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Mill Level 1 Metric Training Tutorial Mastercam X6 Mill Level 1 Training Tutorial MetricCopyright: 1998 - 2012 In-House Solutions Inc. All rights reservedSoftware: Mastercam X6Author: Mariana LendelISBN: 978-1-926955-27-8Revision Date: February 27, 2012NoticeIn-House Solutions Inc. reserves the right to make improvements to this manual at any time and without notice. Disclaimer Of All Warranties And LiabilityIn-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.CopyrightsThis 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.TrademarksMastercam 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, Windows NT and Windows 7 are registered trademarks of Microsoft Corporation.Mill Level 1 Training TutorialGetting Started ...........................................................................................................1Tutorial #1 - Open Contour and Drill Toolpaths ....................................................................................15Tutorial #2 - Facing, Pocket, Contour, Drilling and Contour-Chamfer Toolpaths.................................61Tutorial #3 - Open Pocket, Contour Remachining, Circle Mill, Drill and Contour Toolpaths ..............137Tutorial #4 - 2D HS Core Mill, 2D HS Dynamic Core Mill, Pocket Island Facing and PocketRemachining Toolpaths .......................................................................................................................231Tutorial #5 - 2D HS Dynamic Area Mill, Drill, Circle Mill and Contour Chamfer Toolpaths ................ 311Tutorial #6 - Working with Tool Planes, 2D HS Area Mill, 2D HS Rest Mill, Drill and Slot Mill Toolpaths ............................................................................................................... 417Tutorial #7 - 2D HS Dynamic Core Mill, 2D HS Core Mill, 2D HS Blend, 2D HS Peel Toolpaths ...........567Tutorial #8 - Feature Based Drilling (FBD) Toolpath........................................................................... 635Tutorial #9 - Feature Based Milling Toolpath..................................................................................... 687Mill Level 1 Training Metric Tutorial ContentsMill Level 1 Training TutorialTutorial #10 - 2D HS Dynamic Area Mill, 2D HS Dynamic Rest Mill, 2D HS Dynamic Core Mill, 2D HS Dynamic Contour and Machine Simulation........................................................................................ 751General Notes.........................................................................................................821Creating/Editing Tools ............................................................................................879Quiz Answers........................................................................................................... 887Mill Level 1 Training Tutorial Page|61 TUTORIAL #2Page |62 Mill Level 1 Training TutorialTUTORIAL #22OVERVIEW 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 the tutorial.From the drawing we can decide how to go about creating the geometry in Mastercam.Create the 2D CAD Model used to generate Toolpaths from:The student will only create the Top 2D geometry needed to create the toolpaths.Geometry creation commands such as create rectangle, line parallel, mirror and circle center point will be used.Create the necessary Toolpaths to machine the part:The student will set up the stock size to be used and the clamping method used. An Open Contour toolpath will be created to remove the material on the both steps.A Drilling toolpath will be created to machine the through holes.Backplot and Verify the file:The Backplot will be used to simulate a step by step process of the tools 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 one hour and half to complete.Mill Level 1 Training Tutorial Page|63OVERVIEW OF STEPS TAKEN TO CREATE THE FINAL PART:TUTORIAL #22Page |64 Mill Level 1 Training TutorialTUTORIAL #22SETTING UP THE GRAPHIC USER INTERFACEGEOMETRY CREATION STEP 1: SETTING UP THE GRAPHIC USER INTERFACE Please refer to the Getting Started section to set up the graphics user interface. STEP 2: CREATE RECTANGLEIn this step you will learn how to create a rectangle knowing the width, the height and the anchor position.Step Preview:2.1 Create a rectangle 100.0mm x 75.0mmCreate Rectangle. Enter the Width and Height as shown. Press Enter after typing the values to see a preview of the rectangle.Mill Level 1 Training Tutorial Page|65CREATE RECTANGLETUTORIAL #22 [Select position for first corner]: Select the Origin as shown inFigure: 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 button to exit the Rectangle command. Use the Fit icon to fit the drawing to the screen. NOTE:During the geometry creation of 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. To delete unwanted geometry, select it first and then press Delete from the keyboard.Page |66 Mill Level 1 Training TutorialTUTORIAL #22CREATE THE PARALLEL LINESSTEP 3: CREATE THE PARALLEL LINESIn this step you will learn how to create a parallel line knowing the distance.Step Preview:Create Line.Parallel. [Select a line]: Select Entity A as shown inFigure: 3.0.1. Figure: 3.0.1Mill Level 1 Training Tutorial Page|67CREATE THE PARALLEL LINESTUTORIAL #22 [Select the point to place a parallel line through]: Pick a point below the selected line. Enter the Distance 19.0mm (press Enter). [Select a line]: Select Entity B as shown inFigure: 3.0.2. Figure: 3.0.2 [Select the point to place a parallel line through]: Pick a point below the selected line. Enter the Distance 38.0mm (press Enter). [Select a line]: Select Entity C as shown inFigure: 3.0.3. Figure: 3.0.3NOTE:The color of the geometry is cyan which means that the entity is "live" and you can still change the line parameters if needed.Page |68 Mill Level 1 Training TutorialTUTORIAL #22CREATE THE PARALLEL LINES [Select the point to place a parallel line through]: Pick a point to the right of the selected line. Enter the Distance 19.0mm (press Enter). [Select a line]: Select Entity D as shown inFigure: 3.0.4. Figure: 3.0.4 [Select the point to place a parallel line through]: Pick a point to the right of the selected line. Enter the Distance 63.0mm (press Enter). Select the OK button to exit the command. NOTE:To continue using the same command you can either select the Apply button or press Enter. To exit the command you can either start a new command or select the OK button. Mill Level 1 Training Tutorial Page|69CREATE FILLETSTUTORIAL #22 The part will appear as shown.STEP 4:CREATE FILLETSIn this step you will create the 4 fillets to create the pocket.Step Preview:Create Fillet.Entities. Enter the Radius 10.0 in the Ribbon bar and ensure Trim is enabled.Page |70 Mill Level 1 Training TutorialTUTORIAL #22CREATE FILLETS Select the two lines to create a fillet as shown in Figure: 4.0.1. Figure: 4.0.1 Repeat this step 3 more times for the other corners. Select the OK button to exit the command. The part will appear as shown once complete.Mill Level 1 Training Tutorial Page|71CREATE THE HOLESTUTORIAL #22STEP 5: CREATE THE HOLESIn this step you will create the holes knowing the size and location. Step Preview:Create Arc.Circle Center Point. Enter the Diameter 12.0 in the Ribbon bar. Select the circle icon as outlined above in the ribbon bar to lock the size of the arc. Select the Fast point icon. [Enter the co-ordinate]: 50,-10 and hit Enter. Select the Fast point icon. [Enter the co-ordinate]: 10,-38 and hit Enter. Select the Fast point icon. [Enter the co-ordinate]: 50,-66 and hit Enter. Select the Fast point icon. [Enter the co-ordinate]: 91,-38 and hit Enter. Select the circle icon once more to unlock the diameter value. Once complete choose the OK button to exit the command. Page |72 Mill Level 1 Training TutorialTUTORIAL #22CREATE CHAMFERSSTEP 6: CREATE CHAMFERSIn this step you will create 4 chamfers on the corners knowing 1 distance.Step Preview:Create Chamfer.Entities. Input the Distance 12.0 in the Chamfer Ribbon bar as shown. Select the two lines as shown inFigure: 6.0.1 to create the chamfer. Figure: 6.0.1Mill Level 1 Training Tutorial Page|73SAVE THE FILETUTORIAL #22 Repeat this step 3 more times for the other corners. The part will appear as shown once complete. Once complete choose the OK button to exit the command. STEP 7: SAVE THE FILEFileSave As. File name: "Your Name_2".Page |74 Mill Level 1 Training TutorialTUTORIAL #22SUGGESTED FIXTURE:SUGGESTED FIXTURE:Mill Level 1 Training Tutorial Page|75SETUP SHEET:TUTORIAL #22SETUP SHEET:Page |76 Mill Level 1 Training TutorialTUTORIAL #22SELECT THE MACHINE AND SET UP THE STOCK STEP 8: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 machines capabilities and features. It acts like a template for setting up your machine. The machine definition ties together three main components. The schematic model of your machines components. The control definition that models your control capabilities and the post processor that will generate the required machine code (G-code). For a Mill Level 1 exercise (2D toolpaths) we need just a basic machine definition. To display the Operations Manager press Alt + O. Use the Fit icon to fit the drawing to the screen. Machine type Mill. Default. 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. NOTE:For the purpose of this tutorial, we will be using the Default mill machine.Mill Level 1 Training Tutorial Page|77SELECT THE MACHINE AND SET UP THE STOCK TUTORIAL #22 Change the parameters to matchFigure: 8.0.1. Figure: 8.0.1Program # is used to enter a number if your machine tool 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 From tool uses feed rate, plunge rate, retract rate and spindle speed from the tool definition.Page |78 Mill Level 1 Training TutorialTUTORIAL #22SELECT THE MACHINE AND SET UP THE STOCK Select the Stock setup tab to define the stock. Select the Bounding Box button as shown inFigure: 8.0.2. Figure: 8.0.2 In the Expand dialog boxes enter 3.0 as shown. This will add 3.0mm of stock on each side of your model as shown inFigure: 8.0.3. Figure: 8.0.3 Select the OK button to exit the Bounding Box dialog box. Mill Level 1 Training Tutorial Page|79SELECT THE MACHINE AND SET UP THE STOCK TUTORIAL #22 Input the overall depth of your stock model as shown and set the Stock Origin Z value to 3.0 as shown in Figure: 8.0.4. Figure: 8.0.4 Select the OK button to exit Machine Group Properties. Select the Isometric view from the graphics view toolbar to see the stock. Use the Fit icon to fit the drawing to the screen. NOTE:The stock model that you create can be displayed with the part geometry when viewing the file or the toolpaths, during backplot, or while verifying toolpaths. In the graphics, the plus shows you where the stock origin is. The default position is the middle of the stock. Click on the corner of the part to set it as the stock origin.The Stock Origin values adjust the positioning of the stock, ensuring that you have 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).Page |80 Mill Level 1 Training TutorialTUTORIAL #22FACE THE PART The stock model will appear as shown. Select the Top view from the view toolbar to see the part from the top. STEP 9: FACE THE PARTFacing toolpaths quickly removes material from the top of the part to create an even surface for future operations.Toolpath Preview:ToolpathsFace.NOTE:The stock is not geometry and can not be selected.Mill Level 1 Training Tutorial Page|81FACE THE PARTTUTORIAL #22 If a prompt appears, Enter new NC name, select the OK button to accept the default. When the chaining dialog box appears choose the OK button to exit the chaining dialog box. NOTE:Mastercam will create the Facing toolpath defined from the stock setup.Page |82 Mill Level 1 Training TutorialTUTORIAL #22FACE THE PART In the Toolpath Type page, the Facing icon will be selected.9.1 Select a 50.0mm Face Mill from the library and set the Tool parameters Select Tool from the Tree view list. Click on the Select library tool button. Pick the 50.0mm Face Mill (#270) as shown inFigure: 9.1.1. Figure: 9.1.1 Select the tool in the Tool Selection page and then select the OK button to exit. NOTE: Mastercam updates the pages as you modify them and then marks them, in the Tree view list, with a green check mark. Pages that are not changed are marked with a red circle and slash.Mill Level 1 Training Tutorial Page|83FACE THE PARTTUTORIAL #22 Make all the necessary changes as shown inFigure: 9.1.2. Figure: 9.1.2The Feed rate, Plunge rate, Retract rate and Spindle speed are roughly based on the part material Aluminum and HSS tooling. You may change these values as per your part material and tools. In the Comment field enter a comment to help identify the toolpath in the Toolpaths/Operations Manager such as the one shown above.Page |84 Mill Level 1 Training TutorialTUTORIAL #22FACE THE PART Select Cut Parameters and make the necessary changes as shown inFigure: 9.1.3. Figure: 9.1.3The Style (facing cutting method) Zigzag creates a back and forth cutting motion.Move Between Cuts determines how the tool moves between each cut. This is only available if you select the zigzag cutting method.High Speed Loops to create 180 degrees arcs between each cut.Mill Level 1 Training Tutorial Page|85FACE THE PARTTUTORIAL #22 Select Linking Parameters and make the necessary changes as shown inFigure: 9.1.4. Figure: 9.1.4 Select the OK button to exit the Facing Parameters. NOTE: The top of stock is set to 3.0 because in our Stock Origin we have this set 3.0mm above the origin. The depth is set to 0.0 because this is the depth we want the tool to go to.Clearance sets the height at which the tool moves to and from the part.Retract sets the height that the tool moves up to before the next tool pass.Feed Plane sets the height that the tool rapids to before changing to the plunge rate to enter the part.Top Of Stock sets the height of the material in the Z-Axis.Depth determines the final machining depth that the tool descends into the stock.Page |86 Mill Level 1 Training TutorialTUTORIAL #22MACHINE THE POCKETSTEP 10: MACHINE THE POCKETPocket toolpaths remove the material from an enclosed boundary.Toolpath Preview: 10.1 Chain selectionA chain of entities consists of one or more entities linked together in order and direction. The distance between the endpoints of two consecutive entities of the chain has to be equal or less than the chaining tolerance (0.002mm). In an open chain, the start point is placed at the end of the chain closest to the selection point and the chain direction points to the opposite end of the chain. See the User Notes chapter for more information on chaining. Press Alt +T to remove the toolpath display.ToolpathsPocket.Mill Level 1 Training Tutorial Page|87MACHINE THE POCKETTUTORIAL #22 Enable the Chain button in the Chaining dialog box to be able to select just the pocket. Select the chain, as shown inFigure: 10.1.1. Figure: 10.1.1 Select the OK button to exit Chaining. Page |88 Mill Level 1 Training TutorialTUTORIAL #22MACHINE THE POCKET In the Toolpath Type page, the Pocket icon will be selected.10.2 Select a 12.0mm Flat endmill from the library and set the Tool parameters Select Tool from the Tree view list. Click on Select library tool button. To be able to see all the tools from the library disable Filter Active. Scroll down and select the 12.0mm Flat Endmill (#221) as shown inFigure: 10.2.1. Figure: 10.2.1 Select the tool in the Tool Selection page and then select the OK button to exit. NOTE:The direction of the chain determines the cutter compensation side (Left or Right) to orient the tool on the proper side of the geometry. For our example be sure to chain the contour in a CCW direction. Otherwise, select the Reverse button. NOTE: Mastercam updates the pages as you modify them and then marks them, in the Tree view list, with a green check mark. Pages that are not changed are marked with a red circle and slash.Mill Level 1 Training Tutorial Page|89MACHINE THE POCKETTUTORIAL #22 Make all the necessary changes as shown inFigure: 10.2.2. Figure: 10.2.2Page |90 Mill Level 1 Training TutorialTUTORIAL #22MACHINE THE POCKET10.3 Cut Parameters From the Tree view list, select Cut Parameters and ensure the settings appear similar as shown inFigure: 10.3.1. Figure: 10.3.1Machining direction sets the machining direction for the toolpath.Climb cuts with the tool rotating in the opposite direction of the tool motion.Conventional cuts with the tool rotating in the same direction as the tool motion.Pocket Type defines the type of pocket toolpath Mastercam creates.Mill Level 1 Training Tutorial Page|91MACHINE THE POCKETTUTORIAL #2210.4 Roughing From the Tree view list, select Roughing Parameters. Choose the option Parallel Spiral, Clean Corners and change the necessary settings as shown inFigure: 10.4.1. Figure: 10.4.1Parallel Spiral, Clean corners roughs out the pocket in a similar method to parallel spiral but adds small clean out moves in the corners of the pocket to remove more stock.Spiral Inside To Outside applies to all spiral pocket toolpaths. The toolpaths spiral from the center to the wall of the pocket.Page |92 Mill Level 1 Training TutorialTUTORIAL #22MACHINE THE POCKET10.5 Entry Motion Set the Entry Motion of the Roughing portion of the toolpath to Helix. Make any necessary changes as shown inFigure: 10.5.1. Figure: 10.5.1Helix for pocket roughing will always try to use the maximum radius to use more of the side of the endmill and less plunging. The direction of the helix usually matches the toolpath direction.Mill Level 1 Training Tutorial Page|93MACHINE THE POCKETTUTORIAL #2210.6 Finish From the Tree view list, select Finishing. Once there ensure Finish is enabled. This will add a finish pass after roughing the pocket. Enable Finish outer boundary, Start finish pass at closest entity, Keep tool down and Machine Finish passes only at final depth. For an explanation of these parameters seeFigure: 10.6.1. Figure: 10.6.1Finish, select this option to create a finish pass and to enable the finishing parameters. If this option is unselected only a roughing operation will be created.Finish Outer Boundary makes a finish pass on the pocket wall. Start Finish Pass At Closest Entity finishes the pocket starting with the closest endpoint of the closest entity at the end of the roughing toolpath.Keep Tool Down determines whether or not to retract between finish passes.Machine Finish passes only at final depth performs the finish passes at the final cutting depth only. Page |94 Mill Level 1 Training TutorialTUTORIAL #22MACHINE THE POCKET10.7 Lead In/Out From the Tree view list select Lead In/Out and ensure this option is enabled. Enter an Overlap value, Length, Radius and Sweep angle. The Lead In/Out parameters will only be applied to the finish parametersFigure: 10.7.1. Figure: 10.7.1Lead In/Out moves are a combination of lines and arcs at the beginning and end of a pocket toolpath finish pass. Overlap sets how far the tool goes past the end of the toolpath before exiting for a cleaner finish.Line Length sets the line length for entry or exit lines.Arc Radius defines the entry or exit arcs radius. This arc is always tangent to the toolpath.Sweep sets the sweep angle of the entry or exit arc.Mill Level 1 Training Tutorial Page|95MACHINE THE POCKETTUTORIAL #2210.8 Depth Cuts Choose Depth Cuts from the Tree view list. Input a Max rough step of 6.0 and enable Keep tool down. The depth cuts will only be applied to the roughing portion of the toolpath. Figure: 10.8.1Depth Cuts Mastercam will take the total depth and divide it into separate depth cuts. Mastercam never performs unequal depth cuts. Max Rough Step sets the maximum amount of material removed in the Z axis with each rough cut. Mastercam will calculate equal rough cuts no larger than the maximum rough step until it reaches the final Z depth. Keep Tool Down determines whether or not to retract the tool between depth cuts. Page |96 Mill Level 1 Training TutorialTUTORIAL #22MACHINE THE POCKET10.9 Linking Parameters Select Linking Parameters from the Tree view list. Change the Top of stock to zero and set the depth to -25.0. Ensure all the values are set to Absolute as shown inFigure: 10.9.1. Figure: 10.9.1 Select the OK button to exit 2D Toolpaths - Pocket. Absolute values are always measured from the origin 0,0,0. Incremental values are relative to other parameters or chained geometry.Mill Level 1 Training Tutorial Page|97BACKPLOT THE TOOLPATHSTUTORIAL #22STEP 11: BACKPLOT THE TOOLPATHSBackplotting 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 toolpaths are selected (signified by the green check mark on the folder icon). If both operations are not selected choose the Select all operations icon. Select the Backplot selected operations button. Make sure that you have the following buttons turned on (they will appear pushed down) to see the tool and the rapid moves. Select the Isometric view from the view toolbar to see the stock. Select the Fit button. You can adjust the speed of the backplot. You can step through the Backplot by using the Step forward or Step back buttons. Select the Play button in the VCR bar.Page |98 Mill Level 1 Training TutorialTUTORIAL #22VERIFY THE TOOLPATH The toolpath should look as shown. Select the OK button to exit Backplot. STEP 12: VERIFY THE TOOLPATHVerify allows you to use a solid model to simulate the machining of a part. The model created by verification represents the surface finish, and shows collisions, if any exist. In the Operations Manager both operations are selected. If both operations are not selected choose the Select all operations icon. Choose the Verify selected operations icon from the Operations manager. Set the Verify speed by moving the slider bar in the speed control bar as shown in Figure: 12.0.1. Figure: 12.0.1Mill Level 1 Training Tutorial Page|99VERIFY THE TOOLPATHTUTORIAL #22 Select the Play button to start simulation. The part will appear as shown. Select the OK button to exit Verify. Page |100 Mill Level 1 Training TutorialTUTORIAL #22CONTOUR TOOLPATHSTEP 13: CONTOUR TOOLPATHContour toolpath removes material along a path defined by a chain of curves. A Contour toolpath only follows a chain, it does not clean out an enclosed area.Toolpath Preview:ToolpathsContour. Leave the default settings in the Chaining dialog box.Mill Level 1 Training Tutorial Page|101CONTOUR TOOLPATHTUTORIAL #22 Change the Graphic view to Top. Select the chain and ensure the chaining direction is the same as shown inFigure: 13.0.1. Figure: 13.0.1 Select the OK button to exit the Chaining dialog box. In the Toolpath Type page, the Contour toolpath will be selected.13.1 Select a 16.0mm Flat Endmill from the library and set the Tool parameters Select Tool from the Tree view list. Click on Select library tool button. To be able to see all the tools from the library disable Filter Active.Page |102 Mill Level 1 Training TutorialTUTORIAL #22CONTOUR TOOLPATH Scroll down and select the 16.0mm Flat Endmill (# 225) as shown inFigure: 13.1.1. Figure: 13.1.1 Select the tool in the Tool Selection page and then select the OK button to exit. Make all the necessary changes as shown inFigure: 13.1.2. Figure: 13.1.2Mill Level 1 Training Tutorial Page|103CONTOUR TOOLPATHTUTORIAL #2213.2 Cut Parameters Select the Cut Parameters and make the necessary changes as shown inFigure: 13.2.1. Figure: 13.2.1Roll cutter around corners inserts arc moves around corners in the toolpath.None guarantees all sharp corners.Sharp rolls the tool around sharp corners (135 degrees or less).All rolls the tool around all corners and creates smooth tool movement.Page |104 Mill Level 1 Training TutorialTUTORIAL #22CONTOUR TOOLPATH13.3 Depth Cuts Select Depth cuts and enable it. Input a Max rough step of 10.0 and enable Keep tool down as shown in Figure: 13.3.1. Figure: 13.3.1Mill Level 1 Training Tutorial Page|105CONTOUR TOOLPATHTUTORIAL #2213.4 Lead In/Out Choose the option Lead In/Out and input an Overlap value. Make any other necessary changes as shown in Figure: 13.4.1. Figure: 13.4.1Page |106 Mill Level 1 Training TutorialTUTORIAL #22CONTOUR TOOLPATH13.5 Multi Passes Select Multi Passes from the Tree view list and enable the option. Set the Number of Rough passes to 1 with Spacing of 3 and Number of Finish passes to 1 with Spacing of 1. This will have the system make a rough pass and then proceed with a 1.0mm finish pass. Enable the option to Machine finish passes at the Final depth as shown inFigure: 13.5.1. Figure: 13.5.1Mill Level 1 Training Tutorial Page|107CONTOUR TOOLPATHTUTORIAL #2213.6 Linking Parameters Select Linking Parameters from the Tree view list. Set the Top of stock to zero and the Depth to -31.0 as shown inFigure: 13.6.1. Figure: 13.6.1 Select the OK button to exit2D Toolpaths - Contour. Page |108 Mill Level 1 Training TutorialTUTORIAL #22CONTOUR TOOLPATH To Backplot and Verify the toolpaths page 97 and page 98 to review these procedures.Mill Level 1 Training Tutorial Page|109SPOT DRILL THE HOLESTUTORIAL #22STEP 14: SPOT DRILL THE HOLESSpot Drilling the holes allows you to start the hole. In this operation we will use the spot drill to chamfer the hole before drilling it. Toolpath Preview:ToolpathsDrill. In the Drill Point Selection dialog box choose the option Mask on Arc. Select one of the four arcs. Left click in the upper left corner of the graphics window, holding the left button down drag a rectangle to the lower right corner of the part. Page |110 Mill Level 1 Training TutorialTUTORIAL #22SPOT DRILL THE HOLES Release the left mouse button and click it again once you have created a window encompassing the entire part as shown inFigure: 14.0.1. Figure: 14.0.1 Hit Enter once complete. Select the OK button in the Drill Point Selection dialog box to accept the 4 drill points. In the Toolpath Type page, the Drill toolpath will be selected.14.1 Select a 20.0mm Spot Drill from the library and set the Tool parameters Select Tool from the Tree view list. Click on the Select library tool button. To be able to see just the spot drill, select the Filter button.NOTE: Mask on Arc is a tool for selecting arcs whose diameters match the one that you select within the specified tolerance.Mill Level 1 Training Tutorial Page|111SPOT DRILL THE HOLESTUTORIAL #22 Under Tool Types select the None button and then choose the Spot drill icon as shown inFigure: 14.1.1. Figure: 14.1.1 Select the OK button to exit the Tool List Filter dialog box. At this point you should only see Spot Drills. From that list select the 20.0mm Spot Drill as shown inFigure: 14.1.2. Figure: 14.1.2 Select the tool in the Tool Selection page and then select the OK button to exit. Page |112 Mill Level 1 Training TutorialTUTORIAL #22SPOT DRILL THE HOLES Make the necessary changes to the Tool page as shown inFigure: 14.1.3. Figure: 14.1.3Mill Level 1 Training Tutorial Page|113SPOT DRILL THE HOLESTUTORIAL #2214.2 Set the Cut Parameters Select Cut Parameters and make the necessary changes as shown inFigure: 14.2.1. Figure: 14.2.114.3 Linking Parameters Choose Linking Parameters, ensure Clearance is enabled, set the Top of stock and Depth to zero and Absolute. To input the depth select the Calculator icon. Input the following equation in the Finish diameter area: 12+1 and hit Enter to calculate the Depth as shown in Figure: 14.3.1. Figure: 14.3.1Drill/Counterbore is recommended for drilling holes with depths of less than three times the tools diameter.Dwell sets the amount of time in seconds that the tool remains at the bottom of a drilled hole.Page |114 Mill Level 1 Training TutorialTUTORIAL #22SPOT DRILL THE HOLES Select the OK button to exit the Depth Calculator. You will now see the depth we calculated for the spot drilling operation set in the Depth field as shown in Figure: 14.3.2. Figure: 14.3.2 Select the OK button to exit the Drill/Counterbore parameters. To Backplot and Verify your toolpaths page 97 and page 98 to review these procedures.Mill Level 1 Training Tutorial Page|115DRILL THE HOLESTUTORIAL #22STEP 15: DRILL THE HOLESIn this example we will drill the holes to a specified depth.Toolpath Preview:ToolpathsDrill. In the Drill Point Selection dialog box choose the option Last. This option will automatically select the 4 holes for you based off the selection from the previous drill operation. Select the OK button in the Drill Point Selection dialog box to accept the 4 drill points. Page |116 Mill Level 1 Training TutorialTUTORIAL #22DRILL THE HOLES In the Toolpath Type page, the Drill toolpath will be selected.15.1 Select a 12.0mm Drill from the library and set the Tool parameters Select Tool from the Tree view list. Click on the Select library tool button. To be able to see just the drill select the Filter button. Under Tool Types select the None button and then choose the Drill Icon. Under Tool Diameter select Equal and input a value of 12.0 as shown inFigure: 15.1.1. Figure: 15.1.1 Select OK button to exit the Tool List Filter dialog box. At this point you should only see a 12.0mm Drill.Mill Level 1 Training Tutorial Page|117DRILL THE HOLESTUTORIAL #22 From that list select the 12.0mm Drill as shown. Select the tool in the Tool Selection page and then choose the OK button to exit. Make the necessary changes to the Tool page a shown inFigure: 15.1.2. Figure: 15.1.2Page |118 Mill Level 1 Training TutorialTUTORIAL #22DRILL THE HOLES15.2 Cut Parameters Select Cut Parameters, change the drill Cycle to Chip Break and input a Peck value of 5.0 as shown inFigure: 15.2.1. Figure: 15.2.1Chip Break drills holes with depths of more than three times the tool diameter. The drill retracts partially out of the drilled hole to break material chips.1st peck sets the depth for the first peck move which plunges in and out of the material to clear and break chips.Mill Level 1 Training Tutorial Page|119DRILL THE HOLESTUTORIAL #2215.3 Linking Parameters Choose Linking Parameters, and set the Top of stock to zero. Input a Depth value of -25.0 as shown inFigure: 15.3.1. Figure: 15.3.1 Select the OK button to exit the 2D Toolpaths - Drill/Circles Simple drill parameters. To Backplot and Verify your toolpaths page 97 and page 98 to review these procedures.Page |120 Mill Level 1 Training TutorialTUTORIAL #22CHAMFER THE PARTSTEP 16: CHAMFER THE PARTA Chamfer Toolpath automatically cuts a chamfer around a contour using a chamfer mill.Toolpath Preview:ToolpathsContour. Leave the default settings in the Chaining dialog box as shown.Mill Level 1 Training Tutorial Page|121CHAMFER THE PARTTUTORIAL #22 Select the chains and ensure the chaining direction is the same a shown inFigure: 16.0.1. Figure: 16.0.1 Select the OK button to exitChaining dialog box. In the Toolpath Type page, the Contour toolpath will be selected.16.1 Select a 10.0mm Chamfer Mill from the library and set the Tool parameters Select Tool from the Tree view list. Click on the Select library tool button. To be able to see just the chamfer mill select the Filter button.NOTE:It does not matter which contour you select first. However the first contour you select will be the first contour cut.Page |122 Mill Level 1 Training TutorialTUTORIAL #22CHAMFER THE PART Under Tool Types select the None button and then choose the Chamfer Mill icon as shown inFigure: 16.1.1. Figure: 16.1.1 Select the OK button to exit the Tool List Filter dialog box. At this point you should only see a list of chamfer mills. From the Tool Selection list select the 10/45mm Chamfer Mill. In the Tool Selection page choose the OK button to exit. Mill Level 1 Training Tutorial Page|123CHAMFER THE PARTTUTORIAL #22 A warning that the tools settings are not conforming with the Machine Def/ Control Def appears. Enable Turn off warning for session and select the OK button to continue. NOTE:The warning appears when some of the feed rates or the spindle speed that where use to define the tool are not in the tolerances set up in the Machine definition/ Control definition. The values will appear in italics. Change them as needed.Page |124 Mill Level 1 Training TutorialTUTORIAL #22CHAMFER THE PART Make all the necessary changes as shown inFigure: 16.1.2. Figure: 16.1.2Mill Level 1 Training Tutorial Page|125CHAMFER THE PARTTUTORIAL #2216.2 Cut Parameters Select the Cut Parameters page and change the Contour type to 2D chamfer. Input a Width of 1.0 and a Tip offset of 0.5 as shown inFigure: 16.2.1. Figure: 16.2.12D Chamfer cuts chamfers around a contour.Width sets the chamfer width. Mastercam measures the width from the chained geometry adjusted by the cut depths defined on the linking parameters page.Tip Offset is an amount to ensure that the tip of the tool clears the bottom of the chamfer.Page |126 Mill Level 1 Training TutorialTUTORIAL #22CHAMFER THE PART16.3 Depth Cuts Select Depth Cuts and disable it as shown inFigure: 16.3.1. Figure: 16.3.116.4 Lead In/Out Choose the option Lead In/Out and input an Overlap value of 1.0. Make any other necessary changes as shown inFigure: 16.4.1. Figure: 16.4.1Mill Level 1 Training Tutorial Page|127CHAMFER THE PARTTUTORIAL #2216.5 Multi Passes Select Multi Passes, disable this option as shown inFigure: 16.5.1. Figure: 16.5.116.6 Linking Parameters Select the Linking Parameters from the Tree view list. Set the Top of stock to zero and the Depth to zero as shown inFigure: 16.6.1. Figure: 16.6.1Page |128 Mill Level 1 Training TutorialTUTORIAL #22CHAMFER THE PART To Backplot and Verify your toolpaths page 97 and page 98 to review these procedures. Your part will appear as shown.NOTE:The depth of the chamfer is based on the width and tip offset set in the Cut Parameters page. This is why we set the depth here to zero.Mill Level 1 Training Tutorial Page|129POST THE FILETUTORIAL #22STEP 17: POST THE FILE Ensure all operations are selected, if they are not use the button Select all operations in the Operations Manager. Select the Post selected operations button from the Operations Manager. In the Post processing window make the necessary changes as shown inFigure: 17.0.1. Figure: 17.0.1 Select the OK button to continue. NC File enabled allows you to keep the NC file and to assign the same name as the MCX file.Edit enabled allows you to automatically launch the default editor.Page |130 Mill Level 1 Training TutorialTUTORIAL #22SAVE THE UPDATED MCX FILE Save the NC file. A window with the NC program will appear as shown inFigure: 17.0.2. Figure: 17.0.2 Select the red "X" box at the upper right corner to exit the editor.STEP 18: SAVE THE UPDATED MCX FILEMill Level 1 Training Tutorial Page|131SAVE THE UPDATED MCX FILETUTORIAL #22REVIEW EXERCISE - STUDENT PRACTICEPage |132 Mill Level 1 Training TutorialTUTORIAL #22CREATE THE GEOMETRY FOR TUTORIAL #2 EXERCISECREATE THE GEOMETRY FOR TUTORIAL #2 EXERCISEUse these commands to create the geometry. Create Rectangle. Create Fillets. Create Lines. Create Line Parallel. Create Circle Center Points. Fast Point to position the Circles. Trim.Mill Level 1 Training Tutorial Page|133CREATE THE TOOLPATHS FOR TUTORIAL #2 EXERCISETUTORIAL #22CREATE THE TOOLPATHS FOR TUTORIAL #2 EXERCISECreate the Toolpaths for Tutorial #2 Exercise as per the instructions below.Set the machine properties including the stock.Remove the material on the outside of the part Contour (2D). Use a 12.0mm Flat Endmill. Based on your chaining direction ensure the Compensation direction is set correctly. Enable Depth Cuts and set the Max rough step to 6.0mm. Lead In/Out set Length and radius to 60.0% with a 90.0 degree sweep. No Break Through, Multi Passes. Set the depth according to the drawing.Spot drill the holes. Use a 20.0mm Spot Drill. Set the Cycle to Drill/Counterbore and set a Dwell to 1.0 second. Use the depth calculator to set a 1.0mm chamfer on the hole.Drill the holes. Use a 12.0mm Drill. Set the Cycle to Peck Drill and set your peck values. Set the depth according to the drawing.Page |134 Mill Level 1 Training TutorialTUTORIAL #22CREATE THE TOOLPATHS FOR TUTORIAL #2 EXERCISERemove the Material in the center of the part (Pocket Standard). Use a 12.0mm Flat Endmill. Choose to leave no stock on the walls. Set the Cutting method to Constant Overlap Spiral. The Entry Motion will be Helix. Enable Finish and set the parameters. Lead In/Out set Length and radius to 60.0% with a 90.0 degree sweep. Enable Depth Cuts and set the Max rough step to 6.0mm. Disable Break Through. Set the depth according to the drawing.Mill Level 1 Training Tutorial Page|135NOTES:TUTORIAL #22NOTES:Page |136 Mill Level 1 Training TutorialTUTORIAL #22TUTORIAL #2 QUIZTUTORIAL #2 QUIZ What is a Facing Toolpath used for? What does a Pocket Toolpath allow you to do? What is the difference between Climb and Conventional cutting? What does verify allow you to do?Mill Level 1 Training Tutorial Page|909INDEXNumerics2D Chamfer................................................... 1242D High Speed Area Mill............................... 4522D High Speed Blend Mill............................. 6112D High Speed Core Mill............................... 2622D High Speed Dynamic Area Mill345, 354, 3992D High Speed Dynamic Contour .................. 7952D High Speed Dynamic Core Mill................ 2762D High Speed Dynamic Mill ......................... 5912D High Speed Peel Mill ........................ 618, 6232D High Speed Rest Mill ................................ 4752D/3D Construction.......................................... 5AAdjust Start/End Of Contour ........................... 40Arc Endpoints ........................................ 243, 430Arc Polar....................................... 140, 325, 692Arc Radius....................................................... 93Arc Tangent 3 Entities........................... 242, 324Assign Tool Numbers Sequentially .................. 32Attributes.......................................................... 6BBack Feedrate............................................... 280Backplot.......................................................... 41Bounding Box................................................ 252Break Through.............................................. 172Break Two Pieces.......................................... 592CChamfer Toolpath......................................... 119Chamfers ......................................................... 72Change At Point............................................ 516Change Attributes......................................... 706Chip Break............................................. 117, 201Circle Center Point.......................... 28, 239, 314Circle Mill...................................................... 184Clear Colors..................................................... 27Clearance........................................................ 84Climb............................................................... 89Color .................................................................. 6Comment........................................................ 82Compensation Direction................................. 39Compensation Type........................................ 39Constant Overlap Spiral................................ 291Construction Depth ....................................... 423Construction Mode....................................... 423Contour Remachining................................... 176Contour Toolpath ............................................ 34Conventional ................................................... 89Corner Rounding........................................... 458Counterbore................................................. 536Create A New Toolpath Group ...................... 396Create Letters............................................... 249Creating A New Tool..................................... 822Creating And Renaming Toolpath Groups.... 545Creating/Editing Tools.................................. 821Cut Tolerance ................................................ 272DDelete........................................................... 152Delete Entities ................................................. 21Depth.............................................................. 84Depth Cuts...................................................... 94Divide.................................................... 326, 576Drill Toolpath.................................................. 47Drill/Counterbore......................................... 112Dwell............................................................. 112Dynamic Rest Mill......................................... 772EEdit.................................................................. 53Editing An Existing Tool ................................. 826Ellipse............................................................ 236Entry Feed Rate ............................................. 270Entry Method ................................................ 270Extrude .......................................................... 708FFacing Toolpath.............................................. 79FBM Drill....................................................... 653FBM Mill ........................................................ 724Feed Calculation............................................. 32Feed Plane...................................................... 84Fillets ............................................................... 69Filter Ratio And Total Tolerance................... 272Filter Tolerance............................................. 272Finish Outer Boundary.................................... 92From Tool ........................................................ 32Function Prompt............................................... 2GGraphic Area..................................................... 2Grid................................................................. 11Groups.............................................................. 6GUI - Graphical User Interface.......................... 2Gview................................................................ 5HHelix................................................................ 91High Speed Loops ............................................ 83Hole Mapping............................................... 666IInfinite Look Ahead......................................... 39Page |910 Mill Level 1 Training Tutorial INDEXInsert Arrow.................................................. 465JJoin Entities........................................... 155, 704KKeep Tool Down ........................................ 92, 94Keep Tool Down Within................................ 268LLead In/Out..................................................... 40Level.................................................................. 6Line Length ...................................................... 93Line Style ........................................................... 6Line Width ......................................................... 6MMachine Group Properties............................. 31Machine Simulation...................................... 808Max Radius .................................................... 268Max Rough Step.............................................. 94Micro Lift Distance........................................ 280Mirror .............................................................. 22Move Between Cuts ........................................ 83MRU Toolbar ..................................................... 2Multi Passes.................................................... 44NNC File............................................................. 53OOffset Tolerance........................................... 268Open A SolidWorks File ................................. 637Open Pocket................................................. 163Open Pocket Cutting Method....................... 168Optimize Cut Order ....................................... 280Origin................................................................ 2Output 3D Arc Moves................................... 270Output Arc Moves ......................................... 188Overlap........................................................... 93Override Defaults With Modal Values............ 32PParallel Lines........................................... 20, 424Peck Drill......................................................... 51Planes ................................................................ 5Plunge Angle................................................. 270Pocket Remachining..................................... 297Pocket Toolpath.............................................. 85Pocket Type.................................................... 89Point Style......................................................... 6Polar Lines ..................................................... 580Post A File....................................................... 53Preferred Profile Length............................... 270Profile Tolerance ........................................... 268Program #....................................................... 32QQuick Mask Toolbar.......................................... 2Quiz Answers................................................ 829RRe-Chain ........................................................ 466Rectangle........................................................ 18Rectangular Shapes...................................... 420Redo................................................................ 19Renaming The NC File................................... 210Reorganizing The Toolbars ................................ 4Rest Material................................................ 779Retract............................................................ 84Ribbon Bar........................................................ 2Roll Cutter Around Corners............................ 39Rotate........................................................... 331Rough Passes/Finish Passes............................ 46SSave A File....................................................... 29Scale.................................................................. 2Select A Machine............................................ 31Setting Mastercam To Metric........................... 8Skip Pockets Smaller Than............................ 270Slot Mill......................................................... 548Smoothing ..................................................... 268Sorting ........................................................... 484Spiral Inside To Outside.................................. 90Spot Drilling.................................................. 108Start Angle.................................................... 187Start Finish Pass At Closest Entity................... 92Status Bar .......................................................... 2Stepover Percentage/Stepover Distance ...... 169Stock Origin ..................................................... 33Stock Setup..................................................... 33Sweep............................................................. 93TTangent 1 Entity ............................................ 426Tangent Lines................................................ 317Tangent To Point ........................................... 573Tapping......................................................... 203Tip Comp......................................................... 52Tip Offset...................................................... 124Tool Inspection/Change................................ 267Toolbar States................................................. 10Toolbars............................................................ 2Toolpath Manager............................................ 7Toolpaths/Solid Manager................................. 2Top Of Stock .................................................... 84Page |911 Mill Level 1 Training Tutorial INDEXTotal Tolerance............................................. 272Translate....................................... 253, 335, 436Trim 1 Entity .......................................... 575, 584Trim 2 Entities....................................... 146, 585Trim 3 Entities....................................... 326, 432Trim To Point................................................ 147UUndo............................................................... 19VVerify ............................................................... 43View Port XYZ Axes........................................... 2View The Solids history................................. 640WWarn Of Duplicate Tool Numbers ................... 32Work Coordinate System (WCS)....................... 6XXY Stepover........................................... 268, 730ZZ Clearance................................................... 270Z Depth............................................................. 6Page |912 Mill Level 1 Training Tutorial INDEX Thank you for previewing theMastercam X6 Mill Level 1 Training Tutorial. We hope you like what you see. If you havent already, be sure to check out the Table of Contents included at thebeginningofthissampleforafulllistingoftopicscovered.Ifyoufoundthefirsttutorialuseful,were certain the rest of the book will help you along your way to mastering Mastercam. To thank you for considering our Mastercam Training Solutions, >> We would like to extend a special offer to you. Take 10% off your next purchase of any Mastercam X6 Training Tutorial (Imperial or Metric versions, Print or eBook formats) at our eMastercam Store using coupon code:X6TRAIN If you need some help deciding which title is right for you, email us at books@inhousesolutions.com. Likewise, feel free to drop us any suggestions of what you might like to see in future products. >> Be in the loop! Also consider signing up for the eMastercam.com Community Updates email list. Youll receive more offers like this and be the first to know about new product releases and free downloads. Sign me up!