MasterCam - X4 - Training Tutorials Mill Level 3 Applications - Tutorial #6
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MillLevel3TrainingTutorials
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MastercamX4TrainingTutorialsMillLevel3Applications Date:June15,2009 Copyright©19842009InHouseSolutionsInc.Allrightsreserved. Software:MillMastercamX4 Author:MarianaLendel ISBN:9781926566238 Notice InHouseSolutionsInc.reservestherighttomakeimprovementstothismanualatanytimeand withoutnotice. DisclaimerofAllWarrantiesandLiability InHouseSolutionsInc.makesnowarranties,eitherexpressorimplied,withrespecttothis manualorwithrespecttothesoftwaredescribedinthismanual,itsquality,performance, merchantability,orfitnessforanyparticularpurpose.InHouseSolutionsInc.manualissoldor licensed"asis."Theentireriskastoitsqualityandperformanceiswiththebuyer.Shouldthe manualprovedefectivefollowingitspurchase,thebuyer(andnotInHouseSolutionsInc.,its distributor,oritsretailer)assumestheentirecostofallnecessaryservicing,repair,or correction,andanyincidentalorconsequentialdamages.InnoeventwillInHouseSolutionsInc. beliablefordirect,indirect,orconsequentialdamagesresultingfromanydefectinthemanual, evenifInHouseSolutionsInc.hasbeenadvisedofthepossibilityofsuchdamages.Some jurisdictionsdonotallowtheexclusionorlimitationofimpliedwarrantiesorliabilityfor incidentalorconsequentialdamages,sotheabovelimitationorexclusionmaynotapplytoyou. Copyrights ThismanualisprotectedunderthecopyrightlawsofCanadaandtheUnitedStates.Allrightsare reserved.Thisdocumentmaynot,inwholeorpart,becopied,photocopied,reproduced, translatedorreducedtoanyelectronicmediumormachinereadableformwithoutprior consent,inwriting,fromInHouseSolutionsInc. Trademarks MastercamisaregisteredtrademarkofCNCSoftware,Inc. Microsoft,theMicrosoftlogo,MS,andMSDOSareregisteredtrademarksofMicrosoft Corporation;MastercamVerifyiscreatedinconjunctionwithSiriusSystemsCorporation; Windows95,WindowsNT;andWindowsXPareregisteredtrademarksofMicrosoft Corporation. Acknowledgements "ThankstotheInHouseSolutionsteamforhelpingintheproductionandmarketingofthis book.Itsimplywouldn'tbethesamewithoutallyourefforts.Finally,thankyou,thereaderfor makingthispurchase;Ihopeitservesyouwell." MarianaLendel
TABLEOFCONTENTS
GettingStarted
A1
GraphicUserInterface ...................................................................................................................... A1 NavigateThroughtheSystem ........................................................................................................... A2 SettingtheToolbarStates ................................................................................................................. A4 SettingtheGrid ................................................................................................................................. A6
SurfaceModeling TUTORIALS
B1 11
Tutorial#1,Revolved&FlatBoundarySurfaces,Pocket,Parallel&ContourToolpaths.................. 11 Tutorial#2,RuledandFlatBoundarySurfaces,RadialandScallopToolpaths ................................. 21 Tutorial#3,NetSurface,PocketandRestmill&FinishBlendToolpaths.......................................... 31 Tutorial#4,Swept&FlatBoundarySurfaces,RoughFlowline&Plunge,FinishBlend&Pencil Toolpaths........................................................................................................................................... 41 Tutorial#5,Revolved&FilletSurfaces,HSCoreRoughing&FinishScallop,Pocketfacing,Pencil& ProjectToolpaths .............................................................................................................................. 51 Tutorial#6,Revolvedsurface,HSAreaRoughing,FinishContour,LeftoverandProjectforMachining RaisedLetters .................................................................................................................................... 61 Tutorial#7,Draft,Swept,RevolveandFilletSurfacesandHighSpeedToolpaths: CoreRoughing,HorizontalArea,WaterlineandScallopRestPasses................................................ 71 Tutorial#8,Ruled,Swept,RevolveandFilletSurfacesandHighSpeedToolpaths: CoreRoughing,HorizontalArea,Scallop,ScallopRestPassesandPencil......................................... 81
GeneralNotes
C1
DefaultKeyAssignments ................................................................................................................... C2 Customizing ....................................................................................................................................... C3 KeyMapping...................................................................................................................................... C7 DataEntryShortcuts.......................................................................................................................... C9 SurfaceToolpathParameters ........................................................................................................... C10 CreateGeometryin3D...................................................................................................................... C39 SolidsMenu ....................................................................................................................................... C44 SolidsManager .................................................................................................................................. C45 Chaining............................................................................................................................................. C47 WindowSelection.............................................................................................................................. C50 ChainingandWindowOptions.......................................................................................................... C51 ToolpathsManager ........................................................................................................................... C53 Properties .......................................................................................................................................... C58 MillingGCodes ................................................................................................................................. C61
TUTORIALSERIESFOR
TUTORIAL6 REVOLVEDSURFACEHIGHSPEEDAREAROUGHING,FINISHCONTOUR, FINISHLEFTOVER,ANDFINISHPROJECTTOOLPATHSTOMACHINE RAISEDLETTERS
MillLevel3
TUTORIAL6
Objectives:
TheStudentwilldesigna2dimensionaldrawingby: Creatingarectangle. Creatingparallellines. Creatinglineendpoints. Creatingarctangentthroughapoint. Creatingfillets. Trimmingthegeometry. Movingthegeometry. Creatingtheletters. Creatinganobroundshape.
TheStudentwilldesigna3dimensionaldrawingby: Creatingtherevolvedsurface. Creatingaflatsurfaceusingrectanglecommand. Trimsurfacetocurve. Creatingtheboundingbox. Creatinganoffsetsurface.
TheStudentwillcreatea3dimensionalmillingtoolpathconsistingof: Roughingthecavityusingsurfacehighspeedareamilltoolpath. Finishingthecavityusingsurfacefinishcontourtoolpath. Finishingthefilletsusingsurfacefinishleftover. Creatingtwo2Dpocketstoolpathstobeusedinsurfacefinishproject. Usingfinishprojecttoolpathstomachinetheraisedletters.
TheStudentwillcheckthetoolpathusingMastercam’sVerifymoduleby: Defininga3dimensionalblock,thesizeoftheworkpiece. Runningtheverifyfunctiontomachinethepartonthescreen.
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GEOMETRYCREATION TostartanewfilefromMastercam:
File New Beforestartingthegeometrycreationweshouldcustomizethetoolbarstoseethetoolbarsrequired tocreatethegeometryandmachinea3Dpart.SeeGettingstarted. Operationmanagertotheleftofthescreencanbehiddentogainmorespaceinthegraphicareafor design.PressAlt+Otoremoveit.
BeforestartingthegeometrymakesurethattheGridisenabled.Itwillshowyouwherethepart originis.SeeGettingstartedpageA6fordetails.
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STEP1:CREATETHE2DPROFILETOBEREVOLVED Notethatfortherevolvedsurfacewewillonlyneedhalfofthe2Dwireframe.
StepPreview:
1.1Createthe2.1"by7.25"rectangle SubStepPreview:
Create
Rectangle EntertheWidth
2.1(Tab).
EntertheHeight
7.25(Enter).
MakesurethatAnchortocenterisnotenabled.
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[Selectpositionoffirstcorner]:SelecttheOrigin(centerofthegrid)asshown.
SelectOrigin
UsetheFiticontofitthedrawingtothescreen.
Duringthegeometrycreationofthistutorial,ifyoumakeamistake,youcanundothelaststepusing theUndoicon
.Youcanundoasmanystepsasneeded.Ifyoudeleteorundoastepbymistake,
justusetheRedoicon.
SelecttheOKbutton.
1.2Createalineparallel SubStepPreview:
Create Line
Parallel SelectEntityA [Selectaline]:SelectEntityA. [Selectthepointtoplaceaparallellinethrough]:Pickapoint totherightoftheselectedline. EntertheDistance SelecttheOKbutton.
1.53(PressEnter).
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1.3Createalineknowingoneendpoint,thelengthandtheangle SubStepPreview:
Create Line
Endpoint [Specifythefirstpoint]:SelectEndpointAasshown:
EndpointA
Sketchthelineasshown. IntheRibbonBar,settheLength
to4.5andchangetheAngle
to285andpressEnter. SelecttheOKbutton.
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1.4Createanarctangentthroughapoint SubStepPreview:
Create Arc
ArcTangent EnableTangentpoint. EntertheRadius
3.125
[Specifytheentitythatthearcistobetangentto]:SelectEntityAasshown.
SelectEntityA
SelectEndpointB
[Specifythetangentpoint]:SelectEndpointBasshown:
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[Selectanarc]:Selectthearcasshown:
Selectthisarc
SelecttheOKbutton.
1.5Deletetheextraconstructionlines
SubStepPreview:
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Selectthetwolinesasshown:
Selecttheselines
SelectDeleteentitiesicon.
1.6Trimthegeometry
StepPreview: SelectEntityAhere
Edit Trim/Break
Trim/Break/Extend IntheRibbonBarenableTrim2entitiesicon. [Selecttheentitytotrim/extend]:SelectEntityA [Selecttheentitytotrim/extendto]:SelectEntityB
SelectEntityBhere SelecttheOKbuttontoexitthecommand.
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1.7Filletthecornerswiththe1/4"radius.
StepPreview:
Create Fillet
Entities EnterthefilletRadius
0.250
[Selectanentity]:SelectEntityA. [Selectanotherentity]:SelectEntityB.
SelectEntityA
SelectEntityB SelectEntityC
SelectEntityDhere [Selectanentity]:SelectagainEntityC [Selectanotherentity]:SelectEntityD. SelecttheOKbutton.
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STEP2:MOVETHEGEOMETRYUSINGMOVETOORIGIN
StepPreview: HolddowntheShiftkeyandclicksomewhereonthechain.
Selectthechain
Xform Movetoorigin [Selectthepointtotranslatefrom]:SelecttheMidpointof theverticallineasshown:
SelecttheMidpoint
SelecttheFiticontofitthedrawingtothescreen. SelectClearColoricon.
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STEP3:CREATEANDCENTERTHELETTERS StepPreview:
3.1Changethemaincolortored(No.12) SelecttheColorintheStatusBar Selectcolorredasshown:
3.2Createtheletters
Create
Letters
SelectTrueTypebutton. SelecttheArialBlackfontasshown. SelecttheOKbutton.
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TypeCAMandchangetheHeightandSpacingasshown. SelecttheOKbutton.
[Enterstartinglocationofletters]:Selectapointasshown.
Clickhereforthe startinglocation
PressEsctoexitthecommand.
Thegeometryshouldlookasshown.
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3.3UseBoundingBoxtocreatethecenterpointoftheletters
Create
BoundingBox
IntheBoundingboxleaveCenterPointenabledanddisablefirstLinesArcsandthenAllEntities. NotethatonceyoudisableAllEntitiesthedialogboxdisappers,andthesystempromptsyouto selecttheentitiesaroundwhichtheboxorinourcasethecenterpointwillbecreated.
[Selectentities]:Makeawindowaroundthelettersasshown.
Makeawindow
Thelettersshouldbehighlighted.
PressEntertofinishtheselection. TheBoundingBoxshouldlookasshown. SelecttheOKbuttontoexitBoundingBox.
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Notethepointcreatedatthemiddleoftheletters.
3.4UseTranslatecommandtocentertheletters
Xform
Translate [Translateselectentitiestotranslate]:makeawindowaroundthelettersasshown.
PressEntertofinishtheselection.
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IntheTranslatedialogbox,enableMove. SelectFrompointicon.
[Selectthepointtotranslatefrom]:Selectthecenterpointcreatedinthe previoussubstep.
Selectthispoint
[Selectthepointtotranslateto]:SelecttheOrigin.
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SelecttheOKbuttontoexitTranslatedialogbox.
SelecttheClearColoricon.
Thegeometryshouldlookasshowntothe right.
3.5Deletethepoint FromtheQuickMasktoolbar,selectQMPointicon. SelectDeleteentitiesicon.
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STEP4:CREATETHEOBROUNDSHAPE
StepPreview:
Create
RectangularShapes
Expandthedialogboxifneededbyselectingthedownarrow.
Changetheparametersasshown.
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[Selectpositionofbasepoint]:SelecttheOriginfromtheAutoCursor dropdownlist. SelecttheOKbuttontoexitRectangularShapesOptionsdialogbox
STEP5:CREATETHEREVOLVEDSURFACE(S)
StepPreview:
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5.1Changethemaincolortomagenta(No.13) SelecttheColorintheStatusBarasshowninthepreviousstep Selectcolormagenta ChangethegraphicviewtoIsometric.
5.2CreatetheRevolvedsurface
Create Surface Revolved SelectPartialintheChainingdialogbox [Selectthefirstentity]:SelectEntityAasshown: MakesurethatthechainingdirectionisCCW;otherwiseclickon Unselectbutton,andthenreselectEntityA
SelectEntityAhere
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[Selectthelastentity]:SelectEntityBasshown:
SelectEntityB
SelecttheOKbuttontoexitChainingdialogbox.
[Selecttheaxisofrotation]:Selecttheverticalline
Selecttheverticalline
ChangetheEndAngle
to180,andpressEnter
Thesurfaceshouldlookasshown, otherwise,selecttheReversebutton. SelecttheOKbutton.
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STEP6:CREATETHEFLATSURFACEINSIDEOFARECTANGLE
StepPreview:
6.1Changethemaincolortodarkgreen(No.2) SelecttheColorintheStatusBarasshownintheprevious step Selectthedarkgreencolor Geometrycolormustbedifferentthenliveentitycolor.
6.2Createarectanglewithasurfaceinsideofit
Create
Rectangle EntertheWidth
9.125(Tab).
EntertheHeight 10.0(Enter). EnableAnchortocenterandCreateSurfaceiconsintheRibbonBar. [Selectpositionofbasepoint]:SelecttheOriginfromtheAutoCursordropdownlist. SelecttheOKbutton.
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SelecttheFiticontofitthedrawingtothescreen.
STEP7:TRIMTHEFLATSURFACETOCURVE Totrimasurfaceorasetofsurfacestoachainofcurvesweneedaclosedboundary(Mastercam understandscurvestobelines,arcsorsplines).Youcantrimasurfaceorsetofsurfaceswithanopen chainonlyifthechaincompletelydividestheoriginalsurfacesintwo.
StepPreview:
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7.1UsetheHideentitycommandtokeeponthescreenonly2Dwireframe
SubStepPreview: ClickontheQMLinesandontheQMArcsiconsfromtheQMtoolbarattherightofthe graphicwindow. Notethatalllinesandallarcsfromthegraphicwindowareselected.
Screen
Hideentity
7.2Mirrorthegeometry Wearegoingtomirrorthe2dprofileusedtocreatetherevolvedsurfaces.
SubStepPreview:
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SelecttheprofilebyholdingdowntheShiftkeyandselectingoneentityofthechainasshown.
HolddownShiftkey andclickontheentity asshown
Xform
Mirror EnableMirroraboutYaxisasshown.
Thepreviewshouldlookasshown: SelecttheOKbuttontoexitMirror.
SelectClearColor
icon.
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7.3Deletethecenterlines
SubStepPreview: Notethatthecenterlinewasselectedinthechaintobemirrored.Anothercenterlinewascreated onthetopoftheexistingone.
Selectthelineasshown:
Selectthisline
SelectDeleteentitiesicon.
Repeatthesteptodeletetheotherline
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7.4Unhidetheflatsurface
SubStepPreview: SelectScreen
UnhideSome
Notethattherestoftheentitiesappearonthescreen.
[Selectentitiestokeeponthescreen]:Selectthetopflatsurface.
Selecttheflatsurface
PressEntertofinishtheselection.
7.5Trimthesurfacetoachain(closed)
SubStepPreview:
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Create Surface Trim
Tocurve
[SelectsurfacesandpressEntertocontinue]:Selecttheflatsurfaceasshown.
Selectthissurface
PressEnter [SelectCurves1]:Selectthechainofcurvesasshownbelow.
Selectthischainofcurves
SelecttheOKbuttontoexitChainingdialogbox.
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[Indicateareatokeep–selectasurfacetobetrimmed]:Selecttwopointsonthesurfaceoutsideof thechainasshown. SelecttheOKbutton
Thesurfaceshouldlookasshown: SelectScreen
HideEntitytobringbacktherestofthegeometry.
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STEP8:CREATETHEABOXTHATREPRESENTSTHESTOCK
StepPreview: PreselectthechainbyholdingdowntheShiftkeyandselectingonelineasshown.
Selecttheline
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Xform Translate ChangetheparametersintheTranslatedialogboxasshown.
Thegeometryshouldappearasshownbelow.
STEP9:SAVETHEFILE
File
Saveas
Filename:“YourName_6” SelecttheOKbutton.
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TOOLPATHCREATION SUGGESTEDFIXTURE:
SETUPSHEET:
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STEP10:SETUPTHESTOCKTOBEMACHINED TodisplaytheToolpathsManagerpressAlt+O. Makesurethatnomachineisalreadyselected.
MachineType Mill SelectDefaultorthemachineyouwillbeusing. UsetheFiticontofitthedrawingtothescreen.
SelecttheplussigninfrontofPropertiestoexpandthe ToolpathsGroupProperties.
SelectthePlus
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SelectToolsettings SelectToolsettings.
Changetheparameterwiththeonesinthescreenshotbelow. SelectStockSetuptab. SelectBoundingboxbuttontoautomaticallyfind thepartextents.
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Changetheparameterstomatchthefollowingscreenshot. SelecttheOKbuttontoexitBoundingboxdialogbox.
Thestockvaluesshouldlookasshown: SelecttheOKbuttontoexitToolpathGroupProperties.
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STEP11:ROUGHOUTTHESURFACEUSINGSURFACEHIGHSPEEDROUGHING AREAMILLING Arearoughingtoolpathsaredesignedtoroughoutcavities,pockets,orotherareasthatcanbemost efficientlymachinedwithaninsidetooutsidetoolpath.Theyaregeneratedfromasetofsurfaceprofiles thatdescribetheshapeofyoursurfacesatdifferentZheights,plusasetofoffsetprofilesthatroughout stockasthetoolmovesawayfromthecenter.
ToolpathPreview:
Toolpaths SurfaceHighSpeed SelecttheOKbuttontoaccepttheNCname
[SelectDriveSurface]:SelecttheAllbutton.
SelecttheOKbuttontoexit.
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PressEnterkey. SelecttheOK
buttontoexitToolpath/surfaceselection.
SelectToolpathTypeandenableRoughing. SelectAreaClearance. SelectTool. ClickontheSelectlibrarytoolbutton. UsetheFilterbuttonintoselectthe1.0“BullNoseEndmillwithcornerradius1/8“
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MakethenecessarychangesintheToolpathparameterstomatchthefollowingscreenshot. SelecttheHolder. SelectOpenlibrarybutton. SelecttheCT40.holders
SelecttheOKbutton
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SelecttheC4E31250holder
Holderpageallowsyoutocreateaholderdefinition,loadaholderfromanexistinglibraryor edittheholderafterithasbeenselected Useholderforgougecheckingwhenenabled,activatesthegougecheckingfeature.Mastercam willchecktomakesurethattheholderdoesnotcomeintocontactwithanypartgeometry. Holderclearancefieldestablishestheminimumseparationbetweentheholderandyoursurface model.Settheclearancebiggerthanthestocktoleaveonthewalls.
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SelecttheCutParameterspageandmakethechangestomatchthefollowingscreenshot.
StepdownoptionsallowyoutoconfigurehowMastercamspacesthecutsinZ. StepdownvaluesetsaconstantZspacingbetweencuttingpasses. Addcutsfeatureallowsyoutoinsertadditionalcuttingpassesinareasofyourpartwherethe profileisclosetoflat.Mastercamwilladdnewcutstomaintainthemaximumprofilestepover, whilespacingthemeachbyatleastasmuchastheminimumstepdown. XYstepoversettingsallowyoutoconfigurethespacingbetweenthepassesatthesameZ. Mastercamwillusethelargestvaluepossible(uptothemaximumXYstepover)thatdoesnot leaveunwantedmaterialbetweenthepasses.However,itwillnotseparatethepassesbyless thantheminimumstepover. Stocktoleaveonyourdrivesurfacesletsyouenterseparatevaluesforthewallandfloor surfaces.Notethatthestocktoleaveonwallsmustbegreaterthanorequaltothestocklefton thefloor.Forsurfacesthatarenotexactlyhorizontalorvertical,Mastercamwillinterpolate betweenthewallandfloorvalues. Keeptooldownpreventsthetoolfromretractingifthedistancebetweentheendofonepass andthestartofthenextpassislessthanthespecifiedsettings.
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ExpandCutParametersifneeded,andselectTransitionstosettheEntryhelix.
Selectthe plussignto Expand
Transitionsallowyoutoconfiguretheentrymovethatthetoolwillmakeasittransitions tonewZlevels.Youcanchoosetocreateeitherarampentry,orhelicalentrymove.Ifthe profileistoosmalltocreateahelixofthissize,Mastercamwillcreatearampmove instead.
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SelecttheLinkingParameterspageandchangetheparameterstomatchthefollowingscreenshot.
LinkingoptionsallowyoutoconfigurehowMastercamlinksairmoveswhenthetoolisnotin contactwiththepart MinimumverticalretractisaverticalretractandconstantZmoveatthePartclearanceheight. Leadsfieldssetthetoolmovesontoandoffofthepartatthestartandendofeachcutting pass.Thesemovesareappliedtoeachpassnomatterwhichcuttingpassisselected. Fittingsettingsallowyoutochoosehowtheentryandexitarcsfittotheendsofthecutting passes. Minimizetrimmingsetsthepathtoretracttobeasclosetothesurfaceaspossible, maintainingaminimumdistancefromthesurfacetofitthearc. Maxtrimmingdistanceparameterlimitstheamountoftrimmingappliedtononhorizontal passes. SelecttheOKbuttontoexitparameterpages. SelecttheOKbuttontocontinue.
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Thetoolpathshouldappearlikethefollowingpicture.
STEP12:BACKPLOTTHETOOLPATH SelecttheBackploticonsoyoucanseethetoolpathwhichwejustcreated.
Makesurethatyouhavethefollowingbuttonsturnedon(theywillappearpusheddown).
Displaytool Displaytool
Displayrapidmoves
Displayrapidmoves
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SelectthePlaybutton.
SelecttheOKbuttontoexitBackplot.
STEP13:VERIFYTHEROUGHTOOLPATHANDSAVEITASASTLFILETOBEUSED ASANINTERMEDIATESTOCK SelectToggletoolpathdisplayonselectedoperationstoremovethetoolpathdisplay.
SelecttheVerifyselectedoperationsbutton.
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EnableTurbomode. SelecttheConfigurebutton.
Initialstocksizesourceshould besettoJobSetuptousethe stockinformationfromStock Setup. UseTrueSolidallowsyou,after verifyingthepart,torotateand magnifyittomorecloselycheck features,surfacefinish,or scallops. Changetool/colortochangethe colorofthecutstockto indicatedtoolchangesinthe toolpath. SelecttheOKbuttontoexitVerifyOptions.
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SelecttheMachinebuttontostartthesimulation.
Thepartshouldappearasshowntotheright SelecttheSavestockasafilebutton. SavetheSTLfilewiththesamenameataknownlocation. SelecttheOKbutton.
TospeeduptheVerification,wewillusethisSTLfilewhenweverifytherestoftheoperation.
SelecttheOKbuttontoexitVerify.
SelectToggletoolpathdisplayonselectedoperationsicontohidethetoolpathfromthescreen.
STEP14:FINISHTHESURFACESUSINGSURFACEFINISHCONTOUR ContourRoughandFinishToolpathsperformmultiplecutsatconstantZlevels.Bothtoolpathsare recommendedforpartswithsteepwalls.Youshouldavoidusingthistoolpathforpartswithflat surfaces.Tomachineflatareasuseshalloworparallelsurfacetoolpaths.
ToolpathPreview:
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Toolpaths SurfaceFinish
Contour
[SelectDriveSurface]:FromtheQuickMasktoolbar,selecttheQMSurfacesicon. PressEnterkeytofinishtheselection. SelecttheContainmentselectionbutton. [Chain2Dtoolcontainmentboundary#1]:SelectEntityA.
SelecttheEntityA
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SelecttheOKbuttontoexittheChainingdialogbox.
SelecttheOKbuttontoexittheToolpath/surfaceselectiondialogbox. ClickontheSelectlibrarytoolbuttonanduseFiltertoselect3/4InchBallnoseEndmill. Makeanynecessarychangesasshowninthefollowingscreenshots.
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SelecttheSurfaceparametersandchangetheparametersasshown.
Clearancevaluesetstheheightatwhichthetoolrapidstoorfromthepart. Retractvaluesetstheheightthetoolrapids/feedratesupto,beforethenexttoolpass. Feedplanevaluesetstheheightthetoolrapidstobeforechangingtotheplungerate. Stocktoleave(onDrivesurface)setstheamounttoleaveforthefinishoperationasa constantvalueallthewayaroundthedrivesurfaces.
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SelecttheFinishcontourparametersandchangetheparametersasshown.
Optimizecutordercleansoneareacompletelybeforemovingtoanotherarea. Onewayallowsthetooltomovearoundtheshapeinthesamedirection. Minimizetoolburialgeneratesadditionalretractandplungemoveswhenthetool couldbeengagingmaterialonbothsides,aswhenmachiningbetweentwobosses. Shallowremovestoolmovesoraddstoolmovesintheshallowareas. SelectShallowbuttonandchangetheparametersasshown.
Addcutstoshallowareaallowthesystemtogenerate additionalcutsbetweenadjacentcutswhentheadjacent cutsarefurtherapartthanthelimitingstepovervalue. Limitinganglesetstheanglethatdefinestheshallow areasonthepart.Mastercamaddsorremovescutsinan areathatrangesbetween0to45degrees. Limitingstepoverisusedastheminimumstepoverwhen addingcutstotheshallowareasandasmaximum stepoverwhenremovingcutsfromshallowareas.
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SelecttheOKbuttontoexitShallowdialogbox.
SelecttheOKbuttontoexitFinishcontourparameters.
SelectToggletoolpathdisplayonselectedoperationstoremovethetoolpathdisplay.
STEP15:VERIFYTHEFINISHTOOLPATH SelectonlytheSurfaceFinishContouroperation. SelecttheVerifyselectedoperationsbutton.
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EnableTurbomode. SelecttheConfigurebutton.
EnableFileintheStock Shape,andselecttheStock filebrowsebutton.
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FindtheSTLfilethatyousavedinapreviousstep(YourName_6.STL). SelecttheOKbuttontwicetoexitVerifyOptions.
Thestockshouldlookasshown: SelecttheMachinebuttontostartthesimulation.
Thepartshouldappearasshownto theright: SelecttheOKbuttontoexitVerify.
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STEP16:FINISHTHEFILLETSURFACESUSINGSURFACEFINISHLEFTOVER TOOLPATH Notethatbecausethefilletsurfaceradiusisa1/4Inchthefilletsurfaceswerenotcleaned.
SurfacefinishleftovertoolpathremovesremainingstockthatMastercamcalculatesbasedonthe dimensionsofatoolusedinapreviousoperation.Finishleftoverusesasmallertoolthantheroughing tool.Mastercamlooksatthepart,calculateswheretheroughingtoolcouldnotfit,andcreatestool motiontoremovestockfromtheseareas.
ToolpathPreview:
Toolpaths SurfaceFinish
Leftover
SelectDriveSurface]:FromtheQuickMasktoolbar,selecttheQMSurfacesicon. PressEnterkeytofinishtheselection.
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SelecttheOKbuttontoexitToolpath/surfaceselection.
ClickonSelectlibrarytoolintheToolpathsparametersdialogbox. UsetheFiltertoselectthe1/4"BallnoseEndmill. MakethenecessarychangesintheToolpathparameterstomatchthefollowingscreenshot.
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NotethatbecauseweenabledtheadvancedoptionsintheToolSettingsparameters(Properties);the Clearance,RetractandFeedplanewillbethesameasinthepreviousoperation.
SelectFinishleftoverparameterstabandchangetheparametersasshown.
Totaltoleranceisthesumofthefiltertoleranceandcuttolerance.Youcanadjustthe ratioofthefiltertolerancetothecuttolerance,changethetoleranceamounts,andselect arcoptions. MaximumstepoversetsthesizeofthestepbetweenXYcutsinasurfacetoolpath. Fromslopeangle/toslopanglesettheareatobemachined. Hybridleftovercuttingcombines2Dand3Dcutswherecutsabovethecutoffangle (usuallythesteepestarea)areconstantZandcutsbeloware3D. Keepcutsperpendiculartoleftoverregioncanimprovethefinishbyaddingmoremoves, butitwillincreasethemachiningtime.
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SelecttheLeftovermaterialparameterspageandchangetheparametersasshowninthefollowing screenshot.
Roughingtooldiameteristhediameteroftheprevioustoolthatwasusedtomachinethe part(inourcasethe0.75InchBallnoseendmillusedinthefinishcontourtoolpath). Roughingtoolcornerradiusisthecornerradiusoftheprevioustoolthatwasusedto machinethepart. Overlapdistanceisanadditionaloffsetappliedtotheprevioustoolshape.Thisvalue causestheleftovermaterialtobecalculatedasifithadbeencutbyalargertool.
SelecttheOKbuttontoexit.
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SelectToggletoolpathdisplayonselectedoperationstoremovethetoolpathdisplay.
STEP17:USECHECKHOLDERTOFINDTHEMINIMUMTOOLLENGTHREQUIRED FORTHE1/4“BALLNOSEENDMILL CheckHolderCHookisusedtocheckanoperation'stoolholderforinterferencewiththepart.It calculatesareaswherethereisinterference,andtellsyoutheminimumtoollengthrequiredtoavoidit.
17.1Checkthecurrenttoollength Clickonthe1/4InchBallnoseEndmillSphereinthepenciloperation.
Selectthe1/4InchBall noseendmill
NotetheOverallvalueof2.5“
SelecttheOKbuttontoexit.
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17.2UsetheCheckHolderChooktocheckthetoolholderforinterferencewiththepart. MakesurethatonlytheSurfaceLeftoverisselectedintheToolpathsmanager. EnterAlt+CortheRunUserApplications SelectCheckHolder.dllfromthelist.
iconfromthetoolbarstoopentheChookdirectory.
EntertheHolderclearanceof0.05andkeeptheothersettingsasshown: SelectthePerformtestbutton. NotethatthetestresultisNointerference.
SelecttheOKbuttontoexitCheckholderparameters.
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STEP18:VERIFYTHESURFACEFINISHCONTOURANDTHESURFACEFINISH LEFTOVERTOOLPATHS SelectonlytheSurfaceFinishContourandtheSurfaceFinishLeftoveroperations. ClickontheSurfaceFinishContourfirstandthenholddowntheCtrlkeyandselecttheSurface FinishLeftover.
SelecttheVerifyselectedoperationsbutton.
EnableTurbomodeandStoponcollision.
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SelectMachinebuttontostartsimulation.
Thepartshouldappearasshownbelow: SelecttheOKbuttontoexitVerify.
STEP19:CREATEASTANDARD2DPOCKETTOOLPATHWHICHWILLBE PROJECTEDONTOTHESURFACES
SubStepPreview:
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ChangethegraphicviewtoTop.
Toolpaths Pocket [Selectpocketchain1]:Makeawindowaroundtheobroundasshown: [Sketchapproximatestartpoint]:Clickinsidetheobroundasshown:
PicktheStart pointhere
Makeawindow
SelecttheOKbuttontoexitChainingdialogbox.
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Selecta1/8“BallnoseendmillandmatchtheparametersintheToolpathparametersasshown. SelecttheCutParameterspageandchecktheparameterstomatchthefollowingscreenshot.
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SelecttheRoughingpageandmadethechangesasshown. SelecttheFinishingpageandmadethechangesasshown.
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SelecttheLinkingParameterspageandmadethechangesasshown. SelecttheOKbuttontoexit2DToolpaths–Pocketandgeneratethetoolpath.
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STEP20:BACKPLOTTHETOOLPATH SelecttheBackploticontoviewtheselectedoperationtoolpath.
Makesurethatyouhavethefollowingbuttonsturnedon(theywillappearpusheddown). Displaytool
Displaytool
Displayrapidmoves Quickverify
Displayrapidmoves
Quickverify
SelectthePlaybutton.
Clickinthemiddleofthepocketandusingthemousewheel,Zoomin. TozoominyoucanalsouseZoomtargeticon ;clickinthemiddleofthepocketandthen,move thecursoroutandselectthecornerofthezoomwindowwhenthepocketisincluded.
Notetheareas(insidetheAletterandaroundMletter)thatthe1/8InchBallnoseendmillcould notmachine.Wewillremachinethepocketusinga1/16Ballnoseendmilltocleanuptheseareas. SelecttheOKbuttontoexitBackplot.
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SelecttheToggletoolpathdisplayonicontoremovethetoolpathdisplay.
STEP21:REMACHINETHEPOCKET Remachiningcalculatesareaswheretheroughingtoolcouldnotmachinethestockandcreatesasecond toolpathtocleartheremainingmaterial.
ToolpathPreview: ClickonthePocket(Standard)operationintheToolpathManagerandmakesurethatitistheonly operationselected. RightmouseclickonthePocket,holditdownanddrag SelectCopyafterfromthedropdownlist. SelectParametersinthesecondPocketoperationasshown.
SelectParameters
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SelecttheToolpageandselectfromthelibrarythe1/16InchBallnoseendmill. SelecttheCutParameterspageandselectRemachiningasthePockettype.Changetheparameters tobeasshown.
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SelecttheRoughingpagetomakesurethattheparametersmatchthefollowingscreenshot. SelecttheFinishingpagetomakesurethattheparametersmatchthefollowingscreenshot.
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SelecttheOKbuttontoexitthe2DToolpaths–Pocketandgeneratethetoolpath. SelectRegeneratealldirtyoperationsicontoregeneratethetoolpath.
SelectToggletoolpathdisplayonselectedoperationstoremovethetoolpathdisplay.
STEP22:USESURFACEFINISHPROJECTTOMACHINETHERAISEDLETTERS ProjectRoughandFinishToolpathsallowyoutoprojectcurves,points,oranotherNCIfileontoselected surfaces.Thesetoolpathscancloselymatchthecutmotiontotheshapeofthepartandcanbeusedfor engraving.
ToolpathPreview:
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Tobeabletomachinetheraisedlettersweneedtooffsettheexistingsurfacestoprojectthe toolpathsonthem.
22.1Createtheoffsetsurfaces SubStepPreview:
Create Surface
Offset
[Selectsurfacestooffset]:Selectthetwosurfacesasshown
Selectthesetwosurfaces PressEntertofinishtheselection. ChangetheOffsetdistance
to0.125"andpressEnter.
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Makesurethattheoffsetsurfacesarecreatedbelowtheoriginalonesasshown.
Otherwise;clickontheCycle/Nextbutton first,andthentheFlip buttonto changethesurfacenormalorientation.Repeattheprocedureforthesecondsurfaceifnecessary.
SelecttheOKbuttontoexitOffsetsurfacecommand.
SelectClearColoricon.
22.2SurfaceFinishProject SubStepPreview:
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NotetheredinsertarrowlocationintheToolpathsManager. Thenextoperationisgoingtobecreatedbetweenthetwo pocketsifthearrowisnotmoved.
ClickontheMovetheinsertarrowdownoneitem.Thisensuresthatthenext toolpathwillbecreatedattheendandnotinthemiddleoftheprogram. ChangetheGraphicViewtoIsometric.
Toolpaths SurfaceFinish
Project [SelectDriveSurface]:Selectthetwooffsetsurfacesthatyoujustcreated.
Selectthesesurfaces
SelecttheEndSelectionbutton. SelecttheOKbuttontoexit.
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SelecttheOKbuttontoexitToolpath/Surfaceselection.
Selecttheexisting1/8”InchBallnoseendmillandmakethechangesasshowninthefollowing screenshots.
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SelectSurfaceparametersandchangetheparametersasshown.
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SelecttheFinishprojectparametersandmakesurethatProjectiontypeissettoNCI. Enableoperation4Pocket(Standard)intheSourceoperationsandenableRetractbetweencuts.
Projectiontype NCIallowsyoutoprojectanexisting2Dtoolpath(contourorpocket)ontoselected surfaces. Curveallowsyoutoproject2Dchainsofentities(lines,arcs,splines)ontoselected surfaces.Mastercampromptsyoutoselectthechainsafteryouexitproject parameters. Pointsallowyoutoprojectpointsontoselectedsurfaces.Mastercampromptsyouto selectthechainsafteryouexitprojectparameters. Retractbetweencutsforcesaretractmovebetweencutsandwhenengravingletters (curveprojectiontype)itallowsthetooltoretractbetweenletters. Adddepthsallowyoutoaddcutdepthsfortheroughproject.Itisenabledonlywith projectiontypeNCI.
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SelecttheOKbuttontoexit.
SelecttheToggletoolpathdisplayon icontoremovethetoolpathdisplay.
STEP23:USESURFACEFINISHPROJECTTOCLEANUPTHELETTERS ToolpathPreview: ClickontheSurfaceFinishProjectoperationintheToolpathManagerand makesurethatitistheonlyoperationselected. RightmouseclickontheSurfaceFinishProject,holditdownanddrag SelectCopyafterfromthedropdownlist.
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SelectParametersinthesecondSurfaceFinishProjectoperationas shown.
SelectParameters
SelectToolpathparametersandselectthe1/16InchBallnoseendmill
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SelecttheFinishprojectparametersandselectoperation5Pocket(Remachining)fromthelist. SelecttheOKbuttontoexitthetoolpath.
SelectRegeneratealldirtyoperationsicontoregeneratethetoolpath.
Thetoolpathshouldlookasshowntotheright.
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STEP24:VERIFY BasedonStep19,verifytheSurfaceFinishContour,theSurfaceFinishLeftoverandthetwoSurface FinishProjectoperationsonly,andmakesureyoudon’tselectanyofthe2DPockets.
Torotatethepart,selecttheDynamicRotationicon. [Pickapointtobegindynamics]:Selectapointaroundthemiddleofthepart. Slightlymovethecursorandclickonthepartisintheproperposition.
Thepartshouldlookas showntotheright
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STEP25:POSTPROCESSTHEFILE ClickonthePocket(Standard)operationtoselectonlythisoperationandthen,holdingdownthe Ctrlkey,selectthePocket(Remachining)operation. ClickonTogglepostingonselectedoperationtoturnthepostoffforthesetoolpaths. ClickonSelectalloperationsicontoselectallthetoolpaths.
Note:weghostedthepocketoperations;thereforetheGcodefortheseoperationswillnotbe generated.Rememberthatthesetoolpathswereonlyusedtogeneratetheprojecttoolpaths.
SelectthePostselectedoperationsbuttonfromToolpathManager.
InthePostprocessingwindow,makeallthenecessary changesasshowntotheright. SelecttheOKbuttontocontinue.
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EnterthesamenameasthegeometrynameintheNCFilenamefield.(YourName_6) SelecttheOKbutton.
SelecttheredXboxattheupperrightcornertoexittheEditor.
STEP26:SAVETHEUPDATEDMCXFILE SelecttheSave
icon.
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REVIEWEXERCISE StudentpracticeCreatetheToolpathforExerciseTutorial6aspertheinstructionsbelow; Tips:Youneedonlyflatletters 1.EstablishtheStocksizeY=5.0,X=5.0, Z=2.0 StockoriginX=0,Y=0,Z=1.505 2.CreatearectanglewithsurfaceoptionatZ0,the samesizeasthestock(5X5) 3.SurfaceRoughContour Selectallsurfaces Usea3InchFaceMill(changethelibrarytoBig.Toolsand editthetool:Taperangle=0.0) Clearance=2.5 Retract=2.0 Stocktoleaveondrivesurfaces=0.02 Totaltolerance=0.005 Max.Stepdown=0.1 EnableEntry/exitArcRadius=0.25,ArcSweep=90 EnableShallow Addcuttoshallowareas Minstepdown=0.005 Limitingstepover=0.05 DisableAllowpartialcuts Onewaycutting 4.SurfaceFinishScallop Use1/2"BallnoseEndMill Totaltolerance=0.001 Max.Stepover=0.05 Expandinsidetooutside
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5.SurfaceFinishLeftover Use1/8”BallnoseEndMill Totaltolerance=0.001 Max.Stepover=0.02 Cuttingmethod3DCollapse Roughingtooldia=0.5 Roughingcornerradius=0.25 6.SurfaceFinishProject Usea1/32”BallnoseEndMill Stocktoleaveondrivesurfaces=0.01 ProjectiontypeCurves EnableRetractbetweencuts 7.BackplotandVerifythetoolpaths. 8.Postprocessthefile.
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NOTES:
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TUTORIAL6QUIZ Whatisasurfacenormal? Whenwouldyouusethe“surfacehighspeedareamill”toolpath? Whenwouldyouusea“surfacefinishleftover”toolpath? Whydidweturnoffthepostfunctiononthepocketoperations?
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