Mastercam X4 User Manual

mastercam x getting started tutorials

Basic 3D
Machining

October 2009

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II • BASIC 3D MACHINING

Mastercam® X4 Basic 3D Machining

Date: October 2009
Copyright © 2009 CNC Software, Inc.— All rights reserved.
First Printing: October 2009

Software: Mastercam X4

TERMS OF USE Use of this document is subject to the Mastercam End User License Agreement. A

copy of the Mastercam End User License Agreement is included with the
Mastercam product package of which this document is part. The Mastercam End
User License Agreement can also be found at:

www.mastercam.com/legal/licenseagreement/

Contents

Introduction ......................................................................................... 1

Machining the Connector ......................................................... 5

1. Toolpath Setup........................................................... 7

III

 Tutorial Goals................................................................................... 1

 Before You Begin............................................................................. 1

 If You Need More Help.................................................................... 3

 Additional Documentation..............................................................4

 Lesson Goals.................................................................................... 7

 Exercise 1: Assigning a Machine Definition.............................. 7

 Exercise 2: Setting Stock for Machining................................... 8

 Exercise 3: Creating Toolpath Groups ..................................... 10

2. Roughing the Interior ................................................ 13

 Lesson Goals..................................................................................13

 Exercise 1: Drilling the Holes .................................................. 13

 Exercise 2: Roughing the Pocket ............................................ 19

 Exercise 3: Roughing the Slot................................................. 23

 Exercise 4: Rest Roughing the Interior.................................... 28

3. Finishing the Interior................................................. 33

 Lesson Goals..................................................................................33

 Exercise 1: Finishing the Pocket Floor ....................................33

 Exercise 2: Finishing the Slot.................................................. 36

4. Machining the Exterior ............................................. 41

 Lesson Goals..................................................................................41

 Exercise 1: Roughing the Exterior ........................................... 41

 Exercise 2: Finishing the Exterior............................................ 46

 Exercise 3: Drilling a hole from the Front Plane....................... 49

IV • BASIC 3D MACHINING

Machining the Tool Holder..................................................... 71

5. Adding Details .......................................................... 53

 Lesson Goals..................................................................................53

 Exercise 1: Lettering with a Project Toolpath..........................53

 Exercise 2: Lettering with a Contour Toolpath.........................57

6. Backplot/Verify Your Toolpaths ............................... 63

 Lesson Goals..................................................................................63

 Exercise 1: Backplotting All Toolpaths ....................................63

 Exercise 2: Verifying All Toolpaths.......................................... 64

7. Posting Toolpaths..................................................... 67

 Lesson Goals..................................................................................67

 Exercise 1: Posting All Toolpath Operations............................67

 Sending NC Files to the Machine ................................................69

1. Toolpath Setup.......................................................... 73

 Lesson Goals..................................................................................73

 Exercise 1: Assigning a Machine Definition ............................73

 Exercise 2: Setting Stock for Machining .................................74

2. Roughing the Part..................................................... 77

 Lesson Goals..................................................................................77

 Exercise 1: Roughing the Part .................................................77

 Exercise 2: Creating a Leftover Toolpath................................. 82

3. Semi-Finishing the Part ............................................ 85

 Lesson Goals..................................................................................85

 Exercise 1: Creating a Surface Finish Blend ............................85

 Exercise 2: Creating a Surface Finish Parallel Steep ...............89

 Exercise 3: Copy and Modify an Operation .............................91

4. Finishing the Part...................................................... 95

 Lesson Goals..................................................................................95

 Exercise 1: Creating a Swept 3D............................................. 95

 Exercise 2: Creating a second Swept 3D ................................98

 Exercise 3: Creating a Flowline ............................................. 101

5. Backplot/Verify Your Toolpaths.............................. 105

 Lesson Goals................................................................................ 105

 Exercise 1: Backplotting all Toolpaths .................................. 105

 Exercise 2: Verifying All Toolpaths........................................ 106

6. Posting Toolpaths ................................................... 109

 Lesson Goals................................................................................ 109

 Exercise 1: Posting All Toolpath Operations ......................... 109

 Sending NC Files to the Machine.............................................. 111

Conclusion .........................................................................................112

V

VI • BASIC 3D MACHINING

INTRODUCTION

This tutorial focuses on applying several milling toolpaths to parts previously designed in
Mastercam. The objective is to provide a general overview of a handful of the toolpath options
available to you. The options and parameters selected are intended to get you started on the path
toward learning and exploring all of the features Mastercam has to offer.

The toolpaths created illustrate possible solutions for machining parts using 3D toolpaths - mainly
surfacing operations. There are many solutions for machining these and similar parts. The goal of
this tutorial is to provide the basic concepts for you to explore and expand upon. Alter and adjust
the outline to fit your learning and programming environment after completing the lessons.

Toolpath creation is a repetitive, step-by-step process as demonstrated by this tutorial.
Comprehensive and conceptual information can be found in the Help and other documentation
installed with Mastercam.

Tutorial Goals

 Open multiple part files, assign default machine definitions, and create stock boundaries

for the geometry

 Create and rename toolpath groups

 Create roughing operations to efficiently remove material from the part

 Create semi-finishing operations to safely transition between roughing and finishing the

part

 Create finishing operations to create a complete part with final dimensions

 Copy operations, change parameters, and regenerate the operation

 Assign toolpath parameters to meet the roughing, semi-finishing, and finishing

requirements

 Backplot toolpath operations to review tool motion

 Verify the machining of the part from a stock model display

 Post all toolpath operations to an NC file, review/edit the code as necessary, and save the

NC file

Before You Begin

This is a module of the Mastercam Getting Started Tutorial Series. The series introduces general
Mastercam functions and teaches basic skills for getting started with Mastercam. Other tutorial
series include:

 Focus Series: Focuses on a specific Mastercam feature—for example, Setup Sheets or FBM

Drill, and teaches basic and advanced skills.

 Exploring Series: Explores a single Mastercam product—for example, Mill, Solids, or Wire,

and teaches in-depth skills for working with the product.

The Mastercam tutorial series is in continual development, and we will add modules as we
complete them. For information and availability, please contact your local Mastercam Reseller.

2 • BASIC 3D MACHINING

Note: Screen colors in the tutorial pictures enhance image quality; they may not match your
Mastercam settings.

General Tutorial Requirements

All Mastercam tutorials have the following general requirements:

 You must be comfortable using the Windows

 The tutorials cannot be used with Mastercam Demo/Home Learning Edition (HLE). The

Demo/HLE file format (EMCX) is different from Mastercam (MCX), and basic Mastercam
functions, such as file conversions and posting, are unavailable.

 Each lesson in the tutorial builds on the mastery of preceding lesson’s skills. We

recommend that you complete them in order.

 Focus Series and Exploring Series tutorials require, at minimum, a mastery of the basic

Mastercam skills taught in the Getting Started Series modules. A general knowledge of
machining principals and practices is also required.

 You must have a seat of Mastercam X4 Design or higher to complete most of the tutorials in

the Getting Started Series.

 The Basic 2D Machining module in the Getting Started Series requires, at minimum, a seat

of Mill Entry or Router Entry.

 The Basic 3D Machining module in the Getting Started Series requires Mill Level 3 or Router

Pro.

 Additional files may accompany a tutorial. Unless the tutorial provides specific

instructions on where to place these files, store them in a folder that can be accessed from
the Mastercam workstation, either with the tutorial or in any location that you prefer.

 The Getting Started Series tutorials are available in an Adobe

format. Additional tutorial videos may also be available. Contact your local Mastercam
Reseller for more information.

 You must install Adobe Flash Player to display tutorial videos. You can download Adobe

Flash Player from www.adobe.com.

 You must configure Mastercam to work in metric units. Complete the instructions in the

following section Preparing for a Tutorial to set Mastercam to metric.

®

operating system.

®

Flash® compatible video

Preparing for a Tutorial

Before you start a tutorial, be sure you have completed the following tasks:

1 Start Mastercam using your preferred

method:

 Double-click Mastercam’s desktop

icon.

Or

 Launch Mastercam from the

Windows Start menu.

2 Select the metric configuration file:

a Select Settings, Configuration from

Mastercam’s menu.

b Choose ..\config\mcamxm.config

<Metric> from the Current drop-down

list.

c Click OK.

If You Need More Help

There are many ways to get help with Mastercam, including the following:

INTRODUCTION • 3

 Mastercam Help—Access Mastercam Help by selecting Help, Contents from Mastercam’s

menu bar or by pressing [Alt+H] on your keyboard. Also, most dialog boxes and ribbon

bars feature a Help button that opens Mastercam Help directly to related information.

 Online help—You can search for information or ask questions on the Mastercam Web

forum, located at www.emastercam.com. You can also find a wealth of information,
including many videos, at www.mastercam.com and www.mastercamedu.com.

 Mastercam Reseller—Your local Mastercam Reseller can help with most questions about

Mastercam.

 Technical Support—CNC Software’s Technical Support department (860-875-5006 or

[e-mail]) is open Monday through Friday from 8:00 a.m. to 5:30 p.m. USA
Eastern Standard Time.

 Documentation feedback—For questions about this or other Mastercam documentation,

contact the Technical Documentation department by email at [e-mail].

 Mastercam University—CNC Software sponsors Mastercam University, an affordable

online learning platform that gives you 24/7 access to Mastercam training materials. Take
advantage of more than 180 videos to master your skills at your own pace and help prepare
yourself for Mastercam Certification. For more information on Mastercam University,
please contact your Authorized Mastercam Reseller, visit www.mastercamu.com, or email
[e-mail].

4 • BASIC 3D MACHINING

Additional Documentation

You can find more information on using Mastercam in the following materials, located in the

\Documentation folder of your Mastercam installation:

 Mastercam X4 Installation Guide

 Mastercam X4 Administrator Guide

 Mastercam X4 Quick Start

 Mastercam X4 Reference Guide

 Mastercam X4 Transition Guide

 Mastercam X4 Quick Reference Card

 Mastercam X4 Wire Getting Started Guide

 Version 9 to X Function Map

Section 1

Machining the Connector

6 • BASIC 3D MACHINING

LESSON 1

1Toolpath Setup

Before generating toolpaths for a part, you must select a machine definition. Defining stock creates
a visual representation of the stock placed in your machine. Creating and naming toolpath groups
will organize operations and maintain a logical structure for the part. This lesson covers these
topics.

Lesson Goals

 Open a part file and assign a machine definition.

 Define stock to be used in machining the part.

 Rename toolpath groups.

Exercise 1: Assigning a Machine Definition

Toolpaths are organized in machine groups and toolpath groups. A machine group is created when
a machine definition is assigned. This exercise guides you through selecting a machine definition.

1 Open the tutorial part file Basic_3D_Machining_Part1_Start.MCX, which was provided

with the tutorial.

8 • BASIC 3D MACHINING

2 Click OK if prompted to switch to a metric

configuration.

3 Choose Machine Type, Mill, Default to

open the default Mill machine definition.

In Mastercam, you select a machine
definition before creating any toolpaths.
The machine definition is a model of your
machine tool’s capabilities and features. It
acts like a template for setting up
machining jobs.

Note: Parts that have previously been saved with a machine definition automatically load the
associated machine definition.

4 Choose File, Save As, and save the part under a different file name. This protects the

original tutorial file from being overwritten.

Exercise 2: Setting Stock for Machining

Define stock to help you more clearly visualize toolpaths. The stock can help to generate toolpaths,
or be used when backplotting or verifying toolpaths. This exercise guides you through creating a
stock boundary for your part.

1 In the Toolpath Manager, select Stock

setup. If necessary, click the [+] next to

Properties to expand the list.

The Machine Group Properties dialog box
opens to the Stock Setup tab.

2 Click Bounding box.

The Bounding Box dialog box opens.

Bounding box is a quick and convenient
method for creating stock around the outer
boundary of your geometry.

3 Set the options and parameters as shown,

then click OK.

SECTION 1: TOOLPATH SETUP • 9

4 Click OK in the Machine Group Properties

dialog box.

10 • BASIC 3D MACHINING

5 Press [Alt+F1], or right-click and select Fit, to fit the geometry to the screen.

6 Choose File, Save or click the Save button

to save the part with the machine
definition and defined stock.

Exercise 3: Creating Toolpath Groups

Toolpath groups aid in organizing toolpaths logically. A well organized part file makes it easy for
any user to understand the process involved in making the part. This exercise guides you through
creating and renaming toolpath groups.

1 In the Toolpath Manager, right-click

Toolpath Group-1, select Groups,
Rename.

SECTION 1: TOOLPATH SETUP • 11

2 Ty pe Interior and press [Enter].

3 In the Toolpath Manager, right-click on

Machine Group-1, select Groups, New
Toolpath Group.

The new toolpath group is named
Toolpath Group-1. If you create the second
toolpath group before renaming the first,
the new group is named Toolpath Group-2.

TIP: Right-clicking the machine group name creates the new toolpath group at the same
level in the tree as the Interior toolpath group. You can right-click Interior to create a new
toolpath group one level below Interior.

4 Ty pe Exterior and press [Enter].

The Toolpath Manager should look as
shown.

5 Choose File, Save or click the Save button

to save the part.

12 • BASIC 3D MACHINING

LESSON 2

2Roughing the Interior

The first toolpaths for a part typically involve removing large amounts of material. This is referred
to as roughing the part. This lesson guides you through several roughing toolpaths. These include
drilling the holes, roughing the inner pocket, roughing the inner slot, and rest roughing the interior
portion of the part.

Lesson Goals

 Create a drill toolpath (including drill point selection, choosing tooling, and setting

machine values).

 Create High Speed and surface roughing operations.

 Create a High Speed rest roughing operation (including toolpath refinement).

Exercise 1: Drilling the Holes

1 In the Toolpath Manager, click the Move

insert arrow up one item button.

The Toolpath Manager should look as
shown after performing this step.

The insert arrow controls the location
where new toolpaths will be added to the
Too l pa th M an a ge r.

14 • BASIC 3D MACHINING

2 Right-click in the graphics window and

choose Isometric (WCS) from the menu to
view the part and toolpath in the isometric
view.

You may need to center the part in the
graphics window to see it. The easiest way
to do this is to use the graphics window
right-click menu and select Fit to fit the
part to the screen size [Alt+F1]. Then
unzoom using [Alt+F2]. You can also use
the fit/zoom/unzoom buttons in the View
Manipulation toolbar.

3 Choose Toolpaths, Drill.

4 Click OK when prompted to enter new NC

name.

The name displayed will be the name you
chose to save the file under. You may
change the NC file name now if necessary.

5 Use the default option for Select drill

point position in the graphics screen in

the Drill Point Selection dialog box.

SECTION 1: ROUGHING THE INTERIOR • 15

6 Select the arc centers of the four holes as

indicated.

The autocursor changes to indicate the arc
center as you approach.

7 Click OK in the Drill Point Selection dialog box.

The 2D Toolpaths dialog box opens to the Toolpath Type page. Drill is selected as the
toolpath type. (Do not click OK on the 2D Toolpaths dialog box until all pages are
complete.)

16 • BASIC 3D MACHINING

8 Select To o l from the Tree View pane on the

left.

9 Click the Select library tool button.

The default metric tool library opens.

10 Select the 10mm drill and click OK.

TIP: Use the default tool settings for the purposes of the tutorial. Tool speeds, feeds,

number, and other parameters should be changed to fit your machine and tooling before
cutting the part.

SECTION 1: ROUGHING THE INTERIOR • 17

11 Select Linking Parameters from the Tree View pane and enter values as shown.

These values will control the depth the tool will move to, where the top of stock is located,
as well as the height to retract the tool to.

12 Select Tip Comp from the Tree View pane.

Click the Tip Comp checkbox to activate
this feature. Use default values for the tip
comp parameters.

18 • BASIC 3D MACHINING

13 Click OK in the 2D Toolpath dialog box to generate the drill toolpath.

14 Click the Toggle toolpath display on

selected operations button. If necessary,
select the Drill/Counterbore operation.

The toolpath display for the Drill toolpath
is turned off. Perform this step after the
creation of each operation for clarity in
selecting geometry for subsequent steps.

15 Save your part file.

SECTION 1: ROUGHING THE INTERIOR • 19

Exercise 2: Roughing the Pocket

1 Choose Toolpaths, Surface High Speed.

2 If the New 3D Advanced Toolpath Refinement Feature! dialog box opens, select the

option to eliminate this dialog box and make refinement available for use. Click OK to close
the dialog box.

Note: This dialog box introduces the 3D Advanced Toolpath Refinement feature. Use this feature
to fine-tune your toolpath motion.

20 • BASIC 3D MACHINING

3 Follow the prompt to select drive surfaces as shown.

4 Press [Enter] or click the End Selection

button to accept the selection.

5 Click the Select button in the

Containment area of the Toolpath/Surface
selection dialog box.

The Chaining dialog box opens.

6 Click the C-plane radio button.

C-plane selection limits chaining to
entities that are parallel to the current
construction plane.

SECTION 1: ROUGHING THE INTERIOR • 21

7 Select the chain on the top of the part. The

selection can be in either direction for a
closed containment boundary.

8 Click OK on the Chaining dialog box to return to the Toolpath/Surface selection dialog box.

9 Click OK on the Toolpath/surface selection dialog box.

The Surface High Speed toolpaths dialog box opens on the Toolpath Type page.

10 Select Roughing and Area Clearance on

the Toolpath Type page.

11 Select To o l from the Tree View pane.

12 Click the Select library tool button. The

default metric tool library opens.

13 Select the 10mm bull endmill with 2mm

corner radius and click OK.

TIP: Adjust the Filter options on the right of
the dialog box to limit the types of tools
displayed.

22 • BASIC 3D MACHINING

14 Select Cut Parameters from the Tree View pane. Set the parameters as indicated.

15 Click OK to generate the area clearance toolpath.

SECTION 1: ROUGHING THE INTERIOR • 23

16 Turn off the toolpath display for the operation.

17 Save your part file.

Exercise 3: Roughing the Slot

1 Choose Toolpaths, Surface Rough,

Pocket.

24 • BASIC 3D MACHINING

2 Follow the prompt to select drive surfaces

as shown.

3 Press [Enter] or click the End Selection button.

4 Click the Select button in the Containment area of the Toolpath/Surface selection dialog

box.

The Chaining dialog box opens.

5 Click the C-plane radio button in the Chaining dialog box.

6 Select the chain at the top of the slot as

shown.

7 Click OK on the Chaining dialog box.

8 Click OK on the Toolpaths/surface selection dialog box.

The Surface Rough Pocket dialog box opens to the Toolpath parameters tab.

9 Select the 10mm bull endmill with the

2mm corner radius showing in the tool list.

10 Click the Surface parameters tab.

11 Set Stock to leave on drive to a value of

1mm.

Remaining parameters on this tab will be
left at defaults.

12 Click the Rough parameters tab.

13 Click the Cut Depths button.

14 Set the parameters as shown and click OK.

SECTION 1: ROUGHING THE INTERIOR • 25

15 Click the Pocket parameters tab.

26 • BASIC 3D MACHINING

16 Click Constant Overlap Spiral, set the parameters as shown, and click OK.

17 The following warning message displays because the finish passes are turned off. Click OK

to continue.

SECTION 1: ROUGHING THE INTERIOR • 27

18 The surface rough pocket toolpath is generated on the selected geometry.

19 Turn off the toolpath display for the operation.

20 Save your part file.

28 • BASIC 3D MACHINING

Exercise 4: Rest Roughing the Interior

1 Choose Toolpaths, Surface High Speed.

2 Follow the prompt to select drive surfaces as shown.

3 Press [Enter] or click End Selection to accept the selection.

4 Click the Select button in the Containment area of the Toolpath/Surface selection dialog

box.

The Chaining dialog box opens.

5 Click the C-plane radio button.

SECTION 1: ROUGHING THE INTERIOR • 29

6 Follow the prompt to chain a containment boundary as shown.

7 Click OK in the Chaining and the Toolpath/surface selection dialog boxes.

The Surface High Speed toolpaths dialog box opens.

8 Select Toolpath Type from the Tree View

pane, and then select Roughing and Rest
Roughing on the Toolpath Type page.

9 Select To o l from the Tree View pane.

10 Click the Select library tool button. The

default metric tool library opens.

30 • BASIC 3D MACHINING

11 Select the 6mm bull endmill with the 2mm

corner radius and click OK.

12 Select Cut Parameters from the Tree View

pane.

Set the stock to leave values as indicated.

13 Select Rest Material from the Tree View

pane.

Click the plus sign in front of Cut
Parameters to expand the tree if necessary.

14 Select Roughing Tool and set the values as

shown.

15 Select Arc Filter/Tolerance from the Tree

View pane.

16 Click the Refine toolpath button.

The Refine Toolpath dialog box opens.

SECTION 1: ROUGHING THE INTERIOR • 31

17 Move the slider for Surface quality to the Better setting.

Note: Move the slider(s) to quickly adjust parameters in the dialog box. Consult Help for more
detailed information.

18 Click OK to accept the settings on the Refine Toolpath dialog.

19 Click OK in the Surface High Speed Toolpath dialog box.

20 If the following dialog box displays, select Create a new tool, then click OK.

32 • BASIC 3D MACHINING

21 The rest roughing toolpath is generated on the selected geometry.

22 Turn off the toolpath display for the operation.

23 Save your part file.

LESSON 3

3Finishing the Interior

After roughing a part, or section of a part, finishing operations will generally need to be performed.
Finishing operations remove remaining stock while improving surface finish quality. Tighter
tolerances, smaller stepover values, smaller tools, as well as toolpath refinement will be used in this
lesson to achieve the desired finish quality.

Lesson Goals

 Create a finishing operation for the pocket floor.

 Create a finishing operation for the slot.

Exercise 1: Finishing the Pocket Floor

1 Choose Toolpaths, Surface High Speed.

The prompt to select Drive Surfaces appears.

2 Follow the prompt to select drive surfaces as shown.

3 Press [Enter] or click the End Selection button to accept the selection.

4 Click the Select button in the Containment area of the Toolpath/Surface selection dialog

box.

34 • BASIC 3D MACHINING

The Chaining dialog box opens.

5 Click the C-plane radio button.

6 Follow the prompt to chain a containment boundary as shown.

7 Click OK in the Chaining and the Toolpath/surface selection dialog boxes.

The Surface High Speed toolpaths dialog box opens on the Toolpath Type page.

8 Select the Toolpath Type page, and then

Finishing and Horizontal Area.

Horizontal Area is designed to quickly and
efficiently machine flat areas of a part.

9 Select To o l from the Tree View pane.

10 Select the 6mm bull endmill with the 2mm corner radius showing in the tool list.

11 Select Cut Parameters from the Tree View

pane. Set the tool containment as shown.

12 Select Arc Filter/Tolerance from the Tree View pane.

13 Click the Refine Toolpath button.

14 Move the slider for Surface quality to the Best setting.

SECTION 1: FINISHING THE INTERIOR • 35

15 Click OK to accept the settings on the Refine Toolpath dialog.

36 • BASIC 3D MACHINING

16 Click OK in the Surface High Speed Toolpath dialog box to generate the horizontal area

toolpath.

17 Turn off the toolpath display for the operation.

18 Save your part file.

Exercise 2: Finishing the Slot

1 Choose Toolpaths, Surface Finish,

Contour.

SECTION 1: FINISHING THE INTERIOR • 37

2 Follow the prompt to select drive surfaces

as shown.

3 Press [Enter] or click the End Selection button to accept the selection.

4 Click the Select button in the Containment area of the Toolpath/Surface selection dialog

box.

The Chaining dialog box opens.

5 Click the C-plane radio button.

6 Follow the prompt to chain a containment

boundary as shown.

7 Click OK on the Chaining and Toolpaths/surface selection dialog box.

The Surface Finish Contour dialog box opens to the Toolpath parameters tab.

8 Select the 6mm bull endmill with the 2mm

corner radius showing in the tool list.

38 • BASIC 3D MACHINING

9 Click the Surface parameters tab. Set the parameters as shown.

Note: Retract is set to absolute to ensure proper clearance when the tool is pulling out of the deep
slot.

10 Click the Finish contour parameters tab.

11 Set the parameters as shown.

12 Click the Total tolerance button.

13 Move the slider for Surface quality to the Best setting and click OK.

SECTION 1: FINISHING THE INTERIOR • 39

14 Click the Cut Depths button.

15 Set the parameters as shown and click OK.

16 Click OK from the Surface Finish Contour dialog box to generate the finish contour

toolpath.

17 Turn off the toolpath display for the operation.

18 Save your part file.

40 • BASIC 3D MACHINING

LESSON 4

4Machining the Exterior

Roughing and finishing are required on the exterior of the part provided. The simplicity of the
exterior surfaces allows for a single roughing and a single finishing operation. This lesson will cover
each of those as well as using a different tool plane to drill a hole.

Lesson Goals

 Create a Core Roughing toolpath.

 Create a Surface Finish Contour toolpath.

 Create a Drill toolpath in the Front plane.

Exercise 1: Roughing the Exterior

1 Select the toolpath group Exterior.

Click the minus (-) in front of the Interior
toolpath group to collapse the tree.

2 Click the Position insert arrow after

selected operation or after selected
group button.

The insertion arrow is placed in the
Exterior group.

Moving the insertion arrow ensures new
toolpaths are created in the Exterior
toolpath group. Toolpath organization is
an important ability as the number of
operations grows.

3 Choose Toolpaths, Surface High Speed.

4 Click the All button on the General

Selection ribbon bar when prompted to
select drive surfaces.

42 • BASIC 3D MACHINING

5 Select the Entities and Surfaces

checkboxes in the Select All dialog box as
shown.

6 Click OK in the Select All dialog box.

7 Press [Enter] or click the End Selection button.

8 Click the Select button in the Containment area of the Toolpath/Surface selection dialog

box.

The Chaining dialog box opens.

9 Click the C-plane radio button.

SECTION 1: MACHINING THE EXTERIOR • 43

10 Select two chains as shown to be used as containment boundaries. The chains lie on the

top of the part and the top of the stock boundary created in the Toolpath Setup lesson.

11 Click OK in the Chaining and the Toolpath/surface selection dialog boxes.

The Surface High Speed toolpaths dialog box opens on the Toolpath Type page.

12 Select the Toolpath Type page, and then

Roughing and Core Roughing.

13 Select To o l from the Tree View pane.

14 Select the 10mm bull endmill with the 2mm corner radius showing in the tool list.

44 • BASIC 3D MACHINING

15 Select Cut Parameters from the Tree View pane. Set the tool containment and stock to

leave values as indicated.

16 Select Steep/Shallow from the Tree View

pane. Set the parameters as shown.

Click the plus [+] in front of Cut
Parameters if necessary to expand the tree.

SECTION 1: MACHINING THE EXTERIOR • 45

17 Click OK in the Surface High Speed Toolpath dialog box to generate the core roughing

toolpath.

18 Turn off the toolpath display for the operation.

19 Save your part file.

46 • BASIC 3D MACHINING

Exercise 2: Finishing the Exterior

1 Choose Toolpaths, Surface Finish, Contour.

2 Follow the prompt to select drive surfaces as shown.

3 Press [Enter] or click the End Selection button to accept the selection.

4 Click the Select button in the Check

Surfaces area of the Toolpath/Surface
selection dialog box.

5 Follow the prompt to select check surfaces as shown.

SECTION 1: MACHINING THE EXTERIOR • 47

6 Press [Enter] or click the End Selection button to accept the selection.

7 Click OK on the Toolpath/Surface selection dialog box.

8 Click the Select library tool button.

9 Select the 6mm flat endmill and click OK.

10 Click the Surface parameters tab and set

the stock to leave values as shown.

11 Click the Finish contour parameters tab.

12 Click the Total tolerance button.

13 Move the slider for Surface quality to the Best setting and click OK.

48 • BASIC 3D MACHINING

14 Click the Cut Depths button.

15 Set the parameters as shown and click OK.

16 Click OK to generate the surface finish contour toolpath.

17 Turn off the toolpath display for the operation.

18 Save your part file.

SECTION 1: MACHINING THE EXTERIOR • 49

Exercise 3: Drilling a hole from the Front Plane

1 Click the Planes button located on the

Status bar at the bottom of the screen.

2 Select Front (WCS) from the list.

Planes selection sets your construction
and tool plane.

3 Choose Toolpaths, Drill.

4 Use the default option for Select drill

point position in the graphics screen in
the Drill Point Selection dialog box.

5 Select the arc center as indicated.

6 Click OK in the Drill Point Selection dialog box.

The 2D Toolpaths dialog box opens to the Toolpath Type page. Drill is selected as the
toolpath type.

7 Select To o l from the Tree View pane.

8 Click the Select library tool button.

50 • BASIC 3D MACHINING

9 Select the 6mm drill and click OK.

10 Select Linking Parameters from the Tree

View pane and enter values as shown.

11 Select Tip Comp from the Tree View pane. Click the Tip Comp checkbox to activate this

feature. Use default values for the tip comp parameters.

12 Click OK to generate the drill toolpath.

SECTION 1: MACHINING THE EXTERIOR • 51

13 Turn off the toolpath display for the operation.

14 Save your part file.

52 • BASIC 3D MACHINING

LESSON 5

5Adding Details

The basic part has been machined to the desired quality. Remaining details may now be added to
the part such as engraved numbers or letters, tapping of holes, or any other detail work not
included in the previous operations. This lesson covers two methods for adding lettering to your
part.

Lesson Goals

 Create lettering using a Surface Finish Project toolpath in the front plane.

 Create lettering using a Contour toolpath in a custom plane.

Exercise 1: Lettering with a Project Toolpath

1 Choose Toolpaths, Surface Finish,

Project.

The tool and construction planes should
be set to Front from the previous exercise.
If not, reset them to Front.

54 • BASIC 3D MACHINING

2 Follow the prompt to select drive surfaces as shown.

3 Press [Enter] or click the End Selection button.

4 Click OK from the Toolpath/Surface selection dialog box.

The Surface Finish Project dialog box opens to the toolpath parameters tab.

5 Click the Select library tool button.

6 Select the 2mm ball endmill and click OK.

7 Click the Surface parameters tab and set

the stock to leave values as shown.

A negative stock to leave value creates the
toolpath below the surface. The letters
become engraved into the part.

8 Click the Finish project parameters tab.

SECTION 1: ADDING DETAILS • 55

9 Set the Projection type to Curves.

10 Click the Total tolerance button.

11 Move the slider for Surface quality to the Best setting and click OK.

12 Click the Gap Settings button.

13 Adjust the Distance value in Gap settings

as shown.

Only the value preceded by the radio
button selection will be used in the
toolpath calculation.

14 Click OK in the Gap settings dialog.

15 Click OK from the Surface Finish Project dialog.

The Chaining dialog box opens.

16 Set the chaining mode to window by

clicking the Window button.

17 To select the curves to be used in the

toolpath, click and hold the mouse button
above and to the left of the text.

18 Drag your mouse down and to the right to

draw a selection rectangle.

19 Click again to set the lower right corner of

the rectangle and complete the window.

56 • BASIC 3D MACHINING

20 Click the lower left endpoint of the text

when prompted to Sketch approximate
start point.

21 Click OK to generate the surface finish project toolpath.

22 Turn off the toolpath display for the operation.

23 Save your part file.

SECTION 1: ADDING DETAILS • 57

Exercise 2: Lettering with a Contour Toolpath

1 Click the Planes button on the Status bar.

2 Select Named Views from the list.

The View Selection dialog opens.

3 Select Te x t P l a n e from the list of available

planes. Click OK to set the new plane.

Review Basic 3D Design to see a procedure
for creating named planes.

4 Choose To o l p a t h s , C on t o u r .

5 Set the chaining mode to window by clicking the Window button.

6 Window-select the Mastercam letters that lie in the Text Plane.

7 Click the lower left endpoint of the text

when prompted to Sketch approximate
start point.

8 Click OK from the Chaining dialog box.

The 2D Toolpath dialog box opens to the Toolpath Type page.

9 Select To o l from the Tree View pane.

10 Click the Select library tool button.

58 • BASIC 3D MACHINING

11 Select the 1mm ball endmill and click OK.

12 Select Cut Parameters from the Tree View pane.

13 Set Compensation type to Off.

14 Select Lead In/Out from the Tree View

pane.

Expand Cut Parameters by clicking the [+],
if necessary.

15 Uncheck lead in/out moves.

SECTION 1: ADDING DETAILS • 59

16 Select Linking Parameters from the Tree View pane and set the parameters as shown.

17 Select Planes (WCS) from the Tree View

pane.

The Planes (WCS) page is displayed.

60 • BASIC 3D MACHINING

18 Click the Copy to WCS button highlighted below.

19 The resulting working coordinate system is

as shown.

Click the Help button for details on
working with WCS.

SECTION 1: ADDING DETAILS • 61

20 Click OK from the 2D Toolpaths dialog box to generate the contour toolpath.

21 Turn off the toolpath display for the operation.

22 Save your part file.

62 • BASIC 3D MACHINING

LESSON 6

6Backplot/Verify Your Toolpaths

Now that all toolpaths are complete, it is time to backplot and verify your operations. This process
allows you to review the tool motion before any cutting takes place on the actual machine. This
lesson guides you through the backplot and verify functions.

Lesson Goals

 Backplot all toolpaths.

 Verify all toolpaths.

Exercise 1: Backplotting All Toolpaths

1 In the Toolpath Manager, click the Select

all operations button.

All operations should now have a green
check on them.

2 Click the Backplot selected operations

button in the Toolpath Manager.

The Backplot dialog box and Backplot VCR
bar open.

3 In the Backplot dialog box, select the

Display tool and Display rapid moves
buttons.

These options will display a simulation of
the tool as well as the rapid motion.

64 • BASIC 3D MACHINING

TIP: To further customize your backplot display, choose other buttons on the Backplot

dialog box. For example, choose the Options button to open the Backplot Options dialog
box. This dialog box lets you set various backplot options such as tool display, holder
display, and tool motion colors. Setting the option to Cleanup screen on Tool change is
recommended with a large number of operations.

I4 Use the buttons and sliders on the
Backplot VCR bar to backplot the
operations. The Play button (shown to the
right) begins the backplot.

Click the Help button on the VCR bar for more information on each of the controls.

5 When finished, click OK on the backplot dialog box to exit the backplot function.

TIP: The backplot display is easily customizable. See the Mastercam Help for details on

each of the buttons, fields, and display options in the Backplot and the Backplot Options
dialog boxes.

Exercise 2: Verifying All Toolpaths

1 In the Toolpath Manager, make sure all

operations are selected and click the Veri f y
selected operations button.

The Verify dialog box opens.

2 In the Verify dialog box, select the Machine

button.

The part, stock, and toolpaths are simulated.

TIP: Use the buttons, fields, and controls in the Verify dialog box to customize and manage
the toolpath verification process. Click the Help button in the dialog box for details.

SECTION 1: BACKPLOT/VERIFY YOUR T OOLPATHS • 65

When the verification process is complete, the part should look similar to the image shown
here.

66 • BASIC 3D MACHINING

LESSON 7

7Posting Toolpaths

Operations must be run through a post processor in order to be usable by your machine. This
process is commonly referred to as posting. This lesson will guide you through selecting and
posting all of your operations. Communicating the posted code to your machine is the last step of
the toolpathing process in Mastercam.

Lesson Goals

 Post all toolpaths to create an NC file.

Exercise 1: Posting All Toolpath Operations

1 In the Toolpath Manager, click the Select

all operations button.

2 Click the Post selected operations button.

The Post processing dialog box opens.

68 • BASIC 3D MACHINING

3 Set the post processing options as shown.

4 Click OK.

The Save As dialog box opens.

5 Click Save to save the NC file in the default location with the recommended file name.

Notes:

• Posting may take several minutes. When it is complete, the NC code will display in your
default editor/communicator. This tutorial uses Mastercam Editor to display the NC code.

• Producing the correct NC code for your machine and application depends on properly
configuring the machine definition, control definition, and .PST file. For detailed
information on machine definitions, control, definitions, and posting, please see the
following documentation supplied with Mastercam:

- Mastercam Help

- Mastercam X4 Reference Guide (choose Reference Guide from the
Mastercam Help menu)

- Mastercam NCI & Parameter Reference Guide (in the Documentation folder
under your Mastercam installation folder)

SECTION 1: POSTING TOOLPATHS • 69

6 Your chosen editor opens (in this case, Mastercam Editor), displaying the posted NC code

as shown below.

7 Scroll through the NC code to verify that each line of code meets your expectations. Edit

and save as necessary.

Sending NC Files to the Machine

IMPORTANT: This tutorial is based on the Mastercam Mill Default machine definition for
training purposes only. It is not possible to provide a step-by-step procedure for sending the
NC code to your machine control because machine setups are customizable and most likely
different from the machine definition used here. Following is a general description of how
the NC code is communicated to machines and their controls for machining.

After the NC file is reviewed, edited, and saved, you can set up your machine control to accept the

NC file. This is done according to your machine and control manufacturer’s procedures.

70 • BASIC 3D MACHINING

When the machine control is ready to receive the NC file, configure your preferred editor or
communications program to communicate with your machine control. Refer to your
communications program documentation for details.

Send the NC code to your machine control according to your machine and control manufacturer’s
documentation. Once you start the communication process, the send/receive data processing is
mostly managed by your machine control.

Contact your local Mastercam Reseller for customized machine/control definitions, post (PST)
files, and support.

Section 2

Machining the Tool Holder

72 • BASIC 3D MACHINING

LESSON 1

1Toolpath Setup

Before generating toolpaths for a part, you must select a machine definition. Defining stock creates

a visual representation of the stock placed in your machine. This lesson covers these topics.

Lesson Goals

 Open a part file and assign a machine definition.

 Define stock to be used in machining the part.

Exercise 1: Assigning a Machine Definition

1 Open the tutorial part file Basic_3D_Machining_Part2_Start.MCX, which was provided

with the tutorial.

2 Click OK if prompted to switch to a metric

configuration.

74 • BASIC 3D MACHINING

3 Choose Machine Type, Mill, Default to

open the default Mill machine definition.

In Mastercam, you select a machine
definition before creating any toolpaths.
The machine definition is a model of your
machine tool’s capabilities and features. It
acts like a template for setting up
machining jobs.

Note: Parts that have previously been saved with a machine definition automatically load the
associated machine definition.

4 Choose File, Save As, and save the part under a different file name. This protects the

original tutorial file from being overwritten.

Exercise 2: Setting Stock for Machining

1 In the Toolpath Manager, select Stock

setup. If necessary, click the [+] next to

Properties to expand the list.

The Machine Group Properties dialog box
opens to the Stock Setup tab.

2 Click Bounding box.

The Bounding Box dialog box opens.

Bounding box is a quick and convenient
method for creating stock around the outer
boundary of your geometry.

3 Set the options and parameters as shown,

and then click OK.

SECTION 2: TOOLPATH SETUP • 75

4 Click OK in the Machine Group Properties

dialog box.

5 Press [Alt+S] to shade the geometry, if necessary.

76 • BASIC 3D MACHINING

6 Press [Alt+F1] to fit the geometry to the screen.

7 Choose File, Save or click the Save button

to save the part with the machine
definition and defined stock.

LESSON 2

2Roughing the Part

The first toolpaths for a part typically involve removing large amounts of material. This is referred
to as roughing the part. This lesson guides you through several roughing toolpaths. These include
using a core roughing operation and a leftover operation.

Lesson Goals

 Create a core roughing toolpath to efficiently remove material.

 Create a leftover toolpath.

Exercise 1: Roughing the Part

1 Choose Toolpaths, Surface High Speed.

2 If the New 3D Advanced Toolpath Refinement Feature! dialog box opens, select the

option to eliminate this dialog box and make refinement available for use. Click OK to close
the dialog box.

78 • BASIC 3D MACHINING

Note: This dialog box introduces the 3D Advanced Toolpath Refinement feature. Use this feature
to fine-tune your toolpath motion.

3 Click OK when prompted to enter new NC

name.

The name displayed will be the name you
chose to save the file under. You may
change the NC file name now if necessary.

4 Press [Alt+S] to shade the geometry, if necessary.

5 Follow the prompt to select drive surfaces as shown.

6 Press [Enter] or click the End Selection

button to accept the selection.

7 Click the Select button in the

Containment area of the Toolpath/Surface
selection dialog box.

The Chaining dialog box opens.

8 Click the C-plane radio button.

C-plane selection limits chaining to
entities that are parallel to the current
construction plane.

9 Select the chain on top of the stock

boundary.

SECTION 2: ROUGHING THE PART • 79

10 Click OK on the Chaining dialog box to return to the Toolpath/Surface selection dialog box.

11 Click OK on the Toolpath/surface selection dialog box.

The Surface High Speed toolpaths dialog box opens on the Toolpath Type page.

12 Select Roughing and Core Roughing on

the Toolpath Type page.

13 Select To o l from the Tree View pane.

14 Click the Select library tool button.

The default metric tool library opens.

80 • BASIC 3D MACHINING

15 Select the 10mm bull endmill with 2mm

corner radius and click OK.

TIP: Adjust the Filter options on the right of
the dialog box to limit the types of tools
displayed.

16 Select Cut Parameters from the Tree View pane. Set the parameters as indicated.

17 Select Steep / Shallow from the Tree View

pane. Set the parameters as indicated.

SECTION 2: ROUGHING THE PART • 81

18 Click OK to generate the core roughing toolpath. It might take a few moments to generate.

19 Click the Toggle toolpath display on

selected operations button. If necessary,
select the Core Roughing operation.

The toolpath display for the Core Roughing
operation is turned off. Perform this step
after the creation of each operation for
clarity in selecting geometry for
subsequent steps.

20 Save your part file.

82 • BASIC 3D MACHINING

Exercise 2: Creating a Leftover Toolpath

1 Choose Toolpaths, Surface Finish,

Leftover.

2 Click the Select last button on the General

Selection ribbon bar when prompted for
drive surfaces.

The surface(s) used in the previous operation are selected.

3 Press [Enter] or click the End Selection button to accept the selection.

4 Click OK on the Toolpath/surface selection dialog box.

The Surface Finish Leftover dialog box opens to the Toolpath parameters tab.

5 Click the Select library tool button.

The default metric tool library opens.

6 Select the 4mm bull endmill with 0.2mm

corner radius and click OK.

7 Click the Surface parameters tab. Set the

stock to leave on drive to 1.0.

8 Click the Finish leftover parameters tab.

9 Set the parameters as shown.

10 Click the Leftover material parameters

tab. Enter the roughing tool information as
shown.

SECTION 2: ROUGHING THE PART • 83

84 • BASIC 3D MACHINING

11 Click OK to generate the surface finish leftover toolpath. It might take a few moments to

generate.

Note: Additional toolpath calculation lines may be displayed after generating the toolpath. Your
screen may look slightly different from the image above.

12 Turn off the toolpath display for the operation.

13 Save your part file.

LESSON 3

3Semi-Finishing the Part

After roughing a part, it may be necessary to perform semi-finishing operations. These operations
remove material that remains from roughing while leaving material for finishing operations. They
are an intermediate step in the process to a finished part. In general, the tolerance value, the
stepover, and the stock to leave separate the finishing operations from the semi-finishing
operations. This lesson guides you through surface finish blend, surface finish parallel steep, and
copying and modifying an operation.

Lesson Goals

 Create several finishing operations, including parallel steep and blend.

 Set parameters to create semi-finishing operations.

 Copy an operation and change parameters.

Exercise 1: Creating a Surface Finish Blend

1 Choose Toolpaths, Surface Finish, Blend.

2 Click the Select last button when

prompted for drive surfaces.

3 Press [Enter] or click the End Selection

button to accept the selection.

4 Click OK on the Toolpath/surface selection dialog box.

The Surface Finish Blend dialog box opens on the Toolpath parameters tab.

5 Select the 4mm bull endmill with the 0.2mm corner radius showing in the tool list.

6 Click the Surface parameters tab. Set the stock to leave on drive to 0.25.

86 • BASIC 3D MACHINING

7 Click the Finish blend parameters tab.

8 Set the parameters as shown.

9 Click the Total tolerance button to open the Refine Toolpath dialog box.

10 Set the parameters as shown and click OK.

SECTION 2: SEMI-FINISHING THE PART • 87

11 Click OK from the Surface Finish Blend dialog box.

The Chaining dialog box opens.

12 Click the C-plane radio button.

13 Click the Partial button.

Partial is used to select a section of a full
chain.

88 • BASIC 3D MACHINING

14 Select chain 1 as shown. The start of the chain is at 1 (narrow end of the part) with the end

of the chain at 2 (wide end of the part). Zoom in and out as necessary.

15 Select chain 2 on the opposite side of the part as shown. The start of the chain is at 1

(narrow end of the part) with the end of the chain at 2 (wide end of the part). It will be
necessary to rotate the part to view the left side as shown by the images below. Zoom and
rotate as necessary.

16 Right-click in the graphics area and select Isometric (WCS).

SECTION 2: SEMI-FINISHING THE PART • 89

17 Click OK from the chaining dialog box to generate the surface finish blend toolpath.

18 Turn off the toolpath display for the operation.

19 Save your part file.

Exercise 2: Creating a Surface Finish Parallel Steep

1 Choose Toolpaths, Surface Finish, Parallel

Steep.

2 Click the Select last button when prompted for drive surfaces.

3 Press [Enter] or click the End Selection button to accept the selection.

4 Click OK on the Toolpath/surface selection dialog box.

The Surface Finish Parallel Steep dialog box opens to the Toolpath parameters tab.

5 Click the Select library tool button.

90 • BASIC 3D MACHINING

The default metric tool library opens.

6 Select the 2mm ball endmill and click OK.

7 Click the Surface parameters tab. Set the

stock to leave on drive to 0.25.

8 Click the Finish parallel steep parameters

tab.

9 Set the parameters as shown.

10 Click the Total tolerance button to open the Refine Toolpath dialog box.

11 Set the surface quality to Better, and then click OK.

12 Click OK to generate the parallel steep toolpath.

SECTION 2: SEMI-FINISHING THE PART • 91

13 Turn off the toolpath display for the operation.

14 Save your part file.

Exercise 3: Copy and Modify an Operation

1 Right-click and hold the button down on

the Surface Finish Parallel Steep operation.

2 Drag the operation below the Surface

Finish Parallel Steep operation and release
the mouse button.

92 • BASIC 3D MACHINING

3 Select Copy after from the list of choices.

4 Click Parameters in the new operation.

Click the plus [+] to expand the operation
if necessary.

5 Click the Finish parallel steep parameters

tab.

6 Set the Machining angle to 0.

7 Click OK.

8 Turn on the toolpath display for the copied operation.

Note: The copied operation inherits display settings from the original operation.

9 Click the Regenerate all dirty operations

button in the Toolpath Manager.