Mill 2D & Solids: Handbook Volume 1
Mill 2D & Solids: Handbook Volume 1
Handb
MILL 2 D
&S O LID
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id e to M a s te rcam
The g
Handbook Volume 1
Call 1-800-529-5517 or
Visit www.emastercam.com or
Software: Mastercam X9
Author: In-House Solutions
ISBN: 978-1-77146-384-3
Revision Date: May 8, 2015
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 International copyright laws. 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;
Windows 7 and Windows 8, are registered trademarks of Microsoft Corporation.
This document requires Mastercam Mill Level 1 and Solids for Chapter 5.
TABLE OF CONTENTS
Table of Contents
Legend ........................................................................................................................ 1
Chapters
Introduction To Mastercam ....................................................................................................................3
Mastercam Workspace .........................................................................................................................37
CAD Drawing......................................................................................................................................... 67
Advanced CAD Drawing ......................................................................................................................137
Solid Modeling ....................................................................................................................................191
Drill Toolpaths ....................................................................................................................................229
Contour Toolpaths ..............................................................................................................................305
Pocket, Face, Circle & Slot Mill Toolpaths ..........................................................................................359
High Speed Toolpaths & Feature Based Machining ...........................................................................397
Rotary Toolpaths ................................................................................................................................463
Change Recognition ............................................................................................................................489
Handbook Volume 1
TABLE OF CONTENTS
Handbook Volume 1
LEGEND1
Legend
Conventions
Key words and Mastercam menu items are shown in bold the first time they are used. Columns on the outside
edges of each page and note pages at the end of each chapter provide ample space for taking notes.
Useful tips, recommended settings, best practices, and detailed instruction on the most important features are
included when possible.
Extra credit exercises are included on the student CD in PDF format. These will help build your skill to a higher
level.
Terms
1 Introduction To Mastercam
OBJECTIVES
In this chapter, you will learn what CAD/CAM software is and how Mastercam works. Upon completion of this
chapter, you should be able to do the following:
INTRODUCTION
CAD and CAM are the acronyms of Computer-Aided Design and Computer-Aided Manufacturing, respectively.
CAM/CAM software is used to program CNC (Computer Numerical Control) machine tools.
CAD/CAM software allows you to draw or model a part in the computer. This electronic model is accurate and
can be easily modified.
Machining operations can be applied to remove excessive material and to finish the part. The machining
processes are accurately simulated, allowing you to find and fix problems before running the program on the
machine.
Once you are certain that the machining processes are safe and effective, Mastercam performs all the tedious
calculations and formatting to generate the NC (Numerical Control) code file.
CAD/CAM software is often used to program CNC machine tools because it offers many advantages over manual
programming, including
• Faster programming
• More efficient CNC programs
• Fewer CNC program errors, resulting in fewer scrapped parts and broken tools
CNC SETUPS
Parts must be located precisely and held securely during the machining process. Work holding devices are
referred to as fixtures. A fixture can be as simple as a vise with hard jaws. Very complex fixtures, like those used in
the aerospace industry, may cost many thousands of dollars and be designed by highly experienced tooling
engineers.
For example, many parts can be accurately located and held in a vise. If the part is machined on several sides, pay
careful attention to the order in which each face is machined and how the part is flipped between operations.
Production quantity is an important consideration. Higher production volumes usually justify more expensive
tooling to speed production and reduce scrap rate.
Size and type of material and cutting forces also affect fixture choice. A foam or plastic visual prototype may be
simply glued or taped down. More substantial parts can be bolted, clamped, or held with a vacuum.
A basic vise setup uses a vise , step jaws, vise stop, and stock material machined to size as shown in Figure 1. The
back edge of the fixed step jaw is dial-indicated parallel to the machine’s X-axis. The vise stop sets a limit to slide
the stock against as fresh stock material is loaded.
Figure 1
NOTE: Improperly designed setups are extremely dangerous. Parts, tooling, or fixture components can shatter
or be ejected at high speed, causing serious injury or even death. Always wear safety glasses and observe all
machine safety procedures.
Figure 2 shows the layout of a typical VMC and the location of the spindle when the machine is at its Home
Position.
Figure 2
NOTE: CNC programs are written in terms of the tool tip motion, not table motion. For example, a command of
X1.0 moves the tool to the right (though on a VMC the table will move to the left).
Fixture Offsets
Your probably have noticed that when the machine is at its home position, its coordinate system datum is far
away from the part datum. The reason is presented below.
When you first power-up a CNC machine, the machine does not know where the spindle is in the workspace. The
machine finds the spindle’s position, also known as the machine position, during the startup-home process by
simply driving each machine axis towards its limit. Just before the machine reaches an axis limit, it trips a micro-
switch. This signals the control that the axis is at a known location, called the Machine Home. Home is usually
defined as the center-face of the spindle where the machine is at its axes’ limits.
Once a machine has been to the Machine Home, the machine keeps track of its own position by measuring how
far each axis moves from Home. Coordinates in relation to the Machine Home are called Machine Coordinates.
The Machine Home position is far from the work piece; hence, programs written in Machine Coordinates will
have numbers that hardly exhibit obvious relations to coordinates on the part. Further, if a fixture is removed, it
will be difficult to put back the fixture exactly where it was, and the CNC program writen in Machine Coordinates
will have to be rewritten to account for all the changes. Threfore, Machine Coordinates are rarely employed to
generate CNC programs.
Since a part has its own datum, NC programs can be written in reference to the Part Datum, and such programs
can be easily understood. Figure 3 gives an example of the coordinate system based on the Part Datum.
Figure 3
Any point on the part or fixture can be used to locate the part datum, as long as the point’s position can be
reliably obtained.
In Figure 4, the material is machined to finished size before loading it into a standard six-inch vise with step jaws.
The top of the finished material is Z-Datum.
The fixed (back) vise jaw is dial-indicated parallel to the machine X-axis. A Vise Stop, in this case an adjustable rod,
allows stock material to be loaded into the vise in the exact same position each time.
The part datum must be located precisely, typically +/- .001 or less. There are many ways to find the part datum.
For example, the XY-Datum can be easily obtained using the Edge Finder to locate the back and left edges of the
part.
Figure 4
The coordinate system is shifted from Machine Home to the Part Datum by a Fixture Offset. A fixture offset is
simply a record of the distance between the Machine Home position and the Part Datum point, which is kept by
the machine control. Each time the NC program commands a move, the machine control checks this record, or
Register, and internally adds this value to that move.
G-codes that are assigned for Fixture Offset are usually G54 through G59, and some machines may allocate more.
Each fixture offset has an XYZ shift value.
In Figure 5, the G54 offset register is called on line (N2) of the NC program. This line of code moves the center of
the spindle from the Machine Home position to directly above the Part Datum.
Figure 5
You probably have noticed that the fixture offset in the previous example was used only to shift the datum in X-Y,
not Z. This is because the Z shift distance changes based on the tool length - how far the tool extends below the
center-face of the spindle. Most tools are of different lengths. Length may also change when you replace a worn
or broken tool.
Shifting the Z-datum is completed by using Tool Length Offsets. Tool offsets function similarly to fixture offsets.
They inform the machine of the location of the tool tip in relation to the part Z-datum. Each tool has its own Tool
Length Offset number. For most machines, Tool Length Offset number is an H-value that uses the same number
as the tool (i.e., T1 uses H1, T2 uses H2, etc).
The H-value is called in the G-code file with the first rapid move to depth along with a G43 (Read Tool Height
Offset Register). This requests the machine to check the H-register value and add this to the move, as shown in
Figure 6.
Figure 6
There is another method of using the Tool Length Offsets, which employs preset tooling. This method is used
more often in larger companies and long production run work. A more detailed description of the method is as
follows.
• The tool length (distance from the center-face of the spindle to the tip of the tool) is accurately measured
in the tool room.
• This gage length is entered in the tool-offset register as a positive value.
• The fixture offset Z-value represents the distance from the center-face of the spindle to the part Z-datum.
• Internally, the control first subtracts the fixture offset from a command move. It then adds the tool gage
length to the move.
NOTE: Some machines have automatic tool probes which measure the length automatically. Follow the
instructions in the machine operator manual for use of tool and fixture offsets with a probe.There are other
ways to use fixture and tool offsets.
They all work, and companies have good reasons to adopt a particular method. But, once you understand how
fixture and tool offsets work, will easily adapt to whatever method your company or school uses.
CNC Setups
Plate work refers to machining sheets or plates of material. The material is manufactured to a specified thickness
that is the same as the finish thickness of the part, hence no facing operation is required.
The purpose of the fixture plate is to locate accurately the stock material and then keep the part from moving
during machining.
The illustration below shows a typical fixture plate. The fixture base is machined to be flat, square, and parallel.
The plate is engraved with the part name and the coordinates of the part datum in reference to the upper-left
corner, as shown in Figure 7. This makes it easier to reuse the fixture plate.
Figure 7
The fixture plate below shows the setup just before the first machining operation. After the holes are drilled and
bolts inserted through the part, the dowel pins and clamps should be removed if there is any possibility of a
collision with the tool or holder, as shown in Figure 8.
Figure 8
Component Description
Fixture Plate This is the base on which the fixture is built. For short production and
prototype parts, an aluminum plate is commonly used. It is machined flat,
square, and parallel.
Deburr all sharp edges and holes so that the stock lies flat on the surface
and is not scratched.
Stock A sheet of aluminum stock that is within specification in thickness.
Since an OD contour cut is made all around the part, stock can be sheared
or saw cut to approximate size.
A .093 vent hole is drilled from the bottom of the reamed hole through
the bottom of the plate. This allows air to enter into the space between
the bottom of the dowel pins. Without it, the dowel may become
impossible to remove due to the vacuum created with a blind hole.
Washers Steel cap screws will mar aluminum. Place an aluminum washer or pad
between clamps and an aluminum surface.
Cap Screws Two screws hold the clamps in place during drilling operations. Others are
installed to hold the plate down during the OD contour cut.
Clamps Simple shop-made aluminum clamps hold the part during drilling.
Component Specifications
Component Specifications
Process Overview
The following steps show how a simple fixture plate may be set up and used on a vertical machining center.
NOTE: Remove dowel pins after clamps are tightened if there is any chance of the tool impacting the pins.
NOTE: The machine operator is responsible for part quality. This is more than just adjusting a machine offset
to ensure the part is within specification.
Shoulder Bolts
In cases where you need to position a plate with existing holes, never rely on threaded holes to locate the part.
Instead, use Shoulder Bolts (aka Stripper Bolts) as shown in Figure 9.
Counterbore a hole in the fixture plate the diameter of the bolt shank.
Drill and tap a hole in the bottom of this counterbore to screw in the shoulder bolt.
Figure 9
Mastercam uses several file types, and each file plays a specific role in programming your machine. They are
installed on the computer’s hard drive in the directories shown in the Mastercam directory structure.
Mastercam automatically keeps track of the file location and extension. Below are the extensions that are most
widely used.
Mastercam File MCX-9 Holds drawing and associated tool path information.
Post Processor PST The Post Processor consists of three files: PST (Post), MMD
MMD (Machine Definition), and CONTROL (Control Definition).
CONTROL These act together as a language translator that converts MCX
file tool path information into a NC program file that will run
the CNC machine.
G-Code NC This is the G & M code file used to control your machine. The
default extension can be changed if your machine requires a
different one.
Depending on the type of operating system installed on your computer, Mastercam will install files into different
file paths.
For Windows 7 or Windows 8, you can find individual files and folders located at Libraries\Documents\my
mcamX9. Shared files and folders will be located at C:\Users\Public\Public Documents\shared McamX9.
For a 64 bit version of the software, the Program Files folder will be located at C:\Program Files X86.
NOTE: Above lists the default locations of files. Mastercam will automatically store files there unless another
location is set. The location of these files can be changed to any location on the computer or network at any
time.
STARTING MASTERCAM
To start Mastercam double click on the Mastercam X9 icon on your computer desktop.
GETTING HELP
Mastercam has a network of extensive technical support. Whenever you need help to understand a function or
some setting, click on the Search Help icon or hit Alt+H. The Help menu lists several resources available, including
Contents, an online Reference guide, and the Mastercam website.
If you are a student, your instructor is your primary source for help.
Mastercam has a worldwide network of Authorized Resellers to support industrial customers. Mastercam
resellers are highly qualified and have extensive experience helping customers get the most from their
Mastercam software investment.
The Mastercam forum is an excellent resource. It includes answers to frequently asked questions. Also, the
Forum section lets you post questions and read answers from Mastercam users worldwide. Please visit
www.emastercam.com for more information.
Most functions in Mastercam can be accessed using the Main menu or a toolbar. File operations are used to
open, save, and manage MCX and other file types. File functions are selected from the file toolbar or from
choosing from the main menu.
Item Definition
Item Definition
Open User Folder Opens a folder where you can find saved MCX files.
Open Shared Folder Open a folder where you can find your system defaults.
Project Manager Sets a location to store any or all files related to the active MCX file.
Import Directory Imports the entire contents of a directory from any CAD format into the
Mastercam MCX format.
Export Directory Export the entire contents of a directory into any CAD format.
Update Folder Updates Mastercam files from previous versions.
Migration Folder Migrates files to the current Mastercam version.
Change Recognition Compares the active MCX file with any other MCX or CAD file. Identifies and
isolates differences between the files to allow easy revision updates.
Tracking Used to help keep track of revision changes. Checks for newer revisions of files
with the same name as the active MCX file.
Recent Files List most recently accessed files. Number of files displayed is set in Settings,
Configuration, Files.
Properties List information about the file path, name, create and modify dates, file size,
and descripton.
Exit Leave Mastercam.
File Open
The File, Open dialog box is shown below with sub-menus. You should already know many of the file operations
since they are common in most Windows-based products. The screenshot in Figure 10 is obtained in Windows 7.
Figure 10
Item Definition
Look In Shows current directory. Click on down arrow to see entire path to the current
directory, or to browse to another.
Back Browses to the previously selected directory.
New Folder Creates a new sub-directory under the current directory displayed in Look In.
List Options Select how files in the display list are shown:
Icons: Shows an icon of certain size with file name only.
List: Shows a small icon with the file name.
Details: Shows files with the Name, Date Modified, Size, and Type.
Tiles: Shows a large icon with file name and part size.
Content: Shows a sketch of the file.
File Name Name of file. Be sure to adhere to the windows file name conventions when
naming MCX files.
All Mastercam X Files Lists what type of file to read.
Right Mouse Button Click the RMB with the mouse in the area shown to see more options.
X At the top-right corner. Quit this function and do nothing.
NOTE: When using List or Details options, you can sort the files by a certain criterion by clicking on the column
label. For example, to sort by most recent date, click on the Date Modified label; to sort by smallest to largest
size, click on Size.
Clicking on a banner again will reverse the sort order. For example, to sort by the largest to smallest size, click
on Size again.
File Save
The File, Save As dialog box is shown below. This menu appears when using the Save As option or for the first
time you save a file. By default, Mastercam will automatically add the MCX-9 extension and save the file in the
default MCX-9 directory (C:\Users\User Name\My Documents\mcamx-9\mcx-9).
Other file types listed under Save as type are for sending the file to an earlier version of Mastercam or to a
different CAD/CAM system. The Options button displays a menu that changes depending on the type of file
saved as, as shown below.
Nowadays, most mechanical designs are completed using CAD software rather than a pencil and a paper.
Mastercam can read virtually any CAD data, and hence saves the time for redrawing the part from scratch.
Importing a CAD file to Mastercam offers numerous advantages for both machinists and designers.
• The machinist saves time and avoids errors because the part is already drawn.
• Since many CAD files are full 3D models, it is easier to understand fully the part.
• It saves the designer’s time. Because the geometry is already fully defined, there is no need to dimension
the print to an extent that another person can draw it from scratch. This is referred to as a minimally
dimensioned print.
In some cases, having the CAD data does not eliminate the need to obtain a drawing. Some CAD file formats
contain few or no drafting dimensions or notes.
The machinist may not be able to manufacture the part to specification without these dimensions and notes. For
example, you may not be able to tell if a hole should be drilled, tapped or reamed, or that a certain feature
requires a certain finish.
Each CAD/CAM company structures its graphic database in a unique way. This format is considered a trade secret
and readable only by that system.
For example, Mastercam stores its information in the MCX format that is readable only by Mastercam.
This poses a problem: how can CAD data be shared between systems if the formats are different and the files are
encrypted to prevent others from reading them?
The solution is to use what is called a neutral file. Here is how it works:
• First, data from the CAD system is written from its proprietary form into a format that is not encrypted.
The format of this neutral file is documented and made available to other software developers, like
Mastercam.
• Since other systems can then read and understand the format of this neutral file, they can use it to create
a copy of the CAD file in their own format.
There are many neutral file types. IGES and STEP formats produce the best results.
Native Files
In recent years, some CAD companies have embraced what is called an open architecture approach to software
design.
The owner of the CAD system licenses the structure of their database so that others can read it. This allows other
systems to read or write to that format without using a neutral file.
This type of direct transfer as shown in Figure 11 is referred to as native file translation and it offers numerous
advantages over neutral files:
• In general, native file translations are more robust, because more entities are supported and fewer
translations errors occur.
• The designer no longer has to create a neutral file. This not only saves labor, but simplifies drawing
management since the chance of the native and neutral file not being the same is eliminated.
Figure 11
The table below lists native data translation formats supported by Mastercam. Many are included with
Mastercam; others can be purchased. For more information, contact your Mastercam dealer.
Translation Problems
Occasionally you may have problems converting data between systems. Here are the most common problems
and possible resolutions.
Problem Resolution
Error Reading File "Error reading disk" when attempting to read a file. The only solution is to get
another copy of the file.
Duplicate Entities Use Delete duplicates function.
Breaks Between Entities Use Analyze contour to find and correct errors. If the file has many
disconnected entities, consider asking the sender to output the file again to a
closer tolerance (12 decimal places or more).
Wrong Scale Most mechanical CAD files are 1:1, but exceptions do exist. Check the size of
features on the drawing using the Analyze function. The drawing may also be
in Metric units though you machine uses English units. Use Xform, Scale to
change the scale of the part if needed.
Read Errors Or Missing Or This is probably due to incompatible data translator versions. Make sure the
Corrupt Entities translator versions are compatible. If you have a newer CAD/CAM system and
you are reading a file from an older system, incompatibility may be a problem.
Missing Dimensions For entities to transfer using a neutral file format, both the sending and
receiving systems must support the entity type. This is a common problem,
especially with IGES files.
Always get a hard copy of the file in addition to the CAD database.
Print Dimensions Do Not A likely cause is that the designer changes a dimension note rather than the
Match Actual Size Of geometry it refers to. This is not a problem with solid modelers.
Entities In Drawing
File Compression
CAD files are often transmitted by attachments to emails. Thus, basic Internet skills, such as how to use email, are
essential. There are many good books and instructional CD's available that can help you.
It is a common practice to compress or "zip" a CAD file before transmission. Compression software uses
sophisticated algorithms to reduce temporarily the file size. Small files are easier to store and are faster to
transmit over the Internet.
Compression varies depending on the file type. Some, like IGES, may shrink to just 10 percent of their Original
size. Others, like SLDPRT, may reduce by less than half.
Once you receive the file, uncompress, or "unzip", the file to restore it to its original state.
One of the most commonly used software to compress files is WinZip®, by WinZip Computing, Inc of Mansfield,
CT. WinZip files have a ZIP extension. You can download an evaluation copy of PKZIP (WinZip) from their
website: www.winzip.com
WinZip is an essential tool. It is inexpensive, and it is recommended that your company own a registered copy.
It is important to use virus detection software and to keep the virus definitions up-to-date. Viruses often appear
as EXE (executable) files. Never download or execute a file if you do not know who sent it or if you do not have
the latest updates for your anti-virus software.
Zip2 Go
Mastercam includes a ZIP utility, Zip2Go, under the Help menu. This allows you to ZIP Mastercam files. Use the
Command, Add Files to select files, and Create Zip2Go to make the Z2G file. Use Help to learn more.
This chapter aims at providing some basic computer knowledge and skills that you will need to use Mastercam.
• Mastercam file types and locations.
• How to start Mastercam.
• How to read and save Mastercam files.
• How to get help.
• How to read and write data to other CAD/CAM systems.
2 Mastercam Workspace
OBJECTIVES
In this chapter, you will learn how to use and customize the Mastercam workspace. Upon completion of this
chapter, you should be able to do the following:
• Identify the major areas and components of the Mastercam graphical user interface including the Menu,
Toolbars, Ribbon Bars, Status Bar, Right Mouse Button (RMB), and Keyboard Commands (Hot Keys).
• Understand the purpose and use of the ribbon bar.
• Set drawing attributes such as color, line style, and line width.
• Change viewpoint using the View Manipulation Toolbar, Mouse Menu, and Hot Keys.
• Customize the RMB.
• Simplify, rearrange, and customize toolbars.
• Use Key Mapping to assign functions to keyboard commands.
• Activate the Mastercam Learning Mode.
INTRODUCTION
This chapter explains the overall design and use of Mastercam’s Graphical User Interface (GUI). First you will
study the GUI layout and interface components including Toolbars, Ribbon Bars, Status Bar, Hot Keys, and Dialog
Boxes.
You will then learn about views and how to manipulate views using the Menu, Toolbars, Mouse Menu, and Hot
Keys.
Finally, you will learn to configure and customize Mastercam to suit your own preferences and maximize
productivity.