Machine Simulation

April 2016
 Mastercam 2017 Machine Simulation
Date: April 2016
Copyright 2016 CNC Software, Inc. All rights reserved.
Software: Mastercam 2017
TERMS OF USE Use of this document is subject to the Mastercam End User License Agreement.
The Mastercam End User License Agreement can be found at:
http://www.mastercam.com/companyinfo/legal/LicenseAgreement.aspx

Be sure you Information might have been changed or added since this document was
have the latest published. The latest version of this document is installed with Mastercam or can
information! be obtained from your local Reseller. A ReadMe file (ReadMe.pdf)installed
with each releaseincludes the latest information about Mastercam features and
enhancements.
 iii

Contents
Introduction ....................................................................................................... 5
Tutorial Goals................................................................................................. 5
General Tutorial Requirements ....................................................................... 5
Machine Simulation Tutorial Requirements ................................................... 6
1. Welcome to Machine Simulation ......................................... 7
Lesson Goals ................................................................................................. 7
Exercise 1: Opening the part file ........................................................... 7
Exercise 2: Preparing the simulation environment .............................. 10
Exercise 3: Viewing The Simulation .................................................... 17
Exercise 4: Selecting a Different Machine........................................... 23
2. Using the Machine Simulation Workflow .......................... 25
Lesson Goals ............................................................................................... 25
Exercise 1: Backplotting the Toolpaths ............................................... 25
Exercise 2: Preparing and Simulating the Toolpaths ........................... 29
Exercise 3: Viewing the Simulation..................................................... 33
Exercise 4: Adjusting the Fixture ........................................................ 37
Exercise 5: Verifying Material Removal............................................... 39
3. Toolpath Analysis with Machine Simulation...................... 41
Lesson Goals ............................................................................................... 41
Exercise 1: Analyzing Before Fixturing ................................................ 41
Exercise 2: Analyzing Before Machine Selection ................................ 44
4. Machine Simulation for 3-Axis Toolpaths .......................... 53
Lesson Goals ............................................................................................... 53
Exercise 1: Simulating Stock Removal................................................ 53
iv MASTERCAM 2017 2017

Exercise 2: Adding a Fixture and Stock............................................... 57

Exercise 3: Simulating with Different Fixtures..................................... 60
Conclusion ......................................................................................................... 66
Mastercam Resources ............................................................................... 66
Mastercam Documentation ....................................................................... 67
Contact Us .................................................................................................... 67
Introduction

Mastercam Machine Simulation is a safe, cost-effective way of proving out 3-axis, 4-

axis, or 5-axis Mill or Router toolpaths. Machine simulation helps you detect collisions
between your stock, tool, and any machine components before sending any code to
your machine tool. You can use machine simulation to test possible multiaxis fixture
scenarios and find the ideal location for machining a particular job. It is an additional
tool to help you make clean, efficient, and accurate toolpath programs.

Tutorial Goals
Introduce you to the machine simulation workspace.
Illustrate the machine simulation workflow.
Show the benefits of using machine simulation.
Analyze toolpath motion with machine simulation.
Simulate both 3-axis and multiaxis toolpaths.

Estimated time to complete this tutorial: 2 hours

General Tutorial Requirements

All Mastercam tutorials have the following general requirements:
You must be comfortable using the Windows operating system.
The tutorials cannot be used with Mastercam Demo/Home Learning Edition
(HLE). The Demo/HLE file format (emcam) is different from the Mastercam file
format (mcam), and basic Mastercam functions, such as file conversions and
posting, are unavailable.
Each lesson in the tutorial builds on the mastery of preceding lessons skills.
We recommend that you complete them in order.
Additional files may accompany a tutorial. Unless the tutorial provides specific
instructions on where to place these files, store them in a folder that can be
accessed from the Mastercam workstation, either with the tutorial or in any
location that you prefer.
You will need an internet connection to view videos that are referenced in the
tutorials. All videos can be found on our YouTube channel:
www.youtube.com/user/MastercamTechDocs.
6 MASTERCAM 2017 / Introduction

All Mastercam tutorials require you to configure Mastercam to work in a

default metric or English configuration. The tutorial provides instructions for
loading the appropriate configuration file.

Machine Simulation Tutorial Requirements

In order to run machine simulation, you must have the following:
Mastercam Mill or Router
A Mastercam part file with at least one toolpath and a surface or solid model
of the workpiece

IMPORTANT: The following toolpaths or functions are not currently

supported in machine simulation:
Lathe
Wire
Drill 5axis
Circle Mill 5axis
Translate, rotate, or mirror (Transform)
Block drill
Axis substitution
Aggregate head
Non-motion FBM preparation operations

CAUTION: Machine simulation uses the NCI data from Mastercam to

simulate your toolpaths. It is not a G code simulation product. Also,
machine simulation does not use the machine definition associated with
each toolpath. This allows you to choose any available machine model
and quickly simulate your toolpath.

MACHINE SIMULATION
LESSON 1
1 Welcome to Machine Simulation
This chapter introduces you to the Machine Simulation interface, including selecting a
machine for simulation, running a simulation, and selecting options for displaying your
part.

Lesson Goals
Starting Machine Simulation
Navigating through the Machine Simulation interface
Selecting a different machine

Exercise 1: Opening the part file

1 Start Mastercam using your
preferred method:
Double-click Mastercams
desktop icon.
Or
Launch Mastercam from the
Windows Start menu.
2 Select the default metric configuration file:

a Click the File tab.

8 MASTERCAM 2017 / Welcome to Machine Simulation

b Choose Configuration from

Mastercams Backstage View to
open the System Configuration
dialog box.

c Choose ...\mcamxm.config <Metric> from the Current drop-down list.

d Click OK.
3 Open the Swarf part file that was provided with this tutorial.

NOTE: Machine simulation requires a Mastercam file with solids and/or

surface geometry.

MACHINE SIMULATION
 OPENING THE PART FILE 9

4 Select Levels located with the

Toolpaths Manager tab to open the
Levels Manager.

If the Levels Manager is not displayed, select Levels on the View tab to toggle
the display.

5 Notice that the part is located on the main level and the fixture is on level 6.

MACHINE SIMULATION
10 MASTERCAM 2017 / Welcome to Machine Simulation

Exercise 2: Preparing the simulation environment

1 Select the dialog box launcher in the Machine Simulation group on the
Machine tab.

The Machine Simulation dialog box displays.

2 To see all the machine configurations installed with Mastercam, select the
Machine drop-down list at the top of the dialog box.

MACHINE SIMULATION
 PREPARING THE SIMULATION ENVIRONMENT 11

Mastercam includes models of the most popular mill and router machines in
the industry, including examples of all three major 5-axis machine groups.
Table/table
Table/head
Head/head
The machine names are abbreviated to include information about the
configuration:

Vertical or horizontal milling center

Head/head, head/table, or table/table

Names of axes in machine

MACHINE SIMULATION
12 MASTERCAM 2017 / Welcome to Machine Simulation

3 Select A6_5XRHINO_VMCHTBA from the machine list.

4 Click the Geometry drop-down list.

MACHINE SIMULATION
 PREPARING THE SIMULATION ENVIRONMENT 13

By default, Machine Simulation loads all visible surface and solid geometry as
the workpiece, but you can control this by selecting one of these options.

5 Select All elements from the list.

6 Click the Fixture drop-down list. Select From Level and select level 6.

The options are similar to the Geometry drop-down list.

7 Enter 0.3 for the Simulation tolerance.
This parameter sets the tolerance for detecting collisions between the part or
stock and the machine.

MACHINE SIMULATION
14 MASTERCAM 2017 / Welcome to Machine Simulation

8 Select Use Mastercam Settings in

the Colors and shortcuts group
box.
You can configure Machine
Simulations display colors and
shortcut keys independent of the
Mastercam environment. Selecting
this option reads the Mastercam
configuration file and sets the colors
and shortcut keys to match
Mastercam.

9 To go directly to the simulation, click

Simulate at the bottom of the
dialog box.

Mastercam stores the simulation startup settings in the part file when you
save the file after running simulation. The next time you open this file, you can
go directly to running the simulation.

MACHINE SIMULATION
 PREPARING THE SIMULATION ENVIRONMENT 15

The simulation interface lies on top of the Mastercam interface and shows the
part positioned in the machine.

If you cannot see your part, click Workpiece in the Simulation tab to display
it. If your display includes additional windows, choose View, Reset to match
the picture shown above.
10 Close the CutSim and Measure windows.

11 Select Move List from the View tab.

MACHINE SIMULATION
16 MASTERCAM 2017 / Welcome to Machine Simulation

The Move List displays the coordinates for each toolpath move.
12 Repeat the previous step and select the following windows:

Analysis (Toolpath)
Machine
Report
All of these windows will be used during the tutorial.
The window layout should now look like the following image:

You may have to dock the Machine tab with the other tabs, as it may appear
above the others.

MACHINE SIMULATION
 VIEWING THE SIMULATION 17

Exercise 3: Viewing The Simulation

Machine Simulation provides several options for viewing and analyzing your toolpath
motion in your machine. The VCR-style controls and the slider bar are located in the
Simulation tab.

1 Select the Simulation tab.

2 Move the indicator to the middle of

the slider bar.

Moving the slider bar to the left side decreases the speed of the
simulation, but increases the detail of the simulation.
Moving the slider bar to the right side increases the speed of the
simulation, but decreases the detail of the simulation. The simulation skips
an increasing number of steps and if a collision occurs in the skipped
steps, it is still reported.
3 Click Run to begin the simulation.
The simulation proceeds step by step through the toolpath. Notice that the
progress bar along the bottom of the screen and the Move List in the upper
right corner both update as the simulation continues.
4 An error message will display,
notifying you of a collision. Click Yes
to All to continue running the
simulation.

MACHINE SIMULATION
18 MASTERCAM 2017 / Welcome to Machine Simulation

When the simulation completes, the

Report tab lists events that
happened during simulation. In this
example, the report indicates that
the B and A axes collided. Also,
Value underflow X tells you that
the X axis position was below the
axis limits for the indicated tool
moves.

5 Click on Collision between B1 and A3 in the Report tab and machine

simulation jumps to where the problem occurs. The two axes that collide
display in red.

To look more closely at the motion, move your mouse to the workpiece
center and roll your mouse wheel to zoom in.

MACHINE SIMULATION
 VIEWING THE SIMULATION 19

6 Click the Move List tab at the bottom of the report window to display the list
of coordinates for each toolpath move.

7 In the Move List, scroll to line 213,

which is where the collision begins,
and press the down arrow on your
keyboard to step through the next
several moves in the toolpath.

TIP: You can also move the slider

on the right side of the Move List up
and down to move through the tool
motion.

8 Move the slider on the progress bar at the bottom of the screen all the way to
the left to start at the beginning of the toolpath.

MACHINE SIMULATION
20 MASTERCAM 2017 / Welcome to Machine Simulation

9 Click the arrow below Machine in

the Simulation tab and select
Workpiece/Stock to show only the
tool and the workpiece.
This focus option moves the tool
around a stationary workpiece.

10 Scroll the mouse wheel to zoom out.

11 Right-click in the graphics window

and select Other Views, Left to
rotate the part to the left view.
Machine Simulation includes many
standard Mastercam views.

MACHINE SIMULATION
 VIEWING THE SIMULATION 21

12 Click and hold the left mouse button while moving the cursor down in the
simulation window. This action rotates the part down and allows you to see
the toolpath more clearly.
13 Click Run to play the simulation again.

MACHINE SIMULATION
22 MASTERCAM 2017 / Welcome to Machine Simulation

The workpiece focus mode lets you concentrate on just the tool motion.

14 Set the focus back to Machine and set the view to Isometric.

15 Click Fit to center the machine in the simulation window.

16 Exit the Machine Simulation and return to the main Mastercam screen.

MACHINE SIMULATION
 SELECTING A DIFFERENT MACHINE 23

This exercise includes just a few of the possible viewing options in Machine Simula-
tion. You try more in the following chapters.

Exercise 4: Selecting a Different Machine

One of the benefits of Machine Simulation is being able to prove out a program
without using machine time. Finding issues early can save you time and money. In this
exercise, you select a different machine for simulation based on collisions and under-
flow issues found in the previous exercise.
1 Select the dialog box launcher in the Machine Simulation group on the
Machine tab.

2 Select the 8_5XDMU_VMCTTBC machine from the Machine drop-down list.

3 Enter 0.3 for the Simulation tolerance, if necessary.

4 Click Simulate at the bottom of the dialog box to return to simulation.

MACHINE SIMULATION
24 MASTERCAM 2017 / Welcome to Machine Simulation

5 Increase the simulation speed with the slider (as shown in Exercise 2) and then
click Run.
6 When the simulation is complete, click the Report tab to see the results. No
collisions are reported.
7 Click Exit to close Machine Simulation and return to the main Mastercam
screen.
Testing your parts in different positions and on different machines is an integral part
of the machine simulation process. The next chapter goes into more detail on this
process, including backplot and material removal verification as part of the recom-
mended workflow.

MACHINE SIMULATION
LESSON 2
Using the Machine Simulation
2

Workflow
Now that you have a basic idea of how Machine Simulation works, this lesson goes
into more detail on how Machine Simulation can fit into your machining process.
Adding Machine Simulation to your workflow helps you choose the best setup for
each part and machine.

Lesson Goals
Backplotting toolpaths to analyze toolpath motion
Simulating toolpaths to check fixturing and machine motion
Verifying toolpaths to confirm material removal

Exercise 1: Backplotting the Toolpaths

The first step is to check the quality of the toolpath motion using Mastercams Back-
plot function, which lets you closely examine the tool motion to make sure it meets
your needs.
1 From the Mastercam menu, choose File, Open and open the part file,
visering, provided with this tutorial.

NOTE: This part is configured in inches, so you are prompted to switch

from inch to metric. Choose All settings and click OK to continue.
26 MASTERCAM 2017 / Using the Machine Simulation Workflow

2 If necessary, press [Alt+S] to shade the part.

The toolpaths included in the part file machine the green area of the part. This
part is ideal for 5-axis toolpaths, because you can potentially machine the
whole part in one setup. This would be difficult on a 3-axis machine.
3 Use the Levels Manager to display the vise on Level 2.

MACHINE SIMULATION
 BACKPLOTTING THE TOOLPATHS 27

This is just one possible fixturing solution for this part. In every case, you must
decide how to hold the part in the machine.

4 Select all the toolpaths in the

Toolpaths Manager and click
Backplot selected operations.
The Backplot dialog box displays.

MACHINE SIMULATION
28 MASTERCAM 2017 / Using the Machine Simulation Workflow

5 Click Options on the Backplot

dialog box to adjust the display
settings before running the
backplot.

6 Deselect the following parameters on the Backplot Options dialog box:

Simulate Axis Substitution

Simulate Rotary Axis
Display vectors

Turning these options off keeps the part stationary in the graphics window
and moves the tool around the part.
7 Click OK to close the Backplot Options dialog box.

8 Turn on Display tool and Display

holder on the Backplot dialog box
to see the tool and holder during
the backplot.

9 Click Play on the Backplot VCR bar to run the backplot.

MACHINE SIMULATION
 PREPARING AND SIMULATING THE TOOLPATHS 29

As the backplot progresses, watch the tool and holder for any collisions with
the part or fixture. Rotate the part or zoom out if necessary to get a better
view of the tool motion.

10 Click OK on the Backplot dialog box when the backplot is complete.

The tool motion looks good so far. The next step is to simulate the motion on
a machine.

Exercise 2: Preparing and Simulating the Toolpaths

Backplotting toolpaths is a good initial step to check the tool motion, but it can only
display the tool and holder. It cannot show you how the rest of the machine compo-
nents move around the part. Machine Simulation lets you visualize how all parts of the
machine move when processing the toolpaths.
Before you begin the next exercise, you add a new machine to select for simulation.
This procedure is helpful if you create a new machine that matches one in your shop.

MACHINE SIMULATION
30 MASTERCAM 2017 / Using the Machine Simulation Workflow

For more information on additional machines for simulation, please contact your local
Mastercam Reseller.
1 Copy the HERMLE800 folder provided with this tutorial to the following
location:
C:\Users\Public\Public Documents\shared Mcam
2017\MachineSimulation\MachSim

Each folder represents a machine and contains the files needed to simulate
that machine:
XML file with the kinematic machine structure
GIF file that displays in the startup settings dialog box
STL models that represent the machines physical components

2 Select the dialog box launcher in the Machine Simulation group on the
Machine tab.

MACHINE SIMULATION
 PREPARING AND SIMULATING THE TOOLPATHS 31

3 Set the following parameters:

Click the Machine drop-down list and select the Hermle800 machine
that now appears in the list.
Set Geometry to From Level and 5.
Set Position to Translation in XYZ.
Set Y to 2.5 and Z to -3.
Select From Level and select level 2.
Enter 0.012 for the Simulation tolerance.

MACHINE SIMULATION
32 MASTERCAM 2017 / Using the Machine Simulation Workflow

4 Click Simulate to display the part in the machine.

If necessary, set Machine Housing to Show and set Simulation to focus on

the Machine.

MACHINE SIMULATION
 VIEWING THE SIMULATION 33

5 Click Isometric and Fit to display the entire machine in the simulation
window.

Exercise 3: Viewing the Simulation

1 Click Run to begin the simulation.

2 The Report tab displays collisions in operations 2 and 4.

3 Click on the first collision in the Report tab to jump to that toolpath section.

MACHINE SIMULATION
34 MASTERCAM 2017 / Using the Machine Simulation Workflow

4 Zoom in to the collision by scrolling your mouse wheel.

The fixture is colliding with a section of the tool spindle.

5 To get a better view of what
components are colliding, click the
Machine tab.

6 Right-click the Geometry5

component under the Z axis and
choose Transparent.
You can now see through the
spindle housing to get a better view
of the collision.

MACHINE SIMULATION
 VIEWING THE SIMULATION 35

7 Right-click the Geometry7 component and choose Transparent to provide

even more visibility.
8 Select the Report tab to return to the operation list.

9 Click on the first collision in

Operation 4.

10 In the Simulation tab, click the drop-

down list below the Machine
Housing button and select Hide to
simplify the machine display.

11 Right-click in the graphics view and select Other Views, Right to move to the
right side view.

MACHINE SIMULATION
36 MASTERCAM 2017 / Using the Machine Simulation Workflow

This position gives you a better view of the collision between the spindle and
the fixture.

MACHINE SIMULATION
 ADJUSTING THE FIXTURE 37

12 On the side of the Move List, pull the slider bar down to step through the
two collisions in this operation.

13 Exit Machine Simulation when you are satisfied and return to Mastercam.

Exercise 4: Adjusting the Fixture

By using machine simulation, you can see that this fixture is not optimal for the
selected machine. Machine Simulation makes it easy to try different types of fixturing
and avoid costly mistakes while running the machine.
1 Select the dialog box launcher in the Machine Simulation group on the
Machine tab.

MACHINE SIMULATION
38 MASTERCAM 2017 / Using the Machine Simulation Workflow

2 Set the fixture to Level 7.

3 Click Simulate.

4 Reset the Machine Housing to Show.

5 Click Isometric and Fit to display the entire machine in the simulation
window.
6 Click Run to simulate the toolpaths.

The new, smaller fixture causes no collisions.

7 Click Exit to return to the main Mastercam screen.

MACHINE SIMULATION
 VERIFYING MATERIAL REMOVAL 39

Exercise 5: Verifying Material Removal

Now that you feel confident running the toolpaths on this machine, the final step is to
check the stocks shape after running the toolpaths. Machine Simulation includes the
necessary material removal verification tools.
1 Select the dialog box launcher in the Machine Simulation group on the
Machine tab.
2 Set the stock to From Level and set it to level 4.

3 Click Simulate.
Because you selected stock in the simulation settings, machine simulation
automatically opens in material removal mode.

MACHINE SIMULATION
40 MASTERCAM 2017 / Using the Machine Simulation Workflow

4 Click Run to simulate the toolpaths.

You can see the tool actually removing material from the part as it moves
through the toolpaths.
Flute collisions are reported on two of the operations. One way to fix this
issue would be to return to Mastercam and extend the tool shank length for
the tool that is used by these operations.
5 Click Exit to close the simulation window and return to Mastercam.
The final workflow step is to cut the part on the actual machine. Since you have tested
this machining strategy in several ways, you can feel confident that the part will cut
correctly.

IMPORTANT: While Machine Simulation lets you experiment with

multiple cutting strategies and fixture combinations without using valu-
able machine time, there is no substitute for the first run of a part on a
machine. Always be alert and cautious when running a part for the first
time on a real machine.

The next chapter provides information about additional toolpath analysis in machine
simulation.

MACHINE SIMULATION
LESSON 3
Toolpath Analysis with Machine
3

Simulation
Mastercams Machine Simulation provides several tools for evaluating your toolpath
efficiency and accuracy. These tools can help you determine the best cutting strategy,
fixturing, and positioning for your multiaxis parts.

Lesson Goals
Inspecting part positioning
Analyzing tool motion
Adjusting analysis options

Exercise 1: Analyzing Before Fixturing

Machine Simulations toolpath analysis can provide useful information even before
you select a method for holding your part in your machine. You can see if the tool
motion works in a virtual environment before using valuable machine time.
1 From the Mastercam menu, choose File, Open. Open the part file, curve_5x,
provided with this tutorial.
42 MASTERCAM 2017 / Toolpath Analysis with Machine Simulation

NOTE: This part is configured in metric units, so you are prompted to

switch from inch to metric. Choose All settings and click OK to continue.

2 Click Run on the Machine tab.

The part file has a simulation machine and position already assigned.

3 Click Run to begin the simulation.

MACHINE SIMULATION
 ANALYZING BEFORE FIXTURING 43

4 Select the Report tab.

Machine Simulation reports a value
underflow in the Z axis. This
message means that the Z axis
position was below the axis limits for
the indicated tool moves.

5 Click on the issue in the Report tab and machine simulation jumps to where
the problem occurs.
6 Zoom in to the part and click Right to get a clearer view.

7 Step through the toolpaths problem section.

Before you even select a fixture for the part, you can see that the part has
problems on this machine. You may need to select a different machine in your
shop or position the part closer to the table to avoid the reported issues.
8 Click Exit to close Machine Simulation.

MACHINE SIMULATION
44 MASTERCAM 2017 / Toolpath Analysis with Machine Simulation

Exercise 2: Analyzing Before Machine Selection

No matter what machine you select, Machine Simulation includes analysis tools that
provide additional details on your toolpaths. These details may affect what machine
you select for your part.
1 From the Mastercam menu, choose File, Open. Open the part file,
split_impeller, provided with this tutorial.

2 Select the second toolpath in the

Toolpaths Manager.
Machine Simulation only displays
the selected toolpaths.

MACHINE SIMULATION
 ANALYZING BEFORE MACHINE SELECTION 45

3 Select the dialog box launcher in the Machine Simulation group on the
Machine tab.

The basic 5AxHeadHead machine is selected by default.

4 Enter 0.3 for the Simulation tolerance.

5 Click Simulate to display the part. No machine displays.

6 Click Run to watch the toolpath motion on the part.

MACHINE SIMULATION
46 MASTERCAM 2017 / Toolpath Analysis with Machine Simulation

If the toolpath is not displayed, click Toolpath in the Visibility section of the
Simulation tab.
7 To see the tool motion more clearly,
click the Machine tab, right-click on
the workpiece in the tree control,
and choose Hide.

8 Click the Analysis tab.

This tab includes many options for
closely inspecting your toolpath
motion.

9 Select B Axis Reversal from the

drop-down list at the top of the tab.
This analysis option changes the
toolpath color every time the
rotation axis changes direction. The
color changes can help you identify
areas where direction changes could
impact your surface quality.

MACHINE SIMULATION
 ANALYZING BEFORE MACHINE SELECTION 47

10 Rotate the part and zoom in if necessary to get a better view of the color
changes.

According to the color key in the Analysis tab:

Blue = positive axis direction moves
Green = negative axis direction moves
Red = axis direction reversal
The red areas could create pattern marks on your surface if you are running
an older machine. You may be able to work around these areas by adjusting
the part in the machine.

MACHINE SIMULATION
48 MASTERCAM 2017 / Toolpath Analysis with Machine Simulation

11 To change the color for negative axis

direction moves and make them
easier to see, double-click the green
square to display the Colors dialog
box.

12 Select the yellow color from the Colors dialog box and click OK.

13 Click Refresh on the Analysis tab to

update the colors in the simulation
window.

MACHINE SIMULATION
 ANALYZING BEFORE MACHINE SELECTION 49

The new color provides a better contrast and makes it easier to see the
direction changes.

14 Select Sequence from the drop-down list at the top of the Analysis tab.
This analysis colorizes the toolpath in a hot to cold gradient, which identifies
the following attributes:
Machining start and end points
Cutting method (zigzag or one way)
Cut order (inside to outside, outside to inside)

MACHINE SIMULATION
50 MASTERCAM 2017 / Toolpath Analysis with Machine Simulation

The default colorization uses ten gradients, starting with red at the beginning
of the toolpath and ending with blue. You can see where the toolpath begins
and ends and that it moves in a zigzag pattern.

MACHINE SIMULATION
 ANALYZING BEFORE MACHINE SELECTION 51

TIP: You can add more gradients by clicking the Add button at the top of
the Analysis dialog box.

15 Click Exit to return to the main Mastercam screen.

These analysis options help you adjust your toolpaths to be more efficient and effec-
tive. To learn more about analysis options and about the Machine Simulation in
general, press [F1] while in the Machine Simulation window to bring up the Help.
Although you might think that Machine Simulation is mainly for multiaxis toolpaths,
the following chapter demonstrates the benefits for 3-axis toolpaths as well.

MACHINE SIMULATION
52 MASTERCAM 2017 / Toolpath Analysis with Machine Simulation

MACHINE SIMULATION
LESSON 4
4 Machine Simulation for 3-Axis Toolpaths
Whether youre creating 3-axis or 5-axis toolpaths for your parts, Machine Simulation
lets you see your part being machined virtually so you can optimize your toolpath
motion. Even 3-axis toolpaths can benefit from the stock removal and fixture testing
that Machine Simulation offers.

Lesson Goals
Using an STL file to simulate stock removal
Testing fixturing options in Machine Simulation
Creating a presentation of simulation results

Exercise 1: Simulating Stock Removal

Besides simulating machine motion, Machine Simulation can show stock removal to
confirm your final part shape.
1 From the Mastercam menu, choose File, Open. Open the part file,
pocket_vise, provided with this tutorial.

NOTE: Mastercam will ask you to switch from Metric to English. Select
All settings and click OK.
54 MASTERCAM 2017 / Machine Simulation for 3-Axis Toolpaths

2 Use the Levels Manager to display the vise on level 1000, the jaw on level
1001, and the stop on level 1002.

3 Fit the part and fixture in the graphics window.

4 Select all the toolpaths in the Toolpaths Manager.

MACHINE SIMULATION
 SIMULATING STOCK REMOVAL 55

5 Select the dialog box launcher in the Machine Simulation group on the
Machine tab.

Machine Simulation is already set to use a 3-axis vertical machining center.

MACHINE SIMULATION
56 MASTERCAM 2017 / Machine Simulation for 3-Axis Toolpaths

6 Click Simulate to display the part in the machine.

If you dont see the workpiece, click the drop-down arrow below the
Workpiece button and select Show.
7 Confirm that Toolpath is selected to display the tool motion.

MACHINE SIMULATION
 ADDING A FIXTURE AND STOCK 57

8 Zoom into the part and click Run to view the simulation.

9 When the simulation is complete, click Exit to return to the main Mastercam
screen.
Now that youve seen the basic tool motion, you can adjust the simulation
environment to check stock removal and test fixturing.

Exercise 2: Adding a Fixture and Stock

1 Select the dialog box launcher in the Machine Simulation group on the
Machine tab.

MACHINE SIMULATION
58 MASTERCAM 2017 / Machine Simulation for 3-Axis Toolpaths

2 Click the Fixture drop-down list and

select Selected elements.

3 Click the button to the right of the Fixture drop-down list.

4 Select the vise, jaw, and stop in the graphics window and press [Enter] to
return to the dialog box.

5 Click the Stock drop-down list and select Load STL file.

MACHINE SIMULATION
 ADDING A FIXTURE AND STOCK 59

6 Click the button to the right of the Stock drop-down list and select
pocket_stock.stl that was provided with this tutorial.

7 Click Simulate.

8 Hide the Workpiece and the Toolpath.

9 Zoom in on the part in the machine. The STL file displays as blank stock.

MACHINE SIMULATION
60 MASTERCAM 2017 / Machine Simulation for 3-Axis Toolpaths

10 Click Run to view the material removal.

11 Click Exit to return to the main Mastercam screen.

Exercise 3: Simulating with Different Fixtures

As youve seen with 5-axis toolpaths, using Machine Simulation to test out different
fixtures can save you valuable time and money. You can do the same with 3-axis tool-
paths.
1 From the Mastercam menu, choose File, Open. Open the part file, plate,
provided with this tutorial.

MACHINE SIMULATION
 SIMULATING WITH DIFFERENT FIXTURES 61

2 Press [Alt+S] to shade the part, if necessary.

3 Use the Levels Manager to display the vise on level 999.

4 Fit the part and fixture in the graphics window.

MACHINE SIMULATION
62 MASTERCAM 2017 / Machine Simulation for 3-Axis Toolpaths

5 Select all the toolpaths in the Toolpaths Manager except the FBM Mill
operation.

NOTE: Machine Simulation does not support non-motion FBM prepara-

tion operations.

6 Select the dialog box launcher in the Machine Simulation group on the
Machine tab.
7 Use the following parameters on the Simulation tab:

Select 1_3AXGEN_VMC from the Machine drop-down list.

Select From Level from the Fixture drop-down list and select 999.
Select Use Mastercam stock definition from the Stock drop-down list.

MACHINE SIMULATION
 SIMULATING WITH DIFFERENT FIXTURES 63

Enter 0.012 for the Simulation tolerance.

8 Click Simulate to display the part in the machine.

9 Use the following buttons on the toolbar to make it easier to see the
toolpaths and stock removal:
Click Toolpath on the Simulation
tab to display the tool motion.

Confirm that the Workpiece is

hidden.

MACHINE SIMULATION
64 MASTERCAM 2017 / Machine Simulation for 3-Axis Toolpaths

Confirm that the Stock is

displayed.

Click Current Op. This option

displays one toolpath at a time
using the color assigned to that
operation.

Click Follow. This option displays

the path that has been machined.

MACHINE SIMULATION
 SIMULATING WITH DIFFERENT FIXTURES 65

10 Zoom in on the part and click Run to view the simulation.

11 When the simulation is complete, click Exit to return to the main Mastercam
screen.

MACHINE SIMULATION
66 MASTERCAM 2017 / Machine Simulation for 3-Axis Toolpaths

Conclusion
Congratulations! You have completed the Machine Simulation tutorial. Now that you
have mastered the skills in this tutorial, explore Mastercams other features and func-
tions.
You may be interested in other tutorials that we offer. The Mastercam tutorial series is
in continual development, and we will add modules as we complete them. Visit our
website, or select Help, Tutorials from the File tab to see the latest publications.

Mastercam Resources
Enhance your Mastercam experience by using the following resources:
Mastercam HelpAccess Mastercam Help by selecting Help, Contents from
Mastercams File tab or by pressing [Alt+H] on your keyboard. Also, most
dialog boxes, function panels, and ribbon bars feature a Help button that
opens Mastercam Help directly to related information.
Mastercam ResellerYour local Mastercam Reseller can help with most
questions about Mastercam.
Technical SupportCNC Softwares Technical Support department (860-875-
5006 or [email protected]) is open Monday through Friday from 8:00
a.m. to 5:30 p.m. USA Eastern Standard Time.
Mastercam TutorialsCNC offers a series of tutorials to help registered users
become familiar with basic Mastercam features and functions. The Mastercam
tutorial series is in continual development, with new modules added as we
complete them. Visit our website, or select Tutorials from the Help menu to
see the latest publications.
Mastercam UniversityCNC Software sponsors Mastercam University, an
affordable online learning platform that gives you 24/7 access to Mastercam
training materials. Take advantage of more than 180 videos to master your
skills at your own pace and help prepare yourself for Mastercam Certification.
For more information on Mastercam University, please contact your
Authorized Mastercam Reseller, visit www.mastercamu.com, or email
[email protected].
Online communities You can find a wealth of information, including many
videos, at www.mastercam.com. For tech tips and the latest Mastercam news,
follow us on Facebook (www.facebook.com/mastercam), Twitter
(www.twitter.com/mastercam), or Google+ (plus.google.com/+mastercam).

MACHINE SIMULATION
 MASTERCAM DOCUMENTATION 67

Visit our YouTube channel to see Mastercam in action (www.youtube.com/

user/MastercamCadCam)!
Registered users can search for information or ask questions on the
Mastercam Web forum, forum.mastercam.com, or use the knowledge base at
kb.mastercam.com.
To register, select Community, Link Account from the File tab, and follow
the instructions.

Mastercam Documentation
Mastercam installs the following documents in the \Documentation folder of your
Mastercam installation:
Whats New in Mastercam 2017
Mastercam 2017 Installation Guide
Mastercam 2017 Administrator Guide
Mastercam 2017 Transition Guide
Mastercam 2017 Quick Reference Card
Mastercam 2017 ReadMe

Contact Us
For questions about this or other Mastercam documentation, contact the Technical
Documentation department by email at [email protected].

MACHINE SIMULATION
68 MASTERCAM 2017 / Machine Simulation for 3-Axis Toolpaths

MACHINE SIMULATION
 Attention! Updates may be available.
Go to Mastercam.com/Support for the latest downloads.

671 Old Post Road

Tolland, CT 06084 USA
www.mastercam.com