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1

Introduction

to

MasterCAM X4,7

Spring 2014

By

Meung J. Kim, Ph.D., Professor

Department of Mechanical Engineering

Northern Illinois University

2

Preliminaries

C-Plane: flat Construction plane that can be used for sketching

T-Plane: flat machinable TOOL plane

GW: Graphics Window

WCS: World Coordinate System

OM: Operations Manager

MMB to rotate the model in graphics window

Alt + MMB (middle mouse button) to pan

Selecting WCS and changing Z level

Hint appears at top of graphics window

Alt + G to display grids for easy picking (make sure to check Active and Visible

grids)

If some entities cannot be selected sometimes in graphics window (i.e., bug), use

Unhide/All to show all entities and select. For Chain, the line segments in the curve

must be tangent. If the curve is closed, use Loop.

Settings o Configurations > see or change Units

o Colors > Graphics background color > change it if needed

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I. Sketching and Editing

T/Cplane and WCS (Tool/Construction Plane and World Coordinate System)

1. Construction plane is the plane where any geometry can be constructed and Tool

plane is the plane perpendicular to tool axis for machining.

2. The default level of T/Cplane is at Z=0.0 with x-y axes on the plane aligned with

WCS:TOP. Any sketches are added on this plane.

3. Change the WCS and Z value to change the sketch plane.

4. Change the view to isometric view by right clicking on the graphics window and

selecting it.

5. ESC key can be used to cancel any command. Alternatively, End Selection

without any sketch done cancels sketching.

Sketching

1. Sketching menu is shown below.

2. The sketch menu of Line is shown below.

3. Starting point can be picked on the graphics window. Alternatively, entered above.

4. Further, Fast Point can be used to enter x,y,z values quickly.

5. Enter or select appropriate values and options.

6. Pick the second point and further change any values/options > Apply or OK

LINES

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Example 1. Draw a horizontal line from [0,0,0] with size = 2.

Select Line menu

Enter starting x,y,z. Alternatively, Fast Point and enter 0,0,0 > CR

Enter the size

Select Horizontal option

Move the mouse to the right of starting point and click the graphics window

OK (done)

User can select any sketched lines one by one or using the rubber-band

window, for example, to delete them (hit Delete button)

Example 2. Draw am perpendicular line to the previous line at left end.

Select Line Perpendicular

Pick the line (to which the line will be perpendicular)

Select End Point option

Pick the left end (the line appears on both sides)

Click the side to keep

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Enter the size 3 > CR

OK

Example 3. Draw a parallel line at the other end point to the vertical line.

Parallel Line

Pick the vertical line

Select End Point option

Pick the right end of horizontal line (see above middle)

OK

Example 4. Draw a bisecting line at the lower left corner.

Bisecting Line

Pick both lines at lower left corner

Enter the size 2 > CR (see above right)

OK

Example 5. Extend the bisecting line to right and trim the vertical line above the

intersecting point.

Trim/Break/Extend

Pick the line to extend

Pick the line to extend to

OK

Select Trim/Break/Extend from the recent menus on the right toolbar

Click the side of the line to keep

Pick the line to trim to

OK

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Example 6. Create rounds of radius 0.5 at bottom right corner.

Fillet

Pick both lines at the corner

Enter the radius

OK

CIRCLES/POLYGONS

Example 7. Draw a circle of radius 2 and then inscribe a pentagon with the vertex at

bottom.

Fast Point > enter 0,0,0 > CR

Enter the radius 2 > CR

OK

Create Polygon

Pick the center point and drag to inscribe, and place it by clicking

Enter the number of sides 5

OK

XForm Rotate

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Select all five sides of pentagon > End Selection

Check Move > enter the rotation angle 180

User can play with different angles with Preview/Regen button checked

OK

Example 8. Draw an arc of radius 1/2 between 0 ~ 90 degrees.

Alt + g > check both Active/Visible grids > OK

Right click on GW > Isometric (WCS)

Arc Polar > pick the origin > pick the starting point and ending point

OK

Example 9. Draw a circle by two points at [0,0] and [1,0] as well as by three points

at [0,0], [1,0], and [1,1/2].

Circle Edge Points

Select Two point

Pick the first point and then the second

Select Three point

Pick three points

OK

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Example 10. Draw an arc by two points at [0,0] and [1,0] in positive y-direction.

Arc End Points

Select both points

Pick a point in positive y-direction to anchor it

Enter the radius 0.5 > CR

OK

Note: If the radius was entered first before anchor the arc, both arcs above and below

appear and user can select the one to keep. Select both points first and then,

enter the radius 1 (both arcs appear) > pick the side to keep > OK

Example 11. Draw an arc by three points at [0,0], [1,0], and [1,1/2].

Arc Three Points

Select three points

OK

Example 12. Draw an arc by starting point at [0,0], radius 1/2, starting angle 0, and

ending angle 180.

Arc Polar End Points

Select the starting point

Enter the radius, starting angle, and ending angle > CR

OK

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Example 13. Draw a vertical line at origin and copy it at some horizontal distance.

Then, create a tangent arc to both lines between the lines above tangent points.

Arc Tangents

Select both lines. Four arcs (in two circles) appear.

Pick the arc to keep

OK

Example 14. Use Rectangular Shapes with width = 2 and height = 1.5 and draw a

rectangle starting at origin first. Then, change the shape to Obround and see the

change. Change again to D Shape as well as Double D Shape.

Rectangular Shapes

See the dialog with various options

Enter the width and height

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Pick the starting point at [0,0]

See the rectangle

Change the shape to Obround and see the second figure

Change the shape to D Shape and Double D Shape and see other two shapes

Note that user can also rotate the shapes by entering angles to rotate

OK

Example 15. Draw an ellipse at the origin with semi-major axis of 1 and semi-minor

axis of 1/2.

Ellipse

Select the center at origin

Enter semi-major and minor axes in dialog

OK

Example 16. Create a text “MEE633” at origin.

Letters

Enter text as below with parameters > OK

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Pick the starting point (repeatedly if needed)

ESC (to finish)

SOLIDS

Example 17. Create a right cylinder at center (0,0,0) with radius 2 and height 3.

Cylinder

Check Solids in the dialog

Pick the origin or Fast Point > enter 0,0,0 > CR

Enter the radius 2 and height 3 > CR

OK

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Example 18. Create a box of size 5 x 4 x 3 at center (0,0,0).

Block



Drag to size the width and click > drag to size the height > click

Change the size in the dialog > hit CR after the height 3 is entered

Play with Flip Direction to change the depth to other direction or both

directions (in this case, the center moves to bottom)

OK

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Example 19. Create a torus of radius 3 and the section radius 0.5.

Torus



Move the cursor to size the radius and click the graphics window

Move the cursor to size the section radius (i.e., minor radius) and click

Change the values in the dialog

OK

Analyze

1. This menu can be used to analyze and modify properties of entities. Sketch a

circle > OK

2. Analyze > Entity Properties > pick the circle > change any properties > OK

Transform

1. XForm menu (XForm, Translate, Rotate, Mirror, Scale, Translate 3D, Offset,

etc.) is shown below. Use ESC to cancel.

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2. The following shows Dynamic Translate dialog. Pick any to move > End

Selection button > use either incremental Delta or From/To to specify the

distance.

3. For Dynamic Transform, pick any entities to transform > End Selection >

gnomon triad appears > anchor it to a starting position > move mouse over lower

end of any axis to move and click, otherwise, move over higher end of the axis to

rotate and click > the attached gnomon can be move or rotated to another position

> click at a new position > [user can cancel by successive ESC any time] > OK

Surface

1. Create > Surface > Flat boundary > pick closed boundary like a circle or

polygon

2. Alt + G > check both Active and Visible grid > OK

3. Isometric (WCS) > Cplane = Front (WCS)

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4. Create arc three points > pick any three points to sketch the arc > OK

5. Xform translate > pick the arc > End selection > check Join > enter a value

for Z (make it long) > OK

6. Xform translate > pick either arc > End selection > check Copy > enter a

value for Z and Y to copy it below in the middle > OK

7. Create > Surface > Net > pick all four joined lines in sequence (directions don’t

matter) and then the copied arc (see the second above)

a. Choose Across for Style (the last arc is not included. See the third)

b. Choose Average (average is used between two entities. See the last)

8. Change to 2D for sketching

9. Circle

a. Sketch a circle

b. Change Z-value to 10 > sketch another circle

c. Change Z-value to -8 > sketch another circle > OK

10. Create/Surface > Rules/Lofted > pick three circles in sequence and make sure the

directions are all same > Style = Lofted (see above middle) > Style = Ruled (see

right)

11. 3D > Z = 0.0 > Sketch a closed figure as

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12. Create/Surface > Revolved

a. Chain > pick a point on the figure > OK

b. Angle = 180

c. Select the horizontal line for the axis of rotation (see above)

13. Front (WCS) > sketch a spline > OK

14. Isometric (WCS) > sketch a circle at an end point of spline

15. Create/Surface > Swept

a. Across contour > pick the circle > OK

b. Along the curve > pick the spline > OK

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II. Toolpaths

III. Starting with 2D/3D Contours

Contour

1. Machine Type > Mill / Default

2. Drop down Properties – Generic Mill in OM

3. Now, user needs toolpaths.

4. Line > sketch lines starting at (1,1,0) with horizontal length of 4 and the rest of

lines have length of 3.

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5. Stock Setup > All Entities > add a little more space for each if needed as shown

below > OK. Note that Stock Origin is the position at top surface of stock and the

depth is given by Z value. It can be entered or picked by the mouse (easy to pick

with the grid on [alt+g]).

6. Toolpaths > Contour > enter a name > selection dialog appears as

7. Select the line and choose the direction

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8. Toolpath dialog appears

9. Toolpath Type = Contour. Other toolpath can be chosen here Also, see Chain

geometry if needed.

10. Tool > use Select library tool > select the 5/16 Ball Mill.

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11. Alternatively, right click the tool list window > New Tool

a. Select the ball mill > change the tool diameter = 0.3 and other parameters as

below. In this case the tool holder is not used.

b. Change the name under Parameters tab > OK

12. If needed, right click any tool and choose any menu like Edit tool … > the name

of tool can be changed under Parameters > the tool numbers may be same

13. Holder = no holder display

14. Stock setup > click All Solids > change the size as below

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15. Cut Parameters

a. Select the following parameters for the tool compensation

b. Lead In/Out > check the followings > OK

16. Linking Parameters: Select as below

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17. Planes (WCS): See WCS, Tool plane and Construction plane and make sure they

are correct for current operation.

18. OK (close)

19. Right click Toolpath in OM (Operations Manager) > adjust the speed and play,

see below > OK

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20. Right click the graphics window > WCS:TOP > see the toolpath above right.

21. The toolpath display can be toggled on/off by

22. Observation

a. Tool moves to retract plane above the approach point and plunges to feed

plane, then plunge cut first and follows the toolpath.

b. Approach/Exit movements are along a straight line and a tangent arc.

c. Toolpath compensation is to left to the toolpath. Note that MasterCAM X

produces CL data at compensated positions and does not use any tool

compensation NC codes because the toolpath generated is the final NC code.

23. Click Parameters in OM > Cut Parameters > change the tool compensation

direction to Right > (It can be turned off if not needed) > OK

24. Play the toolpath simulation and see it. Observe the Approach/Exit movements.

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25. Back to Parameters in OM > Lead In/Out > see the approach/exit parameters. By

default, the entry move has a straight line (100% of tool radius) and an arc with

radius (100% of tool radius) and 90o sweep.

Note that the Length or Arc of entry/exit moves can be made zero in order not to

execute the part of entry/exit moves. The following shows tangent entry/exit

moves with Length = 1. The second shows the toolpath with Arc extr/exit moves.

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The first toolpath can be also generated by using Adjust start of contour for both

entry/exit moves as below. The result in this case is same as the above.

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26. Any changes need to regenerate the operations by

.

27. To generate the G-codes, click (Post selected operations) > OK (with only NC

file checked) > enter a name for NC code > see the g-codes and compare every

line with the toolpath simulation.

28. In this case, the toolpath is generated at offset positions off the actual sketched

chain.

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[Generating G-Code for Fadal-Compatible CNC with Tool Compensation]

1. The tool compensation codes like G41 and G42 can be used.

2. Cut Parameters

a. Compensation type = Control > OK

3. Run simulation and generate the g-code and see it as below. Note that the toolpath

refers to original geometry.

4. Back Plot and see the actual tool motion. Quick verify can be turned off if

desired. It uses tool compensation in the first straight approach and cancels in the

last straight exit.

5. The g-code appears as

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(Closed) Contour

When there is a contour that crosses out itself, selecting the contour is tricky. See

some tricks below how to use Entry and Exit moves in both Computer and Control

compensations.

1. Machine Type > Mill / Default

2. Create a workpiece as above

3. Toolpaths > Contour

a. Partial > pick the first two lines 1,2 > Loop > pick the loop 3 > Partial >

pick the last line 4 > OK

b. Select #256 0.5 inch ball end mill for the tool (use Filter to choose) in the

library > right click it > Edit tool > Parameters tab > change the name

c. Cut Parameters > Compensation type = Computer, Compensation

direction = Right > turn off the rest

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d. Linking Parameters > Feed plane = -0.3 with Absolute checked [this will

prevent any back off of the tool at start/end of each chain], Depth = -0.3 > OK

e. See the toolpath below gouging due to last cornering to close the loop.

f. Click Geometry of the toolpath in OM > Rechain all > Partial > pick two

lines 1,2 > pick following two lines 3,4 as below

g. Play and still see gouging at transition of two chains.

h. Alternatively, select 1 and 2, then pick the 3 for branch line. This completes

the first chain. Continue with second chain.

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i. To avoid the abrupt change from one chain to another, Parameters in OM >

Lead In/Out > turn off Entry and Exit > check Adjust end of contour and

Extend for Exit and enter 50 % for Length (this is percentage of tool

diameter) > OK

j. Play and see smooth transition between two chains 1,2.

Now, change the tool compensation to Control (i.e., programming). Tool

compensation by Computer produces toolpath at offset distance from original

positions while Control option generates toolpath with tool compensation g-codes.

4. Parameters in OM > Cut Parameters > Compensation type = Control,

Compensation direction = Right > turn off the rest > OK

5. Play and see the toolpath that the tool compensation restarts at beginning and

cancels at end of each chain (see left figure below)

6. There are various ways to fix this problem.

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7. Method 1: Perpendicular Length at both Entry and Exit and Extend.

a. Lead In/Out > check Entry and Exit > check Perpendicular for both > enter

50% for Length and Arc = 0% for both > uncheck the rest of them > OK

b. Back Plot to see gouging above right

c. At the corner, the tool motion causes gouging. See the actual toolpath.

d. Gouging can be removed as before by Adjust end of contour and Extend for

Exit and enter 50 % for Length.

e. The g-code is still incorrect because of two chains and must be modified

manually.

8. Method 2: Tangent Arcs for both Entry and Exit

a. Lead In/Out > check Entry and Exit > check Tangent for both > enter 0.0

for Length and Arc = 50% for both > uncheck the rest of them > OK

b. Back Plot and Verify and see the toolpath below

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c. Generate the g-code and modify as

9. Method 3: Only the Loop Toolpath with Entry and Exit Moves

a. Entry In/Out with tangent Arc and Line as

b. Linking Parameters > Home/Ref Points > select as below and pick the

starting/ending point

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c. Run and see the good toolpath as

[More Discussion]

When there are several closed loops for toolpath, MasterCAM must split the loops

into several chains. Problem is that each chain begins a new toolpath with entry/exit

moves. To be able to handle this issue, user must understand implications of tool

compensation and entry/exit parameters. The following summarizes them briefly for a

chain.

For all cases, the feed plane = incremental / 0.1 and the retract plane = incremental /

0.25 are used unless changed and the HOME position is at (0,0,0.25).

No Tool Compensation and No Entry/Exit

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Tool Compensation = Computer/Right and No Entry/Exit

Tool Compensation = Computer/Right and Exit/Line=50% Tangent

Tool Compensation = Control/Right and No Entry/Exit

Tool Compensation = Control/Right and Exit=50% Perpendicular & Adjust end

of contour=50% Extend

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Tool Compensation = Control/Right and Entry=50% Perpendicular, Exit=50%

Perpendicular & Adjust end of contour=50% Extend

Now, with both proper Entry and Exit moves above, the second chain can be added to

complete the toolpath. See that the toolpath has redundant transition between chains.

Turn off Retract Plane and change the Feed Plane to same level as the machining

depth. The following shows the toolpath.

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Now, despite the toolpath looks good, user must know that the transition toolpath is

done by G0 code rather than G1 code. This must be corrected in the NC program.

Pocket

1. Using same as above for most, sketch a similar pocket shape as below.

2. It is useful to know how to use both Trim/Break/Extend and Break at

intersections in order to break and trim.

3. Toolpaths > Pocket

a. Choose Loop

b. Pick the contour > switch the direction if necessary

c. Linking Parameters > Depth = -0.25 > OK

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4. Sketch a rectangle along the workpiece top

5. Geometry in OM > right click the collector > Add chain > Loop > select the new

chain > make the direction same as the direction of inner loop > OK

6. Parameters in OM

a. Cut Parameters > Roughing > Entry Motion > Off > OK

7. Toolpath appears as below left

8. Change the direction of second loop so that it is opposite to that of inner loop.

Toolpath appears as below right.

9. Verify shows some leftover materials at four corners.

10. Change the pocket type to Facing [Parameters > Cut Parameters > Pocket type]

and run it again. See it above right.

11. Parameter in OM > change Roughing angle to 90 > play and see

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12. Trim/Break/Extend > trim and extend the inner loop into two loops as

below [First, extend the horizontal lines by Trim_1_entity and then trim

between two lines by Divide/Delete ].

13. Geometry > right click the existing chain and delete it, right click in the Chain

Manager > Add chain > add one loop by clicking near the starting point of the

loop > repeat it for another loop > play and see above

14. Turn off all toolpath displays by and extend the horizontal lines as below and

then select all redundant vertical lines > Delete button > Delete all selected lines

to see the geometry below. Now, use under to break at every intersections

of vertical lines [select the first vertical line on left edge and then pick all

horizontal lines that divide > click End selection to end. Repeat this for right

edge line.]

15. Geometry in OM > delete all chains > use Add chain to add the first chain [click

the line near starting point for each segment until loop is complete]. Repeat this

for two other chains [see above right].

16. Parameters > Cut Parameters > Pocket Type = Open

17. Play and see

18. Change the pocket type to Facing as before and see the better machined part.

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Facing

1. Use same contour for face milling

2. Toolpaths > Face

a. Choose Loop

b. Pick the contour > switch the direction if necessary

c. Linking Parameters > Depth = -0.25 > OK

3. Note that face milling uses two opposite boundaries to cover the area between

them. Also, the tool moves out of the boundary. The color, red, shows the tool

interference with stock.

Contour (3D)

1. Sketch as below using WCS (TOP, FRONT, RIGHT), and Dynamic Transform

or XForm Translate.

2. Stock Setup


a. Chain > pick the first line segment (to select the whole chain) > switch the

direction if necessary

b. Toolpath Type = Contour

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c. Tool = ¼ Flat End Mill

d. Linking Parameters > Depth = -0.25 > OK

e. Look at the g-code how the rightside circular motion on vertical plane is

excuted.

Point

1. Toolpath can be created by Point.

2. Create several points at (0,0,2), (1,1,0.5), (4,1,0.5). Use Z=2 for first point and

Z=0.5 for the rest.

3. Toolpaths > Point

a. Toolpaths > Point

b. Pick the points in sequence > OK

c. Toolpath Type = Point

d. Linking Parameters > Feed plane = 0.5, Top of stock = 1, Depth = 0.5

e. Create a tool and a workpiece as before > OK

4. Create a circular arc at Z=0.5 similar to below [create a large arc and trim]


a. Select the arc > OK

b. Toolpath Type = Contour

c. Tool = same tool

d. Cut Parameters > Compensation Type = Off > turn everything off > OK

6. Create points at two end points of the arc and at (1,3.5,0.5) as below

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7. Toolpaths > Point > create another toolpath from the end of the arc to the first

point as

8. Click Geometry of the first Point toolpath

a. Add > pick the last point > pick the next (new) point at beginning end of arc

9. Select Toolpath Group-1 in OM

a. Play the toolpath in Back Plot and Verify and see below

b. MasterCAM assumes there are collisions of tool with workpiece and shows

the red color that can be ignored.

c. Also, the combination of three sequences leave some redundant moves at

beginning of some toolpath. Paramters of contour toolpath > Linking

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Parameters > turn off Retract plane and make the Feed Plane level same as the

cut depth > OK

d. Regenerate all dirty operations

e. Play the group toolpath that looks ok now.

10. Note that no tool compensation can be used for Point toolpath.

11. Toolpaths > Point

a. Pick the point at the center of arc

b. Tooltype = Helix Bore

c. Cut Paramters > Circle diameter = 1 > Rough/Finish > Rough pitch = 0.15

d. Linking Parameters > Top of stock = 1, Depth = 0.5 > OK

e. Play and see the helical boring as

f. Tooltype = Circle Mill > play and see below

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Tplanes (3D)

1. Create Block

a. Fast Point > enter 0,0,0 > CR

b. Check Solids

c. Enter 5, 4, and 3 for size > OK

d. Right click on graphics window > Isometric View

e. Zoom Fit or scroll up/down and alt + move to position the block

f. Polygon > Fast Point > enter 2.5,2,3 > CR > check Corner and enter 5 for

number of sides as below > OK

g. Gview (at bottom status bar) > View by Solid Face > pick the front face >

accept the orientation

h. Sketch a rectangle with round corners as

2. Toolpaths > Drill

a. Pick all five corners of pentagon at top > OK

b. Tool > Select library tool > ¼ Drill > OK

c. Linking Parameters > enter as below > OK

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3. Stock Setup > All Entities > OK

4. Plane (WCS) > change the origin of the Tool plane if not correct as well as the

Tool plane view.

5. Play and see the drilling as

6. Gview (determines the construction plane view) > View by solid surface > pick

the front face > select the correct orientation of axes by clicking the arrow > OK

7. Sketch a rectangle with corner rounds


a. Chain > pick the front rectangle > OK

b. Linking Parameters > Depth = -0.5 > OK

c. Planes (WCS) > if needed, change the Tool plane and C-plane views as well

as the origins > User can copy one from the other using double arrow key.

d. Play and see above right

9. Gview > View by solid face > pick the right face > OK

10. Sketch another rectangle on rightside face


a. Chain > pick the front rectangle > OK

b. Linking Parameters > Depth = 4.5 > OK

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c. Planes (WCS) > if needed, change the Tool plane and C-plane views as well

as the origins.

12. Select Toolpath Group-1 in OM > Verify selected operation > play and see as

13. See also the toolpath with point-to-point (PTP) motion in light yellow color and

the machining in light blue.

14. Parameters of first Pocket in OM > Entry Motion > Off > OK > Back plot

15. Post

a. Check NC file / Edit / Ask > OK

b. No

c. Enter a name for NC file > CR > NC file appears as below > read and

understand each line.

d. Observation: A-90 changes the Tplane with a local coordinates.

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16. When all toolpaths are generated, the first Gview is identified by G54 WCS, the

second by G55, and so on in sequence.

17. Let’s add a sketch of an ellipse in the rear surface and machine it by Contour.

a. Gview > View by Solid Face > pick the rear surface > choose the correct

coodinates

b. Sketch an ellipse

c. Toolpaths > Contour > Loop > pick the ellipse > change direction for CCW

d. Tool > pick the tool

e. Cut Parameters > Compensation type = Off

f. Linking Parameters > Top of stock = 5 and Absolute > Retract = 0.25 and

Incremental > Feed plane = 0.1 and Incremental > Depth = -0.5 and

Incremental

g. Planes > Tool plane = BACK and Comp/construction plane = BACK >

OK

2D High Speed

This has several toolpath type as shown below.

First, sketch two curves by Spline similar to below.

1. Toolpaths > 2D High Speed

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a. Pick the first contour > change direction if needed > pick the second contour >

OK

b. Toolpath Type = Blend Mill

c. Tool = 0.25 flat end mill

d. Cut Parameters > Cutting method = Zigzag (see also other options) > see

also option of Across/Along > Max stepover = 0.1

e. Linking Parameters > Depth = -0.25 > OK

f. Right click Toolpath in OM > play and see

g. Parameters in OM

h. Change Toolpath Type = Peel Mill

i. Rounding radius = 0.25, Stepover = 0.25

j. Linking Parameters > Depth = -0.25 > OK

k. Right click Toolpath in OM > play and see

l. Delete the contour and sketch two others as below (use Line, Offset, and

Fillet)

m. Parameters in OM

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n. Change Toolpath Type = Core Mill

o. Geometry in OM > right click the collector > Add Chains > add first chain >

Add Chains > add the second one

p. Right click Toolpath in OM > play and see

q. Parameters in OM

r. Change Toolpath Type = Area Mill

s. Right click Toolpath in OM > play and see

t. Parameters in OM

u. Change Toolpath Type = Dynamic Mill

v. Right click Toolpath in OM > play and see

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I. Starting with 3D Model

Case 1.

Sketch 2D shape and extrude features.

1. Alt + g for Grid > check Acitve grid and Visible grid > OK

2. Solids > Extrude

a. Loop > pick a line on inner loop of outline > make sure the loop direction is

CW > OK

b. Cut Body > Extend by specified distance/Distance = 0.25 > OK

c. Repeat this for obround with depth = 0.5 > OK

d. Repeat it by selecting four holes in CW with Extend thru all > OK

3. Machine Type > Mill > Default

4. Expand the Generic Mill in OM > Stock Setup

a. Select corners > select two diagonal corners with some materials on sides

b. Enter the depth = 1 > OK

5. Add another sketch around the workpiece

6. Toolpaths > 2D High Speed

a. Pick the loop on workpiece and the loop of part outline > OK

b. Tool Type = Core Mill

c. Tool > select one inch tool


e. Verify> choose Turbo

7. Toolpaths > Surface Rough > Pocket

a. Pick the surface of part at top

b. Select the 1/2 inch tool > OK

c. Verify > choose Turbo

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a. Pick all four holes at centers > OK

b. Toolpath Type > Drill

c. Tool > Filter > select the drill tool > OK > select 1/8 Drill > OK

d. Break Through > check Break through > Break through amount = 0.1

e. Linking Parameters > Depth = -1 > OK

9. Select Toolpath Group-1 in OM > choose Tool > Verify

Case 2.

Based on a MasterCam X example, produce a revolved cut on a block by Surface

High Speed (i.e., roughing), Surface Finish, Surface Finish Leftover. Then, create a

word “CAM” by Pocket on the top surface and project it onto the bottom of the

previous cut. Also, learn to correct tool handle interference by Surface Finish Pencil.

Note that Surface High Speed milling can find all surfaces and machine them. However,

the tool must be small enough to fit the surfaces to machine them. Otherwise, it skips

any unfit surfaces. Further, if the step depth is greater than the depth of any surface, it

also skips.

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1. Alt + G for Grid > check Active grid and Visible grid > OK

2. Create Line End Point > sketch a vertical line from the origin with length 5 >

OK

3. Create Line Parallel > pick the line > click a point on the right > enter the

distance 2 > CR > pick the same first line > click a point at distance 2 to right >

OK

4. Create Line End Point > sketch a horizontal line at bottom and at top, and an

inclined line with angle 290 as

5. Create Arc Tangent > Tangent Point > enter radius 2, pick the inclined line 1

and the end point 2 of bottom horizontal line > click the part to keep at 3 > OK

6. Trim/Break/Extend > Trim 1 Entity > click the inclined line to trim and click

the line to trim > OK

7. Delete entities > pick both vertical lines on the right > End Selection

8. Fillet > enter the radius 0.125 and pick both lines at upper right corner > both

lines at lower right corner > OK

9. Create > Letters > enter “CAM” > select True Type > Arial/Bold/12 > OK >

pick a starting point > ESC (done)

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10. Click a lower left corner, hold down LMB, drag to another corner, click to select

the text just created > Xform Translate > check Move > From/To > pick

starting and ending point to translate > OK (may repeat to place it at proper

position)

11. Clear Colors (2nd

of toolbar)

12. Shift + pick a line in the loop > Xform Mirror > check X-axis in dialog > OK

13. Clear Colors

14. Isometric View > Fit > alt + g > uncheck both Active and Visible grid > OK

15. Create / Surface / Revolved > pick a line on right side and then the line at center

(to complete a loop) > OK > enter the angle 180 > pick the line at center for

rotation axis > choose correct side by > OK

16. Delete entities > pick the line at center (two of them) > Done Selection > refresh

the screen > repeat this to delete another line at same position (see above right)

17. Top (WCS)

18. Create Rectangle > click Anchor to Center and Create Surface > sketch

a rectangle starting from the center > OK

19. Isometric (WCS) > Fit > pan the geometry by alt + MMB

20. Create > Surface > Trim > To Curves > pick the plane > Done Selection >

Loop (or Chain) > pick a point on the curve along the edge of revolved surface

(it’s a loop showing only an arrow on top of ending arrow) > Done Selection >

pick a point on plane to keep and then pick another point > OK

21. Expand Generic Mill in Operations Manager (OM)

a. Stock setup > Bounding box > increase the depth by 1 > OK > OK

22. Toolpaths > Surface High Speed

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a. Enter a name > OK > All > OK > Done Selection > OK

b. Toopath Type = Area Clearance

c. Tool > Select library tool > #294: 1 inch Bull End Mill with Cor. Rad 0.125

> OK

d. Holder > Open Library > C40.holder > OK > C2C4-1000

e. Cut Parameters (accept defaults)

f. Linking Parameters (accept defaults)

g. OK (dialog)

23. Click Back plot selected operations in the menu or OM > Play

24. Verify selected operations or right click Toolpath in OM > play and see above.

a. User can select Tool Holder to display.

b. Turbo for fast simulation.

c. Also, control the simulation speed bar as needed.

25. Toolpaths > Surface Finish > Contour

a. All > OK > Done Selection

b. Containment in Toolpath/surface selection > try to pick a point on looped

edge of revolved surface. If no edge can be selected, then, try Unhide some

> All > OK > Done Selection > Loop or Chain option > retry to pick

the loop (there must be only one arrow that overlaps the ending arrow) as

below > OK

c. Select library > 1/2 Ball End Mill #256

d. Surface parameters > see

e. Finish contour parameters > see > OK

26. Click Only display selected toolpath in OM > see the toolpath (above right)

27. Select Toolpath Group-1 in OM > Verify selected operations

a. Select Simulate tool and holder > Play

b. See the interference of handle with workpiece

54

28. Toolpaths > Surface Finish > Leftover


b. Select library > Filter > select only Ball End > OK > 1/4 Ball End Mill #252

c. Surface parameters > see

d. Finish leftover parameters > see > OK

e. Verify selected operations > (if no material is left over, an error message

appears) > play and see (no good)

f. Select Toolpath Group-1 in OM > Verify selected operations > play and

see more handle interference with stock (will be fixed later) (above right)

29. Click the insert arrow in OM > move it up

30. Select each operation in OM > click Toggle display on selected operation to

turn off > repeat for all to turn off

31. Create > Surface > Offset > pick all revolved surfaces > Done Selection > enter

offset 0.25 > choose the offset side to outside > OK

32. Clear Colors

33. Top (WCS)

34. Create Rectangular Shapes > Obround > select obround for shape > pick the

center point in graphics window > click center for Anchor > sketch the obround >

OK (see below left)


a. Window > capture the obround and text by Window menu (see below

middle) > pick a point on obround edge for approximate starting point > OK

b. Tool > 1/8 Ball Mill #249 > accept default for all others

c. Choose a handle like C4C4-0020


e. Verify selected toolpath > play and see below right

55

36. Toolpaths > Surface Finish > Project

a. Pick both offset surfaces at bottom > Done Selection > OK

b. Tool > 1/8 Ball Mill > accept default for all others

c. Finish project parameter > Projection type = NCI > check Pocket operation

> OK

d. Backplot selected operation > OK

e. Select Toolpath Group-1 in OM > Verify selected operations > play

f. There is interference of tool handle with workpiece that must be fixed.

37. Right click and hold down Pocket operation in OM, drag down a little, and

release > Copy after

38. Click Parameters of copied operation

a. Tool > select tool #242 from the library

b. Cut parameters > Pocket type = Remachining

c. OK

39. Regerate all dirty operations in OM

40. Ctrl + pick Pocket (Standard) operation and Surface Finish Project in OM (only

last one is highlighted) to select multiple operations > Verify selected toolpaths

> see the toolpath simulation

41. Toolpaths > Surface Finish > Pencil

a. Pick both offset surfaces > OK

b. Tool > 1/8 Ball Mill > accept default for all others > OK

42. [Fixing handle interference] Select Surface Finish Leftover in OM

56

a. Alt + C

b. Select CheckHolder.dll > enter the Holder clearance of 0.05 and defaults for

all others

c. Perform test > if there is interference in the test result, click Modify source

operation d. Toolpath Group-1 in OM > Verify selected operations > select Stop after

each operation or Stop after collision > play to find out problem operations

e. Repeat checking and modifying the tool holder length for all operations where

tool interferes with workpiece.

f. Run the verification of the toolpath group and see it (above right)

43. Turn off Quick verify in Back plot selected toolpath and see the cutter

location (CL) points.

Case 3.

1. Create Block > enter width=5, depth=4, and height=1 and then starting position

X=0, Y=0, Z=0 > OK

2. Create Cone > enter the base radius=1, the top radius=1.5, and the height=1 >

Fast Point > enter the position at bottom center of the block as 2.5,2,0 > OK

3. Stock Setup in OM > enter as below

4. Toolpaths > Surface Rough > Parallel

a. Cavity > OK > enter NC name > OK > pick the cone > End Selection > OK

(toolpath/surface selection) > OK (Surface rough parameters)

b. Click the tool in OM > enter sizes as

57

c. Geometry > pick the cone > OK

d. Parameters > just use the defaults

e. Right click Toolpath > play and see the result

5. Toolpaths > Surface Rough > Radial

a. Cavity > OK > enter NC name > OK > pick the cone > End Selection > OK

(toolpath/surface selection) > OK (Surface rough parameters)

b. Pick the bottom center of cone as the radial point

c. Right click Toolpath > play and see the result

6. Toolpaths > Surface Rough > Pocket

58

a. Pick the cone > End Selection > OK (toolpath/surface selection) > OK

(Surface rough parameters)

b. Pick the bottom center of cone as the radial point

c. Right click Toolpath > play and see the result

7. Toolpaths > Surface Rough > Flowline

a. Pick the cone > End Selection > OK (toolpath/surface selection) > OK

(Surface rough parameters) > OK (Flowline data) [the cone surface becomes

flowline].

b. Right click Toolpath > play and see the result

59

II. Starting with External Model

Case 1. Pro/E Part File

1. Create a model in Pro/E or any CAD software. Alternatively, the model can be

created within MasterCAM.

2. Open the file that was created in other CAD program. The following shows the

imported model created in Pro/E [the file extension must be *.prt].

3. Alt + G and check both Active and Visible grid

4. Isometric (WCS) > rotate it a little and see

5. The milling operation requires the z-axis aligned to the tool axis. In this model,

the z-axis was not aligned with z-axis.

a. XForm > Dynamic XForm

c. All > OK > End Selection

d. Anchor the gnomon axes at lower left corner

e. Choose Move option.

f. Move the mouse over the gnomon axes (below or above axis name) to display

the translation or rotation marks as above

g. Right (WCS)

h. Anchor it at top left corner

i. Click the Y or Z axis name for rotation > rotate place the model by 90 degrees

CCW

j. Isometric (WCS)

60

k. Click to select translation in X-axis > move the point to X = 1 position

l. Click select translation in Y-axis > move the point to Y = 1 position

m. Top (WCS) > see it

n. OK

8. Isometric (WCS) > Fit and zoom in/out with MMB

9. Alt + G > turn off the grid

10. Expand Default Generic Mill in OM > Stock setup

a. All Entities > OK

61

11. Clear Colors

12. Toolpaths > FBM Mill (feature-based milling)

a. Click OK to accept the values in the dialog as it is (see below)

62

b. Enter a new NC name > OK

c. The automatically generated processes appear in OM along with the toolpaths

generated as

d. Move the mouse over Toolpath for 2D High Speed (2D Core Mill) in OM

and right click to bring Verify selected toolpath dialog as

63

e. Adjust the speed control and click Play (don’t see moving?, then probably too

slow) and see the simulation. The above right figure shows the completed part.

f. Right click the other process and play the simulation to see the following.

g. Out of two processes that were generated automatically, the user may keep

either one or both and can modify them further.

13. Add FBM Drill as before from Toolpaths menu > OK (accept all defaults)

a. Now, the Operation Manager (OM)/Toolpaths appear as

64

b. Play both sequences of Drill/Counterbore and Peck Drill as before.

c. Select FBM Drill in OM > click Verify selected operations menu

d. Play the FBM Drill operation and see.

e. Click the drill tool in OM to bring up the tool as

f. See also the Type tab as

65

g. Select Machine Group-1 in OM just created > click Verify selected

operations > Play and see

14. Select 2D High Speed (2D Core Mill) in OM

15. Only display selected toolpath

16. Click Parameters in OM

a. Cut Parameters

Depth Cuts > check Depth cuts > Max rough step = 0.5

Transitions > Entry method > check Profile ramp > Plunge angle = 45

Linking Parameters > Home / Reference. Points > check both

Approach and Retract and enter (0,0,2) for both

OK

a. Backplot selected operation > turn off Quick verify > see the toolpath cutter

location (CL) points. Observe the helical or profile ramp motion has numerous

points that slow down the tool motion (see below).

b. Verify selected operation > play and see > OK

66

Case 2. IGES File

1. Save a part file in CAD software as *.iges (or *.igs) file

2. Open the file in MaxterCam

3. Dynamic Xform > rotate and translate so that the lower left corner is at (1,1,-2)

4. Expand Generic Mill in OM > Stock setup

a. All Entities b. Enter as

5. Using View > Viewport > several views can be manipulated as

67

6. Toolpaths > Facing

a. Select library tool > Filter > select only End Mill > OK > choose 1 inch

with no corner radius (#243)

b. Cut Parameters > Across overlap = 50 (%)

c. Linking parameters > Depth = -0.4 > OK

d. Back plot in OM

e. Verify in OM

7. Toolpaths > Surface High Speed


b. Tool > Select 1/2 Flat End Mill

c. Cut Parameters > Step down = 0.25

d. Transition > check Profile ramp and Plunge angle = 45

68

e. OK

8. Toolpath Group-1 in OM > Verify > the shallow pocket was not captured

9. Parameters of Surface High Speed > select 1/4 Flat End Mill > OK > Verify and

see the above right. Also, the step depth must be less than the pocket depth to

capture it in machining. With smaller step depth, use Steep/Shallow > check Use

Z Depths and Detect limits. Observation: Using a single Surface High Speed

operation may be too costly with small step depth. Use several Surface High

Speed operations.

10. For drilling, create points at centers of hole. Analyze > Dynamic

a. Click an arc > move the mouse to place the position arrow at one end as below

and get y-position

b. Move the arrow to top of arc and get x-position

c. Repeat this for center position of the other arc

11. Z = -0.3 (z-plane level at just above model)

12. Create > Point > Fast Point > enter the first center > CR > enter the second

center > CR


a. Select both centers of hole > OK

b. Tool > select 1/2 drill

c. Linking Parameters > Incremental and Depth = -1.9

d. OK

14. Select Toolpath Group-1 in OM > Verify

70

Problems

Problem. 1 Import the dxf file for key-ring in the textbook and contour mill with the

one-inch thick workpiece. Use 0.1” diameter tool with left tool compensation.

Solution:

Problem. 2 Sketch the contour in Example 2 in the textbook and add a point for SP

(0,0,0). Create the one inch thick workpiece with some extra materials around.

Simulate contour milling with SP as Home/Retract Points.

Soultion:

71

Problem. 3 (a) Sketch the contour in Example 2 in the textbook add a line to the

beginning as shown below. (b) Create the 0.2 inch thick workpiece with some extra

materials around. Simulate contour milling starting from the line added and moving

CCW along the outline. Use SP(0,0,0.25) as Approach/Retract Points and turn off

Lead In/Out. The Linking Parameters are as below.

Soultion:


2. Set up the workpiece with z=0 at top

3. Choose a tool

4. Set up the parameters

5. Geometry

a. Single > pick the starting line > (End)

b. Chain > pick the first line of the loop (and pick the last line of the loop) >

Done

6. Simulation

a. Verify > turn on only the shoulder in Tool Components > Play

b. In Mode group, click Backplot > Play and see the table moves

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7. Note that Loop does not include any hanging lines to it. Thus, the starting line

was a separate chain by itself.

Problem. 4 For the same example problem above, produce MCD (machine control data,

i.e., NC code) for Fadal compatible CNC machines using the tool compensations like

G41, G42, G40.

Hint: Since MasterCAM does not use any such tool compensation codes, produce g-code

without tool compensation and then add tool compensations at proper places in the

program manually.

Problem. 5 Sketch the shape similarly and machine as shown below. Describe the steps.

introduction to mastercam x4,7 - ceet.niu.edu intrduction to... · 1 introduction to mastercam x4,7...

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