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Mill Level 3 Training Tutorial
Mastercam X5 Mill Level 3 Training Tutorial Training Tutorial
Copyright: 1998 -2010 In-House Solutions Inc. All rights reserved
Software: Mastercam X5
Author: Mariana Lendel
ISBN: 978-1-926566-79-5
Revision Date: October 21, 2010
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 praticular 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; N-
See is a registered trademark of Microcompatibles, Inc.; Windows, Windows XP, Windows Vista and
Windows NT are registered trademarks of Microsoft Corporation.
Mill Level 3 Training Tutorial
Mill Level 3 Training Tutorial Contents
Getting Started ...................................................................................................A-1
TutorialsTutorial #1 .........................................................................................................................1-1
Tutorial #2 .........................................................................................................................2-1
Tutorial #3 .........................................................................................................................3-1
Tutorial #4 .........................................................................................................................4-1
Tutorial #5 .........................................................................................................................5-1
Tutorial #6 .........................................................................................................................6-1
Tutorial #7 .........................................................................................................................7-1
General Notes .....................................................................................................B-1
Quiz Answers ...................................................................................................... C-1
Mill Level 3 Training Tutorial Page|4-1
TUTORIAL #41
TUTORIAL #4
Objectives:
The Student will design a 3-dimensional drawing by:
!Creating the 2D wireframe for the revolved surface.
!Creating the revolved surface.
!Creating the wireframe for the draft surfaces.
!Creating the draft surfaces at 3 degree angle
!Creating 2D wireframe for the swept surface.
!Creating the swept surface
!Creating the 2D wireframe for the flat surfaces.
!Creating the wireframe for the draft surfaces.
!Creating the curve at one edge.
!Trimming surface to curves.
!Creating the fillet surfaces.
!Creating the flat surface.
The Student will create surface toolpaths consisting of:
!Surface High Speed - Area Roughing to rough out the part.
!Surface Restmill to clean areas that the previous tool can not.
!Surface High Speed - Hybrid to finish the part.
!Surface Finish Leftover to clean out the part.
The Student will simulate the toolpaths using Mastercam's Verify and Backplot by:
!Defining a 3-dimensional rectangular block the size of the work piece.
!Running the Backplot to see the path the tool takes to cut the part.
!Running the Verify to simulate the tool cutting from the solid model.
This tutorial takes approximately one hour and half to complete.
Page |4-2 Mill Level 3 Training Tutorial
Mill Level 3 Training Tutorial Page|4-3
SETTING UP THE GRAPHIC USER INTERFACE TUTORIAL #41
GEOMETRY CREATION
STEP 1: SETTING UP THE GRAPHIC USER INTERFACE
Before starting the geometry creation we should customize the toolbars to see the toolbars
required to create the geometry and machine a 3D part. See Getting started page A-4 for
details.
Make sure that the Grid is enabled. It will show you where the part origin is. See Getting
started page A-6 for further information.
The Operations Manager to the left of the screen can be hidden to gain more space in the
graphic area for design. From the keyboard, press Alt + O keys simultaneously to hide it.
See Figure: 1.0.1.
Repeat this command to make it visible again.
Figure: 1.0.1
Make sure that in the Status bar the 3D mode is enabled.
Page |4-4 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE RECTANGLE
STEP 2: CREATE THE RECTANGLE
In this step you will learn how to create a rectangle knowing the width, the height and the anchor
position.
Step Preview:
2.1 Create the 9.0" by 6.5" rectangle
Create
Rectangle
Enter the Width and the Height and disable if needed, Anchor to center and
Create surface buttons as shown below.
Press Enter after typing the values to see a preview of the rectangle.
[Select position of first corner]: Select the Origin as shown in Figure: 2.1.1.
Figure: 2.1.1
Mill Level 3 Training Tutorial Page|4-5
CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE TUTORIAL #41
Make sure that when selecting the origin, the visual cue of the cursor changes as shown.
Use the Fit icon to fit the drawing to the screen.
Select the OK button to exit the Rectangle command.
STEP 3: CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE
In this step you will learn how to create different types of lines and fillets. You will also use trimming
options to clean up the geometry. To create a revolved surface you need the 2D profile and the axis of
rotation.
Step Preview:
3.1 Create the axis of rotation
Sub Step Preview:
Create
Line
Parallel
Enter the Distance 5.75 in the Ribbon bar.
NOTE: During the geometry creation of this tutorial, if you make a mistake you can undo the
last step using the Undo icon. You can undo as many steps as needed. If you delete or
undo a step by mistake, just use the Redo icon. To delete unwanted geometry, select it
first and then press Delete from the keyboard.
Page |4-6 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE
[Select a line]: Select the line as shown.
[Indicate the offset direction]: Select a point to the right side of the line.
Select the Apply button to continue in the same command.
The geometry should look as shown.
Mill Level 3 Training Tutorial Page|4-7
CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE TUTORIAL #41
3.2 Create the lines parallel with the center line
Sub Step Preview:
Enter the Distance 1.150 in the Ribbon bar.
[Select a line]: Select the center line as shown.
[Indicate the offset direction]: Select a point to the right side of the line.
Enter the Distance 1.50 in the Ribbon bar.
Select the Apply button.
[Select a line]: Select the same center line as shown before.
[Indicate the offset direction]: Select a point to the right side of the line.
Select the Apply button.
Enter the Distance 2.245 in the Ribbon bar.
[Select a line]: Select the same center line as shown before.
[Indicate the offset direction]: Select a point to the right side of the line.
Page |4-8 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE
Select the Apply button.
Enter the Distance 2.5 in the Ribbon bar.
[Select a line]: Select the same center line as shown before.
[Indicate the offset direction]: Select a point to the right side of the line.
Select the Apply button to continue in the same command.
The geometry should look as shown.
3.3 Create the line parallel with the lower horizontal line
Sub Step Preview:
Enter the Distance 2.75 in the Ribbon bar.
Mill Level 3 Training Tutorial Page|4-9
CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE TUTORIAL #41
[Select a line]: Select the line as shown.
[Indicate the offset direction]: Select a point above the line.
3.4 Create the lines parallel with the new horizontal line
Sub Step Preview:
Enter the Distance 0.25 in the Ribbon bar.
Page |4-10 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE
[Select a line]: Select the line as shown.
[Indicate the offset direction]: Select a point above the line.
Select the Apply button.
Enter the Distance 0.95 in the Ribbon bar.
[Select a line]: Select the same line as shown before.
[Indicate the offset direction]: Select a point above the line.
Select the Apply button.
Enter the Distance 1.65 in the Ribbon bar.
[Select a line]: Select the same center line as shown before.
[Indicate the offset direction]: Select a point above the line.
Select the Apply button.
Enter the Distance 0.5 in the Ribbon bar.
Mill Level 3 Training Tutorial Page|4-11
CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE TUTORIAL #41
[Select a line]: Select the last created line as shown.
[Indicate the offset direction]: Select a point above the line.
Select the Apply button to continue in the same command.
The geometry should look as shown.
Select the OK button to exit the command.
Page |4-12 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE
3.5 Create lines knowing the endpoints
Sub Step Preview:
Create
Line
Endpoint
[Specify the first endpoint]: Select the Intersection point 1 as shown.
Mill Level 3 Training Tutorial Page|4-13
CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE TUTORIAL #41
[Specify the second endpoint]: Select the Intersection point 2 as shown.
[Specify the first endpoint]: Select the Intersection point 1 as shown.
Page |4-14 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE
[Specify the second endpoint]: Select the Intersection point 2 as shown.
Select the OK button to exit the command.
3.6 Create lines knowing one endpoint, the length and the angle
Sub Step Preview:
Create
Line
Endpoint
Mill Level 3 Training Tutorial Page|4-15
CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE TUTORIAL #41
[Specify the first endpoint]: Select the Endpoint point as shown.
[Specify the second endpoint]: Select an approximate point as shown.
In the Ribbon bar, change the Angle to 45 as shown.
Select the Apply button to continue in the same command.
Page |4-16 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE
[Specify the first endpoint]: Select the Endpoint point as shown.
[Specify the second endpoint]: Select an approximate point as shown.
In the Ribbon bar, change the Angle to 100 as shown.
Select the OK button to exit the command.
Mill Level 3 Training Tutorial Page|4-17
CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE TUTORIAL #41
3.7 Create the 0.125 radius fillets and the 0.0625 radius fillet
Sub Step Preview:
Create
Fillet
Entities
Enter the Radius 0.125 and make sure that the rest of the buttons in the Ribbon Bar are
set as shown.
[Select an entity]: Select Entity A as shown in the figure below.
[Select another entity]: Select Entity B as shown in the same figure.
[Select an entity]: Select Entity B as shown in the figure below.
[Select another entity]: Select Entity C as shown in the figure below.
Select the Apply button to continue in the same command.
Page |4-18 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE
Enter the Radius 0.0625 and make sure that the rest of the buttons in the Ribbon Bar
are set as shown.
[Select an entity]: Select Entity C as shown in the figure below.
[Select another entity]: Select Entity D as shown in the same figure.
Select the OK button to exit the command.
The geometry should look as shown.
Mill Level 3 Training Tutorial Page|4-19
CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE TUTORIAL #41
3.8 Create the line parallel with the upper horizontal line
Sub Step Preview:
Create
Line
Parallel
Enter the Distance 0.275 in the Ribbon bar.
[Select a line]: Select the line as shown.
[Indicate the offset direction]: Select a point below the line.
Select the OK button to exit the command.
Page |4-20 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE
3.9 Delete the construction lines
Sub Step Preview:
Select the lines as shown.
Select Delete Entities icon.
Mill Level 3 Training Tutorial Page|4-21
CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE TUTORIAL #41
3.10 Trim the geometry using trim 1 entity command
Sub Step Preview:
Edit
Trim/Break
Trim/Break/Extend
Select the Trim 1 entity button.
[Select the entity to trim/extend]: Select Entity A as shown in Figure: 3.10.1.
[Select the entity to trim/extend to]: Select Entity B.
Figure: 3.10.1
Page |4-22 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE 2D WIREFRAME FOR THE REVOLVED SURFACE
[Select the entity to trim/extend]: Select Entity C as shown in Figure: 3.10.2.
[Select the entity to trim/extend to]: Select Entity D.
Figure: 3.10.2
[Select the entity to trim/extend]: Select Entity C again as shown in Figure: 3.10.2.
[Select the entity to trim/extend to]: Select Entity E.
Select the OK button to exit the command.
The geometry should look as shown.
Mill Level 3 Training Tutorial Page|4-23
CREATE THE WIREFRAME FOR THE SWEPT SURFACE TUTORIAL #41
3.11 Delete the construction lines
Sub Step Preview:
Select the lines as shown.
Select Delete Entities icon.
STEP 4: CREATE THE WIREFRAME FOR THE SWEPT SURFACE
NOTE: The current geometry allows us to create the revolved surface. We are continuing by
creating the wireframe required to generate the swept surface.
Page |4-24 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE WIREFRAME FOR THE SWEPT SURFACE
In this step you will learn how to create different types of arcs and fillets. You will also use offset
contour to offset the geometry with a given distance. To create the swept surface you need the across
contour and two along contours as shown in the Step Preview.
Step Preview:
4.1 Mirror the profile about a line
Sub Step Preview:
Xform
Mirror
Mill Level 3 Training Tutorial Page|4-25
CREATE THE WIREFRAME FOR THE SWEPT SURFACE TUTORIAL #41
[Mirror: select entities to mirror]: Hold down the Shift key and select one entity of the profile
as shown.
Press Enter to continue.
In the Mirror dialog box make sure that Copy is selected and then select the Select line
button as shown.
NOTE: The entire profile is selected.
NOTE: The select line button will bring you back into the graphics window where you can
select the line about which to mirror.
Page |4-26 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE WIREFRAME FOR THE SWEPT SURFACE
[Select line about which to mirror]: Select the line as shown.
The preview should look as shown.
Select the OK button to exit the Mirror dialog box.
Screen
Clear Colors
Mill Level 3 Training Tutorial Page|4-27
CREATE THE WIREFRAME FOR THE SWEPT SURFACE TUTORIAL #41
4.2 Create the circles that we know the center point and the radius
Sub Step Preview:
Create
Arc
Circle Center Point
Enter the Radius value 2.5 (Enter).
[Enter the center point]: Select the Fast Point icon, and in the empty field enter the val-
ues as shown.
Select the Apply button to continue.
Enter the Radius value 5.5 (Enter).
[Enter the center point]: Select the Fast Point icon, and in the enter the values as shown.
Select the OK button to exit the command.
Page |4-28 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE WIREFRAME FOR THE SWEPT SURFACE
4.3 Create the line parallel with the upper horizontal line
Sub Step Preview:
Create
Line
Parallel
Enter the Distance 1.35 in the Ribbon bar.
[Select a line]: Select the line as shown.
[Indicate the offset direction]: Select a point below the line.
Select the OK button to exit the command.
Mill Level 3 Training Tutorial Page|4-29
CREATE THE WIREFRAME FOR THE SWEPT SURFACE TUTORIAL #41
4.4 Create the 0.25 radius fillets
Sub Step Preview:
Create
Fillet
Entities
Enter the Radius 0.25 and make sure that the rest of the buttons in the Ribbon Bar are
set as shown.
[Select an entity]: Select Entity A as shown in the figure below.
[Select another entity]: Select Entity B as shown in the same figure.
[Select an entity]: Select Entity A again as shown in the figure below.
[Select another entity]: Select Entity C as shown in the figure below.
Select the OK button to exit the command.
Page |4-30 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE WIREFRAME FOR THE SWEPT SURFACE
The geometry should look as shown.
4.5 Trim the geometry using trim 1 entity command
Sub Step Preview:
Edit
Trim/Break
Trim/Break/Extend
Select the Trim 1 entity button.
[Select the entity to trim/extend]: Select Entity A as shown in Figure: 4.5.1.
[Select the entity to trim/extend to]: Select Entity B.
Mill Level 3 Training Tutorial Page|4-31
CREATE THE WIREFRAME FOR THE SWEPT SURFACE TUTORIAL #41
Figure: 4.5.1
Select the OK button to exit the command.
4.6 Create a point (0.75, -6.0)
Sub Step Preview:
Create
Point
Position
[Sketch a point]: Select Fast Point icon and enter the coordinates as shown.
Press Enter.
Select the OK button to exit the command.
Page |4-32 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE WIREFRAME FOR THE SWEPT SURFACE
4.7 Create an arc tangent through a point
Sub Step Preview:
Create
Arc
Arc Tangent
From the Ribbon Bar, select Tangent Point icon as shown, and change the Radius to
9.675.
[Select the entity that the arc is to be tangent to]: Select the arc as shown.
Mill Level 3 Training Tutorial Page|4-33
CREATE THE WIREFRAME FOR THE SWEPT SURFACE TUTORIAL #41
[Specify the thru point]: Select the point.
[Select an arc]: Select the arc as shown.
Select the OK button to exit the command.
NOTE: The command gives you all the possible results.
Page |4-34 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE WIREFRAME FOR THE SWEPT SURFACE
The geometry should look as shown.
4.8 Trim the geometry using trim 2 entities command
Sub Step Preview:
Edit
Trim/Break
Trim/Break/Extend
From the Ribbon Bar, select the Trim 2 entities button and make sure that the rest of the
icons are set as shown.
[Select the entity to trim/extend]: Select Entity A as shown in Figure: 4.8.1.
[Select the entity to trim/extend to]: Select Entity B.
Mill Level 3 Training Tutorial Page|4-35
CREATE THE WIREFRAME FOR THE SWEPT SURFACE TUTORIAL #41
Figure: 4.8.1
Select the OK button to exit the command.
4.9 Offset the profile
Sub Step Preview:
Xform
Offset Contour
Page |4-36 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE WIREFRAME FOR THE SWEPT SURFACE
[Offset: select chain 1]: Leave the chaining dialog box settings as they are and select the chain
as shown.
Press OK button to exit Chaining dialog box.
In the Offset Contour dialog box make sure that Copy is selected, the # is set to 1 and the
Distance is set to 0.4 as shown.
NOTE: If your chain direction was as shown in the picture above, you need to click on the
Reverse button. The resulting chain (magenta color) has to be located to the right of
the original chain as shown in Figure: 4.9.1.
Mill Level 3 Training Tutorial Page|4-37
CREATE THE WIREFRAME FOR THE SWEPT SURFACE TUTORIAL #41
Select the Reverse button if needed.
Figure: 4.9.1
[Select the OK button to exit Offset Contour dialog box.
Screen
Clear Colors
Page |4-38 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE WIREFRAME FOR THE SWEPT SURFACE
4.10 Delete the point
Sub Step Preview:
To select the point, from the Quick Mask toolbar, select QM Points.
Select Delete Entities icon.
NOTE: The two contours that we created represent the two along contours needed to
generate the swept surface. Next we will create the arc that represents the across contour.
Mill Level 3 Training Tutorial Page|4-39
CREATE THE WIREFRAME FOR THE SWEPT SURFACE TUTORIAL #41
4.11 Create the 0.25" radius fillets
Sub Step Preview:
Create
Fillet
Entities
Enter the Radius 0.25 and make sure that the rest of the buttons in the Ribbon Bar are
set as shown.
[Select an entity]: Select Entity A as shown in the figure below.
[Select another entity]: Select Entity B as shown in the same figure.
Select an entity]: Select Entity A again as shown in the figure below.
[Select another entity]: Select Entity C as shown in the figure below.
Select the OK button to exit the command.
Page |4-40 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE WIREFRAME FOR THE SWEPT SURFACE
The geometry should look as shown.
4.12 Create the arc in the Right side plane, knowing the endpoints and the radius
Sub Step Preview:
Select the Isometric graphic view.
From the Status Bar, select the Planes button.
From the drop down list select Right plane.
Create
Arc
Endpoints
In the Ribbon Bar enter the Radius value 0.2 (Enter).
Mill Level 3 Training Tutorial Page|4-41
CREATE THE WIREFRAME FOR THE SWEPT SURFACE TUTORIAL #41
[Enter the first point]: Select the Endpoint A as shown.
[Enter the second point]: Select the Endpoint B as shown.
NOTE: Mastercam gives you two choices: two half circles, as shown in the next figure.
Page |4-42 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE WIREFRAME FOR THE SWEPT SURFACE
[Select an arc]: Select the bottom arc as shown.
Select the OK button to exit the command.
Select the Fit icon to fit the geometry to the screen.
The geometry should look as shown.
Mill Level 3 Training Tutorial Page|4-43
CREATE A SWEPT SURFACE TUTORIAL #41
STEP 5: CREATE A SWEPT SURFACE
A Swept Surface is a surface generated by translating or rotating one or more contours (across curves)
along one or two other contours (along curves). In our case we will generate the surface from one
across contour and two along contours.
Step Preview:
5.1 Change the main color to red
From the Status Bar, select the Planes button and choose the Top plane.
From the Status Bar, select the current color field.
From the Colors dialog box, select the red color, no 12.
Select the OK button to exit Color dialog box.
NOTE: It is a good practice to generate the surfaces in different colors. This will make the
further selection of a group of surfaces easier.
Page |4-44 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE A SWEPT SURFACE
5.2 Create the Swept Surface
Create
Surface
Swept
From the Ribbon Bar enable Two rails.
From the Chaining dialog box enable the Single button.
[Swept surface: define the across contour(s)]: Select the arc as shown.
NOTE: The green color arrow shows the start of the chain and the red color arrow shows the
end of the chain. Select the arc as shown (CCW).
Mill Level 3 Training Tutorial Page|4-45
CREATE A SWEPT SURFACE TUTORIAL #41
Select the OK button in the Chaining dialog box to finish the across contours selection and
continue.
Make sure that Partial button is enabled in the Chaining dialog box.
[Swept surface: define the along contour(s)]: Select first Entity A of the contour as shown.
[Select the last entity]: Select Entity B.
[Swept surface: define the along contour 2]: Select first Entity C of the contour as shown.
NOTE: If needed, select the Reverse direction button.
Page |4-46 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE A SWEPT SURFACE
[Select the last entity]: Select Entity D.
Select the OK button to finish the selection.
Select the OK button to finish the Swept Surface command.
The surface should look as shown in Figure: 5.2.1.
Figure: 5.2.1
NOTE: Press Alt +S any time you need to shade or un shade the surfaces
Mill Level 3 Training Tutorial Page|4-47
CREATE THE REVOLVED SURFACE TUTORIAL #41
STEP 6: CREATE THE REVOLVED SURFACE
This command allows you to create revolved surfaces, surfaces that are circular in one direction. You
will be prompted to chain an entity that the revolved surface will use as a profile and then, to choose a
line to use as the axis of rotation.
Step Preview:
6.1 Change the main color to dark green no 2
From the Status Bar, select the current color field as shown in previous step.
From the Colors dialog box, select the green color, no 2.
Select the OK button to exit the Color dialog box.
6.2 Create the revolved surface
Create
Surface
Revolved
Page |4-48 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE REVOLVED SURFACE
From the Chaining dialog box, make sure that Chain (default) button is selected, and the rest
of the dialog box looks as shown.
[Select profile curve(s)]: Select the chain as shown.
Select the OK button to exit the Chaining dialog box.
Mill Level 3 Training Tutorial Page|4-49
CREATE THE REVOLVED SURFACE TUTORIAL #41
[Select the axis of rotation]: Select the line as shown.
In the Ribbon Bar, change the End Angle to 180 and press Enter.
The surface should be created below the original geometry as shown in the Figure: 6.2.1.
Select the OK button to exit the command.
Figure: 6.2.1
NOTE: If the surface is generated above the original geometry, select the Reverse
button to fix it.
Page |4-50 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE FILLET SURFACE WITH THE 0.1"RADIUS
STEP 7: CREATE THE FILLET SURFACE WITH THE 0.1"RADIUS
A Fillet surface is a surface generated by creating fillets (radii) that are tangent to two original surfaces.
You can also create a fillet surface between a surface and a plane, and between a surface and a curve.
Step Preview:
7.1 Change the main color to violet no 151
As shown in previous steps, from the Status Bar, select the current color field.
From the Colors dialog box, select the violet color, no. 151.
Select the OK button to exit the Color dialog box.
7.2 Create the Fillet surface with the 0.10 radius
Create
Surface
Fillet
To Surfaces
Mill Level 3 Training Tutorial Page|4-51
CREATE THE FILLET SURFACE WITH THE 0.1"RADIUS TUTORIAL #41
[Select first set of surfaces and press Enter to continue]: Select the swept surface as shown.
Press Enter to continue.
[Select second set of surfaces and press Enter to continue]: Select the surfaces as shown.
Press Enter to finish the selection.
Page |4-52 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE THE FILLET SURFACE WITH THE 0.1"RADIUS
In the Fillet Surf to Surf dialog box, change the Fillet radius to 0.1 and enable Trim to trim
both original sets of surfaces.
With the mouse wheel, select a point close to the center of the fillet surfaces and spin the
mouse wheel in the upper direction to zoom in from the point
Figure: 7.2.1
NOTE: Some of the fillet surfaces are generated in the wrong direction.
To generate a proper fillet surface you have to have the original surface normals orientated
towards the center of the resulting fillet surfaces. In our case, both sets of surfaces have to
have the normals orientated inwards. As you can see in Figure: 7.2.1 one of the revolved
surfaces is oriented wrong.
Mill Level 3 Training Tutorial Page|4-53
CREATE THE FILLET SURFACE WITH THE 0.1"RADIUS TUTORIAL #41
Select the Flip Normal button as shown.
Click on the surface shown in Figure: 7.2.1 to reverse its normal.
Press Enter to finish the selection and to return to the dialog box.
The fillet surface preview should look as shown.
Fillet Surf to Surf dialog box, select the Options button.
NOTE: The fillet surfaces are generated correctly but the swept surface is not trimmed.
Page |4-54 Mill Level 3 Training Tutorial
TUTORIAL #41 CREATE A FLAT BOUNDARY SURFACE
Enable Extend Surfaces.
Select the OK button to exit the Fillet _Surface Options dialog box.
Select the OK button to exit the Fillet Surf to Surf dialog box.
The fillet surfaces should look as shown.
Select the Fit icon to fit the geometry to the screen.
STEP 8: CREATE A FLAT BOUNDARY SURFACE
NOTE: Extend surfaces will extend the fillet surfaces to make the trimming of both surfaces
possible.
Mill Level 3 Training Tutorial Page|4-55
CREATE A FLAT BOUNDARY SURFACE TUTORIAL #41
In this step you will learn how to create a flat surface inside of a closed boundary. We will have to
create a curve at the open edge of the swept surface and create a line to close the boundary.
Step Preview:
8.1 Create the curve at the edge
Sub Step Preview:
Create
Curve
Curve on One Edge
[Select a surface]: Select the swept surface.
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TUTORIAL #41 CREATE A FLAT BOUNDARY SURFACE
[Move arrow to Desired Edge of Surface]: Move the arrow to the open edge of the surface as
shown and click to select it.
Select the OK button to exit the command.
8.2 Create the line to close the boundary
Sub Step Preview:
With the mouse wheel, select a point close to the middle of the curve and spin the mouse
wheel in the upper direction to zoom in.
Create
Line
Endpoint
[Specify the first endpoint]: Select the Endpoint A as shown.
NOTE: Select the endpoints from the edge curve.
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CREATE A FLAT BOUNDARY SURFACE TUTORIAL #41
[Specify the second endpoint]: Select the Endpoint B as shown.
Select the OK button to exit the command.
8.3 Create the flat surface
Sub Step Preview:
Create
Surface
Flat Boundary
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TUTORIAL #41 CREATE A FLAT BOUNDARY SURFACE
[Select chains to define flat boundary1]: Select the chain as shown.
Select the OK button to exit the Chaining dialog box.
Select the OK button to exit the command.
The geometry should look as shown.
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CREATE THE FILLET SURFACE WITH THE 0.0625"RADIUS TUTORIAL #41
STEP 9: CREATE THE FILLET SURFACE WITH THE 0.0625"RADIUS
In this step you will create a fillet surface with the radius of 0.0625" between the swept surface and the
flat boundary surface.
Step Preview:
Create
Surface
Fillet
To Surfaces
[Select first set of surfaces and press Enter to continue]: Select the swept surface as shown.
Press Enter to continue.
[Select second set of surfaces and press Enter to continue]: Select the flat surface as shown.
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TUTORIAL #41 CREATE THE FILLET SURFACE WITH THE 0.0625"RADIUS
Press Enter to finish the selection.
The warning "No fillets found" will appear on the screen.
Select the OK button to continue.
In the Fillet Surf to Surf dialog box, change the Fillet radius to 0.0625 and enable
Trim to trim both original sets of surfaces.
Select the OK button again to continue, and then select the Flip Normal button as shown.
NOTE: Both normals, as shown in Figure: 9.0.1, need to be reversed.
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CREATE THE FILLET SURFACE WITH THE 0.0625"RADIUS TUTORIAL #41
Figure: 9.0.1
Click on both surfaces to reverse their normals as shown.
Press Enter to finish the selection and to return to the dialog box.
Select the OK button to exit Fillet Surf to Surf dialog box dialog box.
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TUTORIAL #41 CREATE THE TWO DRAFT SURFACES
The fillet surface should look as shown.
Select the Fit icon to fit the geometry to the screen.
STEP 10: CREATE THE TWO DRAFT SURFACES
This step shows you how to create the two draft surfaces knowing the length and draft angle. Draft
surfaces are surfaces generated by extruding one or more contours, along a line defined by an angle
and a length. In our case we will create two draft surfaces with the draft angle 3 degrees that are
closing the revolved surfaces open areas. To generate the surfaces we will need two lines.
Step Preview:
10.1 Change the main color to magenta no. 13
From the Status Bar, select the current color field as shown in previous steps.
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CREATE THE TWO DRAFT SURFACES TUTORIAL #41
From the Colors dialog box, select the magenta color, no. 13.
Select the OK button to exit Color dialog box.
Change the graphic view to Top.
10.2 Create the top polar line
Sub Step Preview:
Create
Line
Endpoint
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TUTORIAL #41 CREATE THE TWO DRAFT SURFACES
[Specify the first endpoint]: Select the Endpoint A as shown.
[Specify the second endpoint]: Sketch the second endpoint as shown.
In the Ribbon bar, change the length and the angle as shown.
Select the OK button to exit the command.
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CREATE THE TWO DRAFT SURFACES TUTORIAL #41
10.3 Extend the line 0.2" using trim/break/extend command
Sub Step Preview:
Edit
Trim/Break
Trim/Break/Extend
Enable the Extension button, and enter 0.2.
[Select the entity to trim/extend]: Select the line as shown.
Select the OK button to exit the command.
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TUTORIAL #41 CREATE THE TWO DRAFT SURFACES
The geometry should look as shown.
10.4 Create the Draft surface with the 3 degrees angle
Sub Step Preview:
Change the graphic view to Isometric.
Select the Fit icon to fit the geometry to the screen.
Create
Surface
Draft
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[Select line, arc, or spline 1]: Leave the settings in the Chaining dialog box as they are and
select the line as shown.
Select the OK button to exit the Chaining dialog box.
In the Draft Surface dialog box, make sure that the Length is enabled and change it to
3.0"and the angle to 3 degrees as shown.
NOTE: The surface is created above the line. Use the Flip button next to the length to
change the direction as shown in Figure: 10.4.1.
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TUTORIAL #41 CREATE THE TWO DRAFT SURFACES
Figure: 10.4.1
Hold down the mouse wheel, click in the center of the draft surface and then slightly move
the mouse to the right to check if the draft angle is inwards as shown.
Select the OK button to exit the Draft Surface dialog box.
Change the graphic view to Top.
Select the Fit icon to fit the geometry to the screen.
NOTE: To rotate the part first click and hold in the middle of the part with the mouse wheel
to select a point. Hold the mouse wheel down, then slightly move the mouse around the
rotation point. Release when the part is in the desired position.
Another way of rotating the geometry is to hold down the Alt key and to click on the
keyboard arrows.
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CREATE THE TWO DRAFT SURFACES TUTORIAL #41
10.5 Create the horizontal line
Sub Step Preview:
Create
Line
Endpoint
From the Ribbon Bar, enable the Horizontal icon.
[Specify the first endpoint]: Sketch the first endpoint as shown.
[Specify the second endpoint]: Sketch the second endpoint as shown.
[Enter the Y value]: as shown.
NOTE: Make sure that the line is extended over the edges of the revolved surface on both
ends.
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Select the OK button to exit the command.
The geometry should look as shown.
10.6 Create the Draft surface with the 3 degrees angle
Sub Step Preview:
Change the graphic view to Isometric.
Select the Fit icon to fit the geometry to the screen.
Create
Surface
Draft
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CREATE THE TWO DRAFT SURFACES TUTORIAL #41
[Select line, arc, or spline 1]: Leave the settings in the Chaining dialog box as they are and
select the line as shown.
Select the OK button to exit the Chaining dialog box.
In the Draft Surface dialog box, make sure that the Length is enabled and change it to 3.0 and
the angle to 3 degrees as shown.
NOTE: The surface is created above the line. Use the Flip button next to the length to
change the direction as shown in Figure: 10.6.1.
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TUTORIAL #41 CREATE THE TWO DRAFT SURFACES
Figure: 10.6.1
Hold down the mouse wheel, click in the center of the draft surface and then slightly move
the mouse to the right to check if the draft angle is inwards as shown.
Select the OK button to exit the Draft Surface dialog box.
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CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS TUTORIAL #41
STEP 11: CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS
In this step you will create two fillet surfaces with the radius of 0.0625" between the revolved surface
and the draft surfaces.
Step Preview:
11.1 Create the fillet surface between the upper draft surface and the revolved surface
As shown in previous steps, from the Status Bar, select the current color field.
From the Colors dialog box, select the violet color, no 151.
Select the OK button to exit the Color dialog box.
Create
Surface
Fillet
To Surfaces
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TUTORIAL #41 CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS
[Select first set of surfaces and press Enter to continue]: Select the revolved surface as
shown.
Press Enter to continue.
[Select second set of surfaces and press Enter to continue]: Select the draft surface as shown.
Press Enter to finish the selection.
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CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS TUTORIAL #41
In the Fillet Surf to Surf dialog box, change the Fillet radius to 0.0625 and enable Trim to trim
both original sets of surfaces.
Figure: 11.1.1
Select the OK button to exit the Fillet Surf to Surf dialog box.
NOTE: The fillet surface is created on the wrong side as shown in. Figure: 11.1.1.
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TUTORIAL #41 CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS
From the Fillet Surf to Surf, select the Options button and check if the Trim Surface options
are set as shown, and the Extend Surfaces is enabled.
Select the Flip Normal button.
Figure: 11.1.2
NOTE: Both normals, as shown in Figure: 11.1.2, need to be reversed.
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CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS TUTORIAL #41
Click on both surfaces to reverse their normals as shown.
Press Enter to finish the selection and to return to the dialog box.
Select the OK button to exit Fillet Surf to Surf dialog box dialog box.
The fillet surface should look as shown.
NOTE: Although the trim options were set for both surfaces and the extend surface was also
enabled to correct any problems, the draft surface is not trimmed. To correct this we will
create the edge curve at the intersection between the fillet surface and the draft. Then we
will trim the surface to this curve.
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TUTORIAL #41 CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS
11.2 Create the curve at the edge
Sub Step Preview:
From the Status Bar, select the current color field as shown in the previous step.
From the Colors dialog box, select the green color, no 2.
Select the OK button to exit the Color dialog box.
Create
Curve
Curve on One Edge
[Select a surface]: Select the fillet surface.
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[Move arrow to Desired Edge of Surface]: Move the arrow to the edge of the surface close to
the draft surface as shown and click to select it.
Select the OK button to exit the command.
The geometry should look as shown.
NOTE: To ensure a proper trimming, next we will need to extend the curve end beyond the
draft surface edges.
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TUTORIAL #41 CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS
11.3 Extend the curve both ends with 0.2" using trim/break/extend command
Sub Step Preview:
Change the graphic view to Isometric.
Select the Fit icon to fit the geometry to the screen.
Edit
Trim/Break
Trim/Break/Extend
Enable the Extension button, and enter 0.2.
[Select the entity to trim/extend]: Select the curve as shown.
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[Select the entity to trim/extend]: Select the curve as shown.
Select the OK button to exit the command.
The geometry should look as shown.
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TUTORIAL #41 CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS
11.4 Trim the draft surface to the curve
Sub Step Preview:
Create
Surface
Trim
To Curves
[Select surfaces and press Enter to continue]: Select the surface as shown below.
Press Enter to finish the surface selection.
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CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS TUTORIAL #41
From the Chaining dialog box, make sure that Chain (default) button is selected, and the rest
of the dialog box looks as shown.
[Select profile curve(s)]: Select the curve as shown.
Select the OK button to exit the Chaining dialog box.
Make sure that the only buttons in the Ribbon bar that are selected are the ones shown.
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TUTORIAL #41 CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS
[Indicate area to keep- select a surface to be trimmed]: Click twice on the surface area that
we want to keep after trimming as shown below.
Press Alt + S to shade the surface.
The preview should look as shown in Figure: 11.4.1.
NOTE: By selecting the Delete button the original (base) surface will be deleted, the
Normal button projects the curve normal to the surface in the specified distance (0.1")
and the Keep multiple regions button allows multiple regions to be created after while
trimming.
NOTE: The area outside of the curves was removed because we select the area to keep after
trimming inside the curve.
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CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS TUTORIAL #41
Figure: 11.4.1
Select the OK button to exit the command.
11.5 Create the fillet surface between the lower draft surface and the revolved surface
Sub Step Preview:
As shown in previous steps, change the color to the violet color, no. 151.
Create
Surface
Fillet
To Surfaces
NOTE: The following Sub steps are similar with the Sub steps 11.1 to 11.5. As a challenge
you could create the surface on your own.
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TUTORIAL #41 CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS
Holding down the mouse wheel, select a point close to the center of the geometry and
slightly move the mouse to rotate the part as shown.
[Select first set of surfaces and press Enter to continue]: Select the revolved surface as
shown.
Press Enter to continue.
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CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS TUTORIAL #41
[Select second set of surfaces and press Enter to continue]: Select the draft surface as shown.
Press Enter to finish the selection.
In the Fillet Surf to Surf dialog box, make sure that the Fillet radius is set to 0.0625 and Trim
is enabled to trim both original sets of surfaces.
NOTE: The fillet surface is created on the wrong side and the surfaces are trimmed as shown
in Figure: 11.5.1.
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TUTORIAL #41 CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS
Figure: 11.5.1
To be able to select the surfaces to change the normals, from the Fillet Surf to Surf, disable
Trim.
Select the Flip Normal button.
Figure: 11.5.2
NOTE: Both normals, as shown in Figure: 11.5.2, need to be reversed.
NOTE: To change the normal directions click on the surfaces not on the arrows. If you have
problems selecting the revolved surface, change the draft surface normal only, press Enter
to exit and then reselect Flip normal button and select only the revolved surface.
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CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS TUTORIAL #41
Click on both surfaces to reverse their normals as shown.
Press Enter to finish the selection and to return to the dialog box.
Enable the Trim option again.
Select the OK button to exit the Fillet Surf to Surf dialog box dialog box.
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TUTORIAL #41 CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS
The fillet surface should look as shown.
11.6 Create the curve at the edge
Sub Step Preview:
From the Status Bar, select the current color field as shown in previous step and select the
green color, no. 2.
Create
Curve
Curve on One Edge
[Select a surface]: Select the fillet surface.
NOTE: Although the trim options were set for both surfaces and the extend surface was also
enabled to correct any problems, the draft surface is not trimmed. To correct this we will
create the edge curve at the intersection between the fillet surface and the draft. Then we
will trim the surface to this curve.
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CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS TUTORIAL #41
[Move arrow to Desired Edge of Surface]: Move the arrow to the edge of the surface close to
the draft surface as shown and click to select it.
Select the OK button to exit the command.
The geometry should look as shown.
NOTE: To ensure a proper trimming, next we will need to extend the curve end beyond the
draft surface edges.
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TUTORIAL #41 CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS
11.7 Extend the curve both ends with 0.2" using trim/break/extend command
Sub Step Preview:
Change the graphic view to Isometric.
Select the Fit icon to fit the geometry to the screen.
Edit
Trim/Break
Trim/Break/Extend
Enable the Extension button, and enter 0.2.
[Select the entity to trim/extend]: Select the curve as shown.
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[Select the entity to trim/extend]: Select the curve as shown.
Select the OK button to exit the command.
The geometry should look as shown.
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TUTORIAL #41 CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS
11.8 Trim the draft surface to the curve
Sub Step Preview:
Create
Surface
Trim
To Curves
[Select surfaces and press Enter to continue]: Select the surface as shown below.
Press Enter to finish the surface selection.
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CREATE THE FILLET SURFACES WITH THE 0.0625" RADIUS TUTORIAL #41
From the Chaining dialog box, make sure that the Chain (default) button is selected, and the
rest of the dialog box looks as shown.
[Select profile curve(s)]: Select the curve as shown.
Select the OK button to exit the Chaining dialog box.
Make sure that the only buttons in the Ribbon bar that are selected are the ones shown.
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TUTORIAL #41 CHANGE AND MOVE SOME ENTITIES ON A NEW LEVEL
[Indicate area to keep- select a surface to be trimmed]: Click twice on the surface area that
we want to keep after trimming as shown below.
Press Alt + S to shade the surface.
The geometry should look as shown Figure: 11.8.1.
Figure: 11.8.1
Select the OK button to exit the command.
STEP 12: CHANGE AND MOVE SOME ENTITIES ON A NEW LEVEL
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CHANGE AND MOVE SOME ENTITIES ON A NEW LEVEL TUTORIAL #41
In this step you will learn how to work with levels. By organizing your files into levels, you can more
easily control which areas of the drawing are visible at any time and which parts are selectable so that
you do not inadvertently make changes to areas of the drawing you do not want to change.
12.1 Change the main level to level 2
From the Status bar, select Level.
Change the Main Level Name to Wireframe geometry as shown.
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TUTORIAL #41 CHANGE AND MOVE SOME ENTITIES ON A NEW LEVEL
Change the Number of the Main Level to 2 and enter in the Name field Toolpath geometry.
Select the OK button to exit Level Manager dialog box.
12.2 Move the outside rectangle and all surfaces to Level 2
To select all surfaces, from the Quick Mask toolbar, select QM Surfaces as shown.
NOTE: The current level number changes to Level 2. Any new entities that we will create will
be saved on this level. The Status bar will be updated as shown.
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CHANGE AND MOVE SOME ENTITIES ON A NEW LEVEL TUTORIAL #41
To select the rectangle, hold down the Shift key and select one of the rectangle lines as
shown.
From the Status bar, right-mouse click on the Level as shown.
Leave the Change Levels dialog box settings as shown.
Select the OK button to exit Change Levels dialog box.
12.3 Make Level 1 invisible
From the Status bar, select Level.
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TUTORIAL #41 CHANGE AND MOVE SOME ENTITIES ON A NEW LEVEL
In the Level Manger, Visible column, click on the X next to Number 1 to remove it as shown.
Select the OK button to exit the Level Manager dialog box.
NOTE: All the wireframe entities that we used to generate the surfaces are gone. To
machine the part we only need the surfaces and the tool containment boundary. The
rectangle will be used to establish the stock.
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CREATE SILHOUETTE BOUNDARY TUTORIAL #41
STEP 13: CREATE SILHOUETTE BOUNDARY
In this step you will learn how to create a boundary curve around a set of surfaces. The command will
create a 2D curve which represents the projection of the selected geometry onto the construction
plane. It will be created at the current Z-depth. This curve is typically used as a tool containment
boundary for toolpathing.
Step Preview:
From the Status Bar, select the current color field as shown in previous steps and change it to
the blue color, no. 9.
Create
Silhouette Boundary
[Select solids, solid faces, or surfaces]: Select the QM surfaces icon to select all surfaces.
Press Enter to finish the selection.
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TUTORIAL #41 CREATE A FLAT BOUNDARY SURFACE
Leave the default settings in the Silhouette Boundary dialog box.
Select the OK button to exit the Silhouette Boundary dialog box.
The geometry should look as shown.
STEP 14: CREATE A FLAT BOUNDARY SURFACE
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CREATE A FLAT BOUNDARY SURFACE TUTORIAL #41
In this step you will create a flat surface between the rectangle and the silhouette boundary.
Step Preview:
From the Status Bar, select the current color field as shown in previous step and select the
orange color, no. 138.
Create
Surface
Flat Boundary
Leave the same settings in the Chaining dialog box.
[Select chains to define flat boundary1]: Select the rectangle and the boundary as shown.
Select the OK button to exit the Chaining dialog box.
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TUTORIAL #41 SAVE THE FILE
Select the OK button to exit the command.
STEP 15: SAVE THE FILE
File
Save As
File name: "Your Name_4"
Select the OK button.
NOTE: You have finished the first part of the tutorial which is the geometry creation.
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SUGGESTED FIXTURE: TUTORIAL #41
TOOLPATH CREATION
SUGGESTED FIXTURE:
SETUP SHEET:
STEP 16: SELECT THE MACHINE AND SET UP THE STOCK.
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TUTORIAL #41 SELECT THE MACHINE AND SET UP THE STOCK.
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 and acts like a template for setting up
machining jobs. The machine definition ties together three main components: the schematic model of
your machine tool’s components, the control definition that models your control unit’s capabilities and
the post processor that will generate the required machine code (G-code). For a Mill Level 3 exercise
(3D toolpaths) we need just a basic machine definition.
Step Preview:
To display the Operations Manager press Alt + O.
Use the Fit icon to fit the drawing to the screen.
Machine type
Mill
Default
NOTE: For the purpose of this tutorial, we will be using the Default mill machine.
NOTE: If you already have the default machine in the Toolpaths Operations Manager, do not
select another machine.
NOTE: To be able to define the stock the construction mode has to be 3D.
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SELECT THE MACHINE AND SET UP THE STOCK. TUTORIAL #41
Select the plus sign in front of Properties in the Toolpaths Manager to expand the Toolpaths
Group Properties.
Select the Tool Settings to set the tool parameters.
Change the parameters to match Figure: 16.0.1.
Figure: 16.0.1
Program # is used to enter a number if your
machine tool requires a number for a program
name.
Assign tool numbers sequentially allows you to
overwrite the tool number from the library with
the next available tool number. (First operation
tool number 1; Second operation tool number 2,
etc.)
Warn of duplicate tool numbers allows you to get
a warning if you enter two tools with the same
number.
Override defaults with modal values enables the
system to keep the values that you enter.
Feed Calculation set From tool uses feed rate,
plunge rate, retract rate and spindle speed from
the tool definition.
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TUTORIAL #41 SELECT THE MACHINE AND SET UP THE STOCK.
Select the Stock setup tab to define the stock.
Click on the Bounding box button.
In the Bounding box leave the settings as shown.
Select the OK button to exit Bounding Box dialog box.
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SELECT THE MACHINE AND SET UP THE STOCK. TUTORIAL #41
Change the Z value for the stock thickness to 2.75 as shown.
Select the OK button to exit Machine Group Properties.
The stock should look as shown.
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TUTORIAL #41 ROUGH OUT THE PART USING SURFACE HIGH SPEED - AREA CLEARANCE
STEP 17: ROUGH OUT THE PART USING SURFACE HIGH SPEED - AREA CLEARANCE
Surface High Speed Area Clearance Roughing toolpath is designed for machining pockets providing a
smooth clean fluid motion. Smoothness settings help create an extremely efficient toolpath, avoiding
sharp corners and direction changes.
Toolpath Preview:
17.1 Surfaces and Containment selections
Toolpaths
Surface High Speed
If a prompt appears to Enter new NC name, select the OK button to
accept the default.
[Select Drive Surfaces]: From the Quick Mask toolbar select QM Surfaces
icon.
Press Enter to finish the selection.
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From the Toolpath/surface selection in the Containment area click on the Select button.
Leave the default Chaining settings.
[Chain 2D tool containment boundary # 1]: Select the boundary as shown.
Select the OK button to exit from the Chaining dialog box.
Select the OK button to exit from the Toolpath/surface selection.
17.2 Setting the Toolpath Type
Toolpath Type page allows you to change the existing toolpath to a different type. Mastercam updates
the parameter pages so that you only see settings for the toolpath type that you selected. You can also
change or reselect the drive surfaces, check surfaces, and the tool containment boundaries.
NOTE: The High Speed toolpaths have three distinct areas: Tree view, Page and Quick View
Settings as shown in Figure: 17.2.1.
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TUTORIAL #41 ROUGH OUT THE PART USING SURFACE HIGH SPEED - AREA CLEARANCE
Figure: 17.2.1
From the Toolpath Type select Roughing and then Area Clearance as shown.
17.3 Setting the Tool page
Tool page allows you to select the tool and enter feeds and speeds and configure automatic tool
inspection.
From the Tree View Area, select Tool.
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To select the tool, click on Select library tool button.
To search for a specific tool within the default tool library, click on the Filter button.
From the Tool List Filter, select the Endmill Bull icon, and in the Tool Diameter area select
Equal and enter 1/2" as shown.
Make sure that all the other settings are as shown in the screenshot above, and then select
the OK button to exit.
From the Tool Selection list select the 1/2" Bull Endmill with the corner radius of 0.0625".
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Select the OK button to exit from the Tool Selection dialog box.
Right mouse click on the tool in the tool display window, and select Feed and speed
calculator.
Select the OK button to accept the default settings.
NOTE: The feeds and spindle speed are based on the tool definition. You can overwrite them
with the feeds and speed that you want to use. You can also let Mastercam calculate the
feeds and speed using the Feed speed calculator as shown next.
NOTE: You can edit the parameters until you get the desired results and then you can save
them to create a new material or tool definition.
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Add a comment in the Comment area to identify the toolpath in the Toolpath Manager and
also in the NC file.
The Tool page should look as shown in Figure: 17.3.1.
Figure: 17.3.1
17.4 Set the parameters in the Cut parameters page
In this page you can set the Cutting method, configure the Z spacing (Stepdown) and the XY spacing (XY
stepover) and the Smoothing. You can also set the tool containment options.
From the Tree View Area, select the Cut parameters page and change the parameters as
shown in Figure: 17.4.1.
NOTE: If you click on the tool from the list the feedrates and the spindle speed will be
updated to the original values. You can lock them in the Settings, Configuration, Toolpaths
page by enabling Lock Feedrates.
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TUTORIAL #41 ROUGH OUT THE PART USING SURFACE HIGH SPEED - AREA CLEARANCE
Figure: 17.4.1
17.5 Set the Transitions page
Transitions page allows you to configure the entry move that the tool will make as it transitions to new
Z levels. You can choose to create either a ramp entry, or helical entry move. If the profile is too small
to create a helix of this size, Mastercam will create a ramp move instead.
Stepdown value sets a constant Z spacing between cutting passes.
Add cuts feature allows you to insert additional cutting passes in areas of your part where the profile is
close to flat. Mastercam will add new cuts to maintain the maximum profile stepover, while spacing them
each by at least as much as the minimum step-down.
Stepdown options allows you to configure how Mastercam spaces the cuts in Z. Mastercam can maintain a
constant Stepdown between passes, or you can choose the Add cuts option to configure adaptive
stepdown strategies.
Corner rounding replaces sharp corners with arcs for faster and smoother tool movements. This lets the
machine tool maintain a higher feed rate and reduces wear on the cutter.
Stock to leave on drive surfaces lets you enter separate values for the wall and floor surfaces. Note that
the stock to leave on walls must be greater than or equal to the stock left on the floor. For surfaces that are
not exactly horizontal or vertical, Mastercam will interpolate between the wall and floor values.
Keep tool down prevents the tool from retracting if the distance between the end of one pass and the start
of the next pass is less than the specified settings.
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ROUGH OUT THE PART USING SURFACE HIGH SPEED - AREA CLEARANCE TUTORIAL #41
From the Tree View Area, select the Transitions page and change the parameters as shown
in Figure: 17.5.1.
Figure: 17.5.1
17.6 Set the Linking Parameters page
The Linking Parameters page options allow you to configure how Mastercam links air moves when the
tool is not in contact with the part.
From the Tree View Area, select the Linking Parameters page.
Change the parameters as shown in Figure: 17.6.1.
Radius value sets the radius of the helix as an absolute
value.
Plunge rate sets the helix feedrate to the plunge rate.
Output 3D arc moves instructs the system to output
circular movements instead of linear movements.
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TUTORIAL #41 BACKPLOT THE TOOLPATH
Figure: 17.6.1
Select the OK button to exit the Surface High Speed Toolpaths - Area Clearance parameters.
Press Alt + T to remove the toolpath display.
STEP 18: BACKPLOT THE TOOLPATH
Backplotting shows the path the tools take to cut the part. This display lets you spot errors in the
program before you machine the part. As you backplot toolpaths, Mastercam displays the current X, Y,
and Z coordinates in the lower left corner of the screen.
Make sure that the toolpath is selected (signified by the green check mark on the folder
icon).
Select the Backplot selected operations button.
Minimum vertical retract is a vertical
retract and constant-Z move at the Part
clearance height.
Leads fields set the tool moves onto and off
of the part at the start and end of each
cutting pass. These moves are applied to
each pass no matter which cutting pass is
selected.
Fitting settings allow you to choose how the
entry and exit arcs fit to the ends of the
cutting passes.
Minimize trimming sets the path to retract
to be as close to the surface as possible,
maintaining a minimum distance from the
surface to fit the arc.
Max trimming distance parameter limits the
amount of trimming applied to non-
horizontal passes.
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VERIFY THE TOOLPATH TUTORIAL #41
Make sure that you have the following buttons turned on (they will
appear pushed down) to see the tool and the rapid moves.
You can adjust the speed of the backplot.
You can step through the Backplot by using the Step forward or Step back buttons.
Select the Play button in the VCR bar to run Backplot.
The toolpath should look as shown.
Select the OK button to exit Backplot.
STEP 19: VERIFY THE TOOLPATH
Verify simulates the machining of a part from a solid stock model display. The stock dimensions are
based on the values that we specified in the Stock Setup
Select the Verify selected operations button.
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TUTORIAL #41 VERIFY THE TOOLPATH
From the Verify dialog box select the Options button.
Make the changes in the Verify Options as shown Figure: 19.0.1.
Figure: 19.0.1
Select the OK button to exit Verify Options.
Set the Verify speed by moving the slider bar in the speed control bar.
Select the Fast Forward button to start simulation.
Stock Shape is automatically set to Solid.
Use True Solid allows you, after verifying the part,
to rotate and magnify it to more closely check
features, surface finish, or scallops.
Cutter comp in control allows Verify to use the
information regarding the tool diameter and to
simulate the cutter compensation. Not used in
surface toolpaths.
Change tool/color allows you to change the color
of the cut stock to indicated tool changes in the
toolpath.
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CLEAN THE REMAINING AREAS USING SURFACE ROUGH RESTMILL TUTORIAL #41
The part, after the roughing operation, should look as shown.
STEP 20: CLEAN THE REMAINING AREAS USING SURFACE ROUGH RESTMILL
NOTE: Some areas of the part can not be machined as the 1/2" Bull Endmill tool was too big.
To clean just the areas that were not machined we will use the Surface Rough Restmill and a
1/4" Bull Endmill.
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TUTORIAL #41 CLEAN THE REMAINING AREAS USING SURFACE ROUGH RESTMILL
Surface Rough Restmill toolpath allows Mastercam to calculate the cutting passes on only the stock
left over from one or more previous roughing operations, instead of the entire drive surfaces. This
toolpath uses the area clearance machining strategies.
Toolpath Preview:
Toolpaths
Surface Rough
Restmill
From the Quick Mask toolbar select QM Surfaces icon.
Press Enter to finish the selection.
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CLEAN THE REMAINING AREAS USING SURFACE ROUGH RESTMILL TUTORIAL #41
From the Toolpath/surface selection in the Containment area click on the Select button.
Leave the default Chaining settings.
[Chain 2D tool containment boundary # 1]: Select the boundary as shown.
Select the OK button to exit from the Chaining dialog box.
Select the OK button to exit from the Toolpath/surface selection.
20.1 Setting the Toolpath parameters page
Toolpath parameters page allows you to select a tool, set the feeds and speeds, enter a comment
about the operation, and set other general toolpath parameters.
NOTE: The toolpath does require the tool containment boundary.
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TUTORIAL #41 CLEAN THE REMAINING AREAS USING SURFACE ROUGH RESTMILL
Using the same steps shown in previous toolpaths, select the 1/4" Bull Endmill with the cor-
ner radius 0.0625".
Use the Feed speed calculator as shown in the first toolpath, to establish the feed rates and
spindle speed.
Add a comment in the Comment area to identify the toolpath in the Toolpath Manager and
also in the NC file.
The Toolpath Parameters page should look as shown in Figure: 20.1.1.
Figure: 20.1.1
20.2 Set the parameters in the Surface parameters page
In this page you can set the Clearance, the Retract and the Feed plane heights. You can reselect the
drive surfaces and boundaries required by the toolpath and also leave stock on drive surfaces and to
leave stock on check surfaces too. The Surface parameters page is the same for all surface toolpaths.
Check the previous toolpath for more info on the parameters.
Select the Surface parameters page and change the parameters as shown in Figure: 20.2.1.
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CLEAN THE REMAINING AREAS USING SURFACE ROUGH RESTMILL TUTORIAL #41
Figure: 20.2.1
20.3 Set the Restmill parameters page
Restmill parameters page allows you to set the total tolerance for machining, the Maximum stepover,
the cutting method and the options that control area to be machined.
Select the Restmill parameters page and change the parameters as shown in Figure: 20.3.1.
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TUTORIAL #41 CLEAN THE REMAINING AREAS USING SURFACE ROUGH RESTMILL
Figure: 20.3.1
20.4 Set the Rest material parameters page
Rest material parameters page is used to calculate the amount of stock left on the part using the
roughing tool dimensions. You can also calculate remaining stock by using one or more source
operations or use an STL file as the source for calculating leftover stock.
Select the Rest material parameters page and change the parameters as shown in
Figure: 20.4.1.
Maximum stepdown sets the distance between
adjacent passes in the Z axis.
Stepover sets the distance between adjacent
passes in the XY plane.
Transition set to Broken moves the tool up and
over, or over and down, between areas smaller
than the gap size.
Optimize cut order keeps the tool in one area to
completely machine it to minimize the retract
motions.
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CLEAN THE REMAINING AREAS USING SURFACE ROUGH RESTMILL TUTORIAL #41
Figure: 20.4.1
Select the OK button to exit Surface Restmill parameters.
Press Alt + T to remove the toolpath display.
20.5 Backplot the Surface Restmill toolpath
Make sure that only the Surface Restmill toolpath is selected in the Toolpaths Operations
Manager (signified by the green check mark on the folder icon).
Select the Backplot selected operations button.
Select the Play button in the VCR bar to run Backplot.
Roughing tool diameter/ Corner radius enables
Mastercam to calculate the remaining stock
based on the previous operation tool size.
Adjustments to remaining stock set to Use
remaining stock as computed makes no
adjustments to the calculated stock.
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TUTORIAL #41 SAVE THE STOCK AFTER ROUGHING AS AN STL FILE
The toolpath should look as shown.
Select the OK button to exit Backplot.
STEP 21: SAVE THE STOCK AFTER ROUGHING AS AN STL FILE
Mastercam saves the part model (stock shape) as an STL (a 3D model) file. The STL file can be used as a
stock model in a subsequent verification. The Save stock file option is only available in TrueSolid mode
in Mastercam Mill and Router.
21.1 Verify both roughing toolpaths
Click on the Select all operations icon to make sure that all toolpaths are selected in the
Toolpaths Operations Manager.
Select the Verify selected operations button.
Select the Fast Forward button to simulate the toolpath.
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SAVE THE STOCK AFTER ROUGHING AS AN STL FILE TUTORIAL #41
The part, after the roughing operations, should look as shown.
21.2 Save the stock shape as an STL file
From the Verify dialog box, select Save stock as a file button as shown.
Select the OK if you want to keep the same name as the tutorial name.
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TUTORIAL #41 FINISH THE PART USING SURFACE HIGH SPEED - HYBRID
Select the OK button to exit Verify.
STEP 22: FINISH THE PART USING SURFACE HIGH SPEED - HYBRID
Surface High Speed Hybrid toolpath addresses steep and shallow areas utilizing both scallop and
constant Z approaches in a single toolpath. The toolpath switches seamlessly between both methods
and cuts in a logical, optimized order.
Toolpath Preview:
22.1 Copy the first operation only
From the Toolpaths Operations Manager, select the first High Speed (Area Clearance).
Below the existing operations, right-mouse click and select Copy.
Right-mouse click again and select Paste.
In the third operation select Parameters as shown.
NOTE: We can copy the existing operation and change the toolpath type to Finishing and
Hybrid. We will save time as the same surfaces and boundary is required.
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FINISH THE PART USING SURFACE HIGH SPEED - HYBRID TUTORIAL #41
22.2 Setting the Toolpath Type
Toolpath Type page allows you to change the existing toolpath to a different type. Mastercam updates
the parameter pages so that you only see settings for the toolpath type that you selected. You can also
change or reselect the drive surfaces, check surfaces, and the tool containment boundaries.
From the Tree View Area, select the Toolpath Type, select Finishing and then Hybrid as
shown.
22.3 Setting the Tool page
Tool page allows you to select the tool and enter feeds and speeds and configure automatic tool
inspection.
From the Tree View Area, select Tool.
To select the tool, click on Select library tool button.
Using the Filter options as shown in the previous step, select the 1/4" Ball Endmill.
From the Tool Selection list select the 1/4" Ball Endmill.
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TUTORIAL #41 FINISH THE PART USING SURFACE HIGH SPEED - HYBRID
Select the OK button to exit from the Tool Selection dialog box.
Add a comment in the Comment area.
The Tool page should look as shown in Figure: 22.3.1.
Figure: 22.3.1
22.4 Set the parameters in the Cut parameters page
In this page you can set the Cutting method, configure the passes (Stepover) and the machining area.
From the Tree View Area, select the Cut parameters page and change the parameters as
shown in Figure: 22.4.1.
NOTE: The feeds and spindle speed are based on the tool definition. You can overwrite them
with the feeds and speed that you want to use. You can also let Mastercam calculate the
feeds and speed using the Feed speed calculator as shown in the previous step.
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FINISH THE PART USING SURFACE HIGH SPEED - HYBRID TUTORIAL #41
Figure: 22.4.1
22.5 Set the Transitions page
Transitions page allows you to configure the type of transition between the passes. Select Smooth to
create high speed arc moves between each pass.
From the Tree View Area, select the Transitions page and change the parameters as shown
in Figure: 22.5.1.
Cutting method is set to Climb to create cuts with the tool rotating opposite the direction of travel along
the cutting side of the tool.
Steep stepdown defines the constant Z distance between adjacent stepdowns. Mastercam first slices the
entire model into sections defined by the Steep Stepdown distance. It then analyzes the drive surface's
slope transition between each stepdown along the specified Limiting Angle. If the drive surface's slope
transition within the stepdown distance is less than the limiting angle, the hybrid toolpath considers it
steep and a single 2D waterline cutting pass is generated.
Shallow stepover defines the spacing between 3D scallop-style cutting passes in shallow stepdowns.
Tool containment compensate to Inside keeps the entire tool inside the containment boundary.
Stock to leave on drive surfaces lets you enter separate values for the wall and floor surfaces. They should
be zero.
Keep tool down prevents the tool from retracting if the distance between the end of one pass and the start
of the next pass is less than the specified settings.
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TUTORIAL #41 FINISH THE PART USING SURFACE HIGH SPEED - HYBRID
Figure: 22.5.1
22.6 Set the Linking Parameters page
The Linking Parameters page options allow you to configure how Mastercam links air moves when the
tool is not in contact with the part.
From the Tree View Area, select the Linking Parameters page.
Select the OK button to exit the Surface High Speed Toolpaths - Hybrid parameters.
To update the toolpath, from the Toolpaths Operations Manager, select Regenerate all
selected operations.
Tangential ramp to create a true high speed transition
between the cutting passes. Mastercam inserts arcs at
the beginning and end of the ramp for the smoothest
tool motion into and out of the move.
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FINISH THE PART USING SURFACE HIGH SPEED - HYBRID TUTORIAL #41
Press Alt + T to remove the toolpath display.
22.7 Backplot the Surface High Speed Hybrid toolpath
Make sure that only Surface High Speed Hybrid toolpath is selected in the Toolpaths
Operations Manager.
Select the Backplot selected operations button.
Select the Play button in the VCR bar to run Backplot.
The toolpath should look as shown.
Select the OK button to exit Backplot.
22.8 Verify both rough and finish toolpaths
Select the Verify selected operations button.
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TUTORIAL #41 FINISH THE PART USING SURFACE HIGH SPEED - HYBRID
From the Verify, select the Options button.
From the Verify Options, in the Stock Shape enable File and click on the Select Stock file
button.
Select the file from where you save it, and then the OK button to exit.
Select the OK button to exit Verify Options.
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FINISH THE AREA USING SURFACE FINISH LEFTOVER TUTORIAL #41
The stock should look as shown.
Select the Fast Forward button to simulate the toolpath.
The part, after the finish operation, should look as shown.
Select the OK button to exit Verify.
STEP 23: FINISH THE AREA USING SURFACE FINISH LEFTOVER
NOTE: We still need to machine the fillet surfaces with the radius 0.0625 which can not be
machined with the 1/4" Ball Endmill. We are going to clean that area with a Surface Finish
leftover toolpath and a smaller tool.
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TUTORIAL #41 FINISH THE AREA USING SURFACE FINISH LEFTOVER
Surface Finish Leftover toolpath removes small amounts of material left by a larger tool in a previous
operation. Finish leftover makes a single pass through the leftover material. You can create multiple
leftover toolpaths using a smaller tool for each toolpath.
Toolpath Preview:
Toolpaths
Surface Finish
Leftover
From the Quick Mask toolbar select QM Surfaces icon.
Press Enter to finish the selection.
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FINISH THE AREA USING SURFACE FINISH LEFTOVER TUTORIAL #41
Select the OK button in the Toolpath/surface selection to continue.
23.1 Setting the Toolpath parameters page
Toolpath parameters page allows you to select a tool, set the feeds and speeds, enter a comment
about the operation, and set other general toolpath parameters.
Using the same steps shown in previous toolpaths, select the 1/8" Ball Endmill.
Use the Feed speed calculator as shown in the first toolpath, to establish the feed rates and
spindle speed.
Add a comment in the Comment area to identify the toolpath in the Toolpath Manager and
also in the NC file.
The Toolpath Parameters page should look as shown in Figure: 23.1.1.
NOTE: The toolpath does not require any tool containment boundary. We are going to
machine all the remaining areas.
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TUTORIAL #41 FINISH THE AREA USING SURFACE FINISH LEFTOVER
Figure: 23.1.1
23.2 Set the parameters in the Surface parameters page
In this page you can set the Clearance, the Retract and the Feed plane heights. You can reselect the
drive surfaces and boundaries required by the toolpath and also leave stock on drive surfaces and to
leave stock on check surfaces too. The Surface parameters page is the same for all surface toolpaths.
Check the previous toolpath for more info on the parameters.
Select the Surface parameters page and change the parameters as shown in Figure: 23.2.1.
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FINISH THE AREA USING SURFACE FINISH LEFTOVER TUTORIAL #41
Figure: 23.2.1
23.3 Set the Finish leftover parameters page
Finish leftover parameters page allows you to set the total tolerance for machining, the Maximum
stepover, the cutting method and the options that control area to be machined.
Select the Finish leftover parameters page and change the parameters as shown in
Figure: 23.3.1.
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TUTORIAL #41 FINISH THE AREA USING SURFACE FINISH LEFTOVER
Figure: 23.3.1
23.4 Set the Leftover material parameters page
Leftover material parameters page is used to calculate the amount of stock left on the part using the
roughing tool dimensions.
Select the Leftover material parameters page and change the parameters as shown
in Figure: 23.4.1.
Figure: 23.4.1
Max. stepover sets the distance between
adjacent passes.
Cutting method is set to 3D Collapse to create a
boundary around the cutting area and then step
in to create each pass by offsetting the outer
boundary by the maximum stepover.
From slope angle sets the minimum slope angle
of the surface to determine the steep areas of
the part.
To slope angle sets the maximum slope angle of
the surface to determine the steep areas of the
part.
Only areas between the From slope angle and
To slope angle are machined
Roughing tool diameter is the diameter of the
previous operation tool that machines the area.
Roughing tool radius is the radius of the
previous operation tool that machines the area.
Overlap distance is an additional offset applied
to the previous tool shape. This value causes the
leftover material to be calculated as if it had
been cut by a larger tool.
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FINISH THE AREA USING SURFACE FINISH LEFTOVER TUTORIAL #41
Select the OK button to exit Surface Finish Leftover parameters.
23.5 Backplot the Surface Finish Leftover toolpath
Make sure that only Surface Finish Leftover toolpath is selected in the Toolpaths Operations
Manager (signified by the green check mark on the folder icon).
Select the Backplot selected operations button.
Select the Play button in the VCR bar to run Backplot.
The toolpath should look as shown.
Select the OK button to exit Backplot.
23.6 Verify only the finish toolpaths
From the Toolpaths Operations Manager, click on Surface High Speed (Hybrid) and hold-
down the Ctrl key and select the Surface Finish Leftover.
Select the Verify selected operations button.
To speed the simulation, select the Turbo button.
Select the Fast forward button to simulate the toolpaths.
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TUTORIAL #41 USE CHECK HOLDER TO FIND THE MINIMUM TOOL LENGTH REQUIRED
The part, after the finish operation, should look as shown.
Select the OK button to exit Verify.
STEP 24: USE CHECK HOLDER TO FIND THE MINIMUM TOOL LENGTH REQUIRED
FOR THE 1/8 INCH BALL END ENDMILL
Check Holder C-Hook is used to check an operation's tool holder for interference with the part. It
calculates areas where there is interference and tells you the minimum tool length required to avoid it.
24.1 Check the current tool length
From Toolpaths Operations Manager, click on the 1/8" Endmill Bull in the Surface Finish
Leftover operation.
NOTE: In this operation we are machining a deep pocket. To ensure that the tool holder
does not interfere with the part, in the next step we will use the CheckHolder C-Hook.
NOTE: If you have only the Home Learning Edition of Mastercam you will not be able to do this
step.
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USE CHECK HOLDER TO FIND THE MINIMUM TOOL LENGTH REQUIRED TUTORIAL #41
Note the Overall value of 2.25".
Select the OK button to exit.
If the Tool definition about to be updated dialog box appears, leave the default setting and
select the OK button.
Enter Alt + C to open the C-hook directory.
Select CheckHolder.dll from the list.
Select the OK button to continue.
Enable Find minimum tool length and enter the Holder clearance of 0.05".
Keep the other settings as shown.
Select the Perform test button as shown in the figure above.
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TUTORIAL #41 USE CHECK HOLDER TO FIND THE MINIMUM TOOL LENGTH REQUIRED
Note the value that the system found.
Select Modify source operation as shown in the above figure.
Enable Modify tool and the tool length will be updated in all the operations where it is used.
Select the OK button to exit.
The Warning "Tool has been modified" appears.
Select the OK button to continue.
Select the OK button to exit the Check holder dialog box.
NOTE: The test result was some interference and the Minimum tool length value is bigger
than the tool length.
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POST PROCESS THE FILE TUTORIAL #41
From the Toolpaths Operations Manager select again the 1/8 Endmill Sphere to check if the
tool Overall distance was updated.
Select the OK button to exit Tool definition dialog box.
STEP 25: POST PROCESS THE FILE
Post processing, or posting, refers to the process by which the toolpaths in Mastercam part files are
converted to a format (NC file) that can be understood by your machine tool's control such as G-codes.
The Post's role is to read the NCI data, read the control definition settings, initiate postblock calls, read
the parameters and output the NC code. Producing the right NC code for your machine and application
depends on properly configuring the machine definition, control definition and the post processor.
Click on Select all operations icon to make sure that all toolpaths are selected in the
Toolpaths Operations Manager.
Select the Post selected operations button from Toolpaths Operations Manager.
In the Post processing window, if needed, make any necessary changes as shown below.
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TUTORIAL #41 SAVE THE UPDATED MCX FILE
Select the OK button to continue.
Enter the same name as the geometry name in the NC File name field.
Select the OK button to save the NC file.
The NC file will appear on the screen as shown in Figure: 25.0.1.
Figure: 25.0.1
Select the red X box at the upper right corner to exit the Editor.
STEP 26: SAVE THE UPDATED MCX FILE
Select the Save icon.
NOTE: How the program is sent to the machine depends on the shop setup.
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SAVE THE UPDATED MCX FILE TUTORIAL #41
REVIEW EXERCISE -STUDENT PRACTICE
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TUTORIAL #41 CREATE THE GEOMETRY FOR TUTORIAL #4 EXERCISE
CREATE THE GEOMETRY FOR TUTORIAL #4 EXERCISE
Create the Geometry for Tutorial #4 Exercise as per the instructions below.
Create the wireframe for the revolved surface.
Create the wireframe for the swept surface.
Create the Revolved surface.
Select the profile and then the axis of
rotation.
Set the End angle to 180 and use Flip button
if needed to get the proper side of the
surface.
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CREATE THE GEOMETRY FOR TUTORIAL #4 EXERCISE TUTORIAL #41
Swept surface.
Enable 2 Rails button in the Ribbon bar.
Using Single selection in the Chaining dialog
box, select the 0.2 radius arc as the across
contour.
Using Partial selection in the Chaining dialog
box, select the 2 contours.
Create the Fillet Surface with the 0.1 radius.
Select the revolved surface as the first set of
surfaces.
Select the swept surface as the second set of
surfaces.
Enter the Fillet radius = 0.1".
Use the Flip normals button to set the
surface normals for both surfaces pointing
inwards.
Enable extend surfaces in options.
Enable Trim in the dialog box.
Create the Draft Surfaces.
Create the two lines as the necessary
wireframe.
Create each draft surface with the Length =
3.0 and the Draft angle =3.
Use the Flip buttons if needed to create the
surfaces in the proper orientation.
Create the upper side Fillet Surfaces with the
0.0625" radius.
Select all the revolved surfaces (there are
two) as the first set of surfaces.
Select the draft surface as the second set of
surfaces.
Disable Trim.
Enter the Fillet radius = 0.0625".
Use the Flip normals button to set the
surface normals for the revolved surfaces
pointing upwards and for the draft surface
towards the center of the part.
In the Options enable Extend surfaces.
Enable Trim in the dialog box.
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TUTORIAL #41 CREATE THE GEOMETRY FOR TUTORIAL #4 EXERCISE
Create the lower side fillet surface with the 0.0625" radius.
Follow the same steps as instructed for the upper side fillet.
.
Create the Flat Boundary surface at the open edge of the swept surface.
Create a line between the endpoints of the
arc.
Create the flat boundary surface.
Create a Fillet surface between swept and the flat boundary with the radius 0.0325".
Flip the surface normal if needed.
Organize the geometry on different levels.
Move all surfaces and the outside rectangle on level 2.
Make visible only level 2.
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CREATE THE GEOMETRY FOR TUTORIAL #4 EXERCISE TUTORIAL #41
Create the Silhouette boundary.
Create the flat boundary surface between the
rectangle and the silhouette boundary.
Select both the rectangle and the silhouette
boundary.
Save the geometry.
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TUTORIAL #41 CREATE THE TOOLPATHS FOR TUTORIAL #4 EXERCISE
CREATE THE TOOLPATHS FOR TUTORIAL #4 EXERCISE
Create the Toolpaths for Tutorial #4 Exercise as per the instructions below.
Set the machine properties including the stock.
Establish the stock using bounding box.
Change the Z thickness to 2.75".
Rough out the part using Surface High Speed -
Area clearance toolpath.
Select all surfaces and as containment
boundaries select the silhouette boundary.
Use the 1/2"Bull Endmill with 0.0625 "corner
radius.
Stepdown= 0.050".
Enable Add cuts and Corner rounding same
as in the tutorial.
XY Stepover percentage of diameter = 45.
Stock to leave on walls/floors = 0.02".
Tool Containment compensate Inside
Transitions = Entry-Helix.
Linking parameters set to Minimum Vertical
Retract and the default settings.
Total tolerance = 0.001".
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CREATE THE TOOLPATHS FOR TUTORIAL #4 EXERCISE TUTORIAL #41
Clean up the areas that the previous tool can not using Surface Restmill toolpath.
Select all surfaces and as containment
boundaries select the silhouette boundary.
Stock to leave on drive surfaces only 0.02".
Set up appropriate Clearance, Retract and
Feed plane (see the tutorial).
Use the 1/4"Bull Endmill with 0.0625 "corner
radius.
Total tolerance = 0.001".
Maximum Stepdown= 0.050".
Stepover = 0.05".
Transitions = Broken.
Enable Optimize cut order.
Compute the remaining stock from the
Roughing tool diameter.
Use remaining stock as computing.
Simulate the roughing operation in Verify and save the stock as an stl file.
Finish the cavity areas using Surface High Speed Hybrid toolpath.
Select all surfaces and as containment
boundaries select the silhouette boundary.
Use the 1/4"Ball Endmill.
Stepdown= 0.020".
Limiting angle = 45.
Shallow stepover = 0.02".
Stock to leave on walls/floors = 0.0".
Tool Containment compensate Inside
Transitions = Tangential ramp.
Linking parameters set to Minimum Vertical
Retract and the default settings.
Total tolerance = 0.001".
Use the stl file as stock when verify the finish
operation.
Finish the remaining areas using Surface
Finish Leftover toolpath.
Use the 1/16"Ball Endmill.
Stock to leave on drive surface = 0.0".
Total tolerance = 0.001".
Maximum stepover = 0.02".
Cutting method = 3D Collapse.
From slope angle = 0.0".
To slope angle = 90.0".
Page |4-156 Mill Level 3 Training Tutorial
TUTORIAL #41 NOTES:
NOTES:
Mill Level 3 Training Tutorial Page|4-157
TUTORIAL #4 QUIZ TUTORIAL #41
TUTORIAL #4 QUIZ
What is a swept surface?
How do you create an arc tangent through a point?
What command should you use if you want to trim a surface to wireframe geometry?
When can you use Surface High Speed Area Clearance toolpaths?
When can you use Surface High Speed Hybrid toolpaths?
When shall you use Surface Restmill toolpath instead of Surface Leftover toolpath?
Page |4-158 Mill Level 3 Training Tutorial
TUTORIAL #41 TUTORIAL #4 QUIZ