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Mastercam University Mill Design and Toolpaths Course Guide Date: November 2010 Copyright 2010 CNC Software, Inc.All rights reserved. Software: Mastercam X5 Part Number: X5-MCfSW-GS
TERMS OF USE
Use of this document is subject to the Mastercam End User License Agreement. A copy of the Mastercam End User License Agreement is included with the Mastercam product package of which this document is part. The Mastercam End User License Agreement can also be found at: www.mastercam.com/legal/licenseagreement/
Mastercam is a registered trademark of CNC Software, Inc. Copyright 1983-2011. All rights reserved. SolidWorks is a registered trademark of DS SolidWorks Corporation.
Contents
Contents .............................................................................................................................................................. 3 Welcome to Mill Design and Toolpaths ................................................................................................................. 1 Recommended Prerequisites ............................................................................................................................... 1 Curriculum Flow, Time Requirement, and Timeline.......................................................................................... 3
Flow ................................................................................................................................................................................ 3 Timeline .......................................................................................................................................................................... 3 Plan of study ................................................................................................................................................................... 3
Design Application Section .............................................................................................................................. 14 Soccer Ball ........................................................................................................................................................ 18 Toolpath Modules ............................................................................................................................................. 19
Testing........................................................................................................................................................................... 19 Chaining: Wireframe..................................................................................................................................................... 20 Toolpath Overview ....................................................................................................................................................... 21 Part 1: Two Setups ........................................................................................................................................................ 22 Part 2 ............................................................................................................................................................................. 23 Part 3: 1st Setup ............................................................................................................................................................. 24 Part 3: 2nd Setup ............................................................................................................................................................ 25 Part 4: Self Test ............................................................................................................................................................. 26 Part 4: 1st Setup ............................................................................................................................................................. 27 Part 4: 2nd Setup ............................................................................................................................................................ 28 Part 4: 3rd Setup ............................................................................................................................................................. 29 Part 6: Multiple Pocket Strategies ................................................................................................................................ 30 Part 7 ............................................................................................................................................................................. 31 Challenge Project .......................................................................................................................................................... 32
Peel Mill ........................................................................................................................................................................ 36 Blend Mill ..................................................................................................................................................................... 37 Area Mill ....................................................................................................................................................................... 38 Rest Mill........................................................................................................................................................................ 39 Chain for Dynamic Pocket ............................................................................................................................................ 40 Area Mill with Thin Wall.............................................................................................................................................. 41
Recommended Prerequisites
We strongly recommend that you master the following concepts and skills prior to taking Mill Design and Toolpaths. These concepts and skills are covered in the Mastercam University Principles for Machining online course.
Mathematics
Introduction
Dial Caliper Customary Units Calibration and Application Examples Reading the Micrometer Conversions (Metric and Customary Units) Introduction to Machining What is machining? Mechanical Removal Techniques Drilling and Milling Mechanical Removal Techniques Reaming, Tapping, and CAD/CAM Terminology Introduction to Milling Machines and Movement Machining Process Video Montage Structures of Matter and Metallurgic Properties Metallurgy Terminology Testing and Heat Treating Metallurgy Keys to Remember Cutting Tools and Tool Holders Cutting Tool Geometry Cutting Tool Materials Cutting Tool Holders Cutting Speeds Revolutions per Minute Feed Rates Chip Formation, Load, and Depth of Cut Chip Formation Video Sample Material Removal Rate and Cutting Time Work Holding Work Setup Machining Square and Parallel Work Setup and Part Locating
Introduction to Machining
Simple Metallurgy
Cutting Speeds, Feeds, and Revolutions per Minute (RPM) Chip formation, Load, and Material Removal Rates Work Holding and Setup
Introduction
Timeline
The Mill Design and Toolpaths curriculum has been designed to be a 40-hour class. Depending on your knowledge and experience, the time required to complete each example and module can vary widely. The next page shows a timeline to use as a guide.
Plan of study
Introduction
Introduction
Design Modules
Introduction
Wireframe geometry is fundamental to CAD/CAM, so mastering wireframe is essential to becoming a CAD/CAM expert. Although many of the following examples can be created using other methods of geometry creation, typically the examples start with wireframe, and then use that geometry to calculate distances, depths, and other dimensional properties. This is good CAD practice, and it will allow you to check your work as you create it.
Testing
The Mill Design and Toolpaths course includes both pre- and post- multiple choice tests in most modules. If you achieve a score of 80% or better on all post-tests and on the final test, you will receive an Associate Level of Mastercam Certification. All post-test grades will display on both the Certificate of Completion and the Associate Level of Certification certificate.
Design Modules
Geometry Overview
This part covers simple geometry creation and exposes you to many trimming functions. Objectives Create a line (FastPoint with an angle) Line (Parallel) Line (Horizontal) Line (Parallel) Trim (Divide)
Goal Complete this part within 5 minutes using the skills covered in the video.
Design Modules
Part 1
This part demonstrates the nuts-and-bolts challenges of working with arcs in a CAD system. Where arcs start and end affect geometry creation as well as trimming. Objectives Circle Center Point (radius) Line Endpoint (angle) Circle Center Point (edge) Trim (three-entity) Translate (rotate) Line Endpoint (horizontal, vertical) Circle Center Point, Translate (copy, join) Line Endpoint (midpoint arc) Trim (three-entity) Translate (copy) Circle Center Point Center Point (lock radius) Circle Fillet Entities Trim (quadrants) Line Endpoint (tangent) Trim (extend)
Goal Complete this part within 15 minutes using the skills covered in the video.
Design Modules
Part 2
In this example, geometry is offset in both single and multiple copies. Many arcs are created using tangent functions. Try to use the method shown in the videos. Many methods will be used in other geometry examples. The Hide function removes unselected entities. This allows the user to focus on the selected geometry without making changes to the file. Right-clicking on attribute boxes allows the user to change existing geometry. This example will create additional wireframe geometry. Wireframe is the most basic geometry and is good for simple toolpaths. This example will create a solid from existing wireframe geometry. Solid modeling can be a quick way to represent a three-dimensional part. Define a solid by extruding, revolving, sweeping, or lofting chains of curves. Solid features can only be planar. Objectives Circle Center Point (radius) Line Endpoint (angle) Trim Offset (arcs and lines) Arc Tangent (three entities) Trim (three-entity, divide) Offset Circle Center Point (0.25-inch diameter) Delete Fillet Chains
Goal Complete this part within 10 minutes using the skills covered in the video.
Design Modules
Part 3
The Hide function removes unselected entities. This allows the user to focus on the selected geometry without making changes to the file. Right-clicking on attribute boxes allows the user to change existing geometry. This part creates additional wireframe geometry. Wireframe is the most basic geometry and is good for simple toolpaths. Objectives Circle Center Point Rotate (by angle, join) Rotate (total sweep, copy) Arc Polar Trim (three entities) Line Endpoint (vertical, horizontal, parallel) Fillet Entities Circle Center Point Break (arc at quadrants) Translate (join) Translate (move) Rotate
Design Modules
Part 3: Solid
This part creates a solid from existing wireframe geometry. Solid modeling can be a quick way to represent a three-dimensional part. Define a solid by extruding, revolving, sweeping, or lofting chains of curves. Solid features can only be planar. Chains determine the direction of extrusion. Chains can be reversed after selection using either the Re-Select button or Reverse direction check box. The re-select button returns the user to the graphics window to redefine the extrusion direction using the Solid Chain Direction ribbon bar. Reverse direction extrudes the curves in the opposite direction from the current extrusion direction.
Objectives Extrude, Create Body Extrude, Cut Body (slots); Reverse chain direction Extrude, Add Boss Extrude, Cut Body (center holes) Goal Complete the wireframe and solid model within 15 minutes using the skills covered in the video.
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Design Modules
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Design Modules
Part 4
Part of mastering three-dimensional geometry creation is thinking about what plane geometry exists in. Often geometry exists in more than one plane, and it is a matter of finding the depth relative to that plane. Setting the Work Coordinate System (WCS) to front allows the geometry to be created in front view as if the part was turned on its side. Because the other features exist on current geometry, planes can be used quickly. The isometric view remains current to the active WCS. The 0.25-inch diameter circle on the side plane is created based on existing geometry in a 3D construction mode. Objectives Set WCS Create Rectangular Shapes Create Rectangle, Relative Position ([Shift] + AutoCursor) Line Endpoint, Relative Position ([Shift] + AutoCursor) Trim (default, divide) Translate (join) Reset WCS, Create new plane by geometry Circle Center Point, Relative Position ([Shift] + AutoCursor) Line Endpoint (quadrant), Trim (three-entity) Translate Line Endpoint (3D construction mode) Circle Center Point (right WCS)
Goal Complete the part within 20 minutes using the skills covered in the video.
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Design Modules
Part 5
The 2D / 3D switch toggles between 2D and 3D construction modes. In 2D mode, all geometry is created parallel to the current construction plane (Cplane) at the current system Z depth. In 3D mode, you can work freely in various Z depths, unconstrained by the current system Z depth and Cplane settings. In 3D mode, you use AutoCursor to select a position or otherwise specify the X, Y, and Z values for the entity. 3D mode now respects construction planes to orientate entities that require a flat plane of reference such as arcs.
Objectives Set Front WCS, Create Rectangle Set 2D plane and Z depth, Create Rectangle Make screen grid visible, Set Z depth Arc Endpoints
Goal Complete the part within 15 minutes using the skills covered in the video.
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Design Modules
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Bike Brake
This part reviews the concepts covered so far. The lines connecting the top and bottom section are tangent and parallel. All radii without center locations are considered fillets. Try to draw this part on your own first. If necessary, watch the videos on the next pages.
Goal Complete the part within 20 minutes using the skills covered in the video.
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Bike Fork
This part requires you to create reference geometry at multiple depths. The part has three flat sections; create these first. Dimensions on the connecting 3D sections are measured to the intersection with the top plane. Create the connecting 3D sections, and then translate the thickness of the part. Try to draw this part on your own first. If necessary, watch the videos on the next pages.
Goal Complete the part within 20 minutes using the skills covered in the video.
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Connect Six
This part can be constructed from four circles created at the appropriate depths. Create the cylinder and fin first. Rotate cylinder and fin, and then Boolean add them together. Cut the blind holes 0.90 inch deep. Use a 0.03-inch fillet radius on the complete solid.
Goal Complete the Solid within 15 minutes using the skills covered in the video.
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Soccer Ball
In this part, geometry and planes are created from existing known geometry. When this part was initially created, only the shapes were known. The line length is the same length and sets the ball diameter.
Goal Complete the part within 30 minutes using the skills covered in the video.
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Toolpath Modules
CNC programming is becoming almost more about database management than moving a machine tool. Today's CNC programmer should understand how to save and retrieve proven machining methods and feed rates. Tool, material, and machining operations can be stored in libraries. This helps the programmer concentrate on efficiently moving the machine tool. Storing machining knowledge is key to becoming an expert CNC programmer.
Testing
This module includes both pre- and post- multiple choice tests. If you achieve a score of 80% or better on all post-tests, you will receive an Associate Level of Mastercam Certification. All post-test grades will display on both the Certificate of Completion and the Associate Level of Certification certificate.
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Toolpath Modules
Chaining: Wireframe
This module overviews how to set direction on multiple entities. Chaining differs from other selection methods because it associates order and direction with the selected geometry. In the case of toolpath linking, entities can also control direction of the tool and climb or conventional machining. Objectives In Wireframe chaining mode, the Chaining dialog box provides chain selection methods including Window, Area, Single, Polygon, Partial, and Vector. Other controls let you manage the selection process (Last, End, Unselect) as well as Reverse chaining direction. In Solids chaining mode, the Chaining dialog box gives you options to manage the chaining of solid entities, including edges and faces (front or back), full loops (closed chains ), and partial loops (open chains). In addition, you can unselect and re-select solid chains, reverse chaining direction, and move the start of a chain.
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Toolpath Modules
Toolpath Overview
This module overviews how to correctly prepare a stock model, select tool and holder, and control depth. It also introduces several toolpath types and shows how different operations see the tool for both diameter and length offsets. Objectives Stock Overview Tools Overview Tool Control Overview Toolpath Overview Tool Tip Offset Chamfer
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Toolpath Modules
Tool List: T1 = 1.5 Face Mill T2 = 0.3125 End Mill T3 = 0.25 End Mill T4 = 0.75 End Mill Material: Aluminum 2024 Goal Within 30 minutes, program all operations to complete this part using the skills covered in the video.
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Toolpath Modules
Part 2
The part demonstrates how to handle slots with the width of the tool. Cut the part leaving a 0.02 floor for vacuum table.
Tool List: T1 = 0.25 End Mill Material: Graphite 7.25 x 10.375 x 0.375 Goal Within 20 minutes, program all operations to complete this part using the skills covered in the video.
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Toolpath Modules
Tool List: T1 = 1.5 Face Mill T2 = 0.5 Spot Drill T3 = 0.5 Drill T4 = 0.5 End Mill T5 = 0.625 End Mill Material: Aluminum
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Toolpath Modules
Tool List: T1 = 1.5 Face Mill T2 = 0.5 Spot Drill T3 = 0.5 Drill T4 = 0.5 End Mill T5 = 0.625 End Mill Material: Aluminum Goal Within 30 minutes, program all operations to complete this part using the skills covered in the video.
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Toolpath Modules
Tool List: T1 = 3/16 Flat E/Mill T2 = 1/2 Spot Drill T3 = 1/4 Dia Drill T4= 3/4 Flat E/Mill T5= 3/8 Flat E/Mill Material: Aluminum
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Toolpath Modules
Tool List: T1 = 3/16 Flat E/Mill T2 = 1/2 Spot Drill T3 = 1/4 Dia Drill T4= 3/4 Flat E/Mill T5= 3/8 Flat E/Mill Material: Aluminum
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Toolpath Modules
Tool List: T1 = 3/16 Flat E/Mill T2 = 1/2 Spot Drill T3 = 1/4 Dia Drill T4= 3/4 Flat E/Mill T5= 3/8 Flat E/Mill Material: Aluminum
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Toolpath Modules
Tool List: T1 = 3/16 Flat E/Mill T2 = 1/2 Spot Drill T3 = 1/4 Dia Drill T4= 3/4 Flat E/Mill T5= 3/8 Flat E/Mill Material: Aluminum Goal Within 30 minutes, program all operations to complete this part using the skills covered in the video.
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Toolpath Modules
Tool List: T1 = 0.5 Flat End Mill T2 = 0.25 Flat End Mill Material: Delrin
Goal Within 40 minutes, program all operations to complete this part using the skills covered in the video .
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Toolpath Modules
Part 7
Objectives This is an advanced practice part. To program this part, you will need to organize the pocket depths and operations. Take your time and have fun. Program the complete part and you are ready for the Challenge Project.
Note: The threads are suppressed in the model to decrease the file size. Thread depth = 0.64 x pitch in inch or metric
Tool List: T1 = 0.5 Flat End Mill T2 = 0.25 Flat End Mill Material: Delrin
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Toolpath Modules
Challenge Project
Instructions Create a 3D wireframe within 20 minutes Create the part to a complete 3D wireframe by any means possible using Mastercam software. You may not import any geometry. Create a CNC program and support information for each setup within one hour Zero is the upper left corner on each setup. Mastercam backplot must not to exceed 5 minutes. Each setup must have a distinct Toolpath Group and group name and must have unique NC file name. Compare the STL file to test.stl file supplied. Use STL Compare. Create a setup sheet and tool list for each setup. The use of the test print as part of documentation is advised.
Tool List: T1 = 0.125 Center Drill T2 = #7 Drill T3 = -20 Tap T4 = 0.125 Flat End Mill T5 = 0.25 Flat End Mill Material: 6061 T6 Aluminum
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Toolpath Modules
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Core Mill
Objectives Respect pocket boundaries Finish off outside boundary Demonstrate consistent engagement Achieve smooth material removal
Tool List: T1 = 3/4 Flat E/Mill Goal Within 10 minutes program, all operations to complete this part using the skills covered in the video.
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Peel Mill
Objectives Use open contour (Can use single chain and parameter-defined width) Use high speed loop toolpath Demonstrate micro lift Achieve consistent chip load Achieve smooth material removal
Tool List T1 = 1/4 Flat E/Mill Goal Within 10 minutes, program all operations to complete this part using the skills covered in the video.
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Peel Mill
Objectives Use open contour (Can use single chain and parameter-defined width) Use high speed loop toolpath Demonstrate micro lift Achieve consistent chip load Achieve smooth material removal
Tool List: T1 = 1/4 Flat E/Mill Goal Within 10 minutes, program all operations to complete this part using the skills covered in the video.
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Blend Mill
Objectives Use two entities for chain Achieve consistent floor finish Achieve consistent chip load Achieve smooth material removal
Tool List T1 = 1/2 Flat E/Mill Goal Within 10 minutes, program all operations to complete this part using the skills covered in the video.
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Area Mill
Objectives Tool motion control on multiple entry Use roughing motion entry Use helical and ramp contour entry
Tool List T1 = 5/8 Flat E/Mill Goal Within 10 minutes, program all operations to complete this part using the skills covered in the video.
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Rest Mill
Objectives Remove leftover material from previous operations Control on stepover
Tool List: T1 = 5/8 Flat E/Mill T2 = 1/4 Flat E/Mill Goal Within 10 minutes, program all operations to complete this part using the skills covered in the video.
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Tool List: T1 = 1/2 Flat E/Mill Goal Within 10 minutes, program all operations to complete this part using the skills covered in the video.
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Tool List: T1 = 1/2 Flat E/Mill Goal Within 20 minutes, program all operations to complete this part using the skills covered in the video.
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Tool List: T1 = 3/4 Flat E/Mill T2 = 1/2 Flat E/Mill T3 = 1/4 Flat E/Mill Goal Within 40 minutes, program all operations to complete this part using the skills covered in the video.
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2D HST Applications
Goal Within 20 minutes, program all operations to complete this part using the skills covered in the video.
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Certification