TUTORIAL SERIES FOR

TUTORIAL 10 5 AXIS MULTISURFACE

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Objectives:

TUTORIAL 10

This tutorial covers Mastercam's 4 and 5-Axis toolpath functionality. To apply these toolpaths to a 5-Axis machine tool, a customized post processor for your machine is required. There are no default 5-Axis post processors included with Mastercam due to the variation in multi-axis machine configurations. Contact your Mastercam reseller to request post processor services such as multi-axis post development. Your post processor may require certain additional programming information not covered in this tutorial. For instance : You may be required to position your stock in machine space rather than at Mastercam's origin You may be required to use the Misc Values box Your post may also prompt for tool gage lengths. The nature of the additional information required depends largely on your machine's configuration. Contact the developer of your post processor for details.

The Student will create a 5 axis milling toolpaths by:

Machining the part using the 5 axis multisurface toolpath.

The Student will check the toolpath using Mastercams Verify verification module by:
Defining a 3-dimensional rectangular block the size of the workpiece. Running the Backplot function by simulating the axis substitution and the rotary axis. Running the Verify function to machine the part on the screen.

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TUTORIAL 10

The geometry file, Tutorial10_geometry.zip, can be downloaded from www.emastercam.com/files The finished part, Tutorial10_finish.zip including the toolpaths, is also provided on the same location www.emastercam.com/files

TOOLPATH CREATION
File
Open Select the Tut10_5axismultisurface.mcx

STEP 1: SET UP THE STOCK TO BE MACHINED.

To display the Toolpaths Manager press Alt + O.
If a machine definition is already selected see Tutorial # 2 page 2-4 to learn how to change it. Select Mill 5-AXIS Table-Head Vertical

Otherwise follow next step.

Machine type
Mill Select Mill 5-AXIS Table-Head Vertical.

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

TUTORIAL 10

Select the Stock setup.

Select Stock setup

The stock shape should be set to Rectangular Shape Enter the Y, X and Z values of the stock size.

Set the Stock Origin values as shown Enable Display stock as Wireframe and enable Fit Screen to the stock.

The Stock Origin values adjust the positioning of the stock, ensuring that you have equal amount of extra stock around the finish part. Display options allows you to set the stock as Wireframe and to fit the stock to the screen.(Fit Screen)

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Select the Tool Settings tab to set the tool parameters and the part material. Change the parameters to match the following screenshot. Assign tool numbers sequentially allows you to overwrite the tool number from the library with the next available tool number. (First operation ttool number 1; Second operation ttool number 2, etc) Warn of duplicate tool numbers allows you to get a warning if you enter two tools with the same number. Override defaults with modal values enables the system to keep the values that you enter. Feed Calculation set From tool uses feed rate, plunge rate, retract rate and spindle speed from the tool definition.

TUTORIAL 10

Select the OK button to exit Toolpath Group Properties.

STEP 2: MULTISURFACE 5 AXIS ROUGHING THE PART.

Toolpath Preview:

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TUTORIAL 10

Multisurface 5 Axis generates a 5 axis surface toolpath over a series of surfaces or solids that allows precise control of the scallop height or constant distance stepovers to create a smooth finish.

Toolpaths
Multiaxis Multisurface 5 Axis Select the OK button to accept the NC name. Change the parameters for Msurf 5-axis as shown in the following screenshot. The Output Format is 5 Axis. Cut Pattern alows you to establish the surfaces for general cutting area. Tool Axis Control allows you to establish the method to control the tool axis orientation. Tool axis control to the Chain will keep the tool axis oriented to the selected chain. Cut Surfaces are surfaces to project the tool position to, to compensate the tool axis vector for gouge protection. Check Surfaces are surfaces to be avoided during machining.

Select Surface(s) button as shown in the previous screenshot.

Select this surface

Hit Enter key to end the selection.

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Select Chain button. [Select tool vector chain]: Select the line as shown.

TUTORIAL 10

Select the line here

Select the OK button to exit from Chaining dialog box. Enable Entire chain per surface in the Chain Option dialog box to allow the tool axis direction to gradually transition along the selected chain one time for the entire surface. Select the OK button to exit from Chain Options dialog box.

Select Comp To Surfaces button as shown in the previous screenshot.

Click on the select button in the Toolpath/surface selection. [Select Comp Surfaces]: Click on Select All button.

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Enable Color and select color magenta no.13 as shown to the right. The top surfaces should be selected as shown below.

TUTORIAL 10

Select the OK button to exit Select All. Hit Enter key to end the selection. Select the OK button twice to exit Msurf 5-axis dialog box. Click on Select library tool button and using Filter select 3/8 Ball Endmill. Make all the necessary changes as shown in the following screenshots.

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TUTORIAL 10

Select Depth cuts button and change the parameters as shown.

Select the OK button to exit Multiaxis Depth Cuts. Select Entry/Exit button and change the parameters as shown.

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Select the OK button to exit Entry/Exit. Select Msurf5ax Parameters page and change the parameters as shown.

TUTORIAL 10

Tool control Sets the tool tilt along the cut direction (Lead/lag angle) and to the right or left side (Side tilt angle). For more details, see Curve5ax Parameters. Cut control Sets the toolpath accuracy. Cut tolerance Sets the tolerance in which the toolpath follows the surfaces. Across Stepover Sets the stepover as a Distance between the cutting passes. Along Stepover Sets the stepover as a Distance along the cutting direction. Cutting method Sets the toolpath motion to Zigzag, One way or Spiral Flow parameters - Allows you to set the Offset, Cut direction,Step direction and Start of the toolpath toggled between the different options (Flip). For more details, see Flow5ax Parameters. Ignore Surface Normals it is used when we are using a separate pattern surface to control the cutting direction. Select the Flow parameters button. If the flowlines look as shown below, across the magenta surfaces, then click on Cut Direction in the Flowline data dialog box.

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The cut direction should be along the magenta surfaces as shown below.

TUTORIAL 10

Select the OK button to exit Flowline data dialog box. Select the OK button to exit Multisurface 5 axis parameters. Enter Alt +T to toggle the toolpath display off.

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TUTORIAL 10

STEP 3: MULTISURFACE 5 AXIS FINISH THE PART USING AXIS LIMITS.

Toolpath Preview:

Toolpaths
Multiaxis Multisurface 5 Axis

Click on Cut Pattern Surface(s) button.

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[Select Tool Pattern Surfaces]: Click on Select All button.

TUTORIAL 10

Enable Color and select color magenta no.13 as shown to the right.

The top surfaces should be selected as shown below.

Select the OK button to exit Select All. Hit Enter key to end the selection.

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TUTORIAL 10

Select Check Surfaces button as shown.

Click on Select button.

[Select Check Surfaces]: Select the two flat surfaces at the top as shown below.

Hit Enter key to end the selection.

Select the OK button twice to exit Msurf 5-axis dialog box. Click on Select library tool button and using Filter select 1/4 Ball Endmill.

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Make all the necessary changes as shown in the following screenshots.

TUTORIAL 10

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Select Msurf5ax Parameters page and change the parameters as shown.

TUTORIAL 10

Select Axis Limits and enable Z Axis and change the angles as shown.

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Select Point Generators tab and disable Angle and enable Distance as shown.

TUTORIAL 10

Point generators role is to add more tool positions for a more accurate toolpath. Distance is a linear distance used by Mastercam to add one or more additional tool position if the distance between two moves exceeds the current value.

Select the OK button to exit Multisurface 5 axis parameters.

Your part should appear as shown

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4/5-Axis STEP 4: BACKPLOT THE 5 AXIS MULTISURFACE TOOLPATHS.

Click on the Toolpath Group 1 in the Toolpaths Manager to select all operations Select Backplot selected operations button. Make sure that you have only the following button turned on (they will appear pushed down). Display tool Display tool

TUTORIAL 10

Select the Options button.

Enable Simulate Axis Substitution and disable Simulate Rotary Axis. Disable Connect Top and Shade.

Select the OK button to exit Backplot Options. Select Play button.

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TUTORIAL 10

Change the graphic view to Front and check the second operation only. Select Step forward button to check it step by step.The toolpath should look as shown below.

Select the OK button to exit Backplot.

STEP 5: VERIFY
Select Verify selected operations button.

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