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Mastercam X2 Advanced Multiaxis Tutorial

1. 5 Exercise 2 Refining the cutting area 11 Exercise 3 Driving the tool with a leading curve 13 Tilt angle and tool control s 16 Exercise 4 Controlling the tool axis 16 GOUPE CDI RIS oeoicocseixe artc deiudi sten essei cuousieiduoeed 20 Exercise 5 Gouge prevention by retracting the tool 21 Exercise 6 Omitting gouge points from the toolpath 25 Approach and retract strategies eeeeeeessssse 29 Exercise 7 Creating entry and exit moves 29 Exercise 8 Using a fixed tool angle 32 Exercise 9 Using a single point for tool axis control 34 Exercise 10 Stopping the toolpath on a gouge 36 Tutorial 2 Multiaxis Toolpath Techniques 38 Exercise 1 Creating cuts parallel to a leading curve 39 Exercise 2 Creating a swarf toolpath 43 Exercise 3 Handling problem areas in the part model 45 Exercise 4 Combining several gouge and collision checks eeeeeeeeseeeeeeees 50 2 Application Examples 57 Example 1 Compressor Armature with 4 Axis Output 58 eel 59 Drive geometry and cutting passes eeeess 60 Tool axis control and gouge chec
2. To leave stock on the drive surface enter a positive value here To cut below the drive surface enter a negative value gt Organizing the cutting passes 1 From the Cutting method list select One way 10 MASTERCAM X2 Advanced Multiaxis Tutorial This makes the tool run around the cylinder in one direction Using Zigzag would alternate the cutting direction with every cut a Sorting Flip step over Cutting method One way Cut order Standard Direction for one way machining Cwise i Enforce cutting direction assume closed contours Start point 2 Setthe Maximum stepover to 10 That sets the distance between every slice to 10mm Surface quality Cut tolerance 0 01 Distance 5 Maxinium stepover T 3 Click OK to generate the tool path TUTORIALS Parallel Cuts on a Cylinder 11 Your cutting passes should look like the following picture Note For clarity s sake most of the toolpath pictures in this tutorial are taken while backplotting Exercise 2 Refining the cutting area In the toolpath above notice that there are gaps between the edge of the model and the first and last cutting passes The gap is approximately half the maximum stepover amount In this exercise you will modify the toolpath to eliminate them You will also start the toolpath at the top of the cylinder instead of the side gt Expanding the cutting area 1 If necessary click the Paramet
3. APPLICATION EXAMPLES Engraving 63 Example 2 Engraving 5 axis engraving is popular in the mold and die industry There are company logos recycling icons volume markers and artistic designs engraved on molding surfaces deep inside cavities or on free form surfaces on cores In this example you will engrave the words Mastercam X2 on the side of the part as shown below You must use a small cutter and you can only get superior results if you stay normal to the surfaces you are cutting 5 axis motion is a requirement In this example you will use a slender V groove cutter with a 3 degree taper The 5 axis engraving toolpath maintains the depth of the cut contour relative to the drive surface This is especially noticeable when using V groove cutters since the width of the engraved contour will remain constant To begin open the following file Documentation ExampleParts Engraving mcx 64 MASTERCAM X2 Advanced Multiaxis Tutorial The following picture shows the desired toolpath APPLICATION EXAMPLES Engraving 65 Tooling For this part use a tapered endmill with the following dimensions Note that this is a metric part so these dimensions are in mm Calc 5peed Feed Taper mill Tool Type Parameters Save to library Halder 25 0 C Finish Holder dia Bath 50 0 Arbor Diameter i0 0 Hadius Tvpe None C Comer al dec Taper angle Diameter O 3 0
4. gt The first strategy is applied to the drive surfaces In this case you want to retract the tool along the axis only enough to prevent the gouge while otherwise continuing the toolpath The second strategy is designed to make sure that the tool shaft and arbor do not gouge the upper part of the electrode when machining the upper fillet In case of a gouge you want to simply tilt the tool away from the electrode body APPLICATION EXAMPLES Electrode Machining 89 In the Check column select Tool shaft and Arbor and select the Tilting tool away options as shown above Select the following check surface The next several examples all discuss the same part an impeller Each example discusses a different operation or type of operation 90 MASTERCAM X2 Advanced Multiaxis Tutorial APPLICATION EXAMPLES mpeller Floor Roughing 91 Example 5 Impeller Floor Roughing An impeller is a rotating component of a pump It transfers energy from the motor that drives the pump to the fluid being pumped by forcing the fluid outwards from the center of rotation They are used in a variety of demanding applications in which they are subjected to high heat fluids and steam Because of this they are often made from very tough materials Combined with their difficult shape this makes them a challenge to machine effectively The next several examples all use the same part the impeller shown here The following ma
5. Mastercam Advanced Multiaxis Tutorial ON L Mastercam X2 Advanced Multiaxis Tutorial September 2006 Mastercam gt ii MASTERCAM X2 ADVANCED MULTIAXIS TUTORIAL IMPORTANT NOTICE Software License Restrictions Mastercam Advanced Multiaxis Tutorial Date September 15 2006 Copyright 2006 CNC Software Inc All rights reserved First Printing September 15 2006 Software Mastercam X2 ISBN 1 883310 61 X PLEASE READ THIS STATEMENT AND THE SOFTWARE LICENSE AGREEMENT COMPLETELY BEFORE USING THIS SOFTWARE BY CONTINUING TO USE THIS SOFTWARE YOU EITHER AN INDIVIDUAL OR A SINGLE ENTITY INDICATE YOUR INTENTION TO BE BOUND BY AND ACCEPT THE TERMS AND CONDITIONS OF THIS SOFTWARE LICENSE IF YOU DO NOT AGREE TO THESE TERMS AND CONDITIONS YOU MAY NOT ACCESS OR OTHERWISE USE THIS SOFTWARE AND WILL IN FACT BE PROHIBITED FROM DOING SO THIS COMPUTER SOFTWARE MAY BE USED ONLY PURSUANT TO THE TERMS AND CONDITIONS SET FORTH BELOW AND SOLELY IN CONJUNCTION WITH THE ACCOMPANYING SECURITY MECHANISM UNLESS OTHERWISE SPECIFIED IN THE EXCEPTIONS TO SECURITY MECHANISM REQUIREMENTS SECTION OF SUCH TERMS AND CONDITIONS WHICH MUST BE PRESENT ON YOUR COMPUTER OR NETWORK AS APPLICABLE AT ALL TIMES DURING SUCH USE Read This If You Have Received This Software From A Third Party If you received this Software from someone other than an authorized CNC Software Inc reseller you do NOT have a legal software
6. Protile Auto C Custom file Custom level fo 66 MASTERCAM X2 Advanced Multiaxis Tutorial Drive geometry and cutting passes Use the following Surface paths settings Toolpath parameters Surface paths Tool axis contral Gouge check Link Roughing Utility Machine definition Misc Pattern Project curves Edit cures Projection i E Drive surfaces Drive surfaces offset E Round comers Sotin 3 r Surface quality Cut tolerance 0 002 Distance 1 5 Use the Project curves pattern to create the cutting passes Click the Projection button and select the geometry to be engraved In the sample file the letters are organized by themselves on level 20 to make selection easier You could also select them easily using a color mask IMPORTANT The curves must already lie on the surfaces before machining APPLICATION EXAMPLES Engraving 67 For drive surfaces select just the surfaces shown To control the engraving depth use the Axial shift parameter on the Utility tab This setting shifts the toolpath along the tool axis by a specified amount Use a negative amount to cut below the surface In this case the value of 0 1mm means that the tool will cut just below the surface Axial shift 01 68 MASTERCAM X2 Advanced Multiaxis Tutorial Linking the cuts Use the following settings on the Link tab Toolpath parameters Surface paths To
7. Standard Direction for one way machining Dwise i Enforce cutting direction assume closed contours gt Setting the tool axis control 1 Goto the Tool axis control tab 2 Choose the Tool axis will be tilted relative to cutting direction strategy 3 Set the Tilt angle at side of cutting direction to 90 Toolpath parameters Surface paths Tool axis control Gouge check Link F Output Format 5 anis I aximum angle step 3 Tool asiz will Be tilted relative to cutting direction Lead angle to cutting 0 direction Tilt angle at side of cutting 30 directian The 90 degree side tilt changes the tool from its almost horizontal orientation normal to the surfaces to a vertical orientation suitable for swarfing gt Creating the gouge check strategy 1 Goto the Gouge check tab and activate strategy 1 2 Select the Tool tip Tool shaft and Arbor to check against 3 Select the Tilting tool away with max angle strategy and select Use side tilt angle option This will tilt the tool away from the drive surfaces just enough to avoid gouging TUTORIALS Multiaxis Toolpath Techniques 45 4 Clear the Check surfaces option since you are only working with drive surfaces in this part Your settings should look like this Check Strategy and parameters Geometry Tool Arbor Holder shaft v Drive surfaces E Tilting tool away with mas angle Check surfaces t1 Use side tilt angle 80 5
8. This is because you don t know the exact spacing between letters so the amount is set very low to capture all of the possible APPLICATION EXAMPLES Engraving 69 transitions The dialog box says of stepover but since there is no stepover for a Project toolpath Mastercam uses the tool diameter instead The retract distance is set by clicking the Distances button Rapid distance Feed distance Air move safety distance cancel In this case the Feed distance is set at 2mm so the tool will retract 2mm from the surface between each letter 70 MASTERCAM X2 Advanced Multiaxis Tutorial Tool axis control and gouge checking Use the following Tool axis control settings Toolpath parameters Surface paths Tool axis control Gouge check Link Roughing tility Machine definition Misc Output Format 5 anig Maximum angle step 3 Tool avis will Not be tited and stays normal to surface For this application it is important that the tool stay normal to the surface and not otherwise tilt The 5 axis output is required to maintain this orientation Gouge checking is turned off for this toolpath because it is not needed The next example introduces a new type of application where the advanced multitasking toolpaths are used on a multitasking lathe APPLICATION EXAMPLES Camshaft on a Multitasking Lathe 71 Example 3 Camshaft on a Multitasking Lathe Multitasking lathes or mi
9. 90 You can verify whether the positive or negative APPLICATION EXAMPLES Camshaft on a Multitasking Lathe 75 angle is correct by verifying the cuts against the selected cut Direction g arti it Flip step over Cutting method Dine wan Cut order Standard F Direction for one way machining If you imagine that you are in the middle of the lathe looking towards the left spindle the tool is properly moving clockwise with the machining angle set to 90 If you select 90 then the Cwise cut direction would actually produce counterclockwise tool motion Note Even though you re working on a lathe machine this toolpath uses world mill coordinates with Z pointing up and the X axis is parallel to the main lathe spindle Click Drive surfaces and select Surface 1 to machine just the left cam 76 MASTERCAM X2 Advanced Multiaxis Tutorial Select the Flip step over option This reverses the order of the cuts so that as the tool feeds between cuts more of the cutting force is on the side of the tool not the bottom Sorting 2 Flip step over T LI J Activate the Distance option When this option is selected Mastercam is forced to calculate a tool position before moving the specified distance It functions like a point generator ensuring that there is at least one calculated tool position every 0 1 inch v Distance 0 1 The settings for the second toolpath are exactly the same as the first one
10. CNC All associated intellectual property rights including without limitation worldwide patent trademark copyright and trade secret rights are reserved CNC retains all right title and interest in and copyrights to the Software regardless of the form or media in or on which the original or other copies may subsequently exist This Software License Agreement shall not constitute a sale of the Software and no title or proprietary rights to the Software are transferred to you hereby You acknowledge that the Software is a unique confidential and valuable asset of CNC and CNC shall have the right to seek all equitable and legal redress which may be available to it for the breach or threatened breach of this Software License Agreement including without limitation injunctive relief Unauthorized copying of the Software or failure to comply with the above restrictions shall result in automatic termination of this License and this Software License Agreement without prejudice to all other legal rights and remedies of CNC You acknowledge that the Software contains proprietary trade secrets of CNC and you hereby agree to maintain the confidentiality of the Software using at least as great a degree of care as you use to maintain the confidentiality of your own most confidential information You agree to reasonably communicate the terms and conditions of this Software License Agreement to those persons employed by you who come into contact with the Softw
11. Click OK and then regenerate the toolpath You should see a single cut with the tool axis aligned with the drive surfaces Exercise 3 Handling problem areas in the part model If you look closely at the toolpath from the previous exercise you can see several problem areas 46 MASTERCAM X2 Advanced Multiaxis Tutorial First there is a sharp corner where the two surfaces meet This results in a fishtail in the toolpath TUTORIALS Multiaxis Toolpath Techniques 47 Second there is a gap in the drive surface that causes the tool to retract even though the lead curve is continuous In this exercise you will learn how to handle both these problems gt Eliminating fishtails in your toolpath 1 Openthe toolpath parameters for the operation and select the Surface paths tab 2 Select the Round corners option v edes Ester z trim This option works like a fillet generator for your toolpath The surface model is rounded filleted in the direction of the toolpath slices with a radius sufficiently large to smooth sharp corners and corners with very small radii The radius used by Mastercam is the radius of the tool plus the current stock to leave value This option is used most often with ball cutters lollipop cutters or conical cutters with a ball tip Using this option with end mills is also appropriate for swarf machining like this part 48 MASTERCAM X2 Advanced Multiaxis Tutorial
12. Lead angle and Tilt angle at 0 This will result in the tool axis staying normal to the surface Typically when this strategy is selected you will enter either a lead lag angle a side tilt angle or both By not entering any tilt angle this produces the same results as the Not be tilted and stays normal to the surface strategy However the difference is that later you will select a gouge check strategy that requires a side tilt so selecting a tool axis strategy that allows a side tilt is necessary 88 MASTERCAM X2 Advanced Multiaxis Tutorial Select the Limits option and enter the following values v Contain tool within conical angles wl 20 Wet 45 Cone axis zzi e This limits the axis tilt to between 20 and 45 degrees to the Z axis Instead of locking the tool axis at a 45 degree angle like the previous toolpath you will allow an extra 25 degrees of movement Select the following strategies on the Gouge check tab Toolpath parameters Surface paths Tool axis control Gouge check Link Roughing LI tility Machine definition Misc Check Strategy and parameters Geometry Tool Tool Arbor Holder tip shaft W Drive surfaces Check surfaces 1 Titing tool away with mas angle Drive surfaces es Mae UI Iv Check surfaces t2 s ee side tit angle Stock ta leave lo Tolerance 0 005 E I z E H Hetracting tool along tool agis M Drive surfaces v Check surfaces 3
13. at exact surface e i Found comers E Extend s trin Sorting Flip step over Cutting method One way Cut order TERE Direction for one way machining Cwise Maximum stepover Enforce cutting direction assume closed contours Surface quality Cut tolerance Distance v Start paint Cancel Apply Help This tutorial focuses on the four most important tabs You will use these tabs for almost every toolpath that you create Typically you will complete them in order working from left to right Surface paths Use this tab to select drive geometry and cut patterns and to organize the cutting passes TUTORIALS ntroducing Advanced Multiaxis Toolpaths 3 Tool axis control Use this tab to define the tool orientation and machining limit angles You can also configure the contact point and choose 3 axis 4 axis or 5 axis output Gouge check Use this tab to configure up to four independent gouge and collision checking routines Each individual gouge check routine can have its own set of check surfaces and geometry and its own type of retract or collision avoidance movement Link Use this tab to configure tool motions for entry and exit moves moves between passes and moves that span gaps in your surfaces or toolpaths You can also specify clearance distances and safety zones The advanced multiaxis toolpaths also include a Toolpath parameters tab for selecting and managi
14. cut pattern For parallel cuts the most important parameters are the angle and orientation of the cuts Pattern Parallel cuts i Machining angle in 7 fo Constant 2 Machining angle in Z ci 30 90 000 Parallel Drive surfaces E Drive surfaces offset Area pe Full start and end at exact surface e v start and end at exact surface e Y 4 Use Machining angle in Z to orient the tool plane in which the cuts are created A value of 0 creates cuts parallel to the XY plane while 90 creates cuts perpendicular to it Use Machining angle in X Y to rotate the orientation of the cuts within the cutting plane A value of 0 creates cuts aligned with the Y axis while 90 creates cuts aligned with the X axis You can type values directly in the fields or use the other buttons to pre set values for typical applications Click Constant Z to create waterline style passes along the surfaces Click Parallel to orient the cutting passes perpendicular to the XY plane Click the button to select other planar orientations Mastercam automatically fills in the machining angles to match the selected plane For this application all you need to do is click Parallel to set the proper machining angles gt Selecting the drive surfaces 1 Click the Drive surfaces button TUTORIALS Parallel Cuts on a Cylinder 9 2 Select the red surface shown below 3 Enter 0 for Drive surfaces offset
15. degrees creating horizontal cuts Click Drive surfaces and select all of the green and purple surfaces APPLICATION EXAMPLES Electrode Machining 83 Tool axis control and gouge checking Use the following settings on the Tool axis control tab Toolpath parameters Surface paths Tool axis control Bouge check Link Roughing Utility Machine definition Misc Output format 5 axis hd asximum angle step 3 Tool asis will Tited with fixed angle to axis Fixed tilt anale E Z axis W Tool axiz crosses tilt anis Reverse tool This will lock the tool axis to a fixed 45 degree angle to the Z axis throughout the toolpath resulting in 4 1 axis output Select the Tool axis crosses tilt axis option to ensure that the tool axis is pointed directly to the Z axis throughout the toolpath In other words when seen from above the tool will always point to X 0 Y 0 This means that all the Y axis moves will be substituted by C axis moves and the only cutting moves will be X and C axis moves 84 MASTERCAM X2 Advanced Multiaxis Tutorial Select the following strategy on the Gouge check tab Toalpath parameters Surface paths Tool axis control Gouge check Link Roughing Utility Machine definition Misc Check Strategy and parameters Geometry Tool Tool Arbor Holder tip shaft E v Drive surfaces Leaving aut gouging points Check surfaces 1 Since this is only a se
16. for the current operation 2 Goto the Gouge check tab and change the gouge strategy to Leaving out gouging points 26 MASTERCAM X2 Advanced Multiaxis Tutorial 3 Setthe Stock to leave for the check surfaces as 2 Your options should look like the following picture Toolpath parameters Surface paths Tool axis control Gouge check Link Roughing Utility Machine definition Misc Check Tool Tool Arbor Holder tip shaft Strategy and parameters Geometry Drive surfaces v Checksurfaces tl Wy Stock to leave 2 dual Tolerance o m 7 Drive surfaces 4 Click OK and then regenerate the toolpath You can see that now when the tool reaches a check surface it retracts to a clearance plane When it approaches the part it still maintains a minimum 2mm from the check surface In the next procedure you will define a better clearance zone Stock to leave TUTORIALS Parallel Cuts on a Cylinder 27 gt Defining clearance planes and safety zones 1 Openthe toolpath parameters for the operation and select the Link tab Use the Link tab to configure non cutting tool movements between cutting passes as well as entry and retract moves Click the Clearance area button 3 From the Type list select Cylinder parallel to X and enter a radius of 65 Enter anchor point coordinates of X20 Y 20 and Z 0 This establishes a clearance plane which wraps around the part 65mm from the cent
17. is TIP Click the Round corners button to increase the implied radius by a fixed amount 3 Click OK and then regenerate the toolpath When you zoom in on the area you should see a clean transition between surfaces gt Handling surface gaps in your toolpath The Link tab includes a section that lets you specify how to handle large and small gaps You can define which gaps are small and large as a percentage of the tool size In this case the gap is approximately 25mm so you will set the separation between small and large gaps at 300 of the tool diameter thereby defining this as a small gap 1 Open the toolpath parameters for the operation and select the Link tab TUTORIALS Multiaxis Toolpath Techniques 49 2 Select Blend spline as the Small gaps strategy Toolpath parameters Surface paths Tool axis control Gouge cheat Link oughing Utility First entry From clearance area Dont use macro Last exit Back ta clearance area Don t use macra Small gaps Blend spline Don t use macro Large gaps Don t use macro Small gap size in of tool diameter 300 C as value Clearance area The goal is to keep the toolpath close to the geometry and not have it retract at all The blend spline strategy connects the drive surfaces with a toolpath move that leaves and enters the existing surfaces tangentially 3 Enter 300 to define the Small gap size 50 MASTERCAM X2 Advance
18. of the tool radius to create a clean edge at the open ends of the part Choose the Zigzag cutting method Tool axis control Use the following Tool axis control settings to orient the tool approximately parallel to the surface so that it fits between the blades Toalpath parameters Surface paths Tool axis control Gouge check Link Roughing Utility Machine definition Misc Output format 5 axis hd Maximum angle step 3 Tool asis will Be tilted relative to cutting direction Lead angle to cutting direction d Tilt angle at side of cutting an direction Side tilt definition Follow surface iso direction Select the Be tilted relative to cutting direction strategy and enter a Tilt angle of 80 APPLICATION EXAMPLES mpeller Blade Semi finishing 105 A tilt angle of 0 zero would orient the tool axis approximately normal to the drive surface as shown in the left picture Tilting the tool 80 degrees allows it to fit between the blades and also to remove stock with its side as shown in the right picture Y Tilt angle 80 To define the tilt direction select the Follow surface iso direction option The following pictures explain how this is used Tilt angle 0 Every surface has two isometric directions Tilt angle aligned with iso direction Ifyou wish click the Advanced button to enter a fanning distance 106 MASTERCAM X2 Advanced Multiaxis Tutorial G
19. terms are used in 48 C ER 12 212 Consistent with 48 C ER 12 212 and 48 C ER 227 7202 1 through 227 7202 4 the Software made available to the United States of America its agencies and or instrumentalities is provided with only those rights set forth in this Agreement Use duplication or disclosure of the Software by the government is subject to the restrictions as set forth in subparagraph c 1 and 2 of the Commercial Computer Software Restricted Rights clause at 48 C ER 52 227 19 as amended or any successor regulations thereto You represent and warrant that you will not without obtaining prior written authorization from CNC and if required of the Bureau of Export Administration of the United States Department of Commerce or other relevant agency of the United States Government export or re export directly or indirectly the Software from the United States to i any country destination to which export is restricted by the Export Administration Regulations of the United States Department of Commerce ii any country subject to sanctions administered by the Office of Foreign Assets Control United States Department of the Treasury or iii such other countries to which export is vi MASTERCAM X2 ADVANCED MULTIAXIS TUTORIAL Exceptions to Security Mechanism Requirements Survival Reservation of Rights Trademarks restricted by any other United States government agency You further agree that you are solely responsible
20. tip shaft Strategy and parameters Arbor Holder Retracting tool along tool axis Moving tool away Tilting tool away with max angle Leaving aut gouging points Stop tool path calculation Retracting tool along tool axis 3 Click OK and then regenerate the toolpath Mastercam generates a partial toolpath and stops toolpath calculations when it detects a gouge 38 MASTERCAM X2 Advanced Multiaxis Tutorial Tutorial 2 Multiaxis Toolpath Techniques The second tutorial introduces a number of more sophisticated multiaxis techniques to machine the interior of this part You will use a 10mm flat endmill Some of the skills you will learn include creating a swarf toolpath handling problem areas in your part model creating multiple collision checks for part fixtures and other check surfaces The part geometry and tool are saved in the following file Documentation ExampleParts Multiaxis_Example2 mcx Load this part to begin the tutorial Note All the parts and tools in this tutorial are metric TUTORIALS Multiaxis Toolpath Techniques 39 Exercise 1 Creating cuts parallel to a leading curve gt Selecting the geometry 1 From the Toolpaths menu choose Advanced Multiaxis 2 Select 5 Axis Multi Surface and click OK Select User Interface Interface Ex Multi Surface B Axis Multi Surface Bx Swarf Impeller FlaorsurFace Port Machining titing through point Impeller floor
21. ITED WARRANTY IS THE ONLY WARRANTY PROVIDED BY CNC REGARDING THE SOFTWARE TO THE MAXIMUM EXTENT PERMITTED BY LAW CNC DISCLAIMS ALL OTHER WARRANTIES OF ANY KIND EITHER EXPRESSED OR IMPLIED INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE CNC IS NOT OBLIGATED TO PROVIDE ANY UPDATES TO THE SOFTWARE SHOULD THE SOFTWARE PROVE DEFECTIVE FOLLOWING ITS PURCHASE YOU AND NOT CNC ITS DISTRIBUTOR OR RETAILER ASSUME THE ENTIRE COST OF ALL NECESSARY SERVICING REPAIR OR CORRECTION AND ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES Note on Documentation While CNC makes every effort to ensure that its Documentation for the Software is accurate and up to date it cannot guarantee the Documentation at all times represents the latest operation and functionality of the Software The content of the Getting Started Guide User Manual and other documentation for the Software is provided for informational purposes only The content of the Documentation may be changed without notice to you CNC expressly disclaims any warranty or representation that the Documentation is an accurate and or current reflection of the Software s operation and performance IN NO EVENT WILL CNC OR ITS EMPLOYEES SHAREHOLDERS DISTRIBUTORS OR SUPPLIERS BE LIABLE TO YOU FOR ANY INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING WITHOUT LIMITATION SPECIAL PUNITIVE OR EXEMPLARY DAMAGES FOR LOSS OF BUSINESS LOSS OF PROFITS B
22. Mastercam will start in the middle and work outwards Enter a Maximum stepover of 0 25 equal to half the tool diameter On the Link tab select the Blend spline strategy to link the cuts and to control gap motion This means that whenever Mastercam encounters a gap it will interpolate a smooth spline from one end of the gap to the other to ensure a smooth transition Toalpath parameters Surface paths Tool axis contral Gouge check Link Roughing LI tility Machine definition Misc First entry From clearance area Don t use macro Last exit Back ta clearance area Dont use macro Gaps along cut Small gaps Blend spline EM Don t use macro Large gaps Blend spline Dont use macro Small gap size in X of tool diameter 20 as value Links between slice Small moves Blend spline Don t use macro Large moves Blend spline Don t use macro Small move as size in of stepover 110 C as value fo 96 MASTERCAM X2 Advanced Multiaxis Tutorial Tool axis control Use the following settings on the Tool axis control tab Output format 5 anis Maximum angle step 3 Tool axis will Tilted through curve Tilt curve Fixed tilt angle fo Curve tilt type Closest point For this toolpath use a guide curve based on the shape of the impeller blades to control the tool axis Select the Tilted through curve strategy Select the magenta
23. RCAM X2 Advanced Multiaxis Tutorial Even while the tool is passing around the check surfaces the tool axis is still normal to the drive surface as set in the Tool axis control tab gt Gouge checking between positions 1 Make a copy of the operation 2 Go to the Gouge check tab for the new copy and select the Check gouge between positions option 3 Click OK and then regenerate the toolpath TUTORIALS Parallel Cuts on a Cylinder 25 When you backplot the toolpath and compare it to the previous operation you should see a subtle difference as the tool rounds the sharp corner of the check surface Check gouge between positions path Normal path Selecting this option causes Mastercam to insert additional nodes in the toolpath that result in more accurate gouge checking around sharp corners and other sharp or discontinuous areas of your model Selecting this option results in increased toolpath processing time but can produce more accurate gouge checking Exercise 6 Omitting gouge points from the toolpath In the previous exercise the tool is effectively machining the check surface since there is 0 stock to leave on those surfaces In this exercise you will apply a different retract strategy to the check surfaces The goal will be to prevent the machining over the check surfaces and maintain a minimum 2mm distance from them gt Applying the Leaving out gouging points strategy 1 Openthe toolpath parameters
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25. Zigzag cutting method Sorting Flip step over Cutting method Zigzag Cut order Standard T 3 Set the Cut tolerance to 0 01 and Maximum stepover to 2 Surface quality Cut tolerance 0 01 Distance Maxinium stepover J 42 MASTERCAM X2 Advanced Multiaxis Tutorial 4 Click OK to generate the toolpath It should look like the following picture TUTORIALS Multiaxis Toolpath Techniques 43 Exercise 2 Creating a swarf toolpath The toolpath in the previous exercise was machined with the tool in an almost horizontal position In this exercise you will modify this toolpath to produce a true swarf toolpath with a single cut along the bottom rail This exercise is also a good illustration of how tool axis control and gouge check settings work together to meet sophisticated tool control needs gt Editing the cutting pattern 1 Inthe Toolpath Manager make a copy of the previous operation and click its Parameters icon to edit it Go to the Surface paths page 3 Change the area type to Determined by number of cuts and set the number of cuts equal to 1 Type Determined by number of cuts Mumber af cuts f E Round comers E Extend zm 44 MASTERCAM X2 Advanced Multiaxis Tutorial Since this will be a swarf toolpath you only need a single pass along the curve 4 Set the Cutting method to One way Sorting Flip step over Cutting method One way L ut erder
26. angle in Z to 90 Since the part is parallel to the X axis the Machining angle in X Y should be left at 0 For Drive surfaces select the single armature surface Select the One way cutting method to keep rotating the part in the same direction for all the passes APPLICATION EXAMPLES Compressor Armature with 4 Axis Output 61 In addition select the following option on the Utility tab q Utility h vw Advanced spiral calculation for all strategies This converts all of the separate parallel cuts into a single continuous spiral which is ideal for this part Tool axis control and gouge checking Use the following Tool axis control settings Toolpath parameters Surface paths Tool axis control Gouge check Link Roughing Utility Machine definition Misc Duputtomat ai Reds axi Masimum angle step 3 Tool asis will Tited around axis X awis C Y axis Tilt anale 80 canis C 2 anis To generate the 4 axis output simply select it as the Output format and click the Rotary Axis button to select the desired axis The other settings lock the tool at a 90 degree angle to the X axis As the part rotates the side of the tool will machine it 62 MASTERCAM X2 Advanced Multiaxis Tutorial There is no need for gouge checking for this toolpath so all the options on the Gouge check tab are turned off In the next example you will learn about settingup an engraving application
27. are and to use reasonable best efforts to ensure their compliance with such terms and conditions including without limitation not knowingly permitting such persons to use any portion of the Software for the purpose of deriving the source code of the Software or defeating the Security Mechanism In the event you become aware that any person or entity in your employ or under your control in a manner not authorized by this Software License Agreement is using the Software you shall immediately use reasonable best efforts to have such unauthorized iv MASTERCAM X2 ADVANCED MULTIAXIS TUTORIAL Limited Warranties Limitation of Liability Indemnification use of the Software immediately cease You shall promptly notify CNC in writing of any unauthorized use of the Software of which you become aware CNC WARRANTS THAT THE MEDIA ON WHICH THE SOFTWARE IS DISTRIBUTED WILL BE FREE OF DEFECTS IN MATERIAL OR WORKMANSHIP FOR A PERIOD OF THIRTY 30 DAYS AFTER PURCHASE THE FOREGOING LIMITED WARRANTY EXCLUDES DEFECTS ARISING OUT OF ACCIDENT NEGLECT MISUSE FAILURE OF ELECTRIC POWER AND CAUSES OTHER THAN ORDINARY AND AUTHORIZED USE EXCEPT FOR THE FOREGOING LIMITED WARRANTY THE SOFTWARE IS PROVIDED AS IS WITH ALL FAULTS YOUR SOLE REMEDY AND CNC S SOLE OBLIGATION HEREUNDER SHALL BE AT CNC S SOLE OPTION REPLACEMENT OF THE DEFECTIVE MEDIA OR REFUND OF THE PURCHASE PRICE OF THE SOFTWARE ANY USE BY YOU OF THE SOFTWARE IS AT YOUR OWN RISK THIS LIM
28. ate cutting passes that transition between two curves and are then projected onto the drive surfaces Select the two drive curves by clicking First and Second and selecting the two red curves Select the light purple floor as the Drive surface 94 MASTERCAM X2 Advanced Multiaxis Tutorial EnteraDrive surfaces offset of 0 02 This represents the stock that will be left on the drive surfaces for the finishing operation Select the Full start and end at exact surface edge option to force Mastercam to calculate cutting passes at the surface boundary Select Advanced and enter margins of 0 25 half the tool diameter so that the edge of the tool is at the boundary not the center which would gouge the blades l d Start margins 0 25 End margins 0 25 k Cancel IMPORTANT This option should be used only with ball nose tools The following option needs to selected on the Utility tab in order for Mastercam to calculate the toolpath accurately Iv Cale based on tool center Select Extend trim to extend each cutting pass by 90 of the tool diameter This forces the tool to cut past the blade boundaries at the open top and bottom resulting in a clean edge Start Percentage of tool diameter fao Value End f Percentage of tool diameter fao Value APPLICATION EXAMPLES mpeller Floor Roughing 95 Select the From center away option Instead of organizing the cuts from one edge to the other
29. ative to cutting direction Lead angle to cutting is E direction Tilt angle at side of cutting o direction 5 Click OK to close all the dialog boxes and then regenerate the tool path The original setting of the tool axis was fixed and normal to the surfaces With the new tool axis strategy you can define a lead lag angle to cutting direction Positive value lead angle tool leans to the movement direction Negative values lag angle tool leans away from the movement direction 18 MASTERCAM X2 Advanced Multiaxis Tutorial When you backplot the toolpath from the right side the lead angle should appear as follows Lead angle No lead angle motion direction gt Applying side tilt angles 1 Click the Parameters icon and select the Tool axis control tab 2 Select the Tilted with fixed angle to axis strategy TUTORIALS Parallel Cuts on a Cylinder 19 3 Enter a Fixed tilt angle of 45 degrees relative to the X axis as shown in the following picture Toolpath parameters Surface paths Tool axis control Gouge check Link Output Format 5 anig Maximum angle step 3 Tool axis will Tilted with fied angle to axis Fixed till angle 4 Click OK to close all the dialog boxes and then regenerate the tool path Use this option to set the tool axis at a fixed angle to any axis or to a line that you choose The tilt axis and surface normal build a plane in which the tool tilt
30. ces 1 Stock to leave 0 05 Tolerance 0 002 Select Retracting tool along tool axis strategy so that at each affected location the tool plunges as far as it can without gouging For Check surfaces select the walls as shown in the following picture Enter a Stock to leave amount of 0 05 100 MASTERCAM X2 Advanced Multiaxis Tutorial Mastercam will start plunging along the previously calculated toolpath Now that you ve seen how to rough the floor continue with the next example to learn how to clean out the back side of the blade APPLICATION EXAMPLES mpeller Blade Semi finishing 101 Example 6 Impeller Blade Semi finishing This example continues with the same impeller part used in the previous example This example discusses the semi finish operation shown below that cleans out the back side of the blade with a tapered tool Open the following file Documentation ExampleParts Impeller mcx 102 MASTERCAM X2 Advanced Multiaxis Tutorial Tooling Many times there is a small fillet between the blade s back surface and the floor A tapered ball nose cutter is recommended Keeping this cutter short and rigid will ensure a quality surface finish 7 Calc 5peed Feed Taper mill Toal Type Parameters Save to library Halder h n C Finish Holder dia Both 2 Arbor Diameter Overall 0 5 2n Radius Type T C Mone Shoulder A C Comer is Flute Fu
31. chining operations are discussed Roughing between the blades using both continuous cuts and plunge roughing techniques Asemi finish operation to clean out the undercut area behind the blades Separate finishing operations for the walls and floor All of the operations are saved in the following file Documentation ExampleParts Impeller mcx 92 MASTERCAM X2 Advanced Multiaxis Tutorial The roughing strategy discussed in this example creates multiple cutting passes shaped like the following picture The tool axis is guided by a curve and driven along the floor surface The tool overlaps the open edges and is tilted to machine under the front blade The tool used is a 0 5 inch ball endmill APPLICATION EXAMPLES mpeller Floor Roughing 93 Drive geometry and cutting passes Use the following Surface paths settings Taolpath parameters Surface paths Tool anis control Gouge check Link Fioughing Utility Machine definition Misc Pattern Morph between z curves E dit curves First Second Drive surfaces Drive surfaces offset Full start and end at exact surface e Advanced Hound comers Extend trim Sorting Surface quality Flip step over Cut tolerance p 002 m Distance o DD Cut order From center away Direction for one way machining Climb Maximum stepover 0 25 Select the Morph between two curves cutting pattern This will cre
32. contact with the blade surface Toalpath parameters Surface paths Tool axis control Gouge check Link Roughing LI tility Machine definition Misc Output format 5 axis Maximum angle step 3 Tool asiz will Be tilted relative to cutting direction Tool axis control on page 104 discusses how the side tilt angle and surface iso directions are used to figure the tool axis angle Gouge check strategies The Gouge check strategies one for the blade and one for the floor are the same as for the semi finish operation Check Strategy and parameters Geometry Tool Tool Arbor Holder tip shaft T v Drive surfaces Titing tool away with mas angle Check surfaces it1 Use zide tilt angle an Retracting tool along tool asis bi Drive surfaces IY Check surfaces H2 v Stock to leave o o Tolerance 0 002 The first strategy applies to the drive surface of the blade This strategy adjusts the side tilt angle as necessary to avoid a APPLICATION EXAMPLES mpeller Blade Finishing 117 gouge while still letting you remove stock with the side of the tool The second strategy applies to the floor surface It simply retracts the tool along its axis enough to prevent gouging the floor while continuing with the toolpath Select Check surfaces and select the floor surface Congratulations You ve completed this tutorial and application examples At this poi
33. curve shown below as the Tilt curve ad APPLICATION EXAMPLES mpeller Floor Roughing 97 TIP To create this curve take one of the boundary curves from the top edge of the impeller blade and rotate it 22 5 degrees The eight blades are spaced 45 degrees apart Then translate it above the part in the direction of the surface normal Roughing options Use the Roughing tab to define the stock model and configure the roughing passes Taalpath parameters Surface paths Tool axis control Gouge check Link Roughing Li tility Machine definition Misc x Iv Stack definition Stack Defined by User selected geometry teen Stock definition tolerance 0 01 Mul passes a Plunge Moran pocket M Depth Cuts v Connect slices by shortest distance Select Stock definition to apply a stock model Mastercam will eliminate air cuts outside the stock boundary This part includes stock model geometry Choose User selected geometry and select all the surfaces on level 5 98 MASTERCAM X2 Advanced Multiaxis Tutorial TIP When you use the User selected geometry option you can select surfaces or solids To use other types of stock models such as an external STL file select From job setup and define the stock model in the Machine Group Properties To create multiple cuts select Depth cuts and enter 4 for the number of cutting passes Plunge roughing Becaus
34. d Multiaxis Tutorial 4 Click OK and then regenerate the toolpath When you zoom in on the area you should see a smooth toolpath in the gap area Exercise 4 Combining several gouge and collision checks In the previous exercises you used the gouge checking function to help define the proper tool position for a swarf toolpath In this exercise you will apply additional gouge checks to keep the tool away from check surfaces TUTORIALS Multiaxis Toolpath Techniques 51 Before beginning this exercise use the Level Manager to make level 100 visible Your part should now display a horizontal bar gt Collision checking the bar 1 In the Toolpath Manager make a copy of the previous operation and click its Parameters icon to edit it Go to the Gouge check tab Select gouge check 2 in the Status column 4 Select the Tool tip Tool shaft Arbor and Holder to check against Set strategy to Retracting tool along tool axis 6 De select Drive surfaces and select Check surfaces There is no need to check the drive surfaces with this test since they are handled in the first test For this test Mastercam will only look at the check surfaces 7 Enter 0 5 as Stock to leave and 0 05 as the Tolerance 52 MASTERCAM X2 Advanced Multiaxis Tutorial The goal of this setting is to prevent machining the check surfaces while staying within 0 5 mm of them Your settings should look like this Check Strategy and parameters Geo
35. e air move safety clearance Approach and retract strategies This section introduces you to different combinations of tool axis control gouge check and link settings that you can use to bring the tool on and off the part and retract from check surfaces Exercise 7 Creating entry and exit moves gt Adjusting the start point 1 Open the toolpath parameters for the operation and select the Surface paths tab 2 Click the Start point button 30 MASTERCAM X2 Advanced Multiaxis Tutorial 3 Change the start point coordinates to X0 Y 40 and Z0 so that the tool will start machining at the side of the part instead of the top 4 Enter a Rotate by Deg angle of 8 and click OK This rotates the starting point of each successive cutting pass by 8 degrees juni Ee o td fo 40 Hels l Rotate by deg E 1 OF Cancel action assume closed contours gt Creating an entry move 1 Goto the Link tab 2 IntheFirst entry area set the entry options to From clearance area and Use entry macro 3 Inthe Last exit area set the entry options to Back to clearance area and Use exit macro Toolpath parameters Surface paths Tool axis contral Gouge check Link Fioughina Utility M First entry From clearance area Use entry macro Last exit Back to clearance area Dont use macra Use exit macro k Don t use macro r haps along cut In this case the word macro
36. e impellers are often made from hard difficult to machine materials they can be good candidates for plunge roughing You can accomplish this by making only a few changes to the toolpath In your Impeller mcx part file the second operation in the Floor Roughing toolpath group demonstrates these changes On the Roughing tab de select Depth cuts and select Plunge Toolpath parameters Surface paths Tool asiz control Gouge check Link Roughing Utility Machine definition Misc v Stock definition Stock definition tolerance Multi passes v Plunge B Morph pocket 5 Depth Cuts v Connect slices by shortest dial lo i Step length 0 2 Slide length fo Plunge height f Hetract angle fo Cancel The plunges will take place along the previously calculated toolpath spaced according to the Step length APPLICATION EXAMPLES mpeller Floor Roughing 99 The Plunge height measures the distance from the beginning of the plunge move to the surface Mastercam automatically trims this if it extends outside the stock boundary Next apply a gouge check strategy to make sure the tool doesn t gouge the walls while it plunges Toolpath parameters Surface paths Tool axis control Gouge check Link Roughing Utility Machine definition Misc Check Strategy and parameters Geometry Tool Tool Arbor Holder tip shaft Drive surfaces Retracting tool along tool axis 4 Iv Check surfa
37. edge This ensures that Mastercam will create a finish pass along the boundary of the surface When selecting this strategy you need to make sure that your surfaces have clean boundaries otherwise your toolpath will have gaps or chatter Click Advanced to enter a small margin so that the toolpath is not calculated along the absolute boundary ica i i Mons E d Start margins 0 002 End margins 0 002 C Cancel Set the Maximum stepover to 0 05 Since the shape of each cutting pass is based on the transition between the two surface boundaries the spacing between the passes will vary from point to point Use this value to set the maximum spacing between two passes APPLICATION EXAMPLES Electrode Machining 87 Tool axis control and gouge checking Use the following settings on the Tool axis control tab Toolpath parameters Surface paths Tool axis control Gouge check Link Roughing LI tility Machine definition Misc Output format 5 axis Maximum angle step 3 Tool axis will Be tilted relative to cutting direction Lead angle to cutting T direction Tilt angle at side of cutting fo direction Side tilt definition Use spindle main direction Advanced Hun toal Auto Iv Limits Select the Be tilted relative to cutting direction strategy This will let the tool axis vary more than the previous toolpath ensuring a finer finish across the entire surface Leave the
38. eometry and cutting passes eeeese 103 TOO aXIS CODUOD ou ihsebis feste crea is Deva Uo oed ax Ra Eds 104 Gouge CHECK strategies eese ese Cue xod ex VERRE ER ENG 106 Example 7 Impeller Floor Finishing 107 Drive geometry and cutting passes eeese 108 TOOL AXIS COM Ol eet a 110 GOUSE CHECK Stfategles aeter FE YRER AR GERRU Py RIT EIER 111 Example 8 Impeller Blade Finishing 113 Drive geometry and cutting passes eeese 114 TOOL aus COTIGEOLDusepediveha Dor a bo brad au 115 Gouge check Strateglessis pore mood n ees Eb eau NS SER RENE RO RUE 116 chapter 1 Tutorials This chapter includes two tutorial examples designed to introduce Mastercam s new advanced multiaxis toolpaths After completing them you should know enough about the basic principles to begin applying them to specific applications Tutorial 1 Parallel Cuts on a Cylinder Creating parallel cutting passes page 5 ae am P dg Refining the cutting area pagell WM Driving the tool with a leading curve page 13 Controlling the tool axis page 16 Gouge prevention by retracting the tool page 21 Omitting gouge points from the toolpath page 25 Creating entry and exit moves page 29 Using a fixed tool angle page 32 Using a single point
39. er This License is for you alone In the event you breach the provisions of this Section CNC shall be entitled to liquidated damages in the amount of Fifteen Thousand Dollars 15 000 plus its reasonable attorney s fees and court costs This Software License Agreement shall be construed interpreted and governed by the laws of the state of Connecticut without regard to conflicts of law provisions The sole jurisdiction and venue for any litigation arising from or related to this Software License Agreement or the subject matter hereof shall be in an appropriate state or federal court located in Hartford Connecticut You hereby submit to the personal jurisdiction of the Federal District Court for the District of Connecticut and to the Superior Court of the State of Connecticut This Software License Agreement shall constitute the entire agreement between you and CNC with respect to the subject matter hereof Any waiver or modification of this Software License Agreement shall be valid only if it is in writing and signed by both parties hereto If any part of this Agreement is found invalid or unenforceable by a court of competent jurisdiction the remainder of this Agreement shall be interpreted so as to reasonably effect the intention of the parties The Software provided hereunder is a commercial item as that term is defined in 48 C ER 2 101 consisting of commercial computer software and commercial computer software documentation as such
40. er i Comer te 0 25 A 0 25 4 Loner Radius Ad pedet na Di Ie que Taper angle lameter 45 0 5 Profile Auto C Custom file C Custom level f The advanced multiaxis toolpaths do not support the Face mill or Chamfer mill tool types so this tool is defined as a Taper mill 74 MASTERCAM X2 Advanced Multiaxis Tutorial Drive geometry and cutting passes For this part you will create two toolpaths For the first toolpath use the following Surface paths settings Toolpath parameters Surface paths Tool axis contral Gouge check Link Roughing Li tility Machine definition Misc Pattern Parallel cuts Machining angle in Y jo Constant Z Machining anale in lt 30 Parallel Drive surfaces Drive surfaces offset o Full avoid cuts at exact edges Raund comers E Etendi trin Sorting v Flip step over Flip step Cut tolerance 0 005 Cutting method One way zn Cut order Standard v Distance jo Direction for one way machining Cwise Maximum stepover 0 1 g M Enforce cutting direction assume closed contours Surface quality Use the Parallel cuts pattern to create the multiple parallel cutting passes around each cam contour Set the Machining angle in Z to 90 to create cuts aligned in a vertical plane An angle of 90 would also align the cuts vertically but the cutting direction would be reversed So should you choose 90 or
41. er to check against See the picture below Select Check surfaces and select the surfaces for the red fixture 7 Edit gouge check 2 Select the Moving tool away strategy Set the retract option to Retract tool in Z Your settings should look like the following picture Check Strategy and parameters Geometry Tool Tool Arbor Holder tip shaft Tilting tool away with mas angle viens Iv Check surfaces it1 x side tilt angle 2 Drive surfaces Moving tool away if Check surfaces t2 En etract tool in Stock to leave 0 5 Tolerance 0 05 TUTORIALS Multiaxis Toolpath Techniques 55 8 Click OK and then regenerate the toolpath You can see the tool axis tilt when the holder approaches the fixture Also look at the new retract strategy around the bar The tool retracts straight up in Z instead of along the tool axis which is 56 MASTERCAM X2 Advanced Multiaxis Tutorial a much more appropriate strategy with the multiple cutting passes Congratulations You have completed the tutorial portion of this book Continue with the next chapter to learn about specific application examples and how they are created chapter 2 Application Examples This chapter introduces several application examples Instead of giving you step by step procedures like the tutorials in the previous chapter this chapter discusses how to apply the advanced multiaxis toolpaths to specific types of parts a
42. erline Clearance area Y vlinder parallel to X k 65 Through X2 o Y o z o E Cancel Clearance area 4 Click OK to close this dialog box but leave the Link tab on the screen gt Defining the motion to and from the clearance plane 1 Click the Distances button 2 Enter 5 for the Rapid distance This establishes an intermediate point to which the tool will rapid from the clearance plane 28 MASTERCAM X2 Advanced Multiaxis Tutorial Il gap alweer IVES OWES ll move Sheet a 3 Enter 3 for the Feed distance Once the tool reaches this distance from the surface it will feed towards the part Both distances are measured along the tool axis from the surface being machined 4 Enter 10 as the Air move safety distance As the tool moves across the clearance area Mastercam ensures that the tool will not come closer to the check surfaces than this distance FH Rapid distance Feed distance Air move safety distance arance area Ent Est macta Distances 5 Click OK and then regenerate the toolpath You can see that the tool movements around the check surfaces are much more efficient and appropriate for this part Notice that the radius of the clearance cylinder is larger than the programmed radius of 65mm Mastercam automatically increases the TUTORIALS Parallel Cuts on a Cylinder 29 size so that the tool moves safely around the check surfaces while maintaining th
43. ers icon in the Toolpath Manager to display the settings for the existing operation 12 MASTERCAM X2 Advanced Multiaxis Tutorial 2 On the Surface paths page change the Area Type to Full start and end at exact surface edge i Area Type Full avoid cuts at exact edges Full avoid cuts at exact edges Full start and end at exact surface edge Limit cuts by one or two points HH Bound comers a Extend trim Use these options to either explicitly include the edge of the surfaces or exclude them For example if there are problems on the edges of your surfaces calculating a cutting pass slightly away from the exact edge might reduce chatter and produce a cleaner toolpath 3 Click the Start point check box and button Sorting Flip step over Cutting method D necis Cut order Chandar Direction for one way machining Cwise i Enforce cutting direction assume closed contours v Start point 4 Entera start point of XO YO Z40 TUTORIALS Parallel Cuts on a Cylinder 13 Note Mastercam uses this point as a hint or guideline only It tries to start the toolpath close to this point subject to the other drive surface and cut pattern settings 5 Click OK and then regenerate the toolpath It should look like the following picture Exercise 3 Driving the tool with a leading curve In this exercise the cutting pattern will be based on a leading curve Mastercam creates cuts normal
44. erwise the source code form of the Software from the executable code of the Software d remove any proprietary notices labels or marks from the Software e sell rent lease distribute or otherwise transfer or provide all or any part of the Software to any person or entity without the prior written consent of CNC f use the Software to provide outsourcing service bureau time sharing or other services to any third party or g sublicense assign delegate or otherwise transfer your rights in the Software under the Software License Agreement or any of the related rights or obligations for any reason without the prior written consent of CNC You shall not circumvent bypass modify reverse engineer disassemble disable alter enhance or replicate the function of the Security Mechanism in any manner whatsoever Any attempt to do so shall result in automatic termination of this License without prejudice to all other legal rights and remedies of CNC You may make one 1 copy of the Software for backup or archival purposes provided that you reproduce all proprietary notices of CNC on any such copy You may not transfer or assign the Software or this Software License Agreement or any rights or obligations hereunder Any attempt to do so will automatically terminate this License without the need for notice This termination is without prejudice to all other legal rights and remedies of CNC The Software is and includes intellectual property of
45. for compliance with any import laws and regulations of the country of destination of a permitted export or re export and any other import requirement related to a permitted export or re export CNC software programs Mastercam Design LT and Mastercam Demo do not require the use of Security Mechanisms and the provisions in this Software License Agreement relating to Security Mechanisms do not apply to your use of such programs provided however that such provisions shall apply to your use of all other Software provided hereunder All provisions of this Software License Agreement relating to confidentiality non disclosure CNC s proprietary rights disclaimers and limits of liability or indemnification by Customer shall survive termination of this License for any reason All rights not expressly granted are reserved by CNC Mastercam is a registered trademark of CNC Windows Windows 95 Windows 98 Windows NT and Windows XP are registered trademarks of Microsoft Corporation Mastercam Verify is created in conjunction with MachineWorks Ltd Printed in the United States of America Printed on recycled paper Contents vii NIU M 1 Introducing Advanced Multiaxis Toolpaths 2 SUC or 3 CIOL CY OULD COUT ecran MR ES MES NUUAM 4 Tutorial 1 Parallel Cuts on a Cylinder 5 Exercise 1 Creating parallel cutting passes
46. for tool axis control page 34 Stopping the toolpath on a gouge page 36 Tutorial 2 Multiaxis Toolpath Techniques Creating cuts parallel to a leading curve page 39 Creating a swarftoolpath page 43 Handling problem areas in the part model page 45 Combining several gouge and collision checks page 50 These tutorials assume that you are generally familiar with using Mastercam including creating and backplotting toolpaths selecting geometry working with surfaces and using the Toolpath Manager If you have any questions about basic Mastercam functions while working on these exercises please click the Help button on any dialog box or consult the Mastercam X2 Reference Guide installed in the N Documentation folder in your Mastercam installation directory 2 MASTERCAM X2 Advanced Multiaxis Tutorial Introducing Advanced Multiaxis Toolpaths Mastercam s new advanced multiaxis toolpaths take advantage of a comprehensive multi tabbed interface to collect all of your toolpath functions in one place Advanced Multiaxis C MCAMX2 MILLWCISCTLINDER NCI ED ajx Toolpath parameters Surface paths Tool axis control Gouge check Link Roughing Utility Machine definition Misc Pattern Parallel cuts od Machining angle in o Constant Z Machining angle in 30 Parallel Dire surfaces Drive surfaces offset 0 1 Full start and end
47. fset jo Area B Limi cuts by one or two points Advanced 2 Click the Advanced button and enter the limits X 25 and X 65 Mastercam will create the toolpath between these two points only TIP If the two points are the same Mastercam will create a single pass through the point 3 Click OK to close all the dialog boxes and then regenerate the tool path 16 MASTERCAM X2 Advanced Multiaxis Tutorial Your cutting passes should look like the following picture Tilt angle and tool control The Tool axis control tab lets you define the tool axis relative to the drive geometry cutting direction guide or construction geometry or a combination of them You can also specify lead lag angles side tilt angles and angle limits tool tip and contact point including user defined locations on the tool tip output type 3 axis 4 axis or 5 axis Exercise 4 Controlling the tool axis For this exercise you will modify the toolpath that you created in Exercises 1 and 2 gt Applying lead lag angles 1 Click the Parameters icon in the Toolpath Manager for Operation 1 TUTORIALS Parallel Cuts on a Cylinder 17 2 Select the Tool axis control tab 3 Select the Be tilted relative to cutting direction strategy 4 Enter a Lead angle of 15 degrees Toolpath parameters Surface paths Tool axis control Gouge check Link Output Format 5 anig Maximum angle step 3 Tool axiz will Be tilted rel
48. g tilting through point Impeller floorsurbace without tilkcurve Projection Cavity Tilteurve Cavity Collision Control curve Electrode Machining 4 1 Asis Conversion to 5 Asis Turblade shaft finishing Impeller Blade Swart Finishing 2 Select 5 Axis Multi Surface and click OK 3 Onthe Toolpath Parameters tab choose the 30mm ball endmill TUTORIALS Parallel Cuts on a Cylinder 7 gt Selecting a cutting pattern 1 Select the Surface paths tab 5 Axis Multi Surface C MCAMX MILESNCPMULTIAXIS EXAMPLEIT NEI E xj Toolpath parameters Surface paths Tool axis control Gouge check Link Roughing LI tility Machine definition Misc Pattern Parallel cuts n Machining angle in Y jo Constant Z Machining angle in Z 30 Parallel Drive surfaces Drive surfaces offset jo Full avoid cuts at exact edges nm Round comers gl Extend s trim Sorting Surface quality Flip step over Cutting method Zigzag Cut order Standard E Cut tolerance Distance Maximum stepover Li Start point Pattern GS Parallel cuts m Parallel cuts Cuts along curve Morph between 2 curves Parallel ta curve Project curves Morph between 2 surfaces Parallel to surface 3 Set the Machining angle in X Y to 0 and the Machining angle in Z to 90 8 MASTERCAM X2 Advanced Multiaxis Tutorial The other options that are available in the Pattern section depend on the selected
49. illet radius in the purple surfaces is 0 05 inches select a tool with a tip radius very slightly larger than this Taper mill Tool Type Parameters Capable of Halder C Rough r a C Finish Holder dia Bath 20 Arbor Diameter 0 1875 Radius Type None Comer Overall Shoulder Flute 0 75 a 375 N a 0 03125 l b e Taper angle iameter 5 0 0625 82 MASTERCAM X2 Advanced Multiaxis Tutorial Cutting parameters semi finish toolpath Drive geometry and cutting passes Use the following Surface paths settings for the first toolpath Toolpath parameters Surface paths Tool auis contral Gouge check Link Roughing Utility Machine definition Misc Pattern Parallel cuts T Machining angle mmis o Machining angle in z fo Dun Parallel Drive surfaces Drive surfaces offset fo Full avoid cuts at exact edges E Bound camera LI Extend rim Sorting Flip step over Cut tolerance 0 062 Cutting method ne Way Cut order st andard Distance 0 002 Direction for one way machining Cewise Maximum stepover T I Enforce cutting direction assume closed contours B Stark poirit e or a i a qu ce i From the Pattern list choose Parallel cuts and click Constant Z to create parallel cuts parallel to the XY plane Mastercam automatically sets the Machining angle in Z to 0 0
50. ing applications are mirror images of the features which need to be removed from molds and dies The EDM process is typically one of the final processes of tool making the parts have been already hardened ground and only need some finishing touches in hard to reach areas The quality of the surface finish on the electrode will directly affect the resulting finish on the workpiece In this example you will machine the electrode shown in the following picture Electrodes like this are typically machined with miniature tapered ball nose cutters The best possible surface finish and detail will be achieved with the shortest tool possible A common practice followed in this example is to tilt the tool axis to a fixed position often by using an aggregate machining head and then create a toolpath for a 4 axis machine To begin open the following file Documentation ExampleParts Electrode mcx 80 MASTERCAM X2 Advanced Multiaxis Tutorial The sample part includes two toolpaths The first toolpath is a semi finish operation over the whole part while the second finishes the fillet shown in the purple surface Tooling For the first toolpath use a tapered ball cutter with the following dimensions Taper mill Tool Type Parameters Halder f O C Finish Holder dia 1 25 0 1875 Overall Diameter 5 D 0 125 APPLICATION EXAMPLES Electrode Machining 81 Since the smallest f
51. king 61 viii Example 2 Engraving esses 63 TOONE eet T 65 Drive geometry and cutting passes ccsseeeeeeee 66 Erie HECU ooo vea viv cenar iu ora Es vea Rehd a dug 68 Tool axis control and gouge checking 70 Example 3 Camshaft on a Multitasking Lathe 71 TOONI MER 73 Drive geometry and cutting passes ssseeeeeeee 74 Tool axis control and gouge checking 77 Example 4 Electrode Machining 79 TOONE vesent uaa ates 80 Cutting parameters semi finish toolpath 82 Drive geometry and cutting passes 82 Tool axis control and gouge checking 83 Cutting parameters finish toolpath 85 Drive geometry and cutting passes 85 Tool axis control and gouge checking 87 Example 5 Impeller Floor Roughing 91 Drive geometry and cutting passes ssseeeeeeee 93 Poolas COn NON erena ipd ede dei EDEN cUm EI iD UNDE UEM 96 ROME MINS OP UIGINS sae caia uos RE ua REN RR UeeH ORE ORE 97 Plunge rous hino grisea ea YR xxx HO EYE AVR UR TRES 98 Example 6 Impeller Blade Semi finishing 101 Berellbopu m 102 Drive g
52. l governed by this License You may not use the Software without a Security Mechanism provided by CNC or CNC s suppliers When CNC or CNC s suppliers provide you with a single user Security Mechanism the Software may only be used in executable code form only on a single computer to which the Security Mechanism is physically attached In the event CNC or CNC s suppliers provide you with a multiple user Security Mechanism for use over an internal network a Network Security Mechanism the Software may be used a in executable code form only b only on end user computers that are connected to the internal network to which the Network Copying Restrictions Non Transferable Intellectual Property Rights Confidentiality Enforcement Obligations Security Mechanism is attached and c only by the number of users and accessed by the number of end user computers for which licenses were purchased and as further allowed by the Network Security Mechanism You may physically transfer the Software from one computer equipped with a single user Security Mechanism to another only if the Security Mechanism is included in the transfer and is installed with the new computer You shall not a copy except as provided below adapt modify the Software b publish display disclose or create a derivative work from the Software or any part thereof c de compile or translate disassemble create or attempt to create by reverse engineering or oth
53. l to the tool radius in this case 0 125 inches However there are some irregularities in the surface boundaries that affect the toolpath Adding just a very small additional space cleans up these problems For this part the extra margin is not a problem since the later toolpath that finishes the walls will also run along the same boundary Set the Maximum stepover to 0 05 inches 110 MASTERCAM X2 Advanced Multiaxis Tutorial Tool axis control The Tool axis control settings are the same as used for the roughing operation Output Format 5 anis Maximum angle step 3 Tool axis will Tilted through curve Tilt curve Fixed tilt angle fo Curve tilt type Closest point Use a guide curve based on the shape of the impeller blades Select the Tilted through curve strategy Select the magenta curve shown below as the Tilt curve ad APPLICATION EXAMPLES mpeller Floor Finishing 111 Gouge check strategies Use the following Gouge check strategy Check Strategy and parameters Geometry Tool Tool Arbor Halder tip shaft me Drive surfaces eavng out gouging points I Check surfaces H1 Stock to leave o m Tolerance 0 002 In this case you are using the two wall surfaces as check surfaces and simply omitting any gouge points from the toolpath since this is a finish operation and the floor has already been machined once The next example illustrates the final
54. license For example if you acquired this Software simply by buying a machine or Software from the former owner or from an auction you do not have a valid license You should contact CNC Software Inc 860 875 5006 in order to obtain a new and valid license Use of this Software without a valid software license is unlawful a violation of the Copyright Act and may expose you to criminal liability under 17 United States Code Sec 506 including fines and damages If you have paid a license fee CNC Software Inc CNC a Connecticut corporation with its principal place of business at 671 Old Post Road Tolland Connecticut 06084 hereby grants to you a non exclusive non transferable license the License to use this software program the Software and its accompanying documentation and if applicable to permit your authorized employees to use them solely in accordance with the terms and conditions of this Software License Agreement You may use the Software solely for your internal business purposes and solely in conjunction with the accompanying hardware or software device method scheme or other security measure provided by CNC which allows a user to access the Software and prevents unauthorized access to the Software the Security Mechanism The Software any updates to the Software including any that you download through the Internet and the Documentation shall hereinafter collectively be referred to as the Software and are al
55. ll 71 25 4 Corner Radius Das n 0 125 ese s angle Diameter 0 25 Frafile Auto C Custom file Custom level fo Ti APPLICATION EXAMPLES mpeller Blade Semi finishing 103 Drive geometry and cutting passes Use the following Surface paths settings Toolpath parameters Surface paths Tool axis control Gouge check Link Roughing Litility Machine definition Misi Pattern Morph between 2 curves E dit curves i First Second Drive surfaces Drive surfaces offset Full start and end at exact surface e Advanced Round comers w Sorting Flip step over Cut tolerance 0 062 Cutting method Zigzag po Cut onder Standard a Maximum stepover 0 15 Surface quality Use the Morph between two curves cutting pattern Select the two curves that define the top and bottom edges of the blade 104 MASTERCAM X2 Advanced Multiaxis Tutorial or or Note When selecting the curves the chaining direction does not matter Select the green surface on the back of the blade as the Drive surface Enter 0 05 for the Drive surfaces offset as the stock to leave for the finish operation Define the cutting area as follows Select the Full start and end at exact surface edge option Click Advanced and enter margins of 0 125 inches equal to the tool radius Click Extend trim and extend the passes by 100
56. ll turn machines are blurring the line between milling and turning They are becoming more affordable and accurate and let you machine an extremely wide variety of parts You can complete a part in one setup faster than ever before but the programing demands are complex Traditional axis substitution is sometimes very limited especially if you like to use advanced cutting techniques In many cases if you want to machine complex contours with bigger tools substituting the Y axis with a rotational move will produce excessive strain on the contour This example demonstrates how to use the advanced multiaxis toolpaths to machine the two cams shown in green in the following picture 72 MASTERCAM X2 Advanced Multiaxis Tutorial You will machine the contours with the chamfered edge of a large endmill as shown in the following picture The tool is mounted in the B axis spindle of a mill turn lathe To machine the other cam create a second toolpath with the tool rotated in the opposite direction Y WW APPLICATION EXAMPLES Camshaft on a Multitasking Lathe 73 To begin open the following file Documentation ExampleParts Camshaft mcx Tooling For this part use a tapered endmill with the following dimensions Calc Speed Feed Taper mill Tool Type Parameters Save to library Mill T urn Holder dia Arbor Diameter 0 Overall E T Radius Type f Mane Should
57. metry Tool Tool Arbor Holder shaft Titing tool away with mas angle i Drive surfaces oe Check surfaces tt Use side tilt angle E 4 fao Hetracting tool along tool axis Drive surfaces Iv Check surfaces 2 Stock to leave Talerance 8 Click the button and select all the red surfaces 9 Click OK and then regenerate the toolpath The toolpath should clear the bar with a 0 5mm clearance like in the following picture TUTORIALS Multiaxis Toolpath Techniques 53 gt Collision checking external fixtures You will now modify the collision checks to verify that the tool and holder do not collide with an external fixture Before continuing make level 101 visible in your part file to expose these surfaces You will also change the cut pattern to create additional cutting passes near the top of the surfaces to check against the fixture 1 Open the toolpath parameters for the operation and select the Surface paths tab 2 Change the Area type to Full avoid cuts at exact edges 3 Change the Cutting method to Zigzag 54 MASTERCAM X2 Advanced Multiaxis Tutorial 4 Change the Maximum stepover to 10 Area Type v Round comers E Extend Sorting Surface quality Flip step over Cut tolerance Cutting methad Lum B Cut order Ihsmdud 8 Distance ns Iv aximum stepover 1 T 5 Go to the Gouge check tab 6 Edit gouge check 1 Add the Hold
58. mi finish operation you can simply omit any points that are creating gouges The strategy is only applied to the drive surfaces not to any check surfaces APPLICATION EXAMPLES Electrode Machining 85 Cutting parameters finish toolpath Drive geometry and cutting passes For the second toolpath use the following Surface paths settings Toolpath parameters Surface paths Tool auis control Gouge check Link Roughing Utility Machine definition Misc Pattern Morph between 2 surfaces Edit surfaces First Second Advanced fo Full start and end at exact surface e Advanced Bound cammers Extend s trim Surface quality Sorting Flip step over Cutting method One Wap Cut order Standard a Cut tolerance Distance 0 002 Maximum stepower 0 05 Direction for one way machining Cowise I Enforce cutting direction assume closed contours i Start port From the Pattern list choose Morph between two surfaces This will create cutting passes whose profile will transition between the boundaries of two surfaces The profiles will then be projected onto the drive surfaces Click First and select the 86 MASTERCAM X2 Advanced Multiaxis Tutorial upper surface shown on the left Click Second and select the lower surface shown on the right For Drive surfaces select all the purple surfaces For Area type select Full start and end at exact surface
59. n option grant schedule or program it may not be used by anyone including you to conduct any computer aided design computer aided drafting computer aided machining or training activities that directly or indirectly generate or otherwise result in monetary revenues for the benefit of any individual or any entity other than the school that originally received this Software This Software License Agreement is effective until terminated You may terminate this Software License Agreement at any time by returning to CNC all copies of the Software under your control and by returning the Security Mechanism to CNC CNC may terminate this Software License Agreement if CNC determines in its sole discretion that you have violated the terms of this Software License Agreement Upon termination of this Software License Agreement you agree to immediately return to CNC all copies of the Software return the Security Mechanism to CNC and certify to CNC in writing that all known copies including backup copies have been returned All provisions relating to confidentiality proprietary rights indemnification and non disclosure shall survive the termination of this Software License Agreement You may not transfer this Software to the purchaser of any equipment on which the Software may be resident You may not transfer this Software via liquidation bankruptcy auction close of business or any other method that does not involve an authorized Mastercam resell
60. nd explains the key settings that make each toolpath appropriate for its application It includes the following examples Example 1 Compressor Armature with 4 Axis Output page 58 Example 2 Engraving page 63 Example 5 Impeller Floor Roughing page 91 Example 6 Impeller Blade Semi finishing page 101 Example 7 Impeller Floor Finishing page 107 Example 8 Impeller Blade Finishing page 113 Completed parts for each exercise can be found in the Documentation ExampleParts folder in your Mastercam installation folder The four impeller examples all use the same part Remember that for almost any multiaxis application there are many possible machining strategies Feel free to use these examples as starting points trying out different settings and techniques that are relevant to your own work and your own preferences 58 MASTERCAM X2 Advanced Multiaxis Tutorial Example 1 Compressor Armature with 4 Axis Output In this example you will machine the outside of this compressor armature The part lies along the X axis The approach will be to machine with the side of the tool using a 4 axis toolpath that rotates around the part in a continuous spiral You can typically get much better surface finishes longer tool life and shorter cycle times when cutting with the side instead of the bottom of the cutter so you will use the advanced multiaxis toolpaths to
61. ng tools and setting feeds and speeds This is the same tab used in other Mastercam toolpaths and so is not described in this tutorial Getting help The advanced multiaxis interface includes many detailed pictures that are linked to individual fields Simply click in a field to display a visual explanation of it Marimum angle step f7 Tool axis will Tilted with the angle Tilt angle E 5 Every dialog box includes a main help button in the lower right corner that you can click to learn more 4 MASTERCAM X2 Advanced Multiaxis Tutorial Before you begin Although these toolpaths are extremely powerful and flexible there are some important limitations that you should be aware of These toolpaths work on surfaces solids and solid faces Solid selection is available for most advanced multiaxis toolpath strategies with the following exceptions Toolpaths that require the selection of a defined edge solid edge Toolpaths that require the selection of only a single surface solid face The orientation ofthe toolpath with respect to your surfaces is determined by the surface normal Before creating the toolpath make sure that your normals point in the proper direction If necessary use the Edit Change normals function before creating the toolpath You can also change the normals after creating the toolpath and simply regenerate the toolpath The defaults for these toolpaths are hard coded and are not s
62. nt you should be able to apply common advanced multiaxis strategies to your own parts To learn more click the Help button on any tab page to learn more about the options and to see examples of specific settings You can also consult the Reference Guide by selecting it from the Help menu 118 MASTERCAM X2 Advanced Multiaxis Tutorial CHC software nc 671 Old Post Road Tolland CT 06084 USA www mastercam com Printed in the USA Mastercam X Advanced Multiaxis Tutorial 1 883310 61 X
63. ol asis control Gouge check Link Roughina Utility Machine definition Misc First entry Use rapid distance Don t use macro Last exit Use rapid distance Don t use macro Gaps along cut Small gaps Blend spline Don t use macro Large gaps Broken feed Don t use macro Small gap size in X of tool diameter 100 as value Links between slice Small moves Direct Don t use macro gt tase moves ficken tee Dortuse aco E Small move as size in X of stepover D as value f Links between passes Link tupe Broken feed Don t use macra Elearance area EntrrEsEmacra Distances The two settings that are marked in the picture are the key ones Use the Gaps along cut settings to control what happens if there are small gaps or discontinuities in the geometry within each letter In this case select the Blend spline strategy to have the tool continue to feed along a smooth tangential connecting spline between any gaps Set a threshold of 100 of the tool diameter to define when a gap is considered small For gaps larger than this the tool will retract from the toolpath Use the Links between slices section to control how the tool moves between letters In this case Broken feed means that the tool will continue at the feed rate but will retract to a feed plane to move to the next letter The size threshold is intentionally very small 10 of the tool diameter
64. operation for the impeller finishing the blades 112 MASTERCAM X2 Advanced Multiaxis Tutorial APPLICATION EXAMPLES mpeller Blade Finishing 113 Example 8 Impeller Blade Finishing This example concludes the impeller machining operations begun in the previous examples This example discusses two operations that finish each side of the impeller blade In addition to finishing the blade the toolpaths cut the fillets between the blade and floor Each operation uses the same 0 25 inch tapered endmill as the previous examples Open the following file Documentation ExampleParts Impeller mcx There are separate operations for the front and back of the blade Unless otherwise noted the toolpath settings are the same for both 114 MASTERCAM X2 Advanced Multiaxis Tutorial Drive geometry and cutting passes The goal is to create a single cutting pass along the bottom edge of the blade finishing the blade with the side of the tool while the ball tip cuts the fillet to the floor surface Use the following Surface paths settings Toolpath parameters Surface paths Tool axis control Gouge check Link Roughing LI tility Machine definition Misc Patlem Parallel to surface Edit surfaces Single edge Drive surfaces Advanced Drive surfaces offset o Determined by number af cuts Advanced Number af cuts 1 Round carriers Extend 7 trim Surface quality So
65. ouge check strategies Create two different Gouge check strategies one for the blade and one for the floor Status Check Strategy and parameters Geometry Tool Tool Arbor Halder tip shaft TE v Drive surfaces Titing tool away with mas angle Check surfaces it1 Use side tilt angle E 4 RE Drive surfaces 4 IY Check surfaces 2 v Stock to leave o o Tolerance 0 002 The first strategy applies to the drive surfaces of the blade This strategy adjusts the side tilt angle as necessary to avoid a gouge while still letting you remove stock with the side of the tool The second strategy applies to the floor surface It simply retracts the tool along its axis enough to prevent gouging the floor while continuing with the toolpath Select Check surfaces and select the floor surface In each case select the options to check against the Tool tip Tool shaft and Arbor There is no harm if you also select Holder but leaving out unnecessary checks speeds up the toolpath calculation The next example continues with this same impeller part Now that the floor and blades have been roughed it continues with a finish operation for the floor APPLICATION EXAMPLES mpeller Floor Finishing 107 Example 7 Impeller Floor Finishing This example continues with the same impeller part used in the previous examples It discusses the toolpath used to finish the floor between the blades This operation
66. plying a gouge check strategy 1 Click the Parameters icon for Operation 1 2 Turn off the tool axis options from the last exercise Select the Tool axis control tab and select the Not be tilted and stays normal to surface strategy 3 Select the Gouge check tab 22 MASTERCAM X2 Advanced Multiaxis Tutorial 4 Activate gouge check number 1 by selecting it in the Status column Toolpath parameters Surface paths Tool axis control Gouge check Link Roughing Utility Machine definition Misc Check Strategy and parameters Geometry Tool Toal Arbor Holder E tip shaft Drive surfaces v Check surfaces t za G Stack to leave fo did Tolerance o n v Drive surfaces IC A 5 Select the Tool tip Tool shaft and Arbor to check against TIP You can define individual clearance values for each tool component by clicking the Clearances for tool parts button 6 Select the Retracting tool along tool axis strategy This will retract the tool along its axis until the gouge condition is no longer present 7 Since the purpose of this test is to check against the red box de select the Drive surfaces option and select Check surfaces Click the button and select all the red surfaces 8 Ifnecessary deselect the Check gouge between positions option TUTORIALS Parallel Cuts on a Cylinder 23 9 Click OK and then regenerate the toolpath It should look like the following picture 24 MASTE
67. rting Flip step over Cutting method One way ES Cut order tds Distance 0 002 Direction for one way machining lim atti e Maximum stepover O05 Use the Parallel to surface cutting pattern This creates a series of cutting passes that are each parallel to the boundary of a check surface projected onto a drive surface Cut tolerance 0 002 APPLICATION EXAMPLES mpeller Blade Finishing 115 Click Single edge and select the floor surface as the check surface This will be the same for each operation For Drive surface select one of the blade surfaces the green surface for one operation the tan surface for the other The cutting area is defined by the Determined by number of cuts option This tells Mastercam to create a fixed number of cuts no matter how big the drive surface area is Enter 1 for the Number to create a single cut along the check surface boundary Select Climb to set the machining direction to climb milling Tool axis control The Tool axis control settings are designed to create a swarf cut that finishes the blade surface with the side of the tool The settings are the same as the semi finish operation except that the side tilt angle is 116 MASTERCAM X2 Advanced Multiaxis Tutorial or or Lead angle to cutting fo Tilt angle at side of cutting an Side tilt definition Folow surface iso direction increased to 90 to ensure that the side of the tool maintains
68. s Notice that Mastercam still calculates the location of the cutting pass based on the 20 MASTERCAM X2 Advanced Multiaxis Tutorial tool tip but offset from the surface to maintain the proper contact point Cutter location point E Tilt angle a oEFe Fra n ee Contact point The tool will stay tilted towards X in a constant angle of 45 degrees all along the tool path Gouge checking The Gouge check tab lets you define up to four independent gouge and collision checks to be applied to your toolpath Each one has three main components the parts of the tool to check tool tip shaft arbor holder or any combination the type of action to take when a collision is detected retract away from the toolpath tilt the tool away omit the points completely or stop processing the toolpath For each option additional parameters let you configure the tool motion the geometry to check against You can select drive surfaces check surfaces or both For maximum flexibility each individual test has its own set of geometry and this can be completely independent of the surfaces selected in the Surface paths tab TUTORIALS Parallel Cuts on a Cylinder 21 To prepare for this exercise make level 2 visible This contains the check surfaces that you will collision check against Your part should look like the following picture Exercise 5 Gouge prevention by retracting the tool gt Selecting and ap
69. simply means that you will configure a series of tool motions to approach and retract TUTORIALS Parallel Cuts on a Cylinder 31 from the part instead of the simple straight linear moves that you have been using so far 4 Click the Entry Exit macro button to begin defining the moves 5 Select Vertical tang arc for both the entry and exit macro This will create an arc move aligned with the parallel cutting passes 6 Setthe Arc diameter to 10096 for both arcs Back id ciearaiice aiga Use Balk Hacia i i i ii INDE 25 TI p Ente macro 4 Exit Macro Type Vertical tang arc Type L2 SF Tool axis orientation Fixed Tool axis orientation red INDE Arc sweep Arc sweep f Arc diameter tool Arc diameter tool diameter diameter X Height Height 7 Click OK and then regenerate the toolpath Your toolpath should look like the following picture The tangential arcs are applied to the first and last cutting passes only In this case the Rapid distance and Feed distance set in the previous exercise are added to the beginning and end of the arc You can see that between 32 MASTERCAM X2 Advanced Multiaxis Tutorial each pass the tool retracts to the clearance plane while Mastercam shifts the start of the next cutting pass by 8 degrees Exercise 8 Using a fixed tool angle gt Locking the tool axis to a fixed angle 1 Open
70. surbace without tilkcurve Projection Cavity Tilteurve Cavity Collision Control curve Electrode Machining 4 1 Axis Conversion to 5 Asis Turblade shaft finishing Impeller Blade Swart Finishing 3 Onthe Toolpath parameters tab select the 10mm flat endmill 4 Select the Surface paths tab Select Parallel to curve as the cutting pattern Toolpath parameters Surface paths Tool axis contral Gouge check Link Hough Pattern E Edt cures lt lt Single edge Drive surfaces Drive surfaces offset lo hat ft This option aligns the cut direction parallel to a leading curve Mastercam s advanced multiaxis toolpaths can handle convex surfaces which are very common in injection molds and forging dies 40 MASTERCAM X2 Advanced Multiaxis Tutorial 6 Click Single edge and select the red curve 7 Click Drive surfaces and select both highlighted surfaces 8 Click Done TUTORIALS Multiaxis Toolpath Techniques 41 gt Configuring the cutting passes 1 Inthe Area section set the type to Full avoid cuts at exact edges Type Full avoid cuts at exact edges m da 0 s Em With this setting the toolpath will be generated on the whole surface but a cutting pass will not be calculated on the exact edge of the surface This is useful in case the boundary of the drive surfaces is not smooth The maximum distance from the edge will be less the half the maximum stepover 2 Select the
71. take advantage of this To begin open the following file Documentation ExampleParts Compressor_armature mcx APPLICATION EXAMPLES Compressor Armature with 4 Axis Output 59 The following picture shows the desired cutting motion Tooling For this part use a 0 375 inch flat endmill Endmilll Flat Tool Type Parameters Capable of Halder C Rough r a C Finish Holder dia Both 20 Arbor Diameter Overall 0 375 20 Shoulder Flute NE on 1 0 Diameter Protile Auto Custom file Custom level fo 60 MASTERCAM X2 Advanced Multiaxis Tutorial Drive geometry and cutting passes Use the following Surface paths settings Toolpath parameters Surface paths Tool asis control Gouge check Link Roughing Li tility Machine definition Misc Pattern Parallel cuts al ee Machining anale in Y a Constant Z Machining anale inz fan Parallel Drive surfaces Drive surfaces offset a Type Full avoid cuts at exact edges Raund comers a Extend him Sorting Surface quality Flip step over qo ee Cut tolerance 0 005 toris Stendad j Distance OTS88585 Direction for one way machining Die tsi Maximum stepover 25 lV Enforce cutting direction assume closed contours E Start pornt Use the Parallel cuts pattern to create the cutting passes Fach cut needs to be parallel to a vertical plane so set the Machining
72. the toolpath parameters for the operation and select the Tool axis control tab 2 Select the Tilted with fixed angle to axis strategy TUTORIALS Parallel Cuts on a Cylinder 33 3 Select X axis and set the Fixed tilt angle to 45 Toolpath parameters Surface paths Tool axis control Gouge check Link Output Format 5 anis Maximum angle step 3 Tool asis will Tilted with fied angle to axis SP JEF TE Fixed tilt angle SF JEF gt Locking the retract moves to fixed plane 1 Go to the Gouge check tab 2 Change the strategy to Moving tool away and Retract tool in YZ plane This will lock the retract moves to a constant X value Toolpath parameters Surface paths Tool axis control Gouge check Link Roughing Ltility Machine definition Misc Check Strategy and parameters Geometry Tool Tool Arbor Holder tip shaft Drive surfaces Iw Check surfaces H1 stock to leave 2 Tolerance jo a 3 Click OK and then regenerate the toolpath You can see that even though the retract moves are locked to a constant Z Mastercam maintains the 45 degree tilt in the tool axis With this retract strategy the tool does not pull all the way out to the 34 MASTERCAM X2 Advanced Multiaxis Tutorial clearance plane but just enough to maintain the Stock to leave amount Exercise 9 Using a single point for tool axis control P Tilting the tool axis to a point 1 Open the
73. to the leading curve and projects them onto the drive surfaces In this case the curve will be a line through the middle of the cylinder For this part this produces results similar to the previous exercise but without needing to set machining angles This technique is often used when the cylinder is a more complex shape such as a head port Note The line that you will use as a drive curve is on level 3 in your part file If necessary make this level visible to display the line 14 MASTERCAM X2 Advanced Multiaxis Tutorial gt Selecting the leading curve 1 Make a copy of the toolpath from the previous exercises You will edit it again in later exercises 2 Click the Parameters icon in the Toolpath Manager for the new operation 3 Onthe Surface paths page change the Pattern to Cuts along curve Toolpath parameters Surface paths Tool axis contral Gouge check Link Pattern Edit curves Lead 4 Click the Lead button 5 Select the line as shown in the following picture The chaining direction of the selected curve determines where the toolpath will begin TUTORIALS Parallel Cuts on a Cylinder 15 gt Limiting the cutting area between two points For this toolpath you will limit the cutting area to the area between two points This lets you limit the cutting zone to a specific portion of the cylinder 1 From the Area Type list select Limit cuts by one or two points Drive surfaces of
74. toolpath parameters for the operation and select the Tool axis control tab Select the Tilted from point away strategy 3 Click the button to select the point and click it again to return to the graphics window TUTORIALS Parallel Cuts on a Cylinder 35 4 Select the midpoint of the purple line that runs along the cylinder axis 5 Mastercam fills in X 40 in the Point dialog box Click OK to close it 6 Set the Tilt angle to 0 and select the X axis Even though you have chosen to base the tool axis on the tilt angle from the point Mastercam lets you enter an additional angle to add to it Taolpath parameters Surface paths Tool axis control Gouge check Link Roughing Ltility Machine definition Misc Output format 5 axis Marimum angle step 3 Tool axis will Tilted from point away Tit ande b o E N 36 MASTERCAM X2 Advanced Multiaxis Tutorial 7 Click OK and then regenerate the toolpath Notice that at all times the tool axis is pointing away from the point TIP Mastercam also includes a Tilt through point option that you can use when the point is outside the part Exercise 10 Stopping the toolpath on a gouge gt Selecting the gouge check strategy 1 Open the toolpath parameters for the operation and select the Gouge check tab TUTORIALS Parallel Cuts on a Cylinder 37 2 Select the Stop tool path calculation strategy Check Tool Tool
75. tored in the defaults file with your other toolpath defaults TUTORIALS Parallel Cuts on a Cylinder 5 Tutorial 1 Parallel Cuts on a Cylinder The first tutorialis a simple toolpath that creates parallel cuts around a cylinder as shown in the following picture It measures 80mm long with a radius of 40mm with its long axis parallel to the X axis You will use a 30mm ball endmill The part geometry and tool are saved in the following file Documentation ExampleParts Multiaxis_Example1 mcx Load this part to begin the tutorial Note All the parts and tools in this tutorial are metric Exercise 1 Creating parallel cutting passes gt Starting the advanced multiaxis toolpaths 1 From the Toolpaths menu choose Advanced Multiaxis 6 MASTERCAM X2 Advanced Multiaxis Tutorial The Select User Interface dialog box displays It gives you the option of selecting one of several application specific interfaces These are simplified interfaces that let you quickly create toolpaths for specific needs most of the options are set automatically behind the scenes and are hidden from you For this tutorial you will use 5 Axis Multi Surface This is the main interface that exposes all of the multiaxis options so it provides a better introduction to the advanced multiaxis capabilities Select User Interface Interface Fx Multi Surface B Axis Multi Surface FAs Swarf Impeller FlaorsurFace Port Machinin
76. uses the same 0 25 inch tapered endmill used in the previous example Open the following file Documentation ExampleParts Impeller mcx 108 MASTERCAM X2 Advanced Multiaxis Tutorial Drive geometry and cutting passes Use the following Surface paths settings Toalpath parameters Surface paths Tool axis control Gouge check Lirik Roughing L tility Machine definition Misc Pattern Morph between 2 curves Edit curves LN First Second Drive surfaces Drive surfaces offset lo Full start and end at exact surface e Advanced Bound comers Extend trim Surface quality Sorting Flip step over Cut tolerance Cutting method Zigzag Distance Doe Cut onder Standard un ue Maximum stepaower 0 05 The drive geometry and cut pattern are the same as the floor roughing operation discussed earlier Many of the other parameters are also discussed in that example Select the Morph between two curves cutting pattern This will create cutting passes that transition between two curves and are then projected onto the drive surfaces APPLICATION EXAMPLES mpeller Floor Finishing 109 Select the two drive curves by clicking First and Second and selecting the two red curves Select the light purple floor as the Drive surface Select the Full start and end at exact surface edge option Click Advanced and enter margins of 0 13 inches Typically these margins are equa
77. with two exceptions For the Drive surfaces select Surface 2 from the above picture De select the Flip step over option This reverses the order of the cuts from the first toolpath which you should do since the tool will be flipped over APPLICATION EXAMPLES Camshaft on a Multitasking Lathe 77 Tool axis control and gouge checking For the first toolpath use the following Tool axis control settings Toolpath parameters Surface paths Tool axis control Gouge check Link Output format 5 axis Maximum angle step 3 Tool asiz will Tilted with Fixed angle ta axis Fixed tilt angle canis Tool axis crosses tilt anis These settings will lock the tool axis at a 45 degree angle relative to the X axis For the second toolpath flip the tool axis by setting the tilt angle to 135 Toolpath parameters Surface paths Tool axis control Gouge check Link Output format 5 asis ha x pp Maximum angle step 3 Tool axis will Tilted with fixed angle to axis IH Fixed tilt angle 135 Haris Mi 1 Tool axis crosses tilt axis Gouge checking is turned off for this toolpath because it is not needed 78 MASTERCAM X2 Advanced Multiaxis Tutorial The next example introduces a new application machining an electrode with a 4 1 axis toolpath APPLICATION EXAMPLES Electrode Machining 79 Example 4 Electrode Machining Electrodes used for EDM electrical discharge machin

Mastercam X2 Advanced Multiaxis Tutorial

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