Getting Started with

Mastercam Mill-Turn
April 2016
 Mastercam® 2017 Mill-Turn Getting Started
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:
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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 release—includes the latest information about Mastercam features and
enhancements.
 iii

Contents
Introduction ....................................................................................................... 7
 Tutorial Goals................................................................................................. 7
General Tutorial Requirements ....................................................................... 7
1. Introduction to Mill-Turn....................................................... 9
 What is Mastercam Mill-Turn?.................................................................... 9
 System Requirements ................................................................................ 10
 Getting Ready to Work ............................................................................... 10
Preparing the Files ........................................................................................ 11
Loading a Missing Machine File ................................................................... 11
 How the Book is Organized ........................................................................ 12
2. Transitioning to Mill-Turn from Lathe................................. 15
 Running Over a Network ............................................................................ 15
 Bringing in Lathe Files ................................................................................ 15
Importing Parts into Mill-Turn....................................................................... 16
 Replacement of Toolpath Parameters that Differ in Mill-Turn ................ 16
 Menu Changes ............................................................................................ 18
 Toolpaths Manager Changes ..................................................................... 19
Toolbar Functions ......................................................................................... 19
Machine Group Properties (Files tab) .......................................................... 20
Machine Group Properties (Job Setup tab) ................................................. 21
 Communications ......................................................................................... 22
3. Workflow Overview............................................................ 25
 Load or Create Part Geometry ................................................................... 25
 Load the Appropriate Machine .................................................................. 26

GETTING STARTED WITH MASTERCAM MILL-TURN

iv MASTERCAM 2017 /

 Complete Job Setup ................................................................................... 26

 Create Toolpath Operations ....................................................................... 34
 Create Part-Handling Operations ............................................................... 36
 Synchronize the Operations ....................................................................... 37
 Simulate the Operations............................................................................. 38
 Post the Operations .................................................................................... 39
4. Working with Machine Files............................................... 41
 Installing Your Machine File....................................................................... 41
 Customizing Your Machine File ................................................................. 42
 Customizing Operation Defaults and Tool Libraries................................. 42
 Editing Machine File Settings and Defaults ............................................. 43
 Opening Code Expert in Multi-Stream View ............................................ 45
 Configuring the Find Extents Feature ....................................................... 46
 Setting the Toolpath Directory .................................................................. 47
 Managing Machine Licenses..................................................................... 49
Verifying that You Have the Proper License ................................................ 49
Reactivating Disabled Licenses.................................................................... 51
5. Working with Tools and Spindles ....................................... 53
 Initial Tool Setup ......................................................................................... 53
Editing Tool Settings ................................................................................... 54
 Insert Up/Down and LH/RH Holders ......................................................... 55
Changing Insert Orientation ........................................................................ 55
Switching Between LH and RH Holders ..................................................... 56
 Specifying the Tool’s Compensation Point .............................................. 58
 Selecting the spindle and turret ................................................................ 59
Selecting an Axis Combination ................................................................... 60
 Setting Up Tools for Pinch Turning ........................................................... 61
6. Reference Positions ............................................................ 63
 Using Reference Positions ......................................................................... 63
 Creating Reference Positions .................................................................... 67

GETTING STARTED WITH MASTERCAM MILL-TURN

 v

7. Configuration and Job Setup .............................................. 71

 Adding a Machine File................................................................................ 71
Adding Your Machine ................................................................................... 71
 Setting Up Your Job.................................................................................... 72
Selecting a Machine ..................................................................................... 72
 Completing Job Setup ................................................................................ 73
Setting WCS, Setup Type, and Stock Type ................................................. 73
Specifying Part Geometry ............................................................................. 74
Specifying Bar Stock Settings ...................................................................... 75
Setting Spindle and Chuck Parameters........................................................ 76
Defining the Pickoff Operation ...................................................................... 78
8. Turning Toolpaths ............................................................... 81
 Programming the Left Spindle ................................................................... 81
The Facing Toolpath...................................................................................... 81
The Roughing Toolpath ................................................................................. 83
The Finishing Toolpath .................................................................................. 86
Simulating the Toolpaths.............................................................................. 87
Synchronizing the Toolpaths ........................................................................ 90
 The Part Handling Operations .................................................................... 94
Creating Part Handling Operations ............................................................... 94
Simulating the New Operations ................................................................... 95
 Programming the Right Spindle................................................................. 98
The Facing Toolpath...................................................................................... 98
The Roughing Toolpath ............................................................................... 101
The Pinch-Turn Toolpath ............................................................................. 104
Synchronizing the Toolpaths ...................................................................... 106
9. Milling Toolpaths ............................................................... 109
 Setting Up the Part ................................................................................... 109
 Importing the Milling Operations ............................................................. 110
 Completing the Pocket Operation ........................................................... 112
 Completing the Facing Operation ............................................................ 115

GETTING STARTED WITH MASTERCAM MILL-TURN

vi MASTERCAM 2017 /

 Completing the Rough Contour Operation ............................................. 118

 Completing the Finish Contour Operation .............................................. 119
10. More about Sync Manager ............................................. 121
 Customizing the Display ........................................................................... 122
 Customizing Operation Settings .............................................................. 125
 Using the Timeline .................................................................................... 128
 Sync Manager and Mastercam Interactions ......................................... 130
Changing Data in Sync Manager................................................................ 130
Changing Data in Mastercam .................................................................... 133
11. More about Machine Simulation .................................... 137
 Starting Machine Simulation ................................................................... 138
 Running a Simulation ............................................................................... 140
12. Posting ............................................................................ 145
 Posting a Part ............................................................................................ 146
 Using the Editing Functions ..................................................................... 147
 Using the Syncs and Tools Functions .................................................... 149
 Using the Right-Click Menu ..................................................................... 150
 Sending the NC Code to Your Control..................................................... 151
Conclusion ....................................................................................................... 153
 Mastercam Resources ............................................................................. 153
 Mastercam Documentation ..................................................................... 154
Contact Us .................................................................................................. 155
A. Loading Multi-Station Tool Locators ................................ 157
Loading the Part and Processing the Toolpaths ....................................... 157
Loading a Tool Locator and Tool ............................................................... 160
Loading the Remaining Tools in the Tool Locator ..................................... 163
Loading the Second Tool Locator and Live Mill Tools .............................. 164
Simulating the Operations ......................................................................... 166

GETTING STARTED WITH MASTERCAM MILL-TURN

Introduction

This tutorial introduces you to the basics of Mastercam Mill-Turn. Mill-Turn is a large
product with several components, each of which is covered in this tutorial. When you
have completed the lessons included in this book, you should have the knowledge you
need to get started with this versatile product.

Tutorial Goals
 Become familiar with the Mill-Turn components.
 Learn the main differences between Mastercam Lathe and Mastercam Mill-
Turn.
 Know the Mill-Turn work flow.
 Explore the contents and use of machine files.
 Understand tool setup and reference positions.
 Setup a Mill-Turn job.
 Create turning and milling toolpaths.
 Use Sync Manager and Machine Simulation effectively.
 Load tools into multi-station tool locators.

Estimated time to complete this tutorial: 8 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 lesson’s 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
8 MASTERCAM 2017 / Introduction

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.
 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.

GETTING STARTED WITH MASTERCAM MILL-TURN

CHAPTER 1
1 Introduction to Mill-Turn
This book presents an overview of Mastercam Mill-Turn and teaches the basics of
preparing, simulating, and posting a Mill-Turn part. Along the way, you learn about the
applications that make up Mill-Turn, including not only Mastercam, but also Code
Expert.

What is Mastercam Mill-Turn?

Mastercam Mill-Turn is a collection of functions, toolpaths, and applications. These
Mill-Turn elements work together to create synchronized G-code for cutting parts on a
multitasking machine.

You begin the Mill-Turn workflow in Mastercam, where you load or create the part to
cut. You then load a Mill-Turn machine, which adds Mill-Turn operations to
Mastercam’s interface (see the following picture). These operations include not only
milling and turning toolpaths, such as facing, pocketing, and pinch-turn, but also part-
10 MASTERCAM 2017 / Introduction to Mill-Turn

handling operations for programming pickoffs, cutoffs, bar feeds, spindle movement,
and more.

When you have designed and toolpathed your part, you continue work in Code Expert,
which is home to Sync Manager, Editor, and Machine Simulation. In Sync Manager you
synchronize operations, in Editor you edit NC files, and in Machine Simulation, you
watch your operations in action.

System Requirements
Up-to-date system requirements are available for Mastercam online:
www.mastercam.com/en-us/Support/System-Requirements.
An internet connection and e-mail access is recommended for support and updates.
Visit www.mastercam.com for more information.

Getting Ready to Work

Now that you know what Mill-Turn can do, it is time to prepare your materials for the
remainder of the book.

GETTING STARTED WITH MASTERCAM MILL-TURN

 GETTING READY TO WORK 11

Preparing the Files

1 Place the part files included with this book in a convenient location on your
hard drive.
2 Place a copy of Generic Fanuc Mill Turn.machine (also included with this
book) in your C:\Users\Public\Documents\shared mcam2017\Mill
Turn\machines directory.

Loading a Missing Machine File

Mill-Turn part files store a reference to their machine file. If the machine file is missing
or moved, Mastercam asks you to reassociate the machine with the part. The following
procedure shows how to complete this important task. (You do not need to do this
now. You only need to do this if your part cannot find its machine file.)
1 Open the part file with Mastercam.

The MT Machine File Missing dialog

box appears, as seen to the right.
2 Click Yes.

The MT Machine Files dialog box

appears.
3 Navigate to the machine file for your part (in the case of this book, the
machine file is Generic Fanuc Mill Turn.machine), and select it.
Mastercam loads the machine file and associates it with the part file.

4 Optional : Save the part file under a new name, so that you do not overwrite
the original.

GETTING STARTED WITH MASTERCAM MILL-TURN

12 MASTERCAM 2017 / Introduction to Mill-Turn

How the Book is Organized

This book’s chapters introduce the concepts, applications, and workflow that make up
Mastercam Mill-Turn. Because the exercises in each chapter are meant to be
completed in order, we highly recommend that you work through this book from the
beginning to the end rather than skip from one chapter or tutorial to another.
The following list describes each of this book’s chapters:
 Chapter 1, Introduction to Mill-Turn introduces the Mill-Turn product and
offers guidelines for using this book.
 Chapter 2, Transitioning to Mill-Turn from Lathe describes the differences
between Mastercam Mill-Turn and Mastercam Lathe, including network
issues, file compatibility, and user-interface changes.
 Chapter 3, Workflow Overview is a general road map for successfully working
with Mastercam Mill-Turn. Topics covered include part geometry, Mill-Turn
machine solutions, job setup, toolpaths, and more.
 Chapter 4, Working with Machine Files, describes how to install, edit, and
customize machine files, as well as how to configure Code Expert Editor and
manage Mill-Turn licenses.
 Chapter 5, Working with Tools and Spindles, explains how to set up tools and
specify axis combinations.
 Chapter 6, Reference Positions demonstrates how to create and use reference
positions to specify where to start and end operations.
 Chapter 7, Configuration and Job Setup presents detailed exercises for
preparing a Mill-Turn part, including specifying a machine and completing job
setup.
 Chapter 8, Turning Toolpaths features step-by-step procedures for creating
and synchronizing turning toolpaths and part-handling operations on the left
and right spindles of your machine.
 Chapter 9, Milling Toolpaths features step-by-step procedures for creating
and synchronizing milling operations, including facing, pocketing, and
contour toolpaths.
 Chapter 10, More about Sync Manager provides an overview of Sync
Manager’s user interface and functionality. This chapter also includes a
discussion of Sync Manager’s interaction with Mastercam.
 Chapter 11, More about Machine Simulation provides an overview of Machine
Simulation’s user interface and functionality.

GETTING STARTED WITH MASTERCAM MILL-TURN

 HOW THE BOOK IS ORGANIZED 13

 Chapter 12, Posting is an overview of Code Expert Editor, including posting,

editing, and navigating an NC file. This chapter also presents a procedure for
sending a file to a machine control.
 Appendix A, Loading Multi-Station Tool Locators describes how to load tool
locators onto a machine’s turrets, as well as load tools into the multi-station
locators. The complete sample program demonstrates many tool locator and
tool combinations.

GETTING STARTED WITH MASTERCAM MILL-TURN

14 MASTERCAM 2017 / Introduction to Mill-Turn

GETTING STARTED WITH MASTERCAM MILL-TURN

CHAPTER 2
2 Transitioning to Mill-Turn from Lathe
Before you start work with Mill-Turn, you must understand how it differs from pre-X7
Mastercam. This chapter provides the information you need to begin using Mill-Turn
effectively.

Running Over a Network

A machine solution (represented by a MACHINE file) includes the post processor and
other files that Mastercam needs to run Mill-Turn. This means that managing Mill-Turn
over a network is simplified. Because Mastercam can access the machine file from any
network location, you can move the file where you wish. You do not need to worry
about the links between the machine solution’s components.
When you load a Mill-Turn part, Mastercam looks for the machine file and reloads it. If
the machine solution’s machine file cannot be found—either because it has been
moved or renamed—you are prompted to find and select it. This interaction is
different from earlier versions of Mastercam, which do not look for the machine defini-
tion when you load your part, but relies on the copy stored in your part file. Mill-Turn
requires that your machine file be available whenever you open your part. This ensures
that if your machine file (or post) has changed, your part will stay up-to-date.

Bringing in Lathe Files

While you can import operations from Lathe parts, the operations require consider-
able modification to function properly. In particular, Lathe miscellaneous operations
(misc ops) cannot be migrated and should not be imported into your Mill-Turn file.
This is true even if they were created with the POCO (Pickoff-Cutoff) utility.
If you need to bring parts into Mill-Turn from non-Mill-Turn Mastercam, follow the
workflow below.
16 MASTERCAM 2017 / Transitioning to Mill-Turn from Lathe

Importing Parts into Mill-Turn

1 Make a copy of the part file.

2 Open the copy, and delete all of the toolpath groups.

3 Save the file.

4 Select a Mill-Turn machine file.

5 Complete the Job Setup process (see Setting Up Your Job on page 72).

6 Import operations from your original file, if desired.

CAUTION: Do not import Lathe misc ops.

7 Re-chain geometry as appropriate, and verify all of the settings for each
operation. Mill-Turn operations are architecturally different from Lathe, so
you must verify the operation settings.
You must complete the Job Setup process before creating or importing operations.
For a more detailed example of importing operations, see Importing the Milling Oper-
ations on page 110.

Replacement of Toolpath Parameters that Differ in Mill-Turn

Many options on the Lathe Toolpath parameters dialog box (highlighted in this
picture) are not present in Mill-Turn:

GETTING STARTED WITH MASTERCAM MILL-TURN

 REPLACEMENT OF TOOLPATH PARAMETERS THAT DIFFER IN MILL-TURN 17

The following picture shows the same dialog box in Mill-Turn:

In Mill-Turn, these functions are all machine-specific features that are configured in
the machine file.
 Coolant options are selected in Sync Manager. Instead of selecting individual
options, you select strategies that combine several different coolant events.

GETTING STARTED WITH MASTERCAM MILL-TURN

18 MASTERCAM 2017 / Transitioning to Mill-Turn from Lathe

Your machine developer defines these strategies based on options that are
available on your machine.
 Mastercam reads home positions from the machine file. You select approach
and retract strategies in Sync Manager.
 Misc values and canned text do not exist in Mill-Turn. You access machine-
specific options and parameters in Sync Manager.
The following picture shows how coolant appears in Sync Manager. Click the small
inverted triangle next to each operation or segment to see what options are available.

Unlike Lathe, where you are limited to 20 miscellaneous ints and reals, Mill-Turn has
no limit on the number of machine-specific options. Plus, the options can be specific
to individual operation types or parts of an operation. Also, while the previous misc
values are limited to numbers, toolpath options in Mill-Turn can be presented as
numbers, checkboxes, list selections, or strings.

Menu Changes
Mill-Turn organizes the single Toolpaths menu from older versions of Lathe into
different contextual tabs, as follows:
 The Turning tab contains Lathe operations, including part handling (formerly
Misc Ops).
 The Milling tab contains 2D, 3D, and Multiaxis Mill operations.
In addition, the Machine Definition Manager and Control Definition Manager are
disabled. You can access many of their settings in Mill-Turn by opening the machine
file in Code Expert, and double-clicking Consumer in Machine Explorer.

GETTING STARTED WITH MASTERCAM MILL-TURN

 TOOLPATHS MANAGER CHANGES 19

Toolpaths Manager Changes

The Toolpaths Manager for Mill-Turn operations has important differences from that
with non-Mill-Turn operations.

Toolbar Functions
The Tool Setup button on the Toolpaths Manager toolbar is used exclusively by Mill-
Turn, whereas the G1 button has a new function in Mill-Turn:
 The Tool Setup button lets you configure how tools are loaded on your
machine.

 The G1 button opens Sync Manager (only in Mill-Turn). From Sync Manager,
you can create syncs, configure toolpath options, post operations, and launch
Simulation.

GETTING STARTED WITH MASTERCAM MILL-TURN

20 MASTERCAM 2017 / Transitioning to Mill-Turn from Lathe

Machine Group Properties (Files tab)

Some options in the Files tab have been removed for Mill-Turn users, since Mill-Turn
stores the individual support files in the machine file.

 Although a default tool library is stored in the machine file, you can still select
a different one here.
 When creating individual operations, you can always select a tool from any
library, just like in Mill and Lathe.
 You can also import operations from any library, just like in Mill and Lathe.
The operations library listed on this tab is only a default selection.
While in non-Mill-Turn Mastercam, you can use the Replace button to select a
different machine definition, in Mill-Turn you cannot do this. You can, however, use
the Edit button to make changes to the current machine, if necessary.

GETTING STARTED WITH MASTERCAM MILL-TURN

 TOOLPATHS MANAGER CHANGES 21

Machine Group Properties (Job Setup tab)

The Job Setup tab is new for Mill-Turn. It replaces the Stock Setup tab from
Mastercam and is available only in Mill-Turn.

Although the Job Setup tab seems to recreate much of the functionality of the Stock
Setup tab in Lathe, it is more closely tied to your workflow.
Follow this general workflow when creating your parts:
1 Create your part geometry. The Mill-Turn workflow proceeds more
smoothly if you minimize later changes to your part.
2 Create a solid model of your finished part. A solid model is not required,
but if you have one, the Machine Simulation and Sync Manager functions
display it with your toolpaths.

GETTING STARTED WITH MASTERCAM MILL-TURN

22 MASTERCAM 2017 / Transitioning to Mill-Turn from Lathe

3 Select your machine file from the Machine tab. The Job Setup function
launches automatically.
4 Complete the Job Setup pages in the order presented.

When you complete Job Setup, Mastercam automatically creates resources that help
you program your part. The following list describes these resources.
 A custom WCS—This is a copy of WCS Top, whose origin is located at the
machine zero location from your machine file.
 New views within the WCS—These views correspond to standard machining
orientations and applications, for programming both left and right spindles.
Each view is created with the proper origin and work offset from your Job
Setup settings. For example, in Job Setup you can choose to locate Z0 at
either the front face or back face of your part; Mastercam then automatically
creates tool planes with the desired origin.
 Viewsheets for each spindle—Each viewsheet contains a copy of the part
geometry properly positioned relative to the chuck jaws.
You learn much more about the individual Job Setup pages when you complete the
exercises later in this book.

Communications
In Mill-Turn, you use Code Expert to configure your communications settings.
1 Open Code Expert from your Start menu (Start, All Programs, Mastercam
2017, Code Expert). If you already have a Mill-Turn machine loaded, Code
Expert will already be open.
2 Select Options from the File tab.

3 Select Editor, NC, Communications.

GETTING STARTED WITH MASTERCAM MILL-TURN

 COMMUNICATIONS 23

4 Set your options as desired. Use Help to learn more.

Mill-Turn uses the same XML-based configuration files as previous Mastercam

versions, so if you have been using a customized file, you can use it in Mill-Turn. You
can also use the same communications program.

GETTING STARTED WITH MASTERCAM MILL-TURN

24 MASTERCAM 2017 / Transitioning to Mill-Turn from Lathe

GETTING STARTED WITH MASTERCAM MILL-TURN

CHAPTER 3
3 Workflow Overview
Mastercam Mill-Turn introduces a streamlined workflow for creating the operations to
cut your part. This chapter presents an overview of this workflow. The following chap-
ters provide more detail and hands-on exercises.
The Mill-Turn workflow comprises the following steps. The remainder of this chapter
explains each step in more detail.
 Load or create part geometry
 Load the appropriate machine
 Complete job setup
 Create toolpath operations
 Create part handling operations
 Synchronize the operations
 Simulate the operations
 Post the operations

Load or Create Part Geometry

Your first step with Mill-Turn is to create your part’s geometry. Often, this means
simply loading the part’s file, although you can use Mastercam’s CAD tools to create
the part’s geometry or to modify an existing part.
26 MASTERCAM 2017 / Workflow Overview

Load the Appropriate Machine

Before you can create Mill-Turn operations on your part, you must load a Mill-Turn
machine. Choose Machine, Mill-Turn, and then select the machine file you need.
The machine file is a group of files stored as a unit. These files include the machine
definition, tool database, and other data that non-Mill-Turn Mastercam stores in sepa-
rate files.

Complete Job Setup

When you choose a Mill-Turn machine, Mastercam not only loads the machine, but
also starts Code Expert, in which you complete many Mill-Turn tasks.
After the machine file and Code Expert load, Mastercam displays the Job Setup tab of
the Machine Group Properties dialog box. (You can also open Job Setup at any time
from the Toolpaths Manager, as shown below.) This tab is where you define the
general parameters for your job. Job Setup arranges these parameters in workflow
order from top to bottom. The following sections describe each page of parameters.

GETTING STARTED WITH MASTERCAM MILL-TURN

 COMPLETE JOB SETUP 27

WCS Page
Use this page to define your Work Coordinate System (WCS) by clicking the Select
Named Plane button (circled in the image below) and choosing the initial WCS from
the Plane Selection dialog box. Use the WCS option when importing geometry that is
aligned incorrectly for machining, orienting the part on the machine differently from
how it is oriented in Mastercam. On this page, you can also change the machine
group’s name, which appears in the Toolpaths Manager.

GETTING STARTED WITH MASTERCAM MILL-TURN

28 MASTERCAM 2017 / Workflow Overview

Setup Type Page

Use this page to set the spindle on which your job will begin. Here, you also specify
your stock type (either continuous bar or single piece) and how to handle the parts as
they are created. Stock type determines which part handling operations—such as pick-
offs, cutoffs, and stock pulls—are available.

GETTING STARTED WITH MASTERCAM MILL-TURN

 COMPLETE JOB SETUP 29

Part Geometry Page

Use this page to select your part geometry and tell Mastercam how to create geom-
etry for the other spindle or for a turn profile. You can also select the color and specify
the levels on which Mastercam creates the geometry.

If Create Opposed Spindle Geometry is selected, Mill-Turn creates the part geom-
etry in both spindles, as shown in the first of the following pictures. If Create Opposed
Spindle Geometry is off, Mill-Turn shows the part geometry in only the starting
spindle, as shown in the second of the following pictures. Having the part geometry in
both spindles lets you program the part on both the starting and opposing spindles.

GETTING STARTED WITH MASTERCAM MILL-TURN

30 MASTERCAM 2017 / Workflow Overview

Bar Stock Page

Use this page to select the type of stock and its dimensions. You can also specify the
number of parts to create and the amount of material to leave for other operations.
Extra face and back stock are commonly used to leave stock for facing operations and
affect the part transfer pickoff/cutoff positions.

NOTE: Mill-Turn supports different stock types, with the stock page
changing depending on your setup type.

GETTING STARTED WITH MASTERCAM MILL-TURN

 COMPLETE JOB SETUP 31

Left and Right Spindle Pages

Use these pages to set chuck parameters for each spindle, including the clamping
method, chuck dimensions, and part stickout.
The Toolplane origin (on the Toolplane origin Z subpage) sets the zero point for
operations on each spindle. Mastercam can calculate the value from the part geom-
etry, or you can enter it yourself.

GETTING STARTED WITH MASTERCAM MILL-TURN

32 MASTERCAM 2017 / Workflow Overview

Pickoff Page
Use this page to set pickoff and cutoff parameters. These include the pickoff location,
the cutoff tool, and the cutoff width. Note that Mill-Turn uses the cutoff width to
adjust the pickoff/cutoff positions.

GETTING STARTED WITH MASTERCAM MILL-TURN

 COMPLETE JOB SETUP 33

Finishing Job Setup

When you have finished setting up your job, click OK in Job Setup to finalize your
choices. Mastercam creates your machine group, plus a set of convenient resources:
 The new WCS
 Viewsheets for each spindle
 Default toolplanes

GETTING STARTED WITH MASTERCAM MILL-TURN

34 MASTERCAM 2017 / Workflow Overview

The viewsheets, subspindle geometry, and the revolved part profile make it easy for
you to program operations on the subspindle.
Mastercam creates planes that correspond to standard machining orientations for
different types of operations in each spindle, with origins keyed to the locations that
you selected on the Job Setup pages.

Create Toolpath Operations

With job setup completed, you can create the operations to cut your part. Choose
between turning and milling operations, each tab having its own galleries in

GETTING STARTED WITH MASTERCAM MILL-TURN

 CREATE TOOLPATH OPERATIONS 35

Mastercam’s Mill-Turn tab. (Note that this tab appears only when you have loaded a
Mill-Turn machine file.)

Creating an operation means choosing not only a specific toolpath, such as facing or
roughing, but also providing information about how your machine will perform the
operation. For example, as part of the toolpath operation, you choose the cutting tool
and specify the axis combination (the pairing of a spindle and a turret).

GETTING STARTED WITH MASTERCAM MILL-TURN

36 MASTERCAM 2017 / Workflow Overview

Create Part-Handling Operations

Next, you tell Mastercam how to handle the part using pickoff and cutoff operations.
You choose these transfer operations from Mastercam’s Part Handling functions on
the Turning tab, whose available operations depend on the type of stock you have
specified. For example, single-piece stock requires only a pickoff, whereas continuous
bar stock requires a cutoff and a pickoff. The part handling functions also include such
operations as bar feeds, stock pulls, and turret parking.
Note that part handling operations are not limited to finished parts. They can be used
for many reasons, including bar feeding, pickoff ops where the opposing spindle
supports the part, and other custom routines written by the machine solution provider.
The Pickoff, Cutoff, and Stock Pull operations are complete strategies with predefined
lists of sub-operations, relieving you from having to create these sub-operations one
by one, although you can modify them as needed. Choosing one of these strategies
adds a group of operations to Mastercam’s Toolpaths Manager, as seen in the right-
hand picture below.

GETTING STARTED WITH MASTERCAM MILL-TURN

 SYNCHRONIZE THE OPERATIONS 37

NOTE: The resulting operations in the part handling group cannot be

moved or deleted individually; the entire group must be deleted. This
restriction allows the machine solution provider to code the post logic to
handle operations in specific fashions required by the machine tool.

Synchronize the Operations

Sync Manager is a visual tool that creates sync points for multi-stream machines. It
also helps you create—for both single- and multi-stream machines—custom job
setups that ensure valid output.

Synchronizing Multi-Stream Jobs

After you have created your operations in Mastercam, run Sync Manager (shown in
the following picture) from the Toolpaths Manager, and synchronize the operations on
your machine. Use your mouse to drag-and-drop operations between streams to
ensure that each can complete successfully without collisions or other problems.

Customizing Settings
Sync Manager provides access to many settings, including coolant strategies, refer-
ence positions, and options traditionally stored as misc values in previous Mastercam
versions. You can modify these settings by clicking the arrow associated with the
option to change, and typing the required values into the provided fields.

GETTING STARTED WITH MASTERCAM MILL-TURN

38 MASTERCAM 2017 / Workflow Overview

Simulate the Operations

Use Mill-Turn to simulate the machine’s motions as it cuts your part. By zooming or
setting the visibility of specific components, you can customize the view to your needs.
For example, the first picture below shows Machine Simulation’s default display, and
the second picture shows the same job with the machine housing turned off.

GETTING STARTED WITH MASTERCAM MILL-TURN

 POST THE OPERATIONS 39

Post the Operations

When you have validated your job, you post the operations, which creates the G-code
that you send to your machine to cut the part. After it is generated, the G-code
displays in the editor, from which you can access the communications functions
needed to transmit the code to your machine.

GETTING STARTED WITH MASTERCAM MILL-TURN

40 MASTERCAM 2017 / Workflow Overview

GETTING STARTED WITH MASTERCAM MILL-TURN

CHAPTER 4
4 Working with Machine Files
This chapter provides basic information on working with machine files, which drive
your entire Mill-Turn experience. A Mill-Turn machine file (which has the MACHINE
extension) differs from the machine and control definition files used in non-Mill-Turn
Mastercam. To help you understand these differences, this chapter includes the
following topics:
 Installing your machine file
 Customizing your machine file
 Customizing operation defaults and tool libraries
 Editing machine file settings and defaults
 Configuring Code Expert Editor
 Setting the toolpath directory
 Managing machine licenses

Installing Your Machine File

Your machine file is packaged in a ZIP file with the PDF version of the machine’s appli-
cation guide. Simply unzip the machine file to your desired location. The default loca-
tion is \shared Mcam2017\Mill Turn\MACHINES. However, you can place the
machine file anywhere you wish.
Unlike non-Mill-Turn Mastercam machines, a Mill-Turn machine file includes all the
resources needed to support your machine application. That is, the machine file does
not need to link to other files, such as posts.
To work with your machine file from a network location, copy it to the desired location
on your network. Since the machine file points to no other files, it works the same from
a network location or from a local drive.
Note, however, that Mastercam looks for the machine file when you load a part that
uses it, so the machine file must be in a location to which your workstation regularly
connects.

NOTE: This guide comes with generic machine files that you can use to
try Mill-Turn. You will use one of them throughout this tutorial. If you
wish, you can experiment with the others.
42 MASTERCAM 2017 / Working with Machine Files

Customizing Your Machine File

When you load your machine file in Mastercam, Mastercam also loads the machine file
into Code Expert. When you switch to the Code Expert window and show Machine
Explorer, you can see the components of your machine file, as described below:
The Control Layers section lists the
resources the post uses. Most of
these resources are hidden by the
post/machine developer. However,
the Consumer layer contains
machine defaults and other settings
that you, as a user, can edit.
The Mastercam Files section lists
support files that are encapsulated
inside the your machine file. In non-
Mill-Turn Mastercam, these support
files are stored throughout your
Mastercam installation; Mill-Turn
brings them together inside the
machine file.
The files in the Mastercam Files
section are disabled because you
cannot edit them in Code Expert.
However, you can edit common files
such as your operation defaults,
operation libraries, and tool libraries
inside Mastercam. To do this, follow
the guidelines in the next section.

Customizing Operation Defaults and Tool Libraries

You can follow this procedure as needed to customize operation defaults and tool
libraries. (You do not need to do this as part of the tutorial.)
1 Start Mastercam.

2 Load your machine file or a part that uses the machine file.

GETTING STARTED WITH MASTERCAM MILL-TURN

 EDITING MACHINE FILE SETTINGS AND DEFAULTS 43

3 In Toolpaths Manager, click the

Files icon in the Properties section.
The Machine Group Properties
dialog box opens with the Files tab
selected.
4 In the Tool Library section, use the
tool editing buttons to make needed
tool library changes.

5 In the Operations Library / Defaults File section, use the edit buttons to
make needed operation and defaults changes.

6 Click the green check to accept your changes and exit the Machine Group
Properties dialog box.

NOTE: You can also make changes using the Toolpaths Parameters
page in any operation.

7 Switch to Code Expert and notice

that your changed file is marked
with an asterisk in Machine Explorer.

8 In Code Expert, click in Machine Explorer to give it the focus, and then press
[Ctrl+S] to save your machine changes.

Editing Machine File Settings and Defaults

Your Reseller typically supplies your machine file ready to use. However, you can
configure many settings according to your preferences and application needs. These
settings include, but are not limited to, the following:

GETTING STARTED WITH MASTERCAM MILL-TURN

44 MASTERCAM 2017 / Working with Machine Files

 Sequence and sync numbering

 Tool offset numbering
 Use of spaces in your NC file
 Job/shop info for your NC header
To find these settings, open your machine file in Code Expert and double-click the
Consumer icon in Machine Explorer.

Most of the settings are grouped into two categories:

 Control Definition
 Output Settings
Select a category from the Category drop-down, and then click the + signs to see the
individual options. (See the following picture.) Some of these options (for example,
sequence number settings) are common to most controls; others are specific to indi-
vidual machines.

GETTING STARTED WITH MASTERCAM MILL-TURN

 OPENING CODE EXPERT IN MULTI-STREAM VIEW 45

These settings serve a variety of functions:

 Mimicking the control definition settings in non-Mill-Turn Mastercam
 Configuring toolpath modes and cycles
 Setting default values for Sync Manager and toolpath options
Most of these settings are self-explanatory, and you can easily configure them by
browsing the interface. After making changes, press [Ctrl+S] to save your machine
file.

Opening Code Expert in Multi-Stream View

Several settings in the machine file configure Code Expert Editor. Access these options
by opening the Consumer layer. For example, you can use Code Expert Editor in either
single-stream or multi-stream mode. To make multi-stream mode the default, do the
following:
1 Open the Consumer layer.

2 Select the Output Settings

category.

3 Open the NC Output group.

4 Select the Open post output in Multi-Stream view option.

GETTING STARTED WITH MASTERCAM MILL-TURN

46 MASTERCAM 2017 / Working with Machine Files

Configuring the Find Extents Feature

The Find Extents feature in Code Expert scans your NC file and displays the minimum
and maximum values for each letter address. By default, Find Extents is set to scan X, Y,
Z, B, C, S and F. If you wish, you can edit the set of addresses that are scanned.
1 Go to the NC Configuration
category.

2 Open the Program group.

3 Enter the desired letter addresses in the list, separated by semi-colons ( ; ).

For example, if you add I;J;K; to the list, the next time you post, you will see them in the
Find Extents table.

GETTING STARTED WITH MASTERCAM MILL-TURN

 SETTING THE TOOLPATH DIRECTORY 47

Setting the Toolpath Directory

In non-Mill-Turn Mastercam, the toolpath directory setting is in the Machine Group
Properties dialog box, as shown below:

In Mill-Turn, the setting in Machine Group Properties is only used to override the
default toolpath directory. The default toolpath directory (the one used for newly
created files) is a property of the machine file. To set it, follow these steps:
1 Open the machine file in Code Expert.

2 If necessary, open the Properties window.

3 In Machine Explorer, click the

machine name.

GETTING STARTED WITH MASTERCAM MILL-TURN

48 MASTERCAM 2017 / Working with Machine Files

4 In Properties, select the desired NC

output Folder.
Mastercam will write your NC files
for this machine to this folder.

5 Select the desired Overwrite Mode.

You can choose whether Mastercam

automatically overwrites NC files
with the same file name or prompts
you to enter a different name.

This Overwrite Mode setting

replaces the setting from the
Posting dialog box in non-Mill-Turn
Mastercam.

6 Save the machine file.

NOTE: For more information on your machine’s settings and capabili-

ties with Mill-Turn, please refer to the application guide that comes pack-
aged with each machine. You can also access this document in Machine
Explorer’s Documentation folder.

GETTING STARTED WITH MASTERCAM MILL-TURN

 MANAGING MACHINE LICENSES 49

Managing Machine Licenses

Before you can use a Mill-Turn machine, you must have a license for it. If you use other
Mastercam products, you are familiar with HASPs, the small device that plugs into your
USB port and verifies your Mastercam license.
Mill-Turn machines, however, use software
licenses administered by a product named
CodeMeter. You can access CodeMeter from your
System Tray, as shown in the picture to the right.
Use CodeMeter to inspect or manage your Mill-
Turn licenses.

Verifying that You Have the Proper

License
Follow these steps to see what licenses are avail-
able on your workstation and to verify their
status:
1 Click the CodeMeter icon in the System Tray.

The CodeMeter Control Center opens. You should see a single item in the
License tab. This is the container that stores all of the Mill-Turn licenses
installed on your system. The Status should tell you that the license is
activated.

GETTING STARTED WITH MASTERCAM MILL-TURN

50 MASTERCAM 2017 / Working with Machine Files

2 Click the WebAdmin button to

inspect the individual licenses.

Your Web browser opens to the CodeMeter WebAdmin page, as shown in the
following image.

GETTING STARTED WITH MASTERCAM MILL-TURN

 MANAGING MACHINE LICENSES 51

3 Click the Licenses tab to see the

licenses that are installed.

The example below shows two installed licenses, a Mill-Turn Consumer license
and one license for a machine. If this user had licenses for more machines, the
additional machines would be listed here.

NOTE: In Mastercam, if you try to open a machine for which you do not
have a license—or open a part file that uses such a machine—
Mastercam displays an error message.

Reactivating Disabled Licenses

If you have a license installed on your system, and you still receive a license message,
the license may have become disabled.

GETTING STARTED WITH MASTERCAM MILL-TURN

52 MASTERCAM 2017 / Working with Machine Files

To run properly, the CodeMeter application needs to maintain a constant connection

with your HASP. If this connection breaks, your software licenses cannot be activated,
and you will be unable to run Mill-Turn.
Common reasons this might happen include:
 You unplug your HASP before shutting down your workstation.
 You run on a NetHASP, and the network connection is broken.
 Your computer has gone into sleep or hibernation mode, and CodeMeter can
no longer detect the HASP.
If your CodeMeter licenses are invalid for any reason, the icon in the System Tray
changes from blue to red. However, you can easily repair the license with CodeMeter.
Follow these steps:
1 Make sure that your workstation is properly connected to the HASP.

2 Start CodeMeter by clicking its icon in the System Tray.

3 When CodeMeter starts, make sure

your Mastercam MT license
container is visible.

CodeMeter should tell you that the license is invalid, as shown in the picture
for the following step.
4 Click the Repair License button.

You should now be able to run Mill-Turn normally. Please contact your
Reseller if you still have problems.

GETTING STARTED WITH MASTERCAM MILL-TURN

CHAPTER 5
5 Working with Tools and Spindles
This chapter explains how tool and toolpath settings work together to produce the
proper NC output for your Mill-Turn machine’s lathe operations and tools. Specifically,
correct tool use is determined by the following:
 Initial tool setup
 Setting up for left or right spindle

Initial Tool Setup

Tools for both upper and lower turrets should be defined so that they are oriented
correctly for the intended turret at the tool change position, with the correct vertical or
horizontal orientation. These settings are stored in the Mastercam tool definition,
shown below.
54 MASTERCAM 2017 / Working with Tools and Spindles

When you first select the tool, it should look as it is oriented at the tool change
regardless of which spindle you are working on. The position shown in the Toolpath
parameters page will be different depending on whether the tool is in the B-axis head
or a lower turret.

 Editing Tool Settings

To review or edit the tool settings, follow these steps. (This general procedure is infor-
mational only and not part of the tutorial.)
1 Right-click the tool in the tool
selection window.
2 Choose Edit tool from the pop-up
menu.
The Define Tool dialog box opens.

3 Click Setup Tool.

The Lathe Tool Setup dialog box opens.

GETTING STARTED WITH MASTERCAM MILL-TURN

 INSERT UP/DOWN AND LH/RH HOLDERS 55

4 Make changes to the tool settings, as needed.

5 Click OK in the Lathe Tool Setup and Define Tool dialog boxes to finalize
your changes.

TIP: When altering the tool definition settings, use the Draw Tool button
to quickly view the tool’s orientation.

Insert Up/Down and LH/RH Holders

When the tool is mounted at the tool change position, it can be in any of four orienta-
tions, depending on whether it is mounted insert up or insert down, and whether you
are using a left-hand or right-hand holder. Any of these orientations is acceptable with
Mill-Turn; the correct choice depends on how you need the tool oriented when you
rotate it into its cutting position.
The tool preview window in Mastercam shows you how the tool is oriented. Notice in
the following picture that the insert color changes to show insert up (yellow) or insert
down (orange).

Left-hand holder, insert up

Left-hand holder, insert down

Right-hand holder, insert up

Right-hand holder, insert down

 Changing Insert Orientation

To change the tool from insert up to insert down, do the following. (This general
procedure is informational only and not part of the tutorial.)
1 Go to the Lathe Tool Setup dialog for the tool. (Click the tool in the
operation, and then click Setup Tool in the Define Tool dialog box.)

GETTING STARTED WITH MASTERCAM MILL-TURN

56 MASTERCAM 2017 / Working with Tools and Spindles

2 Toggle the Reverse tool setting.

3 Change the Spindle Rotation

direction.

 Switching Between LH and RH Holders

To switch between left- and right-hand holders, do the following. (This general proce-
dure is informational only and not part of the tutorial.)
1 Go to the Define Tool dialog box. (Click the tool in the operation.)

2 Click the Draw Tool button.

GETTING STARTED WITH MASTERCAM MILL-TURN

 INSERT UP/DOWN AND LH/RH HOLDERS 57

For your verification, Mastercam

displays the tool in its current
configuration.

3 Press [Enter] to return to the Define Tool dialog box.

4 Select the Holders tab.

In the Style box, the holders are

arranged in left/right pairs.

5 Select the desired left- or right-hand

holder.

6 Click the Draw Tool button to see

the change, and then press [Enter]
to return to the Define Tool dialog
box.

7 Click Setup Tool.

The Lathe Tool Setup dialog box

opens.

GETTING STARTED WITH MASTERCAM MILL-TURN

58 MASTERCAM 2017 / Working with Tools and Spindles

8 Change the Spindle Rotation

setting, and click OK.
The tool positions correctly for the
operation.

9 Click the Draw Tool button to see

and verify your change, and then
press [Enter] to return to the Define
Tool dialog box.

10 Click OK to dismiss the Define Tool dialog box.

Specifying the Tool’s Compensation Point

Depending on how you set up your tools on the machine, you may need to change
the compensation point Mastercam uses to calculate the toolpath. Do this in the
Parameters tab of the Define Tool dialog box, as shown here. If your machine has a
tool eye (touch setter for turning tools) the standard setting is the first option.

GETTING STARTED WITH MASTERCAM MILL-TURN

 SELECTING THE SPINDLE AND TURRET 59

If you are using a tool that is being rotated in the B-axis head, and your toolpath is not
compensated as you expect, use the Cutting Direction options of the Tool Angle
dialog box (shown below) to specify how your tool was touched off on the machine.
Click the Tool Angle button on the Toolpath parameters tab to open this dialog box.

NOTE: If you use this compensation method, you must touch off your
tools differently at the machine.

Selecting the spindle and turret

In Mastercam, to specify which spindle and turret to use, you select an axis combina-
tion. There is a specific axis combination for each possible combination of B-axis head,
left/right spindle, and turret. Even if your machine has only a B-axis head and left
spindle, Mastercam defines at least one axis combination.

GETTING STARTED WITH MASTERCAM MILL-TURN

60 MASTERCAM 2017 / Working with Tools and Spindles

 Selecting an Axis Combination

The following general procedure demonstrates multiple axis combos. Follow these
steps. (This general procedure is informational only and not part of the tutorial.)
1 In the Toolpath parameters tab, click the Axis Combination button.

2 Select the desired turret/spindle

combination. This picture shows the
axis combination set to use the
lower turret on the left spindle.

GETTING STARTED WITH MASTERCAM MILL-TURN

 SETTING UP TOOLS FOR PINCH TURNING 61

Setting Up Tools for Pinch Turning

When creating a pinch turn operation, the settings for the two tools must be correctly
coordinated. Mastercam cannot create the operation if the settings conflict. Follow
these guidelines.
 Insert direction—The insert directions for the two tools must be
complementary. For example, if the upper-turret tool is insert-down, then the
lower-turret tool needs to be insert-up. You can tell the insert direction from
the picture in the tool window. An orange insert means insert-down and a
yellow insert means insert-up.
 Spindle direction—The spindle direction for the two tools must be the same.
 Tool holder—If the above two conditions are met and the toolpath is still not
created correctly, you might need to select a different tool holder. For
information on how to do this, please refer to Switching Between LH and RH
Holders on page 56.

GETTING STARTED WITH MASTERCAM MILL-TURN

62 MASTERCAM 2017 / Working with Tools and Spindles

GETTING STARTED WITH MASTERCAM MILL-TURN

CHAPTER 6
6 Reference Positions
Use reference positions (not to be confused with reference points) to specify where to
start and end operations. For example, you can move to the tool change position
between operations by selecting a reference position for the first operation's retract
and selecting the same reference position for the second operation's starting point.
The following exercises demonstrate how to use and define reference positions in
your Mill-Turn operations.

Using Reference Positions

Mill-Turn machines come with standard reference positions already defined. You can
use these predefined reference positions without changing the machine or your part
files. Just select them as needed in Sync Manager, as the following exercise shows.
1 Load the file CHAP6-PART1 into Mastercam, and save it as CHAP6-PART1-XX,
where XX is your initials. This ensures that you do not accidentally overwrite
the original file.
2 Select all operations in Toolpaths
Manager.

3 Click the G1 button.

Sync Manager opens and displays

the part’s data.

4 Click the small inverted triangle next

to operation 1, Lathe Face.
A set of options appears in a drop-
down box. One of these options is
Reference Position.
5 Open the drop-down menu for the Reference position option, and note that
it contains only one item, named Lower Reference Return.
64 MASTERCAM 2017 / Reference Positions

This is the only reference position currently available for this operation on the
machine’s left spindle, lower turret.

6 Look at the reference position for operation 2, Lathe Rough.

Upper Reference Return is the only reference position currently available for
this operation on the machine’s left spindle, B-axis head.

7 Look at the reference position for operation 3, Lathe Finish.

You see two reference positions, (None) and Lower Reference Return.

8 Expand the Lathe Finish operation, so that you can see the sub-operations. (If
you cannot see the “plus” icon for expanding the operation, make sure the
pane is scrolled all the way to the left.)

GETTING STARTED WITH MASTERCAM MILL-TURN

 USING REFERENCE POSITIONS 65

9 On operation 3’s Retract, change the Reference position setting from Lower
Reference Return to (None).

NOTE: Reference positions are available only on the operation and

retract nodes in the Operations pane.

10 Save the file.

Saving the file in the Sync Manager

updates the part in Mastercam.

11 Run Machine Simulation.

12 Use your mouse wheel to zoom in

on the chuck.

GETTING STARTED WITH MASTERCAM MILL-TURN

66 MASTERCAM 2017 / Reference Positions

13 Click Run on the Simulation tab to

run the simulation, and notice that
the lower turret does not retract to a
reference position after completing
the finish cut.
This is because you set this retract’s
reference position to (None).

14 In Sync Manager, change the reference position for the third operation’s
Retract back to Lower Reference Return.

15 Save the file, relaunch Machine Simulation, and click the Run button.

Now, after completing all cuts, the spindle retracts to the position specified by
the Lower Reference Return reference position.

16 Close Machine Simulation.

GETTING STARTED WITH MASTERCAM MILL-TURN

 CREATING REFERENCE POSITIONS 67

Creating Reference Positions

Although each machine file includes a set of predefined reference positions, you can
use the main Mastercam application to create your own. You might want a custom
reference position, for example, to accommodate special part fixtures or tooling.
Unlike the predefined reference positions, custom reference positions are stored in the
part file, not the machine file.
The following exercise demonstrates how to define and use a custom reference posi-
tion.
1 In Mastercam’s Toolpaths
Manager, click the Edit reference
positions button.
The Machine Reference Position
Manager opens.
2 Right-click Lower Reference Return, and choose Duplicate selected
reference position from the pop-up menu.
Mastercam creates a copy of the reference position.

3 Change the new reference position’s name to Alternate Lower Reference

Return, and set the Z2 Axis value to 500. Click OK to save your changes.

GETTING STARTED WITH MASTERCAM MILL-TURN

68 MASTERCAM 2017 / Reference Positions

Now, Alternate Lower Reference Return, the reference point you just
created, is identical to Lower Reference Return, except for its name and Z2
Axis value.

4 Click the G1 button to update Sync

Manager with the new reference
position.

5 Change the reference position for operation 3’s Retract to the new Alternate
Lower Reference Return.

GETTING STARTED WITH MASTERCAM MILL-TURN

 CREATING REFERENCE POSITIONS 69

6 Save the file, and run the simulation.

Now the turret retracts to a position 500mm farther to the right, compared to
where it started at the original Lower Reference Return reference position.

7 Close Machine Simulation, Code Expert, and Mastercam.

GETTING STARTED WITH MASTERCAM MILL-TURN

70 MASTERCAM 2017 / Reference Positions

GETTING STARTED WITH MASTERCAM MILL-TURN

CHAPTER 7
7 Configuration and Job Setup
Before you create toolpaths with Mastercam Mill-Turn, you must complete configura-
tion and setup tasks. These include choosing a machine and setting the appropriate
options for your job.

Adding a Machine File

Mill-Turn supports many types of machines, each having its own machine solution
(MACHINE file). To see how to add a machine, start Mastercam and perform the
following steps.

Adding Your Machine

1 If you have not already done so, place a copy of Generic Fanuc Mill
Turn.machine (also included with this book) in your
C:\Users\Public\Documents\shared mcam2017\Mill Turn\machines
directory.
2 On Mastercam’s Machine tab,
choose Mill-Turn, Manage List.
The Machine Definition Menu
Management dialog box displays.

3 For the purposes of the exercises in this book, choose Generic Fanuc Mill
Turn.machine, and click Add.

The machine moves to the Machine Definition Menu Items box, which
means that it will now appear in Mastercam’s Machine Type, Mill-Turn
submenu.
72 MASTERCAM 2017 / Configuration and Job Setup

4 Click OK to dismiss the Machine

Definition Menu Management
dialog box.

Setting Up Your Job

You can now select the machine from the Machine, Mill-Turn drop-down menu.
When you do, Job Setup, in which you must define your job’s parameters, displays.
These parameters include the following:
 The Work Coordinate System (WCS) setting
 The spindle on which work will begin
 The type of work to be done (single piece or bar)
 The part geometry
 The stock definition
 The chuck jaw definitions
 The part stickout and pickoff positions

Selecting a Machine
1 Load the part file CHAP7-PART1, which is included with this book.

NOTE: This part file is in Metric units. If your Mastercam system is set
for English units, you will be asked about switching from English to
Metric. Just click OK to proceed.

The part’s geometry displays in Mastercam’s graphics window. However,

because no machine is assigned to the part, the Toolpaths Manager is empty.

GETTING STARTED WITH MASTERCAM MILL-TURN

 COMPLETING JOB SETUP 73

2 From Mastercam’s Machine, Mill-Turn drop-down menu, choose the

Generic Fanuc Mill Turn.machine file.

Mastercam creates a new machine group, and then displays the Job Setup tab
of the Machine Group Properties dialog box.

NOTE: If Code Experts opens on top of Mastercam, minimize Code

Expert. Do not close it.

Completing Job Setup

The Job Setup tab contains the general parameters for your job. These parameters are
arranged in top-down fashion, providing a helpful workflow for successfully config-
uring your job. In this section of the book, you work through the parameter list, setting
up a continuous bar stock job on the left spindle. This job includes pickoff and cutoff
operations.

Setting WCS, Setup Type, and Stock Type

1 Select the WCS page, and ensure
that WCS is set to TOP.

NOTE: In your production work,

you can use the WCS setting to
reorient parts that are not aligned
correctly for machining.

GETTING STARTED WITH MASTERCAM MILL-TURN

74 MASTERCAM 2017 / Configuration and Job Setup

2 Select Setup type in the list, and

ensure that Initial Spindle is set to
Left spindle.
The Left spindle setting specifies
that the job starts on the left spindle.
If a part transfer is required, the part
moves from the left spindle to the
right spindle.

3 Ensure that Continuous bar stock -

Pickoff, Stock Pull, Cutoff is
selected in the drop-down list.
Mill-Turn includes options for
continuous bar stock and single
stock pieces. Your selection
determines the part handling
operations you can create and the
options that are available in the
Pickoff page.

Specifying Part Geometry

1 Select Part geometry from the list,
and click the geometry selection
arrow.
The dialog box minimizes so that
you can access Mastercam’s
graphics window.

2 Click anywhere on the part, and

press [Enter].
Mastercam returns to the Job Setup
tab, with the part’s geometry
selected.

GETTING STARTED WITH MASTERCAM MILL-TURN

 COMPLETING JOB SETUP 75

Mastercam also enables the Delete

previously created geometry and
Create Opposed Spindle
Geometry options. The first ensures
that geometry created in previous
operations is removed from the part.
The second creates geometry for the
opposite spindle, in this instance,
the right spindle.
3 Select the Create turn profile(s)
option, and ensure that Spin is
active.
The Create turn profile(s) option
tells Mastercam to create turn-
profile geometry using either of the
following methods:

 Spin: Mastercam rotates the part geometry around an axis, generating the
profile from the farthest extents of the spun geometry.
 Slice: Mastercam slices the part geometry in the Lathe ZX (WCS XY) plane.
The profile is limited to what the slice encounters and may not include the
geometry’s full extents. For example, bosses not in the slice plane will be
unrepresented in the turn profile.

Specifying Bar Stock Settings

1 Select Bar stock in the job setup list, and ensure that Number of parts is set
to 1.

GETTING STARTED WITH MASTERCAM MILL-TURN

76 MASTERCAM 2017 / Configuration and Job Setup

2 Set Extra stock for the outside

diameter to 2.0 mm.

NOTE: The initial stock settings, such as diameter values, appear when
a solid has been selected as the part or stock model. This is not the case
with wireframe geometry.

3 Set extra stock for face and back to

2.0 mm.

Setting Spindle and Chuck Parameters

1 Select Left Spindle, Chuck jaws in
the job setup list.

2 In the Part Stickout box, click the

“target” button.
Mastercam minimizes the dialog box
so that you can access the graphics
window.

3 Click the part where shown in the following picture.

GETTING STARTED WITH MASTERCAM MILL-TURN

 COMPLETING JOB SETUP 77

The Machine Group Properties dialog box redisplays, and Distance is set to
145.0.

4 In the job setup list, click Left

Spindle, Toolplane origin Z.

5 Notice that the toolplane origin is

on the part’s right face.

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78 MASTERCAM 2017 / Configuration and Job Setup

6 In the job setup list, click Right

Spindle, Toolplane origin Z.

7 Notice that the toolplane origin is

on the part’s left face.

NOTE: The jaw options that you see are based on the Stock type and
other stock settings. For example, you will not see ID jaw options unless
an inner diameter has been specified on the Bar stock page.

Defining the Pickoff Operation

1 In the job setup list, select Pickoff.

2 In the Pickoff box, click the “target”

button.
Mastercam minimizes the dialog box
so that you can access the graphics
window.

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 COMPLETING JOB SETUP 79

3 Click the part where shown in the following picture.

The Machine Group Properties dialog box redisplays, and Distance from
chuck face is set to 88.75. This is where the right spindle will grip the part.

4 In the Cutoff box, set Cutoff width

to 4.0 mm.

5 Click OK to close the Machine Group Properties dialog box.

6 Click OK in the Enter new NC name dialog box.

7 Save the part file as CHAP7-PART2-XX, where XX is your initials.

Your job setup is now complete. In the next chapter, you create the toolpath opera-
tions needed to face the part in the left spindle with the lower turret.

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80 MASTERCAM 2017 / Configuration and Job Setup

GETTING STARTED WITH MASTERCAM MILL-TURN

CHAPTER 8
8 Turning Toolpaths
In this lesson, you create toolpaths to cut the face and OD of a part with both
roughing and finishing operations. You program the initial operations on the left
spindle. You then transfer the part to the right spindle and cut the areas that were
inaccessible in the left spindle.
The operations you create are as follows:
 Facing, using the left spindle and lower turret
 Roughing, using the left spindle and upper turret
 Finishing, using the left spindle and lower turret
 Part transfer from the left spindle to the right spindle, which includes pickoff
and cutoff operations
 Facing, using the right spindle and lower turret
 Pinch Turn, using the right spindle, upper turret, and lower turret

Programming the Left Spindle

In this section, you create a facing toolpath. You also create roughing and finishing
operations for the part’s OD. You program these toolpaths on the left spindle, alter-
nating between the lower and upper turrets.
Continue with your part from the previous chapter.

The Facing Toolpath

1 Click Mastercam’s Turning tab, and
choose Face from the General
toolpaths.
The Lathe Face dialog box appears.
The tools displayed, however, are
not appropriate for the operation
you will create.
82 MASTERCAM 2017 / Turning Toolpaths

2 Click the Axis Combination button.

The Axis Combination / Spindle

Origin dialog box displays.

3 Select the Lower Left axis

combination, and click OK.
The Lathe Face dialog box now
shows tools that are appropriate for
the lower-left axis combination.

4 Select the ROUGH FACE LEFT - 80

DEG tool (your tool may be in a
different position than the one
shown).

5 Click the Face parameters tab.

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 PROGRAMMING THE LEFT SPINDLE 83

6 Ensure that Finish Z is set to 0.0, and activate the Lead In/Out checkbox.

7 Click OK to exit the dialog box.

Mastercam creates the facing

toolpath based on your selected
parameters, and the operation
appears in Toolpaths Manager.

The Roughing Toolpath

1 Choose Rough from the General
toolpaths.
The Chaining dialog box displays.

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84 MASTERCAM 2017 / Turning Toolpaths

2 Select the chain shown in the picture below, by clicking points 1 and 2.

3 Click OK to close the Chaining

dialog box.
The Lathe Rough dialog box
displays.
4 Click the Axis Combination button,
ensure that the Upper Left axis
combination is selected, and click
OK.

5 Choose the OD Left 55 deg tool.

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 PROGRAMMING THE LEFT SPINDLE 85

6 Click the Tool Angle button.

7 In the Tool Angle dialog box, set

the angle to 90, and click OK.

8 Click OK to close the Lathe Rough

dialog box.

Mastercam creates the roughing toolpath, as shown below.

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86 MASTERCAM 2017 / Turning Toolpaths

The Finishing Toolpath

1 Choose Finish from the General
toolpaths.
The Chaining dialog box displays.

2 Select the chain shown in the picture below, clicking points 1 and 2.

3 Click OK to close the Chaining

dialog box.
The Lathe Finish dialog box
displays.
4 Ensure that the Axis Combination is
set to Left Spindle / Lower Turret.

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 PROGRAMMING THE LEFT SPINDLE 87

5 Select the OD FINISH RIGHT - 35

DEG tool.

6 Click OK to close the Lathe Finish dialog box.

Mastercam creates the finishing toolpath.

7 Save the file as CHAP8-PART2-XX, where XX is your initials.

Simulating the Toolpaths

To test your operations, you will now simulate the job in the Machine Simulation
application.
1 In Mastercam’s Toolpaths Manager,
click Machine Group-1.
Mastercam selects all of the
operations.

2 Click the G1 (Post) button.

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88 MASTERCAM 2017 / Turning Toolpaths

After a few moments, Code Expert displays Sync Manager, as shown in the
picture below. (If you see the Properties pane, close it to free up space in the
window.)

3 In the Sync Manager tab, click the

Launch button.

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 PROGRAMMING THE LEFT SPINDLE 89

After a few moments, the Machine Simulation window displays, as shown in

the picture below.

4 In the graphics window, place your

mouse pointer over the left spindle,
and use your mouse wheel to zoom
in closer to the part’s stock, as
shown in the picture to the right.

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90 MASTERCAM 2017 / Turning Toolpaths

5 In the Simulation tab, click the Run

button.

6 Watch as Machine Simulation

simulates the three operations you
created. Notice how the machine
tries to make two cuts
simultaneously, as seen in the
picture to the right.

NOTE: Use the Simulation Run

Speed slider to speed up or slow
down the simulation as needed.

Synchronizing the Toolpaths

1 Close Machine Simulation.

You are now ready to do more work

in Sync Manager.

2 In Sync Manager, click the plus signs

(+) next to the operations in both
the upper and lower streams.
Sync Manager expands the
operations to display the sub-
operations.

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 PROGRAMMING THE LEFT SPINDLE 91

3 Drag the right-hand edge of the Operations pane to the right, expanding the
pane until you can see more of the operations’ descriptions, as shown below.

4 Drag down the bottom edge of the pane, expanding the pane vertically.

5 Use your mouse to drag-and-drop the Lathe Face operation’s Retract to the
Lathe Rough operation’s Approach.
You have now synchronized the end of the facing toolpath with the start of
the roughing toolpath. Sync Manager labels the sync point as Sync 1.

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92 MASTERCAM 2017 / Turning Toolpaths

6 Drag the Lathe Rough operation’s Retract to the Lathe Finish operation’s
Approach.
Sync Manager labels the second sync point as Sync 2.

You have now synchronized the end of the roughing toolpath with the start of
the finishing toolpath. Your upper and lower streams should now look like the
following picture.

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 PROGRAMMING THE LEFT SPINDLE 93

TIP: At this point, the file’s

status icon is yellow, which
means that Mastercam must
be updated from Sync
Manager. For more informa-
tion on how Sync Manager and Mastercam share data, please see Sync
Manager and Mastercam Interactions (page 130).

7 Choose File, Save.

Sync Manager writes the synchronized data back to Mastercam, and the
status icon returns to green.
8 Click the Launch button, and run the simulation again.

Now the operations are synchronized. That is, they are guaranteed to run in
the correct order, without one operation overlapping another.
9 Close Machine Simulation.

10 Back in Mastercam (not Sync Manager), save the part as CHAP8-PART3-XX,

where XX is your initials.

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94 MASTERCAM 2017 / Turning Toolpaths

NOTE: Although you can close Code Expert when not using it, we
suggest that you leave it open for your entire session. Then you do not
need to wait for it to reload when you next need it.

The Part Handling Operations

You now must transfer the part from the left spindle to the right, so that you can
create the toolpaths to complete the job. To do this, you program pickoff, cutoff, or
transfer operations that leave the part clamped in the right chuck, ready for cutting.

Creating Part Handling Operations

1 From Mastercam’s Turning tab,
choose Part Handling, Pickoff/
Cutoff.
The Pickoff, Stock Pull, Cutoff
dialog box displays.

2 Verify that the Strategy is set to Pickoff, Stock Pull, Cutoff (Upper Turret), as
shown in the picture below.
The Strategy selection (A) determines which operations appear in the
Operations list (B).

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 THE PART HANDLING OPERATIONS 95

3 Click OK to accept the default

settings for your part handling
strategy.

Mastercam Mill-Turn creates the

requested set of operations, as seen
in the picture to the right.

Simulating the New Operations

1 In Toolpaths Manager, click
Machine Group-1.
Mastercam selects all of the
operations.

2 Click the G1 button.

Mastercam sends the new data to

Sync Manager, and Sync Manager
displays in Code Expert’s window.

3 Sync operation 4 Turret Park, Lower Park Left to operation 5 Lathe Point,
Approach, as shown in the picture below.

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96 MASTERCAM 2017 / Turning Toolpaths

Sync Manager creates a sync point labeled Sync 3. You have now
synchronized the end of the finishing operation with the right spindle
approach.

4 Save the file back to Mastercam, and

then click the Launch button.
In a few moments, Machine
Simulation displays.

5 Rotate the graphics window so that you can see both spindles. (See the
picture below.) To do this, place your mouse pointer over the graphics
window, hold down your left mouse button, and drag the mouse.

6 Use your mouse to zoom in on the two spindles.

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 THE PART HANDLING OPERATIONS 97

Now you can see the simulation more clearly.

7 Click the Run button.

Machine Simulation begins to simulate the job’s operations, but there is a

collision between the right spindle and the lower turret, as shown below.

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98 MASTERCAM 2017 / Turning Toolpaths

8 If the Collision detected dialog box

opens, click Yes To All.
Machine Simulation will now ignore
collisions of this type. Later
operations will fix the problem.

When the simulation completes, the right chuck will be holding the part, as
seen in the picture below.

9 Close Machine Simulation.

10 In Mastercam, save the part as CHAP8-PART4-XX, where XX is your initials.

Programming the Right Spindle

Your part is now in the right spindle, and you can create the toolpaths to complete the
part. For the following exercise, continue with your part from the previous section or
load part CHAP8-PART4 from the files included with this tutorial.

The Facing Toolpath

1 In Mastercam, select the Machine Group-1.Right viewsheet tab.

The graphics window now displays the right spindle.

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 PROGRAMMING THE RIGHT SPINDLE 99

2 From Mastercam’s Turning tab,

choose General, Face.
The Lathe Face dialog box displays.

3 Click the Axis Combination button.

The Axis Combination / Spindle

Origin dialog box displays.

4 Select the Lower Right axis

combination, and click OK.
The Lathe Face dialog box now
shows tools that are appropriate for
the lower-right axis combination.

5 Select the Rough Face Right / 80

Deg tool.

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100 MASTERCAM 2017 / Turning Toolpaths

6 Click the Face parameters tab.

7 Ensure that the Lead In/Out

checkbox is selected, and then click
the Lead In/Out button.
The Lead In/Out dialog box
displays.

8 Click the Lead out tab.

9 Change Angle to 180.

The tool will now exit away from the

part, rather than toward it.

10 Click OK to exit the Lead In/Out dialog box.

GETTING STARTED WITH MASTERCAM MILL-TURN

 PROGRAMMING THE RIGHT SPINDLE 101

11 Click the Finish Z button.

12 Click the left face of the part, as

shown in the picture to the right.

13 Click OK to exit the dialog box.

Mastercam creates the facing

toolpath based on your selected
parameters, and the operation
appears in Toolpaths Manager.
(Your tool numbers may vary.)

The Roughing Toolpath

1 From Mastercam’s Turning tab,
choose General, Rough.
The Chaining dialog box displays.

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102 MASTERCAM 2017 / Turning Toolpaths

2 Select the chain shown in the picture below, by clicking points 1 and 2.

3 Choose OK to close the Chaining

dialog box.
The Lathe Rough dialog box
displays.
4 Click the Axis Combination button.

The Axis Combination / Spindle

Origin dialog box displays.

5 Ensure that the Upper Right axis

combination is selected, and click
OK.

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 PROGRAMMING THE RIGHT SPINDLE 103

6 Choose the OD ROUGH RIGHT - 80

DEG tool.

7 Click the Tool Angle button.

The Tool Angle dialog box appears.

8 Set Tool Angle to 90, and click OK.

9 Click OK to close the Lathe Rough

dialog box.

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104 MASTERCAM 2017 / Turning Toolpaths

Mastercam creates the roughing toolpath, as shown below.

The Pinch-Turn Toolpath

1 From Mastercam’s Turning tab,
choose General, Pinch Turn.
The Pinch Turn Associated dialog
box opens.

2 Click the Axis Combination button.

The Axis Combination / Spindle

Origin dialog box opens.

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 PROGRAMMING THE RIGHT SPINDLE 105

3 Set the Axis Combination to Lower

Right, and click OK.

4 Choose the OD RIGHT 55 DEG tool.

5 Click the Pinch turn tab.

The Pinch Turn settings appear in

the dialog box.

6 In the operation list, select the Lathe

Rough operation in Toolpath
Group-2.
This is the operation Mastercam will
use to generate the pair of
operations that make up the Pinch
Turn toolpath.
7 Click OK to exit the dialog box.

Mastercam creates the Pinch Turn toolpath.

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106 MASTERCAM 2017 / Turning Toolpaths

8 In Toolpaths Manager. click the Set up tools on the machine button, as

shown below.
The Tool Setup Manager dialog box opens.

9 In the dialog box, select the Unload tools already loaded on the machine
option, and then click the Remove and re-load all tools button.

Mastercam ensures that the tool is loaded correctly for the operation.
10 Click OK to close the dialog box.

Synchronizing the Toolpaths

1 In Toolpaths Manager, click Select
all operations.
Mastercam selects all of the
operations.

2 Click the G1 button.

After a few moments, Code Expert

displays Sync Manager with the
updated part data.

3 In the Upper Stream list, scroll down to operation 18 Turret Park, and click
the plus (+) to show the sub-operations.
4 In the Lower Stream list, open operation 19 Turret Park.

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 PROGRAMMING THE RIGHT SPINDLE 107

5 Drag-and-drop from operation 18 Turret Park, Upper Reference Return to

operation 19 Turret Park, Lower Reference Return, as shown in the picture
below.

You have now synchronized the end of the part handling operations with the
turret park operation.
6 Drag operation 20’s Retract to operation 21’s Approach.

Sync Manager creates the sync point.

7 Choose File, Save.

Sync Manager writes the synchronized data back to Mastercam.

8 Click the Launch button, and run the simulation.

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108 MASTERCAM 2017 / Turning Toolpaths

All operations are synchronized.

9 Close Machine Simulation.

10 Back in Mastercam (not Sync Manager), save the part as CHAP8-PART5-XX,

where XX is your initials.
11 Close Mastercam and Code Expert.

GETTING STARTED WITH MASTERCAM MILL-TURN

CHAPTER 9
9 Milling Toolpaths
These exercises step through basic C- and Y-axis toolpathing using a partially
programmed sample file. For simplicity, you import toolpaths from an existing file.

Setting Up the Part

1 Launch Mastercam.

2 Open the file CHAP9-PART1, which is included with this book, and if the
System Configuration dialog box displays, click OK to switch system units.
In Toolpaths Manager, you can see that four lathe operations are already programmed
(see the picture below). To start the C- and Y-axis milling examples, you will import
operations from a sample part.
110 MASTERCAM 2017 / Milling Toolpaths

Importing the Milling Operations

1 Right-click in Toolpaths Manager,
and select Import.
The Import Toolpath Operations
dialog box appears.

2 Click the Select Operations File

button.

TIP: To see the file when browsing, you must change the file extension
filter from Mastercam Operation Files to Mastercam Files.

3 Browse to and open the file CHAP9-FIX SYNCS, which is included with this
book.
The operations contained in the selected file appear in the Import Toolpath
Operations dialog box.
4 Select operations 5 through 8 (hold
down [Shift] to select multiple
items), and click the Import
Operations button (the one that
looks like a plus sign).

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 IMPORTING THE MILLING OPERATIONS 111

5 Close the Import Toolpath

Operations dialog box by clicking
Done.

After the import, Toolpaths

Manager contains the operations
shown to the right.

6 In your Windows Start menu, go to All Programs, Mastercam 2017,

Utilities, Advanced Configuration.
The Mastercam Advanced Configuration dialog box opens.
7 Select the Backplot properties page, and disable the Classic Backplot entry,
as shown in the following picture. Then click OK.

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112 MASTERCAM 2017 / Milling Toolpaths

Mastercam will now backplot and verify with Mastercam Simulator.

Completing the Pocket Operation

1 Click the Parameters icon in
operation 5.
The 2D Toolpaths - Pocket dialog
box displays.

2 Verify that the Toolpath Type is set

to Pocket.

3 Click the Select chains button.

The Chain Manager dialog box

appears.

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 COMPLETING THE POCKET OPERATION 113

4 Right-click in the dialog box, and

choose Add chain from the pop-up
menu.
The Chaining dialog box appears.

5 Chain the rectangle shown to the

right, and click OK in the Chaining
and Chain Manager dialog boxes.

6 Select Tool, and then verify that the

tool is a ½-inch flat endmill.

7 On the Setup page, ensure that Y-Axis Cross and the Upper Left axis
combination are selected.

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114 MASTERCAM 2017 / Milling Toolpaths

NOTE: Because there is no existing

toolplane for the selected geometry,
Mastercam automatically creates the
proper plane based on the selected
geometry, the operation orientation,
and axis combo. The display at the
bottom of the dialog box tells you the
name of the new plane.

8 Click OK to close the 2D Toolpaths - Pocket dialog box.

9 Click Regenerate all selected

operations.
Mastercam regenerates the pocket
operation.

10 Select operation 5’s Toolpath icon in

the Toolpaths Manager.
The Mastercam Simulator window
opens.

11 In the Home tab’s Visibility group,

ensure that Tool and Workpiece are
selected.
Mastercam Simulator will now show
the tool and the workpiece in its
graphics area.

12 On the View tab, click Isometric.

The view changes to the isometric

orientation. Note that the view in
Mastercam also changes to
isometric.

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 COMPLETING THE FACING OPERATION 115

13 Click the Play button to run

backplot.
Mastercam backplots the operation,
as shown in the following picture.

14 Close Machine Simulation.

Completing the Facing Operation

Next, you finish the short wall in back of the pocket.
1 Click operation 6’s Parameters icon.

The 2D Toolpaths - Contour dialog

box displays.

2 Ensure that Toolpath Type is set to

Contour.

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116 MASTERCAM 2017 / Milling Toolpaths

1 Click the Select chains button.

Chain Manager appears.

2 Right-click, and choose Add chain.

The Chaining dialog box appears.

3 In the Chaining dialog box, choose

the Single button, and then select
the line at the base of the wall, as
shown in the following picture.

4 Click OK in both the Chaining and Chain Manager dialog boxes.

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 COMPLETING THE FACING OPERATION 117

5 On the Setup page, select Y-Axis Cross, Upper Left, and Top, as shown
below.

6 Click OK to close the 2D Toolpaths - Contour dialog box.

7 Click Regenerate all selected

operations.
Mastercam regenerates the
operation.

8 Select operation 6’s Toolpath icon, and backplot the operation in isometric
view, as shown below.

9 Close Mastercam Simulator.

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118 MASTERCAM 2017 / Milling Toolpaths

Completing the Rough Contour Operation

Next, you rough out the triangular section at the front of the part.
1 Re-chain geometry for operation 7 – Contour (3D) as shown here.

2 Set Toolpath Type to Contour, and for Tool, select the ½-inch flat endmill.

3 On the Setup page, select C-Axis Face and the Upper Left axis combo.

4 Regen the operation, and backplot it.

5 Close Machine Simulation.

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 COMPLETING THE FINISH CONTOUR OPERATION 119

Completing the Finish Contour Operation

You next finish the triangular section at the front of the part.
1 Re-chain geometry for operation 8 – Contour (2D) as shown here. (Select the
same contour as in the previous rough operation.)

2 Set Toolpath Type to Contour.

3 On the Setup page, select C-Axis Face and the Upper Left axis combo.

4 Click OK to close the 2D Toolpaths - Contour dialog box.

5 Regen the operation, and select backplot it.

6 In Mastercam, save the part as CHAP9-PART2-XX, where XX is your initials.

7 Close the Simulation, Code Expert, and Mastercam windows.

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120 MASTERCAM 2017 / Milling Toolpaths

GETTING STARTED WITH MASTERCAM MILL-TURN

CHAPTER 10
10 More about Sync Manager
Sync Manager lets you create sync points for multi-stream machines and create
custom job setups that ensure valid output. You have already used Sync Manager in
previous chapters. This chapter demonstrates additional features you might have not
yet discovered.
Sync Manager’s window has six main areas. Refer to the following picture as you work
through the procedures in this chapter.

Ribbon Machine Explorer

Operations pane Properties grid

Graphics window Timeline

122 MASTERCAM 2017 / More about Sync Manager

Customizing the Display

You can easily modify Sync Manager’s display to suit your needs. Try the following
procedure to discover some common features.
1 In Mastercam, load the part file named CHAP10-PART1, which is included with
this book. Click OK to change units when asked. Mastercam should look
similar to the following picture.

Notice that Toolpaths Manager contains a machine group for a Generic Fanuc
MT Machine. Notice also that the toolpath group contains facing, roughing,
and finishing toolpaths for the part displayed in the graphics window.
2 Click the G1 button.

In a few moments, Sync Manager

appears in the Code Expert window,
as shown in the following picture.

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 CUSTOMIZING THE DISPLAY 123

3 If you have Machine Explorer and the Properties grid open, close them so that
you can see more of the part.

4 Click the small arrow in the

Timeline’s upper-right corner, and
choose Auto Hide.
The Timeline minimizes to a tab.

GETTING STARTED WITH MASTERCAM MILL-TURN

124 MASTERCAM 2017 / More about Sync Manager

5 In the Sync Manager tab, experiment with the checkboxes in the Show group
to toggle display elements on and off.

The picture below shows a portion of the graphics window with the fixtures
and stock removed from the display.

6 Click the View tab.

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 CUSTOMIZING OPERATION SETTINGS 125

7 Click the Fit button.

The geometry zooms to fit the

graphics window.

8 Click the view buttons to see the

part from different angles.
The picture below shows the part in
Top view.

Customizing Operation Settings

You can set options for individual parameters by clicking small inverted triangles in
the Operations pane. Try the following procedure to see how this works.

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126 MASTERCAM 2017 / More about Sync Manager

1 With your mouse, drag the right-

hand edge of the Operations pane
to increase its width.

2 Click the plus signs (+) next to the operations in the Operations pane.

Sync Manager expands the operations, as shown below.

3 Go to the View tab, and click

Properties.

The Properties grid appears. The Code Expert window should now look
similar to the following picture.

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 CUSTOMIZING OPERATION SETTINGS 127

4 Click OD Left 55 deg in the

Operations pane.

Information about the selected item

appears in the Properties grid, as
shown in the picture to the right.

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128 MASTERCAM 2017 / More about Sync Manager

5 Back in the Operations pane, click

the small inverted triangle to the
right of Lathe Rough.
A small box appears into which you
can enter option values.

6 Change the Coolant value to

Strategy1, and then click outside of
the box to accept your change.
The option’s value in the Properties
grid also changes. You can edit your
operations in either the Operations
pane or the Properties grid.

7 Save the file in Sync Manager, and in Mastercam, save the file as CHAP10-
PART2_XX, where XX is your initials.

Using the Timeline

1 Click the Timeline tab in Code
Expert’s lower-left corner.
The Timeline displays.

2 In the Timeline’s upper-right corner,

click the pin icon.
The Timeline’s Auto Hide option is
now off, and the Timeline no longer
minimizes to a tab.
The Timeline displays the operations
horizontally instead of vertically, as
they are displayed in the
Operations pane.

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 USING THE TIMELINE 129

3 If necessary, in the Timeline’s lower-

left corner, drag the zoom slider all
the way to the left.
You should see the three operations
and two red lines, as shown below.
(You may need to maximize the Sync
Manager window.) The red lines are
the sync points created in the
Operations pane.

4 Hover your mouse over a sync point in the Timeline.

Sync Manager displays a tooltip for the sync and outlines the equivalent sync
point in the Operations pane, as shown in the following image.

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130 MASTERCAM 2017 / More about Sync Manager

5 Close Code Expert, without saving changes you may have made to the file.

Sync Manager and Mastercam Interactions

Because Sync Manager and Mastercam share data, their interactions are tightly
controlled. When a part is open in both, you can access either application freely only
when the data in both is up to date.
Mastercam is the master application with respect to Sync Manager; the part data in
Mastercam represents the current state of the part. Sync Manager uses a working copy
of that data. When you save data from Sync Manager, you are updating the part file in
Mastercam. To see how these interactions work, try the following exercise.

Changing Data in Sync Manager

1 Load the file CHAP10-PART4 (provided with this book) into Mastercam.

Mastercam not only loads the part, but also starts the Code Expert
application, as seen below. Note that Code Expert is not yet displaying data
for the part you loaded.

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 SYNC MANAGER AND MASTERCAM INTERACTIONS 131

2 In Mastercam’s Toolpaths
Manager, select all operations, and
then click the G1 button.

Sync Manager opens the part. At this point, you can access both Mastercam
and Sync Manager because both applications have a clean operation set.

3 In Sync Manager, notice the green

circle on the file’s tab.
Green indicates that Mastercam’s
and Sync Manager’s data sets
match.
4 In Sync Manager, expand the Lathe Rough and Lathe Face operations, as
shown below.

NOTE: You can use the Connect Stream List Display button
(shown to the right) to lock together the lists, operations, and
sync points so that they remain horizontally aligned.

GETTING STARTED WITH MASTERCAM MILL-TURN

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5 Right-click on a Sync 1 sync point,

and choose Delete Sync Group
from the pop-up menu.
Sync Manager removes the pair of
sync points.

6 Notice that the status indicator is

now yellow, which means
Mastercam’s and Sync Manager’s
data sets no longer match.

7 Try to select something in the Mastercam window.

Sync Manager retains control, disabling access to Mastercam. You cannot use
Mastercam because the loaded part does not yet contain the changes you
made in Sync Manager.
8 In Sync Manager, click the Save
button.
Sync Manager’s status indicator
turns green.

9 Try to select something in the Mastercam window.

Sync Manager lets you access Mastercam because its data is now up to date.

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 SYNC MANAGER AND MASTERCAM INTERACTIONS 133

Changing Data in Mastercam

1 In Mastercam, click the Geometry
icon in the Lathe Rough operation,
and delete the chain.

Mastercam marks the operation as

dirty.

2 Notice that Sync Manager’s status

icon has changed to a lock.
The lock indicates that the changed
part in Mastercam does not match
the data in Sync Manager.

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3 Rechain the geometry (select Geometry, right-click in the Chain Manager

dialog, and choose Add chain), clicking at the points shown below.

4 Click the Regenerate all selected

operations button.
Mastercam regenerates the
operation, resolving its dirty state.

5 Select all operations, and then click

the G1 button.
Mastercam sends the updated part
data to Sync Manager, whose status
indicator again shows green.

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 SYNC MANAGER AND MASTERCAM INTERACTIONS 135

6 In Mastercam, select File, New. (Do

not save changes to the loaded file.)
Sync Manager’s status indicator
shows red, which indicates that
Mastercam and Sync Manager are
no longer linked.

The table below describes Sync Manager’s status icons.

Sync Manager’s data Sync Manager needs to

matches Mastercam’s be rerun from Mastercam.
data.

Changes in Sync Manager Sync Manager and

need to be saved. Mastercam are
disconnected.

7 Close all windows.

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GETTING STARTED WITH MASTERCAM MILL-TURN

CHAPTER 11
11 More about Machine Simulation
Use Machine Simulation to verify your toolpaths, watching as a graphical representa-
tion of the machine cuts the part. Using Machine Simulation helps you find problems
before the actual machining. (For more information about Machine Simulation, please
read the Machine Simulation tutorial, available from your Reseller or the Mastercam
website.)
The Machine Simulation window has the main areas shown below. Refer to this illus-
tration as you work through the procedures in this chapter.

Quick Access Toolbar Data panes

Ribbon Progress slider

Graphics window
138 MASTERCAM 2017 / More about Machine Simulation

Starting Machine Simulation

1 In Mastercam, open the file CHAP11-PART1, which is included with this book.
Then save the file as CHAP11-PART1-XX, where XX is your initials.
Mastercam’s window should look similar to the following picture.

2 In Toolpaths Manager, click the

Select all operations button.

3 Click the G1 button.

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 STARTING MACHINE SIMULATION 139

Sync Manager opens with the part’s data loaded, as shown below. (Note that
you may or may not see the Machine Explorer and Properties panes,
depending on the state of the application when you last closed it.)

4 In Sync Manager, click the Launch

button.

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140 MASTERCAM 2017 / More about Machine Simulation

The Machine Simulation window appears, as shown in the picture below.

NOTE: If you do not see the tabbed panes on the right side of the
window, you can display them by choosing Docking Panes options from
the View tab. The following exercises require you to display the Move
List.

Running a Simulation
1 Place your mouse over the graphics area, and move your mouse wheel.

The view zooms in or out, depending on the direction you spin the wheel.
2 On the Simulation tab, in the Views
group, click the Fit button.
Machine Simulation zooms the
graphics window to exactly display
its contents.

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 RUNNING A SIMULATION 141

3 Click the Run button.

Machine Simulation simulates the operations in your part. As it does, the

Move List displays the running code, as shown below. (If you do not see the
Move List, choose View, Move List.)

In the Visibility group, click the Machine Housing button.

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142 MASTERCAM 2017 / More about Machine Simulation

The machine housing becomes transparent, as shown in the following picture.

4 Click the Machine Housing button again.

Machine Simulation removes the machine housing from the display.

NOTE: You can choose a specific display

state (Show, Transparent, or Hide) by clicking
the small arrow below a component’s button
and selecting the state from the drop-down
menu.

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 RUNNING A SIMULATION 143

5 In the graphics window, place your mouse pointer over the left spindle, and
use your mouse wheel to zoom in closer, as shown in the following picture.

6 Drag the simulation speed slider to

the left, approximately to the
location shown.
Now when you next start the
simulation, it will run slower than it
did the first time.
7 Click the Restart button.

Machine Simulation resets the

operations to the beginning.

8 Click the Run button.

Machine Simulation simulates the

operations with your new settings.

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144 MASTERCAM 2017 / More about Machine Simulation

9 Drag the Progress slider at the bottom of the screen to move backward and
forward through the simulation.

As you drag the slider, notice how the Move List updates to show the current
operation and move. (If you do not see the slider, increase the size of the
Progress area.)
10 Close the Machine Simulation window.

You do not need to save the part.

GETTING STARTED WITH MASTERCAM MILL-TURN

CHAPTER 12
12 Posting
After you have created your operations and verified them in Machine Simulation, you
are ready to post the part. This process creates the program (G-code) that you send to
your machine control to cut the part.
When you post a part, Code Expert opens the resulting G-code in its editor. The editor
window has the main areas shown below. Refer to this illustration as you work through
the procedures in this chapter.

Quick Access Toolbar Machine Explorer

Ribbon Properties grid

Code pane
146 MASTERCAM 2017 / Posting

Posting a Part
1 Load the file CHAP12-PART1 into
Mastercam, and select all operations
in Toolpaths Manager.

2 Click the G1 button.

Sync Manager opens and displays

the part’s data.

3 In Sync Manager, click the Post

button.
Sync Manager processes the part,
and opens the resulting G-code file
into Code Expert’s Editor.

Note that the code is merged into a single stream, with the code for both
turrets shown in the same pane.

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 USING THE EDITING FUNCTIONS 147

4 In the Utilities group, click Multi-

Stream, and then click OK in the
dialog box that displays.

Code Expert divides the code into two streams, with the upper turret on the
left and the lower turret on the right.

Using the Editing Functions

1 Click NC Configuration.

The NC Configuration dialog box

opens.

2 Click the Block Numbering tab.

The Block Numbering page opens.

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148 MASTERCAM 2017 / Posting

3 Change Starting number and Increment to 10, and click OK.

4 In the Editing group, click Insert

Block Numbers.

The Editor adds block numbers to

the code (see the image to the right)
based on the settings you specified
in the Block Numbering page.

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 USING THE SYNCS AND TOOLS FUNCTIONS 149

5 Click Remove Block Numbers.

The Editor removes the block

numbers from the code.

6 Click Remove Comments.

The Editor removes all comments

from the active stream.

7 On your keyboard, press [Ctrl+Z].

The editor undoes the Remove Comments command.

Using the Syncs and Tools Functions

1 Click in the upper turret stream (the
left-hand stream), and then click
Remove Comments.
Code Expert removes comments
from the stream so that the
following step in this tutorial does
not find sync codes in non-code
lines.
2 In the Syncs group, click First.

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150 MASTERCAM 2017 / Posting

The editor jumps to the first

synchronization code in the file.

3 Click Next three times.

The editor shows the next

synchronization code. (In this
example, you click three times to
skip past two occurrences of Pn that
are not actually sync codes.)

4 In the Tools group, click First.

The editor jumps to the first tool

change in the stream.

Using the Right-Click Menu

1 Highlight a line of code, right-click
the line, and choose Lowercase
from the pop-up menu.
The editor changes the selected text
to lowercase, as shown below.

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 SENDING THE NC CODE TO YOUR CONTROL 151

2 Right-click anywhere in the code,

and select Copy File Path.
The editor places the active file’s full
path into the Clipboard.

3 Place the text cursor where you want to insert the file’s path, and press
[Ctrl+V] to paste the file path into your code.

Sending the NC Code to Your Control

1 Click the CHAP12-PART1-Machine Group-1.iof tab, and then click the Post
button to post the part. (If you are asked to save changes, click No.)
Sync Manager regenerates the NC file.
2 Click the File tab.

The file commands display.

3 Click Options.

The Application Options dialog box

appears.

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152 MASTERCAM 2017 / Posting

4 Open the option group Editor, NC,

Communications.
The communications options appear
in the dialog box’s right pane.

5 Set the communications options

appropriately for your machine
control. (If you are unsure, leave
them set to the defaults.)

6 Click OK to close the Application

Options dialog box.

7 On the NC Functions tab, click the

Send (not Send File) button.

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 MASTERCAM RESOURCES 153

Code Expert sends the G-code file to your machine control.

NOTE: For more information on your machine’s settings and capabili-

ties with Mill-Turn, please refer to the application guide that comes pack-
aged with each machine.

8 Close all windows.

Conclusion
Congratulations! You have completed the Getting Started with Mastercam Mill-Turn
tutorial. Now that you have mastered the skills in this tutorial, explore Mastercam’s
other features and functions.
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 Help—Access Mastercam Help by selecting Help, Contents from
Mastercam’s 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 Reseller—Your local Mastercam Reseller can help with most
questions about Mastercam.

GETTING STARTED WITH MASTERCAM MILL-TURN

154 MASTERCAM 2017 / Posting

 Technical Support—CNC Software’s 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 Tutorials—CNC 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 University—CNC 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).
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:
 What’s New in Mastercam 2017
 Mastercam 2017 Installation Guide
 Mastercam 2017 Administrator Guide

GETTING STARTED WITH MASTERCAM MILL-TURN

 155

 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].

GETTING STARTED WITH MASTERCAM MILL-TURN

156 MASTERCAM 2017 / Posting

GETTING STARTED WITH MASTERCAM MILL-TURN

 157

APPENDIX A
1 Loading Multi-Station Tool Locators
Mastercam 2017 introduces multi-station tool locators (see images below), which offer
extensive flexibility for your machine setup. The examples in this appendix provide an
overview of loading tool locators onto a machine’s turrets, as well as loading tools into
the locators. The complete sample program demonstrates many tool locator and tool
combinations.

 Loading the Part and Processing the Toolpaths

1 Copy the machine file Generic Fanuc Mill-Turn TT.machine into your
C:\Users\Public\Documents\shared Mcam2017\Mill Turn\machines
folder.
You use this twin turret machine for the exercises that follow.
2 Open the file Multi-Station Locators.

The file is included with this tutorial and contains many operations that
require tools be loaded into turrets with multi-station tool locators. After
loading the file, Mastercam should look like the following image:

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158 MASTERCAM 2017 / Loading Multi-Station Tool Locators

3 In Toolpaths Manager, click

Machine Group-1 to select all of
the operations.
If you want to see the operations,
click the plus signs in the list to
expand each group.

4 Click the Post selected operations

button.
Mastercam attempts to process the
operations, but generates tool-
loading errors (see below). These
errors must be addressed before
you can continue.

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 159

5 Click the Cancel button to dismiss the IOF Generation Message Log dialog
box.
The Tool Setup Manager appears, showing the tools that Mastercam loaded
into the upper and lower turrets.

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160 MASTERCAM 2017 / Loading Multi-Station Tool Locators

6 Right-click the upper turret in the

Machine tooling setup list, and
choose Remove all children from
the menu that appears.
Mastercam removes all tool locators
and tools from the upper turret.

7 Right-click the lower turret in the Machine tooling setup list, and choose
Remove all children from the menu that appears.
Mastercam removes all tool locators and tools from the lower turret. Both
turrets are now empty.

 Loading a Tool Locator and Tool

1 From the Tool Locators pane, drag the 7.076.328 - UT - 4 Station - 20mm
Cross Turning- HIPM - LPIU - RPIU tool locator to Index 1 on the upper
turret
Mastercam adds the tool locator to the turret.

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 161

2 In the Machine tooling setup list, right-click the upper turret, and select
View component and all children.

Mastercam displays the components in the graphics window.

3 Rotate the components to the view
shown to the right. Note the four
locations for tools. You load those
tools in the next steps.

4 Press [Enter] to return to the Tool Setup Manager.

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162 MASTERCAM 2017 / Loading Multi-Station Tool Locators

5 From the Tools in the machine group list, drag the tool T01 - OD ROUGH
LEFT - 80 DEG to the location Left - Primary - Insert Up.

6 Right-click the upper turret, and choose View component and all children,
as you did in Step 2.
Mastercam displays the components in the graphics window.
7 Rotate the components so that you can see the tool loaded into the tool
locator.

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 163

8 Press [Enter] to return to the Tool Setup Manager.

 Loading the Remaining Tools in the Tool Locator

1 From the Tools in the machine group list, drag the tool T01 - OD ROUGH
RIGHT - 80 DEG to the location Right - Primary - Insert Up.

2 Drag the tool T24 - OD FINISH LEFT - 35 DEG to the location Left - Half
Index Primary Minus - Insert Up.

3 Drag the tool T24 - OD FINISH RIGHT - 35 DEG to the location Right - Half
Index Primary Minus - Insert Up.

The tool locator is now fully loaded.

4 Right-click the upper turret, and choose View component and all children.

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164 MASTERCAM 2017 / Loading Multi-Station Tool Locators

5 Rotate the components so that you can see the four tools loaded into the tool
locator.

6 Press [Enter] to return to the Tool Setup Manager.

 Loading the Second Tool Locator and Live Mill Tools

1 From the Tool Locators pane, drag the 7.077.128 - UT - 2 Station - ER16
Live Face - Offset Left tool locator to Index 2 on the upper turret.
Mastercam adds the tool locator to the turret.
2 In the Machine tooling setup list, right-click the upper turret, and select
View component and all children.
Mastercam displays the components in the graphics window.
3 Rotate the components to the view
shown to the right. Note the new
tool locator for live tooling.

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 165

4 Press [Enter] to return to the Tool Setup Manager.

5 In the Tools in the machine group list, locate the 8MM FLAT ENDMILL tools.

In the list, these tools’ descriptions look identical.

6 Hover your mouse pointer over the

first 8MM FLAT ENDMILL.
A tooltip describes this tool’s
orientation as Face right.

7 Drag the right-facing 8MM FLAT ENDMILL to the location Right - Live Tool.

8 Drag the other 8MM FLAT ENDMILL (left facing) to the location Left - Live
Tool.
9 In the Machine tooling setup list, right-click the upper turret, and select
View component and all children.
Mastercam displays the components in the graphics window.

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166 MASTERCAM 2017 / Loading Multi-Station Tool Locators

10 Rotate the components to the view

shown to the right, and note the two
live tools for milling.

11 Press [Enter] to return to the Tool Setup Manager.

If you wish, you can continue mounting tool locators and loading tools to complete
the part file. The picture below shows what components are loaded and where. Alter-
natively, this tutorial includes the completed file, Multi-Station Locators -
Complete. You can load this file if you wish to continue without loading the remaining
components yourself.

 Simulating the Operations

Before continuing with this part of the tutorial, you should have all required tools
loaded in the machine or have loaded the complete file Multi-Station
Locators - Complete.

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 167

1 If Tool Setup Manager is still open, click the OK button to close it.

2 In Toolpaths Manager, click

Machine Group-1 to select all of
the operations.

3 Click the Post selected operations

button.

Mastercam processes the operations and opens the part in Sync Manager, as
shown here:

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168 MASTERCAM 2017 / Loading Multi-Station Tool Locators

4 Click the Launch button to start

Machine Simulation.

5 If necessary, click Machine Housing

twice to hide the machine’s housing.

6 Rotate the view so that you can easily see the part stock and the turrets.

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 169

7 Click Run to watch the machine cut the part, paying special attention to the
turrets and their tool locators. As the simulation runs, adjust the view by
panning, rotating, and zooming so that you can see each operation clearly.

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GETTING STARTED WITH MASTERCAM MILL-TURN

 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