Mastercam_2017_Mill_Advanced_Training_Tutorial_SAMPLE.pdf

IMPERIAL

TRAI TR AINI NING NG TUTORI TU TORIAL AL SER SERIES IES

MILL ADVANCED

Mill Advanced Training Tutorial

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Mastercam 2017 Mill Advanced Training Tutorial Copyright: 1998 - 2017 In-House Solutions Inc. All rights reserved Software: Mastercam 2017 Author: Mariana Lendel ISBN: 978-1-77146-528-1 Date: June 29, 2016

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 distributer, or its retailer) assumes the entire cost of all necessary servicing, repair, of c orrection and any incidental or consequential damages. In no event will In-House 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 International copyright laws. All rights are reserved. This document may not, in whole or part, be copied, photographed, 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 t rademarks of Microsoft Corporation; Windows 7 and Windows 8 are registered trademarks of Microsoft Corporation.

MASTERCAM SHORTCUTS

MASTERCAM QUICK REFERENCE CARD

MASTERCAM SHORTCUTS Function

Keyboard Shortcut

Function

Keyboard Shortcut

Analyze entities

F4

Mastercam version, SIM serial number

Alt+V

AutoSave

Alt+A

Motion controller rotation point

Alt+F12

C-Hook or user app

Alt+C

Pan

Arrow keys

Configure Mastercam

Alt+F8

Paste from clipboard

Ctrl+V

Copy to clipboard

Ctrl+C

Redo an event that has been undone

Ctrl+Y

Cut to clipboard

Ctrl+X

Repaint

F3

Delete entities

F5

Rotate

Alt+Arrow keys

Drafting global options

Alt+D

Select all

Ctrl+A

Exit Mastercam

Alt+F4

Selection grid parameters

Alt+G

Fit geometry to screen

Alt+F1

Shading on/off

Alt+S

Gview–Back

Alt+3

Show/hide all axes (WCS, Cplane, Tplane) Alt+F9

Gview–Bottom

Alt+4

Show/hide coordinate axes

F9

Gview–Front

Alt+2

Show/hide displayed toolpaths

Alt+T

Gview–Isometric

Alt+7

Show/hide Toolpaths Manager panel

Alt+O

Gview–Left

Alt+6

Undo the last creation or event

Ctrl+U, Ctrl+Z

Previous Plane

Alt+P

Unzoom to 80% of original

Alt+F2

Gview–Right

Alt+5

Unzoom to previous or 50% of original

F2

Gview–Top

Alt+1

Zoom around target point

Ctrl+F1

Help

Alt+H

Zoom with window selection

F1

Hide entities

Alt+E

Zoom/unzoom by 5%

Page Up/Page Down

Level Manager

Alt+Z

Main attributes, set from entity

Alt+X

MASTERCAM QUICK REFERENCE CARD

CUSTOMIZE MASTERCAM

CUSTOMIZE MASTERCAM Create Your Own Keyboard Shortcuts

Customize the Ribbon

Right mouse click in the Ribbon.  Customize the Ribbon.  Keyboard shortcuts, select the Customize button.  Select the Category.  Select a command and under Press new shortcut key enter the key combinations you want to assign to it.



Customize Quick Access Toolbar





Right mouse click on a command in the Ribbon.  Select Add to Quick Access Toolbar. 

Right mouse click in the Ribbon.  Select Customize the Ribbon.  Select a Mastercam command.  Select a Tab or create a New Tab.  Press Add button.

Customize the right click menu Right mouse click in the Ribbon.  Select Customize the Ribbon.  Select Context Menu.  Select the Category and then the command that you want to add.  Once you click on the Add button the function will be added to the Right mouse button menu.

WAYS TO GET THE MOST FROM MASTERCAM Mastercam Training In-House Solutions offers unsurpassed industrial training for Mastercam and Octopuz. We have training facilities in a number of cities across Canada and some of our courses can also be offered onsite, depending on trainer availability. Learn more at eMastercam.com/store. Our library of Mastercam Training Solutions consists of several product lines that cater to any le arning style. Learn Mastercam at your own pace with our Training Tutorials, teach your students with the help of our Instructor Kits, learn the theory behind Mastercam with our Handbooks, get projects à-la-carte with our Single Projects, let our instructors show you best practices with our Video Training or go digital with our eBooks.

Mastercam Community eMastercam is the one-stop web resource for Mastercam users. People from all over the world visit the site whether they are teaching, learning or working with Mastercam daily. Members can post questions, comments or share projects and success stories. Visit eMastercam.com and sign up for your free account today!

For downloaded pdf please visit www.emastercam.com/qrc

MILL ADVANCED TRAINING TUTORIAL PROJECTS

Tutorial

Geometry Functions

Surface and Toolpath Creation

Solid Extrude Create Body Solid Extrude Cut Body Solid Extrude Add Body Solid Fillet

Surface Rough Pocket High Speed Surface Scallop High Speed Surface Scallop With Trim to Stock

Revolved Surface Transform Project Arc Trim To Curve Net Surface Fillet Surface Flat Boundary Surface

High Speed Surface OptiRough High Speed Surface Raster High Speed Surface Pencil

Swept Surface Solid Extrude Solid Trim To Surface Solid Boolean Add Use Levels

High Speed Surface Area Roughing Rest Material High Speed Surface Radial Surface Finish Blend Transform - Rotate By Coordinate

#1

#2

#3



Tutorial

Geometry Functions


Wireframe for Solid Solid Extrude Solid Revolved Swept Surface Solid Trim to Face Solid Fillet Solid Draft Face Boolean Remove Boolean Add

High Speed Surface Dynamic OptiRough High Speed Surface Dynamic OptiRough with Rest Material High Speed Surface Hybrid Edit Projection

Revolved Surface Project Curve Onto Surface Ruled Surface Draft Surface Curve At Intersection Trim Surface To Curves Surface Fillet Fillet Blend Surface

High Speed Surface Area Roughing High Speed Surface Spiral High Speed Surface Scallop Transform-Rotate High Speed Surface Waterline

Draft Surface Swept Surface Fillet Surface Rectangle with Surface Flat Boundary Surface

High Speed Surface Dynamic OptiRough High Speed Surface Horizontal High Speed Surface Waterline High Speed Surface Raster High Speed Surface Pencil

#4

#5

#6



Tutorial

Geometry Functions


Lofted Surface Net Surface (Window Selection) Surface Net (Chain Selection) Fillet Surface Ruled Surface Offset Surface Trim Surface To Curves Flat Boundary Surface Silhouette Boundary

High Speed Surface Dynamic OptiRough Surface High Speed Area Roughing with Rest Material Surface High Speed Scallop Surface High Speed Scallop with Trim to Stock Pocket Standard Surface Rough Project NCI file

#7




TABLE OF CONTENTS

Table of Contents Getting Started ........................................................................................................... 1 Tutorials: Tutorial #1 - Surface Rough Pocket & Surface High Speed Scallop ...................................................11 Tutorial #2 - Surface High Speed Dynamic OptiRough, Raster & Pencil ............................................99

GETTING STARTED

Tutorial #3 - Stock Model, Surface HS Area Roughing - Rest Material & Radial &

Surface Finish Blend ...............................................................................................185 Tutorial #4 - Surface HS Dynamic OptiRough, Surface HS OptiRough - Rest Material, Stock

Model & Surface HS Hybrid .....................................................................................303 Tutorial #5 - Surface HS Area Roughing, Scallop, Spiral & Waterline ..............................................429 Tutorial #6 - Surface HS Dynamic OptiRough, Horizontal, Waterline, Raster & Pencil .....................611 Tutorial #7 - Surface HS Dynamic OptiRough, Area Roughing - Rest Material, Surface HS Scallop,

& Surface Rough Project..........................................................................................697

Quiz Answers ......................................................................................................... 831


TUTORIAL #1


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TUTORIAL #11

OVERVIEW OF STEPS TAKEN TO CREATE THE FINAL PART:

OVERVIEW OF STEPS TAKEN TO CREATE THE FINAL PART: From Drawing to CAD Model:  The student should examine the drawing on the following page to understand what part is being created in this tutorial.  From the drawing we can decide how t o create the geometry in Mastercam.

Create the 3D CAD Model used to generate Toolpaths:  The student will create the wireframe needed to create the solid.  Solid creation commands such as Extrude Create Body, Extrude Cut Body, Extrude Add Boss and Fillet will be used.

Create the necessary Toolpaths to machine the part:  The student will set up the stock size and the clamping method to be used.  A Surface Rough Pocket toolpath will be created to rough out the part.  A Surface High Speed Scallop toolpath will be created to machine the floors.  A Surface High Speed Scallop toolpath with Trim to Stock options will be created to machine the fillets.

Backplot and Verify the file:  The Backplot will be used to simulate a step-by-step process of the tool’s movements.  The Verify will be used to watch a tool machine the part out of a solid model.

Post Process the file to generate the G-code:  The student will then post process the file to obtain an NC file containing the necessary code for the machine.

This tutorial takes approximately two hours to complete.

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OVERVIEW OF STEPS TAKEN TO CREATE THE FINAL PART:

TUTORIAL #11


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TUTORIAL #11

SETTING UP THE GRAPHIC USER INTERFACE

GEOMETRY CREATION

STEP 1: SETTING UP THE GRAPHIC USER INTERFACE Please refer to the Getting Started section to set up the graphical user interface. In this step you will learn how to hide the manager panels to gain more space in the graphics window.



Use the Auto Hide icon to hide all Manager panels as shown.



The panels will be hidden to the left of the graphics window.



To un-hide them temporally, click on one of the managers to open it as shown.

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CREATE RECTANGLES

TUTORIAL #11

STEP 2: CREATE RECTANGLES In this step you will learn how to create rectangles given the width, the height, and the anchor position.

Step Preview:

2.1 Create the 5.0" by 5.0" rectangle WIREFRAME  From the Shapes group, select Rectangle.



Enter the Width, the Height and enable Anchor to center as shown. Make sure that Create surface is not selected.

NOTE: Anchor to center sets the base point of the rectangle to its center and draws the rectangle outward from the center. Create surface creates a surface inside of the rectangle. A surface can be described as the skin on the top of a 3D wireframe. If the surface option is on, instead of the four lines of the rectangle, you will see extra lines which represent the surface display while it is not shaded. You do not need to create a surface at this time.


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TUTORIAL #11

CREATE RECTANGLES

Press Enter after typing the values to see a preview of the rectangle.  [Select position of base point]: Select the Origin as shown in Figure: 2.1.1. 

Figure: 2.1.1



Make sure that when selecting the Origin, the visual cue of the cursor changes as shown.

Select the OK and Create New Operation button to stay in the same command.  To fit the drawing to the screen, press Alt + F1. 

NOTE: While creating the geometry for this tutorial, if you make a mistake, you can undo the last step using the Undo icon.

You can undo as many steps as needed. If you delete or undo a step by mistake, just use

the Redo icon. keyboard.

To delete unwanted geometry, select the geometry first and then press Delete from the

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CREATE RECTANGLES

TUTORIAL #11

2.2 Create the 4.0" by 4.0" rectangle 

Enter the Width, the Height and leave Anchor to center enabled as shown.

Make sure that the Create surface button is not selected (not highlighted).  [Select position of base point]: Select the Origin as shown in Figure: 2.1.1.  The drawing should look as shown below. 



Select the OK and Create New Operation button to stay in the same command.


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TUTORIAL #11

CREATE RECTANGLES

2.3 Create the 2.5" by 2.5"rectangle 

Select the HOME tab and set the construction mode to 3D as shown.

NOTE: The construction mode can be toggled between 2D and 3D. In 2D mode, all the geometry is created parallel to the current construction plane and at the current Z depth setting. However, you can override the Z depth setting by typing coordinate values that include a Z depth value different from the current Z depth setting. In 3D mode, the X, Y, and Z coordinates are all read from AutoCursor when sketching dynamically. The Z depth setting in the HOME ribbon is not used. When working in a 3D environment, you can create entities whose points lie in different planes, or create entities (such as arcs or 2D splines) in planes other than the predefined planes. 

Enter the Width and the Height as shown.

Press Enter.  Press the Space bar and enter the coordinates for t he Rectangle as shown. 

NOTE: When you enter the coordinates of a point in Mastercam, the first value is the X coordinate value followed by a comma. The second value is the Y coordinate value followed by a comma and the third value is the Z coordinate value. If you enter the values in this order you do not need to enter the coordinates labels (X, Y or Z) in front of the values.

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CREATE FILLETS FOR THE TWO RECTANGLES

TUTORIAL #11

Select the OK button to exit the Rectangle command.  Right mouse click in the graphics window and set the graphics view to Isometric. 



The geometry should appear as shown.

STEP 3: CREATE FILLETS FOR THE TWO RECTANGLES In this step you will learn how to create fillets to all corners of the inside rectangle using the Fillet chain command.

Step Preview:


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TUTORIAL #11


WIREFRAME  From the Modify area, select the drop down arrow next to Fillet Entities and select Fillet Chains as shown.



Right mouse click in the graphics window and change the graphics view to the Top.

Press Alt + F1 if needed to fit the geometry to the graphics window.  Make sure that in the Chaining dialog box, the Chain button is enabled as shown. 

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

TUTORIAL #11

[Select chain 1]: Select the rectangle as shown in Figure: 3.0.1. Figure: 3.0.1



Select the OK button to exit the Chaining dialog box.

NOTE: Mastercam will automatically insert fillets at all four corners with the radius to be the default value or the last value used during this Mastercam session. 

Change the Radius to 1.0 and make sure the rest of the parameters are set as shown (press Enter).



Select the OK and Create New Operation button to stay within the command.


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TUTORIAL #11

SUGGESTED FIXTURE:

TOOLPATH CREATION

SUGGESTED FIXTURE:

SETUP SHEET:

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SELECT THE MACHINE AND SET UP THE STOCK

TUTORIAL #11

STEP 14: SELECT THE MACHINE AND SET UP THE STOCK In Mastercam, you select a Machine Definition before creating any toolpaths. The Machine Definition is a model of your machine tool's capabilities and features and acts like a template for setting up machining jobs. The machine definition ties together three main components: the schematic model of your machine tool’s components, the control definition that models your control unit’s capabilities, and the post processor that will generate the required machine code (G-c ode). For a Mill Advanced exercise (3D toolpaths), you need only a basic machine definition.

Step Preview:

NOTE: For the purpose of this tutorial, we will be using the Mill Default machine. 

Press Alt + F1 to fit the drawing to the screen.

14.1 Unhide the Toolpaths Manager and lock it 

The Toolpaths Manager will be hidden to the left of the graphics window as shown.


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TUTORIAL #11




To lock it, click on the Toolpaths tab and then click on the Auto Hide icon a shown.



The Manager panels will be translated to the lower left corner of the graphics window.

NOTE: If a Machine Group already exist in the Toolpaths Manager, skip the next step. MACHINE  From the Machine Type group, select the drop down arrow below Mill.  Select Default.

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TUTORIAL #11



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



Select Tool settings to set the tool parameters.



Change the parameters to match Figure: 14.1.1. Figure: 14.1.1

Program # is used to enter a number if your machine requires a number for a program name. Assign tool numbers sequentially allows you to overwrite the tool number from the library with the next available tool number. (First operation tool number 1; Second operation tool 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 to From tool uses the feed rate, plunge rate, retract rate and spindle speed from the tool definition.


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TUTORIAL #11


Select the Stock Setup tab to define the stock.  Select the All Entities button to allow Mastercam to establish the necessary stock based on the existing geometry as shown. 

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

TUTORIAL #11

Round the values if needed and change the Z value for the stock to 1.5 as shown in Figure: 14.1.2. Figure: 14.1.2

The Stock Origin values adjust the positioning of the stock, ensuring that you have an equal amount of extra stock around the finished part.

Display options allow you to set the stock as Wireframe and to fit the stock to the screen. (Fit Screen)

NOTE: The extra 0.5" added to the stock thickness is for fixture purposes. Select the OK button to exit the Machine Group Properties dialog box.  Press Alt + F1 to fit the drawing to the screen. 


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TUTORIAL #11 

ROUGH OUT THE PART USING SURFACE ROUGH POCKET

The stock should look as shown.

NOTE: Remember that the stock is not geometry and thus cannot be selected.

This tutorial utilizes a set of legacy surface toolpaths to machine the part. We begin by showing you legacy toolpaths as they still have some value in certain situations and the parameters for these toolpaths are easier to understand for someone just getting started with 3D machining. That being said, there are more efficient toolpaths that can be used to machine the same part. If you will actually machine this part, we suggest you use the Surface High Speed OptiArea toolpath as your roughing toolpath of choice.

STEP 15: ROUGH OUT THE PART USING SURFACE ROUGH POCKET Surface Rough Pocket toolpath is used to remove a lot of stock quickly by creating a series of planar cuts (constant Z). It is used to machine both bosses or cavities on surfaces or solid models.

Toolpath Preview:

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TUTORIAL #11

15.1 Surfaces and Containment selections TOOLPATHS  From the 3D group, select the Pocket icon.



If a prompt appears to Enter new NC name, select the OK button to accept the default as shown.



[Select Drive Surfaces]: Select the solid as shown.



Click on the End Selection button or press Enter to finish the selection.


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TUTORIAL #11




To limit the tool motion inside of the boundary, in the Toolpath/surface selection dialog box, click on the Select button to select a Containment as shown.



From the Chaining dialog box, click on the Solids button as shown.



In the Chaining dialog box, make sure that the Loop button is the only one selected as shown.

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

[Select faces, edges, and /or loops]: Select the edge as shown.



The chain selected should look as shown.



The Pick Reference Face dialog box will appear on your screen as shown.



Select the OK button to exit the Pick Reference Face dialog box.



Select the OK button to exit the Chaining dialog box.



Select the OK button to exit the Toolpath/surface selection dialog box.


TUTORIAL #11

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TUTORIAL #11


15.2 Set the Toolpath parameters page The Toolpath parameters page allows you to select a tool, set the feeds and speeds, enter a comment about the operation, and set other general toolpath parameters.



To select the tool, click on the Select library tool button as shown.



Disable Filter Active and click on the # to list the tools based on their numbers.

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INDEX

Numerics

G

2D / 3D Construction ........................................6

Graphic Area .....................................................3 GUI - Graphical User Interface .......................... 3

A Analyze A Spline ........................................... 544 Assign tool numbers sequentially ...................56

L

B

M

Backplot The Toolpath .................................... 72 Backplotting ....................................................72 Boolean Remove ...................................410 424 Bounding Box ..................................................57 Break the fillet at the midpoint .................... 571

Machine Definition ......................................... 53 Material Mode .............................................. 291 Maximum step-down .....................................69 Mirror ...........................................................352 Mirror about a line ....................................... 568 Mirror the profile about the Y axis ............... 534 Mitered Corners ........................................... 435

,

C Change The Main Level ................................... 30 Clearance ........................................................68 Color ................................................................. 6 Constant Radius ............................................435 Control Definition ........................................... 53 Create A Net Surface .................................... 157 Create Arc Endpoints .................................... 383 Create Circle Center Point .............................. 27 Create Circle Center point .............................. 27 Create Curve At Intersection ........................ 576 Create Fillets ...................................................23 Create Fillets For The Two Rectangles ............ 23 Create Parallel Lines ..................................... 110 Create Polar Lines ......................................... 116 Create Rectangles ........................................... 19 Create Revolved Surfaces ............................. 135 Create Silhouette Boundary ......................... 441 Create The Draft Surfaces ............................... 30 Create The Fillet Surface ............................... 558 Create The obround rectangular shape ........ 135 Create The Parallel Lines .............................. 110 Create The Pocket Floor Surface .................. 552 Create The Revolved Surface ........................ 135

D Delete Entities .............................................. 382 Display ............................................................ 58 Divide ............................................................310 Draft Surfaces ........................ 30 34 36 43 46 Drive surfaces ................................................. 68 ,

,

,

,

E Extrusion Operation ................................32 399 ,

F Feed Calculation set From tool .......................56 Feed plane ......................................................68

Level .................................................................. 6

N Net Surface ...................................................157

O Offset Contour .............................................. 370 Offset Surface ...............................................802 Override defaults with modal values .............. 56

P Pocket parameters page ................................. 71 Post Process The File ...................................... 98 Post Processing ...............................................98 Post Processor ................................................ 53 Program # .......................................................56 Project ..........................................................138 Propagate Along Tangencies ........................ 435

R Reorganizing The Toolbars ............................... 4 Retract ............................................................ 68 Rotate - Copy The Surfaces ........................... 606 Rough parameters page ................................. 69

S Scale .................................................................. 3 Select The Machine And Set Up The Stock ..... 53 Setting Mastercam To Metric .........................10 Setup the stock model .................................. 274 Shaded ..........................................................244 Simulate the toolpath in Verify ...................... 74 Solid Revolve ................................................ 400 Steep/shallow ...............................................288 Stock Models ................................................ 274 Stock Origin .................................................... 58 Stock to leave on drive ................................... 68 Surface Finish Blend ..................................... 305 Surface Finish Leftover ................................. 880


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Mastercam_2017_Mill_Advanced_Training_Tutorial_SAMPLE.pdf

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