SAMPLE-X3 4-5 Axis Training Tutorial

8/13/2019 SAMPLE-X3 4-5 Axis Training Tutorial

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4 & 5 Axis Mill Training Tutorials

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Mastercam

X Training Tutorials 4 & 5 Axis Mill ApplicationsRevised Date: September 26, 2008

Copyright 1984 2008 InHouse Solutions Inc. All rights reserved.

Software: Mastercam X Mill

Authors: Mariana Lendel

ISBN: 9781894487993

Notice

InHouse Solutions Inc. reserves the right to make improvements to this manual at any time and without

notice.

Disclaimer Of All Warranties And Liability

InHouse Solutions Inc. makes no warranties, either express or implied, with respect to this manual or

with respect to the software described in this manual, its quality, performance, merchantability, or fitness

for any particular purpose. InHouse 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 notInHouse Solutions Inc., its distributor, or its retailer) assumes the entire cost of all

necessary servicing, repair, of correction and any incidental or consequential damages. In no event will InHouse Solutions Inc. be liable for direct, indirect, or consequential damages resulting from any defect in

the manual, even if InHouse 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 the copyright laws of Canada and the United States. All rights are

reserved. This document may not, in whole or part, be copied, photocopied, 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 MSDOS are registered trademarks of Microsoft Corporation;

Mastercam Verify is created in conjunction with Sirius Systems Corporation; Windows 95, and Windows

NT; Windows XP are registered trademarks of Microsoft Corporation.


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TABLE OF CONTENTS

Getting Started .............................................................................................................A1

Axis Substitution, Rotary Axis Positioning and TransformRotate Tutorial ................... 11

Axis Substitution To Create A Cylindrical And A Conical Helix Tutorial ...........................21

Axis Substitution, Rolldie CHook Tutorial .....................................................................31

Chuck Indexing Tutorial ................................................................................................41

Rotary4Axis Toolpath And Axial 4ax Tutorial................................................................51

Curve 5Axis And Drill 5Axis Tutorial ............................................................................61

Swarf 5Axis With Wall Defined By Using 2 Contours Tutorial........................................71

Flow 5Axis Tutorial ......................................................................................................81

Multisurface 5Axis Tutorial ..........................................................................................91

Port 5Axis Tutorial................................................................................. 101

General Notes....................................................................................... B1


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TUTORIALSERIESFOR

CHUCK INDEXING TUTORIAL


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Objectives:

The Student will design a 3dimensional drawing by:

Creating the 2D geometry in the Right Side view.

Creating the 3D geometry using translate command.

Creating circles knowing the diameter and the center location.

Changing the view of the part for better visualisation.

The Student will create a 2dimensional milling toolpath in different Tplanes consisting of:

Using View Manager to select the Tplane for each face.

Create an operation for each face using the same work offset (G54).

Facing one flat surfaces.

Facing the other two flat surfaces using TransformRotate toolpath.Drilling the two holes.

Removing the material inside of one groove using contour toolpath.

Machine the second groove using TransformRotate toolpath.

The Student will check the toolpath using Mastercams Verify verification module by:

Defining a 3dimensional block, the size of the workpiece.

Running the Verify function to machine the part on the screen.

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GEOMETRY CREATION

STEP 1: CREATE THE 2D GEOMETRY IN THE RIGHT SIDE VIEW.

Option 1The geometry file, Tutorial4_geometry.zip, can be downloaded fromwww.emastercam.com/files

The finish part, Tutorial4_finish.zip including the toolpaths, is also provided on the same location

www.emastercam.com/files

Option 2Create the geometry using the following instructions:

Create the 2D profile in the Righ side view:

Create/Arc/ Create Circle Center Pointand set parameters to:Diameter = 5.0;

Center Origin

Create/Line/ Create Line Endpointand set parameters to:

Specify an endpoint = Origin

Line length = 2.45

Angle = 165 deg.;

Create/Line/ Create Line Perpendicularand set parameters to:

Select line, arc or spline; Select the existing line

Sketch a point; Select the Endpoint of the existing line opposite the origin.

Select which line to keep; Select the line above the existing one.Repeat the steps to select the other perpendicular line below the first line that we created.

Delete the first line

Edit/Join entities

Select the two colinear lines; Press enter to finish the command

Edit/ Trim/Break/ Trim/Break/Extend

Enable divide and select the arc left to the line and the two ends of the line.

Xform/ Xform Rotate

Select the line; Enable Copy and set # to 1; Rotation angle 90 deg

Select these lines andthe arc here

Xform/ Xform Rotate

Select the rotated line; Enable Copy and set # to 1; Rotation angle 105 deg

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Enable divide and select the two arcs one below and

the other one to the right of the rotated lines.

Create/Line/ Create Line Endpointand set

Select Entity A here

parameters to:

Specify an endpoint = Origin

Line length = 2.5

Angle = 120 deg.;

Create/Line/ Create Line Paralleland set parameters to:

Select a line; Select the 120 deg line

Select the point to place a parallel line through; Pick a point above the line; enter the distance 0.25

Select the flip buton several times until you make both parallel lines (above and below the 120 deg. line)


Enable Break in the ribbon bar.

Select an entity to break; Select the first parallel line end that is further away from the origin.

Enable the length button in the Ribbon bar and enter 0.25

Repeat the command to break at 0.25 distance the other parallel line that we created in the previous

step

Deletethe center line and the parallel lines closes to the origin.

Select these entities

Create/Line/ Create Line Endpointand set parameters to:

Select the endpoints of the parallel lines left to close the slot.


Enable Divide in the ribbon bar.

Select the arc between the two parallel lines.


Enable Trim 2 entities in the ribbon bar.

Select the entities at the top corners of the slot.

Xform/ Xform Rotate

Select the three lines of the slot; Enable Copy and set # to 1; Rotation angle 180 deg


Enable Divide in the ribbon bar.


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Select the arc between the two parallel lines that you rotated in the previous step.

Create the cylindrical shape

Xform/ Xform Translate

Select all entities;

Enable Join; # =1;z = 6.0

Create the circles in the Front plan

Select Entity ASet the plane to Front.

Set the Zdepth at the holes plane. (2.45)

Create/Line/ Create Line Paralleland set parameters to:

Select a line; Select line A as shown

Select the point to place a parallel line through; Pick a point below the line; enter the distance 0.50

Select Entity BSelect a line; Select line B as shown

Select the point to place a parallel line through;Pick a point to the right of the line; enter the distance 1.50

Select a line; Select line C as shown

Select the point to place a parallel line through; Pick a point

to the left of the line; enter the distance 1.50Select Entity C

Create/Arc/ Create Circle Center Pointand set parameters to:

Diameter = .375;

Center at intersection between two of the lines created in the previous step.

Diameter = .375;

Center at intersection between two of the lines created in the previousstep.

Deletethe construction lines

File/Save as

File Name: Tut4_Rotary axis indexing.mcx


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TOOLPATH CREATION

STEP 5: DEFINE THE STOCK.

To display the Toolpaths Managerpress Alt + O.

If a machine definition is already selected see Tutorial # 2 page 24 to learn how to change it.

Otherwise follow next step.

Set the construction plane to Top Plane.

Select Mill 4AXIS VMC.MMD

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Select the plus in front of Properties to expand the Toolpaths Group Properties.

Select the plus

Select Stock setup

Select the Stock setup.

The stock shape should be set to

Cylinder.

Enable X Axis

Enter the Diameterand Lengthvalues

of the stock size.

Enable Display stockas Wireframe

and enable Fit Screento the stock.

The Stock Originvalues adjust the

positioning of the stock, ensuring

that you have equal amount of

extra stock around the finish part.

Displayoptions allows you to set

the stock as Wireframeand to fit

the stock to the screen.(Fit

Screen)


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STEP 6: FACE THE FLAT SURFACE AT 165 DEGREES ANGLE.

6.1 About Tool Planes

The tool plane (Tplane) is the plane in which the tool approaches and machines the part. The

Tplane represents the CNC machines coordinate system (XY axis and origin). This is the cutting

plane for a toolpath, typically normal to the tool axis

The Rotary axis for our part is Aaxis. The axis orientation for different views should look as shown

in the following picture.

Compare the planes axis orientation when rotating the part about B axis. (horizontal machining

centers).

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6.2 Create the new view at 165 degrees angle.

Select WCSin the Status Bar.

Select View Manager.

Select Geometrybutton.

[Select a flat entity, 2 lines, or, 3 points]: Select the two lines as shown in the following picture

Select the first line here

Select the second line here

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The axis should be orientated as shown in the following picture. Otherwise select Next View

Select Next View

Select the OKbutton to accept the view.

Enter the Namefor the new view as

shown.

Disable Associativeand Set new origin.

Select the OKbutton to exit.

Change the

parameters to match

the following

screenshot.

Make sure that X, Y, Z

for the Origin are set

to 0and Associative

is disable.

The Work Offset #

should be change to

0(G54 for Fanuc).

We will set only one

work offset at the center

of the cylinder.

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6.3 Set both Cplane and Tplane to the flat at 165 degrees angle.

Click on Set your current tool plane and origin to the selected view button.

Click on Set your current construction plane and origin to the selected view button.

The View Managerwill

look as shown to the right

Select the OKbutton to exit the View Managername.

Set Zto 0.

The grid orientation and origin should look as shown in

the following picture.

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6.3 Face the plane.

Toolpaths

Face toolpath

Select the OKbutton to accept the NC name.

Enable Cplanein the Chainingdialog box.

Select the

chain here

[Select OK to use the defined stock or select chain 1]:Select the

chain as shown

Select the OKbutton to exit Chaining.

Click on the Select library toolbutton.

Select the Filter button in the Tool Selection.

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In the Tool Typesfield select the Nonebutton to disable all tools.

Select the Face mill tool type as shown.

In the Tool Diameterfield click the pulldown arrow and select Equal.

Enter the Tool Diametervalue to 3.0.

Select the OK button to exit Tool List Filter.

Make sure that the tool is selected (highlighted) in the Tool Selectionscreen.

Select the OK button to exit the Tool Selection dialog box.

Make the necessary changes to match the parameters with the screenshot below.

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Select Rotatetab and change the parameters as shown.

Enable Rotationviewand select the arrow button.Select the Right Side View.

Select the OKbutton to exit View Selection

Select the OKbutton to exit Transform Operation

Parameters

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Select Rotatetab and change the parameters as shown.

Make sure that Rotation view is enabled and set to Right Side. Otherwise follow the previous step to select

the Rotation view.

Select the OKbutton to exit Transform Operation Parameters

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STEP 9: DRILL THE 0.375 DIAMETER HOLES.

9.1 Set both Cplane and Tplane.

Note that because of the Y axis orientation (please check page 222) the plane in which the holes are drilled is

not the Back plane.

We will need to define a new plane by rotating the Top plane 90

degrees.

Click on Select all operationsbutton in Toolpaths manager.

Press simultaneous Alt&Tto disable/enable the toolpath display.

Select Planesin the Status Bar.

Select Top plane.


Select Rotate planes.

Enter About X90 degrees.


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Enter the Namefor the new view as

shown.

Disable Set new origin if necessary.




Select the Holes View.

Click on Set your current tool plane and origin to the selected view button.

Click on Set your current construction plane and origin to the selected view button.

Change the Work Offset #to 0

Make sure that Enable origin is not check and x, y, z values for the origin are set to 0 as shown

Select the OKbutton to exit the View Managername.

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9.2 Drilling the hole.

Toolpaths

Drill ToolpathSelect the Entitiesbutton in the Drill Point Selectiondialog box.

Select the arcs as shown in the following picture.

Select these arcs

Select the OKbutton to exit Drill Point Selection.

Click on the Select library tool.

Select the Filter

button in the Tool

Selection.

In the Tool Types

field select the None

button to disable all tools.

Select the Drill tool type as

shown (upper right corner).

In the Tool Diameterfield

click the pulldown arrowand select Equal.

Enter the Tool Diameter

value to 0.375.

Select the OK button to exit

Tool List Filter.

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Enable and select the Tip compbutton.

Make the Breakthrough amount 0

Select the OK button to exit.

The Drill parameters dialog box allows you to establish the height for rapid movement (Clearance)and the

height from where the tool moves with feedrate (Retract); the Top of stock and the final depth (Depth).

Clearance, Retract, Depth and Top of Stock set to Absolute values are relative to the new tool origin.

Select the OK button to exit.

STEP 10: MACHINE THE GROOVE AT THE 120 DEGREES ANGLE.

10.1 Set both Cplane and Tplane.


Select Top plane.


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Select Rotate planes.

Enter About X30 degrees.


Enter the Namefor the new view asshown.

Disable Set new origin.


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Select the Groove at 120 degrees angle view.

Change the Work

Offset #to 0

Make sure that

Enable originis not

check and x, y, z

values for the origin

are set to 0 as shown

above.

Select the OKbutton

to exit the View

Managername.


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10.2 Machine the groove using contour toolpath.

Toolpaths

Contour Toolpath

Select the contour here

Select the contour and the bottom of the groove shape, as shown.

Select the OKbutton to exit Chainingdialog box.

Click on the Select library tool and usingFilter select a0.5 Flat Endmill.

Make the necessary changes to match the parameters with the screenshot below.

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Select the Contour parameterspage and change the settings to match the following screenshot.

Select the Lead in/outbutton to set the parameters that allows to extend the contour start and

end.

Select the OKbutton to exit

Lead In/Out.

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Select the OKbutton twice to exit Contour

parameters.

STEP 11: MACHINE THE SECOND GROOVE USING TRANSFORM ROTATE

TOOLPATH.

Toolpaths

Transform toolpath

Enabled Rotateand the Methodshould be set to Tool planeto be able to create a new tool plane

for the transform toolpath.

Enable Maintain source operationsto keep the same Work offset number.(G54).

Make sure that only the contour operation is selected as shown in the following screenshot.

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Select the Rotatetab and change the parameters as shown.

Make sure that the Rotationviewis enabled and set to the Right Side View.

Select the OKbutton to exit Transform OperationParameters

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STEP 12: BACKPLOT THE TOOLPATH.

Select the Select all operationsbutton.

Select the Backplot selected operationsbutton.

Make sure that you have the following buttons turned on (they will appear pushed down).

Display tool

Display rapid moves

Select the Playbutton.

Display rapid moves

Display tool

Select the OK

button to exit

Backplot.

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VERIFY TOOLPATH VERIFICATION

STEP 13: VERIFY.

Expand the Toolpaths Managerif necessary by dragging the

right side.

Select the Verifyselected operationsbutton.

Select the Configurebutton.

Make the changes as shown.

Initial stock size source should be

set to Job Setup to use the stock

information from Stock Setup.

Use True Solid allows you, after

verifying the part, to rotate and

magnify the part to more closely

check features, surface finish, or

scallops.

Cutter comp in control allows

Verify to use the informationregarding the tool diameter and to

simulate the cutter compensation.

Change tool/color to change the

color of the cut stock to indicated

tool changes in the toolpath.

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Select the OKbutton to exit Verify Options.

Set the Verify speedby moving the slider bar in the speed control bar.

Select the Machinebutton to start simulation.

The finished part should appear as shown in the following picture.

To see the part from a different view select Dynamic Rotationbutton from the

toolbar.

[Pick a point to begin dynamics]: Select the midpoint as shown.

Select this

midpoint

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Slightly move the cursor to the right.

Click the mouse button when done.

To exit Verifyclose select the OK

button.

STEP 14: POST PROCESS THE FILE.

To apply these toolpaths to a vertical machining center with a rotary axis (Aaxis), a customized post processor

for your machine is required.

Make sure that all operations are selected.

Select the Post selected operationsbutton from Toolpath Manager.

In the Post processing window, make all the necessary changes

as shown to the right.

Enable NC fileto keep the NC file assigning the same name as

the MCX file.

Enable Edit to automatically launch the default editor.

Select the OKbutton to continue.

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Select the OKbutton to accept the warnig.(we want only

one work offset G54 for all the views)

Select the Savebutton to accept the same name for the NC file as the geometry name .

Note in line N4 the work offset G54 and the angle A75; line N30 G54 and A90; line N40 G54 and A30.

Select the red Xat the upper right side to exit the Editor.

STEP 15: SAVE THE UPDATED MCX FILE.

Select the Saveicon.


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TUTORIALSERIESFOR

TUTORIAL 9

5 AXIS MULTISURFACE


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The geometry file, Revised Tutorial9_geometry.zip, can be downloaded from

www.emastercam.com/files

The finish part, Revised Tutorial9_finish.zip including the toolpaths, is also provided on the same locationwww.emastercam.com/files

TOOLPATH CREATION

Open

File

Select the Tut9_5axismultisurface.mcx

STEP 1: SET UP THE STOCK TO BE MACHINED.

To display the Toolpaths Managerpress Alt + O.

If a machine definition is already selected see Tutorial # 2 page 24 to learn how to change it. Select Mill

5AXIS TableHead Vertical

Otherwise follow next step.

Machine type

Mill

Select Mill 5AXIS TableHead Vertical

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Select the plus

Select the plus in front of Properties to expand the Toolpaths

Group Properties.

Select Stock setupSelect the Stock setup.

The stock shape should be set to

Rectangular Shape

Enter the Y, X and Zvalues of the stock

size.

Set the StockOriginvalues as shown

The Stock Originvalues adjust

the positioning of the stock,

ensuring that you have equal

amount of extra stock around

the finish part.

Displayoptions allows you to

set the stock as Wireframeandto fit the stock to the screen.(Fit

Screen)

Enable Display stockas Wireframe

and enable Fit Screento the stock.


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Select the Tool Settingstab to set the tool parameters and the part material.

Assign tool numbers

sequentially allows youto

overwrite the tool number from

the library with the next

available tool number. (First

operationtool number 1;

Second operationtool

number 2, etc)

Warn of duplicate tool numbers

allows you to get a warning if

you enter two tools with the

same number.Override defaultswith modal

valuesenables the system to

keep the values that you enter.

Feed Calculationset From tool

uses feed rate, plunge rate,

retract rate and spindle speed

from the tool definition.

Change the parameters to match the following screenshot.

Select the OKbutton to exit Toolpath Group Properties.

STEP 2 5 AXIS MULTISURFACE ROUGHING THE PART.

5 Axis Multisurface generates a 5 axis surface toolpath over a series of surfaces or solids that allows

precise control of the scallop height or constant distance stepovers to create a smooth finish.

Toolpaths

Multiaxis

5 Axis Multisurface Toolpath

Select the OKbutton to accept the NC name.

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The Output Formatis 5 Axis.

Cut Patternalows you to establish thesurfaces for general cutting area.

Tool Axis Controlallows you to establish

the method to control the tool axis

orientation. Tool axis controlto the Chain

will keep the tool axis oriented to the

selected chain.

Cut Surfacesare surfaces to project the

tool position to, to compensate the tool

axis vector for gouge protection.

Check Surfacesare surfaces to be avoided

during machining.

Change the parameters for Msurf 5axisas shown in the following screenshot.

Select this surface

Select Surface(s)button as shown in the

previous screenshot.

Hit Enterkey to end the selection.

Select Chainbutton.

Select the line here

[Select tool vector chain]: Select the line as shown.


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Select the OKbutton to exit from Chainingdialog box.

Enable Entire chain per surface in theChain Option dialog box to allow

the tool axis direction to gradually transition along the selected chain

one time for the entire surface.

Select the OKbutton to exit from Chain Optionsdialog box.

Select Comp ToSurfacesbutton as shown in the previous

screenshot.

Click on the select button in the Toolpath/surface selection.

[Select Comp Surfaces]: Click on Select All

button.

Enable Colorand select color magenta no.13 as shown to the right.

The top surfaces should be selected as shown below.

Select the OKbutton to exit Select All.


Select the OKbutton twice to exit Msurf 5axisdialog box.

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Click on Select library toolbutton and using Filterselect 3/8 Ball Endmill.

Make all the necessary changes as shown in the following screenshots.


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Select Depth cutsbutton and change the

parameters as shown.

Select the OKbutton to exit Multiaxis Depth

Cuts.

Select Entry/Exitbutton and change the parameters as shown.

Select the OKbutton to exit Entry/Exit.

Select Msurf5ax Parameterspage and change the parameters as shown.

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Select Flow parametersbutton.

If the flowlines look as shown below, across the magenta surfaces, than click on Cut Directionin the

Flowline data dialog box.

The cut direction should be along the magenta surfaces as shown below.

Select the OKbutton to exit Flowline data

dialog box.

Select the OKbutton to exitMultisurface 5 axis

parameters.

Enter Alt +Tto toggle the toolpath display off.

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STEP 3: 5 AXIS MULTISURFACE FINISH THE PART USING AXIS LIMITS.

Toolpaths

Multiaxis5 Axis Multisurface Toolpath

Click on Cut Pattern

Surface(s) button.

[Select Tool Pattern Surfaces]: Click on Select All button.

Enable Colorand select color magenta no.13 as shown to the right.

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The top surfaces should be selected as shown below.

Select the OKbutton to exit Select

All.


Select Check Surfacesbutton as shown.

Click on Selectbutton.

[Select Check Surfaces]: Select the two flat surfaces at the top as shown below.


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Select the OKbutton twice to exit Msurf 5axisdialog box.

Click on Select library toolbutton and using Filterselect 1/4 Ball Endmill.

Make all the necessary changes as shown in the following screenshots.

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Select Msurf5ax Parameterspage and change the parameters as shown.

Select Axis Limits and enable Z Axisand change the angles as shown.

Select the OKbutton to exit

Multisurface 5 axis

parameters.

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STEP 4: BACKPLOT THE 5 AXIS MULTISURFACE TOOLPATHS.

Click on the Toolpath Group 1in the Toolpaths Manager to select all

operations

Select Backplotselected operationsbutton.

Display tool

Make sure that you have only the following button turn on (they

will appear pushed down).

Display tool

Select the Optionsbutton.

Enable Simulate Axis Substitutionand disable Simulate Rotary Axis.

DisableConnect Top andShade.

Select the OKbutton to exit Backplot Options.

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Select Playbutton.

Select the OK button to exit Backplot.

Change the graphic view to Frontand check the second operation only.

Select Step forward button to check it step by step.The toolpath should look as shown below.

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STEP 5: VERIFY

To be able to use Verify function Use True solid for 4/5axis toolpaths you have to have the 5axis Verify

option. This option is not included in Mastercam and must be purchased separately. For moreinformation please contact your Mastercam dealer.

Select Verifyselected operationsbutton.

Change the graphic view to Isometric.

Set the Verify speedby moving the slider bar in the speed control bar.

Select Fast forwardbutton to start simulation.

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SAMPLE-X3 4-5 Axis Training Tutorial