Sample - Mastercam X5 Advanced Multiaxis Training Tutorial

Advanced Multiaxis Training Tutorial

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Mastercam X5 Training Tutorials - Advanced Multiaxis Copyright: 1998 -2010 In-House Solutions Inc. All rights reserved Software: Mastercam X5 Author: Mariana Lendel ISBN: 978-1-926566-87-0 Revision Date: November 3, 2010

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 correction 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 trademarks of Microsoft Corporation; N-See is a registered trademark of Microcompatibles, Inc.; Windows, Windows XP, Windows Vista and Windows NT are registered trademarks of Microsoft Corporation.

Advanced Multiaxis Training Tutorial Contents Getting Started ...................................................................................................A-1 Tutorials Tutorial #1 Projection Toolpath ......................................................................................... 1-1 Tutorial #2 Swarf Milling Toolpath ..................................................................................... 2-1 Tutorial #3 Finish Surfaces Toolpath .................................................................................. 3-1 Tutorial #4 Rough & Finish Impeller Without Tiltcurve...................................................... 4-1 Tutorial #5 Collision Control Strategies .............................................................................. 5-1

General Notes ..................................................................................................... B-1


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TUTORIAL #4 ROUGH & FINISH IMPELLER WITHOUT TILTCURVE

Objectives: The Student will create 5-Axis milling toolpaths consisting of: !Create a Impeller floor surface without tiltcurve toolpath from the Custom Application toolpath family to rough the area between two blades. !Switch to the Advanced interface and create a Morph between 2 surfaces toolpath to add depth cuts and avoid gouging the blades. !Finish the impeller floor using the same Morph between 2 surfaces toolpath. !Create an Impeller blade swarf finish toolpaths from the Custom Application toolpath to semifinish one blade. !Switch to the advance interface and create a Parallel to surface toolpath to add multipasses the toolpath. !Create a Parallel to multiple curves toolpath from the Wireframe toolpath family to finish the blade. !Create Transform Rotate toolpaths to machine the entire impeller. The Student will simulate the toolpaths using Mastercam's Verify and Backplot by: !Defining a 3-dimensional shape the size of the work piece. !Running the Backplot to see the path the tool takes to cut the part. !Running the Verify to simulate the tool cutting from the solid model. !Running the Machine simulation to detect collisions between the stock, tool and any machine components. This tutorial takes approximately two hours to complete.


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SELECT THE GEOMETRY FILE

This tutorial covers Mastercam's 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. Your post may also prompt you 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.

STEP 1:

SELECT THE GEOMETRY FILE Resources - Download the file from www.emastercam.com/files File Open Select "TUTORIAL 4 IMPELLER WITHOUT TILTED CURVE.MCX-5" from the directory you saved it in. Use the Fit icon to fit the drawing to the screen.

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SELECT THE MACHINE AND SET UP THE STOCK

STEP 2:

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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-code). For the purpose of this tutorial, we will be using the 5 - AXIS TABLE - HEAD VERTICAL machine.

NOTE: If you already have the default machine in the Toolpaths Operations Manager, do not select another machine. Expand Properties and select Files, and then select Replace button and select the MILL 5 - AXIS VMC.MMD-5.

2.1 Select the Machine type Machine type Mill Select the MILL 5 - AXIS TABLE - HEAD VERTICAL.MMD-5.

2.2 Create the STL file that will be used as stock NOTE: The Tool settings parameters were set as defaults in the Tutorial #4. From the Status Bar, select Levels. Click in the Number column in front of Level 30 to make it the main level. Make Level 22 invisible by clicking, in the Visible column, on the X.

Select the OK button to exit Level Manager. File Save As


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ROUGH OUT THE IMPELLER USING IMPELLER FLOOR WITHOUT TILTCURVE

In the Save as type select the StereoLithography Files.

Save the stl file with the same name as the Mastercam file, to a desired location. Select the Save button to exit.

STEP 3:

ROUGH OUT THE IMPELLER USING IMPELLER FLOOR WITHOUT TILTCURVE Impeller floor surface without tiltcurve toolpath creates a toolpath to finish the floor between two impeller blades. This application does not require a tiltcurve to guide the tool axis. You should create an operation to rough one floor region, and then use Mastercam's Toolpath Transform features to machine the floors between the other blades.

Toolpath Preview:

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Create the Impeller floor surface without tiltcurve toolpath from the Custom Application toolpath family using the following parameters: 3/8" Flat Endmill. Cutting method = Zigzag; Standard. Maximum stepover = 0.05. Stock remaining = 0.05. Cut Tolerance = 0.0005. Lead angle = 0. Tilt angle = 0. Axial shift = 0. Maximum angle step = 3. Clearance area and Distances set to default values. Lead in/out set to Tangential line; Fixed; Length = 0.3; Height = 0.2.

3.1 Make Level 25 the Main Level, and make invisible the rest of the levels From the Ribbon Bar, select Levels. Click in the Number column in front of Level 25 to make it main level. Make Level 30 invisible by clicking, in the Visible column, on the X.

3.2 Create the Impeller floor surface without tiltcurve toolpath Toolpaths Multiaxis Select the OK button to accept the NC name.


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Toolpath Type Toolpath Type page allows you to establish the type of multiaxis toolpath to create. Toolpath type controls the options available as you proceed down the tree structure. The options are based on the toolpath family selected using the Calculation based on buttons, as well as by selecting the picture of the toolpath you wish to create. The Toolpath Type dialog box allows you to select between the different toolpath families Classic, Wireframe, Surface/Solids, Drill/Circle Mill, Convert to 5x or Custom applications. You can then choose one of the toolpaths inside of that family.

Select the Custom App button. Select the Impeller floor surface without tiltcurve.

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

From the Tree View list, select Tool. To select the tool, click on the Select library tool button.

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Select the Filter button.

Select the None button to unselect any previous tool selection as shown. Select the Endmill Flat in the Tool Types list. Select the drop down arrow in the Tool Diameter field and select Equal. Enter 3/8" in the Tool Diameter value box.

Select OK button to exit Tool List Filter. Make sure that the tool in the Tool Selection window is highlighted, otherwise select it. Select the OK button to exit from the Tool Selection dialog box.

NOTE: The feeds and the spindle speed are based on the tool definition. You can overwrite them with the feeds and speeds that you want to use. You can also let Mastercam calculate the feeds and speed using the Feed speed calculator. Add a comment in the Comment area to identify the toopath in the Toolpath Manager and also in the NC file. The Tool page should look as shown in Figure: 3.2.1.


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Figure: 3.2.1

Impeller Floor Surface Without tiltcurve Impeller floor surface without tiltcurve settings determine the geometry the tool follows and how it travels along the geometry. Impeller floor surface without tiltcurve page also allows you to set the Cutting method and the direction for one way machining. In the Impeller floor surface without tiltcurve you can set the Cut tolerance and the Maximum stepover.

From the Tree View list, select Impeller floor surface without tiltcurve. Click on the Right button to select the surfaces. [Select surfaces for machining]: From the Quick Mask toolbar, located to the right side of the graphics window, select the QM color icon.

Select the color violet no. 152 as shown. Select the OK button to exit the Select All dialog box. Press Enter to finish the selection.

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Select Done to exit the Drive srfs Selection dialog box.

Click on the Left button to select the surfaces. [Select surfaces for machining]: From the Quick Mask toolbar, located to the right side of the graphics window, select the QM color icon.

Select the color pink no. 135 as shown.

Select the OK button to exit the Select All dialog box. Press Enter to finish the selection.


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Click on the Floor surfaces button to select the surfaces you want to machine. [Select surfaces for machining]: From the Quick Mask toolbar, located to the right side of the graphics window, select the QM color icon.

Select the color green no. 85 as shown.

Select the OK button to exit the Select All dialog box. Press Enter to finish the selection.

NOTE: Select the Show button any time you want to double check if the desired surfaces are selected. Press Enter to continue.

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Click on the Check surfaces button to select the surfaces you want to machine. [Select surfaces for machining]: From the Quick Mask toolbar, located to the right side of the graphics window, select the QM color icon.

Hold down the Ctrl key and select the color violet no. 152 and the color pink no. 135 as shown.

Select the OK button to exit Select All dialog box. Press Enter to finish the selection.


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The rest of the parameters are set as shown.

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Default Lead In/Out Default Lead In/Out settings determine how the tool feeds into the material as it approaches the part and how it exits the material at the end of the toolpath.

From the Tree View area, expand the Impeller floor surface without tiltcurve and select the Default Lead In/Out. Set the Type to Tangential line and set the rest of the parameters as shown Figure: 3.2.2. Figure: 3.2.2

Clearance area From the Tree View area, select the Clearance area and leave the default values as shown.

Select the OK button to exit Multiaxis Toolpath - Impeller floor surface without tiltcurve.


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TUTORIAL #41 STEP 4:

BACKPLOT THE TOOLPATH

BACKPLOT THE TOOLPATH Backplotting shows the path the tools take to cut the part. This display lets you spot errors in the program before you machine the part. As you backplot toolpaths, Mastercam displays the current X, Y, and Z coordinates in the lower left corner of the screen.

Make sure that the toolpath is selected (signified by the green check mark on the folder icon).

Backplot the toolpath Select the Backplot selected operations button.

Make sure that you have the following buttons turned on to see the tool and the rapid moves.

To be able to easier check the toolpath, click on the Options button. To maintain the part in a stationary position, disable Simulate Rotary Axis. Change the 4-5 Axis tool vector Length to 0.05.

Select the OK button to exit Backplot Options. You can step through the Backplot by using the Step forward You can adjust the speed of the backplot. Select the Play

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button in the VCR bar to run Backplot.


or Step back

buttons.

BACKPLOT THE TOOLPATH

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The toolpath should look as shown.

NOTE: This toolpath is only a finish operation. To add depth cuts for a roughing operation we need to switch to the advanced interface. The advanced interface will allow us to use margins which will shift the tool to avoid gouging. To rotate the part, to visualize the toolpath better, move the cursor close to the middle of the surfaces and holding down the mouse wheel, move the cursor slightly to the left until the geometry looks as shown.

Select the OK button to exit Backplot. Press Alt + T to remove the toolpath display.


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TUTORIAL #41 STEP 5:

MORPH BETWEEN 2 SURFACES

MORPH BETWEEN 2 SURFACES Morph between 2 surfaces toolpaths creates a morphed toolpath on the drive surfaces. The drive surface is enclosed by two check surfaces. A "morphed" toolpath is one that is approximated between the check surfaces and evenly spread over the drive surface. This toolpath pattern is especially useful during impeller machining with twisted turbine blades. The main advantage is the possibility to compensate the tool to the drive surface and check surface in the left and right corner of the workpiece. All you need to do is set the margin, or distance between the tool center and the surfaces, equal to the tool radius.

Toolpath Preview:

5.1 Rough out the area between two blades using Morph between 2 surfaces Select the Parameters in the 5AxMSurf operation.

From the Tree View area select Misc and click on Switch to advanced interface button.

NOTE: Mastercam switches automatically to the Morph between2 surfaces.

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5.2 Add the margins to avoid tool gouging into the blades Change the following parameter: Start/end margin = 0.2.

Additional margin to overcome surface edge inaccuracies = 0.0018.

Margins Margins create additional space so the toolpath is not starting directly on the surface edge. Additional margin to overcome surface edge inaccuracies is a value added to the edge curve tolerance. Surface edges and edge curves are not exact matches due to tolerances. Use this value to eliminate any toolpath calculation issues where ragged edges are encountered.

From the Tree View area, expand Cut Pattern and select Margins. Change both the Start margins and the End margins to 0.2. Leave the Additional margin to overcome surface edge inaccuracies set to 0.00118.

NOTE: To leave some stock on the check surfaces we can give as Start /End margins a value bigger than the tool radius. Select the OK button to exit Multiaxis Toolpath - Morph between 2 surfaces.

5.3 Regenerate the toolpath From the Toolpaths Operations Manager, select the Regenerate all selected operations.


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5.4 Backplot the toolpath Select the Backplot selected operations button.

Select the Play



NOTE: The rapid movements are gone and the tool does not gouge into the side surfaces. Select the OK button to exit Backplot.

5.5 Add the roughing passes Set the Number of Roughing passes to 5 and the Spacing to 0.1. Apply depth to Whole toolpath. Sort by set to Passes. Enable Use ramp.

Select the Parameters in the 5AxMSurf operation.

Roughing From the Tree View area, select Roughing.

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Enable Depth Cuts.

Depth Cuts Depth cuts control the roughing strategy for material removal on both rough and finish passes. Apply depth to the whole toolpath applies depth to the whole toolpath and not to the first slice, or the first pass only. Sort by Passes creates cuts offset from the drive surfaces.

From the Tree View area, expand Roughing and select Depth Cuts. Set the Number of Roughing passes to 5 and the Spacing to 0.1 and set the rest of the parameters as shown.

Select the OK button to exit Multiaxis Toolpath - Morph between 2 surfaces.


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button in the VCR bar to run Backplot. Select the Play Press Alt + S to un shade the surfaces if needed. Change the Graphic view to Top. The toolpath should look as shown.

Select the OK button to exit Backplot.

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FINISH THE IMPELLER FLOOR

STEP 6:

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FINISH THE IMPELLER FLOOR Toolpath Preview:

6.1 Copy the toolpath From the Toolpaths Operations Manager, right mouse click on the existing toolpath and select Copy.

Right mouse click again in the Toolpaths Operations Manager and select Paste.


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6.2 Change the parameters in the Morph between 2 surfaces to finish the floor Select the Parameters in the second operation.

Tool From the Tree View area, select Tool. Click on the Select Tool Library button and using the Filter as shown in Step 5, select the 3/8" Ball Endmill.

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Cut Pattern From the Tree View area, select Cut Pattern. Change the Drive surfaces offset to 0 and enable Round corners for a smoother the toolpath as shown.

Collision Control Collision control establishes clearance values and instructs the toolpath how to move the tool to avoid a collision. A single strategy is usually all that is needed, however you have the ability to set four different strategies if necessary. Tilting tool away with max angle avoids the gouge by tilting the tool away from the surface. Use side tilt angle tilts the tool to the side relative to the cutting direction. Positive angles tilt the tool to the right, negative to the left. The limits are min. +/-0.01° and max. +/-180°.

From the Tree View area, select Collision Control.


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Gouge check for the Flute and Shaft; Tilting tool away with max angle; Use side tilt angle; Check surfaces only Stock to leave 0.015.

Tool Clearances The tool clearance acts as a virtual stock amount added to the holder, arbor, and shaft diameter and length.

From the Tree View area, expand Collision Control and select the Tool Clearance. Holder clearance 0.1, Arbor clearance 0.01 and Shaft clearance 0.

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Linking Linking determines how the tool moves when not cutting material. First entry is the first approach of the tool towards the part. You can specify from where the tool should approach (enter) the part and whether there will be a lead-in move when entering the part. Last exit defines how the tool will leave the part and where it will go after the toolpath is complete. Gaps along cut options define the tool behavior if gaps are detected along a toolpath. Links between slice options define the tool movement when stepping between cuts.

Set the First entry/Last exit to use Lead In/Out. Set the Gaps along cuts and Links between slices as shown.

Roughing From the Tree View area, select Roughing. Disable Depth Cuts. Select the OK button to exit Multiaxis Toolpath - Morph between 2 surfaces.



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Select the Play




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IMPELLER BLADE SWARF FINISHING

STEP 7:

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IMPELLER BLADE SWARF FINISHING Impeller blade swarf finishing creates a swarf toolpath to machine the blades with the side of the tool. You should create an operation to finish one blade, and then use Mastercam's Toolpath Transform features to machine the floors between the other blades.

Toolpath Preview:

7.1 Impeller blade semifinish one pass Create the Impeller blade swarf finish toolpath from the Custom Application toolpath family using the following parameters: 3/8" Ball Endmill. Type area set to Determine by number of cuts. Number of cuts 1. Cut tolerance = 0.0001. Maximum stepover = 0.05. Stock remaining = 0.05. Cut method set to One way; Climb. Maximum angle step = 5 degrees. Side tilt definition set to Follow surface iso direction. Margins enable Add internal tool radius. Default Lead-In/Out; Tangential line; Fixed; Length 0.5; Height 0.5.

7.2 Make Level 10 the Main Level and make the rest of the levels invisible From the Status Bar select Level.


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Make the changes in the Level Manager as shown.

Select the OK button to exit Levels Manager. Toolpaths Multiaxis

Toolpath Type Select the Custom App button. Select the Impeller Blade Swarf Finishing.

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Tool From the Tree View area, select Tool. Select the existing 3/8" Ball Endmill and add a comment to identify the operation in the Toolpath Manager.

Impeller Blade Swarf Finishing Impeller Blade Swarf Finishing settings determine the geometry the tool follows and how it travels along that geometry. Area type lets you define the area on the drive surface to be machined. You can choose between "full" which machines the entire drive surfaces, determine by number of cuts or limit the cuts between points. Sorting allows you to set the cutting method and the direction of the cut. Cut tolerance is the tolerance for the accuracy of the toolpath. This value is the chordal deviation of the toolpath against the surfaces to be machined. To generate more points along the cut for better accuracy you can set the maximum stepover. Maximum angle step sets the maximum allowed angle change between two consecutive toolpath positions. Follow surface iso side tilt definition is a good option if linear surfaces are present. If any surface does not have a compatible U and V direction with the neighboring surfaces, then this function attempts to automatically correct these areas.

From the Tree View area, select Impeller Blade Swarf Finishing. Area type set to Determine by number of cuts. Number of cuts = 1.


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Select the Floor surfaces button and as shown previously, use the QM color and select the color green 10.

Select Blade drive surface button and select the color red 12.

Set the rest of the parameters as shown.

Margins From the Tree View area, expand Impeller Blade Swarf Finishing and select Margins. Leave the Additional margin to overcome surface edge inaccuracies set to 0.00118.

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Enable Add internal tool radius.

Default Lead-in /out From the Tree View area, select the Default Lead-in/out. Set the Type to Tangential line and set the values as shown.

Clearance area Leave the default values. Select the OK button to exit Multiaxis Toolpath - Impeller Blade Swarf Finishing.


Select the Play




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SWITCH TO ADVANCED INTERFACE - PARALLEL TO SURFACE TOOLPATH

NOTE: To add multipasses in this toolpath you have to switch to the Advanced interface.


STEP 8:

SWITCH TO ADVANCED INTERFACE - PARALLEL TO SURFACE TOOLPATH Parallel to surface toolpath generates cuts on the drive surface parallel to a check surface. There are special options for the edge between the check surface and the drive surface. You can define a margin to define the exact position where the tool is located on the edge, positioned as close as possible to both faces.

Toolpath Preview:

8.1 Semifinish the blade using Parallel to surface toolpath Select the Parameters from the third 5AxMSurf operation. From the Tree View area, select Misc and click on the Switch to advanced interface button.

NOTE: Mastercam switches automatically to the Parallel to surfaces toolpath.

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Roughing From the Tree View area, select Roughing and enable Multi passes.

Multi Passes Multi passes determine the number and spacing of cuts made by offsetting the cut pattern as if it were on the final part. Passes creates cuts offset from the drive surfaces.

From the Tree View area, expand Roughing and select Multi Passes Change the Number to 3 and the Spacing to 0.1 and change the Sorting to Passes.

Select the OK button to exit Multiaxis Toolpath - Parallel to surfaces.



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Select the Play




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FINISH THE BLADE SURFACES - PARALLEL TO MULTIPLE CURVES

STEP 9:

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FINISH THE BLADE SURFACES - PARALLEL TO MULTIPLE CURVES The Parallel to multiple curves toolpath pattern will align the cut direction with a leading curve. Adjacent cuts are parallel to each other. It is important to note that the cuts will not simply be copied next to each other. Every new cut is created at an offset from the previous cut. The curve must be located exactly on the surface edge, so the best curve would be the edge itself. This is very important for toolpath generation. If you don't have a proper curve, an incorrect toolpath can be generated.

Toolpath Preview:

9.1 Finish the blade using Parallel to multiple curves Create the Parallel to multiple curves toolpath from the Wireframe toolpath family to finish the blade using the following parameters: 3/16" Ball Endmill. Drive surface offset = 0. Area Type set to Full, start and end at exact surface edges. Enable Round corners. Cut control set to One way; Climb. Enforce cutting direction. Cut tolerance = 0.0005. Maximum stepover = 0.05. Margins; Start margins = 0.0975. Output format 5-Axis. Tool axis = Be tilted relative to cutting direction. Maximum angle step = 3. Tilt angle at side of cutting direction = 80. Side tilt definition set to Ortho to cut dir at each pos. Default Lead-In/Out; Tangential line; Fixed; Length 0.5; Height 0.5.


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Toolpaths Multiaxis

Toolpath type Select Wireframe button and click on Parallel to multiple curves.

Tool From the Tree View area, select Tool. Click on the Select library tool button and using the Filter options as shown previously, select the 3/16" Ball Endmill. Add a comment to identify the operation in the Toolpath Manager.

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Cut Pattern Cut pattern settings determine the geometry your tool follows and how it travels along that geometry. Area type set to Full, start and end at exact surface edges generates the toolpath on the whole surface and will extend exactly to the surface edge or to the nearest possible position.

From the Tree View area, select Cut Pattern. Click on the Edge curves button. [Add Chain 1]: Press Alt + S to un shade the surfaces and select the dark blue color curve as shown.

Select the OK button to exit Chaining dialog box. Click on the Drive surfaces button and using QM Color icon select the red color no. 12.

Select the OK button the exit Select All dialog box. Press Enter to finish the selection. Select the Done button to exit Drive srfs Selection dialog box. Set the Area type set to Full, start and end at exact surface edge to be able to add margins.


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Make sure that the rest of the parameters are set as shown.

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Margins Margins create additional space so the toolpath is not starting directly on the surface edge. Start margins allows you to enter a positive distance to offset the first pass from the surface edge. The offset places the tool inside the surface boundary.

From the Tree View area, expand Cut Pattern and select Margins. Set the Start margins to 0.09493 and leave the Additional margin to overcome surface edge inaccuracies set to 0.00118.

NOTE: The sum of the two values is the radius of the tool.

Tool Axis Control Tool axis control settings determine the tool's orientation in relation to the geometry being cut. Output format set to 5-Axis allows for tool rotation in two planes. Maximum step angle sets the maximum allowed angle change between two consecutive toolpath positions. Be tilted relative to cutting direction allows you to assign a lead/lag angle to the cutting direction and a tilt angle at the side of the cutting direction. Ortho to cut dir at each pos side tilt direction is determined by an orthogonal (perpendicular) line from the current surface contact point to the lower edge curve. That means that the tool axis is always orthogonal to the toolpath.

From the Tree View area, select Tool Axis Control. Set the Tool axis will. to Be tilted relative to cutting direction. Tilt angle at side of cutting direction = 80 degrees. Side tilt definition set to Ortho to cut dir at each pos.


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Set the rest of the parameters as shown.

Linking From the Tree View area, select Linking. First entry set to Approach from clearance area and to Use Lead-In/Out. Last entry set to Retract to clearance area and to Use Lead-In/Out. Set the Small gaps and Small moves to Follow surfaces. Set the Large gaps and Large moves to Retract to clearance area and Don’t use Lead-In/Out. Set the Small gap size to 20% of tool diameter and the Small move size to 400% of stepover.

Select the OK button to exit Multiaxis Toolpath - Parallel to multiple curves.

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MACHINE SIMULATION

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9.2 Backplot the last toolpath Select the Backplot selected operations button.

Select the Play




STEP 10:

MACHINE SIMULATION Machine simulation is an advanced verification module capable of backplotting, verifying stock removal, and full machine tool simulation with collisions check. The machine simulation dialog box allows you to select the machine to be simulated, the work piece that will be shown in the machine simulation, the stock, the fixtures and the tolerances.

From the Toolpaths Operations Manager, click on the Select all operations icon.

10.1 Make Level 22 the Main Level and make Level 10 invisible From the Status Bar, select Levels.


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MACHINE SIMULATION

Change the Level Manger as shown.

10.2 Set the Machine Simulation From the Machine Simulation toolbar, select the Simulation startup settings icon. Select as Machine the 5_5AXGEN_VMCTTAB. As Workpiece Geometry select All elements. Leave Position set to Automatic for the part to be located based on the origin setup in Mastercam. Change the Stock to Load STL file and click on the button next to it as shown. Figure: 10.2.1

Find the location where you saved the STL file at the beginning of this tutorial. Select the TUTORIAL 5 IMPELLER WITHOUT TILT CURVE.STL. Select the Open button.

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MACHINE SIMULATION

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From the Machine Simulation select the Simulate button.

10.3 Simulate the toolpath in tool path mode (backplotting) Select as simulation mode, the Toolpath mode icon. Enable Machine Focus. The machine with the part should automatically be loaded.

From the Visibility toolbar, enable the Toolpath, Tool, Workpiece, Stock and Machine Housing icons to see them displayed while running the simulation. From the Toolpath Rendering toolbar make sure that the Tool Tip, Display Current Operation, Follow, Leads and Links icons are selected as shown. Locate the mouse close to the center of the part and scroll down the mouse wheel to zoom in. Select the Run button in the Control bar to simulate the toolpath.

The simulation should look as shown.


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MACHINE SIMULATION

NOTE: The last operation has collisions reported in the Report List between the stock and the holder.

Click on the collision in the Report list to visualize the toolpath at that location.

Move the cursor to the center of the part. Click and hold down the left mouse and slightly move the cursor upwards and to the left until you see the part as shown.

NOTE: The collision is between the tool holder and the part. Changing the Limits angle should take care of the problem.

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MACHINE SIMULATION

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To exit Machine Simulation select the Exit icon.

10.4 Modify the Limits in the fourth toolpath From the Toolpaths Operations Manager, select the Parameters of the fourth 5-Axis operation.

From the Tree View area, select Tool Axis Control and enable the Limits. From the Tree View area, expand Tool Axis Control and select Limits and change both w1 and w2 to 45 as shown.


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MACHINE SIMULATION

Select the OK button to exit Multiaxis Toolpath - Parallel to multiple curves. Select Regenerate all dirty operations button to regenerate the last 5-Axis toolpaths.

10.5 Run through the machine simulation the last 5-Axis toolpaths In the Toolpaths Operations Manager, select all toolpaths. From the Machine Simulation toolbar, select the Simulation startup settings icon. Click on the Simulate button.

NOTE: The settings in the Machine Simulation are maintained from last session. Select the Run button in the Control bar to simulate the toolpath.

The part should look as shown.

NOTE: No more collisions are reported in the Report list. To exit Machine Simulation select the Exit icon.

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TRANSFORM - ROTATE

STEP 11:

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TRANSFORM - ROTATE Transform toolpaths are used when you want to run the same toolpaths in different locations or at different orientations in the same part file. You can transform single toolpaths, or several at a time.

Toolpath Preview:

11.1 Transform rotate the first operation (Roughing toolpath) Toolpaths Transform

Types and Methods Make sure that just the first operation is selected. Enable Rotate and set the Method to Coordinate (5 - Axis toolpaths support only Coordinate method). To machine all the areas in the Transform toolpath enable Copy source operations and Disable posting in selected source operations.

NOTE: This options allows you to post process only the transform operations and not the original operation. The original operation is included in the Transform toolpath.


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TRANSFORM - ROTATE

Work offset numbering set to Off.

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TRANSFORM - ROTATE

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Rotate Select the Rotate tab. Enable Origin as the Rotate point, and change the Instances number # to 11. Enable Angle between and set the Start angle to 30 and Rotation angle to 30. Rotation view is set to the source operation view as shown.

Select the OK button to exit the Transform toolpath.

11.2 Backplot the transform toolpath Select the Backplot selected operations button.

Select the Play



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TRANSFORM - ROTATE



11.3 Transform rotate the second and third operation (Finish floor and the Semifinish the blade) Toolpath Preview:

Toolpaths Transform

Types and Methods Hold down the Ctrl key and select the second and the third operation.

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TRANSFORM - ROTATE

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The rest of the parameters are maintained from the previous toolpath as shown.

Rotate The parameters are maintained from the previous toolpath as shown.



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TRANSFORM - ROTATE

11.4 Backplot the last transform toolpath Select the Backplot selected operations button.

Select the Play



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TRANSFORM - ROTATE

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11.5 Transform rotate the last operation (Finish the blade) Toolpath Preview:

Toolpaths Transform

Types and Methods Select the last operation only. The rest of the parameters are maintained from the previous toolpath as shown.


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TRANSFORM - ROTATE

Rotate The parameters are maintained from the previous toolpath as shown.


11.6 Backplot the last transform toolpath Select the Backplot selected operations button.

Select the Play

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VERIFY THE TOOLPATH

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STEP 12:

VERIFY THE TOOLPATH Verify simulates the machining of a part from a solid stock model display. The stock is based on the Stock setup.

Hold down the Ctrl key and from the Toolpaths Operations Manager, select all the transform toolpaths. Select the Verify selected operations button.

Enable Simulate tool button to run the verification.

NOTE: Turbo mode is not supported by the 5 - Axis toolpaths. Select the Options button.

From the Stock Shape enable File and click on the browser icon to search for the TUTORIAL 5 IMPELLER WITHOUT TILT CURVE.STL.


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POST THE FILE TO GENERATE THE NC CODE

Select the file and click on the Open button. Select the OK button to exit Verify Options dialog box. Select the Machine button to start simulation.

NOTE: The verification might take 10 minutes or more to complete. The part should look as shown.

Select the OK button to exit Verify.

STEP 13:

POST THE FILE TO GENERATE THE NC CODE Make sure that only the transform toolpaths are selected. Select Post selected operations button from Toolpath Operations Manager.

NOTE: The active Post Processor is a generic fanuc post processor. Please check the information about the post processor at page 1-3.

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SAVE THE UPDATED MCX-5 FILE

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In the Post processing window, if needed, make any necessary changes as shown below.

Select the OK button to continue. We are post processing just the last 3 toolpath, please select No to post all operations warning. Enter the same name as the file name in the NC File name field. Select the OK button to save the NC file. The NC file will appear on the screen as shown in Figure: 13.0.1. Figure: 13.0.1

NOTE: The G code that you have created will appear on the screen, if the code looks okay you can shut the window down without saving it. If you need to change the code, make sure you save it before you close the window down. How the program is sent to the machine depends on the shop setup. Select the red X box at the upper right corner to exit the Editor.

STEP 14:

SAVE THE UPDATED MCX-5 FILE Select the Save icon.


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SAVE THE UPDATED MCX-5 FILE


Sample - Mastercam X5 Advanced Multiaxis Training Tutorial

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