mill dt guide

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Mill Design and Toolpaths

Course Guide


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Mastercam University Mill Design and Toolpaths Course Guide

Date: November 2010

Copyright 2010 CNC Software, Inc.All rights reserved.

Software: Mastercam X5

Part Number: X5-MCfSW-GS

TERMS OF USE

Use of this document is subject to the Mastercam End User License Agreement. A copy of the Mastercam End User License

Agreement is included with the Mastercam product package of which this document is part. The Mastercam End User LicenseAgreement can also be found at: www.mastercam.com/legal/licenseagreement/

Mastercam is a registered trademark of CNC Software, Inc. Copyright 1983-2011. All rights reserved. SolidWorks is a registered trademark of DS SolidWorks

Corporation.


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Contents

Contents .............................................................................................................................................................. 3

Welcome to Mill Design and Toolpaths ................................................................................................................. 1

Recommended Prerequisites ............................................................................................................................... 1

Curriculum Flow, Time Requirement, and Timeline.......................................................................................... 3

Flow ................................................................................................................................................................................ 3

Timeline .......................................................................................................................................................................... 3

Plan of study ................................................................................................................................................................... 3

Design Modules .................................................................................................................................................. 5

Introduction ..................................................................................................................................................................... 5

Testing ............................................................................................................................................................................. 5

Geometry Overview ........................................................................................................................................................ 6

Design Application Section .............................................................................................................................. 14

Soccer Ball ........................................................................................................................................................ 18

Toolpath Modules ............................................................................................................................................. 19

Testing ........................................................................................................................................................................... 19

Chaining: Wireframe ..................................................................................................................................................... 20

Toolpath Overview ....................................................................................................................................................... 21

Part 1: Two Setups ........................................................................................................................................................ 22

Part 2 ............................................................................................................................................................................. 23

Part 3: 1st Setup ............................................................................................................................................................. 24

Part 3: 2nd Setup ............................................................................................................................................................ 25

Part 4: Self Test ............................................................................................................................................................. 26

Part 4: 1st

Setup ............................................................................................................................................................. 27

Part 4: 2nd Setup ............................................................................................................................................................ 28

Part 4: 3rd Setup ............................................................................................................................................................. 29

Part 6: Multiple Pocket Strategies ................................................................................................................................ 30

Part 7 ............................................................................................................................................................................. 31

Challenge Project .......................................................................................................................................................... 32

2D High Speed Toolpaths (HST) ...................................................................................................................... 33

Core Mill ....................................................................................................................................................................... 34

Peel Mill ........................................................................................................................................................................ 35


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Peel Mill ........................................................................................................................................................................ 36

Blend Mill ..................................................................................................................................................................... 37

Area Mill ....................................................................................................................................................................... 38

Rest Mill ........................................................................................................................................................................ 39

Chain for Dynamic Pocket ............................................................................................................................................ 40

Area Mill with Thin Wall .............................................................................................................................................. 41

2D High Speed Toolpath Applications ............................................................................................................. 42

Dynamic Mill Helical Entry .......................................................................................................................................... 42

Feature Based Machining Modules .................................................................................................................. 43

Associate Level of Certification ....................................................................................................................... 44


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Mill Design and Toolpaths 1 Introduction

Welcome to Mill Design and Toolpaths

This guide is designed to accompany the Mastercam UniversityMastercam Mill Design and Toolpaths onlinecourse. While not a necessary component of the course, this guide will help you orient yourself in the course

and give you a reference you can keep.

Note: The videos and parts referred to in this guide are distributed as part of the Mill Design and Toolpathscourse. You will be able to access them as you work through the course.

You will find the following information in this guide. For each module, the guide shows the part used, presentsthe goals and objectives, and lists tools and material, if appropriate:

Recommended Prerequisites Flow, Time Requirement, and Timeline Design Concepts Modules Design Application Modules Toolpath Modules 2D High Speed Toolpaths (HST) Modules 2D HST Application Modules Feature Based Mill (FBM) Modules

Recommended PrerequisitesWe strongly recommend that you master the following concepts and skills prior to takingMill Design and

Toolpaths. These concepts and skills are covered in the Mastercam UniversityPrinciples for Machiningonline

course.

Basics of Engineering Design Basic Design Principles Design - Specifications and Stages Management and Concurrent Engineering Print Reading

Mathematics Fractions Decimals Geometry Cartesian Coordinates and Planes Order of Operations Triangles and Trigonometry

Conversions, Measurements, and Tools Measurement Units US Customary Measurement UnitsMetric Fractional Machinist Scale Millimeter Machinist Scale


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Dial CaliperCustomary Units Calibration and Application Examples Reading the Micrometer Conversions (Metric and Customary Units)

Introduction to Machining Introduction to MachiningWhat is machining? Mechanical Removal TechniquesDrilling and Milling Mechanical Removal TechniquesReaming, Tapping, and CAD/CAM Terminology Introduction to Milling Machines and Movement Machining Process Video Montage

Simple Metallurgy Structures of Matter and Metallurgic Properties Metallurgy Terminology Testing and Heat Treating Metallurgy Keys to Remember

Cutting Tools and Tool Holders Cutting Tools and Tool Holders

Cutting Tool Geometry

Cutting Tool Materials Cutting Tool Holders

Cutting Speeds, Feeds, and Revolutions per Minute (RPM) Cutting Speeds Revolutions per Minute Feed Rates

Chip formation, Load, and Material Removal Rates Chip Formation, Load, and Depth of Cut Chip Formation Video Sample Material Removal Rate and Cutting Time

Work Holding and Setup Work Holding Work Setup Machining Square and Parallel Work Setup and Part Locating


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Curriculum Flow, Time Requirement, and

Timeline

Flow

Each course module builds upon concepts covered in the module that precedes it. To use the work coordinate

system (WCS) as an example, the curriculum introduces creating multiple zero positions in the Mill Designmodules. Later in the Mill Toolpath modules, the WCS is applied to create an additional zero position for

another feature on the part. The principle of using introduction, application, and then practice to instruct

advanced concepts is used throughout all Mastercam U curricula.

It is critical that you complete all example parts in order. This curriculum has been designed to first present all

of the geometry examples, and then introduce the toolpath.

TimelineThe Mill Design and Toolpaths curriculum has been designed to be a 40-hour class. Depending on your

knowledge and experience, the time required to complete each example and module can vary widely. The next

page shows a timeline to use as a guide.

Plan of study


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Mill Design and Toolpaths 5 Design Modules

Design Modules

Introduction

Wireframe geometry is fundamental to CAD/CAM, so mastering wireframe is essential to becoming aCAD/CAM expert. Although many of the following examples can be created using other methods of geometry

creation, typically the examples start with wireframe, and then use that geometry to calculate distances, depths,

and other dimensional properties. This is good CAD practice, and it will allow you to check your work as you

create it.

Testing

The Mill Design and Toolpaths course includes both pre- and post- multiple choice tests in most modules. Ifyou achieve a score of 80% or better on all post-tests and on the final test, you will receive an Associate Level

of Mastercam Certification. All post-test grades will display on both the Certificate of Completion and the

Associate Level of Certification certificate.


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Geometry Overview

This part covers simple geometry creation and exposes you to many trimming functions.

Objectives

Create a line (FastPoint with an angle)

Line (Parallel)

Line (Horizontal)Line (Parallel)Trim (Divide)

Goal

Complete this part within 5 minutes using

the skills covered in the video.


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Part 1

This part demonstrates the nuts-and-bolts challenges of working with arcs in a CAD system. Where arcs start

and end affect geometry creation as well as trimming.

Objectives

Circle Center Point (radius)

Line Endpoint (angle)Circle Center Point (edge)Trim (three-entity)

Translate (rotate)

Line Endpoint (horizontal, vertical)Circle Center Point, Translate (copy, join)

Line Endpoint (midpoint arc)

Trim (three-entity)

Translate (copy)Circle Center Point Center Point (lock radius)

Circle Fillet Entities

Trim (quadrants)Line Endpoint (tangent)

Trim (extend)

Goal

Complete this part within 15 minutes using

the skills covered in the video.


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Part 2

In this example, geometry is offset in both single and multiple copies. Many arcs are created using tangent

functions. Try to use the method shown in the videos. Many methods will be used in other geometry examples.

The Hide function removes unselected entities. This allows the user to focus on the selected geometry without

making changes to the file.

Right-clicking on attribute boxes allows the user to change existing geometry. This example will create

additional wireframe geometry. Wireframe is the most basic geometry and is good for simple toolpaths.

This example will create a solid from existing wireframe geometry. Solid modeling can be a quick way to

represent a three-dimensional part. Define a solid by extruding, revolving, sweeping, or lofting chains of curves.

Solid features can only be planar.

Objectives

Circle Center Point (radius)

Line Endpoint (angle)

Trim Offset (arcs and lines)Arc Tangent (three entities)

Trim (three-entity, divide)

Offset Circle Center Point (0.25-inch diameter)

DeleteFillet Chains

Goal

Complete this part within 10 minutesusing the skills covered in the video.


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Part 3

The Hide function removes unselected entities. This allows the user to focus on the selected geometry without

making changes to the file. Right-clicking on attribute boxes allows the user to change existing geometry.

This part creates additional wireframe geometry. Wireframe is the most basic geometry and is good for simple

toolpaths.

Objectives

Circle Center Point Rotate (by angle, join)

Rotate (total sweep, copy)Arc Polar Trim (three entities)

Line Endpoint (vertical, horizontal, parallel)

Fillet EntitiesCircle Center Point

Break (arc at quadrants)

Translate (join)

Translate (move)

Rotate


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Part 3: Solid

This part creates a solid from existing wireframe geometry. Solid modeling can be a quick way to represent a

three-dimensional part. Define a solid by extruding, revolving, sweeping, or lofting chains of curves. Solidfeatures can only be planar.

Chains determine the direction of extrusion. Chains can be reversed after selection using either the Re-Select

button or Reverse direction check box. The re-select button returns the user to the graphics window to redefinethe extrusion direction using the Solid Chain Direction ribbon bar. Reverse direction extrudes the curves in the

opposite direction from the current extrusion direction.

Objectives

Extrude, Create BodyExtrude, Cut Body (slots); Reverse chain direction

Extrude, Add Boss

Extrude, Cut Body (center holes)

GoalComplete the wireframe and solid model within 15 minutes

using the skills covered in the video.


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WCS and Planes

The Work Coordinate System (WCS) is a way to map the selected view to the top view.Use WCS when turning the part in a vice by hand, or when changing the part orientation from the source file.

Changing the WCS will not provide rotary axis information for the postprocessor. At the CNC machine, thiswill rotate the part, not the fixture.

Objectives

Set zero position on additional parts or features

Define a new plane

Work with Z depth in different planes

Setting zero position on parts Defining a new top plane

Working with Z depth


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Part 4

Part of mastering three-dimensional geometry creation is thinking about what plane geometry exists in. Often

geometry exists in more than one plane, and it is a matter of finding the depth relative to that plane.

Setting the Work Coordinate System (WCS) to front allows the geometry to be created in front view as if the

part was turned on its side. Because the other features exist on current geometry, planes can be used quickly.

The isometric view remains current to the active WCS. The 0.25-inch diameter circle on the side plane iscreated based on existing geometry in a 3D construction mode.

Objectives

Set WCS

Create Rectangular Shapes

Create Rectangle, Relative Position ([Shift] + AutoCursor)Line Endpoint, Relative Position ([Shift] + AutoCursor)

Trim (default, divide)

Translate (join)

Reset WCS, Create new plane by geometryCircle Center Point, Relative Position ([Shift] + AutoCursor)

Line Endpoint (quadrant), Trim (three-entity)

Translate

Line Endpoint (3D construction mode)Circle Center Point (right WCS)

Goal

Complete the part within 20 minutes



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Part 5

The 2D / 3D switch toggles between 2D and 3D construction modes. In 2D mode, all geometry is created

parallel to the current construction plane (Cplane) at the current system Z depth. In 3D mode, you can workfreely in various Z depths, unconstrained by the current system Z depth and Cplane settings. In 3D mode, you

use AutoCursor to select a position or otherwise specify the X, Y, and Z values for the entity. 3D mode now

respects construction planes to orientate entities that require a flat plane of reference such as arcs.

Objectives

Set Front WCS, Create Rectangle

Set 2D plane and Z depth, Create Rectangle

Make screen grid visible, Set Z depthArc Endpoints

Goal

Complete the part within 15 minutesusing the skills covered in the video.


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Mill Design and Toolpaths 14 Design Application Section

Design Application SectionAt this point in the curriculum, you should have a grasp ofMastercams CAD system. Challenge yourself by

creating the geometry before watching the movies. If you have trouble, watch the movie and then practice.

These parts are designed to challenge you. Some of these concepts are not covered in the practical certificationtest. These parts will help you to become more successful in multiple plane and or multi-axis work.


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Bike Brake

This part reviews the concepts covered so far. The lines connecting the top and bottom section are tangent and

parallel. All radii without center locations are considered fillets. Try to draw this part on your own first. Ifnecessary, watch the videos on the next pages.

Goal

Complete the part within 20 minutes using the skills covered in the video.


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Bike Fork

This part requires you to create reference geometry at multiple depths. The part has three flat sections; create

these first. Dimensions on the connecting 3D sections are measured to the intersection with the top plane.

Create the connecting 3D sections, and then translate the thickness of the part. Try to draw this part on your

own first. If necessary, watch the videos on the next pages.

GoalComplete the part within 20 minutesusing the skills covered in the video.


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Connect Six

This part can be constructed from four circles created at the appropriate depths. Create the cylinder and fin first.

Rotate cylinder and fin, and then Boolean add them together. Cut the blind holes 0.90 inch deep.

Use a 0.03-inch fillet radius on the complete solid.

Goal

Complete the Solid within 15 minutes



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Soccer Ball

In this part, geometry and planes are created from existing known geometry. When this part was initially

created, only the shapes were known. The line length is the same length and sets the ball diameter.

Goal

Complete the part within 30 minutes



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Mill Design and Toolpaths 19 Toolpath Modules

Toolpath Modules

CNC programming is becoming almost more about database management than moving a machine tool. Today's

CNC programmer should understand how to save and retrieve proven machining methods and feed rates. Tool,material, and machining operations can be stored in libraries. This helps the programmer concentrate on

efficiently moving the machine tool. Storing machining knowledge is key to becoming an expert CNC

programmer.

Testing

This module includes both pre- and post- multiple choice tests. If you achieve a score of 80% or better on all

post-tests, you will receive an Associate Level of Mastercam Certification. All post-test grades will display on

both the Certificate of Completion and the Associate Level of Certification certificate.


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Chaining: Wireframe

This module overviews how to set direction on multiple entities. Chaining differs from other selection methods

because it associates order and direction with the selected geometry. In the case of toolpath linking, entities canalso control direction of the tool and climb or conventional machining.

Objectives

In Wireframe chaining mode, the Chaining dialog box provides chain selection methods including Window,Area, Single, Polygon, Partial, and Vector. Other controls let you manage the selection process (Last, End,Unselect) as well as Reverse chaining direction.

In Solids chaining mode, the Chaining dialog box gives you options to manage the chaining of solid entities,including edges and faces (front or back), full loops (closed chains ), and partial loops (open chains). In

addition, you can unselect and re-select solid chains, reverse chaining direction, and move the start of a chain.


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Toolpath Overview

This module overviews how to correctly prepare a stock model, select tool and holder, and control depth. It also

introduces several toolpath types and shows how different operations see the tool for both diameter and lengthoffsets.

Objectives

Stock OverviewTools Overview

Tool Control Overview

Toolpath OverviewTool Tip Offset

Chamfer


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Part 1: Two Setups

Setup 1:

Program name: 237OP1.NC Part zero location: top left Circle mill (location hole) Slot Mill Clearance Slot (Ramp Contour) Setup Sheet

Setup 2:

Program name: 237OP2.NC Part zero: 0.3125 center hole Contour (Outside) Setup Sheet

Tool List:

T1 = 1.5 Face Mill

T2 = 0.3125 End Mill

T3 = 0.25 End MillT4 = 0.75 End Mill

Material: Aluminum 2024

Goal

Within 30 minutes, program all operations to complete this part using the skills covered in the video.


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Part 2

The part demonstrates how to handle slots with the width of the tool. Cut the part leaving a 0.02 floor for

vacuum table.

Tool List:

T1 = 0.25 End Mill

Material: Graphite 7.25 x 10.375 x 0.375

GoalWithin 20 minutes, program all operations to complete this part using the skills covered in the video.


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Part 3: 1stSetup

Setup 1:

Set WCS (bottom) Pocket (face) Add tooling hole (requires a change from engineering department) Drill holes Cut slots Clean up boss Center hole

Tool List:

T1 = 1.5 Face MillT2 = 0.5 Spot Drill

T3 = 0.5 Drill

T4 = 0.5 End Mill

T5 = 0.625 End MillMaterial: Aluminum


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Part 3: 2nd Setup

Setup 2:

Flip part (new toolpath group) Cut slots (-0.375 depth) Contour outside Tool library Save and cut STL file

Tool List:

T1 = 1.5 Face MillT2 = 0.5 Spot Drill

T3 = 0.5 Drill

T4 = 0.5 End Mill

T5 = 0.625 End Mill

Material: Aluminum

Goal



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Part 4: Self Test

This module will help you test your skills.

Self-test Instructions

Machine the part in three setups before watching the videos. Use WCS to set the zero to the upper left corner on

all three setups. Rotate the part, keeping the same wall against the solid vice jaw. The third setup will require

soft vise jaws with the correct tilt angle.

1. Download the Part 4 Self Test Kit from the Part 4 page on Mastercam University.2. Create the geometry based on the print.3. Program the part using the tool library.4. Use the STL file for STL compare in Verify.

Tool List:

T1 = 3/16 Flat E/MillT2 = 1/2 Spot Drill

T3 = 1/4 Dia DrillT4= 3/4 Flat E/Mill

T5= 3/8 Flat E/Mill

Material: Aluminum


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Part 4: 1stSetup

Setup 1: 0.125 x 0.25 slot

Create and make WCS active for setup 1o Upper Left Corner (ULC)

Choose machine definition: 3-axis VMC Set Machine Group Properties

o Create bounding Boxo Set stock to wire frameo Set material type

Tool List:

T1 = 3/16 Flat E/Mill

T2 = 1/2 Spot DrillT3 = 1/4 Dia Drill

T4= 3/4 Flat E/Mill

T5= 3/8 Flat E/Mill

Material: Aluminum


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Part 4: 2nd Setup

Setup 2: Drill 0.25 hole

Create and make WCS active for setup 2 (upper left corner (ULC)) Create new machine group (new program #, reset stock) Chamfer hole 0.01 (larger than spot drill)

dia drill (copy the previous drill operation)

Tool List:


T2 = 1/2 Spot Drill

T3 = 1/4 Dia Drill

T4= 3/4 Flat E/Mill

T5= 3/8 Flat E/Mill

Material: Aluminum


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Part 4: 3rd Setup

Setup 3Face milling and 0.5 x 0.375 slot

Create and make WCS active for setup 3 (Upper Left Corner (ULC)) Create new machine group (new program #, reset stock) Create WCS for slot on 120-degree angle ULC

Facing toolpath Pocket for slot

Tool List:


T2 = 1/2 Spot Drill

T3 = 1/4 Dia Drill

T4= 3/4 Flat E/Mill

T5= 3/8 Flat E/Mill

Material: Aluminum

Goal



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Part 6: Multiple Pocket Strategies

Objectives

Create an STL to Verify Standard pocket Open pocket (top)

Open pocket (bottom) Open pocket (with island) Island facing pocket Re-machining Face multi-height islands Verify

Tool List:

T1 = 0.5 Flat End Mill


Material: Delrin

Goal



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Part 7

Objectives

This is an advanced practice part. To program this part, you will need to organize the pocket depths and

operations. Take your time and have fun.Program the complete part and you are ready for the ChallengeProject.

Note: The threads are suppressed in the model to decrease the file size.

Thread depth = 0.64 x pitch in inch or metric

Tool List:



Material: Delrin


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Challenge Project

Instructions

Create a 3D wireframe within 20 minutes

Create the part to a complete 3D wireframe by any means possible using Mastercam software. You may not import any geometry.

Create a CNC program and support information for each setup within one hour

Zero is the upper left corner on each setup. Mastercam backplot must not to exceed 5 minutes. Each setup must have a distinct Toolpath Group and group name and must have unique NC file name Compare the STL file to test.stl file supplied. Use STL Compare. Create a setup sheet and tool list for each setup. The use of the test print as part of documentation is advised.

Tool List:T1 = 0.125 Center Drill

T2 = #7 Drill

T3 = -20 Tap



Material: 6061 T6 Aluminum


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Mill Design and Toolpaths 33 2D High Speed Toolpaths (HST)

2D High Speed Toolpaths (HST)

High speed toolpaths are changing the way parts are machined. With this type of toolpath, many of the

toolpaths can be machined at full depth of cut. The examples in this module are programmed to be safe rather

than to take full advantage of the toolpath. Feed, speed, and depth of cut are determined by machine rigidity,

tool geometry, condition of the cutting tool, as well as maximum RPM and horsepower.

Work closely with your cutting tool representative to get the most out of your cutting tools. This technology is

very new. Ask questions to help determine optimum feed rates for your application.


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Core Mill

Objectives

Respect pocket boundaries Finish off outside boundary Demonstrate consistent engagement Achieve smooth material removal

Tool List:


Goal

Within 10 minutes program, all operations to complete this part using the skills covered in the video.


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Peel Mill

Objectives

Use open contour (Can use single chain and parameter-defined width) Use high speed loop toolpath Demonstrate micro lift Achieve consistent chip load Achieve smooth material removal

Tool List


Goal



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Peel Mill

Objectives

Use open contour (Can use single chain and parameter-defined width) Use high speed loop toolpath Demonstrate micro lift Achieve consistent chip load Achieve smooth material removal

Tool List:




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Blend Mill

Objectives

Use two entities for chain Achieve consistent floor finish Achieve consistent chip load Achieve smooth material removal

Tool List




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Area Mill

Objectives

Tool motion control on multiple entry Use roughing motion entry Use helical and ramp contour entry

Tool List




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Rest Mill

Objectives

Remove leftover material from previous operations Control on stepover

Tool List:



Goal



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Chain for Dynamic Pocket

Objectives

Geometry-controlled entry Entry affects tool motion

Tool List:


Goal



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Area Mill with Thin Wall

Objectives

Dynamic area Solid chain for each pocket for three operations Thin wall pocketing Solid chain all pockets into one operation

Tool List:


Goal



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Mill Design and Toolpaths 42 2D HST Applications

2D High Speed Toolpath Applications

Dynamic Mill Helical Entry

ObjectivesApply the following to the sample geometry:

Outside the part Core Mill Dynamic Contour Rest Mill Inside pocket Dynamic w/Helical entry Trochoidal Medial Entry Profile Entry Dynamic Contour Rest Mill

Tool List:




Goal



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Mill Design and Toolpaths 43 Feature Based Machining

Feature Based Machining Modules

Feature Based Machining (FBM) analyzes a part for specific feature types and automatically creates the

individual toolpaths needed to machine the selected features. Using FBM to find complex chaining and to

apply toolpath operations based on user-defined criteria is a huge timesaver. A programmer can then optimize

what FBM found automatically and save time.

This section of the Mill Design and Toolpaths course does not include pre- and post- testing, nor is it included

in the final test. However, Feature Based Machining is an important new technology that the student should

be familiar with, so we strongly urge you to complete this section.

Objectives

Open a Parasolid file Explore FBM Mill Feature detection options Setting FBM options FBM Drill Verify

Goal



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Associate Level of Certification

The Associate Level of Certification is based on the score you achieve on the post-tests in each of the following

modules: Mill Design, Mill Toolpaths, 2D High Speed Toolpaths, and on the final test. You must complete all

curricula and score 80% or better on the post-tests to achieve the Associate Level of Certification.

Note: You may not retake tests, so be sure you are prepared and have allowed sufficient time beforeattempting the tests.

The certificate is shown below.

mill dt guide

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