Truong Mill11

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com
Truonglana@yahoo.com
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TRAINING
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GUIDE
MILL-LESSON-11
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SURFACE HIGH SPEED AREA

CLEARANCE AND FINISH
FLOWLINE TOOLPATHS
www.mastercam.webs.com and cokhitruong.webs.com
Objectives
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Mastercam Training Guide
You will create the geometry for Mill-Lesson-11, and then generate the toolpaths to machine the
part on a CNC vertical milling machine. This Lesson covers the following topics:
Create a 3-dimensional drawing by:
Creating lines.
Creating arcs.
Trimming geometry.
Creating a net surface.
Creating a Silhouette Boundary.
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Establish Stock Setup settings:

Stock size using Bounding Box.
Material for the part.
Feed calculation.
Generate a 3-dimensional milling toolpath

consisting of:
Surface High Speed Area Clearance.
Finish Flowline Toolpaths.
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Inspect the toolpath using Mastercams Verify and Backplot by:

Launching the Verify function to machine the part on the screen.
Generating the NC- code.
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TRAINING
GUIDE
Mill-Lesson-11 Page - 1
Mill-Lesson-11
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MILL-LESSON-11 DRAWING
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TOOL LIST
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0.500 diameter bull end mill with a 0.125 corner radius to rough machine.
0.500 diameter ball end mill to finish machine.
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MILL-LESSON-11 - THE PROCESS

Geometry Creation
Setting the environment

Create geometry right hand section
Trim right hand section geometry
Create geometry left hand section
Create the profile
Trim profile geometry
Mirror profile geometry
Create the net surface
Create a silhouette boundary
Save the drawing
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TASK 1:
TASK 2:
TASK 3:
TASK 4:
TASK 5:
TASK 6:
TASK 7:
TASK 8:
TASK 9:
TASK 10:
Toolpath Creation
TASK 11:
TASK 12:
TASK 13:
TASK 14:
TASK 15:
TASK 16:
Define the rough stock using stock setup

Rough machine using surface high speed area clearance
Finish machine using finish flowline
Verify the toolpath
Save the updated MCX file
Post and create the CNC code file
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Mill-Lesson-11
TASK 1:
SETTING THE ENVIRONMENT
Before starting the geometry creation you should set up the grid, toolbars and machine type as
outlined in the Setting the environment section at the beginning of this text:
1. Set up the Grid. This will help identify the location of the origin.
2. Customize the toolbars to machine a 3D part.
3. Set the machine type to a Haas Vertical Spindle CNC machine.
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TASK 2:
CREATE GEOMETRY RIGHT HAND SECTION
X0 Y0 Z0 UPPER LEFT CORNER
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The top of the material is at Z 0. The base of the material and the 4.625 x 2.500 dimensions
have been previously machined to size.
In this task you will create the right hand section that will be used to create the net surface. First
will be the creation of line 1 next will be Arc 1 followed by line 2 and 3.
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Create right hand side section

1. Use Alt-O to hide the Operations Manager pane.
2. Change the graphics view to Isometric.
3. On the status bar at the bottom of the screen select 2D/3D to toggle to 2D construction.
4. On the status bar select Planes and then pick Right (WCS). The Z value should be at 0.
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Create Line #1
5. Select from the pull down menu: Create>Line>Endpoint
6. On the graphics screen you are prompted: Specify the first endpoint and the Line ribbon
bar appears.
7. To satisfy the prompt Specify the first endpoint move the cursor over to the Origin (X0Y0)
9. Click on the OK icon
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, pick the origin.

a visual cue appears.
8. Click in the space for Length and enter a value of 2.5 and then hit the tab key. In the space
for Angle enter a value of 0 and hit enter.
to complete this feature.
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Create Arc #1
10. Select Create>Arc>Circle Center Point
11. On the circle ribbon bar enter 0.25 for the radius and hit enter as shown below:
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12. To satisfy the prompt Enter the center point click in the space for the X value and enter a
value of 2.5/2 and then hit enter. Enter a value of -0.375 for the Y and then hit enter twice,
the Z value is already set.
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Create Line #2
15. First click in the space for Length and enter a value of 1.0 and then hit the tab key. In the
space for Angle enter a value of 45 and hit enter.
bar appears. Note that the Tangent function is activated.
17. To satisfy the prompt Specify the first endpoint move the cursor over the area of the circle
shown below left. Ensure there is no visual cue being displayed and click on this point.
After selecting the circle you will be prompted to Select the line pick the line shown below:
18. Click on Apply
to fix the entity.
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Mill-Lesson-11
Create Line #3
19. First click in the space for Length and enter a value of 1.0 and then hit the tab key. In the
space for Angle enter a value of 90+45 and hit enter.
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bar appears. Note that the Tangent

function is activated.
shown below left. Ensure there is no visual cue being displayed and click on this point.
After selecting the circle you will be prompted to Select the line pick the line shown below:
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TASK 3:
TRIM RIGHT HAND SECTION GEOMETRY
In this task you will trim the geometry using Divide / Delete.
1. Select Edit>Trim/Break>Trim/Break/Extend
2. The Trim / Extend / Break ribbon bar appears and you are prompted to Select the entity to
trim/extend.
3. Click on the Divide / Delete

icon to activate it as shown above. Ensure the icon is
pressed down to signal that it is activated.
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4. The prompt changes to Select the curve to divide / delete. Move the cursor over the
various entities and select in order and position as shown below left:
6. Repaint
.
7. Delete the line shown above right by clicking on the line with the mouse and hitting the
delete key on keyboard.
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TASK 4:
CREATE GEOMETRY LEFT HAND SECTION
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In this task you will create the left hand section that will be used to create the net surface. First
a rectangle will be created and then finally the two arcs will be created using fillet.
Create the rectangle

1. Click in the space for the Z value and enter a value of -4.625 as shown below, toggle to 3D,
and hit Enter:
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2. Unzoom to enable the grid to be seen.

3. Select from the pull down menu Create>Rectangle
4. Click in the space for Width and enter a value of 2.0 and then hit the tab key. In the space
for Height enter a value of 0.375 and hit enter.
5. To satisfy the prompt click in the space for the X value and enter a value of 0.25 and then
hit enter. Enter a value of -0.375 for the Y and then hit enter twice, the Z value is already
set.
Mill-Lesson-11
to complete this feature. The completed rectangle is shown
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below:
7. Fit to Screen
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Create Arc #2 and #3

1. Select Create>Fillet>Entities
2. On the Fillet ribbon bar enter .25 for the radius. Ensure the Style of radius is set to normal
and the trim button is depressed to turn the trim on.
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3. When prompted to Fillet: Select an entity, select entity 1 and 2 as shown below. The fillet
radius appears at the corner of entities 1 and 2. To complete the remaining fillet select:
entities 2 and 3. The completed geometry is shown below right:

5. Now select the Fit to screen icon.
Delete Construction line
6. Select the Delete entities icon on the toolbar and then select the line shown below:
7. Now you need to pick the End Selection icon
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TASK 5:
CREATE THE PROFILE
Create Line #1,#2,#3, Arc #1 and Arc #2

1. It is recommended that you watch Mill-Lesson-11 Task 5 on the accompanying CD before
completing this task.
2. Click in the space for the Z value and enter a value of 0 as shown below:
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3. Open up the drop down menu on the Planes toolbar bar and select Top (WCS).
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Create Line #1
bar appears.
6. To satisfy the prompt Specify the first endpoint move the cursor over the endpoint of the
line shown below. When the visual cue for endpoint appears pick this point.
7. Click in the space for Length and enter a value of 4.625-2.0 and then hit the tab key. In the
space for Angle enter a value of 180 and hit enter.
to complete this feature. The line is shown below:
Mill-Lesson-11
Create Arc #1
Construction line for Arc #1
9. Select from the pull down menu: Create>Line>Parallel
10. On the graphics screen you are prompted: Select a line and the Line Parallel ribbon bar
appears.
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11. First click in the space for Distance and input 0.5 then hit enter.
12. To satisfy the prompt Select a line, move the cursor over the line shown below and select it.
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13. To satisfy the next prompt Indicate the offset direction move the cursor above the line and
pick a point as shown below. The line appears as below right:

15. Select Create>Arc>Arc Polar
16. On the arc ribbon bar enter .5 for the radius and hit enter.
17. Click in the space for the Start Angle and enter 180 and hit the tab key. Enter a value of 0
for the End angle and hit enter.
18. To satisfy the prompt Enter the center point move the cursor over the endpoint of the line
shown below. When the visual cue for endpoint appears pick this point.

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to complete this feature. The completed geometry is shown
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below:
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Create Arc #2
20. Select Create>Arc>Circle Center Point
21. On the circle ribbon bar enter .5 for the radius and hit enter.
22. To satisfy the prompt Enter the center point click in the space for the X value and enter a
value of -4.625+1.0 and then hit enter. Enter a value of 1.75 for the Y and then hit enter
twice, the Z value is already set.
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Create Line #2
bar appears. Note that the Tangent function is activated.
shown below. Ensure there is no visual cue being displayed and click on this point.
27. To satisfy the prompt Specify the second endpoint move the cursor over the endpoint of
the line shown below. When the visual cue for endpoint appears pick this point.
28. Click on Apply
to fix the entity.
Mill-Lesson-11
Create Line #3
shown below. Ensure there is no visual cue being displayed and click on this point.
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to complete this feature. The completed geometry is below:
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30. To satisfy the prompt Specify the second endpoint move the cursor over the area of the
circle shown below. Ensure there is no visual cue being displayed and click on this point.
TASK 6:
TRIM PROFILE GEOMETRY
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In this task you will trim the geometry using Divide / Delete.
1. Select Edit>Trim/Break>Trim/Break/Extend
2. The Trim / Extend / Break ribbon bar appears and you are prompted to Select the entity to
trim/extend.
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3. Click on the Divide / Delete

icon to activate it as shown above. Ensure the icon is
pressed down to signal that it is activated.
4. The prompt changes to Select the curve to Divide / Delete. Move the cursor over the
various entities and select in order and position as shown below left:
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6. Delete the line shown above right by clicking on the line and hitting the delete key on the
keyboard.
TRAINING
GUIDE
Mill-Lesson-11
TASK 7:
MIRROR PROFILE GEOMETRY
In this task you will mirror the geometry.
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1. Select Xform>Mirror
2. You are first prompted to Mirror: select entities to mirror. Click on line 1, then click on
arc 2, then click on line 3, then click on arc 4, then click on line 5 as shown below: Note,
the lines and arcs will change colour as you select them.
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3. To move onto the next step you now need to pick the End Selection icon
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4. After selecting End Selection the Mirror dialog window appears. Set the following values:
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6. Click on the Clear Colors at the top right hand corner of the screen.
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TASK 8:
CREATE THE NET SURFACE
In this task you will create a net surface using the geometry you have just created. The net
surface will be created using four chains.
Create Net Surface

Select from the pull down menu: Create>Surface>Net
In the Chaining dialog box set to Partial chain.
On the graphics screen you are prompted: Select the first entity. Select the partial chain by
first selecting line 1, ensure the arrow is pointing downwards and then select line 2.
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Net Surfaces are surfaces constructed from a network of intersecting curves.

Generally, you chain a minimum of two across curves intersecting with two along curves. The
exception is when all of the across contours meet at one or both ends,
When you click OK in the Chaining dialog box, the net surface is created within the intersections
of the chained curves. Each along contour will be intersected with each across contour to
determine the net surface boundaries.
4. On the graphics screen you are again prompted: Select the first entity. Select the partial
chain by first selecting line 1, ensure the arrow is pointing downwards and then select line 2.
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Mill-Lesson-11
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5. On the graphics screen you are prompted: Select the first entity. Select the partial chain by
first selecting line 1, ensure the arrow is pointing to the left and then select line 2.
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6. On the graphics screen you are again prompted: Select the first entity. Select the partial
chain by first selecting line 1, ensure the arrow is pointing to the left and then select line 2.
in the Chaining dialog window.

below:
to complete this feature. The completed net surface is shown
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TASK 9:
CREATE SILHOUETTE BOUNDARY
In this task you will create a silhouette boundary to use as a tool containment boundary.
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Silhouette Boundary
This tool will create a boundary that represents the outer boundary of the silhouette made by the
surfaces or solid faces selected. It is very effective where undercuts or 3+2 machining are
required. This allows the user to easily identify machining limits and can be used as a tool
containment boundary.
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1. Select Create>Silhouette Boundary...

2. You are first prompted to Select solids, solid faces, or surfaces, select the All button on
the General Selection ribbon bar as shown below:
3. The Select All dialog box appears on the left of the screen. Click on the OK icon
complete and exit this feature.
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5. The Silhouette Boundary dialogue box appears. Click on the OK icon

exit this feature.
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to complete and
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TRAINING
GUIDE
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Mill-Lesson-11
TASK 10:
SAVE THE DRAWING
Select File.
Select Save as.
In the File name box, ensure Mill-Lesson-11 is visible as shown below:
Save to an appropriate location.
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1.
2.
3.
4.
to save the file and complete this function.
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5. Select the green check mark button
Toolpath Creation
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TASK 11:
DEFINE THE ROUGH STOCK USING STOCK SETUP
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1. Select the plus in front of Properties to expand the Toolpaths Group Properties. Alt-O will
Show/hide Operations Manager pane if it was not already showing.
2. Select Stock setup in the toolpath manager window.
3. Change the parameters to match the Stock Setup screenshot below: The top of the
material is at Z 0. The base of the material and the 4.625 x 2.500 dimensions has been
previously machined to size.

4. Select the Tool Settings tab and change the parameters to match the Tool Settings
screenshot below. To change the Material type follow the instructions below:
5. To change the Material type to Aluminium

6061 pick the Select button at the bottom
of the Tool Settings page.
6. At the Material List dialog box open the

Source drop down list and select Mill
library.
7. From the Default Materials list select

ALUMINIUM inch -6061 and then select
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8. Select the OK button

again to complete this Stock Setup function.
9. Now select the Fit to screen icon.
Your part should look similar to the screen shot below. With X0 Y0 at the lower right side and Z
zero on top of the stock.
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Mill-Lesson-11
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TASK 12:
ROUGH MACHINE USING SURFACE HIGH SPEED AREA CLEARANCE
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In this task you will use a 0.5 diameter end mill with a 0.125 corner radius to rough the net
surface.
1. From the menu bar select Toolpaths>Surface High Speed
2. When prompted to Enter new NC name ensure Mill-LESSON-11 is entered and then select
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the OK button
3. You are first prompted to Select Drive surfaces, select the All button on the General
Selection ribbon bar as shown below:
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6. Click on the Containment button on the Toolpath/surface selection dialog box.
TRAINING
GUIDE
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7. Chain the silhouette boundary that you created previously. Start at location 1 as shown in
the following picture. The chain is not flat on the C plane so leaving the selection at 3D is
fine.
8. You will be prompted that a branch point has been reached. Select location 2 to move
past the branch. You will again be prompted that a branch has been reached. The
to exit this feature.
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chaining should be completed already so click on the OK icon
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9. Click on OK
to exit the Toolpath/Surface selection window.
10. On the Toolpath Type page, select Roughing and Area Clearance.
11. Select Tool (under Toolpath Type).

12. In the lower left corner of the Tool page select the Select library tool button. Disable
Filter active if required.
13. Use the slider bar on the right of this dialog box to scroll down and locate a 0.5 diameter
bull end mill with a 0.125 corner radius. Select the end mill by picking anywhere along its
row.
Mill-Lesson-11
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to complete the selection of this tool.

15. Make changes to the Tool page as shown below.
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16. Select the Cut parameters page and make changes to this page as shown below. Stock
to leave on walls and floor is set to 0.020.
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17. Select the Trochoidal motion page and make changes to this page as shown below:
Trochoidal motion
stops the burial of
the tool when
moving into a tight
space. Instead of
taking a large cut
that is greater than
the programmed
stepover, the
toolpath will
generate looping
motion to peel
material from the
area. This will
increase tool life,
cutting
performance, and
decrease the
chances of tool
breakage.
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18. Make the following settings on the Arc Filter / Tolerance page.
Profile tolerance
This sets the
maximum deviation
from the calculated
toolpath that the
smoothing will adjust
the smoothed
toolpath to.
Offset tolerance
Works the same way
as the smoothing
tolerance. This
affects offset passes
(toolpath steps that
are away from the
drive geometry).
Loosening the
tolerances here will
result in smoother
motion on the
machine. The trade
off is accuracy. The
profile tolerance for
finishing toolpaths
should be the same
or tighter than the
total tolerance.
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19. Turn on coolant on the Coolant page.
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Mill-Lesson-11

to exit and generate the toolpath.
21. Verify the new toolpath.
22. The verified image should look similar to the image below:
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TRAINING
GUIDE
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TASK 13:
FINISH MACHINE USING SURFACE FINISH FLOWLINE
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In this task you will use a 0.5 diameter Ball end mill to finish the net surface.
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1. From the menu bar select Toolpaths>Surface Finish>Flowline

2. You are first prompted to Select Drive surfaces, select the All button on the General
Selection ribbon bar as shown below:
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5. Click on the Flowline button on the Toolpath/surface selection dialog box.
TRAINING
GUIDE
Mill-Lesson-11
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6. Click on the Cut direction button to toggle the toolpath direction as shown below: Note, the
lines should be inside the cavity as shown below: if they are on the outside click on the
Offset button. If the toolpath display for the roughing path is in the way press the shortcut
Alt+T to remove it.
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to exit the Flowline data dialog box.
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to exit the Toolpath/surface selection dialog box.

9. In the lower left corner of the Toolpath parameters page select the Select library tool
button.
10. Use the Filter function to filter out a selection of cutters. Select the Filter button on the right
side of the Tool selection dialog box.
11. Select the None button in the Tool Types section.
12. Click on the Endmill2 Sphere type icon, first row, and second icon from the left.
13. Select the drop down arrow in the Tool diameter field and set it to Equal. Input the tool
diameter as 0.5.
to exit.
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15. Select the 0.5 ball end mill.
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to complete the selection of this tool.

17. Make changes to the Toolpath parameters page as shown below:
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18. Select the Surface parameters page and make changes to this page as shown below:
Mill-Lesson-11
19. Next, on the Finish flowline parameters page make changes to this page as shown below:
Scallop height
Adjusts the stepover between cuts
to create leftover material at a
specific height.
Surface rough and finish flowline
toolpaths give you precise control
of scallops left on the part.
Scallop height can be set either as
a stepover distance or as an
actual height.
When using the scallop height
option, Mastercam automatically
adjusts the stepover between
cuts, although this amount is not
shown in the stepover entry field.
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20. Select the Gap settings button and make changes to this page as shown below:
Tangential line length
Sets the line length at the entry and exit points of a gap. Not
available for multiaxis toolpaths.
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Motion
Determines the tool motion in areas smaller than the gap size.
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Direct moves the tool directly from position to position.

Broken moves the tool up and over or over and down.
Smooth moves the tool in a fluid motion.
Follow surface(s) matches the Z motion of the surface.

Gap settings.
to exit
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to exit
Finish Flowline parameters.
23. The screen should look like the
image to the right:
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TASK 14:
VERIFY THE TOOLPATH
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1. In the Toolpath Manager pick all the operations to verify by picking the Select All icon
2. Select the Verify selected operations button circled below:
3. Adjust the Verify speed to midway along the speed control bar.
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4. Select the fast forward button to speed up the verification of the toolpaths.
to exit Verify.
TASK 15:
SAVE THE UPDATED MCX FILE
1. Select the save icon from the toolbar
TASK 16:
POST AND CREATE THE CNC CODE FILE
from the Toolpath
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1. Ensure all the operations are selected by picking the Select All icon
manager.
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Mill-Lesson-11
2. Select the Post selected operations button from the Toolpath manager.
3. Please Note: If you cannot see G1 click on the right pane of the Toolpath manger window
and expand the window to the right.
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4. In the Post processing window, make the necessary changes as shown below:
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5.
6.
7.
8.
Select the OK button

to continue.
Ensure the same name as your Mastercam part file name is in the NC File name field.
Select the Save button.
The CNC code file opens up in the default editor:
9. Select the
in the top right corner to exit the CNC editor
This completes Mill-Lesson-11.
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MILL-LESSON-11 EXERCISE
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TRAINING
GUIDE

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SURFACE HIGH SPEED AREA

Mastercam Training Guide

Establish Stock Setup settings:

Generate a 3-dimensional milling toolpath

Inspect the toolpath using Mastercams Verify and Backplot by:

www.mastercam.webs.com and cokhitruong.webs.com

Mastercam Training Guide

MILL-LESSON-11 - THE PROCESS

Setting the environment

Define the rough stock using stock setup

Create right hand side section

Mastercam Training Guide

9. Click on the OK icon

, pick the origin.

to complete this feature.

13. Click on the OK icon

to complete this feature.

18. Click on Apply

to fix the entity.

bar appears. Note that the Tangent

22. Click on the OK icon

to complete this feature.

3. Click on the Divide / Delete

Mastercam Training Guide

to complete this feature.

Create the rectangle

2. Unzoom to enable the grid to be seen.

6. Click on the OK icon

Create Arc #2 and #3

4. Click on the OK icon

7. Now you need to pick the End Selection icon

Mastercam Training Guide

Create Line #1,#2,#3, Arc #1 and Arc #2

8. Click on the OK icon

to complete this feature. The line is shown below:

14. Click on the OK icon

19. Click on the OK icon

to complete this feature.

Mastercam Training Guide

to complete this feature. The completed geometry is shown

23. Click on the OK icon

28. Click on Apply

to fix the entity.

to complete this feature. The completed geometry is below:

31. Click on the OK icon

Mastercam Training Guide

3. Click on the Divide / Delete

to complete this feature.

www.mastercam.webs.com and cokhitruong.webs.com

to complete this feature.

Mastercam Training Guide

Create Net Surface

Net Surfaces are surfaces constructed from a network of intersecting curves.

7. Click on the OK icon

in the Chaining dialog window.

8. Click on the OK icon

to complete this feature. The completed net surface is shown

Mastercam Training Guide

1. Select Create>Silhouette Boundary...

5. The Silhouette Boundary dialogue box appears. Click on the OK icon

www.mastercam.webs.com and cokhitruong.webs.com

to save the file and complete this function.

5. Select the green check mark button

Mastercam Training Guide

5. To change the Material type to Aluminium

6. At the Material List dialog box open the