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TUTORIAL SERIES FORINSTRUCTOR GUIDE FOR MASTERCAM X³ MILL LEVEL 1 TRAINING TUTORIALS

This manual is a guide for instructors and trainers teaching Mastercam X³ Mill

This manual also makes use of Mastercam files, which can be downloaded from the Training Exercises CD that comes with this book.

Legend:

Step to follow to complete the tutorial

Additional explanation for the current step

Callouts that give direction on how to complete the task

Bold text (usually) represents Mastercam terminology

To order Mastercam X³ Mill Level 1 Training Tutorials books:

Contact your Mastercam Dealer, Call 1-800-529-5517 or Place an order through www.inhousesolutions.com

Mastercam Instructor Guide for Mastercam X³ Mill Level 1 Training Tutorials

Date: October 22, 2008

Copyright © 1984 - 2008 In-House Solutions Inc - All rights reserved

Software: Mastercam X³ Mill Level 1

Authors: Mariana Lendel

ISBN: 978-1-894487-98-6

Notice

In-House Solutions Inc reserves the right to make improvements to this manual at any time and withoutnotice

Disclaimer Of All Warranties And Liability

In-House Solutions Inc makes no warranties, either express or implied, with respect to this manual or withrespect to the software described in this manual, its quality, performance, merchantability, or fitness forany particular purpose In-House Solutions Inc manual is sold or licensed "as is." The entire risk as to itsquality and performance is with the buyer Should the manual prove defective following its purchase, thebuyer (and not In-House Solutions Inc., its distributor, or its retailer) assumes the entire cost of all

necessary servicing, repair, of correction and any incidental or consequential damages In no event will House Solutions Inc be liable for direct, indirect, or consequential damages resulting from any defect inthe manual, even if In-House Solutions Inc has been advised of the possibility of such damages Somejurisdictions do not allow the exclusion or limitation of implied warranties or liability for incidental orconsequential damages, so the above limitation or exclusion may not apply to you

In-Copyrights

This manual is protected under the copyright laws of Canada and the United States All rights are reserved.This document may not, in whole or part, be copied, photocopied, reproduced, translated or reduced to anyelectronic medium or machine readable form without prior consent, in writing, from In-House SolutionsInc

Trademarks

Mastercam is a registered trademark of CNC Software, Inc

Microsoft, the Microsoft logo, MS, and MS-DOS are registered trademarks of Microsoft Corporation;Mastercam; Windows 95, Windows 2000 and Windows XP are registered trademarks of MicrosoftCorporation

Lesson #1: Introduction to Mastercam

Lesson #2: Introduction to Geometry Creation

Lesson #3 Geometry Creation (continued)

Lesson #4 Geometry Creation (continued)

Lesson #5 Geometry Creation (continued)

Lesson #6 Geometry Creation (continued)

Lesson #7 Geometry Creation (continued)

Lesson #8 Wireframe and Solid Geometry Creation

Lesson #9 Wireframe and Solid Geometry Creation (continued)

Lesson #10 Geometry Creation - Test

Lesson #11 Introduction to Chaining, Properties and basic 2D Toolpaths

Lesson #12 2D Toolpaths

Lesson #13 2D Toolpaths (continued)

Lesson #14 Introduction to 2D High Speed Toolpaths

Lesson #15 2D Toolpaths using Transform Toolpaths

Lesson #16 2D Toolpaths (continued)

Lesson #17 2D Toolpaths (WCS)

Lesson #18 2D High Speed Toolpaths (continued)

Lesson #19 fbm mill & drill Toolpaths

Lesson #20 Toolpaths - Test

3152834404756616971739197100107111121126133140

Lesson PlanIntroduction to Geometry CreationLesson ObjectivesCreate a rectangle knowing the width

and height

Create parallel lines, by defining the offset direction and distance

Create lines knowing the endpoints

Create arcs knowing the diameter and center point

Create fillets

Trim the existing geometry

Mirror xisting geometry

Move origin to redefine the part

Create points knowing their positionsTimeTeaching / Learning StrategiesResources30 minHave Students follow Tutorial 1 from

the book to create

2D Geometry Page 1-2 to Page 1-9Mastercam &

Mill Level 1 Training Tutorial BookEnhancing Phase1 hourUse the following Training Exercises:

These exercises will help reinforce the commands used to

create the tutorial drawing and aid the students with 2D

geometry.CD Training Exercises

Use PowerPoint : Lesson2.pptAssignments / Quiz30 minHave the students complete Tutorial 1 – Exercise 1 and

Tutorial 1 – Exercise 2 found at the end of Tutorial 1 in

the book; page 1-33 &1-34Mill Level 1 Training Tutorial BookHave students complete the first 2 questions from

Tutorial 1 Quiz found in their books on page 1-36Mill Level 1 Training Tutorial Book

LESSON #2: INTRODUCTION TO GEOMETRY CREATION

Page-15

page 1-2 to page 1-9

The following commands are shown in Tutorial 1:

Create Rectangle knowing the width and the height of the rectangle.

Create Line Parallel by defining the offset direction and distance.

Create Circle Center Point knowing the diameter and the center point.

Mirror existing geometry to complete a part.

Move to Origin to redefine the part origin.

CREATE POINT POSITION COMMAND

Create

Point

Position

Definition: Create Point Position command creates a point defined by its coordinates

X,Y, and Z or creates a point at the endpoint, midpoint, intersection, quadrant or arccenter of already created lines or arcs

PowerPoint Presentation: Lesson 2.ppt

Training Exercises CREATE_POIN T_POS.MCX

File Open Select Create_Point_Pos.mcx

You can start the command from the Menu

Page-16

You can also start the command from the Sketcher toolbar.

Tips: Create the points on the right side drawing to match the left side Use the

Autocursor function to insert the points at the Endpoints, Midpoints, Intersection, Quadrants, Origin and Center locations As Mastercam detects and

snaps to points, it displays a temporary square over the point and the

corresponding cursor icon Use the Fast Point icon to enter the coordinate values

for the rest of the points as per the drawing

Press Enter key.

Mastercam does the math

For the second point you can type 2.25+.5, -1.75 -1 (Enter)

CREATE RECTANGLE & CREATE RECTANGULAR SHAPES

CD Training Exercises CREATE_RECTA NGLE.MCX

File Open Select Create_Rectangle.mcx

Page-17

Mill Level 1 –Lesson 2: Geometry Creation INSTRUCTOR GUIDE

Create Rectangle Tips: Type the coordinate values of the opposite corners of the rectangle as per thdrawing using the Fast Point icon.

Create

Rectangular

Shapes

Definition: Create Rectangular Shapes allows you to create a rectangle, an

obround shape, D shape or a double D shape The shapes can be created using abased point for the anchor and by entering the width and height of the shape Theshapes can also be created using 2 points method by entering the two oppositecorner coordinate values

Create Rectangular Shapes Tips: Select the Drop-down arrow to extend the dialog box.

Type the Width and the Height values Select the approximate anchor placement

in the dialog box, and enter the coordinate values as per the drawing Reselectthe command to change the point placement

CREATE LINE ENDPOINT & CREATE LINE PARALLEL

Definition: Create Line Endpoint command allows to create a line knowing the PowerPoint

Create Line

Endpoint

two endpoint coordinate values It also allows you to create a line polar knowingone endpoint location, the length and the angle of the line You can createhorizontal or vertical lines With this command you can also create multilines ortangent lines

Presentation: Lesson 2.ppt

CD Training Exercises CREATE_LINE S.MCX

Note that Create Line Enpoint allows you to create the following types of lines:

Line Endpoints Line Horizontal Line Vertical Line Polar Multiple Lines Line Tangent

Mill Level 1 –Lesson 2: Geometry Creation

File Open Select Create_Lines.mcx Create

Line Endpoint

Create a horizontal line:

Enable Horizontal icon in the Ribbon Bar.

Sketch the endpoints of the horizontal lineapproximately at the same location from X and Y axis as per left side drawing

Enter 1.5 as the Y coordinate

Press the Enter key.

Select the Apply button to continue.

Create a vertical line:

Enable Vertical icon in the Ribbon Bar.

Sketch the endpoints of the vertical lineapproximately at the same location from X and Y axis as per left side drawing

Enter 1.0 as the X coordinate

Press the Enter key.

Select the Apply button to continue.

Unselect the Vertical icon.

Create a line knowing the endpoints:

Select the Fast Point icon Type the coordinates values for the first point (-1.75, -.5) Enter

Select again the Fast Point icon

Type the coordinates values for the second point (-2.5, -1.75) Enter Select the Apply button to continue.

Create a polar line:

Line Polar Enter the Length 3 and the Angle -25.0

Select the Origin (the center of the

Grid) as the first endpoint

Select the OK button to exit the command.

Mill Level 1 –Lesson 2: Geometry Creation INSTRUCTOR GUIDE

Create

Line Parallel

Definition: Create Line Parallel command creates a line parallel to an existing line.

You can create the parallel line knowing the distances between the lines orknowing a point to position the parallel line

Create Line Parallel

Tips: Enter the Distance 0.50 Select the existing line and indicate the offset

direction by clicking below the existing line

Select the OK button to exit.

CREATE CIRCLE CENTER POINT & CREATE ARC

ENDPOINT COMMANDS

Create

Circle

Center Point

Definition: Create Circle Center Point command creates a circle knowing the

center point location and the radius or the diameter of the circle PowerPoint

Presentation: Lesson 2.ppt

CD Training Exercises CREATE_ARC MCX

File Open Select Create_Arc.mcx Create

Arc Circle Center Point Tips: Enter the Radius = 1.0 and select the point as the center location Select the Apply button to continue in the same command.

Tips: Enter the Diameter = 1.0 and select the point as the center location Select the OK button to exit.

Create

Page-20

Endpoint Definition: Create Arc Endpoint command creates an arc knowing the twoendpoint locations and the radius of the arc

Create Arc Arc Endpoints

Tips: Enter the Radius = 0.25 Select the first point, select the second point The

system gives all possible results Select the arc that you want to keep Select the

Apply button to continue in the same command Following the same steps

create the other arc Select the OK button to exit.

CREATE FILLET ENTITIES & CREATE FILLET CHAIN

COMMANDS

Create

Fillet

Entities

Definition: Create Fillet Entities command creates an arc of a defined radius

tangent to two curves You can trim to the fillet the original entities or leave themuntrimmed You can select different fillet styles (normal, inverse, circle or

PowerPoint Presentation:

Lesson 2.ppt

clearance) before selecting the two entities

CD Training Exercises FILLET.MCX

File Open Select Fillet.mcx Create

Fillet Entities

By default, the Trim icon is enabled and Mastercam trims the curves to

the fillet; however, you have the option to turn off trimmingthe curves on the side that you want to keep after filleting

First rectangle

Enter the Radius = 0.25

Page-21

Always select

The upper left corner settings should be as follows:

Enable Normal and Trim.

Select the Apply button to continue in the same command.

The upper right corner settings should be as follows:

Select the Apply button to continue in the same command.

The lower right corner settings should be as follows:

Select the Apply button to continue in the same command.

The lower left corner settings should be as follows:

Select the OK button to exit the command.

Create

Fillet Chains Definition: Create Fillet Chains command lets you create fillets at sharp corners

along selected chains of curves

Create Fillet Chain

Second rectangle

Enter the Radius: = 0.375

Select one of the rectangle lines and then the OK button to exit Chaining

dialog box

Select the OK button to exit the command.

Page-22

Definition: Trim/Extend/Break function has three commands incorporated in

one Based on what button you enable in the ribbon bar you can trim, break orextend the entities

Definition: Trim command allows you to trim 1, 2 or 3 entities, trim to a selected

point or position You can also divide entities based on the closest intersection

File Open Select Trim.mcx

Edit/

Trim/Break Trim/Break/Extend

Definition: Trim 1 entity trims or extends one curve to its intersection with a

second curve without modifying the second entity

Enable Trim 1 entity

-3button Select the entity to trim on the side that youwant to keep after trimming

Page-23

PowerPoint Presentation: Lesson 2.ppt

CD Training Exercises TRIM.MCX

Definition: Trim 2 entities trims or extends both curves to their intersection.

Trim 2

entities Enable Trim 2 entities button.you want to keep after trimming. Select the entities to trim on the side that

Definition: Trim 3 entities trims or extends all three curves The first two

Trim 3

entities

curves that you select are trimmed to the third selected curve, which acts as atrimming curve The third curve is then trimmed to the first two curves

Enable Trim 3 entities button

Select the entities to trim on the side that

Definition: Trim Divide trims a line or an arc into two disjointed segments by

Trim removing the segment that lies between two dividing curves

Definition: Trim to Point trims or extends a curve to a point or any defined

position in the graphics window If the point that you enter does not lie on theselected entity, Mastercam calculates the closest position on the entity and trimsthe entity to that point

Enable Trim to Point button.

Select the entity to trim/extend and then select the point Select the OK button to

exit the command

P a g e- 2 5

XFORM MIRROR COMMAND

Xform

Mirror

Definition: Xform Mirror command creates reverse images of geometric and

drafting entities with respect to a defined axis or two points The axis can bedefined as X-axis, Y-axis, a point and an angle, an existing line or two points Youhave the option to move or copy the original entities within the drawing

PowerPoint Presentation: Lesson 2.ppt

CD Training Exercises MIRROR.MCX

File Open Select Mirror.mcx Xform

Mirror

Tips for the upper shape

Select the entities to mirror using window by enable Window Selection and mirror twice :once about X-axis, then about Y-

axis

Tips for the middle shape

Select both contours to mirror using chain by enble Chain Selection and enable the Select Line button in the Mirror

dialog box Select the red color line.

Tips for the lower shape

Select both contours to mirror using Chain Selection and enable Select 2 points button in the Mirror dialog box Select two of the open ends of

the contours

Page-26

Use the following commands:

Create Rectangle Create Line Endpoint (Horizontal / Vertical) Create Fillet

Trim Divide

Mill Level 1 Assignment

Tutorial 1 –

Exercise 2

Quiz

The student creates the 2D geometry from Tutorial 1 – Exercise 2

Use the following commands:

Create Rectangle Create Line Parallel Create Line Endpoint Trim Divide

Create Fillet Trim 2 entities Answer the first 2 questions from the Tutorial 1 quiz

Page-27

Training Tutorial page 1-34

Mill Level 1 Training Tutorial page 1-36

Lesson PlanIntroduction to Chaining and setting up Properties and basic 2D

toolpathsLesson ObjectivesLearn about chaining.

Load correct machine type

Create Basic Toolpaths using geometry created in Lesson 2 (Tutorial 1)

Learn about contour toolpath

Learn about drilling toolpath

Backplot the toolpaths

Verify the toolpaths.TimeTeaching / Learning StrategiesResources40 minDownload and demonstrate

ANALYZE CHAIN.MCX

Discuss Chaining problems, encourage students to take

notes and ask questions

Download and demonstrate

CHAIN1.MCX

Show students various methods for chaining geometry.CD Training Exercises

Use PowerPoint: Lesson11a.pptEnhancing Phase40 minLoad toolbar states

Load Machine type

Introduction to icons found under Operations Manager

Present Machine Group Properties and explain settings

found there

Set up bounding boxPowerPoints: Lesson11a.ppt20 minHave students complete the Toolpath Creation from

Tutorial 1 found on pages 1-10 to 1-32.Mill Level 1 Training Tutorial Book40 minContour toolpath parameters

Backploting the toolpaths

Verifying the toolpaths

Drill toolpath parametersPowerPoints: Lesson11b.pptAssignment / QuizHave the students open 2D Geometry from Tutorial 1

Exercises and complete toolpaths on those parts On

pages 1-33 & 1-34Mill Level 1 Training Tutorial BookHave students finish Tutorial 1 Quiz on page 1-36Mill Level 1 Training Tutorial Book

LESSON #11 INTRODUCTION TO CHAINING, PROPERTIES AND BASIC 2D

TOOLPATHS

Page 73

DescriptionCheckFixChain stops; Lines do nottouchZoom in to inspectTrim lines together

Mill Level 1 –Lesson11: Toolpath Creation

CHAINING

INSTRUCTOR GUIDE

About

chaining

Definition: Chaining is a process used to select a number of entities, (lines, arcs,

points, splines etc.) Chaining is used when modifying or transforming existingentities or when creating a toolpath The entities form a chain when the distancebetween two consecutive entities is less than the chaining tolerance (.0001 in thesystem configuration)

When Chaining Geometry to create a toolpath it is important in certain

circumstances to chain the geometry in the proper direction, as it will determinethe direction the cutter travels when machining the part Below is an example ofhow to select geometry using chaining method

Note: To change the direction of the arrows just click on Reverse from the Chaining dialog box.

Arrows will go

Arrows will go counter

clockwise when the

clockwise when theline is selected here

line is selected here

PowerPoint Presentation: Lesson 11a.ppt

CHAINING PROBLEMS

Untrimmed

entities

Page 74

Chain stops; Lines cross Zoom in to inspect Trim lines

Branches Chain stops at Branch Points Note that the chain stopsat the first branch. Enable CPlane to select theentities that are in the

current construction plane;

or guide the chaining byselecting the next branch ifall entities area in the same

Cplane

Lines at

different Z

Lines don’t touch Look at geometry in

Gview Isometric Use Xform, Project.

Page 75

entities

Overlapping entities (Entities

of different lengths on top ofeach other)

Zoom in on the area, useAnalyze commands andmove the cursor to the

Use Findovlp.dll C-hook

top of the entities

FIXING CHAINS

Training Exercises ANALYZE CHAIN.MCX

File Open Select Analyze chain.mcx

Analyze Analyze Chain

Delete

Duplicates

Overlapping

Entities

Upper right corner geometry has Duplicate Entities

Use Delete Duplicates icon to remove all identical entities from

the screen

The system will display how many duplicate entities were erased

The upper left contour has entities of different lengths on top of each other.

To fix the geometry use FindOverlap.dll user application To open the C-Hooks directory hold down Alt key and type C Select FindOverlap.dll and Open button.

Page 76

Mill Level 1 –Lesson11: Toolpath Creation INSTRUCTOR GUIDE

Use All button and All Entities when

you are prompted to select the geometry Hit the

Enter button to end the selection Select the Cleanup button in the Find Overlap C-Hook dialog box and hit OK.

The lower left contour has entities at different z-depth.

To see the geometry use Graphic View Isometric Xform

Project Definition: Xform Project projects all entities at the same z-depth in Top Construction Plane.

When prompted to select the geometry use All button as shown in the previous

step to select all entities

Make sure that Move is enabled and project to construction plane and 0 depth

as shown to ther right

The lower right contour has untrimmed entities.

To fix the geometry use

Edit Trim/Break Trim/Break/Extend Trim 2 entities.

Make sure that you select the entities on the side that you want to keep

Page 77

CHAINING - SELECTION METHODS

Chaining

dialog box

In Wireframe mode, the Chaining dialog box provides chain selection methods

including:

C-plane - allows you to select geometry created in the current construction plane.

3D - allows you to select 3D geometry.

Window Area Single Polygon Partial Vector

Other controls let you manage the selection process:

Last End chain Unselect Reverse chaining direction

Full

Chain mode

Use Chain

File Open

selection to create closed chains.

Select the CHAIN1.MCX Use Analyze Chain command to show the different selection options.

Training Exercises CHAIN1.MCX

Select the chain

as shown

Page 78

Mill Level 1 –Lesson11: Toolpath Creation INSTRUCTOR GUIDE

Enable Chain button and then select the chain as shown

Click on the Reverse button to change the chaining direction

You can also expand the chaining dialog box by selecting the drop down arrow

and show how you can change the start of the chain using Forward ,

Back and Dynamic buttons

Click on Unselect button to continue

Partial

Chain

Use Partial chaining to create open chains.

Analyze Chain

Click the first entity of the chain, and then click the last entity of the chain

Branch point is the position where the endpoints of two or more entities meet.

Branch points indicate where there are different paths that the chain can take.

When Mastercam encounters a branch point during chaining, it prompts you tochoose the path for the chain to follow