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TRAININGSano mpD t f leis otr ributionGUIDEMILL-LESSON-4DRILL AND CONTOUR TOOLPATHS

M astercam Training GuideObjectivesYou will create the geometry for Mill-Lesson-4, and then generate a toolpath to machine the parton a CNC vertical milling machine. This lesson covers the following topics: Create a 2-dimensional drawing by:Creating rectangles.Creating arcs. Establish Stock Setup settings:Stock size.Material for the part.Feed calculation.Sano mpD t f leis otr ribution Generate a 2-dimensional milling toolpathconsisting of:Contour toolpath.Drill toolpath. Inspect the toolpath using Mastercam’s Verify and Backplot by:Launching the Verify function to machine the part on the screen.Using Backplot to identify the correctness of the toolpaths.Generating the NC- code.Mill-Lesson-4-1

M ill-Lesson-4Sano mpD t f leis otr ributionMILL-LESSON-4 DRAWINGMill-Lesson-4-2

M astercam Training GuideTOOL LIST Two cutters will be used to create this part. The .125” diameter two flute center cutting flat end mill will be used to drill the four .125”diameter holes. The .5” diameter two flute flat end mill will be used to machine the contour.MILL-LESSON-4 - THE PROCESSSano mpD t f leis otr ributionGeometry CreationTASK 1: Set the environmentTASK 2: Create a rectangle 3” x 3” – the center is at X0 Y0TASK 3: Create the inside entitiesTASK 4: Create the four .125” fillet radiiTASK 5: Save the drawingToolpath CreationTASK 6: Define the rough stock using stock setupTASK 7: Drill the 4 x .125” diameter holesTASK 8: Machine the contourTASK 9: Backplot the toolpathTASK 10: Modify the contour toolpath to add roughing cuts and a finishpassTASK 11: Verify the toolpathTASK 12: Save the updated Mastercam fileTASK 13: Post and create the CNC code fileMill-Lesson-4-3

M ill-Lesson-4Geometry CreationTASK 1:SETTING THE ENVIRONMENTBefore starting the geometry creation you should set up the grid, toolbars and machine type asoutlined in the Setting the environment section at the beginning of this text:1. Set up the Grid. This will help identify the location of the origin.2. Load the Workspace – SETTINGS Load Workspace 2D Toolpaths to machine a 2D part.3. Set the machine type to a Haas Vertical Spindle CNC machine.TASK 2:CREATE A RECTANGLE 3” X 3” – THE CENTRE IS AT X0 Y0. This task explains how to create the 3” square. These four lines could be created in manydifferent ways, this is just one option.Sano mpD t f leis otr ribution1. Select from the pull down menu CREATE Rectangle RectangleUse this function to create a rectangle using two points. To drawa rectangle, click to set the base point that anchors the rectangle,drag the rectangle outward, then click to set the second corner.You can also enter X, Y, and Z positions in the AutoCursor ribbonbar to position the two points on the rectangle. The rectangle canbe drawn outward from a center point, and can be drawn as asurface. Width and height are lockable so that you can createmultiple rectangles using set dimensions.The rectangle remains a live entity until you click the Apply buttonor start another rectangle.2. The Create Rectangle ribbon bar appears and you are prompted to Select position of firstcorner.3. On the ribbon bar click in the space for Width and enter a value of 3.0, hit the tab key andyou will be moved over to the Height section.4. In the Height section enter a value of 3.0 and then hit Enter.5. Now select the Anchor to Center option - this option is shown above. To activate theAnchor to Center option the icon is pressed down as shown above.Anchor to center: Sets the base point of the rectangle to the center point, and draws therectangle outward from the center.6. Move the cursor to the center of the Grid and snap to the Origin for the base point.7. Click on the OK iconto complete this feature.8. Select the Screen Fit icon found at the top of the screen to fit the part to the screenMill-Lesson-4-4.

M astercam Training GuideTASK 3:CREATE THE INSIDE ENTITIES In this task you will create the four inside lines. These lines form a 2.5” square. You will use Create Rectangle again to construct these four inside lines.Sano mpD t f leis otr ribution1. Select from the pull down menu CREATE Rectangle 2. The Create Rectangle ribbon bar appears and you are prompted to “Select position ofbase point”.3. On the ribbon bar click in the space for Width and enter a value of 2.5, hit the tab key andyou will be moved over to the Height section.4. In the Height section enter a value of 2.5 and then hit Enter.5. Select the Anchor to Center option - this option is shown above. To activate the Anchorto Center option the icon is pressed down as shown above.6. Move the cursor to the center of the Grid and snap to the origin for the base point.7. Click on the OK iconto complete this feature.8. Your part geometry should look as below: 3.0” and 2.5” square.Mill-Lesson-4-5

M ill-Lesson-4TASK 4:CREATE THE FOUR .125” FILLET RADII In this task you will create the four .125 fillet radii on the corners of the 2.5” square you havejust created.1. Select CREATE Fillet Entities Sano mpD t f leis otr ributionFilletUse this ribbon bar to apply fillets to existingentities. Before selecting the entities to fillet,choose the fillet style (normal, inverse, circle,clearance), and enter the desired radius value.Then choose the first and second entities.Mastercam's auto-preview feature displays atemporary fillet at the selected location.You can also choose to trim to the fillet or toleave the selected lines untrimmed.Trimming is the default, so for no trimming,select the No Trim button.2. On the Fillet ribbon bar enter .125 for the radius. Ensure the Style of radius is set toNormal and the trim button is depressed to turn the trim on.3. When prompted to “Select an entity”, select Line 1 and 2 as shown below. The fillet radiusappears at the corner of line 1 and 2.4. To complete the remaining three fillet radii, select:5. Line 2 and 3.6. Line 3 and 4.7. And finally line 4 and 1.BeforeAfter8. Click on the OK iconto complete this feature.9. Your completed part geometry should look like the figure on the right above.Mill-Lesson-4-6

M astercam Training GuideTASK 5:SAVE THE DRAWINGSelect File.Select Save As.In the “File name” box, type “MILL-LESSON-4”.Save to an appropriate location.Select the Save button to save the file and complete this functionSano mpD t f leis otr ribution1.2.3.4.5.File Save AsMastercam lets you read (import) a variety of CAD file types into the Mastercam database.You can also write (export) Mastercam files to a variety of different file formats. See yourMastercam Reseller for more information on the options available for your Mastercamconfiguration.Below is an example of the various Save as type file options.Mill-Lesson-4-7

M ill-Lesson-4Toolpath CreationTASK 6:DEFINING THE ROUGH STOCK USING STOCK SETUP1. For a better view of the part use the toolbar at the top of the screen to change the graphicsview to IsometricSano mpD t f leis otr ribution2. Now select the Fit to screen icon3. Select the plus in front of Properties to expand the Machine Group Properties. Alt-O willShow/hide Toolpaths Manager pane.4. You may need to extend the toolpaths manager window, if so click on the right hand pane,hold the mouse button down and drag to the right.5. Select Stock setup in the Toolpath manager window.Mill-Lesson-4-8

M astercam Training Guide6. Change the parameters to match the Stock Setup screenshot below:Stock SetupStock OriginThe stock origin is the X-Y-Z coordinateposition of the point indicated by the cross inthe picture of the stock model.Use it so Mastercam knows where your stockmodel is located relative to your part andcoordinate system.You can either type in the X-Y-Z coordinatesdirectly in the fields, or choose the Selectbutton to return to the graphics window andselect a position.Sano mpD t f leis otr ributionDisplayChoose this option to display the stock modelin the graphics window.Fit screenChoose this option so that the stock boundarylines are included when you use the Fit toScreen function.7. Select the Tool Settings tab and change the parameters to match the Tool Settingsscreenshot below. To change the Material type follow the next set of instructions.Program #The post processor will use this field if yourmachine tool requires a number for aprogram name.Sequence #Enter the starting sequence number and theincrement in the proper fields.The default values and specific format forthese fields is determined by the NC Outputsection of the control definition.In the code file below note the block numbersare sequenced in increments of 1, N9 N10etc.Mill-Lesson-4-9

M ill-Lesson-48. To change the Material type to Aluminium 6061 pick the Select button at the bottom of theTool Settings page.Sano mpD t f leis otr ribution9. Select Mill - library at the Material List dialog box open the Source drop down list.10. From the Default Materials list select ALUMINIUM inch -6061 and then select11. Select the OK buttonagain to complete this Stock Setup function.Mill-Lesson-4-10.

M astercam Training GuideSano mpD t f leis otr ribution Your screen will look similar to the screenshot below:Mill-Lesson-4-11

M ill-Lesson-4TASK 7:DRILL THE 4 X .125” DIAMETER HOLES In this task you will drill the four .125” diameter holes through the part with a centre cuttingtwo flute end mill that is .125 “ diameter. As the four holes will be drilled at the centre of the .125” fillet radii you need to create pointsat the centre of these arcs, when creating the drilling toolpath you can snap to the centre ofthe arcs.1. Change the graphics view to a Top View by using the toolbar at the top of the screen.Sano mpD t f leis otr ribution2. From the menu bar select TOOLPATHS Drill 3. When prompted to “Enter new NC name” Input Mill-Lesson-4 as shown below and thenselect the OK button.4. Now you are prompted to:Mill-Lesson-4-12

M astercam Training GuideSano mpD t f leis otr ribution5. The Drill Point Selection dialog box appears:6. Your screen will look similar to the screenshot below:Mill-Lesson-4-13

M ill-Lesson-4 As you need to drill the four holes at the centre of the four fillet radii all you need to do nowis snap to the centre of the fillet radius.7. Move the mouse and position the cursor over the center of the top left hand fillet radius,you will notice a circle appears as you move closer to the center of the radius, this is a visualcue.8. This circle demotes you are snapping the centre of this arc. Use the left button of yourmouse to pick this center point.Sano mpD t f leis otr ribution9. Using the method outlined above continue on and pick the remaining three center points, inthis order:10. Lower left.11. Lower right.12. Upper right.13. Your screen should look like the screenshot below after selecting the four center points:14. Select the OK buttonin the Drill Point Selection dialog box.Mill-Lesson-4-14

M astercam Training Guide After selecting the OK button, you are confronted with the Drill Toolpath Type page. Thefirst task here will be to select a .125” diameter end mill.Sano mpD t f leis otr ribution15. Ensure the Toolpath Type is set to Drill as shown below and then select Tool from the liston the left.16. Click on the Select library tool button in the lower left corner.Mill-Lesson-4-15

M ill-Lesson-417. On the right hand side of the Tool Selection dialog box remove the green check mark fromthe Filter Active to review all the tools.Sano mpD t f leis otr ribution18. Use the slider bar on the right of this dialog box to scroll down and locate a .125” diameterflat end mill.19. Select the .125” diameter flat end mill by picking anywhere along the .125 end mill row, asshown below:20. To resize a column in the Tool Selection dialog box, click on the divider between thecolumns with your left mouse button, as shown below, hold the left mouse button down andmove to the right or left.21. Select the OK buttonto complete the selection of this tool.Tool Selection dialog boxUse this dialog box to select tools from a tool library and add them to the current machinegroup. This means that they can be selected and used in a toolpath. Double-click on a tool toselect it, use it in the current operation, and close this dialog box.To see tools from a different library, select the new library from the drop-list. Click on the folderbutton to see libraries from different folders.You can also filter the tool list by a number of different criteria to make it easier to find the righttool. Select Filter active to apply a tool filter, or click the Filter button to edit the selection criteria.Mill-Lesson-4-16

M astercam Training GuideSano mpD t f leis otr ribution22. Make changes to the Tool parameter page as shown below:23. Select Cut Parameters from the list on the left and make changes to this page as shownbelow. The Cycle should be set to Drill/Counterbore.Drill/Counterbore:Recommended for drilling holes with depths of less than three times the tool diameterMill-Lesson-4-17

M ill-Lesson-4Sano mpD t f leis otr ribution24. Select Linking Parameters from the list on the left and make changes to this page asshown below. Input the depth of -0.28 and the other values as shown below. Note all thevalues are set to Absolute.25. Select the plus sign to the left of Linking Parameters to expand the list and click on TipComp.26. Ensure Tip Comp is not activated as shown below. The Tip Comp box is empty. The redcircular icon denotes this option is disabled.Mill-Lesson-4-18

M astercam Training GuideSano mpD t f leis otr ribution27. Select Coolant from the list on the left. Open up the drop down menu for Flood and set it toOn.28. Select the OK buttonto complete this function.29. Your part should look like the screenshot below:Mill-Lesson-4-19

M ill-Lesson-4TASK 8:MACHINE THE CONTOUR. In this task you machine the contour with a .5” diameter 2 flute end mill. Initially you will machine the contour in one cut at a depth of -.125” and then later in thisLesson add roughing and finishing cuts using Depth of Cuts and Multi Passes.1. From the menu bar select TOOLPATHS Contour Contour toolpaths remove material along a path defined by achain of curves. Contour toolpaths only follow a chain; they donot clean out an enclosed area.You can select an unlimited number of chains for each toolpath.You can create either 2D or 3D contour toolpaths.Sano mpD t f leis otr ribution2. On the screen you will now see the Chaining dialog box with Chain set and in the graphicsscreen a prompt to “Select Contour chain 1”. Select the top horizontal line as shownbelow:Chaining dialog boxUse this dialog box to select chains of entities for generating surfaces, solids, or toolpaths, or forperforming certain Analyze, Xform, or other operations.A chain of entities consists of one or more entities linked together in order and direction.The chaining dialog box operates in two modes: Wireframe (default) and Solids. Two buttons atthe top let you switch between modes; however, if either solid or wireframe geometry is notpresent, its button is unavailable.Mill-Lesson-4-20

M astercam Training GuideSano mpD t f leis otr ribution3. After selecting the top horizontal line your graphics screen should looks like the screenshotbelow, with the green arrow pointing to the right, clockwise direction. The material for this part is aluminium so to attain a good finish when contouring climbmilling should be employed.4. If the arrow is not pointing to the right select the arrow from the Chaining dialog box shownbelow to reverse the direction:5. After the contour has been successfully chained select the OK buttonthe Chaining dialog box.Mill-Lesson-4-21at the bottom of

M ill-Lesson-4Sano mpD t f leis otr ribution6. Ensure the Toolpath Type is set to Contour as shown below and then select Tool from thelist on the left.7. Click on the Select library tool button in the lower left corner.Mill-Lesson-4-22

M astercam Training Guide8. Use the slider bar on the right of this dialog box to scroll down and locate a .5” diameter flatend mill. Select the .5” diameter flat end mill by picking anywhere along the .5 end mill row,as shown below:Sano mpD t f leis otr ribution9. Select the OK buttonto complete the selection of this tool.10. Make changes to the Tool page as shown below:Rapid retractSelect this option to retract from the part at the rapid rate set at the machine tool.If you do not select this option, Mastercam will use the programmed Retract rate set in thisdialog box.SFM (inch), CS (metric)Displays the cutting speed in surface feet per minute or surface meters per minute.FPTDisplays the amount of feed per tooth, based on the number of flutes in the tool definition.Mill-Lesson-4-23

M ill-Lesson-4Sano mpD t f leis otr ribution11. Select Cut Parameters from the list on the left and make changes to this page if required.12. Select Lead In/Out from the list on the left and make changes to this page.Mill-Lesson-4-24

M astercam Training GuideSano mpD t f leis otr ribution13. Select Linking Parameters. Input the depth of -0.125 and the other values as shownbelow. Note all the values are set to Absolute.14. Select Coolant from the list on the left. Open up the drop down menu for Flood and set it toOn.15. Select the OK buttonto complete this functionMill-Lesson-4-25

M ill-Lesson-4TASK 9:BACKPLOT THE TOOLPATH In this task you will use Mastercam’s Backplot function to view the path the tools take to cutthis part. Backplot will enable you to review the cutting motions and identify any problem areas whencutting the part. When the toolpaths are being Backplotted Mastercam displays tool path information on theright of the screen. Information such as the current tool position in X, Y, and Z coordinates. For more information on Backplot see the Tips and Techniques section on themultimedia DVD supplied with this text.circled below:Sano mpD t f leis otr ribution1. To pick all the operations to Backplot pick the Select All icon Another method to Select all the operations is by clicking on the Toolpath Group-1 in theToolpaths Manager as shown by the arrow above.2. The next step is to select the Backplot selected operations icon shown below:3. Maximize the Backplot/Verify window if required.4. Select the Home Tab if required.5. Activate the options shown below in the Visibility section of the Home tab.Mill-Lesson-4-26

M astercam Training Guide6. At the top of the screen select the View tab, the Isometric icon and then select Fit.7. Click on the Backplot tab at the top left of the screen.Sano mpD t f leis otr ribution8. Activate the Both option in the Toolpath section of the Backplot tab.9. In the lower right corner of the screen now set the run Speed to slow by moving the sliderbar pointer over to the left as shown below.10. Now select the Play Simulation button to review the toolpaths.11. After reviewing the Backplot of the two toolpaths using a .5 spot drill and .25 drill selec t theClose buttonin the top right hand corner to exit Backplot.Mill-Lesson-4-27

M ill-Lesson-4TASK 10:MODIFY THE CONTOUR TOOLPATH TO ADD ROUGHING CUTS ANDA FINISH PASS In this task you will use Mastercam’s Multi Passes and Depth of cuts to perform aroughing and finishing operation for the contour toolpath. Multi Passes will let the tool approach the part geometry at the cutting depth in stepsinstead of cutting right to the part geometry. Depth of cuts can be used to set the number of depth cuts, you can enter a maximumrough step and Mastercam divides the total depth into equal steps. Or you can enter theexact number of finish steps and the size of each finish step. Mastercam never createsunequal rough depth cuts. For more information on Multi Passes and Depth of cuts see the Tips and Techniquessection on the multimedia DVD supplied with this text.Sano mpD t f leis otr ribution1. In the Toolpaths Manager select Parameters from the contour toolpat

Mastercam Training Guide Mill-Lesson-4-9 6. Change the parameters to match the Stock Setup screenshot below: Stock Setup Stock Origin The stock origin is the X-Y-Z coordinate position of the point indicated by the cross in the picture of the stock model. Use it so Mastercam knows where your stock model is located relative to your part and