TUTORIAL SERIES FOR

INSTRUCTOR GUIDE FOR MASTERCAM X MILL LEVEL 1 TRAINING TUTORIALS

HOW TO USE THIS MANUAL

This manual is a guide for instructors and trainers teaching Mastercam X Mill Level 1. Note: It is intended to be used in conjunction with Mastercam X Mill Level 1 Training Tutorials published by In-House Solutions. This manual makes reference to the Mastercam X Mill Level 1 Training Tutorials throughout. We do not recommend trying to use this Guide without students having a copy of the Mastercam X Mill Level 1 Training Tutorials. This manual also makes use of Mastercam files, which can be downloaded from the Training Exercises CD that comes with this book.

Legend: Step to follow to complete the tutorial Additional explanation for the current step

Callouts that give direction on how to complete the task

Bold text (usually) represents Mastercam terminology

To order Mastercam X Mill Level 1 Training Tutorials books: Contact your Mastercam Dealer, Call 1-800-529-5517 or Place an order through www.inhousesolutions.com

Mastercam Instructor Guide for Mastercam X Mill Level 1 Training Tutorials Date: October 22, 2008 Copyright 1984 - 2008 In-House Solutions Inc. - All rights reserved. Software: Mastercam X Mill Level 1 Authors: Mariana Lendel ISBN: 978-1-894487-98-6 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 distributor, or its retailer) assumes the entire cost of all necessary servicing, repair, of correction and any incidental or consequential damages. In no event will InHouse 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 the copyright laws of Canada and the United States. All rights are reserved. This document may not, in whole or part, be copied, photocopied, 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; Mastercam; Windows 95, Windows 2000 and Windows XP are registered trademarks of Microsoft Corporation.

TABLE OF CONTENT
Lesson #1: Introduction to Mastercam Lesson #2: Introduction to Geometry Creation Lesson #3 Geometry Creation (continued) Lesson #4 Geometry Creation (continued) Lesson #5 Geometry Creation (continued) Lesson #6 Geometry Creation (continued) Lesson #7 Geometry Creation (continued) Lesson #8 Wireframe and Solid Geometry Creation Lesson #9 Wireframe and Solid Geometry Creation (continued) Lesson #10 Geometry Creation - Test Lesson #11 Introduction to Chaining, Properties and basic 2D Toolpaths Lesson #12 2D Toolpaths Lesson #13 2D Toolpaths (continued) Lesson #14 Introduction to 2D High Speed Toolpaths Lesson #15 2D Toolpaths using Transform Toolpaths Lesson #16 2D Toolpaths (continued) Lesson #17 2D Toolpaths (WCS) Lesson #18 2D High Speed Toolpaths (continued) Lesson #19 fbm mill & drill Toolpaths Lesson #20 Toolpaths - Test 3 15 28 34 40 47 56 61 69 71 73 91 97 100 107 111 121 126 133 140

LESSON #2: INTRODUCTION TO GEOMETRY CREATION

Lesson Plan Introduction to Geometry Creation
Lesson Objectives Create a rectangle knowing the width and height Create parallel lines, by defining the offset direction and distance Create lines knowing the endpoints Create arcs knowing the diameter and center point Create fillets Trim the existing geometry Mirror xisting geometry Move origin to redefine the part Create points knowing their positions Time Teaching / Learning Strategies 30 min Have Students follow Tutorial 1 from the book to create 2D Geometry. Page 1-2 to Page 1-9 Enhancing Phase 1 hour Use the following Training Exercises: Create_Point_Pos Create_Rectangle Create_Lines Create_Arc Fillet Trim Mirror These exercises will help reinforce the commands used to create the tutorial drawing and aid the students with 2D geometry. Assignments / Quiz 30 min Have the students complete Tutorial 1 Exercise 1 and Tutorial 1 Exercise 2 found at the end of Tutorial 1 in the book; page 1-33 &1-34 Have students complete the first 2 questions from Tutorial 1 Quiz found in their books on page 1-36

Resources Mastercam & Mill Level 1 Training Tutorial Book CD Training Exercises

Use PowerPoint : Lesson2.ppt

Mill Level 1 Training Tutorial Book

Mill Level 1 Training Tutorial Book

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Mill Level 1 Lesson 2: Geometry Creation

Students complete Tutorial 1 geometry

INSTRUCTOR GUIDE
Mastercam Mill Level 1 Training Tutorial page 1-2 to page 1-9

Students complete Tutorial 1 geometry

The following commands are shown in Tutorial 1: Create Rectangle knowing the width and the height of the rectangle. Create Line Parallel by defining the offset direction and distance. Create Circle Center Point knowing the diameter and the center point. Mirror existing geometry to complete a part. Move to Origin to redefine the part origin.

CREATE POINT POSITION COMMAND

Create Point Position Definition: Create Point Position command creates a point defined by its coordinates
X,Y, and Z or creates a point at the endpoint, midpoint, intersection, quadrant or arc center of already created lines or arcs.

PowerPoint Presentation:
Lesson 2.ppt

Training Exercises CREATE_POIN T_POS.MCX

File Open Select Create_Point_Pos.mcx You can start the command from the Menu.

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Mill Level 1 Lesson 2: Geometry Creation

You can also start the command from the Sketcher toolbar.

INSTRUCTOR GUIDE

Tips: Create the points on the right side drawing to match the left side. Use the Autocursor function to insert the points at the Endpoints, Midpoints, Intersection, Quadrants, Origin and Center locations. As Mastercam detects and snaps to points, it displays a temporary square over the point and the corresponding cursor icon. Use the Fast Point icon to enter the coordinate values for the rest of the points as per the drawing.

Press Enter key. Mastercam does the math. For the second point you can type 2.25+.5, -1.75 -1 (Enter)

CREATE RECTANGLE & CREATE RECTANGULAR SHAPES COMMANDS

Create Rectangle Definition: Create Rectangle command creates a rectangle based on two points, or by entering the width and height in the ribbon bar and an anchor point. The anchor point can be located at a corner or at the center of the rectangle. PowerPoint Presentation: Lesson 2.ppt CD Training Exercises
CREATE_RECTA NGLE.MCX

File Open Select Create_Rectangle.mcx

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Mill Level 1 Lesson 2: Geometry Creation

Create Rectangle

INSTRUCTOR GUIDE

Tips: Type the coordinate values of the opposite corners of the rectangle as per thdrawing using the Fast Point icon.

Create Rectangular Shapes

Definition: Create Rectangular Shapes allows you to create a rectangle, an obround shape, D shape or a double D shape. The shapes can be created using a based point for the anchor and by entering the width and height of the shape. The shapes can also be created using 2 points method by entering the two opposite corner coordinate values. Create Rectangular Shapes
Tips: Select the Drop-down arrow to extend the dialog box. Type the Width and the Height values. Select the approximate anchor placement in the dialog box, and enter the coordinate values as per the drawing. Reselect the command to change the point placement.

CREATE LINE ENDPOINT & CREATE LINE PARALLEL

Create Line Endpoint Definition: Create Line Endpoint command allows to create a line knowing the two endpoint coordinate values. It also allows you to create a line polar knowing one endpoint location, the length and the angle of the line. You can create horizontal or vertical lines. With this command you can also create multilines or tangent lines. PowerPoint Presentation: Lesson 2.ppt CD Training Exercises CREATE_LINE S.MCX

Note that Create Line Enpoint allows you to create the following types of lines:

Line Endpoints Line Horizontal Line Vertical Line Polar Multiple Lines Line Tangent

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Mill Level 1 Lesson 2: Geometry Creation

File Open Select Create_Lines.mcx Create Line Endpoint Line Horizontal

INSTRUCTOR GUIDE

Create a horizontal line:

Enable Horizontal icon in the Ribbon Bar. Sketch the endpoints of the horizontal line approximately at the same location from X and Y axis as per left side drawing. Enter 1.5 as the Y coordinate. Press the Enter key. Select the Apply button to continue.

Create a vertical line:

Line Vertical Enable Vertical icon in the Ribbon Bar. Sketch the endpoints of the vertical line approximately at the same location from X and Y axis as per left side drawing. Enter 1.0 as the X coordinate. Press the Enter key. Select the Apply button to continue. Unselect the Vertical icon.

Create a line knowing the endpoints:

Line Endpoints Select the Fast Point icon . Type the coordinates values for the first point (-1.75, -.5) Enter Select again the Fast Point icon . Type the coordinates values for the second point (-2.5, -1.75) Enter Select the Apply button to continue.

Create a polar line:

Line Polar Enter the Length 3 and the Angle -25.0 Select the Origin (the center of the Grid) as the first endpoint Select the OK button to exit the command.

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Mill Level 1 Lesson 2: Geometry Creation

Create Line Parallel

INSTRUCTOR GUIDE

Definition: Create Line Parallel command creates a line parallel to an existing line. You can create the parallel line knowing the distances between the lines or knowing a point to position the parallel line. Create Line Parallel
Tips: Enter the Distance 0.50. Select the existing line and indicate the offset direction by clicking below the existing line.

Select the OK button to exit.

CREATE CIRCLE CENTER POINT & CREATE ARC ENDPOINT COMMANDS

Create Circle Center Point Definition: Create Circle Center Point command creates a circle knowing the center point location and the radius or the diameter of the circle. PowerPoint Presentation: Lesson 2.ppt CD Training Exercises
CREATE_ARC. MCX

File Open Select Create_Arc.mcx Create Arc Circle Center Point

Tips: Enter the Radius = 1.0 and select the point as the center location. Select the Apply button to continue in the same command. Tips: Enter the Diameter = 1.0 and select the point as the center location. Select the OK button to exit.

Create Page-20

Mill Level 1 Lesson 2: Geometry Creation

Arc Endpoint

INSTRUCTOR GUIDE

Definition: Create Arc Endpoint command creates an arc knowing the two endpoint locations and the radius of the arc. Create Arc Arc Endpoints
Tips: Enter the Radius = 0.25. Select the first point, select the second point. The system gives all possible results. Select the arc that you want to keep. Select the

Apply button to continue in the same command

create the other arc. Select the OK button to exit.

. Following the same steps

CREATE FILLET ENTITIES & CREATE FILLET CHAIN COMMANDS

Create Fillet Entities Definition: Create Fillet Entities command creates an arc of a defined radius tangent to two curves. You can trim to the fillet the original entities or leave them untrimmed. You can select different fillet styles (normal, inverse, circle or clearance) before selecting the two entities. PowerPoint Presentation: Lesson 2.ppt CD Training Exercises
FILLET.MCX

File Open Select Fillet.mcx Create Fillet Entities

By default, the Trim icon is enabled and Mastercam trims the curves to . Always select

the fillet; however, you have the option to turn off trimming the curves on the side that you want to keep after filleting.

First rectangle
Enter the Radius = 0.25 Page-21

Mill Level 1 Lesson 2: Geometry Creation

The upper left corner settings should be as follows:

INSTRUCTOR GUIDE

Enable Normal

and Trim.

Select the Apply button to continue in the same command.

The upper right corner settings should be as follows:

Enable Inverse

and keep Trim

Select the Apply button to continue in the same command.

The lower right corner settings should be as follows:

Enable Circle

and Trim

Select the Apply button to continue in the same command.

The lower left corner settings should be as follows:

Enable Clearance

and Trim

Select the OK button to exit the command. Create Fillet Chains

Definition: Create Fillet Chains command lets you create fillets at sharp corners along selected chains of curves. Create Fillet Chain

Second rectangle
Enter the Radius: = 0.375 Enable Normal and Trim. Select one of the rectangle lines and then the OK button to exit Chaining dialog box. Select the OK button to exit the command.

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Mill Level 1 Lesson 2: Geometry Creation

INSTRUCTOR GUIDE

TRIM COMMAND
Edit Trim/Extend/ Break

Definition: Trim/Extend/Break function has three commands incorporated in one. Based on what button you enable in the ribbon bar you can trim, break or extend the entities. Definition: Trim command allows you to trim 1, 2 or 3 entities, trim to a selected point or position. You can also divide entities based on the closest intersection. File Open Select Trim.mcx

PowerPoint Presentation: Lesson 2.ppt CD Training Exercises

TRIM.MCX

Edit/ Trim/Break Trim/Break/Extend Trim 1 entity Definition: Trim 1 entity trims or extends one curve to its intersection with a second curve without modifying the second entity.
Enable Trim 1 entity button. Select the entity to trim on the side that you want to keep after trimming.

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Mill Level 1 Lesson 2: Geometry Creation

Definition: Trim 2 entities Trim 2 entities

INSTRUCTOR GUIDE

trims or extends both curves to their intersection.

Select the entities to trim on the side that

Enable Trim 2 entities button. you want to keep after trimming.

Trim 3 entities

trims or extends all three curves. The first two Definition: Trim 3 entities curves that you select are trimmed to the third selected curve, which acts as a trimming curve. The third curve is then trimmed to the first two curves.
Enable Trim 3 entities button you want to keep after trimming. . Select the entities to trim on the side that

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Mill Level 1 Lesson 2: Geometry Creation

INSTRUCTOR GUIDE

Trim Divide

Definition: Trim Divide trims a line or an arc into two disjointed segments by removing the segment that lies between two dividing curves.
Enable Trim Divide button. removed.

Select the parts of the entity to be

Trim to Point

trims or extends a curve to a point or any defined Definition: Trim to Point position in the graphics window. If the point that you enter does not lie on the selected entity, Mastercam calculates the closest position on the entity and trims the entity to that point.
Enable Trim to Point button. Select the entity to trim/extend and then select the point. Select the OK button to

exit the command.

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Mill Level 1 Lesson 2: Geometry Creation

INSTRUCTOR GUIDE

XFORM MIRROR COMMAND

Xform Mirror

Definition: Xform Mirror command creates reverse images of geometric and drafting entities with respect to a defined axis or two points. The axis can be defined as X-axis, Y-axis, a point and an angle, an existing line or two points. You have the option to move or copy the original entities within the drawing.

PowerPoint Presentation: Lesson 2.ppt CD Training Exercises MIRROR.MCX

File Open Select Mirror.mcx Xform Mirror

Tips for the upper shape

Select the entities to mirror using window by enable Window Selection and mirror twice :once about X-axis, then about Yaxis.

Tips for the middle shape

Select both contours to mirror using chain by enble Chain Selection and enable the Select Line button in the Mirror dialog box. Select the red color line.

Tips for the lower shape

Select both contours to mirror using Chain Selection and enable Select 2 points button the contours. in the Mirror dialog box Select two of the open ends of

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Mill Level 1 Lesson 2: Geometry Creation

Assignment Tutorial 1 Exercise1

INSTRUCTOR GUIDE
Mill Level 1 Training Tutorial page 1-33

The student creates the 2D geometry from Tutorial 1 Exercise1

Use the following commands: Create Rectangle Create Line Endpoint (Horizontal / Vertical) Create Fillet Trim Divide Assignment Tutorial 1 Exercise 2

The student creates the 2D geometry from Tutorial 1 Exercise 2

Mill Level 1 Training Tutorial page 1-34

Use the following commands: Create Rectangle Create Line Parallel Create Line Endpoint Trim Divide Create Fillet Trim 2 entities

Answer the first 2 questions from the Tutorial 1 quiz Quiz

Mill Level 1 Training Tutorial page 1-36

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Mill Level 1 Lesson11: Toolpath Creation

INSTRUCTOR GUIDE

LESSON #11 INTRODUCTION TO CHAINING, PROPERTIES AND BASIC 2D TOOLPATHS

Lesson Plan Introduction to Chaining and setting up Properties and basic 2D toolpaths
Lesson Objectives Learn about chaining. Load correct machine type. Create Basic Toolpaths using geometry created in Lesson 2 (Tutorial 1). Learn about contour toolpath. Learn about drilling toolpath. Backplot the toolpaths. Verify the toolpaths. Time Teaching / Learning Strategies Resources 40 min Download and demonstrate CD Training Exercises ANALYZE CHAIN.MCX Discuss Chaining problems, encourage students to take notes and ask questions. Use PowerPoint: Lesson11a.ppt Download and demonstrate CHAIN1.MCX Show students various methods for chaining geometry. Enhancing Phase 40 min Load toolbar states PowerPoints: Lesson11a.ppt Load Machine type Introduction to icons found under Operations Manager Present Machine Group Properties and explain settings found there. Set up bounding box 20 min Have students complete the Toolpath Creation from Mill Level 1 Training Tutorial Book Tutorial 1 found on pages 1-10 to 1-32. 40 min Contour toolpath parameters PowerPoints: Lesson11b.ppt Backploting the toolpaths Verifying the toolpaths Drill toolpath parameters Assignment / Quiz Have the students open 2D Geometry from Tutorial 1 Mill Level 1 Training Tutorial Book Exercises and complete toolpaths on those parts. On pages 1-33 & 1-34 Have students finish Tutorial 1 Quiz on page 1-36 Mill Level 1 Training Tutorial Book

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INSTRUCTOR GUIDE

CHAINING
About chaining Definition: Chaining is a process used to select a number of entities, (lines, arcs, points, splines etc.) Chaining is used when modifying or transforming existing entities or when creating a toolpath. The entities form a chain when the distance between two consecutive entities is less than the chaining tolerance (.0001 in the system configuration). When Chaining Geometry to create a toolpath it is important in certain circumstances to chain the geometry in the proper direction, as it will determine the direction the cutter travels when machining the part. Below is an example of how to select geometry using chaining method. Note: To change the direction of the arrows just click on Reverse from the Chaining dialog box. PowerPoint Presentation: Lesson 11a.ppt

Arrows will go clockwise when the line is selected here.

Arrows will go counter

clockwise when the line is selected here.

CHAINING PROBLEMS
Untrimmed entities
Description Chain stops; Lines do not touch Check Zoom in to inspect Fix Trim lines together

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Chain stops; Lines cross Zoom in to inspect

INSTRUCTOR GUIDE
Trim lines

Branches

Chain stops at Branch Points

Note that the chain stops at the first branch.

Enable CPlane to select the entities that are in the current construction plane; or guide the chaining by selecting the next branch if all entities area in the same Cplane.

Lines at different Z depths

Lines dont touch

Look at geometry in Gview Isometric.

Use Xform, Project.

Duplicate entities

Duplicate entities Identical entities on top of each other

Zoom in on the area; a thicker line should become visible

Delete Duplicate entities

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Mill Level 1 Lesson11: Toolpath Creation

Overlapping entities
Overlapping entities (Entities of different lengths on top of each other). Zoom in on the area, use Analyze commands and move the cursor to the top of the entities.

INSTRUCTOR GUIDE
Use Findovlp.dll C-hook

FIXING CHAINS

Training Exercises ANALYZE CHAIN.MCX

File Open Select Analyze chain.mcx Analyze Analyze Chain Delete Duplicates

Upper right corner geometry has Duplicate Entities

Use Delete Duplicates icon to remove all identical entities from the screen. The system will display how many duplicate entities were erased.

Overlapping Entities

The upper left contour has entities of different lengths on top of each other.
To fix the geometry use FindOverlap.dll user application. To open the C-Hooks directory hold down Alt key and type C. Select FindOverlap.dll and Open button.

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Mill Level 1 Lesson11: Toolpath Creation

Use All button and All Entities when you are prompted to select the geometry. Hit the Enter button to end the selection. Select the Cleanup button in the Find Overlap C-Hook dialog box and hit OK.

INSTRUCTOR GUIDE

Entities at different Z depths

The lower left contour has entities at different z-depth.

To see the geometry use Graphic View Isometric Xform Project Definition: Xform Project projects all entities at the same z-depth in Top Construction Plane.
When prompted to select the geometry use All button as shown in the previous step to select all entities. Make sure that Move is enabled and project to construction plane and 0 depth as shown to ther right.

Untrimmed Entities

The lower right contour has untrimmed entities.

To fix the geometry use Edit Trim/Break Trim/Break/Extend Trim 2 entities. Make sure that you select the entities on the side that you want to keep.

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Mill Level 1 Lesson11: Toolpath Creation

INSTRUCTOR GUIDE

CHAINING - SELECTION METHODS

Chaining dialog box In Wireframe mode, the Chaining dialog box provides chain selection methods including: C-plane - allows you to select geometry created in the current construction plane. 3D - allows you to select 3D geometry. Window Area Single Polygon Partial Vector Other controls let you manage the selection process: Last End chain Unselect Reverse chaining direction

Full Chain mode

Use Chain

selection to create closed chains.

File Open Select the CHAIN1.MCX

Use Analyze Chain command to show the different selection options.

Training Exercises CHAIN1.MCX Select the chain as shown

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Mill Level 1 Lesson11: Toolpath Creation

INSTRUCTOR GUIDE

Enable Chain button and then select the chain as shown. Click on the Reverse button to change the chaining direction. You can also expand the chaining dialog box by selecting the drop down arrow and show how you can change the start of the chain using Forward , and Dynamic buttons. Back Click on Unselect button to continue.

Partial Chain

Use Partial chaining to create open chains.

Analyze Chain
Click the first entity of the chain, and then click the last entity of the chain.

First Entity
Press Esc to exit the Chaining dialog box.

Last Entity

Change the Levels

Select Level in the Status bar and make Level 1 invisible and Level 3visible. Leave Level 11 as the current main level.

Chain with Branches

Branch point is the position where the endpoints of two or more entities meet. Branch points indicate where there are different paths that the chain can take. When Mastercam encounters a branch point during chaining, it prompts you to choose the path for the chain to follow.

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Mill Level 1 Lesson11: Toolpath Creation

Analyze Chain

INSTRUCTOR GUIDE

Note the extra dashed lines. Guide the red arrow along the solid line contour to chain the entire contour. Press the Esc to exit the command.

Change the levels

Select Level in the Status bar and make Level 3 invisible and Level 4 visible. Leave the current main level Level 11. Change the Gview to Isometric.

C-Plane

Cplane chains only entities that are parallel to the current construction plane and at the same Z depth as the first entity you chain.

Analyze Chain
Enable C-Plane and chain the bottom chains as shown above. Press Esc to exit.

Chaining Options

Definitions: The chain Mask options speed up chaining for a large number of entities or when branch points are involved. They let you "pre-select" categories of entities to build your chain from. Mastercam provides Entity, Color, and Level. All the mask does is to block all the entities that do not match the mask criteria.

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Mill Level 1 Lesson11: Toolpath Creation

Color Mask

INSTRUCTOR GUIDE

Color Mask chains only entities that form a chain and have the same color as the first entity you chain.

Analyze Chain
Click on the Options shown above. button and enable Color and chain the top chain as

Press Esc to exit.

More about Chaining Options

Definitions: Closed chains allow you to select all entities adjacent to the selected entity in the forward and reverse directions until it reaches the end of a chain or a branch point. Open chains allow you to select a section of the chain by selecting the first entity and the last entity of the chain. Mastercam creates an open chain which includes all adjacent entities between these two points. Section angle applies only to Section chaining. In Section chaining, Mastercam chains along a set of smooth curves. Curves that are less than the section stop angle are considered tangent for this chaining method. When Mastercam encounters an angle that exceeds the section stop angle or a branch point, it ends the chain. Ignore depths (in 3D mode) lets you chain entities that could form a chain (the distance between two consecutive entity endpoints is smaller than the chain tolerance) but have different depths. Start chain at point will start the chaining from a point that you create on an endpoint of an entity in the chain.

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INSTRUCTOR GUIDE

Allow surface edges in Single mode allows you to select, in single mode, the edges of a surface. Break entities in Dynamic sets the system to automatically break the entities at intersection while in Dynamic mode. Nested chains Sorting lets you choose different sorting options while selecting geometry that is completely contained within a closed boundary. You can speed up chaining using next closest. Choosing inside to outside sorts and chains the curves from the innermost to the outermost. You can sort the chains starting with the outermost chains using outside to inside. It also allows you to sort and optimize the chaining using optimize inside to outside or optimize outside to inside. Infinite nesting in area chains one mouse click chains all of the curves and points within a closed boundary. When unchecked, Mastercam chains the outer and inner boundary closest to the point you entered to define the area chain and any curves or points between the two. Reverse inner chains changes the direction of chaining for the inner chains. Sync mode allows Mastercam to break a chain into a number of separate chains for the purpose of creating the surface. The Sync mode option of the Chaining Options dialog box determines how Mastercam should divide up the chains. You may need to choose a sync mode if you have attempted to create a surface and found that it twists. Chaining tolerance sets the default chaining tolerance value. Plane tolerance sets the default plane tolerance value.

TOOLBAR STATES -2D TOOLPATHS

Load Toolbar States Before starting the toolpath creation we should customize the toolbars to see the toolbars required to machine a 2D part. Settings Toolbar states

Select 2D-Toolpaths.

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Mill Level 1 Lesson11: Toolpath Creation

Select the Load button.

INSTRUCTOR GUIDE

Select the OK button to accept it.

Note that the PowerPoint presentation shows another way of setting the toolbar.

MACHINE TYPE
Load the Machine type Selecting the correct machine is an important step in CNC programming. It will automatically have the Machine definition, the Control definition and the Post processor linked to generate the specific code required by the CNC machine tool. Definitions: Machine Definition describes the components of the machine tool and their interrelationship and motion. PowerPoint Presentation: Lesson 11a.ppt

Machine Definition

Control Definition

Control Definition provides the post processor with the information it needs to process the toolpath. Many of the settings in the control definition replace the numbered questions found in posts for earlier versions of Mastercam, so that settings that previously required editing the .PST file should now be set in the control definition.

Post Processor

Post Processor refers to the process by which the toolpaths are converted to a format that can be understood by the machine tool's control (for example, Gcodes).

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INSTRUCTOR GUIDE

TOOLPATHS MANAGER
Toolpaths Manager The Toolpaths Manager lists all operations in the current job. Use this dialog box to sort, edit, regenerate, verify and post any operations. You can enter this dialog box by selecting the Toolpaths tab. PowerPoint Presentation: Lesson 11a.ppt

Toolpaths Manager Icons

PowerPoint Presentation: Lesson 11.ppt

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INSTRUCTOR GUIDE

MACHINE GROUP PROPERTIES

Machine Group Properties Machine group properties include selecting the machine tool that will perform the operations in the group; post and NC settings; tool offsets, default settings and data paths; and setting up stock models and safety zones that will be used by all operations in the machine group. A single part can have multiple machine groups, each containing machining properties folders that identify properties (i.e., support files, tooling, stock, etc.) The functions in this dialog box are divided into four tabs: PowerPoint Presentation: Lesson 11a.ppt

Files tab

Files tab allows you to specify the names and data paths of the files needed to generate the toolpath. It also allows you to set the operations defaults.

Tool Settings tab

Tool Settings tab allows you to control how Mastercam assigns tool numbers, tool offset numbers, and default values for feeds, speeds, coolant, and other toolpath parameters.

Stock Setup tab

Stock Setup tab allows you to define the stock shape and size to use it when verifying the part using Verify.

Safety Zone tab

Safety zones tab allows you to define an area around the system origin to allow the tool to retract a safe position outside this area to avoid collisions caused by indexing. It is used mainly with multiaxis toolpaths.

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Mill Level 1 Lesson11: Toolpath Creation

Students complete Tutorial 1 Toolpaths

INSTRUCTOR GUIDE
Mastercam Mill Level 1 Training Tutorial page 1-10 to page 1-32

Students complete Tutorial 1 Toolpaths

The following settings, toolpaths and verification systems are shown in Tutorial 1: Properties setting the tool numbers, feedrate calculation and stock. Contour Toolpath (open contour) geometry selection, tool selection and specific contour toolpath parameter settings. Backplot toolpath explaning different options that could be used to simulate the toolpath. Verify toolpath explaining different options to verify the toolpath Modifying the contour to add multiple cutting passes for a better clean up of the part. Drill Toolpath used to center drill and drill the holes and the specific parameter description. Backplot and Verify all the operations Post process the file.

CONTOUR TOOLPATH
Contour Toolpath Definition: Contour toolpath is used to drive a tool along a path. You can use the toolpath for both roughing and finishing.

PowerPoint Lesson 11b. ppt

To select the Contour Toolpath use one of the following 3 options:

Select the icon from the 2D toolpaths toolbar (left of Toolpaths Manager).

Select Toolpaths from the menu and click Contour in the drop down list.

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INSTRUCTOR GUIDE

Right click in the Toolpaths Manger area and select Mill toolpaths and then Contour. Right click anywhere in this window

Toolpath Parameters tab

Definition: Toolpath Parameters tab allows you to select a tool, set feed rates and speeds and set other general toolpath parameters. This tab is the same, or very similar, for most Mill toolpaths. For a detailed explanation of the parameters please check the PowerPoint: Lesson11a.ppt

Contour Parameters tab

Definitions: Contour Parameters tab allows you to enter cutting parameters for a contour toolpath. Clearance value sets the height at which the tool rapids to or from the part. Retract value sets the height at which the tool rapids/feed-rates up to, before the next step down. Feed plane value sets the height from which the tool plunge-rates into the part. Depth value sets the final machining depth for the drilling operation. Top of stock value sets the height of the material. Compensation type set to Computer allows Mastercam to compensate the toolpath, and doesnt output G41/G42 in the code.

Compensation direction set to Right offsets the toolpath, with the radius of the tool, to the right side. Roll cutter around corners set to Sharp inserts arc moves around corners in the toolpath. The radius of the arc moves is equal with the radius of the tool. Infinite look ahead prevents the toolpath from crossing itself (fish tail).

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INSTRUCTOR GUIDE

Depth cuts allows you to divide the total depth in increments not bigger than the tool radius. Multipasses allows you to follow the contour geometry in steps in the current cutting plane.

BACKPLOT
Backplot toolpaths Backplotting shows the path the tools follow to cut your part. This display lets you spot errors in your program before you machine the part. PowerPoint: Lesson11b. ppt

Backplot icons

Display with colour codes: Shows the toolpath moves using colours. Display tool: Shows the tool. Display holder: Shows the tool holder. Display rapid moves: Shows rapid moves in the backplot. Display endpoints: Shows entity endpoints in the toolpath. Quick Verify: Shows a shaded path the width of the tool as the backplot progresses. Options: Opens the options available for backplot. Save Tool Geometry: Allows you to take a picture and save it, of the current position of the tool and tool holder. Save as geometry: Allows you to save the visible toolpath motion as geometry to a specific level using specified attributes. Restrict drawing: Removes all currently plotted toolpaths from the screen. The remaining ones become the only ones Mastercam will plot.

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Mill Level 1 Lesson11: Toolpath Creation

INSTRUCTOR GUIDE

Turn off restricted: Turns off the restrictions set with the restrict drawing button allowing you to backplot all of the selected operations.

VERIFY
Verify toolpaths Definition: Verify allows you to verify the machining process from a solid stock model. Verification controls allow you to restart, machine, pause, step and fast forward. Turbo: Displays no tool, generally the fastest option. Use if machining large files witha lot of code. Simulate tool: Displays a solid tool without a holder. Simulate tool and holder: Displays a tool and holder as a solid. PowerPoint: Lesson 11b. ppt

DRILL TOOLPATH
Drill Toolpath Definition: Drill toolpath allows you to drill holes in the part using different cycles that the CNC machine tools are capable of machining. PowerPoint: Lesson 11b. ppt

To select the Drill Toolpath you can use one of the 3 options as described in the Contour operation.
Note that the Toolpaths Parameters tab is similar with the contour toolpath.

Simple drill no peck (Drill Parameters) tab

Drill Parameters tab allows you to select a drilling cycle and enter basic drilling parameters. Clearance value sets the height at which the tool rapids to or from the part. Retract value sets the height at which the tool rapids/feed-rates up to, before the next step down. Depth value sets the final machining depth for the drilling operation. Drill/ Conterbore cycle (G81) is recommended for drilling holes with depths of less than three times the tool diameter. Peck Drill is recommended for drilling holes with depths of more than three times the tool diameter. Retracts fully out of the drilled hole to remove material chips.

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Mill Level 1 Lesson11: Toolpath Creation

INSTRUCTOR GUIDE

Chip Break drills holes with depths of more than three times the tool diameter. Retracts partially out of the drilled hole to break material chips. Tap taps right or left internal threaded holes. Bore #1 drills holes with feed-in and feed-out motion. Bore #2 drills holes with feed-in, stop spindle, and rapid-out motion. Fine bore (shift) stops the spindle at the end of each drill point, then spins to orient the tool to a pre-defined angle, shifts off the wall of the hole, and retracts. Tip comp: adds the tip of the tool (automatically determined based on the tool diameter and the 118 degrees angle of the drill) to the depth. You can also add a breakthrough amount to the depth for the tool to drill all the way through the stock.

POST PROCESSING
Post Definition: Post Processor refers to the process by which the toolpaths are converted to a format that can be understood by the machine tool's control (for example, G-codes). Output MCX file descriptor allows you to include a description of your file. NC file allows you to save your file. Ask prompts the user if you wish to overwrite the file name. Send to machine sends the NC file automatically to the machines tool control through your workstation serial port. Edit allows you to edit the program. NC extension prompts for the extension to be used for the NC files. Overwrite automatically overwrites a file with the same name without asking permission. PowerPoint: Lesson 11b.ppt

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TUTORIAL SERIES FOR

INSTRUCTOR GUIDE FOR MASTERCAM X MILL LEVEL 3 TRAINING TUTORIALS

HOW TO USE THIS MANUAL

This manual is a guide for instructors and trainers teaching Mastercam X Mill Level 3. Note: It is intended to be used in conjunction with Mastercam X Mill Level 3 Training Tutorials published by In-House Solutions. This manual makes reference to the Mastercam X Mill Level 3 Training Tutorials throughout. We dont recommend trying to use this Guide without students having a copy of the Mastercam X Mill Level 3 Training Tutorials This manual also makes use of Mastercam files, which can be downloaded from the Training Exercises CD that comes with the tutorial.

Legend: Step to follow to complete the tutorial Additional explanation for the current step

Callouts that give direction on how to complete the task

Bold text (usually) represents Mastercam terminology

To order Mastercam X Mill Level 1 Training Tutorials books: Contact your Mastercam Dealer, Call 1-800-529-5517 or Place an order through www.inhousesolutions.com

Mastercam Instructor Guide for Mastercam X Mill Level 3 Training Tutorials Date: October 31, 2008 Copyright 1984 - 2008 In-House Solutions Inc. - All rights reserved. Software: Mastercam X Mill Level 3 Authors: Mariana Lendel ISBN: 978-1-926566-11-5 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 distributor, or its retailer) assumes the entire cost of all necessary servicing, repair, of correction and any incidental or consequential damages. In no event will InHouse 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 the copyright laws of Canada and the United States. All rights are reserved. This document may not, in whole or part, be copied, photocopied, 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; Mastercam; Windows 95, Windows 2000 and Windows XP are registered trademarks of Microsoft Corporation.

TABLE OF CONTENT
Lesson #1 Introduction to 3D Wireframe Lesson #2 Introduction to Curves and Surface Creation: Revolved Lesson #3 Surface Creation: Draft, Extruded, Primiteves, Ruled/Lofted Lesson #4 Surface Creation: Net Lesson #5 Surface Creation: Swept Lesson #6 Surface Creation: Fillet Lesson #7 Surface Creation: Trim and Offset Lesson #8 Surface Creation: Blend and Fillet Blend Lesson #9 Surface Creation (Continued) Lesson #10 3D Wireframe and Surfaces Creation - Test Lesson #11 Introduction to 3D Toolpaths: Rough Pocket, Finish Parallel & Finish Contour Lesson #12 3D Toolpaths: Rough Radial and Finish Scallop Lesson #13 3D Toolpaths: Rough Restmill and Finish Blend Lesson #14 3D Toolpaths: Rough Flowline, Rough Plunge, Finish Shallow and Blend Lesson #15 Surface HS Core Roughing, Surface Pencil and Project Finish Lesson #16 Surface HS Area Clearance and Surface Finish Contour, Leftover and Project Lesson #17 Surface HS Core Rough, Horizontal Area, Waterline and Scallop Rest Passes Lesson #18 Surface HS Core Rough, Horizontal Area, Scallop, Scallop Rest Passes and Pencil Lesson #19 Surface Toolpaths - Test 1 9 17 29 37 46 54 64 70 72 73 80 85 90 96 103 108 114 121

LESSON #3 SURFACE CREATION: DRAFT, EXTRUDED, PRIMITIVES AND RULED/LOFTED

Lesson Plan Surface Creation: Draft, Extruded, Primitives and Ruled/Lofted
Lesson Objectives Create 3D wireframe Create Ruled/Loft surface Create a Flat Boundary surface Create Primitives Create Draft Surfaces Time Teaching / Learning Strategies 15 min Have students follow Tutorial 2 from the book to create 3D wireframe, Ruled & Flat boundary surface page 2-2 to page 2-11. Enhancing Phase 1 hour Download the Training Exercises and demonstrate these exercises: Draft_Extrude Primitives LOFT AND RULED SURFACE.MCX Ruled-Sync Rul2 20 min Have the students create the wireframe from Tutorial 2 Exercise on page 2-28. Assignments / Quiz 5 min Have students complete the first 2 questions from Tutorial 2 Quiz found in their books on page 2-30.

Resources Mastercam & Mill Level 3 Training Tutorial Book

CD Training Exercises CD PowerPoint:Lesson 3

Mill Level 3 Training Tutorial Book

Mill Level 3 Training Tutorial Book

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Mill Level 3 Lesson 3: Geometry Creation

Students complete

INSTRUCTOR GUIDE
Mastercam Mill Level 3 Training Tutorial Page 2-2 to page 2-10

Students complete Tutorial 2 geometry

Tutorial 2 geometry

The following commands are shown in Tutorial 2: Create the 3D wireframe Create Ruled Surface Create Flat Boundary Create Rectangular Shapes with the surface option enabled.

EXERCISES USING PRIMITIVES

Primitives Surfaces Definition: Primitives creation functions can make solid or surface shapes. These functions are found on the Sketcher toolbar. The following shapes can be created using the primitives commands: Cylinder, Cone, Block, Sphere and Torus. PowerPoint Presentation: Lesson 3.ppt

File Open Select PRIMITIVES.MCX

Training Exercises PRIMITIVES. MCX

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Mill Level 3 Lesson 3: Geometry Creation

Create the sphere.
Sphere Create Primitives Sphere

INSTRUCTOR GUIDE

Tips: You can draw the sphere by clicking in the graphics window to set the base point, dragging outward to set the radius. While the sphere is live you can change the base point, radius, and sweep angle.

Create the torus.

Torus Create Primitives Torus
Tips: Use different color to create the torus. You can draw the torus (in Isometric view) by clicking in the graphics window to set the base point, dragging outward to set the major radius. After setting the major radius, enter the minor radius. While the torus is live you can change the base point, major and minor radius, sweep angle and the axis.

Create the cylinder.

Cylinder Create Primitives Cylinder
Tips: Use different color to create the cylinder. You can draw the cylinder (in Isometric view) by clicking in the graphics window to set the base point, dragging outward to set the radius, then dragging up or down to set the height. While the cylinder is live you can adjust the dimensions, extend the cylinder in two directions, select a new base point, change the primary axis, or change the sweep to create a slice of a cylinder.

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Mill Level 3 Lesson 3: Geometry Creation

INSTRUCTOR GUIDE

DRAFT AND EXTRUDED SURFACES

Draft Surface Definition: A Draft Surface is a surface generated by extruding one or more contours, along a line defined by an angle and a length. Applications: the surface is used to create an angled surface, a tapered wall, or cones and cylinders. PowerPoint Presentation: Lesson 3.ppt

Examples:

You can select multiple entities to chain. Mastercam creates a separate draft surface for each individual entity in each chain. A zero value entered in the Angle field produces no tilt and is the equivalent of an extrusion perpendicular to the construction plane.

Training Exercises DRAFT_ EXTRUDED. MCX

File Open Select DRAFT_EXTRUDED.MCX Page-20

Mill Level 3 Lesson 3: Geometry Creation

Create the draft surface in the upper right corner.

INSTRUCTOR GUIDE

Draft Surface

Create Surface Draft

Tips: Make sure that the current Cplane is set to Top plane. Note that the extrusion is always perpendicular to the Cplane.

Select the chain and then enter the values in the dialog box to match the ones from the finish geometry in the right colummn. (Length = 1.0; Angle = 5 deg.)

Create the draft surface in the middle

Create Surface Draft

Tips: Make sure that the current Cplane is set to Front plane.

Select the chain and then enable Plane instead of Length in the dialog box. Enter Angle = 5 deg. and select the Plane button.

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Mill Level 3 Lesson 3: Geometry Creation

Define the plane by selecting Entities button graphic window two lines that intersect.

INSTRUCTOR GUIDE
, and then select from the

Make sure that the resulting arrow will point towards the original chain.

Definition: Extrude Surface command creates CAD surfaces over the closed chains. Applications: the surface is used to create an angled surface, a tapered wall, or cones and cylinders.
Note that the different between the draft surface command and the extrude surface command is that the last creates extra surface at the top and bottom of the shape.

Extrude Surface

Create the extrude surface in the lower right corner.

Create Surface Extrude Select the chain and then enter the values in the dialog box to match the ones from the finish geometry in the right colummn. (Length = 1.0; Angle = 5 deg.)
Note that changes that you make using the Extruded Surface dialog box affect the surface model only, not the curves from which it was created.

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Mill Level 3 Lesson 3: Geometry Creation

INSTRUCTOR GUIDE

RULED / LOFTED SURFACES

Ruled Surfaces Definition: Ruled Surface is a surface generated by connecting straight lines between two or more open or closed contours. When creating a ruled surface with three or more curves defining the boundary, Mastercam creates separate surfaces between each pair of curves rather than one surface with sharp corners and ridges. Applications: any time a surface must be fit between two or more open or closed contours. PowerPoint Presentation: Lesson 3.ppt

Example:

Loft Surfaces

Definition: Loft Surface is a surface generated by blending together more than 3 open or closed contours. As a result the surface has rounded edges at the intermediate contours. Applications: any time a surface must be parabolically blended through more than two curves. Note that the system will automatically create a ruled surface through two chains of entities.

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Mill Level 3 Lesson 3: Geometry Creation

To generate a proper ruled or lofted surface you need to:
Select the contours in the order Aligned the starting locations Select all contours in the same direction.

INSTRUCTOR GUIDE

Ruled/ Lofted Surface Ribbon bar buttons

Chain

- allows you to return to the graphics window to select new chains. - creates Ruled surfaces using linear blending of a minimum two curves or chains of curves. - creates Lofted surfaces using a smooth blending of a minimum two curves or chains of curves.

Ruled

Training Exercises LOFT AND RULED SURFACE. MCX

File Open Select LOFT AND RULED SURFACE.MCX

Create a Ruled Surface in the upper right corner

Create Surface Ruled/Loft
Tips: Select the contours in the order, from the same starting locations, and in the same direction.

Enable the Ruled button.

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Mill Level 3 Lesson 3: Geometry Creation

Create a Lofted surface in the lower right corner
Create Surface Ruled/Loft

INSTRUCTOR GUIDE

Tips: Select the contours in the order, from the same starting locations, and in the same direction.

Enable the Lofted button.

RULED AND LOFT CONTOUR SYNCHRONIZATION

Training Exercises Ruled-Sync. MCX

File Open Select Ruled-Sync.MCX Create Surface Ruled/Loft No Synchronization

Create ruled surfaces without Synchronization.

Tips: Select the contours in the order, from the same starting locations, and in the same direction.

Select the ok button to accept the warning that sharp corners will be ignored.

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Mill Level 3 Lesson 3: Geometry Creation Create ruled surfaces with Synchronization.
Synchronization

INSTRUCTOR GUIDE

In order to better match the curves or chains of curves, you may want to select your curves using the Sync chaining method (Chaining Options dialog box), which lets you match curves manually or by entity, branch, node, or point. Synch by branch match the curves at the branches.

Tips: In the Chaining dialog box select the Options button and enable Mask on Color. The color mask excludes from chaining all entities except those whose colors match any of the color(s) you select. Note that the chains are green color, while the branches are blue.

CREATE RULED/LOFT SURFACES USING WINDOW SELECTION.

Training Exercises Rul2.MCX

File Open Select Rul2.MCX

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Mill Level 3 Lesson 3: Geometry Creation

Create Surfaces Ruled/Loft
Tips: Select Options button in the Chaining dialog box. Make sure that you disable Mask on Color and turn Sync mode to None. In the Chaining dialog box enabled the Window button.

INSTRUCTOR GUIDE

Window selection

Make a window around the wirefame and select as the search point one of the endpoints of the first contour as shown.

Enabled Loft icon.

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Mill Level 3 Lesson 3: Geometry Creation

Assignments

INSTRUCTOR GUIDE
Mill Level 3 Training Tutorial page 2-28

The student creates the 3D wireframe and surfaces of Tutorial 2 Exercise

Tutorial 2 Exercise

Use the following commands: Create Ruled/Lofted Surface Create Flat Boundary Surface Create Rectangular Shape with surface option on. Quiz

Answear the first question from the Tutorial 2 quiz

Mill Level 3 Training Tutorial page 2-30

Page-28

LESSON #15 SURFACE HIGH SPEED CORE ROUGHING, PENCIL AND PROJECT TOOLPATHS
Lesson Plan Surface High Speed Core Roughing, Pencil and Project Toolpaths
Lesson Objectives High Speed Core Toolpath Finish Boss shape using Scallop Toolpath Finish the Floor using Rough Pocket with facing option on Finish the part using Pencil Toolpath Use Check Holder to check the to find the minimum required tool length Engrave the letters using Finish Project Toolpath Time Teaching / Learning Strategies Resources 40 min Have the students complete Tutorial 5 toolpaths creation Mill Level 3 Training Tutorial Book found on pages 5-26 to 5-73 Enhancing Phase 60 min Go over PowerPoint to reinforce toolpaths used in PowerPoint: Lesson 15.ppt Tutorial 5 Assignment / Quiz 30 min Have the students open the geometry from Tutorial 5 Mill Level 3 Training Tutorial Book Exercise. Complete the toolpaths on the part found on pages 5-74 5 min Have students complete Tutorial 5 Quiz found on page 577

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Mill Level 3 Lesson 15: Toolpath Creation

Students complete Tutorial 5 toolpaths

INSTRUCTOR GUIDE
Mastercam Mill Level 3 Training Tutorial Page 5-26 to page 5-73

Students complete Tutorial 5 toolpaths

The following toolpaths are shown in Tutorial 5: Surface HS - Core Roughing Surface Finish Scallop Surface Rough Pocket with Facing option Surface Finish Pencil Check Holder C-Hook Surface Finish Project

SURFACE HIGH SPEED CORE ROUGHING

HS Core Roughing toolpath Definition: Surface HS Core Roughing toolpaths are designed for machining cores which can be approached from the outside. An important feature of core roughing is that Mastercam can change the machining strategy within the same operation if the part has, for example, a mixture of bosses and cavities. In these cases, Mastercam will cut the cavities inside to out (like an area clearance cutting pass), and machine the bosses from the outside. PowerPoint: Lesson 15.ppt

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Mill Level 3 Lesson 15: Toolpath Creation

Specific Surface HS Core Roughing Parameters
Cut Parameters Cut Parameters Step-down value sets a constant Z spacing between cutting passes.

INSTRUCTOR GUIDE

Add cuts feature allows you to insert additional cutting passes in areas of your part where the profile is close to flat. Mastercam will add new cuts to maintain the maximum profile stepover, while spacing them each by at least as much as the minimum step-down. Smoothing inserts arcs at corners to create smoother tool motion. The amount of smoothing is constrained by the maximum radius that you enter. XY stepover settings allows you to configure the spacing between the passes at the same Z. Mastercam will use the largest value possible (up to the maximum XY stepover) that does not leave unwanted material between the passes. However, it will not separate the passes by less than the minimum stepover. Transitions Transitions Transitions allow you to configure the entry move that the tool will make as it transitions to new Z levels. You can choose to create either a ramp entry, or helical entry move. If the profile is too small to create a helix of this size, Mastercam will create a ramp move instead. Linking Parameters Linking options allow you to configure how Mastercam links air moves when the tool is not in contact with the part. Minimum vertical retract is a vertical retract and constant-Z move at the Part clearance height. Leads fields set the tool moves onto and off of the part at the start and end of each cutting pass. These moves are applied to each pass no matter which cutting pass is selected. Fitting settings allow you to choose how the entry and exit arcs fit to the ends of the cutting passes. Minimize trimming sets the path to retract to be as close to the surface as possible, maintaining a minimum distance from the surface to fit the arc. Max trimming distance parameter limits the amount of trimming applied to nonhorizontal passes.

Linking Parameters

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Mill Level 3 Lesson 15: Toolpath Creation

Arc Filter/ Tolerance

INSTRUCTOR GUIDE

Profile tolerance determines the maximum deviation between the smoothed and unsmoothed toolpaths and is only applied on the outermost cutting pass. Offset tolerance is defined in the same way as the Profile tolerance, but it is applied to all the inner passes.

SURFACE ROUGH POCKET WITH FACING

Rough Pocket Facing Definition: Surface Rough Pocket Facing automatically detects and creates motion on the flat surfaces within a pocket.

PowerPoint Presentation: Lesson 15.ppt

Specific Surface Rough Pocket-Facing Parameters

Floor extensions a 2D offset that extends the toolpath off the flat surface. This will allow the tool to start just off the flat floors in open areas of the pocket Floor adjustment an additional Z stock offset, positive or negative can be used Wall clearance additional clearance from wall surfaces in X and Y direction.

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Mill Level 3 Lesson 15: Toolpath Creation

INSTRUCTOR GUIDE

SURFACE FINISH PENCIL

Finish Pencil toolpath Definition: Surface Finish Pencil toolpaths can be used as a finish operation to clean leftover materials from corners. The toolpath is generating a trace between the sharp edges of the selected surfaces.

PowerPoint Presentation: Lesson 15.ppt

Specific Surface Finish Pencil Parameters

Parallel passes None creates a single pencil toolpath. Number per side allows you to specify the number of passes on each side of the pencil trace. Unlimited allows Mastercam to create an unlimited number of offset passes all the way across the selected drive surface. Bitangency angle defines the angle between surfaces that can be machine with the pencil toolpath. Over thickness value is added to the cutter radius. It is used when the cutters radius is very close or smaller than any fillets in the drive surfaces.

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Mill Level 3 Lesson 15: Toolpath Creation

INSTRUCTOR GUIDE

SURFACE FINISH PROJECT

Finish Project toolpath Definition: Surface Rough and Finish Project Toolpaths allow you to project curves, points, or another NCI file onto selected surfaces. These toolpaths can closely match the cut motion to the shape of the part and can be used for engraving.

PowerPoint Presentation: Lesson 15.ppt

Specific Surface Finish Project Parameters

Projection type NCI allows you to project an existing 2D toolpath (contour or pocket) onto selected surfaces. Curve allow you to project 2D chains of entities (lines, arcs, splines) onto selected surfaces. Mastercam prompts you to select the chains after you exit project parameters. Points allow you to project points onto selected surfaces. Mastercam prompts you to select the chains after you exit project parameters. Retract between cuts forces a retract move between cuts and for engraving letters (curve projection type) allows the tool to retract between letters. Add depths allow you to add cut depths for the rough project. It is enabled only with projection type NCI.

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Mill Level 3 Lesson 15: Toolpath Creation

Assignment Tutorial 5 Exercise1

INSTRUCTOR GUIDE
Mill Level 3 Training Tutorial pages 5-73 to 5-75

The student creates the 2D geometry of Tutorial 5 Exercise1

Use the following toolpaths: Surface High Speed Core Roughing Surface Rough Pocket - Facing Surface Finish Scallop 2D Pocket Surface Finish Project Mill Level 3 Training Tutorial page 5-77

Quiz

Answear the first question from the Tutorial 5 quiz

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