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IHS Professional Courseware

Mill 2D

Copyright: 1998 - 2023 In-House Solutions Inc All rights reserved

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Trademarks

Mastercam is a registered trademark of CNC Software, Inc

Table Of Contents

3

Step 4: Set The 2D Toolpath Parameters 66

2D Geometry Selection Reference Information: 111

5

Part Drawing 181

Step 3: Set The Construction Plane And Change Wireframe Color 217

Create The Solid 227

7

Drilling Toolpaths 296

Step 4: Dynamic Toolpath To Machine The Bosses 353

9

Step 11: Dynamic Mill The Closed Pocket 436

Step 16: Post Process The Toolpaths To Generate The G-Code 460

Step 4: Rough Out The Inside Pockets Using Dynamic 526

11

Machine Nested Parts 596

Advanced Pocket -Exercise 1 651

Mill 2D Projects

n Starting Mastercam

n Graphical User Interface (GUI)

n Navigate through Mastercam

n Setting the Attributes

n Manager Panels

n Setting Mastercam Unit

n Setting the Grid

Exercise 1: Geometry Tools - Part 1 Topics Covered

n The important components of theMastercam Interface

n Important Function Key shortcuts

n Cartesian Coordinate System

n How to create a Point knowing itsPosition

n Line Creation - Several line creationmethods with emphasis on Endpointsand Parallel

n How to Trim and Extend Lines

n How to Create Rectangles andRectangular Shapes

Exercise 2: Contour Toolpaths Part 1 Topics Covered

n How to create and locate geometry incorrect orientation for machining

n How to create the job setup prior tomachining

n How to select the portions of the model

to machine

n Contour toolpath parameter selection

n Verifying the results of the toolpath

n Making changes to completedtoolpaths

n Creating programming code to send tothe CNC Machine

15

Create Circles

n Create Arcs

n Create Fillets

n Create Chamfers

n Break and Join entities

n Delete Duplicate entities

n Create Tangent Lines and Arcs

n Create Letters

n Overview of remaining Wireframe tab Items

Exercise 4: Contour Toolpath Part 2 Topics Covered

n 2D Geometry Review

n Locate geometry and Job Setup

n Facing rough stock

n 2D High Speed Area Mill to cut an openpocket shape

n Removing excess stock

n Chamfer contour toolpath

n Multiple techniques for contour chainselection

n Chain Manager options

n Review of basic Mastercam general workflowprocedures

Exercise 5: Geometry Manipulation Topics Covered

n Transform commands such as Mirror,Translate, Offset and Rotate

n Analyze geometry and measurement values

n Setting and changing attributes of geometry

n The Mastercam Levels manager

n Geometry selection techniques

n The Chaining dialog box

n Analyzing and fixing problems in chaining

n Importing 2D geometry

Exercise 6: Basic Drilling Topics Covered

n Bolt Circle command to create the holes

n Set a cylindrical stock

n Drilling parameter settings options

n Verify the toolpaths

n Post processing Drill operations

n Importing 2D geometry

n Set the Origin

n Scale the geometry

n Organize the geometry on levels

n Extrude Create Solid

n Extrude Cut Solid

n Extrude Add Boss

n Solid Hole

n Solid Fillet

n Solid Chamfer

17

n Saving Job Setup settings for future usage.

n Extrude Create Solid

n Extrude Cut Solid

n Closed Pocket toolpath

n Open Pocket toolpath

n Remachining Pocket toolpath

n Remachining Contour toolpath

n Slot Mill toolpath

n Merge / Import a SolidWorks file

n Align the part in the vise

n Create the holes using Add Historycommand

n Set a stock from a solid

n Drilling parameter settings options

n Spot Drilling holes

n Tapping holes

n Circle mill operations on large holes withFlat Endmills

n Thread Mill toolpath and Thread mill tool

n Verify the toolpaths with the part and thefixture displayed

n Using the Section view option for bettervisualization of toolpaths

n Post processing Drill operations

Exercise 11: Dynamic Mill Topics Covered

n Open the file and check the fixture

n Setup the part origin

n Machine the standing bosses using Dynamictoolpath

n Cutting the slot shapes using Ramp Contourtoolpath and Slot Mill toolpath

n Machine open pocket areas, closed pocketareas and pocket area with Island facingusing a Dynamic toolpath Machine multiplepockets at different depths

n Remachine the pockets using Dynamictoolpath with Rest Mill option

n Extracting depth values from the model whilecompleting parameters

n Finish the walls using Contour toolpath

n Machine the outside profile using Dynamictoolpath

n Finish the outside profile using Contourtoolpath

n Imported a Parasolid model

n Create the stock using Bounding boxcommand

n Merge the vise

n 2D HST Geometry / boundary selectionrules

n Setting the 2D HST cut parameters

n Dynamic Milling toolpaths

n Dynamic Rest Mill toolpaths

n Model Chamfer toolpath

Exercise 13: 2D Blend & Chamfer Drill Topics Covered

n Create a Stock Model

n High Speed Blend Mill to finish the floors

n Chamfer Drill toolpath

n Review of Model Chamfer toolpath

19

n Using Toolpath Groups.

n Review Contour

n Review High Speed Dynamic Mill

n Review High Speed Area Mill

n Compare the machined part to Workpiece

n Review Stock Model

n Review High Speed Blend

n Review Circle Mill

n Review Chamfer Drill

n Review Drill

n Review Model Chamfer

Exercise 15: Nesting (For router users) Topics Covered

n Geometry Nesting

n Tabs

n Toolpath Nesting

Getting Started

21

INTRODUCTION “WHAT IS “MASTERCAM“?

Mastercam® is the world’s most widely-used CAM software from CNC Software, Inc

Machine tool programmers can program parts graphically in Mastercam, using the innovative, time tested,proven toolpaths and machining strategies preferred the most by shops around the world This book is astep-by-step “hands-on” book of examples to have you programming quickly without knowing NC Machineprogramming languages

WHO THIS BOOK IS FOR:

This book is for the machine tool programming student who wants to learn how to program parts usingMastercam This book is intended to be used as reinforcement exercises as part of classroom training While

a student can learn from books or videos if they are highly motivated, there is no substitution for the

interaction with a “live” instructor

This book covers Mastercam Mill (2D toolpaths) and assumes you are new to the Mastercam programmingenvironment This book also assumes that the student using this book is familiar with machining processes,tools and how Numerical Control (NC) machines operate This book is intended to teach you how to get yourjob done using Mastercam

PROGRAMMING TECHNIQUES USED IN EXAMPLES:

The example exercises in this book can be programmed an infinite number of ways In fact, any two

programmers would likely approach each part a different way and probably use different tools or toolpaths.For the exercises in this book, we used settings that were the personal preference or that came from theexperience of multiple Mastercam authorized instructors All of the examples and exercises have options thatcan be set or changed to suit your experiences or company standards

We chose one method rather than clutter the book with all of the possible options and disrupting the workflow

of the exercises Utilize the Mastercam Help that is accessible from most dialog boxes whenever you needmore information about options

Getting Started The Mastercam® User Interface:

THE MASTERCAM® USER INTERFACE:

Mastercam is a complete graphic programming interface that includes built in CAD tools You will find theinterface to be very streamlined and find it easy to access all of the toolpath generating commands Thereare several places you need to know to access all of the Mastercam commands The locations for the

Mastercam commands and tools are shown in the screen display below

Quick Access Toolbar QuickAccessToolbar (QAT) allows you to quickly access the most

commonly used functions

Ribbon Tabs Access to all Mastercam commands, features and functions

Expanded Gallery and Tooltips Additional icons to start toolpaths and hints on the toolpath.

General Selection Bar Used to access AutoCursor settings and selection options

Mini Toolbar Quick access to attributes

Right Mouse Click Menu Quick access to commands relevant to the graphics view and analyze

commands

Quick Mask Toolbar Used to control entity masking for easier selection

Mastercam Toolpath Manager

This is where all toolpath operations you create are stored They can

be accessed here for editing the Parameters, Tools, and theGeometry of the toolpaths

Toolpath Manager Right

Mouse Click Menu Special commands for working with the operations you have created.Managers Tabs Tabs to control which panel is displayed in the Manager panel

Status bar Displays the current WCS, Tool and Construction plane info and

current cursor location and also displays the Section View

23

SETTING THE GRID

Before starting the geometry enable theGrid It will show you where the origin of the part is

n Select theOK button to exit

n Select theYesbutton to save the

settings in theSystem

Configuration

n To see theGridin

the graphics

window, from the

Viewribbon enable

Show Gridas

shown

Getting Started Conventions Used In This Book:

CONVENTIONS USED IN THIS BOOK:

We have attempted to make this manual as uncluttered as possible and provide you with reference

information when it is appropriate It is not intended to be a Reference Guide or all-encompassing usermanual

The text styles used are the following:

Bold Text - Represents menu commands, dialog box settings or other similar items from the screen

Standard Text - Represents normal wording needed to provide you the instruction

STEP 1: STEP TITLES

1.1 Sub step titles

Information about the current step or terms or parameter definitions describing the parameters

Note: Represents information about the process step that is important or may require an explanation.

n Bulleted text is step by step instructions that have to be followed

TUTORIALS FILES:

The training files are Mastercam parts, SolidWorks parts, assemblies or drawing files These files are

available for download at http://www.emastercam.com/files/

25

MASTERCAM® PARAMETER DIALOG BOXES:

When you begin creating toolpaths with Mastercam® you will be required to supply information so you cancreate the toolpath exactly the way you want it Mastercam® utilizes a tree-style dialog box interface that ismade up of several distinct areas as shown

Tree View Area Displays a list of all of the available dialog box pages

Page View Area Changes with each new Tree Menu item selected Each page has

selections to be made

Getting Started Mastercam® Work Flow:

MASTERCAM® WORK FLOW:

The process to generate a toolpath will be repeated over and over through the tutorials in this book You willfind the process simple and straightforward once you have programmed a few parts Following is an outline

of the process we will follow to create programs:

1 Create the Geometry or Open the CAD file

and select the Machine if it is different than

Default

2 Transform the Geometry if needed,

identify the work face/view.

3 (Optional) Add extra stock for the fixture.

27

4 (Optional) Open the fixture.

5 (Optional) Merge the part and align it

into the fixture.

6 Set the part origin using Move to Origin

command.

Getting Started Mastercam® Work Flow:

7 Machine Group Setup to define

the stock size that your part will be

cut from and set tool information.

8 Select a toolpath operation type such as Contour,

Drilling or 2D High Speed Dynamic.

9 Select the geometry of the part you

will cut with the selected operation

using geometry selection tools.

29

10 Confirm or adjust the Chain direction, Start Point, End Point, etc., if

needed.

11 Fill in the necessary information on

the Parameters pages of the dialog box

that appears for the toolpath type you

choose

12 Verify the toolpath on your computer

screen to confirm the results are as you

expected, using Backplot and/or Solid

Verify.

Getting Started Mastercam® Work Flow:

13 Make any changes as required by

changing parameters.

14 Regenerate the “Dirty” operation to update the

parameter changes

Note: To skip this step enable Generate toolpath in the

toolpath parameters before exit it

15 Verify again to make sure the

toolpath is correct

16 Convert the graphical toolpath

information into machine code by Post

Processing and sending it to the CNC

machine

31

Geometry Tools - Part 1

OVERVIEW OF EXERCISE:

In this lesson we will become familiar with the Mastercam screen components and learn tools and shortcuts

to begin creating basic geometry shapes

NEW CONCEPTS COVERED IN THIS LESSON:

n The important components of the Mastercam Interface

n Important Function Key shortcuts

n Cartesian Coordinate System

n How to create a Point knowing its Position

n Line Creation - Several line creation methods with emphasis on Endpoints and Parallel

n How to Trim and Extend Lines

n How to Create Rectangles and Rectangular Shapes

33

INSTRUCTOR DEMONSTRATION PREVIEW:

Note: This entire lesson is a joint Instructor / Student exercise No instructor demo for this lesson.

Topics

NOTES:

GEOMETRY TOOLS PART 1: BASIC STEPS REFERENCE

In this first lesson the students and instructor will work through the topics as a group

STEP 1: EXPLORE MASTERCAM INTERFACE

MASTERCAM INTERFACE VIDEO

1.1 Load the part: MCAM

INTERFACE.MCAM

We will do a “Preview” of some of the

different components of the Mastercam

screen The goal is just to see where

things are, not to master their usage yet

1.2 Tabs Buttons

-Submenus - Tooltips

Like many Windows programs,

many have submenus or options

We will not go through any uses at

this point, just review how they

work

1.3 Quick Access Toolbar

User can customize it to add often used functions by

right-clicking beside the toolbar or selecting the drop down menu

1.4 The Esc (Escape) Key

(Master key for ending most functions)

35

(Since these commands are used extensively, it may be useful to memorize

the keyboard shortcut keys)

Standard View Choices RMB (Right Mouse Button

options) Free Spin rotation with middle mouse button

Zoom in and out with middle mouse wheel

1.8 Appearance

n Wireframe Choices

n Shaded Choices

n Appearance

n Stock Display options

Shaded and Wireframe Display of Solid Alt+S

1.9 Axis and Gnomon Display

1.10 The Managers Panel

(Preview of the location and purpose only Functions to

be covered when needed.)

1.11 MRU (Most Recently Used) Panel Preview

1.12 Quick Mask Preview

1.13 Status Bar

1.14 Wireframe Tab preview

37

STEP 2: ABOUT THE CARTESIAN COORDINATE SYSTEM

Cartesian Coordinate System

For Mastercam to display a part, you must define its exact shape, size, and location You can do this bydrawing lines, arcs, points, solids, surfaces and other geometric entities that precisely describe the part.These geometric entities exist in a Cartesian Coordinate System

ACartesian Coordinate Systemconsists of two or three perpendicular number lines (coordinate axis) Anumber line is a line divided into equal segments The point on the line designated as zero is called theOrigin

TheCartesian Coordinate Systemallows you to define each point uniquely in a plane using a pair of

numerical coordinates, which are the signed distances to the point from the origin, measured in the same unit

of length

A two-dimensionalCartesian Coordinate Systemconsists of two

number lines set at a 90-degree angle to each other One line is

horizontal (left to right) and is labeled as theX-axis The other is

vertical (up and down) and labeled as theY-axis The point where the

axes cross is theOriginas shown

All points in this space, also called aPlane, orConstruction Plane,

are precisely defined given its axes label, sign, and value

Cartesian coordinates may be written in two different ways One

uses the axis label, sign and value For example: X3 Y2

The other writes coordinates as an Ordered Pair Numbers are

written in a specific order (X,Y) separated by commas For example:

3,2

If the point is defined in 3D, the coordinate of the Z value should

follow the Y value

Absolute coordinatesare always in reference to theOrigin,

regardless of the previous position Starting at the Origin, the diagram

shows a move to N1 and then to N2, written in absolute coordinates

Incremental coordinates(sometimes called Delta or Rectangular

coordinates) are always in reference to the current position This

example, shows a move to N1 starting at the Origin, and then to N2,

written in incremental coordinates

Polar Coordinatesare always in reference to a position (called the

Anchor Point), a Distance and an Angle Starting at the position (X2,

Y1), this figure shows a move to N2, written in polar coordinates

A plane can be divided along its axes into four

quadrants Starting in the upper-right corner and

moving Counterclockwise, the quadrants are labeled: I,

II, III, IV It's important to know which quadrant the part

is in because the sign of the coordinates changes

based on the quadrant

Geometry Tools - Part 1 Step 2: About The Cartesian Coordinate System

39

STEP 3: CREATE POINT POSITION COMMAND

Note: The following instructor led training exercises cover different basic geometry creation commands.

The student has to complete the right side geometry based on the left side geometry and dimensions

Create Point Position

Instructor recommended settings

n From the General Selection

Toolbar select the AutoCursor

Configuration icon.

n Set the settings as shown

n Select the OK button to accept the

changes

3.3Wireframe / Point Position