TUTORIAL SERIES FOR

INSTRUCTOR GUIDE FOR

MASTERCAM X³ MILL LEVEL 1 TRAINING TUTORIALS
 HOW TO USE THIS MANUAL

This manual is a guide for instructors and trainers teaching Mastercam X³ Mill
Level 1.

Note: It is intended to be used in conjunction with Mastercam X³ Mill Level 1 Training

Tutorials published by In-House Solutions.

This manual makes reference to the Mastercam X³ Mill Level 1 Training Tutorials
throughout. We do not recommend trying to use this Guide without students having a
copy of the Mastercam X³ Mill Level 1 Training Tutorials.

This manual also makes use of Mastercam files, which can be downloaded from the
Training Exercises CD that comes with this book.

Legend:

Step to follow to complete the tutorial

Additional explanation for the current step

Callouts that give direction on how to complete the task

Bold text (usually) represents Mastercam terminology

To order Mastercam X³ Mill Level 1 Training Tutorials books:

Contact your Mastercam Dealer,
Call 1-800-529-5517 or
Place an order through www.inhousesolutions.com
Mastercam“ Instructor Guide for Mastercam X³ Mill Level 1 Training Tutorials
Date: October 22, 2008
Copyright © 1984 - 2008 In-House Solutions Inc. - All rights reserved.
Software: Mastercam X³ Mill Level 1
Authors: Mariana Lendel
ISBN: 978-1-894487-98-6
Notice
In-House Solutions Inc. reserves the right to make improvements to this manual at any time and without
notice.
Disclaimer Of All Warranties And Liability
In-House Solutions Inc. makes no warranties, either express or implied, with respect to this manual or with
respect to the software described in this manual, its quality, performance, merchantability, or fitness for
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This document may not, in whole or part, be copied, photocopied, reproduced, translated or reduced to any
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Corporation.
 TABLE OF CONTENT

Lesson #1: Introduction to Mastercam 3

Lesson #2: Introduction to Geometry Creation 15

Lesson #3 Geometry Creation (continued) 28

Lesson #4 Geometry Creation (continued) 34

Lesson #5 Geometry Creation (continued) 40

Lesson #6 Geometry Creation (continued) 47

Lesson #7 Geometry Creation (continued) 56

Lesson #8 Wireframe and Solid Geometry Creation 61

Lesson #9 Wireframe and Solid Geometry Creation (continued) 69

Lesson #10 Geometry Creation - Test 71

Lesson #11 Introduction to Chaining, Properties and basic 2D Toolpaths 73

Lesson #12 2D Toolpaths 91

Lesson #13 2D Toolpaths (continued) 97

Lesson #14 Introduction to 2D High Speed Toolpaths 100

Lesson #15 2D Toolpaths using Transform Toolpaths 107

Lesson #16 2D Toolpaths (continued) 111

Lesson #17 2D Toolpaths (WCS) 121

Lesson #18 2D High Speed Toolpaths (continued) 126

Lesson #19 fbm mill & drill Toolpaths 133

Lesson #20 Toolpaths - Test 140

 LESSON #2: INTRODUCTION TO GEOMETRY CREATION


Lesson Plan
Introduction to Geometry Creation
Lesson Objectives
Create a rectangle knowing the width and height
Create parallel lines, by defining the offset direction and distance
Create lines knowing the endpoints
Create arcs knowing the diameter and center point
Create fillets
Trim the existing geometry
Mirror xisting geometry
Move origin to redefine the part
Create points knowing their positions
Time Teaching / Learning Strategies Resources
30 min Have Students follow Tutorial 1 from the book to create Mastercam &
2D Geometry. Page 1-2 to Page 1-9 Mill Level 1 Training Tutorial Book
Enhancing Phase
1 hour Use the following Training Exercises: CD Training Exercises
Create_Point_Pos
Create_Rectangle
Create_Lines Use PowerPoint : Lesson2.ppt
Create_Arc
Fillet
Trim
Mirror
These exercises will help reinforce the commands used to
create the tutorial drawing and aid the students with 2D
geometry.
Assignments / Quiz
30 min Have the students complete Tutorial 1 – Exercise 1 and Mill Level 1 Training Tutorial Book
Tutorial 1 – Exercise 2 found at the end of Tutorial 1 in
the book; page 1-33 &1-34
Have students complete the first 2 questions from Mill Level 1 Training Tutorial Book
Tutorial 1 Quiz found in their books on page 1-36

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Mill Level 1 –Lesson 2: Geometry Creation INSTRUCTOR GUIDE

Students Students complete Tutorial 1 geometry Mastercam

complete Mill Level 1
Tutorial 1 Training
geometry Tutorial
page 1-2 to
page 1-9

The following commands are shown in Tutorial 1:

Create Rectangle knowing the width and the height of the rectangle.
Create Line Parallel by defining the offset direction and distance.
Create Circle Center Point knowing the diameter and the center point.
Mirror existing geometry to complete a part.
Move to Origin to redefine the part origin.

CREATE POINT POSITION COMMAND

Create Definition: Create Point Position command creates a point defined by its coordinates PowerPoint
Point X,Y, and Z or creates a point at the endpoint, midpoint, intersection, quadrant or arc Presentation:
Position center of already created lines or arcs. Lesson 2.ppt

Training
Exercises
CREATE_POIN
T_POS.MCX

File
Open
Select Create_Point_Pos.mcx
You can start the command from the Menu.

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Mill Level 1 –Lesson 2: Geometry Creation INSTRUCTOR GUIDE

You can also start the command from the Sketcher toolbar.

Tips: Create the points on the right side drawing to match the left side. Use the
Autocursor function to insert the points at the Endpoints, Midpoints,
Intersection, Quadrants, Origin and Center locations. As Mastercam detects and
snaps to points, it displays a temporary square over the point and the
corresponding cursor icon. Use the Fast Point icon to enter the coordinate values
for the rest of the points as per the drawing.

Press Enter key.

Mastercam does the math.
For the second point you can type 2.25+.5, -1.75 -1 (Enter)

CREATE RECTANGLE & CREATE RECTANGULAR SHAPES

COMMANDS
Definition: Create Rectangle command creates a rectangle based on two points, PowerPoint
Create or by entering the width and height in the ribbon bar and an anchor point. The Presentation:
Rectangle anchor point can be located at a corner or at the center of the rectangle. Lesson 2.ppt

CD Training
Exercises
CREATE_RECTA
NGLE.MCX

File
Open
Select Create_Rectangle.mcx

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Mill Level 1 –Lesson 2: Geometry Creation INSTRUCTOR GUIDE

Create
Rectangle
Tips: Type the coordinate values of the opposite corners of the rectangle as per
thdrawing using the Fast Point icon.

Create Definition: Create Rectangular Shapes allows you to create a rectangle, an

Rectangular obround shape, D shape or a double D shape. The shapes can be created using a
Shapes based point for the anchor and by entering the width and height of the shape. The
shapes can also be created using 2 points method by entering the two opposite
corner coordinate values.

Create
Rectangular Shapes
Tips: Select the Drop-down arrow to extend the dialog box.
Type the Width and the Height values. Select the approximate anchor placement
in the dialog box, and enter the coordinate values as per the drawing. Reselect
the command to change the point placement.

CREATE LINE ENDPOINT & CREATE LINE PARALLEL

Definition: Create Line Endpoint command allows to create a line knowing the PowerPoint
two endpoint coordinate values. It also allows you to create a line polar knowing Presentation:
Create Line
one endpoint location, the length and the angle of the line. You can create Lesson 2.ppt
Endpoint
horizontal or vertical lines. With this command you can also create multilines or
tangent lines. CD Training
Exercises
CREATE_LINE
S.MCX

Note that Create Line Enpoint allows you to create the following types of lines:
Line Endpoints
Line Horizontal
Line Vertical
Line Polar
Multiple Lines
Line Tangent

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Mill Level 1 –Lesson 2: Geometry Creation INSTRUCTOR GUIDE

File
Open
Select Create_Lines.mcx
Create
Line
Endpoint

Line
Create a horizontal line:
Horizontal Enable Horizontal icon in the Ribbon Bar.
Sketch the endpoints of the horizontal line
approximately at the same location from X and Y axis as per left side drawing.

Enter 1.5 as the Y coordinate.

Press the Enter key.
Select the Apply button to continue.

Create a vertical line:

Line Vertical Enable Vertical icon in the Ribbon Bar.
Sketch the endpoints of the vertical line
approximately at the same location from X and Y axis as per left side drawing.

Enter 1.0 as the X coordinate.

Press the Enter key.
Select the Apply button to continue.
Unselect the Vertical icon.

Create a line knowing the endpoints:

Select the Fast Point icon .
Line Type the coordinates values for the first point (-1.75, -.5) Enter
Endpoints
Select again the Fast Point icon .
Type the coordinates values for the second point (-2.5, -1.75) Enter
Select the Apply button to continue.

Create a polar line:

Enter the Length 3 and the Angle -25.0
Line Polar
Select the Origin (the center of the
Grid) as the first endpoint
Select the OK button to exit the command.

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Mill Level 1 –Lesson 2: Geometry Creation INSTRUCTOR GUIDE

Create Definition: Create Line Parallel command creates a line parallel to an existing line.
Line Parallel You can create the parallel line knowing the distances between the lines or
knowing a point to position the parallel line.

Create
Line
Parallel

Tips: Enter the Distance 0.50. Select the existing line and indicate the offset
direction by clicking below the existing line.

Select the OK button to exit.

CREATE CIRCLE CENTER POINT & CREATE ARC

ENDPOINT COMMANDS
Create Definition: Create Circle Center Point command creates a circle knowing the
center point location and the radius or the diameter of the circle. PowerPoint
Circle
Presentation:
Center Point
Lesson 2.ppt

CD Training
Exercises
CREATE_ARC.
MCX

File
Open
Select Create_Arc.mcx
Create
Arc
Circle Center Point

Tips: Enter the Radius = 1.0 and select the point as the center location. Select

the Apply button to continue in the same command.

Tips: Enter the Diameter = 1.0 and select the point as the center location. Select

the OK button to exit.

Create

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Mill Level 1 –Lesson 2: Geometry Creation INSTRUCTOR GUIDE

Arc Definition: Create Arc Endpoint command creates an arc knowing the two
Endpoint endpoint locations and the radius of the arc.
Create
Arc
Arc Endpoints

Tips: Enter the Radius = 0.25. Select the first point, select the second point. The
system gives all possible results. Select the arc that you want to keep. Select the

Apply button to continue in the same command . Following the same steps

create the other arc. Select the OK button to exit.

CREATE FILLET ENTITIES & CREATE FILLET CHAIN

COMMANDS
Create Definition: Create Fillet Entities command creates an arc of a defined radius PowerPoint
Fillet tangent to two curves. You can trim to the fillet the original entities or leave them Presentation:
Entities untrimmed. You can select different fillet styles (normal, inverse, circle or Lesson 2.ppt
clearance) before selecting the two entities.
CD Training
Exercises
FILLET.MCX

File
Open
Select Fillet.mcx
Create
Fillet
Entities

By default, the Trim icon is enabled and Mastercam trims the curves to
the fillet; however, you have the option to turn off trimming . Always select
the curves on the side that you want to keep after filleting.

First rectangle
Enter the Radius = 0.25

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Mill Level 1 –Lesson 2: Geometry Creation INSTRUCTOR GUIDE

The upper left corner settings should be as follows:

Enable Normal and Trim.

Select the Apply button to continue in the same command.

The upper right corner settings should be as follows:

Enable Inverse and keep Trim .

Select the Apply button to continue in the same command.

The lower right corner settings should be as follows:

Enable Circle and Trim .

Select the Apply button to continue in the same command.

The lower left corner settings should be as follows:

Enable Clearance and Trim .
Select the OK button to exit the command.

Create
Definition: Create Fillet Chains command lets you create fillets at sharp corners
Fillet Chains
along selected chains of curves.

Create Fillet Chain

Second rectangle
Enter the Radius: = 0.375
Enable Normal and Trim.
Select one of the rectangle lines and then the OK button to exit Chaining
dialog box.
Select the OK button to exit the command.

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Mill Level 1 –Lesson 2: Geometry Creation INSTRUCTOR GUIDE

TRIM COMMAND
PowerPoint
Definition: Trim/Extend/Break function has three commands incorporated in Presentation:
Edit
one. Based on what button you enable in the ribbon bar you can trim, break or Lesson 2.ppt
Trim/Extend/
Break
extend the entities.
CD Training
Definition: Trim command allows you to trim 1, 2 or 3 entities, trim to a selected Exercises
point or position. You can also divide entities based on the closest intersection. TRIM.MCX

File
Open
Select Trim.mcx

Edit/
Trim/Break
Trim/Break/Extend

Definition: Trim 1 entity trims or extends one curve to its intersection with a
Trim 1
second curve without modifying the second entity.
entity
Enable Trim 1 entity button. Select the entity to trim on the side that you
want to keep after trimming.

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Mill Level 1 –Lesson 2: Geometry Creation INSTRUCTOR GUIDE

Definition: Trim 2 entities trims or extends both curves to their intersection.

Trim 2
Enable Trim 2 entities button. Select the entities to trim on the side that
entities
you want to keep after trimming.

Definition: Trim 3 entities trims or extends all three curves. The first two
curves that you select are trimmed to the third selected curve, which acts as a
Trim 3
trimming curve. The third curve is then trimmed to the first two curves.
entities
Enable Trim 3 entities button . Select the entities to trim on the side that
you want to keep after trimming.

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Mill Level 1 –Lesson 2: Geometry Creation INSTRUCTOR GUIDE

Definition: Trim Divide trims a line or an arc into two disjointed segments by
Trim removing the segment that lies between two dividing curves.
Divide
Enable Trim Divide button. Select the parts of the entity to be
removed.

Definition: Trim to Point trims or extends a curve to a point or any defined

Trim to
position in the graphics window. If the point that you enter does not lie on the
Point
selected entity, Mastercam calculates the closest position on the entity and trims
the entity to that point.
Enable Trim to Point button.
Select the entity to trim/extend and then select the point. Select the OK button to
exit the command.

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Mill Level 1 –Lesson 2: Geometry Creation INSTRUCTOR GUIDE

XFORM MIRROR COMMAND

PowerPoint
Definition: Xform Mirror command creates reverse images of geometric and Presentation:
Xform drafting entities with respect to a defined axis or two points. The axis can be
Mirror Lesson 2.ppt
defined as X-axis, Y-axis, a point and an angle, an existing line or two points. You
have the option to move or copy the original entities within the drawing. CD Training
Exercises
MIRROR.MCX

File
Open
Select Mirror.mcx
Xform
Mirror

Tips for the upper shape

Select the entities to mirror using window by enable Window
Selection and mirror twice :once about X-axis, then about Y-
axis.

Tips for the middle shape

Select both contours to mirror using chain by enble Chain
Selection and enable the Select Line button in the Mirror
dialog box. Select the red color line.

Tips for the lower shape

Select both contours to mirror using Chain Selection and enable Select 2
points button in the Mirror dialog box Select two of the open ends of
the contours.

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Mill Level 1 –Lesson 2: Geometry Creation INSTRUCTOR GUIDE

Assignment The student creates the 2D geometry from Tutorial 1 – Exercise1 Mill Level 1
Tutorial 1 – Training
Exercise1 Tutorial page
1-33

Use the following commands:

Create Rectangle
Create Line Endpoint (Horizontal / Vertical)
Create Fillet
Trim Divide
Mill Level 1
The student creates the 2D geometry from Tutorial 1 – Exercise 2 Training
Assignment
Tutorial 1 – Tutorial page
Exercise 2 1-34

Use the following commands:

Create Rectangle
Create Line Parallel
Create Line Endpoint
Trim Divide
Create Fillet
Trim 2 entities
Mill Level 1
Training
Answer the first 2 questions from the Tutorial 1 quiz Tutorial page
1-36
Quiz

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Mill Level 1 –Lesson11: Toolpath CreationINSTRUCTOR GUIDE


LESSON #11 INTRODUCTION TO CHAINING, PROPERTIES AND BASIC 2D
TOOLPATHS


Lesson Plan
Introduction to Chaining and setting up Properties and basic 2D toolpaths
Lesson Objectives
Learn about chaining.
Load correct machine type.
Create Basic Toolpaths using geometry created in Lesson 2 (Tutorial 1).
Learn about contour toolpath.
Learn about drilling toolpath.
Backplot the toolpaths.
Verify the toolpaths.
Time Teaching / Learning Strategies Resources
40 min Download and demonstrate CD Training Exercises
ANALYZE CHAIN.MCX
Discuss Chaining problems, encourage students to take
notes and ask questions. Use PowerPoint: Lesson11a.ppt
Download and demonstrate
CHAIN1.MCX
Show students various methods for chaining geometry.
Enhancing Phase
40 min Load toolbar states PowerPoints: Lesson11a.ppt
Load Machine type
Introduction to icons found under Operations Manager
Present Machine Group Properties and explain settings
found there.
Set up bounding box
20 min Have students complete the Toolpath Creation from Mill Level 1 Training Tutorial Book
Tutorial 1 found on pages 1-10 to 1-32.
40 min Contour toolpath parameters PowerPoints: Lesson11b.ppt
Backploting the toolpaths
Verifying the toolpaths
Drill toolpath parameters
Assignment / Quiz
Have the students open 2D Geometry from Tutorial 1 Mill Level 1 Training Tutorial Book
Exercises and complete toolpaths on those parts. On
pages 1-33 & 1-34
Have students finish Tutorial 1 Quiz on page 1-36 Mill Level 1 Training Tutorial Book

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Mill Level 1 –Lesson11: Toolpath Creation INSTRUCTOR GUIDE

CHAINING
Definition: Chaining is a process used to select a number of entities, (lines, arcs,
About PowerPoint
points, splines etc.) Chaining is used when modifying or transforming existing
chaining Presentation:
entities or when creating a toolpath. The entities form a chain when the distance
Lesson
between two consecutive entities is less than the chaining tolerance (.0001 in the
11a.ppt
system configuration).

When Chaining Geometry to create a toolpath it is important in certain

circumstances to chain the geometry in the proper direction, as it will determine
the direction the cutter travels when machining the part. Below is an example of
how to select geometry using chaining method.
Note: To change the direction of the arrows just click on Reverse from the
Chaining dialog box.

Arrows will go
clockwise when the Arrows will go counter
line is selected here. clockwise when the
line is selected here.

CHAINING PROBLEMS
Description Check Fix
Untrimmed Chain stops; Lines do not Zoom in to inspect Trim lines together
entities touch

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Mill Level 1 –Lesson11: Toolpath Creation INSTRUCTOR GUIDE

Chain stops; Lines cross Zoom in to inspect Trim lines

Chain stops at Branch Points Note that the chain stops Enable CPlane to select the
Branches at the first branch. entities that are in the
current construction plane;
or guide the chaining by
selecting the next branch if
all entities area in the same
Cplane.

Lines don’t touch Look at geometry in Use Xform, Project.

Lines at
Gview Isometric.
different Z
depths

Duplicate entities Identical Zoom in on the area; a Delete Duplicate entities

Duplicate entities on top of each other thicker line should
entities become visible

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Mill Level 1 –Lesson11: Toolpath Creation INSTRUCTOR GUIDE

Overlapping Overlapping entities (Entities Zoom in on the area, use Use Findovlp.dll C-hook
entities of different lengths on top of Analyze commands and
each other). move the cursor to the
top of the entities.

FIXING CHAINS

Training
Exercises
ANALYZE
CHAIN.MCX

File
Open
Select Analyze chain.mcx

Analyze
Analyze Chain

Upper right corner geometry has Duplicate Entities

Delete Use Delete Duplicates icon to remove all identical entities from
Duplicates the screen.
The system will display how many duplicate entities were erased.

The upper left contour has entities of different lengths on top of each other.
Overlapping To fix the geometry use FindOverlap.dll user application. To open the C-Hooks
Entities directory hold down Alt key and type C. Select FindOverlap.dll and Open button.

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Mill Level 1 –Lesson11: Toolpath Creation INSTRUCTOR GUIDE

Use All button and All Entities when

you are prompted to select the geometry. Hit the
Enter button to end the selection. Select the Cleanup
button in the Find Overlap C-Hook dialog box and hit OK.

Entities at The lower left contour has entities at different z-depth.

different Z To see the geometry use Graphic View Isometric
depths Xform
Project
Definition: Xform Project projects all entities at the same z-depth in Top
Construction Plane.
When prompted to select the geometry use All button as shown in the previous
step to select all entities.
Make sure that Move is enabled and project to construction plane and 0 depth
as shown to ther right.

Untrimmed The lower right contour has untrimmed entities.

Entities To fix the geometry use
Edit
Trim/Break
Trim/Break/Extend
Trim 2 entities.
Make sure that you select the entities on the side that you want to keep.

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Mill Level 1 –Lesson11: Toolpath Creation INSTRUCTOR GUIDE

CHAINING - SELECTION METHODS

In Wireframe mode, the Chaining dialog box provides chain selection methods
Chaining
including:
dialog box
C-plane - allows you to select geometry created in the current construction plane.
3D - allows you to select 3D geometry.
Window
Area
Single
Polygon
Partial
Vector
Other controls let you manage the selection process:
Last
End chain
Unselect
Reverse chaining direction

Use Chain selection to create closed chains.

Full File
Chain mode Open
Select the CHAIN1.MCX
Use Analyze Chain command to show the different selection options.

Training
Exercises
CHAIN1.MCX

Select the chain

as shown

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Mill Level 1 –Lesson11: Toolpath Creation INSTRUCTOR GUIDE

Enable Chain button and then select the chain as shown.

Click on the Reverse button to change the chaining direction.
You can also expand the chaining dialog box by selecting the drop down arrow
and show how you can change the start of the chain using Forward ,
Back and Dynamic buttons.
Click on Unselect button to continue.

Use Partial chaining to create open chains.

Partial
Analyze
Chain
Chain
Click the first entity of the chain, and then click the last entity of the chain.

First Entity Last Entity

Press Esc to exit the Chaining dialog box.

Change the Select Level in the Status bar and make Level 1 invisible
Levels and Level 3visible. Leave Level 11 as the current main
level.

Chain with Branch point is the position where the endpoints of two or more entities meet.
Branches Branch points indicate where there are different paths that the chain can take.
When Mastercam encounters a branch point during chaining, it prompts you to
choose the path for the chain to follow.

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Mill Level 1 –Lesson11: Toolpath Creation INSTRUCTOR GUIDE

Analyze
Chain
Note the extra dashed lines. Guide the red arrow along the solid line contour to
chain the entire contour. Press the Esc to exit the command.

Change the Select Level in the Status bar and make Level 3 invisible
levels and Level 4 visible. Leave the current main level Level
11.

Change the Gview to Isometric.

C-Plane Cplane chains only entities that are parallel to the current construction plane and
at the same Z depth as the first entity you chain.

Analyze
Chain
Enable C-Plane and chain the bottom chains as shown
above. Press Esc to exit.

Chaining Definitions:
Options The chain Mask options speed up chaining for a large number
of entities or when branch points are involved. They let you
"pre-select" categories of entities to build your chain from.
Mastercam provides Entity, Color, and Level. All the mask
does is to block all the entities that do not match the mask
criteria.

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Mill Level 1 –Lesson11: Toolpath Creation INSTRUCTOR GUIDE

Color Mask Color Mask chains only entities that form a chain and have the same color as the
first entity you chain.

Analyze
Chain
Click on the Options button and enable Color and chain the top chain as
shown above.
Press Esc to exit.

More about Definitions:

Chaining Closed chains allow you to select all entities adjacent to the selected entity in the
Options forward and reverse directions until it reaches the end of a chain or a branch
point.

Open chains allow you to select a section of the chain by selecting the first entity
and the last entity of the chain. Mastercam creates an open chain which includes
all adjacent entities between these two points.

Section angle applies only to Section chaining. In Section chaining, Mastercam

chains along a set of smooth curves. Curves that are less than the section stop
angle are considered tangent for this chaining method. When Mastercam
encounters an angle that exceeds the section stop angle or a branch point, it ends
the chain.

Ignore depths (in 3D mode) lets you chain entities that could form a chain (the
distance between two consecutive entity endpoints is smaller than the chain
tolerance) but have different depths.

Start chain at point will start the chaining from a point that you create on an
endpoint of an entity in the chain.

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Mill Level 1 –Lesson11: Toolpath Creation INSTRUCTOR GUIDE

Allow surface edges in Single mode allows you to select, in single mode, the
edges of a surface.

Break entities in Dynamic sets the system to automatically break the entities at
intersection while in Dynamic mode.

Nested chains
Sorting lets you choose different sorting options while selecting geometry that is
completely contained within a closed boundary. You can speed up chaining using
next closest. Choosing inside to outside sorts and chains the curves from the
innermost to the outermost. You can sort the chains starting with the outermost
chains using outside to inside. It also allows you to sort and optimize the chaining
using optimize inside to outside or optimize outside to inside.

Infinite nesting in area chains one mouse click chains all of the curves and points
within a closed boundary. When unchecked, Mastercam chains the outer and
inner boundary closest to the point you entered to define the area chain and any
curves or points between the two.

Reverse inner chains changes the direction of chaining for the inner chains.

Sync mode allows Mastercam to break a chain into a number of separate chains
for the purpose of creating the surface. The Sync mode option of the Chaining

Options dialog box determines how Mastercam should divide up the chains. You
may need to choose a sync mode if you have attempted to create a surface and
found that it twists.

Chaining tolerance sets the default chaining tolerance value.

Plane tolerance sets the default plane tolerance value.

TOOLBAR STATES -2D TOOLPATHS

Load Before starting the toolpath creation we should customize the toolbars to see the
Toolbar toolbars required to machine a 2D part.
States Settings
Toolbar states

Select 2D-Toolpaths.

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Mill Level 1 –Lesson11: Toolpath Creation INSTRUCTOR GUIDE

Select the Load button.

Select the OK button to

accept it.

Note that the PowerPoint presentation shows another way of setting the toolbar.

MACHINE TYPE
Load the Selecting the correct machine is an important step in CNC programming. It will PowerPoint
Machine automatically have the Machine definition, the Control definition and the Post Presentation:
type processor linked to generate the specific code required by the CNC machine tool. Lesson
11a.ppt
Definitions:
Machine Machine Definition describes the components of the machine tool and their
Definition interrelationship and motion.

Control Control Definition provides the post processor with the information it needs to
Definition process the toolpath. Many of the settings in the control definition replace the
numbered questions found in posts for earlier versions of Mastercam, so that
settings that previously required editing the .PST file should now be set in the
control definition.

Post Post Processor refers to the process by which the toolpaths are converted to a
Processor format that can be understood by the machine tool's control (for example, G-
codes).

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Mill Level 1 –Lesson11: Toolpath Creation INSTRUCTOR GUIDE

TOOLPATHS MANAGER
Toolpaths PowerPoint
The Toolpaths Manager lists all operations in the current job. Use this dialog box
Manager Presentation:
to sort, edit, regenerate, verify and post any operations. You can enter this dialog
Lesson
box by selecting the Toolpaths tab.
11a.ppt

Toolpaths
Manager PowerPoint
Icons Presentation:
Lesson 11.ppt

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Mill Level 1 –Lesson11: Toolpath Creation INSTRUCTOR GUIDE

MACHINE GROUP PROPERTIES

Machine Machine group properties include selecting the machine tool that will perform PowerPoint
Group the operations in the group; post and NC settings; tool offsets, default settings Presentation:
Properties and data paths; and setting up stock models and safety zones that will be used by Lesson
all operations in the machine group. A single part can have multiple machine 11a.ppt
groups, each containing machining properties folders that identify properties (i.e.,
support files, tooling, stock, etc.) The functions in this dialog box are divided into
four tabs:

Files tab Files tab allows you to specify the names and data paths of the files needed to
generate the toolpath. It also allows you to set the operations defaults.

Tool Tool Settings tab allows you to control how Mastercam assigns tool numbers, tool
Settings tab offset numbers, and default values for feeds, speeds, coolant, and other toolpath
parameters.

Stock Setup tab allows you to define the stock shape and size to use it when
Stock Setup verifying the part using Verify.
tab

Safety zones tab allows you to define an area around the system origin to allow
Safety Zone the tool to retract a safe position outside this area to avoid collisions caused by
tab indexing. It is used mainly with multiaxis toolpaths.

Page 85
Mill Level 1 –Lesson11: Toolpath Creation INSTRUCTOR GUIDE

Mastercam
Students Students complete Tutorial 1 Toolpaths Mill Level 1
complete Training
Tutorial 1 Tutorial
Toolpaths page 1-10 to
page 1-32

The following settings, toolpaths and verification systems are shown in Tutorial 1:
Properties – setting the tool numbers, feedrate calculation and stock.
Contour Toolpath (open contour) – geometry selection, tool selection and specific
contour toolpath parameter settings.
Backplot toolpath explaning different options that could be used to simulate the
toolpath.
Verify toolpath explaining different options to verify the toolpath
Modifying the contour to add multiple cutting passes for a better clean up of the
part.
Drill Toolpath used to center drill and drill the holes and the specific parameter
description.
Backplot and Verify all the operations
Post process the file.

CONTOUR TOOLPATH PowerPoint

Lesson 11b.
Definition: Contour toolpath is used to drive a tool along a path. You can use the
Contour ppt
toolpath for both roughing and finishing.
Toolpath
To select the Contour Toolpath use one of the following 3 options:
Select the icon from the 2D toolpaths toolbar (left of Toolpaths Manager).

Select Toolpaths from the menu and click Contour in the

drop down list.

Page 86
Mill Level 1 –Lesson11: Toolpath Creation INSTRUCTOR GUIDE

Right click in the Toolpaths Manger area and select Mill toolpaths and then
Contour.

Right click anywhere

in this window

Toolpath Definition: Toolpath Parameters tab allows you to select a tool, set feed rates and
Parameters speeds and set other general toolpath parameters. This tab is the same, or very
tab similar, for most Mill toolpaths. For a detailed explanation of the parameters
please check the PowerPoint: Lesson11a.ppt

Contour Definitions: Contour Parameters tab allows you to enter cutting parameters for a
Parameters contour toolpath.
tab
Clearance value sets the height at which the tool rapids to or from the part.

Retract value sets the height at which the tool rapids/feed-rates up to, before the
next step down.

Feed plane value sets the height from which the tool plunge-rates into the part.

Depth value sets the final machining depth for the drilling operation.

Top of stock value sets the height of the material.

Compensation type set to Computer allows Mastercam to compensate the

toolpath, and doesn’t output G41/G42 in the code.

Compensation direction set to Right offsets the toolpath, with the radius of the
tool, to the right side.

Roll cutter around corners set to Sharp inserts arc moves around corners in the
toolpath. The radius of the arc moves is equal with the radius of the tool.

Infinite look ahead prevents the toolpath from crossing itself (fish tail).

Page 87
Mill Level 1 –Lesson11: Toolpath Creation INSTRUCTOR GUIDE

Depth cuts allows you to divide the total depth in increments not bigger than the
tool radius.

Multipasses allows you to follow the contour geometry in steps in the current
cutting plane.

BACKPLOT
Backplotting shows the path the tools follow to cut your part. This display lets you PowerPoint:
Backplot spot errors in your program before you machine the part. Lesson11b.
toolpaths ppt

Backplot Display with colour codes: Shows the toolpath moves using colours.
icons
Display tool: Shows the tool.

Display holder: Shows the tool holder.

Display rapid moves: Shows rapid moves in the backplot.

Display endpoints: Shows entity endpoints in the toolpath.

Quick Verify: Shows a shaded path the width of the tool as the backplot
progresses.

Options: Opens the options available for backplot.

Save Tool Geometry: Allows you to take a picture and save it, of the current
position of the tool and tool holder.

Save as geometry: Allows you to save the visible toolpath motion as geometry
to a specific level using specified attributes.

Restrict drawing: Removes all currently plotted toolpaths from the screen.
The remaining ones become the only ones Mastercam will plot.

Page 88
Mill Level 1 –Lesson11: Toolpath Creation INSTRUCTOR GUIDE

Turn off restricted: Turns off the restrictions set with the restrict
drawing button allowing you to backplot all of the selected operations.

VERIFY
Verify Definition: Verify allows you to verify the machining process from a solid PowerPoint:
toolpaths stock model. Lesson 11b.
ppt
Verification controls allow you to restart, machine, pause,
step and fast forward.

Turbo: Displays no tool, generally the fastest option. Use if machining

large files witha lot of code.

Simulate tool: Displays a solid tool without a holder.

Simulate tool and holder: Displays a tool and holder as a solid.

DRILL TOOLPATH

Drill Definition: Drill toolpath allows you to drill holes in the part using different cycles PowerPoint:
Toolpath that the CNC machine tools are capable of machining. Lesson 11b.
ppt
To select the Drill Toolpath you can use one of the 3 options as described in
the Contour operation.

Note that the Toolpaths Parameters tab is similar with the contour toolpath.

Simple drill Drill Parameters tab allows you to select a drilling cycle and enter basic drilling
no peck parameters.
(Drill
Parameters) Clearance value sets the height at which the tool rapids to or from the part.
tab
Retract value sets the height at which the tool rapids/feed-rates up to, before the
next step down.
Depth value sets the final machining depth for the drilling operation.

Drill/ Conterbore cycle (G81) is recommended for drilling holes with depths of
less than three times the tool diameter.

Peck Drill is recommended for drilling holes with depths of more than three times
the tool diameter. Retracts fully out of the drilled hole to remove material chips.

Page 89
Mill Level 1 –Lesson11: Toolpath Creation INSTRUCTOR GUIDE

Chip Break drills holes with depths of more than three times the tool diameter.
Retracts partially out of the drilled hole to break material chips.

Tap taps right or left internal threaded holes.

Bore #1 drills holes with feed-in and feed-out motion.

Bore #2 drills holes with feed-in, stop spindle, and rapid-out motion.

Fine bore (shift) stops the spindle at the end of each drill point, then spins to
orient the tool to a pre-defined angle, shifts off the wall of the hole, and retracts.

Tip comp: adds the tip of the tool (automatically determined based on the tool
diameter and the 118 degrees angle of the drill) to the depth. You can also add a
breakthrough amount to the depth for the tool to drill all the way through the
stock.

POST PROCESSING
Definition: Post Processor refers to the process by which the toolpaths are
converted to a format that can be understood by the machine tool's PowerPoint:
Post
control (for example, G-codes). Lesson
11b.ppt
Output MCX file descriptor allows you to include a description of your file.

NC file allows you to save your file.

Ask prompts the user if you wish to overwrite the

file name.

Send to machine sends the NC file automatically to

the machine’s tool control
through your workstation serial port.

Edit allows you to edit the program.

NC extension prompts for the extension to be used

for the NC files.

Overwrite automatically overwrites a file with the

same name without asking permission.

Page 90
 TUTORIAL SERIES FOR

INSTRUCTOR GUIDE FOR

MASTERCAM X³ MILL LEVEL 3 TRAINING TUTORIALS
 HOW TO USE THIS MANUAL

This manual is a guide for instructors and trainers teaching Mastercam X³ Mill
Level 3.
Note: It is intended to be used in conjunction with Mastercam X³ Mill Level 3 Training
Tutorials published by In-House Solutions.

This manual makes reference to the Mastercam X³ Mill Level 3 Training Tutorials
throughout. We don’t recommend trying to use this Guide without students having a
copy of the Mastercam X³ Mill Level 3 Training Tutorials

This manual also makes use of Mastercam files, which can be downloaded from the
Training Exercises CD that comes with the tutorial.

Legend:

Step to follow to complete the tutorial

Additional explanation for the current step

Callouts that give direction on how to complete the task

Bold text (usually) represents Mastercam terminology

To order Mastercam X³ Mill Level 1 Training Tutorials books:

Contact your Mastercam Dealer,
Call 1-800-529-5517 or
Place an order through www.inhousesolutions.com
Mastercam“ Instructor Guide for Mastercam X³ Mill Level 3 Training Tutorials
Date: October 31, 2008
Copyright © 1984 - 2008 In-House Solutions Inc. - All rights reserved.
Software: Mastercam X³ Mill Level 3
Authors: Mariana Lendel
ISBN: 978-1-926566-11-5
Notice
In-House Solutions Inc. reserves the right to make improvements to this manual at any time and without
notice.
Disclaimer Of All Warranties And Liability
In-House Solutions Inc. makes no warranties, either express or implied, with respect to this manual or with
respect to the software described in this manual, its quality, performance, merchantability, or fitness for
any particular purpose. In-House Solutions Inc. manual is sold or licensed "as is." The entire risk as to its
quality and performance is with the buyer. Should the manual prove defective following its purchase, the
buyer (and not In-House Solutions Inc., its distributor, or its retailer) assumes the entire cost of all
necessary servicing, repair, of correction and any incidental or consequential damages. In no event will In-
House Solutions Inc. be liable for direct, indirect, or consequential damages resulting from any defect in
the manual, even if In-House Solutions Inc. has been advised of the possibility of such damages. Some
jurisdictions do not allow the exclusion or limitation of implied warranties or liability for incidental or
consequential damages, so the above limitation or exclusion may not apply to you.
Copyrights
This manual is protected under the copyright laws of Canada and the United States. All rights are reserved.
This document may not, in whole or part, be copied, photocopied, reproduced, translated or reduced to any
electronic medium or machine readable form without prior consent, in writing, from In-House Solutions
Inc.
Trademarks
Mastercam is a registered trademark of CNC Software, Inc.
Microsoft, the Microsoft logo, MS, and MS-DOS are registered trademarks of Microsoft Corporation;
Mastercam; Windows 95, Windows 2000 and Windows XP are registered trademarks of Microsoft
Corporation.
 TABLE OF CONTENT

Lesson #1 Introduction to 3D Wireframe 1

Lesson #2 Introduction to Curves and Surface Creation: Revolved 9

Lesson #3 Surface Creation: Draft, Extruded, Primiteves, Ruled/Lofted 17

Lesson #4 Surface Creation: Net 29

Lesson #5 Surface Creation: Swept 37

Lesson #6 Surface Creation: Fillet 46

Lesson #7 Surface Creation: Trim and Offset 54

Lesson #8 Surface Creation: Blend and Fillet Blend 64

Lesson #9 Surface Creation (Continued) 70

Lesson #10 3D Wireframe and Surfaces Creation - Test 72

Lesson #11 Introduction to 3D Toolpaths: Rough Pocket, Finish Parallel & Finish Contour 73

Lesson #12 3D Toolpaths: Rough Radial and Finish Scallop 80

Lesson #13 3D Toolpaths: Rough Restmill and Finish Blend 85

Lesson #14 3D Toolpaths: Rough Flowline, Rough Plunge, Finish Shallow and Blend 90

Lesson #15 Surface HS Core Roughing, Surface Pencil and Project Finish 96

Lesson #16 Surface HS Area Clearance and Surface Finish Contour, Leftover and Project 103

Lesson #17 Surface HS Core Rough, Horizontal Area, Waterline and Scallop Rest Passes 108

Lesson #18 Surface HS Core Rough, Horizontal Area, Scallop, Scallop Rest Passes and Pencil 114

Lesson #19 Surface Toolpaths - Test 121

 LESSON #3 SURFACE CREATION: DRAFT, EXTRUDED, PRIMITIVES AND
RULED/LOFTED


Lesson Plan
Surface Creation: Draft, Extruded, Primitives and Ruled/Lofted
Lesson Objectives
Create 3D wireframe
Create Ruled/Loft surface
Create a Flat Boundary surface
Create Primitives
Create Draft Surfaces
Time Teaching / Learning Strategies Resources
15 min Have students follow Tutorial 2 from the book to create Mastercam &
3D wireframe, Ruled & Flat boundary surface page 2-2 to Mill Level 3 Training Tutorial Book
page 2-11.
Enhancing Phase
1 hour Download the Training Exercises and demonstrate these CD Training Exercises
exercises:
Draft_Extrude CD PowerPoint:Lesson 3
Primitives
LOFT AND RULED SURFACE.MCX
Ruled-Sync
Rul2
20 min Have the students create the wireframe from Tutorial 2 Mill Level 3 Training Tutorial Book
– Exercise on page 2-28.
Assignments / Quiz
5 min Have students complete the first 2 questions from Mill Level 3 Training Tutorial Book
Tutorial 2 Quiz found in their books on page 2-30.

 Page-17 

Mill Level 3 – Lesson 3: Geometry Creation INSTRUCTOR GUIDE

Students Students complete Tutorial 2 geometry Mastercam

complete Mill Level 3
Tutorial 2 Training
geometry Tutorial
Page 2-2 to
page 2-10

The following commands are shown in Tutorial 2:

Create the 3D wireframe
Create Ruled Surface
Create Flat Boundary
Create Rectangular Shapes with the surface option enabled.

EXERCISES USING PRIMITIVES

Primitives Definition: Primitives creation functions can make solid or surface shapes. These PowerPoint
Surfaces functions are found on the Sketcher toolbar. The following shapes can be created Presentation:
using the primitives commands: Cylinder, Cone, Block, Sphere and Torus. Lesson 3.ppt

File
Open Training
Select PRIMITIVES.MCX Exercises
PRIMITIVES.
MCX

Page-18
Mill Level 3 – Lesson 3: Geometry Creation INSTRUCTOR GUIDE

Create the sphere.

Sphere Create
Primitives
Sphere

Tips: You can draw the sphere by clicking in the graphics window to set the base
point, dragging outward to set the radius. While the sphere is live you can
change the base point, radius, and sweep angle.

Create the torus.

Torus Create
Primitives
Torus

Tips: Use different color to create the torus. You can draw the torus (in Isometric
view) by clicking in the graphics window to set the base point, dragging outward
to set the major radius. After setting the major radius, enter the minor radius.
While the torus is live you can change the base point, major and minor radius,
sweep angle and the axis.

Create the cylinder.

Create
Cylinder Primitives
Cylinder

Tips: Use different color to create the cylinder. You can draw the cylinder (in
Isometric view) by clicking in the graphics window to set the base point, dragging
outward to set the radius, then dragging up or down to set the height. While the
cylinder is live you can adjust the dimensions, extend the cylinder in two
directions, select a new base point, change the primary axis, or change the sweep
to create a slice of a cylinder.

Page-19
Mill Level 3 – Lesson 3: Geometry Creation INSTRUCTOR GUIDE

DRAFT AND EXTRUDED SURFACES

Definition: A Draft Surface is a surface generated by extruding one or more PowerPoint
Draft
contours, along a line defined by an angle and a length. Presentation:
Surface
Lesson 3.ppt
Applications: the surface is used to create an angled surface, a tapered wall,
or cones and cylinders.

Examples:

You can select multiple entities to chain. Mastercam creates a separate draft
surface for each individual entity in each chain.
A zero value entered in the Angle field produces no tilt and is the equivalent of an
extrusion perpendicular to the construction plane.

Training
Exercises
DRAFT_
EXTRUDED.
MCX

File
Open
Select DRAFT_EXTRUDED.MCX

Page-20
Mill Level 3 – Lesson 3: Geometry Creation INSTRUCTOR GUIDE

Draft Create the draft surface in the upper right corner.

Surface

Create
Surface
Draft
Tips: Make sure that the current Cplane is set to Top plane. Note that the
extrusion is always perpendicular to the Cplane.

Select the chain and then enter the values in the dialog box to match the ones
from the finish geometry in the right colummn. (Length = 1.0; Angle = 5 deg.)

Create the draft surface in the middle

Create
Surface
Draft
Tips: Make sure that the current Cplane is set to Front plane.

Select the chain and then enable Plane instead of Length in the dialog box.
Enter Angle = 5 deg. and select the Plane button.

Page-21
Mill Level 3 – Lesson 3: Geometry Creation INSTRUCTOR GUIDE

Define the plane by selecting Entities button , and then select from the
graphic window two lines that intersect.
Make sure that the resulting arrow will point towards the original chain.

Definition: Extrude Surface command creates CAD surfaces over the closed
chains.
Applications: the surface is used to create an angled surface, a tapered wall, or
cones and cylinders.
Note that the different between the draft surface command and the extrude
surface command is that the last creates extra surface at the top and bottom of
the shape.

Extrude
Surface Create the extrude surface in the lower right corner.

Create
Surface
Extrude

Select the chain and then enter the values in the dialog box to match the ones
from the finish geometry in the right colummn. (Length = 1.0; Angle = 5 deg.)
Note that changes that you make using the Extruded Surface dialog box affect
the surface model only, not the curves from which it was created.

Page-22
Mill Level 3 – Lesson 3: Geometry Creation INSTRUCTOR GUIDE

RULED / LOFTED SURFACES

PowerPoint
Ruled Definition: Ruled Surface is a surface generated by connecting straight lines Presentation:
Surfaces between two or more open or closed contours. When creating a ruled surface Lesson 3.ppt
with three or more curves defining the boundary, Mastercam creates separate
surfaces between each pair of curves rather than one surface with sharp corners
and ridges.

Applications: any time a surface must be fit between two or more open or closed
contours.
Example:

Definition: Loft Surface is a surface generated by blending together more than 3

Loft open or closed contours. As a result the surface has rounded edges at the
Surfaces intermediate contours.
Applications: any time a surface must be parabolically blended through more than
two curves.
Note that the system will automatically create a ruled surface through two chains
of entities.

Page-23
Mill Level 3 – Lesson 3: Geometry Creation INSTRUCTOR GUIDE

To generate a proper ruled or lofted surface you need to:

Select the contours in the order
Aligned the starting locations
Select all contours in the same direction.

Ruled/
Lofted Chain - allows you to return to the graphics window to
Surface select new chains.
Ribbon bar
buttons Ruled - creates Ruled surfaces using linear blending of a
minimum two curves or chains of curves.

- creates Lofted surfaces using a smooth blending

of a minimum two curves or chains of curves.

Training
Exercises
LOFT AND
RULED
SURFACE.
MCX

File
Open
Select LOFT AND RULED SURFACE.MCX

Create a Ruled Surface in the upper right corner

Create
Surface
Ruled/Loft

Tips: Select the contours in the order, from the same starting locations, and in the
same direction.
Enable the Ruled button.

Page-24
Mill Level 3 – Lesson 3: Geometry Creation INSTRUCTOR GUIDE

Create a Lofted surface in the lower right corner

Create
Surface
Ruled/Loft

Tips: Select the contours in the order, from the same starting locations, and in the
same direction.
Enable the Lofted button.

RULED AND LOFT CONTOUR SYNCHRONIZATION

Training
Exercises
Ruled-Sync.
MCX

File
Open
Select Ruled-Sync.MCX
Create
Surface
Ruled/Loft

No Create ruled surfaces without

Synchroni- Synchronization.
zation
Tips: Select the contours in the
order, from the same starting
locations, and in the same direction.

Select the ok button to accept the warning that sharp corners will be ignored.

Page-25
Mill Level 3 – Lesson 3: Geometry Creation INSTRUCTOR GUIDE

Create ruled surfaces with Synchronization.

Synchroni-
zation In order to better match the curves or chains of curves, you may want to select
your curves using the Sync chaining method (Chaining Options dialog box), which
lets you match curves manually or by entity, branch, node, or point. Synch by
branch match the curves at the branches.

Tips: In the Chaining dialog box select the Options button and enable Mask
on Color. The color mask excludes from chaining all entities except those whose
colors match any of the color(s) you select. Note that the chains are green color,
while the branches are blue.

CREATE RULED/LOFT SURFACES USING WINDOW SELECTION.

Training
Exercises
Rul2.MCX

File
Open
Select Rul2.MCX

Page-26
Mill Level 3 – Lesson 3: Geometry Creation INSTRUCTOR GUIDE

Create
Surfaces
Ruled/Loft

Tips: Select Options button in the Chaining

dialog box. Make sure that you disable Mask on Color
and turn Sync mode to None. In the Chaining dialog
box enabled the Window button.

Window Make a window around the

selection wirefame and select as the
search point one of the
endpoints of the first contour
as shown.

Enabled Loft icon.

Page-27
Mill Level 3 – Lesson 3: Geometry Creation INSTRUCTOR GUIDE

Assignments The student creates the 3D wireframe and surfaces of Tutorial 2 – Exercise Mill Level 3
Tutorial 2 – Training
Exercise Tutorial page
2-28

Use the following commands:

Create Ruled/Lofted Surface
Create Flat Boundary Surface
Create Rectangular Shape with surface option on.

Quiz Answear the first question from the Tutorial 2 quiz Mill Level 3
Training
Tutorial page
2-30

Page-28

LESSON #15 SURFACE HIGH SPEED CORE ROUGHING, PENCIL AND PROJECT
TOOLPATHS

Lesson Plan
Surface High Speed Core Roughing, Pencil and Project Toolpaths
Lesson Objectives
High Speed Core Toolpath
Finish Boss shape using Scallop Toolpath
Finish the Floor using Rough Pocket with facing option on
Finish the part using Pencil Toolpath
Use Check Holder to check the to find the minimum required tool length
Engrave the letters using Finish Project Toolpath
Time Teaching / Learning Strategies Resources
40 min Have the students complete Tutorial 5 toolpaths creation Mill Level 3 Training Tutorial Book
found on pages 5-26 to 5-73
Enhancing Phase
60 min Go over PowerPoint to reinforce toolpaths used in PowerPoint: Lesson 15.ppt
Tutorial 5
Assignment / Quiz
30 min Have the students open the geometry from Tutorial 5 Mill Level 3 Training Tutorial Book
Exercise. Complete the toolpaths on the part found on
pages 5-74
5 min Have students complete Tutorial 5 Quiz found on page 5-
77

 Page-96 
Mill Level 3 – Lesson 15: Toolpath Creation INSTRUCTOR GUIDE

Students Students complete Tutorial 5 toolpaths Mastercam

complete Mill Level 3
Tutorial 5 Training
toolpaths Tutorial
Page 5-26 to
page 5-73

The following toolpaths are shown in Tutorial 5:

Surface HS - Core Roughing
Surface Finish Scallop
Surface Rough Pocket with Facing option
Surface Finish Pencil
Check Holder C-Hook
Surface Finish Project

SURFACE HIGH SPEED – CORE ROUGHING

Definition: Surface HS Core Roughing toolpaths are designed for machining cores PowerPoint:
HS Core which can be approached from the outside. Lesson 15.ppt
Roughing
toolpath An important feature of core roughing is that Mastercam can change the
machining strategy within the same operation if the part has, for example, a
mixture of bosses and cavities. In these cases, Mastercam will cut the cavities
inside to out (like an area clearance cutting pass), and machine the bosses from
the outside.

Page-97
Mill Level 3 – Lesson 15: Toolpath Creation INSTRUCTOR GUIDE

Specific Surface HS Core Roughing Parameters

Cut Cut Parameters

Parameters Step-down value sets a constant Z spacing between cutting passes.

Add cuts feature allows you to insert additional cutting passes in areas of your
part where the profile is close to flat. Mastercam will add new cuts to maintain
the maximum profile stepover, while spacing them each by at least as much as the
minimum step-down.

Smoothing inserts arcs at corners to create smoother tool motion. The amount of
smoothing is constrained by the maximum radius that you enter.

XY stepover settings allows you to configure the spacing between the passes at
the same Z. Mastercam will use the largest value possible (up to the maximum XY
stepover) that does not leave unwanted material between the passes. However, it
will not separate the passes by less than the minimum stepover.

Transitions Transitions
Transitions allow you to configure the entry move that the tool will make as it
transitions to new Z levels. You can choose to create either a ramp entry, or
helical entry move. If the profile is too small to create a helix of this size,
Mastercam will create a ramp move instead.

Linking Linking Parameters

Parameters Linking options allow you to configure how Mastercam links air moves when the
tool is not in contact with the part.

Minimum vertical retract is a vertical retract and constant-Z move at the Part
clearance height.

Leads fields set the tool moves onto and off of the part at the start and end of
each cutting pass. These moves are applied to each pass no matter which cutting
pass is selected.

Fitting settings allow you to choose how the entry and exit arcs fit to the ends of
the cutting passes.

Minimize trimming sets the path to retract to be as close to the surface as

possible, maintaining a minimum distance from the surface to fit the arc.

Max trimming distance parameter limits the amount of trimming applied to non-
horizontal passes.

Page-98
Mill Level 3 – Lesson 15: Toolpath Creation INSTRUCTOR GUIDE

Arc Filter/ Profile tolerance determines the maximum deviation between the smoothed and
Tolerance unsmoothed toolpaths and is only applied on the outermost cutting pass.

Offset tolerance is defined in the same way as the Profile tolerance, but it is
applied to all the inner passes.

SURFACE ROUGH POCKET WITH FACING

PowerPoint
Presentation:
Definition: Surface Rough Pocket Facing automatically detects and creates
Rough Lesson 15.ppt
motion on the flat surfaces within a pocket.
Pocket -
Facing

Specific Surface Rough Pocket-Facing Parameters

Floor extensions a 2D offset that extends the toolpath off the flat surface. This
will allow the tool to start just off the flat floors in open areas of the pocket

Floor adjustment an additional Z stock offset, positive or negative can be used

Wall clearance additional clearance from wall surfaces in X and Y direction.

Page-99
Mill Level 3 – Lesson 15: Toolpath Creation INSTRUCTOR GUIDE

SURFACE FINISH PENCIL PowerPoint

Presentation:
Definition: Surface Finish Pencil toolpaths can be used as a finish operation to Lesson 15.ppt
Finish
clean leftover materials from corners. The toolpath is generating a trace between
Pencil
the sharp edges of the selected surfaces.
toolpath

Specific Surface Finish Pencil Parameters

Parallel passes
None creates a single pencil toolpath.

Number per side allows you to specify the number of passes on each side
of the pencil trace.

Unlimited allows Mastercam to create an unlimited number of offset

passes all the way across the selected drive surface.

Bitangency angle defines the angle between surfaces that can be machine with
the pencil toolpath.

Over thickness value is added to the cutter radius. It is used when the cutter’s
radius is very close or smaller than any fillets in the drive surfaces.

Page-100
Mill Level 3 – Lesson 15: Toolpath Creation INSTRUCTOR GUIDE

SURFACE FINISH PROJECT PowerPoint

Presentation:
Lesson 15.ppt
Finish Definition: Surface Rough and Finish Project Toolpaths allow you to project
Project curves, points, or another NCI file onto selected surfaces. These toolpaths can
toolpath closely match the cut motion to the shape of the part and can be used for
engraving.

Specific Surface Finish Project Parameters

Projection type
NCI allows you to project an existing 2D toolpath (contour or pocket) onto
selected surfaces.
Curve allow you to project 2D chains of entities (lines, arcs, splines) onto
selected surfaces. Mastercam prompts you to select the chains after you
exit project parameters.
Points allow you to project points onto selected surfaces. Mastercam
prompts you to select the chains after you exit project parameters.

Retract between cuts forces a retract move between cuts and for engraving
letters (curve projection type) allows the tool to retract between letters.

Add depths allow you to add cut depths for the rough project. It is enabled only
with projection type NCI.

Page-101
Mill Level 3 – Lesson 15: Toolpath Creation INSTRUCTOR GUIDE

Assignment The student creates the 2D geometry of Tutorial 5 – Exercise1 Mill Level 3
Tutorial 5 – Training
Exercise1 Tutorial pages
5-73 to 5-75

Use the following toolpaths:

Surface High Speed Core Roughing
Surface Rough Pocket - Facing
Surface Finish Scallop
2D Pocket
Surface Finish Project

Mill Level 3
Training
Quiz Answear the first question from the Tutorial 5 quiz Tutorial page
5-77

Page-102