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PROJECT 12 VERSION 9 FORMULA 1 BEGINNER TRAINING TUTORIAL Mill Level 3 – Solids, Surface Machining

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PROJECT 12

VERSION 9

FORMULA 1BEGINNER TRAINING TUTORIAL

Mill Level 3 – Solids, Surface Machining

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STEP 1:CREATE ½ OF THE CAR BODY

Open F1 Template File MAIN MENU File / Get Select the Beginner F1 Template.mc9 file[If you cannot find the file ask the teacher where to locate it][For those with internet access go to www.emastercam.com/files] Download the BeginnerF1Template.zip file and ask your teacher where to copy it to. MAIN MENU File/Save Name the file accordingly (do not use Beginner F1 Template.mc9) Save Click on Level, as shown in the diagram below

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[The Level Manager is displayed as shown below;][Note that Level 10 is highlighted in Yellow. This indicates that all the geometry created will be on Level 10, therefore your car will be created on level 10][Note that Level 10 also has a check mark beside it. This indicates that level 10 is visible] Click on Used or named[this will show all the levels being used in this drawing]

Scroll to Level 1 and click in the area under Visible, this will turn level 1 on and a checkmark will be displayed.

[The Level Manager should look as shown below]

Click OK

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Change your Gview to Isometric (if it is not already) MAIN MENU Select Solids / Extrude / chain chain your geometry as shown in the diagram below:

Done[make sure the arrow is pointing in a Z+ direction (up)] Done Extend by specified distance of Z 2.400" as shown in the picture below:

OK The following solid body should be created as shown in the picture below:

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Hold the ALT key and select the S key to turn the shading on. Hold the Alt key and select the S key to turn the shading back off.[You may want to keep the shading turned off in order to see the selection lines that will be opening as you go through this tutorial.]

STEP 2:CREATE THE COCKPIT SHAPE

Change your Gview to Isometric (if it is not already) Click on Level Select levels 2 and turn off level 1 OK

Fit to Screen Select MAIN MENU / Solids / Extrude / chain chain the geometry as shown in the picture below:[the direction of the arrow can point either way]

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Done Done Select; Cut Body / Extend through all / Both directions / as shown in the diagram below;

OK Select Alt and S to turn the shading on Turn shading off

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STEP 3:UNDERBODY

Click on Level Select level 3 and turn off level 2 OK

Fit to Screen Select MAIN MENU / Solids / Extrude / chain [now chain the geometry as shown below];

Done [the direction of the arrow does not matter] Done Fill out the selections as shown in the diagram below;

OK Turn on Shading (Alt S)

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Moving the part on the screen;

Select the Dynamic rotation icon (or right click on your mouse and select Dynamic Spin).

Click on the screen and move the mouse around and the part will spin around.

Select the Isometric icon (or right click on your mouse and select Isometric).

STEP 4:CREATING THE HOOD AND DRIVERS SEAT

Click on Level Select level 4 and turn off level 3 OK

Fit the part to the screen Select MAIN MENU / Solids / Extrude / chain Chain the geometry as shown below

Done[the direction of the arrow does not matter] Done Fill out the selections as shown in the diagram below;

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OK

STEP 5CREATE THE FRONT FENDER

Select Level Turn off level 4 and turn on level 5 OK Select MAIN MENU Solids / Extrude / chain Chain the geometry as shown below;

Done[the direction of the arrow should be pointing towards you, if it is not, click on Reverse it] Done Fill in the Extrude Chain parameter screen as shown below; be sure to type in Front Fender

beside name and enter the distance you want your fender to extrude to [minimum of 0.4" and maximum of 1.4"]

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OK

STEP 6:CREATE THE WHEEL WELL

Select Level Turn off level 5 and turn on level 6 OK

Fit to screen Select MAIN MENU / Solids / Extrude / chain Chain the geometry as shown below:

Done [the direction of the arrow should be pointing towards you, if it is not, click on Reverse it] Done

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Fill in the Extrude Chain parameter window as shown below: [type in Wheel Well beside name and enter in the distance you want your wheel well to extrude to minimum of 0.5" and maximum of 1.4"]

OK

STEP 7:CREATE THE REAR SPOILER Select Level Turn off level 6 and turn on level 7 / OK Fit to Screen Select MAIN MENU / Solids / Extrude / chain Chain the geometry as shown below;

[Note: you may have to dynamically spin the part to see the geometry to chain]

Done

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[the arrow should be pointing towards you, if it is not, click on Reverse it] Done Fill in the Extrude Chain parameter screen as shown below;[type in Rear Spoiler beside name and extrude to the length desired to a maximum of 1.4"]

OK

Don’t forget that you can always shade the part (Alt S) and move it around to get a good look at your car.

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STEP 8:CREATE THE SIDE AIR DAM

Select Level Turn off level 7 and turn on level 8 / OK Select MAIN MENU / Solids / Loft / chain Chain the geometry as shown below

Done [do not chain the line that connects the two geometries] Done Fill in the Loft Chain parameter screen as shown below;

OK

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STEP 9:CREATE HOLES FOR AXLES

Select Level Turn off level 8 and turn on level 9 / OK Select MAIN MENU / Solids / Extrude / chain Chain the holes as shown below:

Done [the direction of the arrows do not matter] Done Fill in the Extrude Chain parameter screen as shown below;

OK Select Level Turn off level 9 and enable level 100 / OK

Fit to Screen

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STEP 10:MIRROR THE ½ CAR BODY TO CREATE FULL CAR Select MAIN MENU / XForm Mirror Select the car body Done Line Select the line as shown below

Fill in the Mirror parameter screen as shown below;

OK

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Your car should look something like the diagrams below;

STEP 11:SAVING YOUR WORK Select MAIN MENU File Save Ask your teacher where the file should be saved to

STEP 12: (OPTIONAL)MODIFYING THE CARYou now have the option to modify your car if you choose. You have the option to modify the front Fender, Wheel Wells and the Rear Spoiler as shown in the diagram below;

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STEP 12A:MODIFY THE FRONT FENDER MAIN MENU Solids / Solids mgr Click on the plus sign in front of Solid and Copy of Solid [The solids manager parameter

screen is displayed as shown below;]

Select Copy of Solid Right click your mouse and select delete Click on Regen All

OK [one half of the car should disappear] [you may have to fit to screen or repaint to see the change]

MAIN MENU Solids / Solids Mgr Click on the + in front of Front Fender and double click the parameters folder To modify the overall length of the front fender change the number in Distance. [this number

has to be a minimum of 0.4" and maximum of 1.4".]

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Click on OK [note the red x over Solid and Front Fender. This indicates that a change has been made to the parameters and in order to take effect the Regen All Button has to be selected]

Select Regen All

OK [Note how the Front Fender changes]

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STEP 12B:MODIFY THE WHEEL WELLS MAIN MENU Solids / Solids mgr Click on the + in front of Wheel Well and double click the parameters folder To modify the overall length of the Wheel Well change the number in Distance. [this number

has to be a minimum of 0.4" and maximum of 1.4".]

Click on OK [note the red x over Solid and Wheel Well. This indicates that a change has been made to the parameters and in order to take effect the Regen All Button has to be selected]

Select Regen All OK [Note how the Wheel Well changes]

STEP 12C:TO MODIFY THE REAR SPOILER MAIN MENU Solids / Solids mgr Click on the + in front of Rear Spoiler and double click the parameters folder To modify the overall length of the Rear Spoiler change the number in Distance[extrude to

the length desired to a maximum of 1.4"] Click on OK [note the red x over Solid and Rear Spoiler. This indicates that a change has

been made to the parameters and in order to take effect the Regen All Button has to be selected]

Select Regen All OK [Note how the Rear Spoiler changes]

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Save your work Go back to step 10 page 1-15 to Mirror the car

STEP 13MAKE THE 2 SOLID HALFS ONE SOLID

MAIN MENU Solids Boolean Add Make sure Solid is set to Yes (y) and From back is set to No (N) Click on the car Solid as shown below;

Click on the other half of the car Solid Done Save your work

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TOOLPATH CREATION

STEP 14:JOB SETUP

Click on Level Turn on Level 252 Job Setup OK MAIN MENU Toolpaths Job Setup The Job Setup Screen will be displayed as shown below;

Click on the [Select Corners] Button in the Job Setup Screen

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Select the two corners of the rectangular boundary as shown below;

Make sure the Display Stock window is checked as shown in the Job Setup Screen above OK

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STEP 15CREATE ROUGHT TOOLPATH CPlane Top MAIN MENU Surface Make sure Contain is set to Y (Yes) Rough Pocket Solids [Make sure only Solids has a Y beside it. If the other items have a Y displayed click on the

item and it will change to an N] Select the Car Solid with the mouse Done Done The Surface Rough Pocket screen

will displayed as shown; Fill in the Tool parameters as

shown. [NOTE if there is no tool displayed in the Tool window follow the Selecting a Tool instructions below.]

Instructions for;Selecting a Tool1. Right click the mouse cursor in

the white box area near the top of the Surface Rough Pocket Screen.

2. Click on Get Tool from library3. Scroll down and select the ¼ inch

ball endmill from the library4. OK

Click on the Change NCI button; Replace the name of the file with

C:\MCAM9\MILL\NCI\(your name) Rough as shown below;

OK No [to Update all operations the

share the same nci path?

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Click on the Surface Parameters tab

Make the necessary changes in the Surface Rough Pocket screen as shown;

Click on the Pocket Parameters Tab

Click on the checkmark in front of Finish to turn this feature off

OK

Click OK on the Warning screen.

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[Mastercam will ask you to select a Tool containment boundary] Chain Options Click on Plane Mask to turn the checkmark on OK Click on the line as shown below;

Done The screen should look as follows;

To remove the toolpath display press Alt and T at the same time.

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STEP 16CREATE THE TOP TOOLPATH

MAIN MENU Surface Make sure Contain is set to Y Finish Parallel Solids Select the Car Solid Done Done Fill in the parameter screen as

shown; Click on Change NCI button

Replace the name of the file with C:\MCAM9\MILL\NCI\(your name) Top as shown below;

No [to Update all operations the share the same nci path?

OK Select the Surface parameters

Tab Make the changes as shown in

the Surface parameters screen; OK

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Click on the line as shown below;

Done

STEP 17CREATE THE FRONT TOOLPATH

Click on Cplane Select Rotate Select Y+ Up Type in 90 and Enter Save

MAIN MENU Toolpaths Surface Finish Parallel Solids Select the Solid Car Done Done Fill in the parameter screen as

shown (if it is not already); Click on Change NCI

Replace the name of the file with C:\MCAM9\MILL\NCI\(your name) Front OK No [to Update all operations the share the same nci path?

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OK

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Select the line as shown below;

Done

STEP 18CREATE THE BOTTOM TOOLPATH

Click on Cplane Select Rotate Select Y+ Up Type in 90 and Enter Save

MAIN MENU Toolpaths Surface Finish Parallel Solids Select the Solid Car Done Done

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Fill in the parameter screen as shown (if it is not already);

Click on Change NCI

Replace the name of the file with C:\MCAM9\MILL\NCI\(your name) Bottom OK No [to Update all operations the share the same nci path? OK Click on the line as shown below;

Done

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STEP 19CREATE THE BACK TOOLPATH

Click on Cplane Select Rotate Select Y+ up Type in 90 and Enter Save

MAIN MENU Toolpaths Surface Finish Parallel Solids Select the Solid Car Done Done Fill in the parameter screen as

shown (if it is not already); Click on Change NCI

Replace the name of the file with C:\MCAM9\MILL\NCI\(your name) Back

OK No [to Update all operations the share the same nci path? OK

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Select the line as shown below;

Done

STEP 20CHECK THE TOOLPATH USING BACKPLOT

MAIN MENU Toolpaths Operations The Operations Manager screen

will displayed as shown; Click on Select All [this will select

all the toolpaths] Click on Backplot Make sure Show Tool and Show

Path are set to Yes (Y) Click on Run The toolpath will be animated

and displayed. [Note on the lower left area of the screen, the time will be displayed.

Once the toolpath has finished being displayed you can step through the backplot by clicking on step

Back up

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STEP 21CHECK THE TOOLPATH USING VERIFY

Click on the Verify Button Click on the Play Button as shown;

The screen should look like the one below;

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STEP 22CREATING THE NC CODE

[We will be creating 5 different NC programs. This will allow you change the cars position between programs. It will also help if the program takes longer than the class time allows.]

The 5 different programs will be;1. (your name) rough.nc2. (your name) top.nc3. (your name) front.nc4. (your name) bottom.nc5. (your name) back.nc

Click on Post in the Operations Manager Click OK You will prompted to name the NC file. Select the default name (it should be (your name)

Rough.NC. Save The NC file may be displayed in another window. Close this window. You will prompted to name the second NC file. Select the default name [it should be (your

name) Top.NC. The NC file may be displayed in another window. Close this window. You will prompted to name the second NC file. Select the default name [it should be (your

name) Front.NC. The NC file may be displayed in

another window. Close this window.

You will prompted to name the second NC file. Select the default name [it should be (your name) Back.NC.

The NC file may be displayed in another window. Close this window.

You will prompted to name the second NC file. Select the default name [it should be (your name) Bottom.NC.

The NC file may be displayed in another window. Close this window

The operations manager should be displayed as shown;

Ok to close the Operations Manager

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STEP 22SAVE THE FILE

MAIN MENU File Save Save

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