CAM - Training (CNC Simulator)

TSC - CAM
Training Menu
Computer Logon Information User Name: tsc Password: hku
The menu is used for this workshop only. Please return this menu on each day you leave. You can download the menu from:
http://www.hku.hk/tscofhku/download/index.html
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Workshop Training
Workshop Training is a compulsory course for engineering students. The Workshop Training Programs are developed in collaboration with the engineering departments concerned. The Training Timetable is available. Students can change the personal training timeslot as far as facilities allow. One hundred percent (100%) attendance is required in order to satisfy the training requirements. Application for leave of absence will not be approved except on very strong and justifiable grounds. Make-up training is required in all cases. Students working in the workshop shall wear proper safety attire according to the instructions given by the Instructors concerned. Assessment is based on (1) The behavior and performance in the workshop; (2) The quality of work produced; and (3) Training log book. The deadline for submitting the Training Log Book is on Friday in the week of the first semester in the following academic year. Students are strongly recommended to read the Guidelines on Workshop Training.
Contact: Dr. T. Y. Lee Mr. K. W. Wong Link: http://www.hku.hk/tscofhku/training/Year1.htm
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THE UNIVERSITY OF HONG KONG Technology Support Centre

Training Module: CAD / CAM Code: CAM
Content
No. A B C D E Mcam 1 Mcam 2 Mcam 3 Mcam 4 Mcam 5 Mcam 6 Mcam 7 Mcam 8 Mcam 9 Mcam 10 Mcam 11 Mcam 12 Mcam 13 Mcam 14 F G H I J K Project 1 Project 2 Project 3 Project 4 Project 5 Project 6 Project 7 Project 8 Project 9 Project 10 Description Introduction to the modular Workshop schedule Summary MicroTech CNC simulator Mastercam version 8 : Introduction Basic CAD Modify Chain Xform Creating 2D Part Machining Parameters and Verification Creating 2D Contour Toolpath Creating 2D Pocket Toolpath Engraving Details 3D Wireframe Design Surface model Curve Surface Toolpath Cadem seeNC mill Cadem seeNC turn HKPC 3D-Mill CNC machine Dophen CNC wirecut machine Dophen CNC Electric Discharge Machine Projects : CNC program concept study 2D NC program edit and operate 3D-Mill CNC machine 2D drawing 2D NC program for wirecut and operate CNC wirecut machine 2D milling program 3D drawing Surface modeling Surface machining CNC program for lathe turning process CNC Electric Discharge Machine (EDM) Page 3 4 5 8 -12 16 18 20 21 22 24 27 35 39 41 45 64 65 73 77 80 81 85 -88 89 91 93 94 97 99 103 105 108
Prepared by: Y. C. Tam
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No.
Description
Page
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A.
Aim:
Introduction to the module

Mastercam is provided in the training, which is an integrated CAD/Cam software package that creates 2D and 3D geometry, prepares engineering details, finished blueprints, graphical toolpaths and NC program for supporting design work and milling, lathes, wire EDM, etc. machining processes.
Equipment: A. CNC machines

a. b. c. a. b. c. HKPC 3D-Mill CNC Machine Dophen CNC EDM Dophen CNC Wire Cut Machine
B. Software
Mastercam version 8.0 MicroTech ISO introduction MicroTech CNC simulator d. Cadem CNC mill / lathe simulator
Project:
This module consists of several projects. Students may be assigned to work as team (2 or 3 members) to run their programs on CNC machines making prototypes, and simulates programs on computer.
Objective:
A. Understanding the construction of NC program and the functions of G, M codes. B. Writing NC programs to operate CNC machines (Electrical Discharge Machine, Wire Cut Machine and Milling Machine) for machining desired part geometry. C. Using Mastercam software to draw components and prepare NC programs for machining
Timetable:
Day Time 9:00am to 10:30am 10:30am to 11:00am 11:00am to 1:00pm 1:00pm to 2:00pm 2:00pm to 5:00pm 9:00am to 1:00pm 1:00pm to 5:00pm Event Workshop Break Workshop Lunch Workshop Workshop Logbook (Library)
Mon to Thu
Fri
Logbook:
The procedure of making and / or testing parts and the final product should be recorded in the Logbook. In addition, each project may consist of specific areas that the student is required to address in the Logbook. The Logbook should be completed as and when the training is progress. Legible handwriting and freehand sketching will be sufficient for assessment.
Reference:
a) http://www.mastercam.com b) http://www.cncsimulator.com c) http://www.cadem.com
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B.
Day
Workshop schedule:
Workshop Introduction CNC program concept study Activities Movie a) IsoIntro software b) CNC program concept .pdf c) CAM Training Menu a) CncSimulator software for program editing and verification b) Work on CNC machine to make prototype Using Mastercam v.8 to create drawings a) Create product geometry on Mastercam b) Operate Dophen CNC Wire Cut Machine to make prototype a) Mastercam b) Operate HKPC CNC Engraving Machine to make prototype c) Verify on Cadem seeNC mill simulator Mastercam Mastercam Mastercam a) Mastercam b) Verify on Cadem seeNC mill simulator Edit and verify on Cadem seeNC lathe simulator Dophen CNC EDM Library Time 0.5 hr 1 hr
2D NC program edit for milling process 2D drawing 2D NC program for wirecut
2.5 hr 3 hr 3 hr
2D milling program
4 hr 3 hr 4 hr 1.5 hr 5.5 hr 3 hr 1 hr
3 4
3D drawing Surface modeling Surface modeling (cont.) Surface machining CNC program for lathe turning process EDM process Logbook
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C.
1
Summary
Introduction:
Numerical Control (NC) is the operation of a machine tool by a series of coded instructions consisting of numbers, letters of the alphabet, and symbols, which the machine control unit can understand. These instructions are converted into electrical pules of current which the machines motors and controls follow to carry out machining operations on a workpiece. The numbers, letters and symbols are coded instructions which refer to specific distance, positions, functions, or motions which the machine tool can understand as it machines the workpiece. At first, NC program was manually prepared; however, it soon became apparent that manual programming was too slow and cumbersome for complex part geometry. Today, NC programming is assisted by computer-aided design (CAD) and computer-aided machining (CAM), where the geometry can be drawn on CAD software and translated into NC programs on CAM software. As a result, CAD / CAM software can make this task easier. MasterCAM is provided in the training, which is an integrated CAD/CAM software package that creates 2D and 3D geometry, prepares engineering details, finished blueprints, graphical toolpaths and NC program for supporting design work and 2 through 5-axis milling, lathes, 2 and 4-axis wire EDM, ... ... etc. machining processes.
Useful NC codes: 2.1 The most commonly used words in a program are called G-codes and M-codes. They use the
addresses G and M respectively. G-codes: Preparatory functions, which involve tool motions like rapid motions, feed motions, circular motions, dwells and canned cycle codes. M-codes: Miscellaneous functions, which involve machine actions, like spindle on and off, tool change, coolant on off, program stops. 2.2 Addresses used in a program Words Description Block number - specifies the star of the block N Preparatory functions G Miscellaneous functions M X-axis co-ordinate X Z-axis co-ordinate Z X-axis location of arc center I Z-axis location of arc center K Radius of arc center R Spindle speed or Cutting speed S Feed rate F Tool to be used T 2.3 Examples of block formats
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2.4 List codes:

Code G00 G01 G02 G03 G20 G21 G40 G41 G42 G54 G55 G56 G57 G58 G59
G90 G91 M02 M03 M04 M05 M06 M08 M09 M30
Description Positioning rapid traverse Linear interpolation (feed) Circular interpolation CW Circular interpolation CCW Inch unit Metric unit Tool nose radius compensation cancel Tool nose radius compensation left Tool nose radius compensation right Work co-ordinate system 1 selection for workpiece zero point position register Work co-ordinate system 2 selection for workpiece zero point position register Work co-ordinate system 3 selection for workpiece zero point position register Work co-ordinate system 4 selection for workpiece zero point position register Work co-ordinate system 5 selection for workpiece zero point position register Work co-ordinate system 6 selection for workpiece zero point position register Absolute command Incremental command
Program end Spindle ON clock wise (CW) Spindle ON counter clock wise (CCW) Spindle stop Tool change Flood coolant ON (coolant 2 ON) Coolant OFF End of program, Reset to start
Construction of a simple NC program

Step 1st 2nd 3rd 4th Description Specify a selected work coordinate system (Usually, CNC machines include six coordinate systems from G54 to G59.) for multiple workpieces machining Input the programming system: Incremental (G91) or Absolute (G90), which is selected. Specify machining method, moving coordinate and moving feed rate. (G00, G01, G02 or G03 + X, Y, Z, + F) At the end of NC program that must be specified a control functional code to stop the machine. (M02)
Example: go to (100, 100) and then drill a hole to 15mm depth G54 The first zero point position register G90 Absolute coordinate value G00 X100. Y100. Go to starting point G00 Z30 Down to repaid depth G01 Z-15. F100 (Where the F code specifies feed rate and default unit is mm / min of the tool for machining.) drilling G00 Z30 Return to repaid depth M02 Program stop Prepared by: Y. C. Tam Page: 6 of 108 Rev: 06 Date: 2006-12-18

Electrical Discharge Machining (EDM)
EDM is a process that is used to remove metal through the action of an electrical discharge of low voltage and high current density between the cutting tool (Electrode) and workpiece. EDM has proved especially valuable in the machining of supper-tough, -hard, -brittle conductive materials that would be difficult to machine by conventional cutting methods. EDM process is widely used for plastic mould making and die making in Hong Kong Industry. EDM is a controlled metal removal process whereby an electric spark is used to cut the workpiece, which then takes the shape opposite to that of the electrode. The electrode and workpiece are both submerged in a dielectric fluid, which is a light lubricating oil and non-conductivity. A servomechanism maintains a gap about 0.01 to 0.5mm between electrode and workpiece, preventing them from coming into contact with each other. The electrical discharges are the result of controlled pulse of direct current and occur between the tool electrode (usually negative) and the workpiece (positive). The functions of dielectric fluid 1. It acts as a coolant for reducing heat caused by the spark. 2. Flushing particles out of the spark gap to prevent shorting. 3. It serves as an insulator between electrode and workpiece.
Wire Cut EDM Machine
The Wire Cut machining is also an electrical discharge machining process, which uses NC programs (e.g. using G01, G02, G03 ... ... etc. G codes for machining) to make the desired contour or shape on workpiece. It does not require a special-shaped electrode; instead, it uses a continuous traveling wire (from 0.05 to 0.3mm) under tension as the electrode. The path that wire follows is controlled along a two-axis (X, Y) contour, cutting a narrow slot through the workpiece. A dielectric fluid flushing system is applied on the machine to carry out removal particles and reduce the heat caused by the spark. Wire Cut machines are equipped with a servo-mechanism that automatically maintains a constant spark gap of 0.005 to 0.05mm.
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D.
1.
MicroTech CNC simulator

Screen Layout:
Click this icon to open the program (default is milling process screen, you can select lathe turning process from Screen menu and select Help menu for more details.)
Menu & Toolbar 2D/3D solid
Text editor
3D wire-frame Plot
Status window
The CncSimulator is used to simulate CNC code for mills and lathes. On startup you will use the program window divided in several panes. These are: a. Simulation panes, these show the tool movements in 2D, 3D and block graphics. b. Status pane, this pane shows the current tool, tool position, rotation etc. c. Editor pane, (blue background) In this pane, you edit the CNC code and it also shows the current CNC block during simulation. There is also a full screen mode where one of the three simulation windows is maximized to cover the entire screen. (Press ESC return to normal screen)
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2.
Open existing file to startup demonstration: ///file: \Program File \MicroTech \CncSimulator \ncfiles \demo.nc
a. b. c. d. e.
Switch on the Simulation box. To run the file. Step by step to run the file. Stop the simulation. Slowdown the speed.
3.
Example: to demonstrate the Edit Tools, Details Settings and Zero Point Register for simulation. Edit Tools: Milling mode: Here you can fill in the tool number, diameter, length, feed data, spindle and the name of each tool. Turning mode: Here you can see the contour of the tool. You can fill in the name, cutting data and tool number of each tool. Details Settings: This is used to set the size of the work piece as well as the color scale if the CncSimulator is in the milling mode. By clicking the milling depth button you can decide which colors represent different depths. Zero Point Register: Here you can edit the zero points that are called by G54-G59
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Settings: a. Size of the Workpiece is 250 x 150 x 6 mm b. Set the first zero point (G54) on the middle top of the above workpiece c. Set the rapid depth is z=10.mm, the machining depth is z=-1.mm, and the cutting tool is 2mm diameter stopped at the upper right Conner of the machine.
Program zero point register position
Program details:
N1 G54 N2 G90 N3 G00 X0 Y60. N4 G00 Z10. N5 G01 Z-1. F300 N6 G01 X75. F500 N7 G02 X100. Y35. I0 J-25. F500 N8 G01 Y-35. F500 N9 G02 X75. Y-60. I-25. J0 F500 N10 G01 X-75. F500 N11 G02 X-100. Y-35. I0 J25. F500 N12 G01 Y35. F500 N13 G02 X-75. Y60. I25. J0 F500 N14 G01 X0 F500 N15 G00 Z10. (Set to the first coordinate system) (Use the absolute coordinate system) (Go to the starting point) (Down to the rapid depth) (Down to the machining depth at 1mm) (Start machining) (Close the contour) (Go to the rapid depth)
N16 M02
(Program stop)
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c d
a. b. c. d.
Copy (c:\CAM\demo\CNCsimEG.nc) the program into the text editor Modify the first tool to 2mm diameter of Tool Number 1 Input the size of the workpiece (X=250, Y=150, Z=6) Offset the X / Y distance to register the zero point on the middle top position
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Mcam 1: Introduction
It is a powerful CAD/CAM application that lets you design parts and choose from 2- to 5-axis milling, turning wire EDM. Leasers, mold base development, surface, and solid modeling.
Click the icon to open
A. Setup Mastercam A.1. Configure system environment a. System Configuration (Select from: Main Menu > Screen > Configure, or press Alt+F8)
To configure screen, allocations, CAD and NC settings, etc. It is stored in a configuration file (.CFG). You can create many CFG files and just load the one you need for a particular type of job or customer. Tool Manager (Select from: Main Menu > NC utils > Def. tools > Library) Mastercam includes several libraries of standard tool definitions to get you started.
b.
A.2. A.3. A.4. A.5. A.6. A.7.
Design and draft your part

To use Mastercam to create drawing or convert other format.
Machining setup
Define stock size, and select material. Select a suitable processor for your CNC machine.
Create toolpath Simulation

Backplot toolpath (preview the tool motion (wire frame mode)) Verification (preview stock to removal (solid mode))
Select suitable command for your parts. (E.g. Drill, Contour, Pocket, Surface, etc.)
Run Post Processor to create NC file Transmit the NC file to CNC machine to make your parts.
B.
Mastercam Interface Main Menu: Provides CAD / CAM

commands and file management. Menu Operation Buttons: Changes existing main contents. Secondary Menu: Modifies CAD environment. Prompt Area: Displays drawing properties.
Toolbar icon / Function Keys:

Quickly open commands and change environment. User right-click menu: It is to extensively to highlight useful commands and functions. If you are unsure about what to do, right-click to see a list of relevant functions.
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C. Identifying Construction Plane (Cplane) & Graphics View (Gview) Click the Cplane or Gview button or icons to create custom views or planes based on part geometry.
There are 8 standard Gviews and Cplanes, identified by number: 1 = Top 5 = Right Side 2 = Front 6 = Left Side 3 = Back 7 = Isometric 4 = Bottom 8 = Axonometric Press Alt + w to configure 2 or more viewport on a screen.
D.
Measuring Arcs and Angles
For all angle, 3 oclock = zero degree Measure Positive angles counter-wise, Negative angles clockwise. All angles use degrees, not radians.
E.
Main menu:
To gives you options for viewing data about entities and, in some cases, editing the data. When the construction plane is set to 3D, Mastercam calculates data using absolute, or world, coordinates relative to the system origin (0,0,0). In any other Analyze (F4) construction mode, the system calculates data using coordinates relative to the current Cplane. These functions let you create basic Mastercam entity types: points, lines, arcs, Create (F8) splines, surfaces, drafting entities, etc. File management for drawing and NC files, and convert drawing to/from other format. Choose Next menu to access a second menu that lets you see file properties, open a DOS window (shell) within Mastercam, recover RAM memory, print files, File (F6) set up communications with other devices, and renumber NC files. The Mastercam Exit function (Alt+F4) is also located on this menu. To gives you options for modifying entities: Fillet, Trim, Break, Join, Extend, Modify (F7) etc. To gives you options for moving entities and optionally creating copies of them by mirroring, rotating, scaling, offsetting, translating, stretching, and rolling them. With some functions, you have the option to join the copied entities to the Xform originals. When you perform a transform function, Mastercam creates a temporary group from the original entities and a result from the transformed entities. To gives you options for deleting entities and restoring deleted entities. There are Delete (F5) undelete-function up to 256 entities being restored. To lets you specify default system settings and manage the display of geometry in Screen the graphics window. To let create solid geometry (not provided in these module) Solids To shows where a tool removes material from a part. Mastercam Mill has several Toolpaths (Alt+O) types of toolpaths that you can create on wireframe, surface, and solid geometry. To provides functions that help you prepare for machining and manage workflow. NC utils
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F.
Functions Keys
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G. Point Entry Menu:

Throughout your work in Mastercam the system prompts you to enter points in everywhere (Create, Modify, Analyze, etc). By entering points you define positions in 3D space. You can enter points using one of two methods: Mastercam's AutoCursor feature or the Point Entry menu. When you enter a point, Mastercam projects the selected position onto the current construction plane. If the current Cplane is set to 3D, Mastercam uses the actual position of the selected point. The AutoCursor that can auto select Center, Endpoint, Intersection and Midpoint of relative entity. If you want to switch off this function, you can right click on drawing screen to unselect this function. Heres the tricky part. To keep the menu simple, one commonly used method of entry data, Enter Coordinates, is not listed. To enter Cartesian Coordinates, simply type them on the computer keyboard. (E.g. X1Y1 or 1,1) Origin is the system zero coordinate (0, 0, 0)
Tips for inputting coordinate data:

May enter either fractions or decimal values. (eg. 0.375 or 3/8) To enter a fraction with a whole number, use the + sign. (eg. X1.375, Y1.5 that you can input as: 1+3/8, 1+1/2) Positive numbers are implied. You do not have to include the (+) sign. (eg. 1.5 not +1.5) Negative numbers require the (-) sign, and it must come after the axis label if an axis label is used.. (eg. Y-1.5 not Y1.5) The prompt line accepts math equations and nested parenthesis (( )). This saves having to use a calculator. (eg. ((5+0.25) (3/8)), (3*2.25) that is X5 Y6.75)
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Mcam 2: Basic CAD

1 Create Horizontal / Vertical Line 1.1 Create a horizontal line cross the Y50 coordinate
Select /Main Menu /Create /Line /Horizontal Select Sketch method to specify 2 points on drawing screen (note: the line length is equal the distance between the 2 sketched positions) Enter the coordinate at Prompt Area
1.2 Sketch a vertical line, which top endpoint cross the right endpoint of above horizontal line
Select /Main Menu /Create /Line /Vertical Use the AutoCursor function to specify the 1st endpoint, move the cursor near the right endpoint of above horizontal line (note: the 1st endpoint has defined the X/Y coordinates to draw Vertical/Horizontal line at desired position) Use sketch method to specify the 2nd endpoint at Y direction Press Enter to accept the default X coordinate that is defined by the 1st endpoint.
Note:
There will display messages on the bottom of Prompt Area or top of menu bar to request what information is being input. So you must follow these requirements then you can create entities successfully. 2 Create Arc and circle 2.1 The Arc is 50mm radius, angle from 600 to 1350, and center on (0, 0)
Select /Main Menu /Create /Arc /Polar /Center pt Select Origin from Point Entry menu, or input 0, 0at Prompt Area Enter the radius, 50, at Prompt Area Enter the initial angle, 60, at Prompt Area Enter the final angle, 135, at Prompt Area Note: If you want to create a circle by this method, you can input the angle from 0 to 360
2.2 Create a circle of 100mm diameter on (18, 28)

Select /Main Menu /Create /Arc /Circ pt + rad Enter the radius and specify the center position Or Select /Main Menu /Create /Arc /Circ pt + dia - Enter the diameter and specify the center position
Try these function keys: F1, Alt+F1, F2, Alt+F2, F3, F4, F5, F6, F7, F8, F9, ESC, Alt+A, Alt+U and Alt+H Note: If you have applied more function keys, a warning message box will display. You should press ESC or mouse click BACKUP / Main Menu for initialize.
Creating tangent line, 450 at above circle and 100mm length

3.1 Choose Main Menu, Create, Line, Tangent, Angle. 3.2 Select an arc or spline. Note: Select the entity close to where you want to create the tangent line because multiple solutions may be possible.
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3.3 In the prompt area, enter the angle of the line. 3.4 Enter the length of the line. 3.5 Select the line to keep. Note: The line may be created on an extended portion of the selected entity that means one is started from the tangent point to upper, another one to lower. 3.6 Repeat steps 2 through 5 to create additional tangent lines. 3.7 Press [Esc] to exit the function.
Creating rectangular of 100 x 60, center at (-30, -80)

4.1 4.2 4.3 4.4 4.5 4.6 Choose Main Menu, Create, Rectangle. Choose Options. Select a rectangular shape from the list. Set the remaining parameters, then choose OK. Choose 1 point. Set parameters on the Rectangle One Point dialog box, and then choose OK. Note: Be sure to select the square that represents the placement point to use on the rectangular shape. 4.7 Enter a point to position the rectangular shape in the graphics window. 4.8 If prompted, enter the angle increment. 4.9 Note: The angle increment is used to calculate the number of lines contained in the ellipse shape. A smaller value results in a smoother shape. 4.10 Repeat steps 7 and 8 to create the shape in additional positions in the graphics window. 4.11 Press [Esc] to exit the function.
Create a polygon (3 sides or more)

You can create a polygon as a NURBS spline or as a collection of individual linked lines. 5.1 Choose Main Menu, Create, Next menu, Polygon. 5.2 Set parameters on the Polygon menu, then choose Do it. 5.3 Enter a point for the center of the polygon. 5.4 Repeat step 3 to create additional polygons using the current values. 5.5 Press [Esc] then repeat steps 2 and 3 to create polygons using different values, or press [Esc] twice to exit the function.
Creating a spline using manual point entry

Choose Main Menu, Create, Spline. Set the Type and Ends parameters on the Spline menu. Choose Manual from the Spline menu. Enter points (use Sketch method to create a sine curve) for the spline to pass through, then press [Esc]. 6.5 If prompted, define the end condition of the splines endpoints. 6.6 Repeat steps 3 and 4 to create additional splines. 6.7 Press [Esc] to exit the function. Note: The resulting spline passes through the points you enter in step 3 in the order in which you enter them. You can create a closed spline by entering the same point for the first and last points in step 4. 6.1 6.2 6.3 6.4
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Mcam 3: Modify
Trim is one of the most commonly used Modify commands. As the name implies, it is used to trim, or cut back one, two, or more entities to a specified intersection point. It is also used to extend geometry in a similar way. Using Trim is easy. First pick the type of trim operation needed, and then select the geometry. Where the entities are picked, and the order they are picked, determines how the trim operation works. Always select the part of the geometry to keep, not the part to discard The following diagrams and instructions show how to use Trim. Numbers indicate where and which order to pick entities, and the icon for that trim function is shown to the right.
1 Entity trims one entity to another. The first entity picked is the one that will be trimmed. The side of the entity picked is saved, the other side is discarded.
2 Entities trims two entities to each other. Dont pick right on the intersection itself. Pick on each entity far enough away from the intersection so it is clear which entity is selected
3 Entities trims an entity back to two others. This is especially useful for breaking an arc as shown.
To Point trims an entity back to a point selected on the Point Entry menu. This is a very useful function. Make sure to understand how it works.
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Many trims many entities back to another. Select Done after picking the entities to trim, and then indicate with the mouse which side to keep. Pick the lines one at a time, or use Window or other methods to select all at once. The Window command is covered later in this chapter. Close arc turns a partial arc into a full circle. The arc is closed by trimming it in a clockwise direction. The endpoint of the new arc is not at the 3:00 position, but at the counterclockwise start point, as shown by the circle (o) on the diagram.
Divide cuts away a section of an entity between two other entities. This is a very useful function that saves having to break the entity before trimming. However, this does not work well on arcs. For arcs, use the 3 Entities function instead.
Fillet is the other commonly used modify command, which is similar to Trim 2 entities. When you fillet curves, you create an arc of a defined radius tangent to the curves. By default, Mastercam trims the curves to the fillet, although you have the option to turn off trimming. You can select this command from Modify menu, or Create menu
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Mcam 4: Chain
Mastercam displays the Chaining Methods menu whenever chaining is required to complete a function. The method is available on any selection submenu to help you faster selected entities. Chaining methods divide into two groups: methods for creating a single chain at a time and methods for creating multiple chains all at once. The single chain methods provide more control in setting the start and endpoints of chains, chaining order, and chaining direction. The multiple chain methods require less effort but provide less control.
Move the cursor to select an endpoint for open contour, or any one side for close contour. There will appear an arrow and move very fast around the contour. When the arrow has stopped that means selection process is completed.
So what happens if the arrow wont go al the way around a chained profile? This is almost always the result of one of the following: Small Breaks in Profile Duplicate Entities Overlapping Entities Here is how to find and fix these problems Small Breaks in Profile: There is a difference between close and closed. Even though two entities may look connected, they may be separated by a small, even microscopic break, perhaps 0.001 mm or less. To find these, start zooming up on the areas where the reb arrow stopped. As you zoom, any gap will become visible. Another excellent troubleshooting tool is the Screen, Endpoints function. This places small white point at the end of each entity. This helps spot small gaps, since two marks will appear close together at the gap. Gaps can normally be avoided by using the AutoCursor when drawing, and exercising cares to make a completely watertight drawing to begin with. Duplicate Entities are what the name implies: two identical entities where there should be only one. Chain sees these like a branch point and stops. Getting rid of duplicate entities is easy. Just select Delete, Duplicate, Entities. This only works if the entities are true duplicates. It wont work on overlapping entities. It usually wont work on splines from CAD data either. Why? These splines normally are placed on the edges of adjacent surface. Though the splines share the same shape, their underlying definition (node points, etc) re different, so they are not true duplicate entities.
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Mcam 5: Xform
The Xform menu gives you options for moving entities and optionally creating copies of them by mirroring, rotating, scaling, offsetting, translating, stretching, and rolling them. With some functions, you have the option to join the copied entities to the originals. When you perform a transform function, Mastercam creates a temporary group from the original entities and a result from the transformed entities. After you have completed entities selection procedure, an optional dialog box of which you selected Xform command will appear. For example: The options on the Translate dialog box set the type of operation to perform, the number of times to perform the transformation, and the attributes of the transformed entities. Move transforms the selected entities to a new position in the graphics window. Copy transforms a copy of the selected entities to a new position in the graphics window and maintains the position of the original entities. Join transforms a copy of the selected entities to a new position in the graphics window and maintains the position of the original entities. Mastercam creates lines or arcs to connect the endpoints of the original entities to the endpoints of the transformed entities. Number of steps determines how many times Mastercam performs the transform function. Entering a value greater than 1, results in multiple copies of the original entities. Example of Translate: a) Select Main Menu /Create /Rectangle /1 point b) Input Width = 100, Height = 60, and select Point Placement at center position c) Select Origin from point entry menu Now there is a rectangle center at (0, 0) d) Select Main Menu /Xform /Translate /Chain /mouse select the contour /Done /Done e) Select Between pts f) Origin for 1st point, (100, 100) for 2nd point g) Select Move operation, Number of steps = 1 h) Press Alt+F1, then press F2 Now, the rectangle is moved to (100, 100) i) Select Main Menu /Xform /Translate /Chain /mouse select the new contour /Done /Done j) Select Polar k) Enter the translate distance: 100 l) Enter the translate angle: 450 m) Select Copy operation, Number of steps = 10 n) Press Alt+F1, then press F2 How many contours are there, now? o) Press F5, then select Result, yes How many contours are there, now? p) Press Alt+F1, then press F2 q) Select Main Menu /Xform /Translate /Chain /mouse select the contour /Done /Done r) Select Rectang s) Enter the translate vector: X100 Y100 t) Select Join operation, Number of steps = 1 u) Press Alt+F1, then press F2
Compare the difference between Translate and Offset command.

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Mcam 6: Creating 2D Part

Create the arm shape dimension as shown below. The system origin is placed at the hinge center.
Create 2 arc of 8mm radius at (0, 0) and (50, 0) a) Select Main Menu /Create /Arc /Circ pt + rad /Enter the radius is 8 /center at origin b) Select Main Menu /Create /Arc /Polar /Center pt /center at origin c) Enter the radius is 8 /initial angle is 210 /final angle is 150 d) Press Alt+F1, then press F2 and F9
Create a line tangent 50 at left arc, and then Mirror copy along X-axis e) Main Menu /Create /Line /Tangent /Angle /mouse click about the tangential position f) Input angle is 50 , the length is 50, then mouse to select which line to keep g) Main Menu /Xform /Mirror /mouse click the Line /Done /X axis /select copy operation
Create fillet at the neck position h) Main Menu /Modify /Fillet /Radius /Input radius is 4 /mouse click to select entities
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Rotate the arm to 1050 about the origin i) Main Menu /Xform /Rotate /Chain /Done /Done /Origin /select Copy, 1050 j) Press Alt+F1, then press F2 and F9
Fillet and trim entities about the hinge
Save the drawing file Select Main Menu /File /Save
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Mcam7:
Machining Parameters and Verification

Ball /Spherical Endmill Ballnose /Bull Endmill Drill
Type of milling cutters:

Flat Endmill
Spacing Cuts (or, called stepover): moving over the cutter

along X or Y direction for next step metal removal. Value of Spacing 75% of used cutter diameter For example, cutter diameter is 6mm, then the max. Spacing is 4.5mm
Depth Cut: step down the cutter along Z direction

Depth per cut 50% of used cutter diameter For example, cutter diameter is 6mm, then the max. Spacing is 3mm
Note:
The above value is for your reference. Actually, the calculation of accuracy metal removal rate that you should consider with the physical properties of the cutter and machined material.
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Roughing and Finishing cuts:

Roughing for faster and heavy metal cutting. Finishing for fine and accurate metal removal. You should remain allowance at Rough process for next Finishing cut.
Setting job parameters:

Setting parameters for your job can include setting the stock boundaries, configuring your NCI and NC files, and entering tool offsets. You can access the Job Setup dialog box by choosing Toolpaths, Job setup from this menu, through the right-click menus on the Tool parameters dialog box or the Operations Manager, or by pressing [Alt+J]. Define the stock size that can help you for accurate calculation how many metal required to be removed.
Operations Manager
The Operations Manager is a central location where you can manage all the elements of the current job. An operation consists of all the information needed to cut a particular toolpath. The right figure shows you how a number operation appears in the Operation Manager Each operation has a name that describes the kind of machining action it includes, such as Contour and Pocket. A single part can have many operations; they are grouped in Toolpath Groups. You can select from Main Menu /Toolpaths /Operations. Or press [Alt+O] to access.
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Using toolpath verification

The Verify product uses solid models to simulate the material removal process. The stock shape is updated as the tool moves along the toolpath and produces the final part. The resulting model can be inspected, ensuring that programming errors are eliminated before they reach the shop floor. If you have an MC8 file displayed in the graphics window, the system verifies the current MC8 file. If you do not have an MC8 file displayed in the graphics window, the system prompts you to select an NCI file to verify. To access this function, choose the Verify button from the Operations Manager or choose the Verify option from the NC Utilities menu
Backplotting a toolpath
Backplot displays the NCI file and lets you catch any errors in the program before you machine the part. The path displays in the current graphics view (Gview). When backplotting finishes, the approximate machining time displays in the prompt area at the bottom of the screen. You can access the backplot function by choosing the Backplot button on the Operations Manager or by choosing Backplot from the NC Utilities menu.
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Mcam 8
Creating 2D Contour Toolpath
This chapter shows you the basic steps for creating a contour toolpath. A toolpath shows how material is removed along a cutter path. A contour toolpath removes material along a cutter path defined by a curve or chain of curves. The toolpath you will create is for the part you created in Mcam 6 (or download 2D.mc8 from server, or get from C:\CAM\demo\2D.mc8). You will use: Job setup: select from Toolpath menu, Operation Manager, or press [Alt+J] Toolpaths Menu: Contour, or Operations, or the function keys of Alt+O. Chaining method that decides the toolpath direction. Tool library and Contour parameters Backplot or Verify toolpath Run post processor to generate NC program a) Draw the outer rectangle to make it easy Job b) Press [Alt+J] to open Job Setup dialog box. Choosing [Select corners] to select the outer corners, it defines Setup defines. The lower is (-21, -8) and the upper is (58, 57) the X, Y and Stock Origin. Finally, input the Z is 40.
Open the Operation Manager: select Operations from toolpath menu or press Alt+O. d) Right click on Toolpath Group, then Select [Contour] Note: We will use a cutter of 12mm diameter flat end mill to cut the contour at 30mm depth
c)
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e)
Use Chain to define the contour toolpath and click DONE to accept the chaining contour. Auxiliary functions: use Reverse, Move forward / backward to change the chaining direction, change starting point, or check that The chaining direction is represented the motion of cutter. Usually, the clockwise chaining direction is defined for cutting outside boundary; the counterclockwise for inside cavity. (Now, we should place the cutter at outside.)
f) Input machining parameters: Feed rate = 500; Plunge rate = 300; Retract rate = 500; Spindle speed = 1000; Tool dia. = 12
Or, Select a Tool from the library: Right click in the tool display area, choose Get tool from library, and select required cutter size. (This method can save more useful data for next programming, or select pervious data) Note: Unselect the [Filter Active] optional box, there will show all tools.
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You can right click on the tool icon to define more information and save it in tool library (use default name for saving)
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f)
Input the contour parameters Feed plane = 10 (ABS) Depth = -30 (ABS) Compensation in computer = Left
g) Your defined contour parameters, tools, chains and NCI data files that are saved in the Operations Manager. The manager helps you to define / manager more toolpaths and provides simulations to check toolpaths. Try to run Backplot / Verify to check your toolpath, and run the Post Processor to generate NC program for CNC.
Backplot: Select the [Backplot] button on Operation Manager. Or, exit the manager, then select command from Main Menu /NC utils /Backplot: Change the Gview from second menu to Isometric. Press [Alt+F1], then [Alt+F2] for better view. Try: Run; Step, Show Tool, Show Path
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Why? There are some problems. The tool length is too short. The depth cut is 30mm, so the cutter must longer than this depth value.
Click the tool information from the operations.
Increase the length to 40, 50, and 60, and then save to library again.
Simulate this toolpath as right figure shown, but there are problems have not solved yet. More metal have not removed; More heavy cutting loads during machining that will cause the tool broken. We should consider with more machining parameters, as: Roughing / Finishing cuts; Stepover per cut; Depth per cut; etc.
Depth cuts:
Define number steps and step distance of rough and finish cuts.
Multi passes:
Define number steps and spacing distance of roughing and finishing passes.
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a) Click the [Parameters] from Operations
Define [Depth Cuts] b) Open the [Depth cuts] dialog box
c) Define the max rough step size (equal or less then 75% of used cutter dia) and finishing allowance size. Note: Mastercam divides the total depth into equal step based upon the input values between [Top of stock] and [Depth] at Contour parameters dialog box. There will be required min 1 finish cut for any finishing process.
d) Completed the above settings and then click OK return to Operations Manager, where will appear a red-cross-mark on NCI data file. You must press the Regen Path button to resume and update all paths. e) Try to run [Verify] again. There are step down for depth machining, but it is more metal has not removed yet. You must define the [Multi passes] at next stage.
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a) Click the [Parameters] from Operations
Define [Multi passes] b) Open the [Multi passes] dialog box
c) Input data as followings. (Note: The amount of stock the rough pass leaves for finish passes equals the number of finish passes multiplied by the finish pass spacing. For example, if you enter 2 finish passes with a spacing of 0.125, the system would leave 0.25 remaining stock after the last roughing pass.)
d) Regen Path to resume and update program, and then run Verification for checking.
Question: How do calculate the roughing passes number? There are spent more time for tool moving around the workpiece (means no cutting), did you see. Prepared by: Y. C. Tam Page: 33 of 108 Rev: 06 Date: 2006-12-18

Calculate the max number of rough passes during machining
Evaluate where is the max distance and value. Max Number x Roughing Spacing The max distance
Where: Dark Blue represents the stock size; Green represents designed geometry; Light Blue represents the tool motions for each depth cuts; Yellow represents the tool retraction to Feed Plane; The toolpaths, which is inside the Blue Rectangle, is effective paths for metal cutting, but which is outside the Blue Rectangle is noncutting motion. So, this example is noneffective cost for production. Solution: Break down the close contour into several chains for independent operation programming. Each operation is given difference Roughing passes number. Another solution: Using Pocket command (described in next chapter), or using Trim Toolpathe advance command.
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Mcam 9: Creating 2D Pocket Toolpath

Pocket toolpaths rough and/or finish closed geometry. All geometry used to define a pocket and any islands must be in the same construction plane - you cannot select a 3D chain for a pocket toolpath. Types of Pocket examples To make a flat cavity: Only defined an outside boundary for the 1st chain, without any islands defined. Note: Any chains must be closed contour. No cutter compensation consideration, because all toolpaths must be run inside the boundary.
To make island(s) inside cavity: Define 1st for the outside boundary; and defined the 2nd and other chains for island(s). Note: When Island(s) defined, you must carefully define the cutter side for machining that criteria The used cutter diameter is less than the distance between island and island, island and boundary.
To make island(s) only: Defined a hidden outside boundary; and than defined other chains within the hidden boundary for islands. Note: The required hidden boundary side and shape is just larger than the stock side or desired shape for one diameter of used cutter. Note: We can use this method to create aforesaid 2D contour toolpath. It is most wanted method for practical machining.
The example will use the below geometry to explain the 2D POCKET toolpaths.
Note: Its stock size is 180x160x50, and the cavity depth is 30mm. Using 12mm flat endmill for machining. (Download from server, or get from c:\CAM\demo\Pocket.mc8)
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Geometry: Pocket.mc8
Verification
a) Press [Alt+J] to setup stock size
b) Press [Alt+O] to select Pocket
c) Select the boundary chain
d) Select the tool that saved at aforesaid chapter
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e) Input data: Feed plane = 10 (ABS) Top of stock = 0 (ABS) Depth = -30 (ABS) Standard pocket type Press [Depth cuts] button to define max step size and finishing passes.
f) Depth cuts: Note: These definitions are the same as aforesaid Contour descried.
g) Define cutting method (ZigZag is most common method for practical machining) h) Input stepover size (either % or distance value) i) Min given one Finish pass at 0.5mm allowance for general purpose.
Note: The roughing angle sets the angle for roughing passes for One Way and Zigzag pocket toolpaths. The right graphic shows examples of roughing angles. At general workshop, we would like to set an angle (like 150, 300, 450, etc) for machining. This angle will cause two axes moving at the same for machining. If the angle is 0/90/180/270 that will be one axis in lock status, another is driving axis for machining. If two axes is in motion status, it can prevents backlash.
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Backplot the toolpath in Isometric view
Backplot the toolpath in Top view
Verification during in roughing process, you can see Verification during in finishing process, there is the edges are too rough for zigzag cutting method. smoothly cutting edges.
Question: What can you find in there as using another roughing cut methods? Modify the cavity geometry where is an island of 25mm diameter at the middle position, and then create new toolpath for machining. Change the cavity shape to core as page 35 shown.
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Mcam 10:
Engraving Details
Toolpath Verifcation with 0.5mm cutter
Using Contour command without cutter compensation to engrave very shape details onto workpiece. Drawing in area 60 x 70
Download the file server, or get from c:\CAM\demo\Engrave.mc8 Procedures: 1) Press [Alt+J] to define stock size of 60 x 70 x 6 and origin on to top middle position. 2) Press [Alt+O] to open operations manager and select 2D Contour command 3) Using Window selection command to define all detail-chains. 4) Select [Endpoint] command from point entry menu, and then click the red circle at 3 oclock position. (Note: When you use [Window] to select entities, then the prompt area to ask you that give a searching point for1st chain selection) 5) Now, going to define machining parameters 6) Select 1mm flat endmill from tool library 7) Click at the 1st menu from Define Tool dialog window screen, than change the diameter to 0.5mm
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8) Input feed rate, plunge rate, etc. 9) Modify the Tool Name for easier searching 10) Save these information for next requisition
Finally step: Input machining Depth to 0.5mm (ABS), and feed plane etc. Remember that turn off all cutter compensation. Not required Multi passes and Depth cuts define, because there is very light cutting.
Try to program another example: (download from server, or get from c:\CAM\demo\Engrave_HKU.mc8) 0.5mm cutter without any cutter compensation depth to 0.5mm
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Mcam 11:
3D Wireframe Design
This chapter describes the functions of [Gview], [Cplane] and [Z (axis depth)]. Gview (Graphic View) The graphics view is the plane from which you view your work in the graphics window. When you choose Gview from the Secondary Menu, the Gview menu displays. Gview does not move or otherwise translate the geometry. Rather, Gview moves your vantage point. However, it appears the geometry is rotating when you change the Gview, especially when using Gview, Dynamic. Cplane (Construction Plane) The Cplane is a flat, two-dimensional plane on which you create geometry and that you can define anywhere in three-dimensional space. When creating geometry, you are always working on a Cplane. When working in a 2D environment, all geometry creation takes place on a single plane. Usually the default plane (Top XY) is adequate for 2D work. Further, when in the 2D environment, you do not usually need to change the Cplane or use Gviews. The Cplane button shows the current setting with a letter or number. (Number 1 to 8 are system defined, 9 to 255 are user defined, refer to Page 13 of this menu.) When working in a 3D environment, you can use any of the eight predefined construction planes (six planes that correspond to the six faces of a cube; isometric, axonometric) and the 3D construction plane. You can also define planes yourself. You will need to be aware of the current Cplane and Z depth or you will create the geometry in wrong and unintended orientations. One way to avoid this mistake is to set the graphics view (Gview) to the same setting as the Cplane or to Isometric. Cplane and Gview have many of the same available settings. Cplanes that you define can also be used as Gviews. Also, be sure to check, and if necessary, change, the Z depth when you change the Cplane. For example: No define a suitable Construction Plane to draw entities; where: Line-1 is parallel to Front Plane (X-Z), Line-2 is parallel to Side Plane (Y-Z). Go to create fillet between these lines at Front Plane.
As a result, the created fillet is not joined with Line-1 and Line-2, because the Construction Plane is not set on requested plane. Therefore, defining and/or selecting a Cplane are the most important element of geometry creation. A good understanding of this concept is essential. The user may select any existing view as a Cplane, or graphics view (Gview), or use other commands (e.g. 2 lines, Arc...) to create requested 2D construction plane to draw the fillet.
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World / View Coordinate System World: Inputting axis direction and position are the same as the actual threedimensional Construction Plane.
Example 1: Draw a line on 3D space. 1st: set the Cplane to 3d, 2nd: set the Gview to Isometric, 3rd: input coordinates (input X, Y, Z values at the same time to represent a point.), Point-1 (X-80, Y-50, Z60) Point-2 (X50, Y80, Z-30), 4th: the line is created. Note: World Coordinate System is only suitable for 3d Cplane, not for Top, Front, Side ... etc. The 3D Cplane is no need to concern axis depth (Z). View: Assume Cplane (except 3d) is equal to the Monitor Screen, where horizontal direction is X-axis, vertical direction is Yaxis, and perpendicular to screen is Z-axis. User applies the Left Hand Rule to indicate each axis direction and position. Thumb represents Z-axis, 1st Finger represents Y-axis and 2nd Finger represent X-axis. Pointing direction of each finger represent +ve side at any time. The 1st Finger and 2nd Finger are parallel to the Cplane or Monitor Screen. Example 2: Draw a circle and triangle parallel to Front Cplane. 1st: set up Cplane and axis depth Cplane and Gview are set to Front; the axis depth (Z) is set to 50. 2nd: press Alt-F9 to see the view axes. User can see the drawing axis of the current Cplane, which displayed on the left hand side lower corner. 3rd: to draw the circle and triangle. Circle: Center on X-30, Y40, radius 20. Triangle: Point 1 (X20, Y-15), Point 2 (X35, Y-55), Point 3 (X100, Y-30).
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Example 3: Create the rectangle wireframe and two circles on Front / Side plane.
Discussion: 1. Describe the relationships between Cplane, Gview and Axis depth (Z). 2. Compare the difference between World / View coordinate system. 3. To create Arc on 3D space. 4. To define a new construction plane.
Procedures: Cplane Gview Z depth Top Top 0 Top Isometric 0
Data (0,0) & (100,60) Vector: Z30 and select Join (Now, you have created the 3D wireframe, go to create circle on rear and right side position.) Front Isometric -60 Press the [Z] on secondary menu, then input Z-60, or use the point entry function select endpoint (or, midpoint, intersection, etc) at relative entity to obtain which Z value. Front Isometric -60 Create /Arc /Circ pt + dia Center (50, 15) Diameter is 20 Side Isometric 100 Define the Z axis depth of required Side plane Side Isometric 100 Create /Arc /Circ pt + dia Center (30, 15) Diameter is 20 3d Isometric No concern Create /Line /Multi Select endpoints: P1, P2, P3, P4, and Then press F5 to delete lines as above figure. then P1 (press ESC to stop) (Now, you need to define a new construction plane for the middle circle as above figure.) User Isometric Calculated Press the Cplane from secondary, then select Entity from existing Define by system menu to define two perpendicular lines. -51.450 Mouse click at first line (P1-P2) and last line (P1-P3) Select Save from existing menu to store the new construction plane. (The system will generate a new number to represent the plane, and the Z depth is also generated and display on menu. Note: this value is calculated from the origin perpendicular to this plane.) Create /Arc /Circ pt + dia Center at the intersection of these cross lines. Diameter is 20 Finished
Command Create /Rectangle Xform /Translate /Chain the rectangle /Rectang
Dynamic -51.450 (mouse click)
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Example 4: To trim entities on 3D space, if they have not any intersection points. Create two cross lines on Top plane at difference axis depth. 1. Create a horizontal line on Top plane at Z: 0.000: Dates: first endpoint: (-100, -20); second endpoint: (100, -20). 2. Create a horizontal line on Top plane at Z: 120.000: Dates: first endpoint: (0, -100); second endpoint: (0, 100). Note: Actually, these two lines have not any intersection point at the 3D space. But, when you set the Cplane & Gview at TOP, you have found that these lines are across to anther one. (i.e. They are not parallel lines.) So, you can use Trim command to change their length. Example 5: download file, or get from c:\CAM\demo\3D.mc8 Given drawing for Side construction
Finish geometry
Procedures: Change the Cplane to Side, and Giew to Isometric Select Xform /Translate /Chain entities / Rectang /Translate Vector is Z-44 /select Join Press Cplane from secondary menu, and then select Entity to select two perpendicular lines at the plane. Select Xform /Offset copy lines to construct the window box position. Use Modify /Trim to correct length. Select Xfrom /Translate /to draw the box depth.
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Mcam 12:
Surface Model
The Surface menu gives you options for creating and modifying surfaces. A surface is a 2D or 3D shape that has area but no thickness, which you create from curves (lines, arcs, splines), from other surfaces, or from pre-defined shapes. Create functions Modify functions Creating a lofted surface Creating fillet surfaces Creating a Coons surface Offsetting surfaces Creating a ruled surface Trimming surfaces Creating a revolved surface Extending a surface by a defined length Creating a swept surface Extending a surface to a plane Creating draft surfaces using a defined length Blending two surfaces Creating draft surfaces using a defined plane Blending three surfaces Creating surfaces in pre-defined (primitive) shapes Blending three intersecting fillet surfaces Extracting surfaces from solids Setting the display of surface: The Surface Display menu gives you options for specifying how surfaces appear in the graphics window. While this menu is displayed, current surface display settings (Show back, Back color, and Density) are shown in the prompt area. You can access the Surface Display menu by choosing Main Menu, Screen, Surf disp. Surface density is the concentration of display curves (not geometric entities) used to show wireframe (unshaded) surfaces and solids in the graphics window. Mastercam determines the appropriate number of curves for a density value based on the composition of the surface. Surface density settings do not affect shaded surfaces. Surface density is measured by a value between 1 (least dense) and 15 (most dense). Entering a density of zero displays the outline of the surface and one curve in each of the surface directions. The current density is shown in the prompt area. Choosing the Density option on the Surface Display menu lets you set the surface density for the current drawing session. 1. Choose Main Menu, Screen, Surf disp, Density. 2. Type a value from 0 to 15 in the text box, then press [Enter]. Example: download from server, or get from c:\CAM\demo\PocketSurface.mc8
Shading is intended primarily to help you visualize 3D geometry while you work, not to provide a permanent, savable image. Shaded images update to reflect the changes you make to the geometry. You can select the command from Screen menu, or press [Alt+S]. Prepared by: Y. C. Tam Page: 45 of 108 Rev: 06 Date: 2006-12-18

Normal Direction: A surface normal is a vector (direction) that is perpendicular to the tangent plane of a surface at the point of tangency. Each surface has two normal vectors, which point in opposite directions. One is referred to as the positive (front, outward, and display the default color) direction; the other is referred to as the negative (back, inward, and display gray color) direction. When a surface is created, the default positive normal direction is based on the relative directions of the curves defining the surface. In the following graphics, the arrow shows the normal vector directions of a surface at the position of the base of the arrow.
You can select [Normal] command from Modify menu, to change surfaces normal direction. For machining, the Normal Direction indicates the cutter compensation; means cutter is always following the Positive Direction.
Notes: Selection suitable command to fit your defined entities to generate a perfect surface -Draft and Revolve are 2D commands that all entities should be created on the same construction plane and requests set the Cplane at this construction plane to generate surfaces. Ruled and Loft are 3D commands that requests you define two (or, up to 255 max) parallel contours, where you can set the Cplane at this parallel plane or 3D plane. Sweep is 3D commands that requests you define two (or, up to 255 max) cross or interested contours, where you must set the Cplane at Top or 3D plane to generate surfaces. Coons is 3D command that request you define min 4 contours to form a closed patch, you can define up to 50 patches per single surface, where you must set the Cplane at 3D to generate surfaces. For Draft, Revolve, Ruled and Loft, we call these entities as across contours. For Sweep and Coons, we will classify these entities into two directions dependent on their function: Along Contours Across Contours
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Draft Surface:
It is created by extruding (or, driving out) the shape of a curve (line, arc, or spline) in a linear direction perpendicular to some view, often with an angle, or degree of tilt. The draft surface extends to a defined length or plane. The pictures below show an example of a draft surface:
Note: Follow the arrow direction is positive length or positive angle. Example: Using Draft to create a cylinder Create a Diameter of 50mm circle at Origin on Top plane Select Draft from surface menu, and then Chain the circle Given length = 50; Angle = -150
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Revolve Surface:
This option creates a surface that is circular in one direction. The system revolves one or more selected chains of curves (profile entities) about a single line (axis of rotation). When you select the axis, the system displays a temporary arrow at one end of the axis to indicate the rotation direction. The following graphics identify a profile entity and axis of rotation and show them used in a full and partial rotation.
Create the Profile Entity: /Arc /3 Points /Given Coordinates (100, 50); (0, 80); (-100,50) Create rotation axis: Select Create menu /Line /Endpoints /Given Coordinates (100, 0); (-100, 0) From the Main Menu, choose Create /Surface /Revolved. (The Chaining Methods menu displays.) Select one or more chain of curves, select the ARC (click at left side endpoint), then choose Done. Select a line for the axis of rotation, select the LINE (click at left side endpoint) Set parameters on the Revolved Surface menu, as needed, then choose Do it to create surfaces.
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Ruled Surface / Loft Surface

They create a surface by transitioning between two or more chains of curves (or contours) in the order. The Ruled Surface is using linear blending between each section. But the Loft Surface is using line, arc, spline and curve to calculate a smooth blend by consideration of all the selection chains at once.
Ruled Surface Loft Surface They use the same contours to define surface, but the outputs are difference.
They are similar commands; their difference are shown below: Loft Ruled Curve fitting between contours Linear matching between contours Cutting direction either along or across Cutting direction parallel to along direction No trimming plane Trimming planes can be set on tool path Using these commands to create surfaces, we should chain two or more contours. We must carefully select each contour. It is important to select each chain of curves at the same relative position to each other. 1) Selection in sequence: starting selection at any end side contour 2) Same chaining direction 3) Same starting angle for each chain, when you defined close contours.
They are the chaining direction from point-A and point B
They are the same chaining direction and starting angle at point-A and point B
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This examples show the different selected chaining direction:
They are the same direction and in sequence selection
This result is non-sync direction
Example: Rule01.mc8, you can download from server or get from c:\CAM\demo Select Ruled from Surface menu Select Single to select the green Arcs Note: Because these contours are single entity, so you can use Single for selection easier. If the contour is constructed by two or more entities, you should use CHAIN for selection. The selection should be in sequence and same chaining direction.
Example: Rule02.mc8, you can download from server or get from c:\CAM\demo Select Ruled from Surface menu Select Chain to select the green contours (pick at 3 oclock near A / B) Note: The selection should be in same chaining direction and start angle.
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Example: Car.mc8, you can download from server or get from c:\CAM\demo Select Loft from Surface menu Select Window to select all green contours Specify an endpoint for automatically searching all contours Note: Compare Loft and Ruled results.
Example: Rule_Loft.mc8, you can download from server or get from c:\CAM\demo Select Loft / Ruled from Surface menu Select Single to select all green contours Note: Compare Loft and Ruled results.
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Sweep Surface:
The Sweep function creates a surface by sweeping chains of curves along a path. The chains that you select to sweep are called Across chains. These chains define cross-sections of the resulting surface. The chains that define the path of the sweep are called Along chains. You can define this surface using the following combinations of across (section) and along (path) chains: 1 across/1 along: Mastercam sweeps one section chain along one path chain. You have the option to Translate or Rotate the cross-section chain along the path. 2 or more across/1 along: Mastercam transitions from one section chain to the next in the order in which you defined them while following one path chain. This is known as a linear blend. 1 across/2 along: Mastercam proportionally scales one section chain between two path chains. Selection procedures: 1. Choose Main Menu, Create, Surface, Sweep. 2. Select two or more Across chains to define the cross-sections of the surface, then choose Done. 3. Select one or two Along chains for the sweep path, then choose Done. Note: If you selected more than one chain in step 2, you can select only one path chain. In this case, you do not have to choose Done; Mastercam moves to the next step automatically. 4. In the prompt area, Mastercam displays the current surface error tolerance, surface type, and translate/rotate settings. If necessary, use the Swept Surface menu to edit these settings. 5. Choose Do it to create the Swept surface. 6. Repeat steps 2 through 5 to create additional swept surfaces, or press [Esc] to exit the function. Note: The following graphics show three swept surfaces created using various combinations of across and along chains. Samples of Sweep Surface: There is the same start point (or position) for each chain. You have the option to Translate or Rotate the cross-section chain along the path.
Base upon the same start point / position selection method: If you select the across entities starting at the point A, which along entities are near this point, so it is the first along direction.
These entities are no any intersection points, we should depend on the along path to define each across section. If the 1st across direction starting at point A, then the along path will be started at point C, so the 2nd Across chain is starting at point B.
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Example: Sweep01.mc8, download from server or get from c:\CAM\demo Select the single green Arc starting at point A for Across chain Select the green rectangle near the point A for Along chain If you want to fix the across contour then copy along the path, you can select [Translate] option. If you want the Across contour turn around the path, you should select [Rotate] option.
Example: Sweep02.mc8, download from server or get from c:\CAM\demo
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Coons Surface:
The Coons surface function creates a surface from a grid of curves (Patches). Note: Two across chains and two along chains construct a Patch as a closed contour. The longest contour direction is defined as along direction. Each group of along and across contours must be intersected and cut each other into several pieces as grids. Each intersection point of along group and across group that should be a real endpoint. There should be same starting point for the First Along and First Across For example, several across and along contours construct the bottom. At the top view, we can find there are six patches are build by these intersected contours. Note: Before starting select chains, the mastercam will request you give information as: How many patches in along and across direction. (The total number of patches = Along no.s x Across no.s)
The along in 3 patches
The across in 2 patches
Selection procedures: The patch boundaries are laid out in a grid. The along contours for the entire surface are defined first (not patch by patch), followed by all the across contours. For this example, the point 1 is the starting point, so the along contours are 3; the across contours are 4. The mastercam system will prompt you select each portion step by step as following table -Select Along Rows at first stage Select Across Columns at second stage
1 of row 1 (1-2); 2 of row 1 (2-3); 3 of row1 (3-4); Row 1 finished. 1 of row 2 (5-6); 2 of row 2 (6-7); 3 of row 2 (7-8); Row 2 finished. 1 of row 3 (9-10); 2 of row 3 (10-11); 3 of row 3 (11-12); Finished. Completed all rows selection then go to select columns. 1 of column 1 (1-5); 2 of column 1 (5-9); Column 1 finished. 1 of column 2 (2-6); 2 of column 2 (6-10); Column 2 finished. 1 of column 3 (3-7); 2 of column 3 (7-11); Column 3 finished. 1 of column 4 (4-8); 2 of column 4 (8-12); Column 4 finished.
Chaining completed; surface will be generated. Prepared by: Y. C. Tam Page: 55 of 108 Rev: 06 Date: 2006-12-18

Blending: There are four options that can be selected by user: Linear, Parabolic, Cubic, and Cubic with slope matching. Parabolic and cubic blending tends to produce flat spots, on the surface. Use linear blending on single patch surfaces or cubic with slope matching blending on multiple patch surfaces whenever possible.
Start creating COONS surface The system prompt will ask you using Automatic. Click [No] Because it is not suitable for complex geometry.
Example: c:\CAM\demo\Coons-01.mc8 The along and across path number is 1 also. Select 1 of row 1: click the red Arc near point A Select 1 of row 2: click the red Arc near point C Select 1 of column 1: click the green line near point A Select 1 of column 2: click the green curve near point B Chaining completed; surface generated.
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Example: c:\CAM\demo\Coons-02.mc8 The along patches are 3; across patch is 1. Select point A for starting the 1st Along Row and Across Column (Note: there are two rows in along path and 4 columns in across section.)
Example: c:\CAM\demo\Coons-03.mc8 The along patches are 3; across patch is 2. With refer to Page 54 for selection procedures.
Example: c:\CAM\demo\Coons-04.mc8 The along patches are 8; across patch is 1. Because the along paths are closed rectangle, so the 1st across arc also be the last column.
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Example: c:\CAM\demo\Coons-05.mc8 The along patches are 4; across patch is 1. The Row 1 is the red rectangular contours; the Row 2 is the Point. The columns are the green cross curves that are broken at the blue point. Because the along paths are closed rectangle, so the 1st across arc also be the last column.
Note: [POINT] is the base element for creating any geometry.
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Trim Surface
The Trim Surface menu gives you options for trimming, un-trimming surfaces. You can access the Trim menu by choosing Main Menu, Create, Surface, Trim/extend. Trimming surfaces to curves Trimming surfaces to a plane Trimming surfaces to surfaces Creating a trimmed surface within a flat boundary Un-trim a surface (change the trimmed surface to original shape, not pervious step.) Trimming a surface to curve: This function trims surfaces to curves (lines, arcs, and splines or surface curves). If the trimming curves do not lie directly on the surfaces, Mastercam projects them onto the surfaces in order to calculate the intersection where the surface will be trimmed. When Mastercam trims a surface, it creates the trimmed surface as a new surface, and you can keep, blank, or delete the original (default option) surface. Procedures: 1. Choose Main Menu, Modify, Trim, Surface, To curves. 2. Select one or more surfaces to trim, then choose Done. 3. Select a curve or chains of curves to use to trim the surfaces, then choose Done. Note: You must select lines, arcs, and/or splines as the trimming curves in this step. However, you can replace these trimming curves with surface curves in step 5, if necessary. 4. Choose Options. Set the step method and trimming parameters, then choose OK. Note: Chord height is generally the most precise step method, but it may take longer to calculate the trimmed surfaces than Fixed step. 5. Set the remaining parameters on the Trim to Curves menu, then choose Do it. Note: To trim the surfaces to surface curves instead of using the trimming curves selected in step 3, choose Surf crvs, then select one or more surface curves in the graphics window. 6. Select a highlighted surface. Mastercam displays an arrow on the surface. 7. Move the base of the arrow to the area of the surface to keep after trimming, and then click. Note: Avoid selecting the outer boundary of the surface, which may produce unintended results. 8. Press [Esc] to exit the function.
Trimming surfaces to plane: This function trims surfaces to a construction plane (input X/Y/Z depth value). The selection procedures are similar to above steps. But not use mouse click to indicate where to keep. The system will display Flip Arrow to let you toggle which side to keep. Note: Easier to view the [Flip Arrow], you should turn off the shading function (Toggle Alt+S again).
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Trimming surfaces to surfaces This function looks for intersections between two sets of surfaces, one of which must contain only one surface, and trims one or both of the sets of surfaces. The selection procedures are similar to aforesaid, but you should use mouse click the two set surfaces where to keep.
Note: You can define more than two surfaces a time for each trimming set. Creating a trimmed surface within a flat boundary Define one closed 2D chain, or the chain consists other closed chains. (These chains must be created at the same plane, if not, system will project the second and other chains onto the plane of first selected chain.)
Example: c:\CAM\demo\Ball.mc8 Change the Cplane to TOP Select Trim to Plane Select Z = 0 Flip the arrow position at figure shown Now, the ball is trimmed to half. Try to use untrrim surfaces function to view what happens. Change the Cplane to TOP Select Trim to Curve Select the red circle Mouse click where to keep as figure shown Now, the surface is punched a hole.
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Example: c:\CAM\demo\TF01.mc8 (Trim surface to surface)
Example: c:\CAM\demo\TrimSurf.mc8 (Trim two intersected surfaces for each time) There are 3 trimming processes for these 4 single surfaces.
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Creating a fillet surface between two surfaces

This option creates one or more fillet surfaces, each of which is tangent to two surfaces. When you choose this option, the system prompts you to select two sets of surfaces. Note: The fillet surfaces will be generated in where dependent on your mouse click. For example: there are two vertical draft surfaces created at TOP plane. The selection procedures are Trim option: similar to aforesaid Trim Surface. Without Trim function Trim Both sets
If you want to generate the surface at the Region II, you should select the end side A & B and using [Check Normal] function to Flip each Arrow direction pointing to the Region II. Such that you can create this fillet surface at required position. There are two operations for you select: Single / Cycle. Single manually mouse click each surface again to Flip the arrow direction. Cycle system will automatically prompt to you one by one to check arrow direction. Remember that turn off the auto shading function for easier selection. Example: c:\CAM\demo\TF01.mc8 (Create fillet surface of R10 around the intersected area)
Example: c:\CAM\demo\TF02.mc8 (Fillet surface of R5)
Example: c:\CAM\demo\TF03.mc8 (Fillet surface of R5)
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Offsetting Surfaces: This function offsets one or more surfaces by a distance and a direction relative to the surface normal direction of each selected surface. When Mastercam offsets a surface, it creates the offset surface as a separate surface from the original surface. 1. Choose Main Menu, Create, Surface, Offset. 2. Select one or more surfaces to offset, then choose Done. Mastercam displays the Offset menu. The default offset values display in the prompt area. 3. To change the offset distance, choose Offset dist. In the prompt area, enter a new value for the distance to offset the surfaces. Note: You can enter a positive or negative value. A positive value offsets the surfaces in the positive surface normal direction. A negative value offsets the surfaces in the negative surface normal direction. 4. To check the surface normal directions, choose Check norms. Mastercam displays the Check Surface Normals menu. You can check the normal direction of one or all surfaces in the selection. For more information, press [Alt+H] from the menu. 5. Indicate what to do with the original surfaces once the offset surfaces have been created. Toggle Dispose to K to keep the surfaces, B to blank the surfaces, or D to delete the surfaces. 6. Choose Do it to create the offset surfaces. Example: c:\CAM\demo\OffsetSurf.mc8 (Offsetting Surfaces for 5mm distance)
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Mcam 13:
Curve
Creating curves on surfaces

The Curve menu gives you options for creating lines, arcs, splines on surfaces and for creating surface curves on surfaces. You can access this menu by choosing Main Menu, Create, Curve. Function Creating flowline curves on a surface Creating curves at the intersections of two sets of surfaces Projecting curves onto surfaces Creating parting line curves on surfaces Creating a curve along one edge / all edges of a surface Example: c:\CAM\demo\Project.mc8 Create all edge curves at this surfaces edges. Description This function creates multiple curves on a surface in one direction of the surface. This function is similar to [Trim Surface to Surface] with curves defined It is more useful for designer to define 3D entities. This function is similar to [Trim Surface to Plane] with curves defined Finding the edge dimension from surfaces.
Project the blue contour onto the surface.
We can use the projected curve and the green contour to generate a ruled surface.
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Mcam14:
Surface Toolpath
Surface toolpaths are used to machine single surfaces, multiple surfaces, solids, solid faces and/or STL files. When you select a solid for a surface toolpath, Mastercam extracts the exact surface data for each solid face. To create a surface toolpath, choose Toolpaths, Surface from the Main Menu or from the Operations Manager right-click menu. Normal direction (refer to Page 46) is more important data to define Surface Toolpath. The cutter compensation always follows the positive direction. You can select from Modify /Normal to reverse the surfaces normal direction before starting the surface toolpaths. The surface toolpaths are two main processes: Surface Rough and surface Finish, which are similar to 2D Contour and 2D Pocket Toolpaths. Surface rough toolpaths remove large amounts of material from surfaces as rapidly as possible. Surface finish toolpaths are used to create precise surfaces after roughing. You can access surface Rough / finish toolpaths by choosing Toolpaths, Surface, Rough / Finish from the Main Menu or by choosing Toolpaths, Surface Rough / Finish from the right-click menu in the Operations Manager. This chapter will describe the following Surface Toolpaths Surface Rough Pocket: Pocket rough toolpaths create pocket boundaries from selected surfaces. Surface Finish Flowline: Flowline finish toolpaths allow precise control of the scallops left on the part, creating an exact, smooth finish. You can only use flowline toolpaths on a row of adjacent drive surfaces. Plunge: Plunge rough toolpaths machine surfaces Parallel: Parallel finish toolpaths are the most quickly with a drilling-type motion. common type of finish toolpaths Note: Contour: Contour rough and finish toolpaths Generally, the raw material that use for machining, perform multiple cuts at constant Z levels, is round or rectangular shape. So the Surface Pocket which can be an ideal machining method for and Surface Plunge are more suitable for our certain tools. Unlike other surface toolpaths, requirements. both contour rough and finish use the same If we rough cut a casting product, we would use the dialog box. Contour Rough for machining because it required Radial: Radial finish toolpaths are primarily used machining time less then Surface Rough. for creating more precise surface toolpaths on round parts.
Example: c:\CAM\demo\SurfMc01.mc8 Checks the normal direction for each surface before starting toolpath defines. Use Surface Pocket for roughing cut Use Flowline for finishing step Cutter information Dia. 6mm Ball endmill; feed rate 500; plunge rate 300; retract rate 500 and spindle speed 1000. Procedures as following tables:
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Select surface rough /pocket from operations manger. System will prompt you select entities: using [All] command to all surfaces (if you do not want to all, you should mouse click one by one). Click [Done] to finish selection
Go to tool parameters screen to set: Dia 6mm ball endmill Feed rate = 500 Plunge rate = 300 Retract rate = 500 Spindle speed = 1000
Surface parameters screen: Only change the feed plane at suitable rapid depth No need to define machining depth due to all geometrical dimension being calculated from the surface.
The rough pocket parameters screen is similar to 2D pocket. Click to [OK] to finish setting.
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Define the outside boundary: Select [Chain] the outside edge curves Waiting the system for toolpath calculation.
After calculation, the system backplot the toolpath once.
Verify the roughing process as below figures
Set the toolpath display to off, where will be easier for next toolpath selection.
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Create Surface Finishing Toolpath: Select Surface Finish /Flowline from operations manager. Select All surfaces
Go to tool define and surface parameters screens that are similar to surface rough packet, as below figures. Using the 6mm ball endmill Using default values Note: If you want to make a very finer product, you can decrease these values.
Now, going to Flip direction menu screen: You can change this direction of Offsetting and Cutting direction for tool metal removal; step and start position. The right figure shows the correct position that cutter places inside, and the cutting direction along the longest position. You can flip to outside or change the moving follows the across direction, as below figures.
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Try to backplot the toolpath, and Verification to check the product.
As shown below:
Try to select other finishing command: Select Parallel surface finishing toolpath from Operations Manager Select all surfaces Go to parameter menu screen: Select 6mm ball endmill Finish Parallel Parameters menu screen: The surface finishing is depend on the value of [Max Stepover] The machining angle is depend on the geometry, the below figures show: There are excessive cuts for machining angle is 0 degree.
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Using Surface Pocket for roughing and Surface Contour for finishing toolpath. Get SurfMc02.mc8 from c:\CAM\demo -Stock size is 160x140x20 Use 12mm Flat endmill Before machining the green island, we should define a flat surface and boundary are larger than the stock Where the red box is stock Surface Pocket Roughing toolpath: Select 12mm flat endmill Chain the outside boundary: click the white rectangle Surface Contour Roughing toolpath: Select this command from Surface Finishing Select all surface Use 12mm flat endmill
Surface Contour Finishing Parameters menu screen Note: You can decrease the value of [Max Stepdown] to obtain good surface finishing.
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Example: Get SurfMc03.mc8 from C:\CAM\demo Using Plunge for surface roughing, Parallel for surface finishing with a12mm ball endmill. Note: After you have completed surfaces selection, the prompt will request you define the upper and lower position for the Plunge roughing boundary: Click the Point A & B Notice on Rough Plunge parameters: The max stepover is less 75% of cutter dia.
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Example: c:\CAM\demo\SurfMc04.mc8 First step, use 2D Contour and Pocket toolpaths to cut outside boundary and inside holes. Last step, use Radial Surface finishing the profile.
Finish Radial parameters: The calculation of cutting stepover value is not linear, base on the rotating angle. You should identify the rotating center position and give to system. The geometry center is the Origin.
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F.
Cadem seeNC mill
SeeNC is special purpose CNC part program verification software. This software designed to be used with ISO standard G codes similar to FANUC CNC. Click this icon to open the simulator.
When you entry the system, there will display prompt screen menu for you select an event, as right figure shown. The Main screen of seeNC mill as show below --
Getting started: To simulate an existing NC file that used to machine [Hook] as the right figure shown. Open an existing part from [c:\CAM\demo\HookMill.nc]
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Procedures: 1) Define Blank Select [Blank] from menu bar, or click this icon from tool bar. The workpiece size is 100 x 50 x 30 (mm) and the origin point set at the top surface on middle position. The system request you input the min (lower corner coordinate) and max (upper corner coordinate) and specify the lowest Z coordinate with thickness defined that used to calculate the origin point. 2) Machine Selection
Select [Machine] or click this icon The NC file is used the FANUC controller to generate, so we will select [Fanuc 0M] (The Fanuc controller is most popular used for CNC to control each axis movement.) 3) Checking syntax Select [Syntax] or click this icon Checking process Syntax error message The below errors are no problems, because the demo version cannot support the 4th axis code (A0) and (%) is used for some older version control software to start/stop reading program.
Correcting errors: If there appears wrong G code constructed, you must Go to the program editor and correct the erroneous blocks. Run the syntax check once again. Repeat this procedure until no errors are detected. (For example: given wrong starting coordinate for next G02/G03 circular path.) 4) Assigning Tools When you initially configure an NC file, the system automatically displays the Configure screen. Otherwise, you can select [Tools], or click this icon This NC file requires tools as T1 = 6mm Flat endmill; T2 = 6mm Ball endmill Click [Assign tool] button to configure tools from 1st to last, as blow figure shown. (Otherwise, you can click the tool no 1 or 2 that you want to edit or change.)
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For T1: expand the End mill and then select End mill finish 4 flute /6mm dia. /[Edit tool geometry] to check or edit suitable length for machining.
For T2: expand the Ballnose end mill and then select Ball nose end mill /6mm dia. /[Edit tool geometry] to check or edit suitable length for machinin
Note: If there no suitable tool size for you, you can select any tool size and then using [Edit tool geometry] function to change its size. (For example: you need 6.5mm flat endmill.)
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Tool path simulation:
Note: Save you current configurations, but except these verification graphics. Because the system only store the stock and tool data. You want to demo these simulation on next entry the system, you should press the [Syntax] checking once again then the system will verify it. Otherwise, if you have not save any configuration, you will get all above procedures again on next visit.
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G.
Cadem seeNC turn
SeeNC is special purpose CNC part program verification software. This software designed to be used with ISO standard G codes similar to FANUC CNC. Click this icon to open the simulator. The seeNC Turn which operations are similar to seeNC mill, as shown below:
Procedures: Edit or get NC file /Define Blank /Machine Selection (Fanuc OT-Type A is widely used) /Syntax Check /Assign Tools /Toolpath simulation. Note: The lath turning tools are more complex than milling tools. Milling tools are almost round shaft shape, but lathe tools are more and more, which depend on different processes (external /internal) and different shapes (groove, thread, left or right edge side etc.). There are some tools shown below figure.
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Example: get file from seeTurn.txt Stock size: dia. 80 x 100mm, origin at top center; Select Fanuc OT-Type A controller; Syntax Checking; Define tool.
Note: the [M series] used for general purpose (rough and finish); [P series] used for heavy rough cuts; [S series] used for fine finish cuts.
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Edit Tool Geometry:
Simulation:
Note: the Left and Right Hand external turning tools are widely used for general purpose. Right Hand external turning tool Left Hand external turning tool
The above blue arrow represents the stepover direction; red arrow represents the cutting direction.
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H.
HKPC 3D-Mill CNC machine
3D-Mill is 3-axis CNC desktop machine using 200AC, so it is suitable for any workshop to make prototype. It uses PC with DNC program to control all motion. Procedures: 1) Power on all device, except the Spindle Motor (it is safety requirement) 2) Entry the 3dmill directory on PC: cd\3dmill ---- (Go to C:\3dmill) enter nc.exe to control screen 3) You can type G code commands step by step to control each motion, except the Spindle Speed (which is controlled by the Spindle Speed Controller). For example command: G00X0Y0 4) You can input an NC file to auto run, the format as: command: ]test.nc Where ] represents file opening, input the file name with its extension (eg .nc). Remember that the file must be stored in the same directory {C:\3dmill\ test.nc} Note: You can save NC files to the server which path is {\\server\ncdata} and this PC has mapped this server path as {T:\}. So you can copy your NC file directly on this PC, command format as Copy t:\test.nc c:\3dmill The file name do not longer than 8 letters, because the PC is DOS system. When you auto run a NC file, you can select F1 for Control Screen step go or F10 for continous.
Machining Start
As program running, you can press F1 to PAUSE, or ESC to STOP, if there are problems.
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I.
Dophen CNC wirecut machine
Electric Discharge Machining (EDM) is a metal removal process by means of electrical energy released by spark discharges occurred between an electrode and the workpiece with electrical conductivity. Wire EDM is a process in which a thin electrode, a brass wire of usually dia 0.2 mm, is used to cut conductive materials such as steel, copper and aluminium. The wire is continuously spooled, much like a handsaw blade, passes through a starter hole in the workpiece and cuts complex shapes following a programmed path. G.M.-Code and DXF formatted files are compatible. The Dophen wirecut machine can cut 2D shape up to 75mm thickness and with max 3-degree draft angle. Example: to cut the 2D shape as right figure Where the start point is (-5, 0) and the toolpath direction is clockwise; the thickness is 4mm. Procedures: 1) Create geometry and convert to DXF file. 2) Drive the wire near the sheet metal plate (less than 1mm between sheet metal and wire); and than set this position as the start point coordinate. 3) Copy the DXF into Dophen wirecut machine. 4) Setting machining parameters. 5) Start machining (1)
(2) Use arrow key move to [SCALE INPUT]; and key in X or Y then input coordinate.
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(3a) Press [ESC] to main screen, and then select [4] (3b) Select input source from A drive (so, you should to copy file copy your DXF into a floppy disk)
(3c) Select DXF file to input
(3d) Input file name same as the file in floppy
(3e) Input start point coordinate
(3f) If there are branch points, you should input [select number] to correct toolpath direction run.
(3g) System reading entities until it appears message of [Press any key to continuous] that means all paths are corrected and you can go to next step for machining.
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(4a) Add the safety guard before start machining
(4b) Select [3] to configure parameters (or select [1] return to Scale Display screen.)
(4c) Input 4mm thickness and select matl of Steel
(4d) Base on the ref. Data to adjust electric data The current can be max 3 unit, for this thickness we should adjust to 1 unit.
(4e) Select file for machining that you stored. (4f) Select suitable cutter compensation direction (You can key in file name or move arrow key to (1 or 2) select.)
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(4g) The compensation value is 0.1 mm
(4h) No drafting angle setting
(4i) Press [ENT] key to start point coordinate.
(4j) Press [G] to start machining
(4k) Wirecut EDM in process: you can see there are injecting fluid and sparking light.
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J.
Dophen CNC Electric Discharge Machine
Electric Discharge Machining (EDM) is a metal removal process by means of electrical energy released by spark discharges occurred between an electrode and the workpiece with electrical conductivity to produce a desired -shaped form in a work-piece. EDM can be classified into diesinking and wirecutting. Die-sink uses a copper or graphite to produce an electrode that is a reversed shape of the final product.
Programming Using internal graphic input software or G, M codes compatible. Some examples are shown below: Plastic Mold Internal Thread 3-axis Engraving
Example: To make 4 cavities with the CAR electrode, which coordinates are (43, 16); (-43, 16); (-43, -16) and (43, -16). We should use CNC milling machine for roughing and then use this electrode for finishing.
Procedures: 1) On the scale display screen, using arrow key moved to [SCALE] input function and then key in X, Y or Z for value input. Note: Using axis controller move the electrode near the position and then set value for this position. 2) When you have completed scale input, use arrow key move function button to [EXIT] then press [ENT] key; the system return to MAIN MENU for other function.
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3) Press [1] for programming or modification
4) Input file number (from 1 to 10)
5) Select [NEW] to edit the four coordinates.
6) (43, 16); (-43, 16); (-43, -16) and (43, -16)
7) Input DEPTH, CURRENT etc.
8) The system creates electric machining data
9) Check the door is closed before start machining
10) Switch on the fluid pump
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11) Pumping fluid
12) Press [4] from Main Menu to start file select
13) If it is corrected, select [START] for next step
14) Press [2] for 5mm then press [1] to confirm data.
15) Now, starting process.
16) Sparking
Note: If you want to stop machining, press [ESC].
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Project 1
Objective:
CNC program concept study
What is the ISO Language Coordinate system Describe the structure of an NC program Cutting tools used in mills and laths
Duration: Reference:
1hr
IsoIntro software CNC program concept .pdf CAM Training Menu Workshop: Running the IsoIntro software to study writing an NC program, click this icon to open it.
a) Press [Close] to use the demo version
b) Press [OK] for self study; no data recorded.
c) Select [INTRODUCTION] for first step
d) Click [] to start
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Project 2
Objective:
2D NC program edit and operate 3D-Mill CNC machine
Understanding the construction of NC program and the functions of G, M codes.
Duration: Equipment:
2.5hr
MicroTech CncSimulator HKPC 3D-Mill CNC Machine
Workshop:
1) Using MicroTech CncSimulator to edit NC program for machining the contours as right figure shown. Dimension as shown below Workpiece size = 200 x 150 x 6 (mm) Milling Cutter = 2mm Flat endmill Depth cut = 1mm Origin at the lower left corner of the workpiece The top surface is Z 0.
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2) Using HKPC 3D-Mill CNC machine to engrave the part as below figure shown -Using software to simulate your program to make sure it is OK Copy your file to server, the path is {\\server\NCdata} (Note: the file name is not more than 8 letters and saves as [.nc] extension.)
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Project 3
Objective:
2D drawing
To study the technique of using the MasterCAMs CAD functions to create drawings. The CAD function consists of the following menus: Analyze, Create, File, Modify, Xform, Delete and Screen.
3hr
MasterCAM version 8
Exercises:
Create six 2D geometry (without dimensioning) as the followings -Note: When you have completed these drawings, each Student Group send one copy to server. Instructor will check it later. The server path is {\\Server\CAMex\ Group name}
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Project 4
Objective:
2D NC program for wirecut and operate CNC wirecut machine
To understand the working principle and operations of the wirecut machine. The wirecut machining is an electric discharge machining (EDM) process that uses NC programs to produce the desired contour or shape on workpiece. It does not require a special-shape electrode; instead, it uses a continuous traveling wire (0.2mm dia.) under tension as the electrode.
3 hr
MasterCAM version 8 Dophen CNC wirecut machine
Workshop:
Make 4 pieces of this shape , which can assemble square shape as right figure shown. These shapes will be cut from 1mm sheet metal plate and stack 4 pieces for machining once. First step, you create 2D geometry of this shape and then converted to DXF file. Using floppy disk copy the DXF to CNC wirecut machine. Last step, operate the wirecut machine to make prototypes. Its dimension as below
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Project 5:
Objective:
2D milling program
The MasterCAM provides CAM system defines toolpath for CNC machining. Now, using 2D contour and pocket commands to generate programs.
4hr
MasterCAM version 8 Cadem seeNC mill HKPC 3D-Mill CNC machine
Exercise:
Get files from C:\CAM\Exercise\ Project5A.mc8; Project5B.mc8; Project5C.mc8 Using MasterCAMs Operation Manager defines toolpaths and then post NC files for next simulation on Cadem seeNC mill. Using Cadem seeNC mill to simulate these NC files Note: You define the Tool configures to the NC file that must be the same as defined on MasterCAMs environment. When you have completed above NC files and simulation, each Student Group send one copy to server. Instructor will check it later. The server path is {\\Server\CAMex\ Group name}. The copy includes NC files and the configuration files of that NC simulates on Cadems enviroment (the files extension is *.mtl for example: 5aa.nc with the configuration file is 5aa.mtl). Setting parameters as followings Project5A.mc8 (as right figure shown) Stock size is 180 x 60 x 20 (mm) Origin on the top middle position You will make two different shapes by using the drawing one is letter islands with 5mm height; another is cavities with 3mm depth Uses 6mm flat endmill: Uses 4mm flat endmill:
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Project5B.mc8 (as right figure shown) Stock size is 102 x 102 x 10 (mm) Origin on the top middle position Using two cutters 12mm flat endmill for outside contour to Z 10 mm 6mm flat endmill for inside holes and cavities to Z 10 mm
Project5C.mc8 (as right figure shown) Stock size is 75 x 70 x 33 (mm) Origin on the top middle position Using three cutters 12mm flat endmill for outside contour to Z 33 mm and islands to Z 3 mm 6mm flat endmill for inside holes and cavity (where holes to Z 28 mm; cavity to Z 15 mm).
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Project 6
Objective: Duration:
3D drawing
To study the 3D construction method on MasterCAM Cplane, Gview, Axis Depth (Z) 3 hr
Equipment: MasterCAM version 8 Exercise:

Create two 3D wireframe models without dimensioning --
Note: When you have completed these drawings, each Student Group send one copy to server. Instructor will check it later. The server path is {\\Server\CAMex\ Group name} Project6A details as shown below:
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Project6B details as shown below:
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Project 7
Surface modeling
To familiar with MasterCAM to design a more realistic model. 5.5 hr

Create three sufrace models without dimensionings -1. Using Project6 exercise of [Project6A] to create half shape. 2. Get from provided file [C:\CAM\Exercise\Project7B.mc8] to create TV Screen model 3. Get from provided file [C:\CAM\Exerceise\Roject7C.mc8] to create Hook model Note: When you have completed these drawings, each Student Group send one copy to server. Instructor will check it later. The server path is {\\Server\CAMex\ Group name} Project7A: Using above exercise of [Project6A] to create half shape.
Note: The provided file where is only a quarter entities. You can use Xform to copy another three. Finished TV model Provided file: Project7B.mc8
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Procedures: a. Create Swept surface of its top screen b. Project the inside contour (From R900 to R700) vertically onto this swept surface c. Using the projected curve with the outside contour to create a ruled surface. d. Create fillet surface (R3mm) between the ruled and swept surfaces e. Using Trim/Flat Boundary and Draft commands to create the TV casing. f. Finally, Xform functions to copy another three quarters. Details of TV Screen are shown below.
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Provided file: Project7C.mc8
Finished Hook model
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Details of Hook are shown below.
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Project 8
Surface machining
Using MasterCAM s 2D & 3D suface machining commands to make complex model. 5.5 hr

1. 2. 3. 4. There are five models for CNC programming -Prepare NC programs to make the shape of Project7A exercise Prepare NC programs to make the shape of Project7B exercise Prepare NC programs to make the shape of Project7C exercise Prepare NC programs to make the shape of provided file get from {C:\CAM\Exercise\Project8D.mc8} 5. Prepare NC programs to make the shape of provided file get from {C:\CAM\Exercise\Project8E.mc8} Note: When you have completed defining toolpaths, each Student Group send one copy to server. Instructor will check it later. The server path is {\\Server\CAMex\ Group name} Project8A: Modify the position of your [Project7A exercise], as right figure shown. Stock size is 130 x 100 x 50 (mm) Cutter is 12 mm Ball endmill for roughing and finishing processes Using Surface Rough Pocket for roughing You must define an outside boundary before you start getting surface rough pocket command. (refer to right figure) Using Surface Finish Flowline for finish
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Project8B: Using the shape of your Project7B exercise Stock size is 180 x 150 x 50 (mm) Cutter is 6mm Ball endmill with Surface Parallel commands for roughing and finishing processes Note: If any surfaces that are not required to make program, please blank or freeze it. Such that, you are easier to select surfaces for programming. Project8C: Using the shape of your Project7C exercise Stock size is 100 x 50 x 30 (mm) Cutter is 6mm Ball endmill for roughing and finishing processes What commands are you selected for this machining? Which commands are suitable for this machining that no excessive cuts and good surface finishing? If you want to use Parallel finishing command, you must add a flat boundary on the hook bottom to prevents excessive cuts. Project8D: Get from C:\CAM\Exercise\Project8D.mc8 Stock size is 100 x 80 x 40 (mm) Cutter is 12mm Ball endmill for roughing and finishing processes Using the black color contour for the Surface Rough Pocket Boundary. Note: a) The fillet surface is R10 mm b) These surfaces are larger than the stock size. Because there are opening edges, if not, these edges will be roughly
Project8E: Get from C:\CAM\Exercise\Project8E.mc8 Stock size is 50 x 50 x 50 (mm) Cutter is 4mm Ball endmill for finishing these surfaces What commands are you selected for roughing / finishing processes? Does it require more surfaces to help you generate toolpaths?
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Project 9 CNC program for lathe turning process

Using seeNC turn to edit and simulate toolpath for CNC lathe 3 hr
Equipment: Cadem seeNC turn CNC lathe programming codes:

Code T G97 S M03 M04 M05 G00 G01 G02 G03 R F G28 U W Description Tool Number: format is Txxyy (where the 1st two digit represent tool number; last two digit represent length offset number. E.g. T0101) Spindle speed in revolutions per minute (E.g. G97 S1000 M03) Spindle speed value Spindle on at CW Spindle on at CCW Spindle off Rapid transfer Linear machining that must be specified with feed rate Circular machining at CW that must be specified with feed rate Circular machining at CCW that must be specified with feed rate Radius of arc or circle Feed rate that unit is mm per revolution Axis return to machine zero position (E.g. G28 U0 W0) Increment moving parallel to X axis Increment moving parallel to Z axis
Canned cycles: G70 Finishing Cycle It is used for calling up the finishing passes after the roughing out has taken place, which format is { G70 P_ _ Q _ _ F _ _ } Where P is the start block number (Nxxxx) of the finish part profile definition and Q is the finishing block number. The F is the feed rate, if required. G71 Longitudinal area clearance routine, which format are two line commands together G71 U _ _ R _ _ Where U is value of depth per cut along X axis R is value of tool lift off per depth cut G71 P _ _ Q _ _ U _ _ W _ _ F _ _ Where the P, Q and F are same meaning of above G70 command. Where U is value of finishing allowance on X axis; W is is value of finishing allowance on Z axis G72 Transverse area clearance routine, which are also two line commands together G72 W _ _ R _ _ Where W is value of depth per cut along Z axis R is value of tool lift off per depth cut G72 P _ _ Q _ _ U _ _ W _ _ F _ _ Where the P, Q and F are same meaning of above G70 command. Where U is value of finishing allowance on X axis; W is is value of finishing allowance on Z axis
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Example 1: Get from C:\CAM\demo\Lathe1.txt and Lathe1.ttl (where the *.ttl is configure file) O1234 (Program File Number) G21 (Unit in mm) T0100 (Get the tool T01 with any offset [00]) G97 M03 S1000 G00 X90. Z10. T0101 M08 G00 X85. Z2. G01 X75. F0.5 G01 Z-50. G01 X85. G00 X90. Z10. G00 X85. Z2. G01 X70. F0.5 G01 Z-40. G01 X85. G00 X90. Z10. G00 X85. Z2. G01 X65. F0.5 G01 Z-30. G01 X85. G00 X90. Z10. G28 U0. W0. T0100 M05 M09 M30 (Spindle CW rotate at 1000 rpm) (The tool T1 being set with offset number [01] and open water pump) (move the tool near the workpiece) (Go to first cut)
(Go to second cut)
(Go to last cut)
(Return to machine zero position and cancel offset) (Program End)
Example 2: Get from C:\CAM\demo\Lathe2.txt and Lathe2.ttl (where the *.ttl is configure file) O1234 G21 T0100 G97 M03 S1000 G00 X90. Z10. T0101 M08 G00 X82. Z2. G71 U5. R1.5 (G71 cancel cycle) G71 P10 Q20 U2. W1. F0.3 N10 G00 X30. (The starting block number) G01 Z-40. N20 G01 X82. (The last block number) G70 P10 Q20 F0.2 G28 U0. W0. T0100 M05 M09 M30
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Example 3: Get from C:\CAM\demo\Lathe3.txt and Lathe3.ttl (where the *.ttl is configure file) O1234 G21 T0100 G97 M03 S1000 G00 X90. Z10. T0101 M08 G00 X82. Z2. G72 W5. R1.5 G72 P10 Q20 U2. W1. F0.3 N10 G00 Z-40. G01 X30. N20 G01 Z2. G70 P10 Q20 F0.2 G28 U0. W0. T0100 M05 M09 M30
Exercise:
Ex1
There are two shafts for CNC programming -Ex2
Note: When you have completed above exercises, each Student Group send one copy (the NC files with their configure file[*.ttl]) to server. Instructor will check it later. The server path is {\\Server\CAMex\ Group name}
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Project 10
CNC Electric Discharge Machine (EDM)

To understand the working principle and operations of the EDM machine. 1 hr
Equipment: Dophen CNC EDM

Exercise:
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CAM - Training (CNC Simulator)

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CAM - Training (CNC Simulator)

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TSC - CAM

Computer Logon Information User Name: tsc Password: hku

Contact: Dr. T. Y. Lee Mr. K. W. Wong Link: http://www.hku.hk/tscofhku/training/Year1.htm

THE UNIVERSITY OF HONG KONG Technology Support Centre

Prepared by: Y. C. Tam

THE UNIVERSITY OF HONG KONG Technology Support Centre

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Introduction to the module

Equipment: A. CNC machines

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THE UNIVERSITY OF HONG KONG Technology Support Centre

2D NC program edit for milling process 2D drawing 2D NC program for wirecut

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THE UNIVERSITY OF HONG KONG Technology Support Centre

Prepared by: Y. C. Tam

THE UNIVERSITY OF HONG KONG Technology Support Centre

2.4 List codes:

Construction of a simple NC program

THE UNIVERSITY OF HONG KONG Technology Support Centre

Electrical Discharge Machining (EDM)

Wire Cut EDM Machine

Prepared by: Y. C. Tam

THE UNIVERSITY OF HONG KONG Technology Support Centre

MicroTech CNC simulator

Menu & Toolbar 2D/3D solid

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THE UNIVERSITY OF HONG KONG Technology Support Centre

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THE UNIVERSITY OF HONG KONG Technology Support Centre

Program zero point register position

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THE UNIVERSITY OF HONG KONG Technology Support Centre

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Click the icon to open

A.2. A.3. A.4. A.5. A.6. A.7.

Design and draft your part

Create toolpath Simulation

Mastercam Interface Main Menu: Provides CAD / CAM

Toolbar icon / Function Keys:

Prepared by: Y. C. Tam

THE UNIVERSITY OF HONG KONG Technology Support Centre

Measuring Arcs and Angles

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G. Point Entry Menu:

Tips for inputting coordinate data:

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THE UNIVERSITY OF HONG KONG Technology Support Centre

Mcam 2: Basic CAD

2.2 Create a circle of 100mm diameter on (18, 28)

Creating tangent line, 450 at above circle and 100mm length

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THE UNIVERSITY OF HONG KONG Technology Support Centre

Creating rectangular of 100 x 60, center at (-30, -80)

Create a polygon (3 sides or more)

Creating a spline using manual point entry

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