Mastercam to Mazatrol Post-Processor Tutorial 2/4/2011

Mastercam to
Mazatrol Post-Processor Tutorial
Introduction
The following tutorial instructs the user in the approach to programming that allows a
Mastercam file with its associated toolpaths to output the desired Mazatrol code.
It is not the intention of this tutorial to teach the user the use of Mastercam or the
Mazatrol conversational system. It is assumed that the user of this product has been
instructed in the use of the former items. Mastercam instruction can be provided by your
local Mastercam reseller. For mazatrol instruction please consult your Mazak/ Mazatrol
Programming Manuals or contact your local Mazak representative.
Note: This text was compiled using Version 1.18.3 of the Mazatrol Post Processor and
Mastercam Version X4 some dialogs presented may have changed or you may be
using either an earlier or later version of Mastercam.

Contents
Section 1a. Programming a 2-1/2 axis Mill Part
Section 1b. Programming a 3 axis Mill Part
Section 1c Programming a 4 axis Mill Part
Section 1d Programming a 5 axis Mill Part
Section 2a. Programming a 2-axis Lathe Part
Section 2b Programming a Mill/Turn Part

Mastercam to Mazatrol Post-Processor Tutorial 2/4/2011

Section 1a - Programming a 2-1/2 axis Mill Part

1. Creating simple face and contour toolpaths

Exercise 1 - Opening the part file

1. Choose File, Open
2. Navigate to the folder with the tutorial parts.
3. Select Mazak_1_Mill.mcx; then choose Open.
Figure 1

Exercise 2 - Creating Facing Toolpath using outside

profile
1. Choose Toolpaths, Face
2. Select outside profile as shown using chain

Mastercam to Mazatrol Post-Processor Tutorial 2/4/2011

Select
Chain

2. Select Done
3. Select or Create a 1.5Dia Face Mill as shown.

Mastercam to Mazatrol Post-Processor Tutorial 2/4/2011

4.

Click on Misc. Values button and set Face Machining to Face as shown below

Mastercam to Mazatrol Post-Processor Tutorial 2/4/2011

Please note that we are using line machining to output line ctr unit type to Mazatrol.
We will discuss also using Standard Pocket type units such as Face. PCKT and Slot
later in this tutorial
5. Click OK when done.
6. Set Facing Toolpath Parameter Values as shown;

Mastercam to Mazatrol Post-Processor Tutorial 2/4/2011

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7. Click on OK when completed.

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Exercise 3 - Creating Contour Toolpath for outside

profile
1.
2.

Choose Main Menu, Toolpaths, Contour

Select outside profile as shown using chain

3.
4.

Select Done
Select 0.5 Dia Flat end Mill as shown.

Select
Chain

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5. Click on Misc. Values button and modify settings as shown below

Mastercam to Mazatrol Post-Processor Tutorial 2/4/2011

Values for fin-z and

in-fin-r will be auto
updated from
Roughness setting

Note: As you may notice the Misc. Values dialog box allows every setting in the
mazatrol SNO line and UNIT (UNO) line to be set by the user and override the
automatically set values output by the post-processor. This will be shown in more detail
in the next chapter.

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Note: Another advantage of using the Mazatrol Post-Processor is that we can output
lead-in and lead-out values from mastercam. In the previous settings we have computer
compensation with left direction. Therefore only use LINE-CTR so that correct
accuracy is maintained. You can of course also use other type of compensation such as
LINE-LFT and LINE-RGT but in those cases it would be safer to set Compensation to
Control so that the Control picks up the tool radius and compensates accordingly.
6. Select Done. This should return you to the operations manager. Select Post icon
in operations Manager Menu to post. When Post processing dialog appears settings
should be as shown below

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Name of post-processor
will vary from this
depending on your setup

7. Select OK. The file name dialog should then appear as shown below:
Note: We do not need to create an NC file but Mastercam needs to have this setting so
that the post-processor can function. This file can be created just as you would with a
standard NC post processor. It is not used for actual output.

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8. Click OK

9. Select a number between 1 and 9999 and hit ENTER. This will be the program
number for your Mazatrol output file (Mazatrol Work No.).

The readable output file will open up by default in Notepad.

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10. Close this window to continue Processing.

Congratulations! You have created your first Mastercam to Mazatrol program. The actual
output file is placed in the default NC directory in Mastercam.
Save Mastercam File as Mazak_1_Mill_1

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2. Adding Pocketing and Drill Toolpaths

Exercise 1 - Creating Pocket Toolpath

We will re-open the file we had previously created to add some more toolpaths
1. Choose File, Open
2. Navigate to the folder with the tutorial parts.
3. Select Mazak_1_Mill_1.mc9; then choose Open.
4. Choose Main Menu, Toolpaths, Pocket
5. Chain outside profile shown in Blue and Inside Island as shown in Green

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6. Select Done

7. Select 3/8 Flat End mill as shown

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8. Set Misc. Values as shown:

9. Set Pocketing Parameters and Roughing/Finishing Parameters as shown below

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Switch off Entry Motion.

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Note: It is best not to use Depth Cuts when machining pockets. If depth cuts are used
unnecessarily long code is output. It is best if you set the value SRV-Z within the misc.
values dialog.

Note: To have the option of either using one tool or two tools for roughing and finishing
we can set this at the Rough and Finish pull down menu in the Misc. Values dialog box
(this option is also available for contour machining equivalent to LINE machining in
Mazatrol). We have also set specific Bottom finishes and Wall finishes. In the mastercam
toolpaths it is not possible to create or activate many of these types of conversational
language settings therefore in many cases the only access to these parameters will be
through the misc. values pages as shown above.
Sample output below when this is processed.
-------------------------------------------------------------------------------UNO UNO
DEPTH SRV-Z SRV-R BTM WAL FIN-Z FIN-R
1 PCKT.MT 0.0912 0.0912 *
1 1 0
0
SNO SNO NOM. NO. APRCH-X APRCH-Y TYPE ZFD DEP-Z WID-R C-SP FR M M
1 E-MILL 0.38 E
?
?
CW
G01 0.0912
0.27 203 0.450 3 8
2 E-MILL 0.38 E
?
?
CW
G01
0.27 203 0.450 3 8

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Exercise 2 - Creating Drill Toolpaths with Multiple

Tools
Select the following:

1.
2.
3.
4.

Toolpaths
Drill
The five (5) x 0.5dia circles
Done

Select 0.5center drill as shown

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6. In order for all the tools to be captured and appear at the top of the drill line set
the Program # to the value shown. (Values of 10001 and larger may be used to
group common tools together for this type of operation) you will need select the
operation then Edit selected operations then Change Program# as shown below.

7. Misc. Values Leave settings on Auto as shown

By leaving set to Auto the output will use the values set in the toolpath dialog

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8. Go to Cut Parameters and set DRILLING DRI as shown

Note: All the Drill Cycles available to Mazatrol are accessible via Drill Cycle Menu as
shown above.
9.OK

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Now we will copy the previous operation. Therefore the only changes we need to make
will be the tool we want to use and the drilling depth. All the other values will stay the
same.

Please note that the

program number is
set to 10001 for the
drilling operation

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11. Paste new operation

12. Select 0.5 tool as shown

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13. Set Depth as shown.

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14. OK.
Below see an example of posted output read into a Mazatrol Control Editor below (NOT
INCLUDED FOR ILLUSTRATION PURPOSES ONLY).

DRILLS
GROUPED
TOGETHR

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15. Save File

16. Post File and view output.

3. Modifying a previously programmed part

Exercise 1 - Opening Part File
In this exercise the object is to modify an existing part previously programmed perhaps
for another type of control such as a Fanuc or perhaps a situation where the
programmer wishes to get all the toolpaths built before adapting the output for Mazatrol.

1. Choose File Open

2. Navigate to the folder with the tutorial parts.
3. Select Mazak_2_Mill.mc9; then choose Open.
4. Go to Operations Manager you should see dialog as below

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In this file we have created a part using pocketing that would be very difficult to program
in Mazatrol because the pocket has multiple islands. We have also used a tool that is too
big to complete the machining of the pocket and then taken advantage of Mastercams
Pocket Remachining routine. As the part already has defined stock go ahead and run
verify out of the Operations Manager to see the current toolpaths.

Exercise 2 - Line-Center output for Pockets

We have two options in this case. We could program all the pockets using line-center and
modifying settings as shown below this would take advantage of mastercams many
different type of pocketing strategies available when setting the Roughing component or
we could program separate areas of the part using either Mazatrols Pocket or Pocket
MT. In this section we will program output as Line center.

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1.Click on 1st Operation in Pocketing Group and Fill in settings as shown below:

Switch Off
Depth Cuts,
Do not use
Entry Motion,

*** IMPORTANT NOTE: Mazatrol adds (for line machining units) an extra lead in and
lead out value equal to the tool radius programmed therefore when selecting an entry
and exit position when using the strategy described above that you select positions which
do not gouge the part.

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2. Set all other pocket toolpaths programmed likewise using Edit Common Toolpath
parameters and go to Misc. Values button

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A section of the Mazatrol output will be as below:

UNo.MAT INITIAL-Z ATC MODE MULTI MODE
1 ALUMINUM 0.70000
0
1
00

UNo.UNo.
2 WPC-0

X
Y
0.00000

UNo.UNo.
3 OFFSET

0
Z
0.00000

MULTI FLG PITCH-X PITCH-Y

0.00000 0.00000

4
0.00000

0.00000

0.00000

U(X)
V(Y) D(0) W(Z)
0.00000
0.00000
0.00000 0.00000

UNo. UNIT DEPTH SRV-Z SRV-R RGH CHMF

FIN-Z FIN-R
3 LINE CTR 0.90000 0.25000 0.25000 4.00000
0.00000 0.02000 0.02000
SNo. TOOL NOM- NO APRCH-X APRCH-Y TYPE ZFD DEP-Z WID-R C-SP FR M M
1 E-MILL0.50000 0.00000 0.00000 0 0 0.25000 0.25000 1069.00000 6.41760

FIG PTN
1 LINE
2 LINE
3 CCW
4 LINE

X
Y R/ANGLE
7.0535 2.8850
4.9465 2.8850
5.2600 3.5000 0.75999
5.2600 5.9378

CNR

There will be times when you may wish to modify the settings that are automatically
calculated for those parameters on both the UNO (unit Line) and SNO (Tool Cutting
Definition Line) this will be done as shown below. Again you will need to access the
Misc. Values Button.
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For example above we will change the output for SRV-Z and SRV-R to values shown
below:

Change
values

A section of the Mazatrol output will be as below:

As you see the settings are output and shown in bold text below:
PNR MAT
INITIAL-Z ATC MODE MULTI MODE MULTI FLG PITCH-X PITCH-Y
0 ALUMINUM 1.0
0
OFF
-------------------------------------------------------------------------------UNO UNO
DEPTH SRV-Z SRV-R RGH CHMF FIN-Z FIN-R
1 LINE-CTR 0.3000 .255
.125 3 *
0
0
SNO SNO NOM. NO. APRCH-X APRCH-Y TYPE ZFD DEP-Z WID-R C-SP FR M M
1 E-MILL 0.50
?
?
* G01 0.2550 * 1069 6.417 3 9
FIG PTN
X
Y
R/0
I
J
P
CNR
1 LINE
8.7198 9.2517
2 CCW
8.7600 9.4741 0.6350 8.1250 9.4741
3 LINE
8.7600 10.0514
4 CCW
8.2298 10.6777 0.6350 8.1250 10.0514
5 LINE
9.0401 11.1456
6 CCW
9.7400 10.7415 0.4601 9.5000 11.1340
7 LINE
9.7400 10.3717
8 CCW
9.2801 9.5752 0.4601 9.5000 9.9793
9 LINE
8.7198 9.2517
10 CCW
8.7577 9.4200 0.6350 8.1250 9.4741
11 LINE
8.9961 10.4767
12 LINE
8.8260 10.7017
13 LINE
8.9987 10.5517
14 LINE
8.7198 9.2517
-------------------------------------------------------------------------------UNO UNO
DEPTH SRV-Z SRV-R RGH CHMF FIN-Z FIN-R

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2 LINE-CTR 0.6000 .255
.125 3 *
0
0
SNO SNO
DEP-Z WID-R C-SP FR M M
1 E-MILL 0.50
?
?
* G01 0.2550 * 1069 6.417 3 9
FIG PTN
X
Y
R/0
I
J
P
CN

NOM. NO. APRCH-X APRCH-Y TYPE ZFD

Exercise 2 - Mazatrol Style Pocket output for Pockets

In order to use the Mazatrol Pocket Styles we have to disable Mastercams Pocket
Roughing routines. The Mazatrols Pocketing styles will be based upon the Parameters
that are set within the controller itself. We will set the Mastercam Parameter Pages as
Follows for all the pocket toolpaths:

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Set Misc. Values as below:

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Exercise 3 - Modifying Drill Cycles in Counter Boring

Group
In this section we will modify the Toolpath Group labeled as Counter Boring. If we were
to post this section each one of the tools would be in a separate UNO section a with a
drill cycle defined by what is shown currently in the Operations Manager. Therefore we
need to Group these operations together and also we need to make sure that the drill cycle
type is consistent. In this case we will set it to Mazatrols RGH CBOR.
We need to do the following:
1. Using EDIT COMMON PARAMETERS highlight the Counter Boring Group in the
Operations Manager set the Program # as follows:

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Make sure
Program # is
set as shown

2. We now need to make sure that for all the operations in this group the drill cycles are
set as follows:

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Note: We have used 6 tools in the previous section - the Mazatrol will allow this many
tools for this type of cycle - but the number of tools used by the mazatrol when manually
programming at the control is based upon internal calculations which reference BuiltIn Parameters.

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Operations manager should then look as below

Exercise 4 - Modifying Drill Cycles in Tapping Group

As in the previous exercise we will modify the three operations grouped as .1900-24
TAP RH so that the output will be more efficient and readable as Mazatrol format. In
addition we will add an operation to create a chamfer before the final tapping operation.
We need to do the following:
1. Using EDIT COMMON PARAMETERS highlight the Tapping Group in the
Operations Manager set the Program # as follows:

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2. Set all Drill Cycles to TAP as below:

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3.Now to add chamfering toolpath copy and paste the second operation within the group
as shown

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4. Then paste this operation so that it precedes the final tap operation.
5. Select Tool as shown.

As you have copied the operation within the group the Program # is still correct as
shown.
6. Set TAP page as follows:

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7. Select OK and REGEN path.

8. Save file and post to create Mazatrol Code.

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Section 2 :Lathe
1. Programming a Basic Part.
Obviously one can access these to create a toolpath but what is important to mention is
the following: When programming for Mazatrol output use
LATHE
Mastercam
Face
Canned Rough
Canned Finish
Canned Groove
Thread
Drill
Cutoff
Manual
MILL IN LATHE
Mastercam
C-axis Drill
C-axis Drill
C-axis Drill
Cross Contour
C-Axis Contour
C-Axis Contour
C-Axis Contour
Manual

Mazatrol Output
- EDG; FCE
- BAR; IN, OUT, FCE, BAK Also some GRV
- BAR; IN, OUT, FCE, BAK
- GRV; IN, OUT, FCE, BAK
- THR
- DRL
- GRV
- LMP

Mazatrol Output
- MDR
- MTP
- BOR
- MGV
- LCT
- RGT
- LFT
- MMP

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We will Rough and Finish outside profile, Drill and Thread ID then thread OD and final
step will be grooving OD.

Finished part is shown verified

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Operations List for Finished Part are listed below:

Exercise 1 - Opening the part file and Job Setup

1. Choose, File, Open
2. Navigate to the folder with the tutorial parts.
3. Select Mazak_ENG_Sample_2.mc9; then choose Open.
4. Choose, Stock Setup
5. Enter settings as shown.

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Note: Stock Setup settings will affect the first line of the mazatrol UNO 0 and MAT data
i.e. the material selected will be output and the OD will be OD-Max and Length will be
Length will be based on the values entered in the job setup see below:

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Exercise 2 - Creating Facing Toolpath

1. Choose, Toolpaths, Face
2. Select outside profile as shown using chain

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Important note: TO access to the material line i.e. the first line of the Mazatrol
Program where the size and material of the stock are defined. These values in some
cases such as the length and diameter will overwrite previously defined values in the
Job Setup. See below:
Go back to the first parameter page of the Facing Toolpath and click on Misc. Values.
Then click on the Material Line. You should then see the following display:

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Lets change the finish allowance values to FIN-X = 0.02 and FIN-Z = 0.01 by entering
in the dialog as shown below:

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Click OK and in the Operations Manager Move this newly created Manual Operation to
be the first operation.

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Move to here

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Sample output for material line and facing :

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Exercise 3 - Creating Rough and Finish Toolpath

Select the following:

1. Toolpaths
2 Canned Rough
3.. Select Chain as Shown Below

5.

Set Parameters as in the following Roughing Param. Pages.

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6.

Click on OK when completed

If we were to post for output now, we would get window as shown below. We
provide this to illustrate our progress. When we have completed the complete part
program we will then document how to run the post.

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Exercise 4 - Creating Drill Toolpaths

To create Drill Toolpaths select the following:
1. Toolpaths
2. Drill - set Param. Pages as shown on the following pages

3. Select Tool as shown

4. Set next page as shown.

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5. Click on OK when done

6. Set Misc. Values as shown

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Exercise 5 - Threading Toolpaths

We will now Thread the ID
1. Set Thread Parameters as shown on the following pages.

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We will now Thread the OD, set the Parameters as shown below

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Note: As you may notice the Misc. Values dialog box allows every setting in the
mazatrol SNO line and UNIT (UNO) line to be set by the user and override the
automatically set values output by the post-processor.

Select OK when done.

Exercise 5 - Creating Groove Toolpath

As with the Roughing and Finishing toolpaths it is generally unnecessary to have both a
rough and a finish operation programmed in mastercam to get the correct output in
Mazatrol
We will now create a 1 point groove on the OD.
Select the following:
1. Toolpaths
2. Canned Groove
3. Select 1 pt
4. Click pt shown on OD
5. Set Parameter Pages as shown

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We do not need to select a finish for grooving. So set as shown above

Exercise 6 - Creating Cutoff Toolpath

We will now finish the part by creating a cutoff operation.
Set Parameter Pages using Cutoff Toolpath

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6. Select Done. This should return you to the operations manager. Select Post

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7. Select OK. The file name dialog should then appear as shown below:

Note: We do not need to create an NC file but Mastercam needs to have this setting so
that the post-processor can function

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11. Select a number between 1 and 9999 and hit OK. This will be the WORK NOr for
your Mazatrol output file.
.

8. Hit Enter

You should then see output as shown below

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12. Close this window.
We will then send this program to the controller
Congratulations! You have created your first mastercam to mazatrol program.

Save File

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Mill/Turn
Essentially we program as normal but there are a few rules to follow when programming
for a C/Y axis milling capable lathe using the Mazatrol Post Processor. Please be sure to
go through the previous sections of this tutorial before working throught his section.

Open Mazatrol_Mill_Turn.MCX

You will notice that there are pre-built operations which cover the c-axis toolpaths that
are available in Mastercam. We have the option of machining the front face profile using
Mastercam 2D Contour OR C-Axis Contour we have included the 2D Contour
essentially because it allows the user more control and can add a lead-in and lead-out
although this is technically not necessary as Mazatrol will handle entry and exit
conditions. Only Line Center-Machining will output LFT and RGT are not available as
output choices.

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If you run Verify or Backplot on all the operations you will notice that Operation#2 needs
to be modified as it is cutting at 0.00 depth.
2. Double click on this operation and set Depth shown.

3. Disable Lead and Lead out

One of the limitations in creating toolpaths from Mastercam may be that some of the
ouput may be too big to fit in a Mazatrol unit.
The Misc Values will be rarely used when using the Mill Turn Toolpaths.

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Using Indexing /4th axis Positioning

The aim of this exercise is to show the user how to output an index (and for later
generations of control index + wpcshift units).
To make sure that you get the 4th axis output please make sure the indexing switch is set
in the Post Processor as shown below
indexing

:1

# 0 = Index_off, 1= 4th axis index only 2= 5 axis index only #

Note: Currently not available for Man Pro as positioning or simultaneous (future)
Using the rules described earlier for programming 2 axis toolpaths we supply a sample
file with the toolpaths already built
1. Open mazatrol_4th_axis.mcx

Using Indexing /5th axis Positioning

The aim of this exercise is to show the user how to output an index (and for later
generations of control index + wpcshift units).
To make sure that you get the 4th axis output please make sure the indexing switch is set
in the Post Processor as shown below
indexing

:2

# 0 = Index_off, 1= 4th axis index only 2= 5 axis index only #

Note: Currently not available for Man Pro as positioning or simultaneous (future)
Using the rules described earlier for programming 2 axis toolpaths we supply a sample
file with the toolpaths already built
1. Open mazatrol_5th_axis.mcx

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Appendix
Working with the Misc. Values Dialog to modify /override
automatically generated output.
There will be times when you will wish to adjust the output at the mastercam
programming stage or when a part has been programmed for a non-mazatrol control. As
has been discussed earlier any value of the SNO and UNO lines can be overridden
through the Misc. Values Page.
In the following example we will take the automatically generated groove of the
previously programmed part and enter values which will then appear in the mazatrol
code.
Below is Current Misc. values Dialog with current Auto Settings and then outputted
code.

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We will adjust the following:

We want a different grooving pattern say #2 Right-tapered grooves
Maybe multiple grooves based off of original No.of 3 with a Pitch of 1.5
Maybe different values for feeds 200 for RV and 166 for FV
We would modify the Misc. Values as shown

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Mastercam to Mazatrol Post-Processor Tutorial2/4/2011

You can then see in the output below that those setting are now in transferred over.

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Mastercam to Mazatrol Post-Processor Tutorial2/4/2011

This can be done with every toolpath and operation and allows complete control to the
programmer.

FOR ADDITIONAL INFORMATION ON THE USE OF THIS PRODUCT CONTACT:

Camaix USA
Industrial Technology Development
[email protected]

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