Hinh Truong Multi Axis Lesson 6

Truonglana@yahoo.
com
TRAINING
GUIDE
MULTI-AXIS-LESSON-6
TRUNNION-TABLE SWARF 5 AXIS
Truonglana@yahoo.com
Mastercam Training Guide

Objectives
For Multi-Axis-Lesson-6 you will generate the toolpaths to machine the part shown below on a
CNC vertical milling machine with multi-axis capability. The part will be roughed out using
Contour and Pocket toolpaths. To finish machine Swarf 5-Axis toolpath is used to machine the
contour and the inside of the pockets. The part is in inch units. The part will be held on a fixture
using socket head cap screws through the two outside holes. This setup will be located on a
Trunnion table.
This Lesson covers the following topics:
Open an existing file containing:
Solid geometry for the part
Generate toolpaths consisting of:
Contour toolpath.
Pocket toolpath.
Swarf 5 Axis toolpath
Inspect the toolpath using Mastercams
Backplot by:
Launching the Backplot function to machine the part on the screen
Generating the NC- code
Multi-Axis-Lesson-6-1
Multi-Axis-Lesson-6
TOOL LIST
MULTI-AXIS-LESSON-6 - THE PROCESS

Toolpath Creation
TASK 1:
TASK 2:
TASK 3:
TASK 4:
TASK 5:
TASK 6:
TASK 7:
TASK 8:
TASK 9:
TASK 10:
TASK 11:
TASK 12:
TASK 13:
TASK 14:
TASK 15:
Setting the environment

Introduction - Watch the video
Open an existing file from the Multimedia CD
Identify the entities on each Level
Rough large pocket and circular island
Rough the small pocket
Engrave Mastercam in base of large pocket
Finish machine inside contour Swarf 5-axis
Finish machine circular island Swarf 5-axis
Finish machine small pocket Swarf 5-axis
Rough machine the contour
Finish machine outside contour Swarf 5-axis
Backplot the toolpath
Verify the toolpath
Post and create the CNC code file
Multi-Axis-Lesson-6
Toolpath Creation
TASK 1:
SETTING THE ENVIRONMENT
Before starting the geometry creation you should set up the grid, toolbars and machine type as
outlined in the Setting the environment section at the beginning of this text:
1. Set up the Grid: Size= 1.0, X & Y Spacing= 0.25. This will help identify the location of the
origin.
2. Customize the toolbars to machine a 4-5 Axis part.
TASK 2: INTRODUCTION WATCH THE VIDEO

1. Before you start to work on this Lesson review the Introduction video on the multimedia CD
that came with this text. You will find the video in the Lesson-6 section, it is entitled
Introduction - 10 Minutes.
The video will review the techniques that will be used to generate the toolpaths to cut this
part.
TASK 3:
OPEN EXISTING FILE FROM THE MULTIMEDIA CD
On the multimedia CD that came with this text is a folder called Mastercam-Files. The file
is in inch units and contains the wireframe and surface (solid) geometry of the.
The part is already setup for a: GENERIC HAAS VF-TR_SERIES 5X MILL.
1. Select File>Open> Multi-Axis-Lesson-6.MCX.
2. If confronted with the System Configuration dialog box activate the radio button for All
settings.
System Configuration (switch units) dialog box

When you open a part file that uses different units (English or metric) from those currently in
use, Mastercam automatically displays this dialog box, which informs you that Mastercam is
switching units and loading an alternate default configuration file. In order to complete the
operation, select one of the following options:
Units: Tells Mastercam to use only the units from the new configuration file. (default)
All settings: Tells Mastercam to load all settings from the new configuration file.
3. Select the OK button
to exit the System Configuration dialog box.
4. Activate a shaded view by selecting the icon at the top of the screen. The file should appear
as below. The Stock setup has already been setup.
5. Display the Operations Manager. Selecting Alt-O will Show/hide the Operations Manager
pane.
Multi-Axis-Lesson-6
TASK 4:
IDENTIFY THE ENTITIES ON EACH LEVEL
Before you start to work on the two toolpaths lets first identify the entities on each Level.
Levels are a primary organizational tool in Mastercam. A Mastercam file can contain
separate levels for wireframe, surfaces, drafting entities, and toolpaths.
By organizing your files into levels, you can more easily control which areas of the drawing
are visible at any time and which parts are selectable so that you do not inadvertently make
changes to areas of the drawing you do not want to change.
1. From the Status bar at the bottom of the screen select Level.
Note that the Z depth is set to 0.575
The Level Manager dialog window will now appear.

As you can see in the picture below there are two Levels in this part named: 1 and 2.
Level 1 contains the part geometry
Level 2 contains the Swarf geometry that will be used to cut the outside contour, the inside
contour and the small pocket
Level 1 is the only Level visible as noted by the X in the Visible column.
to exit the Level Manager dialog box.
TASK 5:
ROUGH LARGE POCKET AND CIRCULAR ISLAND
In this task you will use a 0.5 diameter bull end mil with a 0.125 corner radius to rough the
large pocket and machine around the top surface of the circular island using Pocket Island
Facing.
The pocket depth is 0.5.
1. Activate a wireframe view by selecting the icon at the top of the screen.
2. From the menu bar select Toolpaths>Pocket
3. When prompted to Enter new NC name Input Multi-Axis-Lesson-6 and then select the OK
.
button
4. 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 for the first chain and then select
the arc of the island as shown below. The graphic below shows the screen after you have
selected the line and circle.
After selecting the arc your graphics screen should look like the screenshot above. As this is
a roughing operation do not concern yourself with climb or conventional cutting of the
pocket.
5. After the pocket has been successfully chained select the OK button
the Chaining dialog box.
at the bottom of
Multi-Axis-Lesson-6
6. Select the Tool page, then the Bull Endmill 0.125 Rad. Make the rest of the changes
to the page parameters as shown below:
7. Select the Linking Parameters page and make changes to this page as shown below:

8. Select the Cut Parameters page and make the changes shown below. Be sure to select
Island facing from the Pocket type drop down:
9. Select the Roughing page and make the changes shown below:
Multi-Axis-Lesson-6
10. Expand the Roughing menu and select the Entry Motion page; make the changes shown
below:
Entry Motion - Helix Ramp

Use this to add a ramp entry move to the pocket roughing operation. You can add either a helix
or a ramp entry, but not both. To switch to a helical entry, just select the Helix tab and enter the
desired entry dimensions.
11. Select the Finishing page and make sure the finishing pass has been disabled:
12. Select the Depth Cuts page and make the changes shown below:
13. Select the Coolant page and turn on the Flood option:
to exit Pocket parameters.

15. Save your file.
16. Backplot the toolpath you have just created.
Multi-Axis-Lesson-6
TASK 6:
ROUGH THE SMALL POCKET
In this task you will use a 0.25 diameter flat end mil to rough the small pocket
The pocket depth is 0.187.
1. From the menu bar select Toolpaths>Pocket
screen a prompt to Select Pocket chain 1. Select the line as shown below, zoom as
required. The graphic below shows the screen after you have selected the line.
3. After selecting the line your graphics screen should look like the screenshot above, with the
green arrow pointing to the left, if not see below.
4. If the arrow is not pointing to the left 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
at the bottom of
6. Select the Tool page. Select the Flat Endmill. Make changes to the parameters as
shown below:
7. Select the Linking Parameters page and make changes to this page as shown below.
Multi-Axis-Lesson-6
8. Select the Cut Parameters page. Open up the Pocket type drop down menu and set to
Standard.
9. Select the Roughing page and set the parameters as shown below:
10. Select the Entry Motion page for Roughing, and make sure Entry Motion is turned Off:
11. Select the Finishing page and set the parameters as shown below:
Multi-Axis-Lesson-6
12. Select the Lead In/Out page for the Finishing. Set the parameters as shown below:
13. Select the Depth Cuts page and set the parameters as shown below:
14. Select the Coolant page and make sure the Flood option is turn On:

to exit Pocket parameters.
16. Save your file.
Multi-Axis-Lesson-6
TASK 7:
ENGRAVE MASTERCAM IN BASE OF LARGE POCKET
In this task you will use a center drill to engrave the word MASTERCAM in the large pocket.
and zoom in on the
1. Change the view to Top by clicking on the Top view icon
word Mastercam in the bottom of the pocket as shown below:
2. From the menu bar select Toolpaths>Contour
3. On the screen you will now see the Chaining dialog box select the Window button.
4. Now left mouse click approximately at position 1 hold the mouse button down and drag to
the right and down and release the mouse button at approximately position 2. Then pick
at approximately position 2.
5. After describing the window around the word Mastercam the prompt changes to Sketch
approximate start point, pick a point where indicated as shown below:
6. After the contour has been successfully chained select the OK button
at the bottom of
7. Select the Centerdrill form the tool list and make changes to the Toolpath parameters
page as shown below:
8. Select the Linking Parameters page and make changes to this page as shown below.
Multi-Axis-Lesson-6
9. Select the Cut Parameters page. The Compensation type is set to Off, because the
letters will be engraved online as oppose to the left or right of the line.
10. Select the Lead In/Out page and make sure the it has been disabled:

11. Select the Coolant page and make sure the Flood option is turn On:

to exit Contour parameters.
13. Save your file.
Multi-Axis-Lesson-6
TASK 8:
FINISH MACHINE INSIDE CONTOUR SWARF 5-AXIS
In this task you will use a 0.25 diameter ball end mill to machine the angled inside contour
of the large pocket.
Swarf 5-axis toolpaths cut along a parts walls using the side of a tool. Swarf 5-axis
toolpaths can use bull, ball, tapered, and flat tools.
1. Before you start to work on this Task review the Lesson-6 Task 9 video on the multimedia
CD that came with this text. You will find the video in the Lesson-6 section; there is some
tricky selection of surfaces in this task so please check out the video before you proceed.
2. Set the graphics view to Isometric View and then select the Screen Fit icon.
3. Turn off the display of toolpaths by selecting Alt-T on your keyboard.
5. The Level Manager dialog window will now appear as shown below. Only Level 1 is visible
as noted below by the X in the Visible column. At the bottom of the Level Manager dialog
box ensure to remove the check mark from Make main level always visible.
6. Make only Level 2 visible as well as shown below. Level 2 contains the surface geometry
that will be used to cut the inside, outside and the small pocket contour using the Swarf 5axis toolpath. These surfaces for the walls are angled not vertical.
8. From the menu bar select Toolpaths>Multiaxis>Swarf 5-axis

9. At the Swarf 5-axis dialog box activate the 5-axis radio button and the remaining radio
buttons shown below.
Walls - Surfaces
Uses surfaces as the drive walls.
Choose the Surfaces button to
return to the graphics window and
select the wall surfaces.
Tip Control - Surfaces
Uses surfaces for the toolpath
floor and to position the contact
point of the tool tip.
10. Now click on the Surfaces button in the Walls section.

11. On the graphics screen you will be prompted Select wall surface(s). Start by selecting the
surface at position 1 and then move around and select all of the inside surface walls of
this pocket. You will find it easier to select the various surfaces if you dynamically rotate the
display to facilitate the selection of each surface.
12. Click on the End Selection icon.

13. Set the graphics view to Isometric View.
Multi-Axis-Lesson-6
14. You will now see the prompt to Select first surface. Select the surface shown below.
Just a reminder to review the
Lesson-6 Task 9 video on the
multimedia CD that came with
this text.
You will find the video in the
Lesson-6 section; there is
some tricky selection of
surfaces in these next few
steps so please check out the
video before you proceed.
15. To satisfy this next prompt Select first lower rail. Select the position shown below.
16. After selecting this position your graphics screen should look like the screenshot below, with
the arrows pointing to the left. If the arrow is not pointing to the left select the Reverse
Direction button from the Set Edge Direction dialog box shown below left to reverse the
direction. If you have trouble finding the direction arrow on the screen hit the Reverse
Direction button a few times to help you locate the position of the arrow.
to exit.
Set Edge Direction - Use this dialog to reverse the machining direction of the drive
geometry. Both curve 5-axis and swarf 5-axis toolpaths can use a surface edge as drive
geometry.
18. Back at the Swarf 5-axis dialog box click on the Surfaces button in the Tip Control section.
19. The Toolpath/surface selection dialog box will appear now select the selection arrow
shown below left:
Edit comp geometry dialog box
Compensation surfaces, or comp surfaces, are used as a
method of tool tip compensation for multiaxis toolpaths.
Comp surfaces are selected from the part geometry.
Use this dialog box to add to or change the selection of comp
surfaces for a multiaxis toolpath.
Returns you to the graphics window to change the
selection of comp surfaces. Use the General selection ribbon
bar to select or deselect surfaces.
Use the Solid selection button to enter solid selection
mode:
20. On the screen you will now see the prompt to Select Comp Surfaces. Select the surface
shown below, the bottom flat surface of the pocket.
Multi-Axis-Lesson-6
21. After selecting the surface at the bottom of the pocket click on the End Selection icon.
.
to exit the Toolpath/surface selection dialog box.
to exit the Swarf 5-axis dialog box.
24. Select the 1/4 ball end mill and make changes to this page as shown below.
25. Select the Multiaxis parameters page and set the values as shown below:
26. Click on the Entry/Exit button and set the values as shown below:
Entry/Exit
Entry and exit moves for multiaxis
toolpaths are controlled by
several parameters, including
length, thickness, height, and
pivot angle.
You can have entry and exit
moves on all multiaxis toolpaths
except drill 5-axis.

to exit Entry/Exit.
28. Select the Swarf5ax Parameters page and set the values as shown below:
Swarf5ax Parameters
Swarf 5-axis toolpaths cut along a
parts walls using the side of a
tool. Swarf 5-axis toolpaths can
use bull, ball, tapered, and flat
tools.
Multi-Axis-Lesson-6
29. Select the Axis Limits page and set the values as shown below:
Axis limits
Axis limits set a range of tool
motion for a rotary axis that limits
the amount of head tilt relative to
the tool position.
Using axis limits provides
protection against axis over-travel,
and lets you select the action to
take were axis over-travel to
occur.
Note: Axis limits are not available
for Rotary 4-axis toolpaths.
30. Select the Point Generator page and set the values as shown below:
to exit Swarf 5-axis.
32. Save your file.

33. Backplot the toolpath you have just created. Your backplot should be similar to the image
shown below. Ensure the cutter is on the inside of the pocket.
Multi-Axis-Lesson-6
TASK 9:
FINISH MACHINE CIRCULAR ISLAND SWARF 5-AXIS
In this task you will use a 0.25 diameter ball end mill to machine the circular island inside
the large pocket.
CD that came with this text. You will find the video in the Lesson-6 section; there is some
tricky selection of surfaces in this task so please check out the video before you proceed.
2. If required set the graphics view to Isometric View and then select the Screen Fit icon.
3. If required turn off the display of toolpaths by selecting Alt-T on your keyboard.
7. On the graphics screen you will be prompted Select wall surface(s). Select the surface on
the circular island at the position shown below,

.
Lesson-6 Task 10 video on
the multimedia CD that came
with this text.
Multi-Axis-Lesson-6

to exit.
shown below left:
Edit comp geometry dialog box
Compensation surfaces, or comp surfaces, are used as a
method of tool tip compensation for multiaxis toolpaths.
Comp surfaces are selected from the part geometry.
Use this dialog box to add to or change the selection of comp
surfaces for a multiaxis toolpath.
Returns you to the graphics window to change the
selection of comp surfaces. Use the General selection ribbon
bar to select or deselect surfaces.
Use the Solid selection button to enter solid selection
mode:
.

20. Select the Ball Endmill and make changes to this page as shown below:
Multi-Axis-Lesson-6
Entry/Exit
pivot angle.
to exit Entry/Exit.
Swarf5ax Parameters
tools.
Axis limits
the tool position.
occur.

Multi-Axis-Lesson-6

28. Save your file.
shown below. Ensure the cutter is on the outside of the circular island.
TASK 10:
FINISH MACHINE SMALL POCKET SWARF 5-AXIS
In this task you will use a 0.25 diameter ball end mill to machine the small pocket.
CD that came with this text. You will find the video in the Lesson-6 section.
2. If required set the graphics view to Isometric View and then select the Screen Fit icon.
Walls - Surfaces
Uses surfaces as the drive walls.
Choose the Surfaces button to
return to the graphics window and
select the wall surfaces.
Tip Control - Surfaces
Uses surfaces for the toolpath
floor and to position the contact
point of the tool tip.
Multi-Axis-Lesson-6
7. Zoom in as required on the small pocket. On the graphics screen you will be prompted
Select wall surface(s). Start by selecting the surface at position 1 and then move around
and select all of the inside surface walls of this pocket. You will find it easier to select the
various surfaces if you dynamically rotate the display to facilitate the selection of each
surface,

.
with this text.
to exit.
shown below left:
Multi-Axis-Lesson-6
.
20. Select the Ball Endmill and make changes to this page as shown below:
Entry/Exit
pivot angle.
to exit Entry/Exit.
Multi-Axis-Lesson-6
Swarf5ax Parameters
tools.
Axis limits
the tool position.
occur.


28. Save your file.
shown below. Ensure the cutter is on the inside of the pocket.
Multi-Axis-Lesson-6
TASK 11:
ROUGH MACHINE THE CONTOUR
In this task you will use a 0.5 diameter flat end mill, to rough the contour.
3. Make only Level 1 visible as shown below. Level 1 contains the part geometry.

5. From the menu bar select Toolpaths>Contour
screen a prompt to Select Contour chain 1. Select the line shown below. The graphic
below shows the screen after you have selected the line.
7. After selecting the line your graphics screen should look like the screenshot above, with the
green arrow pointing left in a clockwise direction, climb milling.
8. If the arrow is not pointing to the left select the arrow from the Chaining dialog box shown
below to reverse the direction.
9. After the contour has been successfully chained select the OK button
at the bottom of
Multi-Axis-Lesson-6
10. Select the Tool page. Select the Flat Endmill and make changes to the Toolpath
parameters page as shown below:
11. Select the Linking Parameters page and make changes to this page as shown below:
12. Select the Cut Parameters page and set the parameters as shown below:
13. Select the Depth Cuts page and set the parameters as shown below:
Multi-Axis-Lesson-6
14. Select the Lead In/Out page and set the parameters as shown below:
15. Select the Break Through page and enter the parameters as shown below:

16. Select the Multi Passes page and enter the parameters as shown below:
17. Select the Coolant page and make sure the Flood option is set to On:
to exit Contour parameters.

19. Save your file.
Multi-Axis-Lesson-6
TASK 12:
FINISH MACHINE OUTSIDE CONTOUR SWARF 5-AXIS
In this task you will use a 0.5 diameter flat end mill to machine the outside contour.
CD that came with this text. You will find the video in the Lesson-6 section.
6. Make only Level 2 visible as well as shown below. Level 2 contains the surface geometry
that will be used to cut the inside, outside and the small pocket contour using the Swarf 5axis toolpath. These surfaces for the walls are angled not vertical.

Lower Rail
Positions the tool axis at the lower
rail of the toolpath.
The lower rail is the lowest surface
edge if you selected surfaces for
the walls.
This option can be used if the part
does not have a floor.
You can also enter a distance
above the lower rail to position the
floor.

11. On the graphics screen you will be prompted Select wall surface(s). Start by selecting the
surface at position 1 and then move around and select all of the outside surface walls of
this contour. You will find it easier to select the various surfaces if you dynamically rotate
the display to facilitate the selection of each surface.

Multi-Axis-Lesson-6
with this text.

to exit.
19. Select the 1/2 flat end mill and make changes to this page as shown below.
Multi-Axis-Lesson-6
Entry/Exit
pivot angle.

to exit Entry/Exit.
Swarf5ax Parameters
tools.

Axis limits
the tool position.
occur.
Multi-Axis-Lesson-6
27. Save your file.

shown below. Ensure the cutter is on the outside of the contour.
TASK 13:
BACKPLOT THE TOOLPATHS
In this task you will use Mastercams Backplot function to view the path the tools take to cut
this part.
2. Un-zoom .8
3. Activate a shaded view by selecting the icon at the top of the screen.
5. The Level Manager dialog window will now appear. Now click in the Visible column to turn
on the display of Level 1 as shown below:
Your part should look similar to the screen shot below.
circled below:
7. To pick all the operations to backplot pick the Select All icon
8. The next step is to select the Backplot selected operations icon shown below:
9. After reviewing the backplot of the toolpaths select the OK button
to exit Backplot.
Multi-Axis-Lesson-6
TASK 14:
VERIFY THE TOOLPATHS
In this task you will verify all the toolpaths.
1. In the Toolpath Manager pick all the operations to verify by picking the Select All icon
2. Select the Verify selected operations button circled below and hit the play button:
3. At the Verify dialog window activate Simulate Tool.
4. Next click on the Verify options icon as shown below:
5. At the Verify Options dialog window set the Miscellaneous options as shown below:
to exit Verify options.
7. Select the play button to verify the toolpath.
to exit Verify.
Multi-Axis-Lesson-6
TASK 15:
POST AND CREATE THE CNC CODE FILE
1. Ensure all the operations are selected by picking the Select All icon
manager.
from the Toolpath
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.
4. In the Post processing window, make the necessary changes as shown below:
to continue.

6. Enter the same name as your Mastercam part file name in the NC File name field MULTIAXIS-LESSON-6 and select the Save button
7. Select the Save button and review the CNC code.
in the top right corner to exit the CNC editor.

8. Select the
9. This completes Multi-Axis-Lesson-6.
Multi-Axis-Lesson-6
MULTI-AXIS-LESSON-6 EXERCISE #1: SHAFT SUPPORT BASE

MULTI-AXIS-LESSON-6-EX-1.MCX
MULTI-AXIS-LESSON-6 EXERCISE #2: BASE PLATE

MULTI-AXIS-LESSON-6-EX-2.MCX

Hinh Truong Multi Axis Lesson 6

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Mastercam Training Guide

Mastercam Training Guide

MULTI-AXIS-LESSON-6 - THE PROCESS

Setting the environment

TASK 2: INTRODUCTION WATCH THE VIDEO

Mastercam Training Guide

System Configuration (switch units) dialog box

The Level Manager dialog window will now appear.

2. Select the OK button

to exit the Level Manager dialog box.

Mastercam Training Guide

Mastercam Training Guide

Entry Motion - Helix Ramp

Mastercam Training Guide

to exit Pocket parameters.

Mastercam Training Guide

Mastercam Training Guide

Mastercam Training Guide

15. Select the OK button

Mastercam Training Guide

Mastercam Training Guide

12. Select the OK button

7. Select the OK button

to exit the Level Manager dialog box.

Mastercam Training Guide

8. From the menu bar select Toolpaths>Multiaxis>Swarf 5-axis

10. Now click on the Surfaces button in the Walls section.

12. Click on the End Selection icon.

Mastercam Training Guide

Mastercam Training Guide

27. Select the OK button

31. Select the OK button

to exit Swarf 5-axis.

Mastercam Training Guide

32. Save your file.

6. Now click on the Surfaces button in the Walls section.

Mastercam Training Guide

8. Click on the End Selection icon.

13. Select the OK button

Mastercam Training Guide

to exit the Toolpath/surface selection dialog box.

to exit the Swarf 5-axis dialog box.

23. Select the OK button

Mastercam Training Guide

Note: Axis limits are not available

to exit Swarf 5-axis.

Mastercam Training Guide

6. Now click on the Surfaces button in the Walls section.

8. Click on the End Selection icon.

Mastercam Training Guide

Mastercam Training Guide

23. Select the OK button

Mastercam Training Guide

to exit Swarf 5-axis.

4. Select the OK button

Mastercam Training Guide

Mastercam Training Guide

Mastercam Training Guide

to exit Contour parameters.

to exit the Level Manager dialog box.

Mastercam Training Guide

10. Now click on the Surfaces button in the Walls section.

12. Click on the End Selection icon.