS,andMSDOSareregisteredtrademarksofMicrosoft Corporation;MastercamVerifyiscreatedinconjunctionwithSiriusSystemsCorporation; Windows95,WindowsNT;andWindowsXPareregisteredtrademarksofMicrosoft Corporation. Acknowledgements "ThankstotheInHouseSolutionsteamforhelpingintheproductionandmarketingofthis book.Itsimplywouldn'tbethesamewithoutallyourefforts.Finally,thankyou,thereaderfor makingthispurchase;Ihopeitservesyouwell." MarianaLendel

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NavigateThroughtheSystem ... A2 SettingtheToolbarStates ... A4 SettingtheGrid ... A6

SurfaceModeling

B1

TUTORIALS

11 Tutorial#1,Revolved&FlatBoundarySurfaces,Pocket,Parallel&ContourToolpaths... 11 Tutorial#2,RuledandFlatBoundarySurfaces,RadialandScallopToolpaths ... 21 Tutorial#3,NetSurface,PocketandRestmill&FinishBlendToolpaths... 31 Tutorial#4,Swept&FlatBoundarySurfaces,RoughFlowline&Plunge,FinishBlend&Pencil Toolpaths... 41 Tutorial#5,Revolved&FilletSurfaces,HSCoreRoughing&FinishScallop,Pocketfacing,Pencil& ProjectToolpaths ... 51 Tutorial#6,Revolvedsurface,HSAreaRoughing,FinishContour,LeftoverandProjectforMachining RaisedLetters ... 61 Tutorial#7,Draft,Swept,RevolveandFilletSurfacesandHighSpeedToolpaths: CoreRoughing,HorizontalArea,WaterlineandScallopRestPasses... 71 Tutorial#8,Ruled,Swept,RevolveandFilletSurfacesandHighSpeedToolpaths: CoreRoughing,HorizontalArea,Scallop,ScallopRestPassesandPencil... 81

GeneralNotes

C1 DefaultKeyAssignments ... C2 Customizing ... C3 KeyMapping... C7 DataEntryShortcuts... C9 SurfaceToolpathParameters ... C10 CreateGeometryin3D... C39 SolidsMenu ... C44 SolidsManager ... C45 Chaining... C47 WindowSelection... C50 ChainingandWindowOptions... C51 ToolpathsManager ... C53 Properties ... C58 MillingGCodes ... C61

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TUTORIAL6

REVOLVEDSURFACEHIGHSPEEDAREAROUGHING,FINISHCONTOUR,

FINISHLEFTOVER,ANDFINISHPROJECTTOOLPATHSTOMACHINE

RAISEDLETTERS

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Objectives:

TheStudentwilldesigna2dimensionaldrawingby:

Creatingarectangle. Creatingparallellines. Creatinglineendpoints. Creatingarctangentthroughapoint. Creatingfillets. Trimmingthegeometry. Movingthegeometry. Creatingtheletters. Creatinganobroundshape.

TheStudentwilldesigna3dimensionaldrawingby:

Creatingtherevolvedsurface. Creatingaflatsurfaceusingrectanglecommand. Trimsurfacetocurve. Creatingtheboundingbox. Creatinganoffsetsurface.

TheStudentwillcreatea3dimensionalmillingtoolpathconsistingof:

Roughingthecavityusingsurfacehighspeedareamilltoolpath. Finishingthecavityusingsurfacefinishcontourtoolpath. Finishingthefilletsusingsurfacefinishleftover. Creatingtwo2Dpocketstoolpathstobeusedinsurfacefinishproject. Usingfinishprojecttoolpathstomachinetheraisedletters.

TheStudentwillcheckthetoolpathusingMastercam’sVerifymoduleby:

Defininga3dimensionalblock,thesizeoftheworkpiece. Runningtheverifyfunctiontomachinethepartonthescreen.

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GEOMETRYCREATION

TostartanewfilefromMastercam:

File

New Beforestartingthegeometrycreationweshouldcustomizethetoolbarstoseethetoolbarsrequired tocreatethegeometryandmachinea3Dpart.SeeGettingstarted. Operationmanagertotheleftofthescreencanbehiddentogainmorespaceinthegraphicareafor design.PressAlt+Otoremoveit. BeforestartingthegeometrymakesurethattheGridisenabled.Itwillshowyouwherethepart originis.SeeGettingstartedpageA6fordetails.

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STEP1:CREATETHE2DPROFILETOBEREVOLVED

Notethatfortherevolvedsurfacewewillonlyneedhalfofthe2Dwireframe.

StepPreview:

1.1Createthe2.1"by7.25"rectangle

SubStepPreview:

Create

Rectangle EntertheWidth 2.1(Tab). EntertheHeight 7.25(Enter).

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[Selectpositionoffirstcorner]:SelecttheOrigin(centerofthegrid)asshown. UsetheFiticontofitthedrawingtothescreen. Duringthegeometrycreationofthistutorial,ifyoumakeamistake,youcanundothelaststepusing theUndoicon .Youcanundoasmanystepsasneeded.Ifyoudeleteorundoastepbymistake, justusetheRedoicon. SelecttheOKbutton.

1.2Createalineparallel

SubStepPreview:

Create

Line Parallel [Selectaline]:SelectEntityA. [Selectthepointtoplaceaparallellinethrough]:Pickapoint totherightoftheselectedline. EntertheDistance 1.53(PressEnter). SelecttheOKbutton. SelectOrigin SelectEntityA

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1.3Createalineknowingoneendpoint,thelengthandtheangle

SubStepPreview:

Create

Line Endpoint [Specifythefirstpoint]:SelectEndpointAasshown: Sketchthelineasshown. IntheRibbonBar,settheLength to4.5andchangetheAngle to285andpressEnter. SelecttheOKbutton. EndpointA

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1.4Createanarctangentthroughapoint

SubStepPreview:

Create

Arc ArcTangent EnableTangentpoint. EntertheRadius 3.125 [Specifytheentitythatthearcistobetangentto]:SelectEntityAasshown. [Specifythetangentpoint]:SelectEndpointBasshown: SelectEntityA SelectEndpointB

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[Selectanarc]:Selectthearcasshown: SelecttheOKbutton.

1.5Deletetheextraconstructionlines

SubStepPreview:

Selectthisarc

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Selectthetwolinesasshown: SelectDeleteentitiesicon.

1.6Trimthegeometry

StepPreview:

Edit

Trim/Break Trim/Break/Extend IntheRibbonBarenableTrim2entitiesicon. [Selecttheentitytotrim/extend]:SelectEntityA [Selecttheentitytotrim/extendto]:SelectEntityB SelecttheOKbuttontoexitthecommand. Selecttheselines SelectEntityAhere SelectEntityBhere

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1.7Filletthecornerswiththe1/4"radius.

StepPreview:

Create

Fillet Entities EnterthefilletRadius 0.250 [Selectanentity]:SelectEntityA. [Selectanotherentity]:SelectEntityB. [Selectanentity]:SelectagainEntityC [Selectanotherentity]:SelectEntityD. SelectEntityA SelectEntityB SelectEntityC SelectEntityDhere

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STEP2:MOVETHEGEOMETRYUSINGMOVETOORIGIN

StepPreview:

HolddowntheShiftkeyandclicksomewhereonthechain.

Xform

Movetoorigin [Selectthepointtotranslatefrom]:SelecttheMidpointof theverticallineasshown: SelecttheFiticontofitthedrawingtothescreen. SelectClearColoricon. Selectthechain SelecttheMidpoint

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STEP3:CREATEANDCENTERTHELETTERS

StepPreview:

3.1Changethemaincolortored(No.12)

SelecttheColorintheStatusBar Selectcolorredasshown:

3.2Createtheletters

Create

Letters SelectTrueTypebutton. SelecttheArialBlackfontasshown.

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TypeCAMandchangetheHeightandSpacingasshown. SelecttheOKbutton. [Enterstartinglocationofletters]:Selectapointasshown. PressEsctoexitthecommand.

Thegeometryshouldlookasshown.

Clickhereforthe startinglocation

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3.3UseBoundingBoxtocreatethecenterpointoftheletters

Create

BoundingBox IntheBoundingboxleaveCenterPointenabledanddisablefirstLinesArcsandthenAllEntities. NotethatonceyoudisableAllEntitiesthedialogboxdisappers,andthesystempromptsyouto selecttheentitiesaroundwhichtheboxorinourcasethecenterpointwillbecreated. [Selectentities]:Makeawindowaroundthelettersasshown. Thelettersshouldbehighlighted. PressEntertofinishtheselection. TheBoundingBoxshouldlookasshown. SelecttheOKbuttontoexitBoundingBox. Makeawindow

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Notethepointcreatedatthemiddleoftheletters.

3.4UseTranslatecommandtocentertheletters

Xform

Translate [Translateselectentitiestotranslate]:makeawindowaroundthelettersasshown. PressEntertofinishtheselection.

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IntheTranslatedialogbox,enableMove. SelectFrompointicon. [Selectthepointtotranslatefrom]:Selectthecenterpointcreatedinthe previoussubstep. [Selectthepointtotranslateto]:SelecttheOrigin. Selectthispoint

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SelecttheOKbuttontoexitTranslatedialogbox. SelecttheClearColoricon.

Thegeometryshouldlookasshowntothe

right.

3.5Deletethepoint

FromtheQuickMasktoolbar,selectQMPointicon. SelectDeleteentitiesicon.

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STEP4:CREATETHEOBROUNDSHAPE

StepPreview:

Create

RectangularShapes Expandthedialogboxifneededbyselectingthedownarrow. Changetheparametersasshown.

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[Selectpositionofbasepoint]:SelecttheOriginfromtheAutoCursor dropdownlist. SelecttheOKbuttontoexitRectangularShapesOptionsdialogbox

STEP5:CREATETHEREVOLVEDSURFACE(S)

StepPreview:

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5.1Changethemaincolortomagenta(No.13)

SelecttheColorintheStatusBarasshowninthepreviousstep Selectcolormagenta ChangethegraphicviewtoIsometric.

5.2CreatetheRevolvedsurface

Create

Surface Revolved SelectPartialintheChainingdialogbox [Selectthefirstentity]:SelectEntityAasshown: MakesurethatthechainingdirectionisCCW;otherwiseclickon Unselectbutton,andthenreselectEntityA SelectEntityAhere

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[Selectthelastentity]:SelectEntityBasshown: SelecttheOKbuttontoexitChainingdialogbox. [Selecttheaxisofrotation]:Selecttheverticalline ChangetheEndAngle to180,andpressEnter

Thesurfaceshouldlookasshown,

otherwise,selecttheReversebutton.

SelecttheOKbutton. SelectEntityB Selecttheverticalline

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STEP6:CREATETHEFLATSURFACEINSIDEOFARECTANGLE

StepPreview:

6.1Changethemaincolortodarkgreen(No.2)

SelecttheColorintheStatusBarasshownintheprevious step Selectthedarkgreencolor Geometrycolormustbedifferentthenliveentitycolor.

6.2Createarectanglewithasurfaceinsideofit

Create

Rectangle EntertheWidth 9.125(Tab). EntertheHeight 10.0(Enter). EnableAnchortocenterandCreateSurfaceiconsintheRibbonBar. [Selectpositionofbasepoint]:SelecttheOriginfromtheAutoCursordropdownlist. SelecttheOKbutton.

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SelecttheFiticontofitthedrawingtothescreen.

STEP7:TRIMTHEFLATSURFACETOCURVE

Totrimasurfaceorasetofsurfacestoachainofcurvesweneedaclosedboundary(Mastercam understandscurvestobelines,arcsorsplines).Youcantrimasurfaceorsetofsurfaceswithanopen chainonlyifthechaincompletelydividestheoriginalsurfacesintwo.

StepPreview:

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7.1UsetheHideentitycommandtokeeponthescreenonly2Dwireframe

SubStepPreview:

ClickontheQMLinesandontheQMArcsiconsfromtheQMtoolbarattherightofthe graphicwindow. Notethatalllinesandallarcsfromthegraphicwindowareselected.

Screen

Hideentity

7.2Mirrorthegeometry

Wearegoingtomirrorthe2dprofileusedtocreatetherevolvedsurfaces.

SubStepPreview:

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SelecttheprofilebyholdingdowntheShiftkeyandselectingoneentityofthechainasshown.

Xform

Mirror EnableMirroraboutYaxisasshown.

Thepreviewshouldlookasshown:

SelecttheOKbuttontoexitMirror. SelectClearColor icon. HolddownShiftkey andclickontheentity asshown

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7.3Deletethecenterlines

SubStepPreview:

Notethatthecenterlinewasselectedinthechaintobemirrored.Anothercenterlinewascreated onthetopoftheexistingone. Selectthelineasshown: SelectDeleteentitiesicon.

Repeatthesteptodeletetheotherline

Selectthisline

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7.4Unhidetheflatsurface

SubStepPreview:

SelectScreen UnhideSome Notethattherestoftheentitiesappearonthescreen. [Selectentitiestokeeponthescreen]:Selectthetopflatsurface. PressEntertofinishtheselection.

7.5Trimthesurfacetoachain(closed)

SubStepPreview:

Selecttheflatsurface

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Create

Surface Trim Tocurve [SelectsurfacesandpressEntertocontinue]:Selecttheflatsurfaceasshown. PressEnter [SelectCurves1]:Selectthechainofcurvesasshownbelow. SelecttheOKbuttontoexitChainingdialogbox. Selectthissurface Selectthischainofcurves

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[Indicateareatokeep–selectasurfacetobetrimmed]:Selecttwopointsonthesurfaceoutsideof thechainasshown. SelecttheOKbutton

Thesurfaceshouldlookasshown:

SelectScreen HideEntitytobringbacktherestofthegeometry.

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STEP8:CREATETHEABOXTHATREPRESENTSTHESTOCK

StepPreview:

PreselectthechainbyholdingdowntheShiftkeyandselectingonelineasshown. Selecttheline

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Xform

Translate ChangetheparametersintheTranslatedialogboxasshown.

Thegeometryshouldappearasshownbelow.

STEP9:SAVETHEFILE

File

Saveas Filename:“YourName_6” SelecttheOKbutton.

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TOOLPATHCREATION

SUGGESTEDFIXTURE:

SETUPSHEET:

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STEP10:SETUPTHESTOCKTOBEMACHINED

TodisplaytheToolpathsManagerpressAlt+O. Makesurethatnomachineisalreadyselected.

MachineType

Mill SelectDefaultorthemachineyouwillbeusing. UsetheFiticontofitthedrawingtothescreen. SelecttheplussigninfrontofPropertiestoexpandthe ToolpathsGroupProperties. SelectthePlus

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SelectToolsettings. Changetheparameterwiththeonesinthescreenshotbelow. SelectStockSetuptab. SelectBoundingboxbuttontoautomaticallyfind thepartextents. SelectToolsettings

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Changetheparameterstomatchthefollowingscreenshot. SelecttheOKbuttontoexitBoundingboxdialogbox. Thestockvaluesshouldlookasshown: SelecttheOKbuttontoexitToolpathGroupProperties.

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STEP11:ROUGHOUTTHESURFACEUSINGSURFACEHIGHSPEEDROUGHING

AREAMILLING

Arearoughingtoolpathsaredesignedtoroughoutcavities,pockets,orotherareasthatcanbemost efficientlymachinedwithaninsidetooutsidetoolpath.Theyaregeneratedfromasetofsurfaceprofiles thatdescribetheshapeofyoursurfacesatdifferentZheights,plusasetofoffsetprofilesthatroughout stockasthetoolmovesawayfromthecenter.

ToolpathPreview:

Toolpaths

SurfaceHighSpeed SelecttheOKbuttontoaccepttheNCname [SelectDriveSurface]:SelecttheAllbutton. SelecttheOKbuttontoexit.

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PressEnterkey. SelecttheOK buttontoexitToolpath/surfaceselection. SelectToolpathTypeandenableRoughing. SelectAreaClearance. Select

Tool

. ClickontheSelectlibrarytoolbutton. UsetheFilterbuttonintoselectthe1.0“BullNoseEndmillwithcornerradius1/8“

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MakethenecessarychangesintheToolpathparameterstomatchthefollowingscreenshot. SelecttheHolder. Select

Openlibrarybutton.

Select

theCT40.holders

Selectthe

OK

button

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SelecttheC4E31250holder Holderpageallowsyoutocreateaholderdefinition,loadaholderfromanexistinglibraryor edittheholderafterithasbeenselected Useholderforgougecheckingwhenenabled,activatesthegougecheckingfeature.Mastercam willchecktomakesurethattheholderdoesnotcomeintocontactwithanypartgeometry. Holderclearancefieldestablishestheminimumseparationbetweentheholderandyoursurface model.Settheclearancebiggerthanthestocktoleaveonthewalls.

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SelecttheCutParameterspageandmakethechangestomatchthefollowingscreenshot. StepdownoptionsallowyoutoconfigurehowMastercamspacesthecutsinZ. StepdownvaluesetsaconstantZspacingbetweencuttingpasses. Addcutsfeatureallowsyoutoinsertadditionalcuttingpassesinareasofyourpartwherethe profileisclosetoflat.Mastercamwilladdnewcutstomaintainthemaximumprofilestepover, whilespacingthemeachbyatleastasmuchastheminimumstepdown. XYstepoversettingsallowyoutoconfigurethespacingbetweenthepassesatthesameZ. Mastercamwillusethelargestvaluepossible(uptothemaximumXYstepover)thatdoesnot leaveunwantedmaterialbetweenthepasses.However,itwillnotseparatethepassesbyless thantheminimumstepover. Stocktoleaveonyourdrivesurfacesletsyouenterseparatevaluesforthewallandfloor surfaces.Notethatthestocktoleaveonwallsmustbegreaterthanorequaltothestocklefton thefloor.Forsurfacesthatarenotexactlyhorizontalorvertical,Mastercamwillinterpolate betweenthewallandfloorvalues. Keeptooldownpreventsthetoolfromretractingifthedistancebetweentheendofonepass andthestartofthenextpassislessthanthespecifiedsettings.

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ExpandCutParametersifneeded,andselectTransitionstosettheEntryhelix. Selectthe plussignto Expand Transitionsallowyoutoconfiguretheentrymovethatthetoolwillmakeasittransitions tonewZlevels.Youcanchoosetocreateeitherarampentry,orhelicalentrymove.Ifthe profileistoosmalltocreateahelixofthissize,Mastercamwillcreatearampmove instead.

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SelecttheLinkingParameterspageandchangetheparameterstomatchthefollowingscreenshot. SelecttheOKbuttontoexitparameterpages. SelecttheOKbuttontocontinue. LinkingoptionsallowyoutoconfigurehowMastercamlinksairmoveswhenthetoolisnotin contactwiththepart MinimumverticalretractisaverticalretractandconstantZmoveatthePartclearanceheight. Leadsfieldssetthetoolmovesontoandoffofthepartatthestartandendofeachcutting pass.Thesemovesareappliedtoeachpassnomatterwhichcuttingpassisselected. Fittingsettingsallowyoutochoosehowtheentryandexitarcsfittotheendsofthecutting passes. Minimizetrimmingsetsthepathtoretracttobeasclosetothesurfaceaspossible, maintainingaminimumdistancefromthesurfacetofitthearc. Maxtrimmingdistanceparameterlimitstheamountoftrimmingappliedtononhorizontal passes.

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Thetoolpathshouldappearlikethefollowingpicture.

STEP12:BACKPLOTTHETOOLPATH

SelecttheBackploticonsoyoucanseethetoolpathwhichwejustcreated. Makesurethatyouhavethefollowingbuttonsturnedon(theywillappearpusheddown). Displaytool Displayrapidmoves Displaytool Displayrapidmoves

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SelectthePlaybutton. SelecttheOKbuttontoexitBackplot.

STEP13:VERIFYTHEROUGHTOOLPATHANDSAVEITASASTLFILETOBEUSED

ASANINTERMEDIATESTOCK

SelectToggletoolpathdisplayonselectedoperationstoremovethetoolpathdisplay. SelecttheVerifyselectedoperationsbutton.

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EnableTurbomode. SelecttheConfigurebutton. SelecttheOKbuttontoexitVerifyOptions. Initialstocksizesourceshould besettoJobSetuptousethe stockinformationfromStock Setup. UseTrueSolidallowsyou,after verifyingthepart,torotateand magnifyittomorecloselycheck features,surfacefinish,or scallops. Changetool/colortochangethe colorofthecutstockto indicatedtoolchangesinthe toolpath.

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SelecttheMachinebuttontostartthesimulation.

Thepartshouldappearasshowntotheright

SelecttheSavestockasafilebutton. SavetheSTLfilewiththesamenameataknownlocation. SelecttheOKbutton. TospeeduptheVerification,wewillusethisSTLfilewhenweverifytherestoftheoperation. SelecttheOKbuttontoexitVerify. SelectToggletoolpathdisplayonselectedoperationsicontohidethetoolpathfromthescreen.

STEP14:FINISHTHESURFACESUSINGSURFACEFINISHCONTOUR

ContourRoughandFinishToolpathsperformmultiplecutsatconstantZlevels.Bothtoolpathsare recommendedforpartswithsteepwalls.Youshouldavoidusingthistoolpathforpartswithflat surfaces.Tomachineflatareasuseshalloworparallelsurfacetoolpaths.

ToolpathPreview:

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Toolpaths

SurfaceFinish Contour [SelectDriveSurface]:FromtheQuickMasktoolbar,selecttheQMSurfacesicon. PressEnterkeytofinishtheselection. SelecttheContainmentselectionbutton. [Chain2Dtoolcontainmentboundary#1]:SelectEntityA. SelecttheEntityA

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SelecttheOKbuttontoexittheChainingdialogbox. SelecttheOKbuttontoexittheToolpath/surfaceselectiondialogbox. ClickontheSelectlibrarytoolbuttonanduseFiltertoselect3/4InchBallnoseEndmill. Makeanynecessarychangesasshowninthefollowingscreenshots.

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SelecttheSurfaceparametersandchangetheparametersasshown. Clearancevaluesetstheheightatwhichthetoolrapidstoorfromthepart. Retractvaluesetstheheightthetoolrapids/feedratesupto,beforethenexttoolpass. Feedplanevaluesetstheheightthetoolrapidstobeforechangingtotheplungerate. Stocktoleave(onDrivesurface)setstheamounttoleaveforthefinishoperationasa constantvalueallthewayaroundthedrivesurfaces.

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SelecttheFinishcontourparametersandchangetheparametersasshown. SelectShallowbuttonandchangetheparametersasshown. Optimizecutordercleansoneareacompletelybeforemovingtoanotherarea. Onewayallowsthetooltomovearoundtheshapeinthesamedirection. Minimizetoolburialgeneratesadditionalretractandplungemoveswhenthetool couldbeengagingmaterialonbothsides,aswhenmachiningbetweentwobosses. Shallowremovestoolmovesoraddstoolmovesintheshallowareas. Addcutstoshallowareaallowthesystemtogenerate additionalcutsbetweenadjacentcutswhentheadjacent cutsarefurtherapartthanthelimitingstepovervalue. Limitinganglesetstheanglethatdefinestheshallow areasonthepart.Mastercamaddsorremovescutsinan areathatrangesbetween0to45degrees. Limitingstepoverisusedastheminimumstepoverwhen addingcutstotheshallowareasandasmaximum stepoverwhenremovingcutsfromshallowareas.

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SelecttheOKbuttontoexitShallowdialogbox. SelecttheOKbuttontoexitFinishcontourparameters. SelectToggletoolpathdisplayonselectedoperationstoremovethetoolpathdisplay.

STEP15:VERIFYTHEFINISHTOOLPATH

SelectonlytheSurfaceFinishContouroperation. SelecttheVerifyselectedoperationsbutton.

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EnableTurbomode. SelecttheConfigurebutton. EnableFileintheStock Shape,andselecttheStock filebrowsebutton.

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FindtheSTLfilethatyousavedinapreviousstep(YourName_6.STL). SelecttheOKbuttontwicetoexitVerifyOptions.

Thestockshouldlookasshown:

SelecttheMachinebuttontostartthesimulation.

Thepartshouldappearasshownto

theright:

SelecttheOKbuttontoexitVerify.

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STEP16:FINISHTHEFILLETSURFACESUSINGSURFACEFINISHLEFTOVER

TOOLPATH

Notethatbecausethefilletsurfaceradiusisa1/4Inchthefilletsurfaceswerenotcleaned. SurfacefinishleftovertoolpathremovesremainingstockthatMastercamcalculatesbasedonthe dimensionsofatoolusedinapreviousoperation.Finishleftoverusesasmallertoolthantheroughing tool.Mastercamlooksatthepart,calculateswheretheroughingtoolcouldnotfit,andcreatestool motiontoremovestockfromtheseareas.

ToolpathPreview:

Toolpaths

SurfaceFinish Leftover SelectDriveSurface]:FromtheQuickMasktoolbar,selecttheQMSurfacesicon. PressEnterkeytofinishtheselection.

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SelecttheOKbuttontoexitToolpath/surfaceselection. ClickonSelectlibrarytoolintheToolpathsparametersdialogbox. UsetheFiltertoselectthe1/4"BallnoseEndmill. MakethenecessarychangesintheToolpathparameterstomatchthefollowingscreenshot.

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NotethatbecauseweenabledtheadvancedoptionsintheToolSettingsparameters(Properties);the Clearance,RetractandFeedplanewillbethesameasinthepreviousoperation. SelectFinishleftoverparameterstabandchangetheparametersasshown. Totaltoleranceisthesumofthefiltertoleranceandcuttolerance.Youcanadjustthe ratioofthefiltertolerancetothecuttolerance,changethetoleranceamounts,andselect arcoptions. MaximumstepoversetsthesizeofthestepbetweenXYcutsinasurfacetoolpath. Fromslopeangle/toslopanglesettheareatobemachined. Hybridleftovercuttingcombines2Dand3Dcutswherecutsabovethecutoffangle (usuallythesteepestarea)areconstantZandcutsbeloware3D. Keepcutsperpendiculartoleftoverregioncanimprovethefinishbyaddingmoremoves, butitwillincreasethemachiningtime.

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SelecttheLeftovermaterialparameterspageandchangetheparametersasshowninthefollowing screenshot. SelecttheOKbuttontoexit. Roughingtooldiameteristhediameteroftheprevioustoolthatwasusedtomachinethe part(inourcasethe0.75InchBallnoseendmillusedinthefinishcontourtoolpath). Roughingtoolcornerradiusisthecornerradiusoftheprevioustoolthatwasusedto machinethepart. Overlapdistanceisanadditionaloffsetappliedtotheprevioustoolshape.Thisvalue causestheleftovermaterialtobecalculatedasifithadbeencutbyalargertool.

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SelectToggletoolpathdisplayonselectedoperationstoremovethetoolpathdisplay.

STEP17:USECHECKHOLDERTOFINDTHEMINIMUMTOOLLENGTHREQUIRED

FORTHE1/4“BALLNOSEENDMILL

CheckHolderCHookisusedtocheckanoperation'stoolholderforinterferencewiththepart.It calculatesareaswherethereisinterference,andtellsyoutheminimumtoollengthrequiredtoavoidit.

17.1Checkthecurrenttoollength

Clickonthe1/4InchBallnoseEndmillSphereinthepenciloperation. NotetheOverallvalueof2.5“ SelecttheOKbuttontoexit. Selectthe1/4InchBall noseendmill

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17.2UsetheCheckHolderChooktocheckthetoolholderforinterferencewiththepart.

MakesurethatonlytheSurfaceLeftoverisselectedintheToolpathsmanager. EnterAlt+CortheRunUserApplications iconfromthetoolbarstoopentheChookdirectory. SelectCheckHolder.dllfromthelist. EntertheHolderclearanceof0.05andkeeptheothersettingsasshown: SelectthePerformtestbutton. NotethatthetestresultisNointerference. SelecttheOKbuttontoexitCheckholderparameters.

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STEP18:VERIFYTHESURFACEFINISHCONTOURANDTHESURFACEFINISH

LEFTOVERTOOLPATHS

SelectonlytheSurfaceFinishContourandtheSurfaceFinishLeftoveroperations. ClickontheSurfaceFinishContourfirstandthenholddowntheCtrlkeyandselecttheSurface FinishLeftover. SelecttheVerifyselectedoperationsbutton. EnableTurbomodeandStoponcollision.

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SelectMachinebuttontostartsimulation.

Thepartshouldappearasshownbelow:

SelecttheOKbuttontoexitVerify.

STEP19:CREATEASTANDARD2DPOCKETTOOLPATHWHICHWILLBE

PROJECTEDONTOTHESURFACES

SubStepPreview:

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ChangethegraphicviewtoTop.

Toolpaths

Pocket [Selectpocketchain1]:Makeawindowaroundtheobroundasshown: [Sketchapproximatestartpoint]:Clickinsidetheobroundasshown: SelecttheOKbuttontoexitChainingdialogbox. Makeawindow PicktheStart pointhere

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Selecta1/8“BallnoseendmillandmatchtheparametersintheToolpathparametersasshown. SelecttheCutParameterspageandchecktheparameterstomatchthefollowingscreenshot.

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SelecttheRoughingpageandmadethechangesasshown. SelecttheFinishingpageandmadethechangesasshown.

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SelecttheLinkingParameterspageandmadethechangesasshown. SelecttheOKbuttontoexit2DToolpaths–Pocketandgeneratethetoolpath.

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STEP20:BACKPLOTTHETOOLPATH

SelecttheBackploticontoviewtheselectedoperationtoolpath. Makesurethatyouhavethefollowingbuttonsturnedon(theywillappearpusheddown). Displaytool Displayrapidmoves Quickverify SelectthePlaybutton. Clickinthemiddleofthepocketandusingthemousewheel,Zoomin. TozoominyoucanalsouseZoomtargeticon ;clickinthemiddleofthepocketandthen,move thecursoroutandselectthecornerofthezoomwindowwhenthepocketisincluded. Notetheareas(insidetheAletterandaroundMletter)thatthe1/8InchBallnoseendmillcould notmachine.Wewillremachinethepocketusinga1/16Ballnoseendmilltocleanuptheseareas. SelecttheOKbuttontoexitBackplot. Displaytool Displayrapidmoves Quickverify

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SelecttheToggletoolpathdisplayonicontoremovethetoolpathdisplay.

STEP21:REMACHINETHEPOCKET

Remachiningcalculatesareaswheretheroughingtoolcouldnotmachinethestockandcreatesasecond toolpathtocleartheremainingmaterial.

ToolpathPreview:

ClickonthePocket(Standard)operationintheToolpathManagerandmakesurethatitistheonly operationselected. RightmouseclickonthePocket,holditdownanddrag SelectCopyafterfromthedropdownlist. SelectParametersinthesecondPocketoperationasshown. SelectParameters

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SelecttheToolpageandselectfromthelibrarythe1/16InchBallnoseendmill. SelecttheCutParameterspageandselectRemachiningasthePockettype.Changetheparameters tobeasshown.

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SelecttheRoughingpagetomakesurethattheparametersmatchthefollowingscreenshot. SelecttheFinishingpagetomakesurethattheparametersmatchthefollowingscreenshot.

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SelecttheOKbuttontoexitthe2DToolpaths–Pocketandgeneratethetoolpath. SelectRegeneratealldirtyoperationsicontoregeneratethetoolpath. SelectToggletoolpathdisplayonselectedoperationstoremovethetoolpathdisplay.

STEP22:USESURFACEFINISHPROJECTTOMACHINETHERAISEDLETTERS

ProjectRoughandFinishToolpathsallowyoutoprojectcurves,points,oranotherNCIfileontoselected surfaces.Thesetoolpathscancloselymatchthecutmotiontotheshapeofthepartandcanbeusedfor engraving.

ToolpathPreview:

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Tobeabletomachinetheraisedlettersweneedtooffsettheexistingsurfacestoprojectthe toolpathsonthem.

22.1Createtheoffsetsurfaces

SubStepPreview:

Create

Surface Offset [Selectsurfacestooffset]:Selectthetwosurfacesasshown PressEntertofinishtheselection. ChangetheOffsetdistance to0.125"andpressEnter. Selectthesetwosurfaces

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Makesurethattheoffsetsurfacesarecreatedbelowtheoriginalonesasshown.

Otherwise;clickontheCycle/Nextbutton first,andthentheFlip buttonto changethesurfacenormalorientation.Repeattheprocedureforthesecondsurfaceifnecessary. SelecttheOKbuttontoexitOffsetsurfacecommand. SelectClearColoricon.

22.2SurfaceFinishProject

SubStepPreview:

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NotetheredinsertarrowlocationintheToolpathsManager. Thenextoperationisgoingtobecreatedbetweenthetwo pocketsifthearrowisnotmoved. ClickontheMovetheinsertarrowdownoneitem.Thisensuresthatthenext toolpathwillbecreatedattheendandnotinthemiddleoftheprogram. ChangetheGraphicViewtoIsometric.

Toolpaths

SurfaceFinish Project [SelectDriveSurface]:Selectthetwooffsetsurfacesthatyoujustcreated. SelecttheEndSelectionbutton. SelecttheOKbuttontoexit. Selectthesesurfaces

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SelecttheOKbuttontoexitToolpath/Surfaceselection. Selecttheexisting1/8”InchBallnoseendmillandmakethechangesasshowninthefollowing screenshots.

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SelectSurfaceparametersandchangetheparametersasshown.

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SelecttheFinishprojectparametersandmakesurethatProjectiontypeissettoNCI. Enableoperation4Pocket(Standard)intheSourceoperationsandenableRetractbetweencuts.

Projectiontype

NCIallowsyoutoprojectanexisting2Dtoolpath(contourorpocket)ontoselected surfaces. Curveallowsyoutoproject2Dchainsofentities(lines,arcs,splines)ontoselected surfaces.Mastercampromptsyoutoselectthechainsafteryouexitproject parameters. Pointsallowyoutoprojectpointsontoselectedsurfaces.Mastercampromptsyouto selectthechainsafteryouexitprojectparameters. Retractbetweencutsforcesaretractmovebetweencutsandwhenengravingletters (curveprojectiontype)itallowsthetooltoretractbetweenletters. Adddepthsallowyoutoaddcutdepthsfortheroughproject.Itisenabledonlywith projectiontypeNCI.

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SelecttheOKbuttontoexit. SelecttheToggletoolpathdisplayon icontoremovethetoolpathdisplay.

STEP23:USESURFACEFINISHPROJECTTOCLEANUPTHELETTERS

ToolpathPreview:

ClickontheSurfaceFinishProjectoperationintheToolpathManagerand makesurethatitistheonlyoperationselected. RightmouseclickontheSurfaceFinishProject,holditdownanddrag SelectCopyafterfromthedropdownlist.

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SelectParametersinthesecondSurfaceFinishProjectoperationas shown. SelectToolpathparametersandselectthe1/16InchBallnoseendmill SelectParameters

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SelecttheFinishprojectparametersandselectoperation5Pocket(Remachining)fromthelist. SelecttheOKbuttontoexitthetoolpath. SelectRegeneratealldirtyoperationsicontoregeneratethetoolpath.

Thetoolpathshouldlookasshowntotheright.

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STEP24:VERIFY

BasedonStep19,verifytheSurfaceFinishContour,theSurfaceFinishLeftoverandthetwoSurface FinishProjectoperationsonly,andmakesureyoudon’tselectanyofthe2DPockets. Torotatethepart,selecttheDynamicRotationicon. [Pickapointtobegindynamics]:Selectapointaroundthemiddleofthepart. Slightlymovethecursorandclickonthepartisintheproperposition.

Thepartshouldlookas

showntotheright

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STEP25:POSTPROCESSTHEFILE

ClickonthePocket(Standard)operationtoselectonlythisoperationandthen,holdingdownthe Ctrlkey,selectthePocket(Remachining)operation. ClickonTogglepostingonselectedoperationtoturnthepostoffforthesetoolpaths. ClickonSelectalloperationsicontoselectallthetoolpaths. Note:weghostedthepocketoperations;thereforetheGcodefortheseoperationswillnotbe generated.Rememberthatthesetoolpathswereonlyusedtogeneratetheprojecttoolpaths. SelectthePostselectedoperationsbuttonfromToolpathManager. InthePostprocessingwindow,makeallthenecessary changesasshowntotheright. SelecttheOKbuttontocontinue.

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EnterthesamenameasthegeometrynameintheNCFilenamefield.(YourName_6) SelecttheOKbutton. SelecttheredXboxattheupperrightcornertoexittheEditor.

STEP26:SAVETHEUPDATEDMCXFILE

SelecttheSave icon.

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REVIEWEXERCISE

StudentpracticeCreatetheToolpathforExerciseTutorial6aspertheinstructionsbelow; Tips:Youneedonlyflatletters 1.EstablishtheStocksizeY=5.0,X=5.0, Z=2.0 StockoriginX=0,Y=0,Z=1.505 2.CreatearectanglewithsurfaceoptionatZ0,the samesizeasthestock(5X5) 3.SurfaceRoughContour Selectallsurfaces Usea3InchFaceMill(changethelibrarytoBig.Toolsand editthetool:Taperangle=0.0) Clearance=2.5 Retract=2.0 Stocktoleaveondrivesurfaces=0.02 Totaltolerance=0.005 Max.Stepdown=0.1 EnableEntry/exitArcRadius=0.25,ArcSweep=90 EnableShallow Addcuttoshallowareas Minstepdown=0.005 Limitingstepover=0.05 DisableAllowpartialcuts Onewaycutting 4.SurfaceFinishScallop Use1/2"BallnoseEndMill Totaltolerance=0.001 Max.Stepover=0.05 Expandinsidetooutside

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5.SurfaceFinishLeftover Use1/8”BallnoseEndMill Totaltolerance=0.001 Max.Stepover=0.02 Cuttingmethod3DCollapse Roughingtooldia=0.5 Roughingcornerradius=0.25 6.SurfaceFinishProject Usea1/32”BallnoseEndMill Stocktoleaveondrivesurfaces=0.01 ProjectiontypeCurves EnableRetractbetweencuts 7.BackplotandVerifythetoolpaths. 8.Postprocessthefile.

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NOTES:

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TUTORIAL6QUIZ

Whatisasurfacenormal? Whenwouldyouusethe“surfacehighspeedareamill”toolpath? Whenwouldyouusea“surfacefinishleftover”toolpath? Whydidweturnoffthepostfunctiononthepocketoperations?