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MILL-LESSON-7
FACE, POCKET FACE, DRILL,
POCKET AND CONTOUR
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Objectives
Previously in Mill-Lesson-6 the geometry was completed. This lesson will complete all the
toolpath operations.
You will generate the toolpaths for Mill-Lesson-7 to machine the part on a CNC vertical milling
machine.
This Lesson covers the following topics:
Establish Stock Setup settings:
Stock size.
Material for the part.
Feed calculation.
Generate a 2-dimensional milling toolpath
consisting of:
Drill toolpath.
Tap toolpath.
Face toolpath.
Pocket face toolpath.
Pocket toolpath.
Contour toolpath.
Inspect the toolpath using Mastercams Verify and Backplot by:
Launching the Verify function to machine the part on the screen.
Generating the NC- code.
Mill-Lesson-7 - 1
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Mill-Lesson-7
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Toolpath Creation
Duplicate Lesson-6 for Lesson-7
Define the rough stock using stock setup
Face the part to .45 thick
Machine to .325 thick and machine around the 2.0 boss
Spot drill 3/8-16 UNC holes
Center Drill the bolt hole circle holes
Drill the bolt hole circle holes
Tap Drill for 3/8-16 UNC holes
Tap 3/8-16 UNC holes
Verify the toolpath
Rough and finish the triangular shaped pockets
Rough and finish the 1.25 dia bore
Rough and finish the slot
Verify the toolpath
Save the updated Mastercam file
Post and create the CNC code file
Mill-Lesson-7 - 5
TASK 1:
DUPLICATE LESSON-6 FOR LESSON-7
In this lesson you will use Mill-Lesson-6 to complete Mill-Lesson-7.
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1. Click on File>Open>Mill-Lesson-6.MCX-5
2. The screen should look like the one below:
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3. Select File>Save as
4. In the File name box, type Mill-Lesson-7.
5. Save to an appropriate location.
6. Select the green check mark button
Mill-Lesson-7 - 6
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Toolpath Creation
TASK 2:
DEFINE THE ROUGH STOCK USING STOCK SETUP
Defining the Rough Stock using stock setup.
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1. Select the Fit to screen icon
2. Select the plus in front of Properties to expand the Toolpaths Group Properties. Alt-O will
Show/hide Operations Manager pane.
3. Select Stock setup in the toolpath manager window as shown above on the right:
4. Change the parameters to match the Stock Setup screenshot below:
The bottom face of the material has been pre-machined and is not part of the toolpath
operations for this lesson.
The material has also been pre-machined to 4.5 x 4.5 and is not part of the toolpath
operations for this lesson.
Z zero is at the bottom of the part.
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5. Select the Tool Settings tab and change the parameters to match the Tool Settings
screenshot below. To change the material type, follow the next set of instructions.
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6. To change the Material type to Aluminium 6061 pick the Select button at the bottom of the
Tool Settings page.
7. At the Material List dialog box open the Source drop down list and select Mill library.
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8. From the Default Materials list select ALUMINIUM inch -6061 and then select
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TASK 3:
FACE THE PART TO .45 THICK
In this task you will use a 3.0 diameter face mill to face the top of the part to 0.45 thick.
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2. When prompted to Enter new NC name ensure Mill-Lesson-7 is displayed and then select
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the OK button
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button
3. On the screen you will now see the Chaining dialog box with Chain set and in the graphics
screen a prompt to Select OK to use defined stock or select chain 1. Select the OK
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6. Use the slider bar on the right of this dialog box to scroll down and locate a 3.0 face mill.
Select the 3.0 face mill by picking anywhere along the row.
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9. Select Cut Parameters from the list on the left and make changes to this page as shown
below:
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10. Select Linking Parameters from the list on the left and make changes to this page as
shown below. Note that Z zero is at the bottom of the part.
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Mill-Lesson-7
TASK 4:
MACHINE TO .325 THICK AND MACHINE AROUND THE 2.0 BOSS
In this task you will use a 1.0 diameter flat end mill to face the part to 0.325 thick and
machine around the 2.0 diameter boss.
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2. On the screen you will now see the Chaining dialog box with Chain set and in the graphics
screen a prompt to Select Pocket chain 1. Select the line first and then the circle as shown
below:
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4. If the arrow is not pointing down, select the arrow from the Chaining dialog box shown
below to reverse the direction.
5. After the pocket has been successfully chained, select the OK button
the Chaining dialog box.
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at the bottom of
Mill-Lesson-7
6. Ensure the Toolpath Type is set to Pocket as shown below:
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7. Select Tool from the list on the left and click on the Select library tool button in the lower
left corner.
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8. Use the slider bar on the right of this dialog box to scroll down and locate a 1.0 diameter
flat end mill. Select the 1.0 diameter flat end mill by picking anywhere along the 1.0 end
mill row as shown below:
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Mill-Lesson-7
11. Select Cut Parameters from the list on the left and make changes to this page. Pocket type
should be set to Facing.
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12. Select Roughing from the list on the left and make changes to this page.
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14. Select the plus sign to the left of Finishing to expand the list and click on Lead In/Out.
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15. Make certain the green check mark in front of Lead In/Out is showing. Make the following
changes as shown below:
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16. Select Linking Parameters from the list on the left and make changes to this page as
shown below. As the part has been machined to a thickness of 0.45 the Top of stock is
now 0.45.
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17. Select Coolant from the list on the left. Open up the drop down menu for Flood and set it to
On.
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2. Move the mouse and position the cursor over the center of circle #1; you will notice a circle
appears as you move closer to the center of the circle. This circle denotes you are snapping
the centre of this arc. Use the left button of your mouse to pick this center point.
3. Using the method outlined above continue on and pick the remaining three circle center
points, in the order 2, 3 and 4.
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Mill-Lesson-7
4. Select the OK button
selection of points.
After selecting the OK button you are confronted with the 2D Toolpaths-Drill/CirclesSimple
drill page. The first task here will be to select a 0.5 diameter spot drill.
5. Ensure the Toolpath Type is set to Drill as shown below and select Tool from the list on
the left.
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6. Click on the Select library tool button in the lower left corner.
7. Select the 0.5 spotdrill by picking anywhere along its row as shown below:
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10. Select Cut Parameters from the list on the left and make changes to this page as shown
below. The Cycle should be set to Drill/Counterbore.
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Mill-Lesson-7
11. Select Linking Parameters from the list on the left and make changes to this page as
shown below. Input the Depth to 0.325, Top of stock to 0.325 and other values as shown
below. Note all the values are set to Absolute.
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12. The spot drill is going to be used to put a countersink on the holes as well. To get
Mastercam to calculate the appropriate depth, click on the calculator button beside the
depth field.
13. Change the values in the Depth Calculator window as shown below. The Finish diameter
for the countersink will be 0.4375 (Hole dia. 3/8+1/16).
Use the Depth Calculator to calculate the proper
drilling depth when the finish diameter of the hole
is different from the drill diameterfor example,
when countersinking a hole.
Once you calculate the depth, you have two
options:
Choose Overwrite depth to replace the existing
depth value on the parameter page.
Choose Add to depth to add the calculated depth
to the existing depth value on the parameter page.
16. Select Coolant from the list on the left. Open up the drop down menu for Flood and set it to
On.
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Mill-Lesson-7
TASK 6:
CENTER DRILL THE BOLT HOLE CIRCLE HOLES
In this task you will center drill the bolt hole circle with a .25 center drill.
There are many different methods to select the center points of the .1875 diameter holes, in
this example you will use the Mask on Arc function.
1. Select Alt and T on the keyboard to hide the toolpaths.
2. From the menu bar select Toolpaths>Drill
Now you are prompted to Select Points and the Drill Point Selection dialog box appears.
3. As you need to center drill all the bolt hole circle holes at the center of the circles, click on
the Mask on Arc button in the Drill Point Selection dialog window to activate it as shown
below. The Mask on Arc icon is pressed down to signal that it is activated and the prompt
on the screen changes to Select arc to match.
4. At the prompt Select arc to match click on the 3/16 diameter circle shown below:
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5. The prompt now changes to Select arcs hit Enter when finished. Click on All on the
General Selection ribbon bar as shown below:
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8. Lets now explore how you can change the order of drilling and start with the hole at 12
oclock first and continue in the order shown below. To change the order click on Sorting
in the Drill Point Selection dialog window:
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Mill-Lesson-7
9. At the 2D sort page select the sorting method button shown below Point to Point.
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The holes have been re-sorted and will now start drilling at hole 1 and drill in the order
shown below counter clockwise:
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13. Ensure the Toolpath Type is set to Drill as shown below and then select Tool from the list
on the left.
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Mill-Lesson-7
14. Click on the Select library tool button in the lower left corner.
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15. Select the .25 diameter center drill by picking anywhere along its row as shown below:
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Mill-Lesson-7 - 30
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18. Select Cut Parameters from the list on the left and make changes to this page as shown
below. The Cycle should be set to Drill/Counterbore.
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19. Select Linking Parameters from the list on the left and make changes to this page as
shown below. Input the Absolute depth of 0.3 and the other values as shown below. Note
all the values are set to Absolute.
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20. Select Coolant from the list on the left. Open up the drop down menu for Flood and set it to
On.
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Mill-Lesson-7 - 32
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TASK 7:
DRILL THE BOLT HOLE CIRCLE HOLES
In this task you will drill all the.1875 diameter holes on the bolt hole circle through the part.
For this example you will copy the center drill operations and then modify the copied
operations into the .1875 diameter drilling operation.
1. On the left of the screen in the Toolpath manager the center drilling operation is the fourth
operation. To copy this operation Hold down the Right mouse button over the folder for
this operation. Keep holding the right mouse button down and drag below the red arrow
and release.
2. Select Copy after from this menu.
3. Your screen will look similar to the screenshot below on the left. Move the Insert arrow
to the bottom of the list of operations by clicking the
toolbar:
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4. In the Toolpath manager click on the folder Parameters for the fifth operation as shown
below:
5. Select Tool from the list on the left and click on the Select library tool button in the lower
left corner as shown below:
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6. Scroll down and select the 3/16 (.1875) diameter drill by picking anywhere along its row as
shown below:
Mill-Lesson-7 - 34
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9. Select Cut Parameters from the list on the left and make changes to this page as shown
below. Open up the Cycle drop down menu and select Peck Drill.
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Peck
Sets the depth that the tool rapids to between peck
moves. This value is added to the previously drilled
peck depth
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11. Select Linking Parameters from the list on the left and make changes to this page as
shown below. Input the Absolute depth of 0 and the other values as shown below. Note all
the values are set to Absolute.
12. Select the plus sign to the left of Linking Parameters to expand the list and click on Tip
Comp.
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14. Select Coolant from the list on the left. As the Coolant was set to Flood in the previous
operation it still remains set to Flood On.
15. Select the OK button
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TASK 8:
TAP DRILL FOR 3/8-16 UNC HOLES
In this task you will use a 0.3125 diameter drill to drill the holes prior to the tap operation.
Once again you will use copy to duplicate the spotdrill operations and then modify the
copied operations into the 0.3125 diameter drilling operation.
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1. Before moving on, lets organize the operations in the Toolpath manager. Right mouse click
in the white space of the Toolpath manager window. And select Collapse. The Toolpath
manager now looks like the screen shot immediately below right. Dont panic the operations
have not been deleted; click on the plus sign for the Toolpath Group-1 and the operations
are laid out as in the screen shot in the lower right corner.
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Mill-Lesson-7 - 38
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2. On the left of the screen in the Toolpath manager the spotdrilling operation is the third
operation. To copy this operation Hold down the Right mouse button over the folder for
this operation. Keep holding the right mouse button down and drag below the red arrow
and release, then click on Copy after.
3. Your screen will look similar to the screenshot below on the left. Move the Insert arrow
icon on the Toolpath manager
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4. In the Toolpath manager click on the plus sign next to the # 6 Drill/Counterbore folder
operation as shown below left to expand the folder.
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Mill-Lesson-7
5. In the Toolpath manager click on the folder Parameters for the sixth operation as shown
below:
6. Select Tool from the list on the left and Click on the Select library tool button in the lower
left corner as shown below:
7. Scroll down and select the .3125 diameter drill by picking anywhere along its row, as
shown below.
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Mill-Lesson-7 - 40
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10. Select Cut Parameters from the list on the left and make changes to this page as shown
below. Open up the Cycle drop down menu and select Peck Drill. Change the Peck
amount to 0.3
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Mill-Lesson-7
11. Select Linking Parameters from the list on the left and make changes to this page as
shown below. Input the Absolute depth of 0 and the other values as shown below. Note all
the values are set to Absolute.
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12. Select the plus sign to the left of Linking Parameters if required to expand the list and click
on Tip Comp.
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13. Ensure the Tip Comp is activated by clicking on the small Tip Comp box and make certain
the green check mark is showing. The Breakthrough amount should be set to 0.1 as
shown below:
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14. Select Coolant from the list on the left. As the Coolant was set to Flood in the previous
operation it still remains set to Flood On.
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Mill-Lesson-7
TASK 9:
TAP 3/8-16 UNC HOLES
In this task you will tap the four 3/8-16 holes.
Once again you will use copy to duplicate the 0.3125 drilling operations just completed and
then modify the copied operations into a tap operation.
1. On the left of the screen in the Toolpath manager the 0.3125 drilling operation is the last in
the list of the six operations. To copy this operation Hold down the Right mouse button
over the folder for this operation. Keep holding the right mouse button down and drag
below the red arrow and release, then click on Copy after.
2. Your screen will look similar to the screenshot below on the left. Move the Insert arrow
to the bottom of the list of operations by clicking the
toolbar:
Mill-Lesson-7 - 44
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3. Before moving on click on the negative sign to the left of the folder of the sixth operation to
collapse it.
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4. In the Toolpath manager click on the folder Parameters for the seventh operation as
shown below:
5. Select Tool from the list on the left and click on the Select library tool button in the lower
left corner as shown below:
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Mill-Lesson-7
6. Scroll down and select the tap, 3/8-16 TAPRH.
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10. Select Linking Parameters from the list on the left and make changes to this page as
shown below. Input the Absolute depth of -0.2 and the other values as shown below. Note
all the values are set to Absolute.
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11. Select the plus sign to the left of Linking Parameters if required to expand the list and click
on Tip Comp.
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12. Ensure the Tip Comp is de-activated by clicking on the small square to the left of the Tip
Comp button and make certain the green check mark is not showing.
13. Select Coolant from the list on the left. As the Coolant was set to Flood in the previous
operation it still remains set to Flood On.
to exit tapping operation.
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Mastercam's Verify utility allows you to use solid models to simulate the machining of a part.
The model created by the verification represents the surface finish, and shows collisions, if any
exist.
This allows you to identify and correct program errors before they reach the shop floor.
1. For a better view of the part use the toolbar at the top of the screen to change the graphics
view to Isometric.
3. In the Toolpath Manager pick all the operations to verify by picking the Select All icon
4. Select the Verify selected operations button circled below:
5. Adjust the Verify speed to midway along the speed control bar.
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7. Select the OK button
to exit Verify.
Mill-Lesson-7 - 49
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Mill-Lesson-7
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TASK 11:
ROUGH AND FINISH THE TRIANGULAR SHAPED POCKETS
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In this task you will use a 0.5 diameter flat end mil to rough and finish the triangular shaped
pockets.
The pocket depth is 0.25.
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1. If required select Alt and T from the keyboard to hide the toolpath lines.
2. Before moving on select the negative sign to the left of the folder of the seventh operation to
collapse it.
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6. After selecting the lines your graphics screen should look like the screenshot below, with the
arrow pointing counter clockwise, if not see below.
The material for this part is aluminium so to attain a good finish when pocketing climb milling
should be employed.
Mill-Lesson-7 - 51
Mill-Lesson-7
8. After the pocket has been successfully chained, select the OK button
the Chaining dialog box.
9. Ensure the Toolpath Type is set to Pocket as shown below:
at the bottom of
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10. Select Tool from the list on the left and click on the Select library tool button in the lower
left corner.
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Mill-Lesson-7 - 53
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14. Select Cut Parameters from the list on the left and make changes to this page. The Pocket
type should be set to Standard.
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15. Select Roughing from the list on the left and make changes to this page.
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18. Select Finishing from the list on the left and make changes to this page:
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Mill-Lesson-7
19. Select the plus sign to the left of Finishing to expand the list and click on Lead In/Out.
20. Ensure the Lead In/Out is activated by clicking on the small Lead In/Out box and make
certain the green check mark is showing. Make the following changes as shown below:
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Mill-Lesson-7 - 56
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22. Select Linking Parameters from the list on the left and make changes to this page as
shown below. Input the depth of 0.075 and the other values as shown below. Note the
Top of stock value of 0.325; this is the absolute Z value at the top of the pocket.
23. Select Coolant from the list on the left. Open up the drop down menu for Flood and set it to
On.
Mill-Lesson-7 - 57
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Mill-Lesson-7
26. Make sure the cursor is in the toolpath manager as shown above (2) and select Alt and T
from the keyboard to unhide the toolpath lines.
Your screen will look similar to the screenshot below:
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3. On the screen you will now see the Drill Point Selection dialog box and a prompt to
Select points. Click on the Entities button in the Drill Point Selection box. The prompt
changes to Select entities, now select the circle as shown below:
4. After the circle has been selected click on the End Selection button as shown below:
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Mill-Lesson-7
6. Ensure the Toolpath Type is set to Circle Mill as shown below:
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7. Select Tool from the list on the left and use the 0.5 diameter end mill. Make any changes to
the Toolpath parameter page as shown below:
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9. Select Finishing from the list on the left and make changes to this page as shown below:
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10. Select the plus sign to the left of Finishing to expand the list and click on Transitions.
Make the following changes as shown below:
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11. Select Depth cuts from the list on the left. Ensure the Depth cuts are activated by clicking
on the small Depth cuts box and make certain the green check mark is showing. Make the
following changes as shown below:
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Break through
Select the check box to add a break through amount to the final toolpath depth.
Use this option to ensure that the tool cuts all the way through the part for a cleaner finish.
13. Select Linking Parameters from the list on the left and make changes to this page as
shown below. Input the depth of 0 and the other values as shown below. Note the Top of
stock value of 0.45.
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14. Select Coolant from the list on the left. Open up the drop down menu for Flood and set it to
On.
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Mill-Lesson-7 - 64
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In this task you will machine the slot with a 0.375 diameter end mill.
The slot will be roughed and finished using Multi Passes and Depth Cuts.
The slot is 0.5 wide. Using a 0.5 diameter end mill would not allow you to rough the slot.
1. From the menu bar select Toolpaths>Contour
2. On the screen you will now see the Chaining dialog box with Chain set and in the graphics
screen a prompt to Select Contour chain 1. Select the line shown below:
3. After selecting the line your graphics screen should look like the screenshot above, with the
green arrow pointing right in a counter clockwise direction, climb milling.
4. If the arrow is not pointing to the right, select the arrow from the Chaining dialog box shown
below to reverse the direction.
5. After the contour has been successfully chained, select the OK button
the Chaining dialog box.
Mill-Lesson-7 - 65
at the bottom of
Mill-Lesson-7
6. Ensure the Toolpath Type is set to Contour as shown below:
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7. Select Tool from the list on the left and click on the Select library tool button in the lower
left corner.
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8. Use the slider bar on the right of this dialog box to scroll down and locate a 0.375 diameter
flat end mill. Select the 0.375 diameter flat end mill by picking anywhere along the row.
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11. Select Cut Parameters from the list on the left and make changes to this page if required.
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12. Select Depth cuts from the list on the left and make the following changes as shown below:
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14. Select Break Through from the list on the left and make changes to this page as shown
below:
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15. Select Multi Passes from the list on the left and ensure the Multi Passes are activated by
clicking on the small Multi Passes box. Make certain the green check mark is showing and
make changes to this page.
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16. Select Linking Parameters. Input the depth of 0 and the other values as shown below.
Note all the values are set to Absolute.
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TASK 14:
VERIFY THE TOOLPATH
Mastercam's Verify utility allows you to use solid models to simulate the machining of a part.
The model created by the verification represents the surface finish, and shows collisions, if
any exist.
This allows you to identify and correct program errors before they reach the shop floor.
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1. For a better view of the part use the toolbar at the top of the screen to change the graphics
view to Isometric.
2. In the Toolpath Manager pick all the operations to verify by picking the Select All icon
3. Select the Verify selected operations button circled below:
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4. Adjust the Verify speed to midway along the speed control bar.
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to exit Verify.
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1. Select File.
2. Select Save
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TASK 15:
SAVE THE UPDATED MASTERCAM FILE
TASK 15:
POST AND CREATE THE CNC CODE FILE
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1. Ensure all the operations are selected by picking the Select All icon
manager.
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2. Select the Post selected operations button from the Toolpath manager.
3. Please Note: If you cannot see G1 click on the right pane of the Toolpath manger window
and expand the window to the right.
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4. In the Post processing window, make the necessary changes as shown below:
to continue.
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6. Ensure the same name as your Mastercam part file name is displayed in the NC File name
field as shown below:
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9. Select the
In the following exercise drawings for this lesson the geometry is similar to the lesson you have
just completed.
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GUIDE
TRAINING
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