Welcome Mill Lesson 15 – Part-2 Computer Aided Manufacturing Using Mastercam.

Welcome Welcome Mill Lesson 15 – Part-2 Mill Lesson 15 – Part-2

Computer Aided Computer Aided ManufacturingManufacturing

Using Using MasterMastercamcam

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Mill Lesson 15 The Mill Lesson 15 The ProcessProcess Toolpath CreationToolpath Creation

TASK 1: Setting the environmentTASK 1: Setting the environment TASK 2: TASK 2: Open existing file from Open existing file from

the multimedia CDthe multimedia CD TASK 3: Define the rough stock TASK 3: Define the rough stock

using stock setupusing stock setup TASK 4: Rough mold core using TASK 4: Rough mold core using

surface high speed (core surface high speed (core roughing)roughing)

TASK 5: Finish profile surfaces TASK 5: Finish profile surfaces using surface high speed using surface high speed (waterline)(waterline)

TASK 6: Finish all remaining stock TASK 6: Finish all remaining stock using surface finish leftoverusing surface finish leftover

TASK 7: Verify the toolpath and TASK 7: Verify the toolpath and compare to STL filecompare to STL file

TASK 8: Save the updated MCX TASK 8: Save the updated MCX filefile

TASK 9:Post and create the CNC TASK 9:Post and create the CNC code filecode file

TASK 10:Create ActiveReportTASK 10:Create ActiveReport

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Demonstration of Demonstration of MasterMastercam?cam?

1.1. Verify Lesson 15Verify Lesson 15

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Toolpaths>Surface High Speed… In this task you will use a 1.0 diameter end In this task you will use a 1.0 diameter end

mill with a 0 corner radius to rough the partmill with a 0 corner radius to rough the part Stock to leave on drive is set to 0.010Stock to leave on drive is set to 0.010

Rough Out Mold Core Rough Out Mold Core UsingUsing

Surface High SpeedSurface High Speed

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The Surface High Speed ToolpathsThe Surface High Speed Toolpaths are a set of machining are a set of machining strategies that are specially designed to produce the smoothest, strategies that are specially designed to produce the smoothest, most efficient tool motions when machining surface models or most efficient tool motions when machining surface models or solid faces. Mastercam uses two main techniques to achieve this:solid faces. Mastercam uses two main techniques to achieve this: Each cutting pass can be configured with advanced smoothing Each cutting pass can be configured with advanced smoothing

techniques to reduce the impact of corners, sharp angles, and other techniques to reduce the impact of corners, sharp angles, and other discontinuities so that you can maintain a constant load on the tool.discontinuities so that you can maintain a constant load on the tool.

An advanced suite of linking tools lets you optimize the transitions An advanced suite of linking tools lets you optimize the transitions between cutting passes and the lead in/out to each cutting pass.between cutting passes and the lead in/out to each cutting pass.

Rough Out Mold Core Rough Out Mold Core UsingUsing

Surface High SpeedSurface High Speed

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Core Roughing ToolpathsCore Roughing Toolpaths are designed for machining are designed for machining cores which can be approached from the outside.cores which can be approached from the outside.

They minimize the need for helical ramp moves or full-They minimize the need for helical ramp moves or full-width cutting. width cutting.

Core roughing toolpaths are generated from a set of Core roughing toolpaths are generated from a set of surface profiles that describe the shape of your surfaces surface profiles that describe the shape of your surfaces at different Z heights, plus a set of offset profiles that let at different Z heights, plus a set of offset profiles that let you rough out stock as you approach the part from the you rough out stock as you approach the part from the outside.  outside.  

Rough Out Mold Core Rough Out Mold Core UsingUsing

Surface High SpeedSurface High Speed

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Rough Out Mold CoreRough Out Mold Core - - Drive Drive SurfacesSurfaces

The surfaces, solid faces, solid bodies, or CAD files The surfaces, solid faces, solid bodies, or CAD files thatthat

will be cut.will be cut.

• You are first prompted You are first prompted to Select Drive to Select Drive surfaces, select all of surfaces, select all of the entities on the the entities on the screen.screen.

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Rough Out Mold CoreRough Out Mold Core

Containment CurveContainment Curve

CplaneCplane - Chains only entities that - Chains only entities that are parallel to the current are parallel to the current construction plane and at the same construction plane and at the same Z depth as the first entity you chain.Z depth as the first entity you chain.

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Tool ParametersTool Parameters By clicking on the tool on this page, you will automatically load the By clicking on the tool on this page, you will automatically load the

values for FPT (feed per tooth) and SFM (surface feet per minute). values for FPT (feed per tooth) and SFM (surface feet per minute). This is because we selected This is because we selected From MaterialFrom Material on the on the Tool Settings tabTool Settings tab

of the of the Machine Group PropertiesMachine Group Properties..

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Tool ParametersTool Parameters Right Click on the tool, select Edit Tool. Then go to the Right Click on the tool, select Edit Tool. Then go to the

ParametersParameters tab. tab. % of matl cutting speed% of matl cutting speed allows the user a further adjustment allows the user a further adjustment

of SFM based on the particular tool.of SFM based on the particular tool. % of matl feed per tooth% of matl feed per tooth allows the user a further adjustment allows the user a further adjustment

of FPT based on the particular tool.of FPT based on the particular tool.

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SmoothingSmoothing activates the toolpath smoothing feature, which activates the toolpath smoothing feature, which replaces sharp corners with arcs for faster and smoother replaces sharp corners with arcs for faster and smoother transitions in tool direction. transitions in tool direction.

Max radiusMax radius Enter the radius of the largest arc that you will Enter the radius of the largest arc that you will allow Mastercam to insert to replace a corner. Larger arcs allow Mastercam to insert to replace a corner. Larger arcs will result in a smoother toolpath, but with greater will result in a smoother toolpath, but with greater deviation from the originally programmed toolpath. deviation from the originally programmed toolpath. 

Cut ParametersCut Parameters

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Use this page to configure the entry move that the tool will Use this page to configure the entry move that the tool will make as it transitions to new Z levels. make as it transitions to new Z levels.

You can choose to create either a You can choose to create either a rampramp entry, or entry, or helicalhelical entry entry move. The entry ramp will be a profile ramp that follows the move. The entry ramp will be a profile ramp that follows the contour of the cutting pass for a smoother transition into the contour of the cutting pass for a smoother transition into the cut.  cut.  

RadiusRadius Enter the radius of the entry helix. If the profile is too Enter the radius of the entry helix. If the profile is too small for a helix ramp of this diameter, Mastercam will create small for a helix ramp of this diameter, Mastercam will create a profile ramp instead. a profile ramp instead.

TransitionsTransitions

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On the On the Steep/ShallowSteep/Shallow page set the page set the Minimum Minimum DepthDepth of the cut to 0.1 of the cut to 0.1 this is the top of stock.this is the top of stock.

Right click in the Right click in the Maximum DepthMaximum Depth then select Z then select Z = Z coordinate of a point.= Z coordinate of a point. Select the Z at the top Select the Z at the top of the mold base as shown below left:of the mold base as shown below left:

Steep/ShallowSteep/Shallow

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Arc Filter Arc Filter ToleranceTolerance The Profile toleranceThe Profile tolerance represents the maximum represents the maximum

distance that the outermost profile of the distance that the outermost profile of the smoothed toolpath will deviate from the smoothed toolpath will deviate from the original toolpath. original toolpath.

The Offset toleranceThe Offset tolerance represents the maximum represents the maximum distance that any other profile of the smoothed distance that any other profile of the smoothed toolpath will deviate from the original toolpath.toolpath will deviate from the original toolpath.

Total toleranceTotal tolerance displays the sum of the filter displays the sum of the filter tolerance and cut tolerance.   tolerance and cut tolerance.  

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Arc Filter Arc Filter Tolerance - Tolerance - Refine Refine

ToolpathToolpath Use this dialog box to refine Mastercam's 3D Use this dialog box to refine Mastercam's 3D

surface and high speed surface toolpaths, surface and high speed surface toolpaths, reducing machining time and improving reducing machining time and improving machined surface quality. machined surface quality.

Mastercam uses the values you enter here to Mastercam uses the values you enter here to convert the toolpath— convert the toolpath— originally created using originally created using G1, G2, G3G1, G2, G3 motions—to a refined set of motions—to a refined set of "smoothed" G1 motions"smoothed" G1 motions wherever possible, and wherever possible, and within the tolerances you specify.within the tolerances you specify.

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Demonstration of Demonstration of MasterMastercam?cam?

1.1. Verify Lesson 15 – First OperationVerify Lesson 15 – First Operation