Dept.

of Industrial and Systems Engineering, UW-Madison ISyE 415 Lab Manual

4.0 TOOL PATH GENERATION USING MASTERCAM

4.1 Mill Tool Path Generation
This section highlights the procedure to create the tool path and the NC code to manufacture the part. This lab will
take you step by step through all the processes to generate tool paths and select the right tool for each operation.
This lab will use the part drawing that you created in the previous lab and assign tool path information to it. Upon
completion of this lab, one should be able to produce the posted machine (NC) code to manufacture the part.
The steps involved in toolpath generation are:

1. Draw the part in MasterCAM or import a CAD file.

2. Define the Stock and Setup.
3. Define Features and Machining Strategy.
4. Run simulation to verify the tool path.
5. Generate NC code.

Step 1: Draw the part or import a CAD file

Select File -> Open and open the MasterCAM file 415millexample.emcam that you created last time.

Please check that your file looks as shown in Figure 4.1 when you open it. If not, ensure that you have completed
all the steps in the previous chapter of the lab manual.

Fig 4.1: 2D Model with Defined Stock

Step 2: Define Features and Machining Strategy

The next step in the process is to define the features in the part geometry that will be machined. If necessary, shift
to Isometric view using the Mini Toolbar by right clicking on the Graphics Window.

Click Solids on the Menu Bar and select Extrude. The Chaining dialog box opens (see Figure 4.2).

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Figure 4.2: Extrude - Chaining dialog box

Ensure that Wireframe mode and Chain selection method are selected. Place the mouse on the Top Rectangle outer
edges of the part and click to select. Click each edge of the top rectangle in sequence until all four edges are
highlighted. Then, click the green checkmark for the Chaining window.

In the Solid Extrude function panel that appears, click the Reverse All arrow (highlighted in yellow in Figure 4.3)
in the Chains section to extrude in the opposite direction, and enter the Distance as 1.0 (see Figure 4.3). Click the
green checkmark.

Figure 4.3: Solid Extrude function panel

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Select Extrude again. This time, place the mouse on the feature which must be pocketed as shown in Figure 4.4.
Click the green checkmark.

Figure 4.4: Pocketed feature selection

In the Solid Extrude function panel, select Cut Body and specify the Distance as 0.5 (see Figure 4.5). Click the
green checkmark.

Figure 4.5: Solid Extrude function panel

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After the second Solid Extrude, the part looks like Figure 4.6.

Figure 4.6: Part geometry after two Extrude operations

Choose the Toolpaths tab and then Drill (2D operation on the left side of the screen).

Select the centers of the four circles in the corners of the block. Click the green checkmark.

The 2D Toolpaths dialog box opens to the Toolpath Type page (see Figure 4.7). Drill is selected as the Toolpath
type. (Do not click the green checkmark on the 2D toolpaths dialog box until all pages are complete.)

Figure 4.7: 2D toolpaths dialog box

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Select Tool from the Tree View pane on the left. Click the ‘Select library tool’ button.

A tool selection window opens. Make the tool name column wider so that you can see the tool options more
clearly. Select the 1/4 drill (tool #124) and click the green checkmark.

Figure 4.8: Tool selection from library

Enter Spindle Speed as 2000 and the Feed Rate as 2.5; the units are revolutions per minute (RPM) and inches per
minute (IPM), respectively. Change the tool # and length offset to 1.

Select Linking parameters from the Tree View pane and enter values as shown in Figure 4.9:
Retract = 0.1 Absolute
Top of Stock = 0.0 Absolute
Depth = -0.5 Absolute
These values will control the depth the tool will move to, where the top of the stock is located, and the height the
tool will retract to.

Figure 4.9: Linking parameters

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Select Tip Comp from the Tree View pane. Click the Tip Comp checkbox to activate the feature. Use default
values for the tip comp parameters.
Finally, click the green checkmark for the 2D Toolpath dialog box to generate the drill toolpath (see Figure
4.10).
Save your part file.

Figure 4.10: Part with drill toolpath completed

Choose Toolpaths, Pocket (from the 2D section on the left side of the screen, you may need to scroll down to find it).
Notice the prompt “Select Pocket Chain 1” displayed in the upper left of the graphics window. Select the upper
boundary of the pocket geometry as shown in Figure 4.11. Click the green checkmark.

Figure 4.11: Selection of pocket geometry

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The 2D toolpath pocket dialog box opens (see Figure 4.12).

Figure 4.12: Pocket – 2D Toolpaths dialog box

Select Tool from the Tree View pane on the left. Click the ‘Select library tool’ button.

Select the 1/4 flat end mill (tool #285) and click the green checkmark. The diameter of the tool should
correspond to the smallest diameter needed in the part geometry. Set tool # and length offset to 2.

Enter Spindle Speed as 2000 RPM, Feed rate as 2.5 IPM and Plunge rate as 2.5 IPM. Check the box for Rapid
Retract.

Select Cut Parameters from the Tree View. Specify the stock to leave on walls and floors as 0 (see Figure 4.13).

Figure 4.13: Cut parameters stock to leave specifications

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Select Roughing from the Tree View. Choose the cutting method as True Spiral.

Figure 4.14: Cutting method specification

Choose Finishing from the Tree View. Uncheck this option.

Choose Lead In/Out from the Tree View. Uncheck this option.

Figure 4.15: Lead In/Out screen

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Select Depth Cuts from the Tree View pane and check the box. Leave the default values of 0.1 for the Max rough
step and 0 for #Finish cuts.

Figure 4.16: Depth cuts specifications

Select Linking parameters from the Tree View pane and enter values as shown in Figure 4.17:
Retract = 0.1 Absolute
Feed plane = 0.1 Incremental
Top of Stock = 0.0 Absolute
Depth = -0.5 Absolute

Figure 4.17: Linking parameters specifications

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Choose Arc Filter/Tolerance from the Tree View. Select Smoothing Settings and Use Fixed Segment Length of
0.02. Click the green checkmark to generate the mill toolpath (Figure 4.18).

Save your part file.

Figure 4.18: Part with pocket milling toolpath completed

Step 4: Run simulation to verify the tool path

In the Toolpaths tree structure on the left, ensure that both the Drill and the Pocket operations are selected. To do
this, find the Select All Operations button. It is in the Toolpaths Manager window, just under where it says
Toolpaths on the left side. After clicking this button, both toolpaths should show up with green checkmarks over
the folder images. Then, two buttons to the right, select Regenerate All Selected Operations. This updates any
new changes to the operations and checks them for completion. Four buttons over to the right from this, find and
click Verify Selected Operations.
Experiment with playing the simulation as well as stepping through it incrementally using the controls on the
bottom of the screen (see Figure 4.19).

Figure 4.19: MasterCAM Verify (simulation) window

Notice that the Elapsed Time mentioned in the Toolpath Info on the right of the screen is very high (over 6
hours). This can be reduced by using a larger diameter tool for the pocket roughing operation, followed by using
the ¼” tool for a finishing pass. Altering the linking parameters and roughing toolpath type will also aid with
saving time. We will use some of these techniques on the project to ensure that parts can be machined in under
20 minutes.

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Step 5: Generate NC code

G-Code is a simple text file that the CNC machine understands (as explained in Chapter 2 of the lab manual). We
can produce these text files by selecting one or more tool paths and pressing the button on the Toolpaths window
that says G1 (Post selected operations). Use the default post-processor and click the green checkmark. Change
the storage location for the file to your desired location and click Save.
A MasterCAM editor opens up and displays the G code for the program (see Figure 4.20).

Figure 4.20: MasterCAM Code Expert window opens with the G code

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4.2 Lathe Tool Path Generation

Step 1: Draw the part or import a CAD file
Select File -> Open and open the MasterCAM file 415latheexample.emcam that you created last time.

Ensure that your file looks like Figure 4.21 (Axes should show as D,Z; not X,Y,Z on the status bar). If not,
follow the instructions given in Chapter 3 of the lab manual.

Figure 4.21: 2D view with stock setup

Step 3: Define Features and Machining Strategy

Choose the Turning tab and then Rough from the General section of the Ribbon. Do NOT use Dynamic Rough.
The Chaining dialog box opens. Click the 3D radio button and the chain option for selection method.

Figure 4.22: Chaining dialog box

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Now select the part geometry as shown in Figure 4.23. The Green arrow shows the line that needs to be clicked.
We have now defined the entry point (Green Arrow) and the retraction point (Red Arrow) of our cut.

Figure 4.23: Selecting the chain for the finishing operation

Click the green checkmark on the Chaining dialog box. A window appears saying the WCS does not match the
stock plane. ‘Set operation WCS to the stock plane now?’ Select Yes.

A Lathe Rough parameters window opens. Select the ‘T1212 R0.0313 OD 55 Deg Right’ as shown in Figure
4.24. In practice, the feed rate and spindle speed might need to be adjusted. We will leave them at the default
values for this tool. The tool number should be changed. Set the tool number, station number, and offset values
all to 1.

Figure 4.24: Tool selection from library

In the same window, choose the Rough parameters tab (see Figure 4.25). Change stock to leave in X and Z to 0.
Now, select Lead In/Out on the right side of the dialog box.
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Set Lead In Angle as -135 Deg. Set Lead Out Angle as 45 Deg. Click the green checkmark to close the window.

Select Plunge Parameters. Set the Plunge Cutting by selecting the radio button for ‘Allow Plunge in both
directions’. Leave the clearance values as default. Click the green checkmark to close the window.

Figure 4.25: Lathe rough parameter settings

Click the green checkmark to generate the toolpath. Toolpath collision warnings will occur. Click the green
checkmark for all of them. These will be discussed below. The generated toolpath will look like the one shown
in Figure 4.26.

Figure 4.26: Part with roughing toolpath completed

The toolpath collision warnings, as well as issues with not getting the stock cut to our design, relate to having a
design that cannot be feasibly cut using the tool selected. This shows that it is important for a designer to ensure
that manufacturing capability exists to accommodate the part design. A fix for this would be either the designer
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creating a new design (if the part spec allows this) or using different tools and different operations (like using a
right-hand tool to cut the right arc and a left hand tool to cut the left arc).

Save your part file.

Steps 4 and 5: Running the Simulation and Generating the Code

Follow the same procedure as with the Mill example to view the simulation and generate the NC Code, clicking
through all toolpath collisions warnings.

Figure 4.27: MasterCAM Verify (simulation) window

G code generation is not allowed in the Home Learning Edition of MasterCAM. For project files, we will collect the
*.emcam files and generate the G codes ourselves to verify them.

References
1. CNC Software, Inc., Introduction to Mastercam, Mastercam 2017 Tutorials.
2. CNC Software, Inc., Basic 3D Machining, Mastercam X5 Tutorials.
3. Taylor Hokanson, Learning Mastercam, Lynda.com.

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Homework 4: MasterCAM – Tool Path

Develop tool paths for the part drawing made in Homework 3 in MasterCAM.

Figure 4.28: Bounding Box Generation

Assume a stock thickness (Z) of 1.0 inch as shown in Figure 4.28. Set X and Y both to 9.0. The purpose of this is
to define a stock slightly larger than the 2D design, so the contour can be milled out of the stock piece as a pocket.
There is no need to create a 3D solid extrusion and extrude cut it like we did in this chapter for the mill. You may
choose to do so if it helps you better visualize the part and/or the machining operation.

The 2D design (main contour) should be machined to a depth of 0.5 inches in five depth passes using a pocket
operation. Machine the squares (eyes), oval (nose), and big semi-circle (mouth) also using a pocket operation with
a depth of 0.7 inches total (an additional 0.2 inches below the first pocket that was cut); these features should be
machined with an additional two passes. Use a 1/2” End Milling tool for the main pocket and a 1/4” End Milling
tool for all internal pockets. The final file should look as shown below in Figure 4.29 when verifying.

Figure 4.29: Verified Toolpath

You should submit the MASTERCAM file to the course website with your name and lab section on it.
Name the files as follows:
LastnameFirstnameSectionNumberHomework4model.emcam
EX: YauchCharlene301Homework4model.emcam

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Homework 5: MasterCAM – Design & Tool Paths for Turning

Develop the part design and tool paths in MasterCAM for the part shown below following the methods described
for turning in Chapters 3 and 4 of the lab manual.

Figure 4.30: Part drawing for Homework #5

Point Number D Value Z Value

1 0 0
2 0.75 -0.75
3 0.75 -1.25
4 0.5 -1.5
5 0.5 -1.75
6 0.75 -2
7 0.75 -2.5
8 1.5 -3
9 1.5 -3.5

In Stock properties, set OD = 1.75 and Length as 3.5.

Select the ‘T1212 R0.0312 OD 55 Deg Right’ in Toolpath parameters tab.
Select Lead In/Out on the right side of the dialog box.
Set Lead In Angle as -135 Deg. Set Lead Out Angle as 45 Deg.

You should submit the MASTERCAM file to the course website with your name and lab section on it.
Name the files as follows:
LastnameFirstnameSectionNumberHomework5model.emcam
EX: YauchCharlene301Homework5model.emcam

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