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V10.7
For Mastercam X7
Quick Start Guide
CONTENTS
INTRODUCTION ................................................................................................................ 1
PREREQUISITIES ............................................................................................................... 1
SOFTWARE .................................................................................................................... 1
MOLDPLUS LICENSING ....................................................................................................... 1
TO CONFIGURE THE LICENSE ........................................................................................... 1
DRAFT ANGLE ANALYSIS .................................................................................................... 5
CREATING PARTING LINES, 3D PART EDGES AND 2D PART EDGES.......................................... 8
CORE AND CAVITY SEPARATION ....................................................................................... 11
ELECTRODE MAKER ......................................................................................................... 18
INTRODUCTION
This document will walk you through the configuration process and introduce you to Core and
Cavity separation and electrode extraction and creation. The Quick Start Guide for the 5-axis
toolkit can be used to learn the features of that tool. The Online Help will help you understand
more about these features.
PREREQUISITIES
Please ensure the following items are installed and configured correctly before using this
application guide.
SOFTWARE
MOLDPLUS LICENSING
After Moldplus 10.7 has been installed, you will need to configure the license to enable the
features. Licenses are delivered as an XML file by your reseller.
As long as your maintenance is current, you can run the new features in the 5-axis toolkit.
The Moldplus STL Utilities, Fixture Design and Welding products will need new licenses to be
purchased in order to function.
New software purchases or license purchases will need to follow the routine as described to
register the licenses.
1. Click Moldplus->About on the Mastercam menu. The About Moldplus dialog is displayed.
This dialog is also displayed when you click on any Moldplus toolbar button for the first time. Note
the actual SIM number and user type are displayed.
2. Click Register. Browse to the location where the XML License file was saved, select the file
and click Open.
Valid products are indicated with a green tick and invalid ones with a cross. To request a new
license or an updated version of your current license, please contact your reseller.
If you check the box for View All, all the Moldplus product licenses available are displayed.
Once the server is active and identified through the client, the following is displayed:
This guide will walk you through: Draft Analysis, parting line creation, Solid Sep (core and cavity
separation) and electrode extraction, creation and report generation in about 10 minutes or less.
The files referred to here can be found in the \SHARED MCAMX7\MCX\
Moldplus_Examples_MM folder.
Moldplus offers very powerful tools for analyzing parts for undercut surfaces, etc. With 1 click of
the mouse, you should be able to analyze the part and automatically trim the undercut surfaces
and place them in different colors and levels. This feature alone will eliminate the need to
machine prototypes before realizing that the mold cannot be pulled apart because there are
undercut surfaces. To do this:
Step 1:
You can analyze this part in the Top view and determine if there any undercuts or not.
With this part, it is pretty obvious that you will not have any undercuts but it is good to
verify the draft analysis before starting the separation.
Step 3:
Review the settings: Click
Settings to display the Draft
Angle settings dialog.
Change the values as shown.
The Above value defines the
positive angles with respect to the
current CPlane that are positive.
Surfaces in the part with this angle
will be colored green and moved to
the layer shown.
Surfaces with angles between 3 and
0 degrees as colored yellow.
Undercut surfaces are colored
green.
Click OK to close the dialog.
. The Draft
Analyzing draft angles: Verify the CPlane is set to Top and click Do it.
You will notice that all geometry between and above 3 degrees are marked in green. The
yellow surfaces indicate the 0 to 3 degree range. In this part, they can be machined as
part of the cavity. The red surfaces are all marked as undercut since they lie beneath the
cavity faces. All the surfaces considered as an undercut here can be considered as core
geometry.
Step 5:
Verification of results: To see that the surfaces are trimmed and moved to
different levels, press Alt+Z or click Level at the bottom of the Mastercam graphics
window to display the Mastercam Level Manager.
Disable Level 1 (the surface geometry level). Click OK. Only the yellow and red surfaces
will be left. You can also disable the Level 3 to see only the red surfaces if you prefer.
An overall analysis at this stage tells you that there are no undercuts in this part, a core
and cavity can be created and machined and that there is no need to have any slides or
lifter geometries to manufacture this part. Only electrodes are needed to burn the cavity
ribs.
Step 6:
Restore the surfaces: Undo the Draft Angle analysis by clicking Undo/Redo.
This will restore all the surfaces to the original levels, ready for parting line creation.
This completes Draft Angle analysis.
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Moldplus allows the quick creation of Parting Lines, 3D part edges and 2d projected part edges.
All these are helpful to complete a mold design (for example, creating Run-offs to mold edges).
You can easily create the 3D parting edges for molds. This is useful where you need these
external edges to create run-offs to the mold edges using manual run-off creation methods. Since
we analyzed the part and found no undercuts, we know that the parting lines for this part are the
external edges of the part.
Step 1:
Start 3D part edges: Click 3D Edges
on the
Moldplus toolbar. The Moldplus: Surface Edges dialog is
displayed.
Step 2:
Reviewing settings:
Click Settings to open the
Settings dialog. Review the
settings and verify they are set
correctly.
Create the 3d part edges: Click Part Edges to create the edges.
Note: There will probably be additional edges created where the software identifies gaps
between the faces. This feature will quickly tell you if there are inconsistencies/ gaps
between surfaces and is useful to check the consistency of a surface model. In many cases
the gaps may be irrelevant due to a bad conversion of a solid to a surface model or loose
tolerances while importing the model.
Step 4:
Delete internal edges: Delete the internal edges using the Mastercam tools.
The exterior edges can be then be used to create the run-off surfaces easily using the
Moldplus Partsurf functions.
Step 6:
Change the Mastercam system color to 1.Click Part Edges to create lines and arcs
representing the part edges.
Using this quick contouring or pocketing can be done, or whatever else you wish to do.
Step 7:
This completes the creation of the parting lines, 3D edges and 2D projected edges. You can
also do those for single surfaces or get all the edges of all the surfaces if desired.
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Core and cavity separation using Moldplus is a very powerful tool that automates the process of
identifying core and cavity geometry. This means what would take hours manually can be done in
a few clicks.
Step 1:
Load the file: Continue with the same part or
reload the SOLID_SEP_ELECTRODES_MM.mcx file.
Step 2:
SolidSep
dialog.
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Review Settings: Click Settings and verify the settings are as shown below.
The Settings dialog allows you to organize the splitting process by colors and levels for
easy identification and manipulation.
As normal practice, the cavity (the external shell of the mold) would be what is considered
here as CP Z+ (Construction Plane Z Positive) and the core (the internal shell of the
mold) would be CP Z-.
When the Open Mold option is selected, , the CP Z+ geometry will be translated by the
distance specified in CP translation heights above the original location, set to color 10
and moved to Level 2. The CP Z- surfaces will stay in the current location and have its
properties changed to Level 3 and color 4. Any straddle (surfaces that straddle the parting
line of the geometry) or vertical or unknown surfaces will be moved to half the distance
(75 mm in this case) to allow the user to decide which side they belong to and marked
with the corresponding colors and moved to the set levels.
If you are starting with a solid model directly, Moldplus will convert the Solids to a surface
model first and move the solid to the level specified in Converted Solid level.
Upon reviewing the settings, click Done to close the dialog.
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You are prompted with the dialog that gives the user a warning that the properties of the
surfaces will be changed. This is a friendly warning! Click OK to continue.
The separation takes place within a few seconds and the following will the presented.
The surfaces are now split for core and cavity and displayed according to the settings. You
will notice that there are no verticals, straddles or unknown surfaces (would normally be
displayed in the middle). From the main Core and Cavity menu, you can easily move
surfaces between core and cavity by simply clicking on them. Since this was a perfect
split, we dont have to do anything more to this part.
Step 5:
Restore surfaces to original heights: Click on Open/Close to return all the
surfaces to the original Z heights. You are done with the separation part.
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Step 6:
Set the Mastercam levels: Click Level on the Mastercam status bar or press
Alt+Z to open the Mastercam Level Manager.
Disable Level 2 (the CP Z+ level) to leave only the CP Z- surfaces visible.
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Partsurf
Step 8:
Set stock limits: Click Stock Limits. The Mastercam Chaining dialog is displayed.
Click on any of the entities forming the stock boundaries to select the chain.
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With the run-off created, you will need to create the shut-offs for the core and cavity.
We will create the shut-off surfaces using the Moldplus Supertrim functions. Note that these
functions are part of the Moldplus Supertrim bundle.
Step 10:
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Click the holes to be filled near any edge as shown in the figure.
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ELECTRODE MAKER
This section will cover Moldplus Electrode Maker. There is far more automation and user control
built in to isolating electrodes, inserting electrode stocks, preparing them for machining with
proper extensions for strength and proper burning and finally generating textual and visual HTML
reports. The steps outlined will allow you to review Electrode Maker in a matter of few minutes
without having to understand all the details of the Settings.
Step 1:
Load the file: Continue with the same file that you split the core and cavity from.
You will notice there are several ribs and inserts to burn into the core. We will create a few
electrodes from this part a rough electrode to burn multiple ribs and a few finish
electrodes.
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Step 3:
Review and change settings: Click Settings to review and change the settings
for the electrodes created on this part.
Click Part Configuration in the tree and change the settings as shown below:
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Click
to show the Select Postprocessor File dialog and select the file \shared
Mcamx6\mill\Posts\MPE_EDM_MACH_X6.PST as shown below.
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Note: The gaps configured in the Gaps settings page are used only for documentation. Electrode
Maker does not yet create surfaces that are offset from the originals by the gaps set here.
Click OK to save the settings and exit the settings dialog. If the folder does not exist, it is
automatically created.
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Step 6:
Launch the Mastercam
Level Manager. Turn off all
levels except for Level 3.
Step 7:
Create new electrode:
Right-click on the electrode list.
From the menu, select New
Electrode.
Next, we will select the surfaces that make up the electrode. This can be done via the
Surfaces Selection dialog that replaces the Electrode List
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Hold down the Shift key and select the surface shown.
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Next, we will add draft to the extensions to make the electrode stronger.
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Most electrodes will also have chamfers for ease of setup during machining. These can be
created automatically.
Change the options as shown to the right:
Face XY defines the distance from the
machined sides of the electrode to the raw
stock.
Stock XY defines the distance from added
from the extents of the electrode surfaces to
the machines side of the electrode.
Under Stock definition, click Rect. This will
recalculate all the electrode dimensions to
suit the dimensions entered for the stock
values.
The preview will update to show the correct
stock sizes. Note the chamfers are shown as
well.
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We will now create a finish electrode for one of the ribs. The other ribs can be finished using the
same electrode.
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Step 17: Add raw stock and holder: Doubleclick Raw stock to start the Stock and
Holder Definition dialog.
Under Stock Definition, note the size of the
raw stock displayed. This will allow us to
select the appropriate holder for this
electrode.
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You can also select the box to display the electrode and unselect it to hide it.
Clicking on an electrode will temporarily make it visible.
Step 18:
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Hide the first electrode: Hide Elec-1 by clearing the check box.
Click Capture checked to capture images of all the electrodes. This captures images of
the electrodes and the part. The images are displayed under Image.
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Once you are satisfied with the images, click Make XML to generate the report and view it
using your Internet Browser.
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Click Default to set the output folder to a folder that is based on the name of the
current part.
Click the Export Levels list box and select the option Surf+Ext: Surf Holder: no
change option. This will ensure that all the surfaces and extensions are one level and the
holder levels are unchanged from the part.
Click the Translation list box and select the Top Base (Pt1) to origin option to
automatically translate the electrodes burn point to the origin. Select Flip to ensure the
electrodes are oriented correctly for machining.
Click OK to create the electrodes.
This concludes the review of the process of splitting Core and Cavity and creating 2 electrodes on
the same file.
We will review the Electrode Maker on another example file now and review other options within
the Electrode Maker tool.
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SETTING UP A JOB
Step 1:
Load the 0_ELEC4.MCX-7 file from the Examples
folder.
Start ElectrodeMaker by selecting Moldplus>ElectrodeMaker->ElectrodeMaker V10 on the
Mastercam menu or clicking the
toolbar.
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Click Settings to review and change the settings for the electrodes created on this
Click Part Configuration in the tree and change the settings as shown below:
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Note: The gaps configured in the Gaps settings page are used only for documentation.
ElectrodeMaker does not yet create surfaces that are offset from the originals by the gaps set
here.
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Step 5:
To add an electrode,
right-click on the list of
electrodes.
From the menu, select New
elec.
Step 6:
The
Electrode
Properties
dialog is
displayed. The
electrode
prefix is
named with
the settings
defined in Step
2.
Click OK to
add the
electrode.
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Once the electrode has been added, the next step is selecting the surfaces on the part to
be burned with the electrode.
ElectrodeMaker allows surface selection via one three methods:
1. Manual selection
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Step 9:
Verify the correct surfaces are
selected by selecting the Show
selected surfaces only check box.
This will show only the selected
surfaces.
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list
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Once the electrode surfaces are created, they need to be extended beyond the burn depth to
prevent unwanted burns on the part. Extensions can be created automatically in one of many
different ways in ElectrodeMaker.
Step 11: Double-click First Tangent in
the ElectrodeMaker dialog to start
adding the first extension.
This will launch the Extension
Properties dialog.
Change the options as shown in the
figure.
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The next step is to add the stock from which the electrode will be machined. ElectrodeMaker can
automatically calculate the size needed for the raw stock. In addition, a holder can be selected
from a list of standard holders.
Step 15:
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Double-click Raw stock. This will show the Stock and Holder definition dialog.
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Step 19:
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Click On/Off.
button.
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To complete the job, more electrodes are needed to burn other profiles in the part. The process
for adding these electrodes will be the same as the previous electrode.
Step 21: Add a new electrode
right-clicking on the
electrode list and selecting
New Elec.
Step 22:
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by
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The Moldplus Junction Surface function can be used to create the extensions between the
surfaces.
Step 28: Click JunctSurf
on the Moldplus
toolbar. This will launch the Moldplus Junction
Surfaces dialog.
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it
1
2
Step 30: Select the edges as shown in the figure. The second junction surface is created as
shown on the inner shape.
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Select the two edges as shown in the figure. The gap is bridged as shown in the figure on
the right.
Step 32:
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Double-click Raw stock. This will show the Stock and Holder definition dialog.
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You can manipulate the values using the different rounding methods and get your desired
results for the electrode extensions and stock size.
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Often, parts have the same profile in multiple locations. Instead of creating multiple electrodes at
each location, the ElectrodeMaker clone feature can be used to copy the electrodes at each
location.
The geometry for each electrode is not copied instead the burn locations are computed and
written to the reports.
Step 36: Right-click Elec1 in the
Electrodes list and select
Edit/Create Clone from the
menu.
The part is automatically placed in the Top Gview and the other electrodes are hidden.
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All the electrodes are saved in the same MCX file as the part. To machine them and create the
toolpaths, the electrodes have to be saved to individual MCX files.
ElectrodeMaker can export these electrodes automatically.
Step 40: In the ElectrodeMaker dialog,
click Export and select Elecs to folder
from the menu.
The Elecs to
folder dialog is
displayed.
If the output
folder is
different, click
Default to set
it to the correct
folder.
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ElectrodeMaker can automatically generate reports for shop floor documentation. The reports are
generated in XML folder and can be opened with any internet browser.
If any of the images are not displayed, click Check all and Capture checked to capture
the images.
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Ensure that the style sheet Style1.xsl is selected under XSL Settings.
Click the browse button and locate the file, if a different XSL file is selected.
Click Make XML to create the report and open it in the browser.
Note that the clone for Elec-1 has its burn location listed in the report below the gap
values.
Click Close to close the XML Report dialog and return to ElectrodeMaker.
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Review the settings and click Create Mach. Report to generate the report.
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This completes the process for making some electrodes using ElectrodeMaker.
More electrodes can be added to complete all the operations in the part using similar
methods to those outlined in this guide.
For more information on the advanced functions and options available in ElectrodeMaker,
please consult the help file and application guides.
CONCLUSION
This concludes the Moldplus Quick Start Guide! For any further details on the product, please
refer to the on-line help.
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