Mill Level 1 Training Tutorial Contents

Mill Level 1 Training Tutorial

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Mastercam X5 Mill Level 1 Training Tutorial Copyright: 1998 -2010 In-House Solutions Inc. All rights reserved Software: Mastercam X5 Author: Mariana Lendel ISBN: 978-1-926566-78-8 Revision Date: October 13, 2010 Notice In-House Solutions Inc. reserves the right to make improvements to this manual at any time and without notice. Disclaimer Of All Warranties And Liability In-House Solutions Inc. makes no warranties, either express or implied, with respect to this manual or with respect to the software described in this manual, its quality, performance, merchantability, or fitness for any praticular purpose. In-House Solutions Inc. manual is sold or licensed "as is." The entire risk as to its quality and performance is with the buyer. Should the manual prove defective following its purchase, the buyer (and not In-House Solutions Inc., its distributer, or its retailer) assumes the entire cost of all necessary servicing, repair, of correction and any incidental or consequential damages. In no event will In-House Solutions Inc. be liable for direct, indirect, or consequential damages resulting from any defect in the manual, even if In-House Solutions Inc. has been advised of the possibility of such damages. Some jurisdictions do not allow the exclusion or limitation of implied warranties or liability for incidental or consequential damages, so the above limitation or exclusion may not apply to you. Copyrights This manual is protected under International copyright laws. All rights are reserved. This document may not, in whole or part, be copied, photographed, reproduced, translated or reduced to any electronic medium or machine readable form without prior consent, in writing, from In-House Solutions Inc. Trademarks Mastercam is a registered trademark of CNC Software, Inc. Microsoft, the Microsoft logo, MS, and MS-DOS are registered trademarks of Microsoft Corporation; NSee is a registered trademark of Microcompatibles, Inc.; Windows, Windows XP, Windows Vista and Windows NT are registered trademarks of Microsoft Corporation.

Mill Level 1 Training Tutorial Contents Getting Started ...................................................................................................A-1 Tutorials Tutorial #1 ......................................................................................................................... 1-1 Tutorial #2 ......................................................................................................................... 2-1 Tutorial #3 ......................................................................................................................... 3-1 Tutorial #4 ......................................................................................................................... 4-1 Tutorial #5 ......................................................................................................................... 5-1 Tutorial #6 ......................................................................................................................... 6-1 Tutorial #7 ......................................................................................................................... 7-1 Tutorial #8 ......................................................................................................................... 8-1 Tutorial #9 ......................................................................................................................... 9-1 Tutorial #10 ..................................................................................................................... 10-1

General Notes ..................................................................................................... B-1 Creating/Editing tools ......................................................................................... C-1 Quiz Answers ......................................................................................................D-1


TUTORIAL #31

TUTORIAL #3 Objectives: The Student will design a 2-dimensional drawing by: !Create arcs polar knowing the diameter, location, start and end angles. !Create parallel lines, by defining the offset direction and distance. !Create fillets knowing the radius size. !Create lines on an angle knowing the starting point and angle. !Mirror the part to create the other 1/2 of the part. The Student will create toolpaths consisting of two setups: !An open pocket toolpath to remove the material in the open area. !Contour remachining toolpath to cut the material which the open pocket left. !A circle mill toolpath to remove the material in the arc. !Three drill toolpaths to, spot drill, drill and tap the holes. !A contour toolpath to remove the material at the parts exterior. !The contour toolpath will be part of setup #2 The Student will simulate the toolpaths using Mastercam's Verify and Backplot by: !Defining a 3-dimensional rectangular block the size of the workpiece. !Running the Backplot to see the path the tool takes to cut the part. !Running the Verify to simulate the tool cutting from a solid model. This tutorial takes approximately one hour to complete.


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SETTING UP THE GRAPHIC USER INTERFACE

TUTORIAL #31

GEOMETRY CREATION

STEP 1:

SETTING UP THE GRAPHIC USER INTERFACE Before starting the geometry creation we should customize the toolbars to see the toolbars required to create the geometry and machine a 2D part. See Getting started page A-4 for details. Make sure that the Grid is enabled. It will show you where the part origin is. See Getting started page A-6 for further information. The Operations Manager to the left of the screen can be hidden to gain more space in the graphic area for design. From the keyboard, press Alt + O keys simultaneously to hide it. Repeat this command to make it visible again.

Figure: 1.0.1

NOTE: We will create 1/2 of the geometry.


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TUTORIAL #31 STEP 2:

CREATE ARCS POLAR

CREATE ARCS POLAR In this step you will learn how to create arcs polar. To create arcs polar you need to define center point, radius, start point or angle and end point or angle.

Step Preview:

2.1 Create the 1.5" diameter arc Create Arc Arc Polar [Select position for the center of the arc]: Select the Origin. Figure: 2.1.1

Make sure that when selecting the origin, the visual cue of the cursor changes as shown.

Input a Diameter End Angle

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of 1.5 inches, hit tab and enter a Start Angle

of 180 degrees.


of 0.0 degrees and a

CREATE ARCS POLAR

TUTORIAL #31

Your drawing will appear as shown up to this point. Figure: 2.1.2

Choose the Apply button to continue.

NOTE: During the geometry creation of this tutorial, if you make a mistake you can undo the last step using the Undo icon

. You can undo as many steps as needed. If you delete or

undo a step by mistake, just use the Redo icon first and then press Delete from the keyboard.

. To delete unwanted geometry, select it

Select the Fast Point icon from the Auto Cursor ribbon bar . Input the value 1.25, 0.0 and hit enter to place the Arc center point.

Enter a Diameter

of 0.25 inches, hit tab and enter a Start Angle

of 0.0 degrees and a

End Angle of 180 degrees. Your drawing will appear as shown up to this point. Figure: 2.1.3

Choose the apply button to continue. Select the Origin for the arc center point. Enter a Radius an End Angle

of 1.5 inches, hit tab twice and enter a Start Angle

of 90 degrees and

of 180 degrees.


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TUTORIAL #31

CREATE HORIZONTAL LINES


Select the OK button to exit the Arc Polar command Use the Fit icon to fit the drawing to the screen

STEP 3:

.

.

CREATE HORIZONTAL LINES In this step you will learn how to create horizontal lines.

Step Preview:

Create Line Endpoint Select the horizontal icon

.

NOTE: Once this icon has been selected you will only be able to create horizontal lines. Select a point to the left of the large arc. Select another point to the right of the small arc to create a horizontal line. Enter a value to offset that line in the Y-Axis direction of 1.25".

Select the Apply button to continue . Repeat this same step creating a line offset in the Y-Axis direction of 0.75".

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CREATE VERTICAL LINES

TUTORIAL #31


STEP 4:

CREATE VERTICAL LINES In this step you will learn how to create vertical lines.

Step Preview:

Create Line Endpoint Select the vertical icon

.

NOTE: Once this icon has been selected you will only be able to create vertical lines. Select a point to the right of the small arc. Select another point above the original selected point to create a vertical line. Enter a value to offset that line in the X-Axis direction of 1.75".

Choose the apply button to continue. Repeat this same step creating a line offset in the X-Axis direction of 3.0". Select the OK button once complete

.

Pick the Fit icon to view all of the entities

.


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TUTORIAL #31

TRIM TWO ENTITIES


STEP 5:

TRIM TWO ENTITIES In this step you will learn how to trim two entities to each other.

Step Preview:

Edit Trim/Break Trim/Break/Extend Select the trim 2 entities command

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and ensure the option to Trim is enabled


.

TRIM TWO ENTITIES

TUTORIAL #31

Select the two lines. Figure: 5.0.1

NOTE: When selecting the second line you will notice the lines change to a hidden line style. This is a preview of what is going to be trimmed and lets you select another entity if necessary. Repeat the step selecting the lines as shown. Figure: 5.0.2



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TRIM A LINE TO A POINT

TRIM A LINE TO A POINT Trim to point trims an entity to a point or any defined position in the graphics window. If the point that you enter does not lie on the selected entity, Mastercam calculates the closest position on the entity and trims the entity to that.

Step Preview:

Edit Trim/Break Trim/Break/Extend Select the trim to point command and ensure the option to trim is enabled Select the line as shown and then select the Origin as the point to trim to.

.

Figure: 6.0.1

Select the OK button to exit the trim command

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.

CREATE LINE ENDPOINT

STEP 7:

TUTORIAL #31

CREATE LINE ENDPOINT Create Line Endpoint lets you create lines from a selected endpoint or intersection to a selected point at a given angle.

Step Preview:

Create Line Endpoint Select the intersection point for the first endpoint.

NOTE: Ensure the vertical or horizontal is not enabled. Figure: 7.0.1

Pick the second line endpoint point roughly in the area as shown. Figure: 7.0.2

Change the line Length to 3.0 inches and Angle to 5.00 degrees.

Choose the Apply button once the values have been input

.


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TUTORIAL #31

CREATE LINE ENDPOINT

Pick the intersection point for another line. Figure: 7.0.3

Pick the second Line Endpoint point roughly in the area as shown. Figure: 7.0.4

Change the line Length to 3.0 inches and angle to 175.0 degrees.

Select the OK button once the values have been input Your drawing will appear as shown up to this point.

.

Figure: 7.0.5

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CREATE FILLETS

STEP 8:

TUTORIAL #31

CREATE FILLETS Fillets are used to round sharp corners.

Step Preview:

Create Fillet Entities Enter a fillet radius of 0.25. Ensure the fillet style is set to Normal and trim is enabled.

Select the Arc and Line. Figure: 8.0.1

Select the two angled lines. Figure: 8.0.2


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TUTORIAL #31

CREATE FILLETS

Pick the angled line and the vertical line. Figure: 8.0.3

Select the Apply button Input a Fillet Radius of 0.125 in the ribbon bar.

Select the two lines. Figure: 8.0.4


Select the OK button to exit the create fillet command

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.

DELETE THE CONSTRUCTION LINE

STEP 9:

TUTORIAL #31

DELETE THE CONSTRUCTION LINE Delete the construction line to remove it from the graphics user interface.

Select the line as shown. Figure: 9.0.1

Pick the Delete icon to remove the line.

STEP 10:

XFORM MIRROR Mirror entities by reflecting them symmetrically with respect to a defined axis or point.

Step Preview:

Xform Mirror


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TUTORIAL #31

XFORM MIRROR

Create a box around the part. Left click and hold the mouse down, drag the mouse down to the lower left area of the part and left click again. Figure: 10.0.1

Select the End Selection button. When the Mirror dialog box appears enable Copy and choose the option to mirror about the X axis. Figure: 10.0.2

Select the OK button to exit the Mirror dialog box. Pick the Clear Colour icon to re-set the drawing colors to the original system colour Your drawing will appear as shown.

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.

JOIN ENTITIES

TUTORIAL #31

Figure: 10.0.3

STEP 11:

JOIN ENTITIES Join entities is used to join collinear lines, arcs that have the same center and radius.

NOTE: There is no step preview for this step because the drawing will appear the same. Edit Join Entities Select the entities as shown. Figure: 11.0.1

Once those entities have all been selected pick the End Selection button.

NOTE: If you move your mouse over those entities now they should appear as one solid entity.


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SAVE THE FILE

SAVE THE FILE Figure: 12.0.1

File Save As File name: "Your Name_3" Select the OK button to save your file.

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SUGGESTED FIXTURE:

TUTORIAL #31

TOOLPATH CREATION

SUGGESTED FIXTURE:

NOTE: In order to machine this part we will have 2 setups and output 2 NC files. To view the second setup see page 58.

SETUP SHEET:


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SELECT THE MACHINE AND SET UP THE STOCK.

SELECT THE MACHINE AND SET UP THE STOCK. In Mastercam, you select a Machine Definition before creating any toolpaths. The Machine Definition is a model of your machines capabilities and features. It acts like a template for setting up your machine. The machine definition ties together three main components. The schematic model of your machines components. The control definition that models your control capabilities and the post processor that will generate the required machine code (G-code). For a Mill Level 1 exercise (2D toolpaths) we need just a basic machine definition.

NOTE: For the purpose of this tutorial, we will be using the Default milling machine. To display the Operations Manager press Alt + O. Use the Fit icon to fit the drawing to the screen Figure: 13.0.1

Machine type Mill Default Select the plus sign in front of Properties in the Toolpaths Manager to expand the Toolpaths Group Properties. Figure: 13.0.2

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TUTORIAL #31

Select Tool Settings to set the tool parameters. Figure: 13.0.3

Change the parameters to match the screen shot as shown. Figure: 13.0.4

Program # is used to enter a number if your machine tool requires a number for a program name. Assign tool numbers sequentially allows you to overwrite the tool number from the library with the next available tool number. (First operation tool number 1; Second operation tool number 2, etc.) Warn of duplicate tool numbers allows you to get a warning if you enter two tools with the same number. Override defaults with modal values enables the system to keep the values that you enter. Feed Calculation set From tool uses feed rate, plunge rate, retract rate and spindle speed from the tool definition.

Select the Stock setup tab to define the stock. Select the Bounding Box button near the bottom of the Stock Setup page.


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TUTORIAL #31


Figure: 13.0.5

In the Expand dialog boxes enter 0.125 as shown. This will add 0.125" of stock on each side of your model. Figure: 13.0.6

Select the OK button to exit the Bounding Box.

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TUTORIAL #31

Input the overall depth of your stock model. Figure: 13.0.7

The Stock Origin values adjust the positioning of the stock, ensuring that you have equal amount of extra stock around the finished part. Display options allow you to set the stock as Wireframe and to fit the stock to the screen. (Fit Screen)

NOTE: The stock model that you create can be displayed with the part geometry when viewing the file or the toolpaths, during backplot, or while verifying toolpaths. In the graphics, the plus shows you where the stock origin is. The default position is the middle of the stock. Click on the corner of the part to set it as the stock origin. Select the OK button to exit Machine Group Properties. Select the Isometric view from the graphics view toolbar to see the stock. Use the Fit icon to fit the drawing to the screen

.


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TUTORIAL #31

OPEN POCKET

The stock model will appear as shown. Figure: 13.0.8

NOTE: The stock is not geometry and can not be selected. Select the Top view from the view toolbar to see the part from the top.

NOTE: There will not be facing toolpath because the stock is already to size.

STEP 14:

OPEN POCKET Open Pocket Mastercam automatically enters and exits the pocket through the opening.

Toolpath Preview:

Toolpaths Pocket

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OPEN POCKET

TUTORIAL #31

If a prompt appears, Enter new NC name, select the OK button to accept the default. Figure: 14.0.1

When the chaining dialog box appears, choose Partial as the chaining method. Figure: 14.0.2

Select the first entity. Figure: 14.0.3


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TUTORIAL #31

OPEN POCKET

Select the second entity. Figure: 14.0.4

Choose the OK button to exit the chaining dialog box. In the Toolpath Type page, the Pocket icon will be selected. Figure: 14.0.5

NOTE: Mastercam updates the pages as you modify them and then marks them, in the Tree view list, with a green check mark. Pages that are not changed are marked with a red circle and slash.

14.1 Select a 1/2" Flat Endmill Select a 0.5" Flat Endmill from the library and set the Tool parameters. Select Tool from the Tree view list. Click on Select library tool button. Select the Filter button. Figure: 14.1.1

Select the None button and then under Tool Types choose the Flat Endmill Icon.

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OPEN POCKET

TUTORIAL #31

Under tool diameter pick Equal and input a value 0.5. Figure: 14.1.2

Select the OK button to exit the Tool List Filter. In the Tool Selection dialog box you should only see a 1/2" Flat Endmill. Figure: 14.1.3

Select the 1/2" Flat Endmill in the Tool Selection page and then select the OK button to exit.


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TUTORIAL #31

OPEN POCKET

Make all the necessary changes. Figure: 14.1.4

The Feed rate, Plunge rate, Retract rate and Spindle speed are roughly based on the part material Aluminum and HSS tooling. You may change these values as per your part material and tools. In the Comment field enter a comment to help identify the toolpath in the Toolpaths/Operations Manager such as the one shown above.

14.2 Cut Parameters Select Cut Parameters and make the necessary changes. Figure: 14.2.1

Pocket Type lets you select from a list several pocket types which are based on your pocket geometry. Open Pocket Mastercam automatically enters and exits the pocket through the opening. Open pocket cutting method starts the toolpath at the open end of the pocket and cuts from the inside to the outside.

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OPEN POCKET

TUTORIAL #31

14.3 Roughing Select Roughing and make the necessary changes. Figure: 14.3.1

Cutting Method determines the cutting method. When using open pocket the cutting method is set to Open. Stepover percentage/ Stepover distance sets the distance between cutting passes in the X and Y Axes as a percentage of the tool diameter. Changing this value automatically adjusts the stepover distance.

14.4 Entry Motion Select Entry Motion and pick Off as the entry motion used. We do not need an entry motion because you will be plunging the tool off the material. Figure: 14.4.1

Off turns off any entry helix or ramp moves for the pocket toolpath’s roughing passes. Mastercam plunges the tool to the pocket depth at the start of the toolpath.


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TUTORIAL #31

OPEN POCKET

NOTE: We are using Off because the tool will plunge off the material. This way we won’t waste any time waiting for the tool to get to its cut depth.

14.5 Finishing Select Finishing and make the necessary changes. Figure: 14.5.1

For more information regarding these parameters please see page 28 in Tutorial #2.

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OPEN POCKET

TUTORIAL #31

14.6 Lead In/Out Select Lead In/Out and disable this option. Figure: 14.6.1

14.7 Depth Cuts Choose Depth Cuts and enable this option. Input a Max rough step of 0.2. Enable the option Keep tool down. Figure: 14.7.1


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TUTORIAL #31

OPEN POCKET

14.8 Break Through Pick Break Through from the Tree view list. Enable this option and input a break through amount of 0.1. Figure: 14.8.1

Break Through allows you to specify an amount that the tool will completely cut through the material by. This values is always a positive number.

14.9 Linking Parameters Pick Linking Parameters and make the necessary changes. Figure: 14.9.1

Select the OK button to exit the Pocket parameters.

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BACKPLOT THE TOOLPATHS

STEP 15:

TUTORIAL #31

BACKPLOT THE TOOLPATHS Backplotting shows the path the tools take to cut the part. This display lets you spot errors in the program before you machine the part. As you backplot toolpaths, Mastercam displays the current X, Y, and Z coordinates in the lower left corner of the screen.

Make sure that the toolpaths are selected (signified by the green check mark on the folder icon). If the operation is not selected choose the Select all operations icon Select the Backplot selected operations button

.

Make sure that you have the following buttons turned on (they will appear pushed down) to see the tool and the rapid moves. Figure: 15.0.1

Select the Isometric view from the view toolbar to see the stock. Select the Fit button You can adjust the speed of the backplot. You can step through the Backplot by using the Step forward or Step back buttons. Select the Play button in the VCR bar. Select the OK button to exit Backplot

. Figure: 15.0.2


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VERIFY THE TOOLPATH

VERIFY THE TOOLPATH Verify allows you to use a solid model to simulate the machining of a part. The model created by verification represents the surface finish, and shows collisions, if any exist.

In the Operations Manager both operations are selected. If the operation is not selected choose the Select all operations icon. Choose the Verify selected operations icon from the operations manager. Set the Verify speed by moving the slider bar in the speed control bar as shown. Select the Play button to start simulation. Figure: 16.0.1

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REMACHINE THE POCKET CORNERS

TUTORIAL #31

The part will appear as shown up to this point. Figure: 16.0.2

STEP 17:

REMACHINE THE POCKET CORNERS Contour Remachine removes the material where the previous tool couldn’t fit.

Toolpath Preview:

17.1 Chain selection Toolpaths Contour Enable the Last button in the chaining dialog box this will reselect the geometry we chained in the previous toolpath.


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TUTORIAL #31


Figure: 17.1.1

Select the OK button to exit Chaining. In the Toolpath Type page, the Contour icon will be selected. Figure: 17.1.2

NOTE: Mastercam updates the pages as you modify them and then marks them, in the Tree view list, with a green check mark. Pages that are not changed are marked with a red circle and slash.

17.2 Select a 1/8" Flat endmill from the library and set the Tool parameters Select Tool from the Tree view list. Click on Select library tool button. Select the Filter button as shown.

Select the None button and then under Tool Types choose the Flat Endmill Icon. Under tool diameter pick Equal and input a value 0.125.

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TUTORIAL #31

Figure: 17.2.1

Select the OK button to exit the Tool List Filter. In the Tool Selection dialog box you should only see a 1/8" Flat Endmill. Figure: 17.2.2

Select the 1/8" Flat Endmill in the Tool Selection page and then select the OK button to exit.

Make all the necessary changes as shown. Figure: 17.2.3


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TUTORIAL #31


17.3 Cut Parameters From the Tree view list, select Cut Parameters and ensure the settings appear as shown. Figure: 17.3.1

For more information regarding these parameters please see page 36 in Tutorial #2.

17.4 Depth Cuts From the Tree view list, select the Depth Cuts Parameters. Enable Depth cuts and input a Max rough step of 0.05 as well enable the option to Keep tool down. Figure: 17.4.1

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TUTORIAL #31

17.5 Lead In/Out Select Lead In/Out from the Tree view list. Disable the option to enter/exit at midpoint in closed contours. Enter an arc radius value of 0.0%. Enable the option to Adjust start of contour input a length of 100% and choose the option Extend. Select the copy button to copy the parameters from the entry to the exit options. Figure: 17.5.1

17.6 Break Through From the Tree view list, select Break Through and make the necessary changes. Figure: 17.6.1


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TUTORIAL #31


17.7 Linking Parameters Select Linking Parameters and input the Depth as shown. Figure: 17.7.1

Once complete pick the OK button to generate the toolpath. To Backplot and Verify your toolpath see page 33 to review these procedures.

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CIRCLE MILL THE LARGE HOLE

STEP 18:

TUTORIAL #31

CIRCLE MILL THE LARGE HOLE Circle mill toolpath is used to mill circular pockets based on a single point. Mastercam will pocket out a circular area of the diameter and to the depth that you specify. After milling the center of the circle, Mastercam calculates an entry arc before approaching the perimeter and then a similar exit arc. You can add enhancements such as multiple passes, multiple depth cuts and helical plunge moves as well fine tuning the entry and exit arcs.

Toolpath Preview:

Toolpaths Circle Paths Circle Mill

18.1 Select the Geometry When the Drill Point Selection dialog box appears choose Entities. Figure: 18.1.1


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TUTORIAL #31


Select the arc. Figure: 18.1.2

Choose the OK button once the arc has been selected. On the Toolpath Type page Circle Mill will be picked. Figure: 18.1.3

18.2 Select the 1/2" Tool Figure: 18.2.1.

NOTE: Pick the 1/2" Flat Endmill from the tool page to use the tool for this toolpath.

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TUTORIAL #31

18.3 Cut Parameters From the tree view list select Cut Parameters ensure the parameters appear the same. Figure: 18.3.1

Start Angle sets the angle where the helix bore toolpath begins.

18.4 Roughing Enable Roughing and ensure your parameters appear as shown. Figure: 18.4.1 Roughing select to activate roughing passes and apply a step-over amount and helical entry move to your circle mill toolpath. Helical entry creates a helix at the center of the circle to begin the roughing motion. Output arc moves writes the entry helix to the NCI file as arcs. Use this option to create shorter NC files. If this option is off the helix is turned into linear segments.


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TUTORIAL #31


18.5 Depth Cuts Choose Depth Cuts from the tree view list. Input a Max rough step of 0.25 and enable keep tool down. The depth cuts will only be applied to the roughing portion of the toolpath. Figure: 18.5.1

18.6 Break Through Select Break Through from the Tree view list and enable the option. Input a Break through amount of 0.1. Figure: 18.6.1

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SPOT DRILL THE HOLE

TUTORIAL #31

18.7 Linking Parameters Select Linking Parameters from the Tree view list. Set the depth to -0.75. Figure: 18.7.1

Select the OK button to exit the Circle Mill Parameters. To Backplot and Verify your toolpath see page 33 to review these procedures.

STEP 19:

SPOT DRILL THE HOLE Spot Drilling the holes allows you to start the hole. In this operation we will use the spot drill to chamfer the hole before drilling it.

Toolpath Preview:

Toolpaths Drill


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TUTORIAL #31

SPOT DRILL THE HOLE

In the Drill Point Selection dialog box choose the option Entities. Figure: 19.0.1

Select the small arc. Figure: 19.0.2

Select the OK button in the Drill Point Selection dialog box once you have picked the arc.

In the Toolpath Type page, the Drill toolpath will be selected. Figure: 19.0.3

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SPOT DRILL THE HOLE

TUTORIAL #31

19.1 Select a 1/2" Spot Drill from the library and set the Tool parameters Select Tool from the Tree view list. Click on Select library tool button. To be able to see just the spot drill select the filter button.

Under Tool Types select the None button and then choose the Spot Drill Icon. Figure: 19.1.1

Select OK button to exit the Tool List Filter dialog box. At this point you should only see Spot Drills. From that list select the 1/2" Spot Drill. Figure: 19.1.2

Select the tool in the Tool Selection page and then select the OK button to exit.


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TUTORIAL #31

SPOT DRILL THE HOLE

Make the necessary changes to the Tool page. Figure: 19.1.3

19.2 Cut Parameters Select Cut Parameters and make the necessary changes. Figure: 19.2.1

Drill/Counterbore recommended for drilling holes with depths of less than three times the tools diameter. Dwell sets the amount of time in seconds that the tool remains at the bottom of a drilled hole.

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SPOT DRILL THE HOLE

TUTORIAL #31

19.3 Linking Parameters Choose Linking Parameters, ensure clearance is enabled and set the Top of stock to zero. To input the depth select the Calculator icon . Input the following equation in the Finish diameter area. 0.25+0.05 and hit Enter to calculate the Depth. Figure: 19.3.1

Select the OK button to exit the Depth Calculator. You will now see the depth we calculated for the spot drilling operation set in the Depth field. Figure: 19.3.2

Select the OK button to exit the Drill/Counterbore parameters. To Backplot and Verify your toolpath see page 33 to review these procedures.


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DRILL THE HOLE

DRILL THE HOLE In this example we will drill the holes to a specified depth.

Toolpath Preview:

Toolpaths Drill In the Drill Point Selection dialog box choose the option Last. Figure: 20.0.1

This option will automatically select the hole for you based off the selection from the previous drill operation. Select the OK button in the Drill Point Selection dialog box to accept the drill point.

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DRILL THE HOLE

TUTORIAL #31


20.1 Select a #7 Drill from the library and set the Tool parameters Select Tool from the Tree view list. Click on Select library tool button. To be able to see just the Spot Drill select the Filter button.

Under Tool Types select the None button and then choose the drill Icon. For the Tool Diameter select Ignore. Figure: 20.1.1

Select OK button to exit the Tool List Filter dialog box. At this point you should see a list of drills. From that list, select the NO. 7 Drill as shown. Figure: 20.1.2

Select the tool in the Tool Selection page and then choose the OK button to exit.


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TUTORIAL #31

DRILL THE HOLE


20.2 Cut Parameters Select Cut Parameters, change the drill cycle to Chip Break and input a 1st peck value of 0.1. Figure: 20.2.1

Chip Break drills holes with depths of more than three times the tool diameter. Retracts partially out of the drilled hole to break material chips. 1st peck sets the depth for the first peck move which plunges in and out of the material to clear and break chips.

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DRILL THE HOLE

TUTORIAL #31

20.3 Linking Parameters Choose Linking Parameters and input a depth value of -0.75. Figure: 20.3.1

20.4 Tip Comp Pick Tip Comp and enable this option. Input a Break through amount of 0.1. Figure: 20.4.1



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TAP THE HOLE

TAP THE HOLE Tap cycle Taps right or left internal threaded holes.

Toolpath Preview:

Toolpaths Drill In the Drill Point Selection dialog box choose the option Last. Figure: 21.0.1

This option will automatically select the hole for you based off the selection from the previous drill operation. Select the OK button in the Drill Point Selection dialog box to accept the drill point.

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TAP THE HOLE

TUTORIAL #31


21.1 Select a 1/4 - 20 RH Tap from the library and set the Tool parameters Select Tool from the Tree view list. Click on Select library tool button. To be able to see just the spot drill select the filter button.

Under Tool Types select the None button and then choose the Tap RH Icon. Under Tool Diameter select Ignore. Figure: 21.1.1

Select OK button to exit the Tool List Filter dialog box. At this point you should see a list full of taps. From that list select the 1/4 - 20 Tap RH. Figure: 21.1.2

Select the tool in the Tool Selection page and then choose the OK button to exit.


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TUTORIAL #31

TAP THE HOLE


21.2 Cut Parameters Select Cut Parameters, change the drill cycle to Tap. Figure: 21.2.1

Tap Cycle Taps right or left internal threaded holes.

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TAP THE HOLE

TUTORIAL #31

21.3 Linking Parameters Choose Linking Parameters and input a depth value of -0.75. Figure: 21.3.1

21.4 Tip Comp Pick Tip Comp and enable this option. Input a Break through amount of 0.1. Figure: 21.4.1



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TUTORIAL #31

SUGGESTED FIXTURE:

TOOLPATH CREATION

SUGGESTED FIXTURE:

NOTE: In order to machine this part we will have 2 setups and output 2 NC files. Setup Sheet:

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CREATING AND RENAMING TOOLPATH GROUPS

STEP 22:

TUTORIAL #31

CREATING AND RENAMING TOOLPATH GROUPS To machine the part in two different setups, we will need to have two separate programs. To be able to post process separately the operations of each setup, we will create them under different toolpath groups with different NC names.

22.1 Rename the current Toolpath Group - 1 and NC file Click two times on the Toolpath Group - 1 to highlight it and rename it "Setup #1." Figure: 22.1.1

Right mouse click on the toolpath group and select Edit selected operations and then, select Change NC file name. Figure: 22.1.2

Enter the new NC name: Setup #1. Figure: 22.1.3


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TUTORIAL #31

CONTOUR TOOLPATH

Select the OK button to accept the new NC name. Create a new Toolpath Group. Right mouse click on the Setup #1 and hold the mouse button down. Drag the cursor below the insert arrow and select Copy After. This will create a new toolpath group and copy the toolpaths below. At this time with the toolpaths selected press delete on your keyboard. A message will pop up asking you if you want to delete the toolpaths. Select Yes from this message. Rename the toolpath group "Setup #2". Figure: 22.1.4

STEP 23:

CONTOUR TOOLPATH Contour toolpath removes material along a path defined by a chain of curves. A Contour toolpath only follows a chain, it does not clean out an enclosed area.

Toolpath Preview:

Toolpaths Contour

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CONTOUR TOOLPATH

TUTORIAL #31

Leave the default settings in the Chaining dialog box as shown. Figure: 23.0.1

Select the chain and ensure the chaining direction is the same. Figure: 23.0.2

Select the OK button to exit the chaining dialog box. In the Toolpath Type page, the Contour toolpath will be selected. Figure: 23.0.3


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CONTOUR TOOLPATH

23.1 Pick a 1.0" Flat endmill from the library and set the Tool parameters Select Tool from the Tree view list. Click on Select library tool button. To be able to see all the tools from the library disable Filter Active.

Scroll down and select the 1.0" Flat Endmill. Figure: 23.1.1

Select the tool in the Tool Selection page and then select the OK button to exit. Make all the necessary changes. Figure: 23.1.2

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CONTOUR TOOLPATH

TUTORIAL #31

23.2 Cut Parameters Select the Cut Parameters page and make the necessary changes. Figure: 23.2.1 Roll cutter around corners inserts arc moves around corners in the toolpath None guarantees all sharp corners Sharp rolls the tool around sharp corners (135 degrees or less) All rolls the tool around all corners and creates smooth tool movement.

23.3 Depth Cuts Select Depth Cuts and enable it. Input a Max rough step of 0.5 and enable Keep tool down. Figure: 23.3.1


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CONTOUR TOOLPATH

23.4 Lead In/Out Choose the option Lead In/Out and input an Overlap value of 0.05. Make any other necessary changes. Figure: 23.4.1

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CONTOUR TOOLPATH

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23.5 Multi Passes Select Multi Passes, enable the option. Set the Number of Rough passes to 1 with Spacing of 0.1 and number of Finish passes to 1 with Spacing of 0.02. This will have the system make a rough pass and then proceed with a 0.02" finish pass. Enable the option to Machine finish passes at the Final depth. Figure: 23.5.1


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CONTOUR TOOLPATH

23.6 Linking Parameters Select the Linking Parameters from the Tree view list. Set the Depth to -0.75. Figure: 23.6.1

Select OK exit the Contour parameters. To Backplot and Verify your toolpath see page 33 to review these procedures.

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RENAME NC FILE

STEP 24:

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RENAME NC FILE The contour operation in Setup #2 kept the NC name from Setup #1. We need to rename this operation.

Right Click on Operation #7, choose the option Edit selected operations and then pick Change NC file name. Figure: 24.0.1

When the Enter new NC name dialog box appears select "Setup #2". Figure: 24.0.2

Select the OK button apply the changed NC name to operation #7. The result you should see Setup #2.NC in the last item of text for operation #7. Figure: 24.0.3


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POST THE FILE

POST THE FILE Ensure all operations are selected, if they are not use the button Select all operations the Operations Manager.

in

Select the Post selected operations button from the Operations Manager. In the Post processing window make the necessary changes. Figure: 25.0.1

NC File enabled allows you to keep the NC file and to assign the same name as the MCX file. Edit enabled allows you to automatically launch the default editor.

Select the OK button to continue. Select the OK button to save Setup #1 NC file. Select the OK button to save Setup #2 NC file.

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SAVE THE UPDATED MCX FILE

TUTORIAL #31

A window with both NC programs will appear. Figure: 25.0.2

To view the two files as shown in the graphic above select window and pick Tile Horizontal. Figure: 25.0.3

Select the red "X" box at the upper right corner to exit the editor.

STEP 26:

SAVE THE UPDATED MCX FILE Select the Save icon

.


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TUTORIAL #31

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CREATE THE GEOMETRY FOR TUTORIAL #3 EXERCISE

TUTORIAL #31

CREATE THE GEOMETRY FOR TUTORIAL #3 EXERCISE Use these commands to create the geometry. Create 1/2 of the geometry. Create circle center point. Fast Point to locate arcs. Create Vertical and Horizontal lines. Create Tangent Lines. Edit Trim/Break Two Pieces. Create Line Parallel. Create fillet entities.


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CREATE THE TOOLPATHS FOR TUTORIAL #3 EXERCISE

CREATE THE TOOLPATHS FOR TUTORIAL #3 EXERCISE Create the Toolpaths for Tutorial #3 Exercise as per the instructions below.

Set the machine properties including the stock setup. Remove the material in the open pocket. Use a 1/2" Flat Endmill. Set the Pocket type to Open. The cutting method will be set to Open. Entry Motion set to Off. Enable finishing and set the necessary parameters. Disable Lead In/Out. Use Depth Cuts. Enable Break through. Set the Depth according to the drawing.

Drill the 3/4" Hole. Choose a 3/4" Drill. Set the Cycle to Drill/Counterbore. Input a Depth according to the drawing. Enable Tip Comp.

Machine the Pocket. Use a 1/4" Flat Endmill. Set the Pocket type to Standard. Choose a cutting method. Entry Motion set to Off. Enable finishing and set the necessary parameters. Disable Lead In/Out. Use Depth Cuts. Disable Break through. Set the Depth according to the drawing.

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CREATE THE TOOLPATHS FOR TUTORIAL #3 EXERCISE

TUTORIAL #31

Setup on 2nd Fixture. Remove the Material around the part (Contour 2D) Select the 1/2" Flat Endmill from the Tool page. Set your compensation direction according to your chaining direction to ensure your tool is cutting on the correct side of the part. Enable Depth cuts. Enable and set the Lead In/Out parameters. Set a Break through amount. Enable Multi Passes and set Parameters. Set the Depth according to the drawing.


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TUTORIAL #31

NOTES:

NOTES:

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TUTORIAL #3 QUIZ

TUTORIAL #31

TUTORIAL #3 QUIZ What does Open Pocket cutting method do?

What does Contour Remachine do?

What does the Open Pocket cutting method do?

What is the process used to be able to post different operations as different programs?


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TUTORIAL #31

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TUTORIAL #3 QUIZ
