Mastercam 2017 Handbook Volume 2 SAMPLE

IMPERIAL HANDBOOK VOLUME 2

3D MODELING & MACHINING THE GUIDE TO MASTERCAM

Handbook Volume 2

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Mastercam 2017 Handbook Volume 2 for Mastercam 2017 Copyright: 1998 -2017 In-House Solutions Inc. All rights reserved Software: Mastercam 2017 Author: In-House Solutions ISBN: 978-1-77146-566-3 Date: June 10, 2016

Notice In-House Solutions Inc. reserves the right to make improvements to this manual at any time and without notice. Disclaimer Of All Warranties And Liability In-House Solutions Inc. makes no warranties, either express or implied, with respect to this manual or with respect to the software described in this manual, its quality, performance, merchantability, or fitness for any particular purpose. In-House Solutions Inc. manual is sold or licensed "as is." The entire risk as to its quality and performance is with the buyer. Should the manual prove defective following its purchase, the buyer (and not In-House Solutions Inc., its distributer, or its retailer) assumes the entire cost of all necessary servicing, repair, of correction and any incidental or consequential damages. In no event will In-House Solutions Inc. be liable for direct, indirect, or consequential damages resulting from any defect in the manual, even if In-House Solutions Inc. has been advised of the possibility of such damages. Some jurisdictions do not allow the exclusion or limitation of implied warranties or liability for incidental or consequential damages, so the above limitation or exclusion may not apply to you. Copyrights This manual is protected under International copyright laws. All rights are reserved. This document may not, in whole or part, be copied, photographed, reproduced, translated or reduced to any electronic medium or machine readable form without prior consent, in writing, from In-House Solutions Inc. Trademarks Mastercam is a registered trademark of CNC Software, Inc. Microsoft, the Microsoft logo, MS, and MS-DOS are registered trademarks of Microsoft Corporation; Windows 7 and Windows 8 are registered trademarks of Microsoft Corporation. This document requires Mastercam Mill Essentials.

Table of Contents Legend ........................................................................................................................ 1 Chapters Introduction To 3D Workspace .............................................................................................................. 3 Splines ..................................................................................................................................................33 Surface Modeling .................................................................................................................................65 Surface Rough Machining ..................................................................................................................129 Surface Finish Machining ...................................................................................................................183 Surface High Speed Machining ..........................................................................................................207 Mold Project ......................................................................................................................................259 Prototype Project ..............................................................................................................................273

Handbook Volume 2

Introduction To 3D Workspace

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OBJECTIVES This chapter introduces the 3D Cartesian coordinate system and how to create and manipulate 3D wireframe drawings. Upon completion of this chapter, you should able to do the following: • • • • •

Understand the 3D Cartesian coordinate system. Set and use any of the seven pre-defined Construction Planes (Cplane). Set the Z: working depth on the active Cplane. Understand the purpose and how to use the 2D/3D setting. Create new Construction Planes by selecting two lines, a flat entity, a normal line, or by rotating an existing Cplane. • Draw in 3D space using wireframe entities. • Translate, or move, geometry using all available methods. • Use the Translate 3D function to move the part and rotate about all three axes simultaneously to place and orient as desired.

INTRODUCTION Surface modeling and machining requires the ability to visualize parts in three dimensions. You must also be able to visualize the entire machining process from start to finish. How will the part be held while being machined? What it will look like as it goes from one machining operation to the next? This spatial ability is, to some degree, a natural talent, but it can be developed with training and experience. You must also be able to work efficiently and accurately in the Mastercam 3D workspace. This includes being able to create wireframe, surface, and solid entities, and to define and manipulate views and 2D work planes within this space. You have to be able to move the part between any two points in space and rotate it precisely about any axis. This chapter provides the basic knowledge and skills you will need to accomplish all of these tasks. Study the information and examples in this chapter carefully. They form the foundation that will help you work with speed, confidence, and precision.

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MASTERCAM WORKSPACE An illustration of the Mastercam workspace is shown below. Because this workspace is dynamic and customizable, your screen may appear somewhat different from that shown. For instructional purposes, this example shows notes and interface components that are not normally displayed together. For example, the Screen Grid and RMB menus are active, and Drop Down/Fly Out menus are shown offset from their normal position for clarity.

Item Window Control Quick Access Toolbar

Definition Minimize, Restore Down or Close Mastercam. Groups functions that are most used and displays them as Icons. Icons are picture representations of functions. This is customizable.

Backstage

By selecting FILE you open the Backstage where you have access to functions that are used to open, save, and manage MCAM and other file types.

Ribbon Tabs

The Ribbon tabs allows you to select all Mastercam functions. These functions have been grouped together into different categories. These categories are displayed as ribbons.

Panels/ Dialog boxes

A window that opens to allow input of information and setting options. Dialog boxes are tailored for specific functions and often feature descriptive graphics to simplify user input.

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Item Drop-down Menu Graphic Area Origin

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Definition Menus that expand downward. Area where geometry and toolpaths are created, edited, and displayed. Intersection of X, Y, Z axes.

Mouse Cursor

Shows mouse location. Appears as a cross hair over the graphic area and as an arrow when over a menu item.

Mini Toolbar

Displays the current attributes and allows the users to quick change them.

RMB Function Prompt Viewport Axes Plane Information Toolpaths/Solids/Planes/ Levels Managers

Keyboard Command

Right Mouse Button. Clicking on Right Mouse Button with cursor in the graphics area opens the RMB menu. Prompts for user input. Provide information and prompts for next expected action. Shows orientation of the view in relation to the global coordinate system. Information regarding the active planes, and WCS (Work Coordinate System) History manager for toolpath operations and solids bodies. Planes manager allows you to set the current Graphic view, the World Coordinate System, the Construction plane and the Tool plane. Levels manager allows you to manage the level settings for the current part file. Not shown. Keyboard Function keys [F1-F12] and other key combinations can be assigned to functions.

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Mastercam Coordinate System The Mastercam coordinate system is a 3D Cartesian coordinate system. Three number lines are set at 90 degree angles to each other and labeled X, Y, and Z. The point where the axes cross is called the Origin. Numbers on one side of the origin are labeled positive. Those on the other side are labeled negative. The coordinate system comprises the total workspace that you can work on in Mastercam. It extends, for all practical purposes, infinitely in all directions.

Any point in this workspace is precisely defined given its axes label, sign, and value. For example, the point "X3, Y2, Z4" is located by counting, from the Origin, three units along the X+ axis, then up two units parallel to the Y+ axis, and then up four units parallel to the Z+ axis. 3D Cartesian coordinates may be written two different ways. One way uses the axis label, sign and value. For example: X3, Y2, Z4. The other writes coordinates as an ordered pair. Numbers are written in a specific order (X, Y, Z) separated by commas. For example:( 3, 2, 4). Within the Mastercam coordinate system, any number of Construction Planes (Cplanes) can exist. A Cplane is a flat working plane that can be located in any position or orientation in the Mastercam coordinate system.

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Screen Grid (Alt-G) shows the position and orientation of the active Cplane.

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System Defined Cplanes Cplanes are used to create flat, two-dimensional workspaces anywhere in the Mastercam workspace. These make drawing easier since coordinates can be entered in relation to the active Cplane rather than the coordinate system. Cplanes are also required to define arcs and 2D splines. Mastercam pre-defines the most common Cplanes; those aligned with the coordinate system XYZ axes. These can be selected from the Cplane, Named option on the Status Bar. The illustration below shows the position and orientation of Mastercam's pre-defined Cplanes and their relation to the coordinate system. The shaded square shows the origin and position of the first quadrant (X+Y+) of these planes.

Arcs and 2D Splines are 2D entities and must exist on a Cplane. If needed, Mastercam will automatically create Cplanes to support these entities. For example, if an arc is rotated such that it is not parallel to an existing Cplane, Mastercam will create one for it. These Cplanes are assigned a number (8, 9, 10, etc.) or can be given a name.

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CONSTRUCTION DEPTH (Z:) Work on any space parallel to the active Cplane by changing the Construction Depth setting, Z: setting in the HOME tab, Organize group as shown.

You can also change the Z value in the Mini Toolbar as shown (Right Mouse Click).

By default, Z: is zero, meaning that any geometry is created right on the active Cplane. To change construction depth, do any of the following: • Enter the value in the field next to the Z: setting. Positive values move the construction depth above the active Cplane. Negative values move it below the active Cplane. • Pick a previously entered value from the Z: drop down list. • Click on Z: and then select a point for the new construction depth from existing geometry in the graphic area.

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Construction Depth Practice how construction depth works by completing the following example: Start with the part, GussetPlate.MCAM which is included on your student CD. Extrude the 2D profile to create a 3D wireframe model using the TRANSFORM tab, Translate, Join option and setting Delta Z to -0.5. Add the rectangular shape at the bottom of the part as follows: • Step 1: Set Cplane to Top. • Step 2: Right mouse click in the graphics window and change the Gview to Isometric so that all geometry can be seen and selected. • Step 3: Right mouse click in the graphics window and set the Construction Depth by entering -0.5 in the Z: field as shown, or by clicking on Z: and pick any endpoint at the bottom of the part.

• Step 4: Draw the rectangle using any method you wish.

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Drawing Using Cplane As you can see, working in 3D space requires awareness of both the Cplane (construction plane orientation and position) and Z: (construction depth) settings. Practice using Cplane and Z: by completing the following example:

Step 1: Create a 1.0 square rectangle. Step 2: Extrude to form a 1.0 cube. Step 3: Change to an isometric or other 3D view. Step 4: Select a pre-defined Cplane. Step 5: Set the working depth of the face you want to draw on by clicking on Z: and picking the endpoint or midpoint of existing geometry on that face. Step 6: Create a 0.5 diameter arc at the center of the face.

Before Step 6: above, you may want to create a diagonal line across the face. This allows you to place the arc at the center of the face by picking the midpoint of the diagonal line. This construction geometry can be deleted after all arcs are drawn. You can also hover the cursor above the opposite endpoints and the midpoint will be automatically found by the system.

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2D/3D Drawing Mode So far, you have been drawing on flat planes. This is referred to as working in a 2D drawing mode, since all inputs are X-Y coordinates only in relation to the active Cplane. The 2D/3D setting, located in the HOME ribbon, Attributes group or in the Mini Toolbar allows you to switch to the 3D drawing mode as shown.

2D Mode: • Wireframe geometry is created on the active Cplane. • Z sets construction depth: in the HOME ribbon. • Z-value input selections from the mouse are ignored.

3D Mode: • The Construction depth Z: settings in the HOME ribbon are ignored. • Z-value inputs from the mouse are used. Practice using the 3D drawing mode by completing the following example: • Create a one-inch cube. Then draw lines between endpoints and midpoints in a zigzag pattern as shown. Try this using the 3D mode and then the 2D mode to see how the two methods differ.

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User Defined Cplanes Mastercam provides many ways to define new Cplanes or to select and manipulate existing planes. The most commonly used ways to define a new Cplane are:

• Two Lines • Flat Entity • Dynamic - Rotate • Normal

Creating Cplanes Create a Cplane using the Planes Manager panel. To open the Planes Manager panel, from VIEW tab, in the Managers group select Planes as shown.

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The Planes Manager options should look as shown.

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Item Create a new plane

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Definition Allows you to select one of the options to define a new plane.

From Geometry

Defines a Cplane by selecting a flat entity, two lines, or three points. A flat entity is an arc, 2D spline, flat surface, or flat solid face.

From Solid Face

Selects a plane by picking on a flat solid geometry face.

From Gview From Line Normal Relative to WCS Dynamic Select lathe plane Lathe Diameter

Creates a Cplane the same as the current Graphics View. Uses a line to define the Z-axis of a Cplane. Sets Cplane to be the same as a defined WCS. Creates a plane through the use of an interactive gnomon in the graphics window. Allows you to select one of the available planes used to draw and machine a lathe part. Predefined Cplanes Lathe planes that are using the diameter and the z coordinates such as +D +Z, -D +Z, +D -Z, -D -Z.

Lathe Radius

Predefined Cplanes Lathe planes that are using the radius and the z coordinates such as +X +Z, -X +Z, +X -Z, -X -Z.

Find a plane

Allows you to find an existing plane previously defined.

Display options

Allows you to customize which planes are shown, and if the gnomon and plane info are displayed.

Follow Rules

Allows you to enable rules such as updating the Cplane and Tplane when changing Gview.

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PLANES FROM GEOMETRY Construction Plane From Two Lines Example Any two lines that intersect can define a Cplane. Ideally, the lines intersect at a 90-degree angle and share an endpoint. This is a preferred way to define Cplanes since it is easy to set the orientation, origin, and axes directions based on how the entities are selected.

Step 1: Select Planes, Planes by Geometry from the Status Bar. Step 2: Select one line that represents the new Cplane X+ axis. Pick the line near the new Cplane origin. Then select a line that represents the new Cplane Y+ axis near the new Cplane origin.

Step 3: Observe the axes indicator. Use the arrows to toggle through the possible solutions until you see the one you want and then click on the green checkmark.

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Step 4: By default, the new Cplane is assigned a number. Name the Cplane by entering it in the Name field. The origin of the new plane is where the two lines intersect. Shift the origin by clicking on the arrow below the origin field and then picking a point on the part.

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Flat Entity This option is easy to use, but it is more difficult to control the Cplane X-Y axes direction. Simply click on a flat entity to set the new plane Z-axis normal (piercing at 90 degree angle all-around) to the flat entity. A flat entity is a(n):

• Arc. • 2D Spline. • Flat Surface. • Flat Solid Face.

Item Arc

Definition An arc must exist on a plane. This method sets the new plane Z-axis normal to this plane.

2D Spline

2D splines lie on a plane. Certain geometric shapes, such as an ellipse and some arcs, are modeled using 2D splines.

Flat Surface

A flat surface has an infinite radius of curvature. Check the radius of curvature using Analyze, Dynamic.

Solid Face

Any flat face on a Solid can be used to set a Cplane similar to the Flat Surface method.

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Cplane Dynamic Dynamic uses an interactive gnomon to create a plane in the graphics window. The gnomon comprises three axes connected at the origin, with selection points on the gnomon's segments. The selection points on the gnomon are defined as shown.

Item

Definition

Transform Align

Allows you to align entities to existing geometry using an interactive gnomon. The alignment can be applied to the gnomon axes or to the geometry depending on the option selected with the button next to the gnomon.

Translate Along

Allows you to move entities along an axis by selecting the axis leg. A ruler appears allowing you to indicate the direction and to snap at different positions. You can control the snap increment with the zoom function. You can also enter the value directly into the input box.

3D Translate XYZ/Polar XY Orient

Allows you to translate the gnomon origin in XYZ (delta). Use the XY orient function to orient the gnomon's XY axis to a face or a surface, whether it is tangent to a curved surface/face or on a flat surface/ face. To turn on this function, click on the area between the gnomon's X and Y axes.

2D Transform Rotate

Allows you to rotate the gnomon around an axis by selecting the center segment of the curved control.

3D Transform Rotate

Allows you to rotate the gnomon around an axis by selecting the center segment of the curved control and also to snap to another axis and rotate it with an angle too.

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The Dynamic Plane dialog box allows you to set some of the parameters used to create a new plane.

Item Name

Allows you to enter the name of the new plane.

Origin XYZ

Displays the location of the gnomon at all times.

Move to

Moves the gnomon to the origin. The origin used is based on the pull down selection. You may select WCS, World, Cplane, or Tplane origin.

Align to

Aligns the gnomon to a chosen set of axes. The axes used are based on the pull down selection. You may select WCS, World, Cplane, Tplane axes, or Graphics view.

Work Offset # Set as WCS

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Definition

Assigns a work offset code to the plane when you use the plane for a Tplane and create a toolpath. Automatically aligns the Work Coordinate System (WCS) to this view when you exit this dialog box.

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The next example shows the steps to follow when you rotate the surface around the X axis using the Dynamic plane. • Step 1:In the Planes Manager panel ensure that the WCS, Cplane and Tplane are set to top while the Gview is Isometric. • Step 2: Select the Create new plane icon and then Dynamic. • Step 3: Place the gnomon origin as shown.

• Step 4: Pick the center segment that controls the Z axis rotation and enter the angle or snap to the angle on the dial as shown in Figure 1.

Figure 1

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• Step 5: In the Dynamic Plane dialog box enter the plane name and then select the OK button to exit.

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Right Hand Rule The Right Hand Rule is used to determine the positive direction of rotation about any axis in a Cartesian coordinate system. It works by imagining that you wrap your right hand about the axis with the thumb pointing in the positive direction of the axis. In the illustration below, the X - axis is gripped with the thumb pointing in the direction + X. The positive direction of rotation for the gripped axis is the same direction as the curled fingers.

Cplane Normal A Normal line is a line that pierces an entity at 90 degrees all-around. Click on a line to set the Z-axis of the new Cplane along the line.

After picking the Normal line, you will be prompted to select another entity to define the new plane X-axis. Choose to skip this option.

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INDEX Numerics 2 Surface Blend ............................................. 120 3 Fillet Blend ................................................. 124 3 Surface Blend ............................................. 122 3D Contour Toolpath ...................................... 55 3D Cutter Compensation ................................ 54 3D Mode ......................................................... 12 3D splines ....................................................... 53

A Advanced Settings ........................................ 164 Analyze Test Surfaces ................................... 139 Automatic Spline ............................................ 39

B Ball Nose Mil ................................................. 130 Boss ............................................................... 130 Break many places .......................................... 47 Bull Nose ....................................................... 130

C cad geometry types ........................................ 66 Cavity ............................................................ 130 Check Surfaces .............................................. 130 Chordal Deviation ......................................... 130 Chordal deviation ........................................... 41 Climb vs. Conventional Machining ............... 155 Construction Depth (Z 9 Continuity ....................................................... 36 Core .............................................................. 130 CPlane 2 Lines Example .................................. 16 Cplanes ............................................................. 8 Curve ............................................................... 33 Curves Spline .................................................. 40 Cut Depths .................................................... 159 Cut Tolerance ................................................ 130 Cutting Methods ........................................... 167 Cutting Speeds & Feeds ................................ 134

D Direction ....................................................... 150 Draft .............................................................. 130 Draft surface ................................................... 77 Drive Curves .................................................... 68 Drive Surfaces ............................................... 130 Drop Down Menu ............................................. 5 Dynamic Planes ............................................... 15

E

Extruded Surface ............................................ 79

F Facing ............................................................ 158 Fence Surface ................................................. 85 Fill holes ........................................................ 106 Fillet Surface ................................................. 110 Fillet Surfaces To Surfaces ............................ 110 Fillet to curves .............................................. 119 Fillet To Plane ............................................... 118 Filter ................................................................ 51 Flat Boundary Surfaces ................................. 104 Flat Endmill ................................................... 130 Flat Entity ........................................................ 18 Flats .............................................................. 192 Function Prompt ............................................... 5

G Gap Settings .................................................. 162 Graphic Area ..................................................... 5

H Helix Parameters .......................................... 189 High Speed Machining .................................. 130 High Speed Parameters ................................ 169

K Keyboard command ......................................... 5

L Lathe Radius Lathe Diameter .......................... 15 Lofted Surface ................................................. 72

M Modify spline .................................................. 43 Mouse Cursor ................................................... 5

N Net Surface ..................................................... 89 Normal Line .................................................... 23 Nurbs Splines .................................................. 35

O Offset Surface ............................................... 109 Origin ................................................................ 5

P Parametric Splines .......................................... 34 Planes = Gview ................................................ 15 Planes = WCS .................................................. 15 Planes By Geometry ....................................... 15 Plunge Control .............................................. 173 Pocket Parameters ....................................... 165

Entry Options ................................................ 156

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INDEX R Refine Toopath ............................................. 155 Remove Bounday .......................................... 105 Revolved Surface ............................................ 73 Right Hand Rule .............................................. 23 RMB .................................................................. 5 Rough Parallel ............................................... 170 Rough Parallel Parameters ........................... 171 Rough Pocket ................................144, 152, 210 Ruled Surface .................................................. 69 Runoff Surface .............................................. 130

User Defined Cplanes ..................................... 13 UV Curves ....................................................... 68 UV curves ........................................................ 67

V Variable Fillet Indicators ............................... 115 Viewport Axes ................................................... 5

W Window Control ............................................... 4 Wireframe ...................................................... 66

S Scallop Height ............................................... 130 Shade Settings .............................................. 140 Shading ........................................................... 68 Shallow .................................................190, 191 Simplify ........................................................... 46 Solids ............................................................... 66 Split surface .................................................. 106 Stepover ....................................................... 130 Stock Allowance ............................................ 130 Surface From Solid ........................................ 125 Surface Normal ............................................... 68 surface normal ................................................ 67 Surface Parameters ...................................... 147 Surface Terms ................................................. 67 Surfaces .......................................................... 66 Swept Surface ................................................. 81 System Defined Cplanes ................................... 8

T Tapered End Mill ........................................... 130 Tip Comp ....................................................... 130 Tool Center Boundary ................................... 131 Tool Parameters ........................................... 146 Tool Selection ............................................... 132 Tool Tip Compensation ................................. 135 Toolpath/Surface Selection .......................... 145 Toolpaths/Solids Manager ................................ 5 Translate 3D .................................................... 24 Translucent ..................................................... 68 Trim Surfaces To A Plane ................................ 99 Trim Surfaces To Curves ................................. 95 Trim Surfaces To Surfaces ............................. 101 Trimmed Surfaces ........................................... 93 troubleshooting splines .................................. 49

U Un-Trim Surfaces .......................................... 104

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Handbook Volume 2

Mastercam 2017 Handbook Volume 2 SAMPLE

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