IHS Professional Courseware

Mill 2D
Mastercam 2024 IHS Professional Courseware - Mill 2D

Copyright: 1998 - 2024 In-House Solutions Inc. All rights reserved

Software: Mastercam 2024

Date: March 4, 2023

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 Table Of Contents

Getting Started 22

Introduction “What Is “Mastercam“? 23

Who This Book Is For: 23

Programming Techniques Used In Examples: 23

The Mastercam® User Interface: 24

Setting The Grid 25

Conventions Used In This Book: 26

Tutorials Files: 26

Mastercam® Parameter Dialog Boxes: 27

Mastercam® Work Flow: 28

Geometry Tools - Part 1 33

Introduction: 34

Instructor Demonstration Preview: 35

Step 1: Explore Mastercam Interface 35

Step 2: About The Cartesian Coordinate System 38

Step 3: Create Point Position Command 41

Step 4: Create Line Endpoints & Parallel Commands 43

Step 5: Create Rectangle Commands 45

Step 6: Trim Commands 47

Exercise #1 51

Exercise #2 52

Contour Toolpath Part 1 53

Introduction 54

Part Drawing 55

Contour Toolpath Information: 56

Instructor Demonstration Preview: 57

Contour Toolpath Part 1: Basic Steps Reference 57

Step 1: Create And Locate Part Geometry 57

Step 2: Create The Job Setup 60

4
 Step 3: Toolpath Selection 64

Step 4: Set The 2D Toolpath Parameters 66

Step 5: Verify The Toolpath Using Backplot 72

Step 6: Simulate The Toolpath In Verify 74

Step 7: Editing The Toolpath Parameters 77

Step 8: Post Process The Toolpaths 78

Step 9: Save Your Mastercam File 79

Exercise #1 80

Exercise #2 81

Geometry Tools - Part 2 82

Introduction: 83

Instructor Demonstration Preview: 83

Geometry Tools Part 2: Basic Steps Reference 84

Step 1: Create Circles And Arcs Command 84

Step 2: Create Tangent Arcs 86

Step 3: Create Tangent Lines 88

Step 4: Create Fillet Commands 89

Step 5: Create Chamfer Commands 92

Step 6: Break 94

Step 7: Delete Duplicates & Join 96

Step 8: Create Letters 98

Step 9: Other Geometry Creation Tools 98

Exercise #1 100

Step 10: Lab 1 Suggested Steps 101

Exercise #2 103

Contour Toolpath Part 2 104

Introduction 105

Instructor Demonstration 106

Area Mill Toolpaths Information 106

Part Drawing 107

5
 2D Geometry Selection Reference Information: 108

Step 1: Create And Locate Part Geometry 108

Step 2: Create The Job Setup 110

Step 3: Facing Toolpath 114

Step 4: Set The Facing Parameters 114

Step 5: Machine The Open Pocket - Area Mill 120

Step 6: Machine The 4 Corners Using Contour 125

Step 7: Contour The Outside Profile 131

Step 8: Chamfer The Top Of The Part 134

Step 9: Post Process The Toolpaths 137

Step 10: Save The Mastercam File 137

Exercise #1 138

Exercise #2 139

Exercise #3 140

Geometry Manipulation 141

Introduction: 142

Instructor Demonstration Preview: 143

Step 1: Selection Method For Design 144

Step 2: Transform Mirror Command 146

Step 3: Transform Translate Command 147

Step 4: Transform Offset Commands 149

Step 5: Transform Rotate Commands 151

Step 6: Analyze Commands 152

Step 7: Managing Attributes & Levels 155

Attributes 155

Levels 157

Step 8: Chaining - Wireframe Mode 163

Step 9: Analyze Chains And Fix Their Problems 170

Basic Drilling 175

Introduction 176

6
 Instructor Demonstration: 176

Point/Circle Toolpaths Information 177

Part Drawing 178

Step 1: Create The 2D Geometry 179

Step 2: Create The Job Setup 182

Step 3: Drill The Holes 185

Step 4: Drill The 5/8" 4 Holes 190

Step 5: Verify The Part With The Fixture 193

Step 6: Post Process The Toolpaths 193

Step 7: Save Your File 193

Exercise 194

Import CAD Files 195

Introduction: 196

Instructor Demonstration Preview: 196

Step 1: Import A Cad File 197

Step 2: Transform Move To Origin 198

Step 3: Prepare Imported Geometry - Suggested Steps 199

Exercise #1 207

Exercise #2 208

Solids Extrude 209

Introduction 210

Part Drawing 211

Instructor Demonstration Preview 212

Step 1: Setting Up The Graphical User Interface 212

Step 2: Set The Planes Follow Rules 213

Step 3: Set The Construction Plane And Change Wireframe Color 213

Step 4: Create Rectangles Given The Size And Anchor 214

Step 5: Create The Parallel Lines 217

Step 6: Clean Up The Geometry Using Divide 220

Step 7: Remove The Leftover Lines Using Divide 221

7
 Step 8: Chamfer The Inside Rectangle 222

Create The Solid 223

Step 9: Change The Solid Color To Red 223

Step 10: Change The Main Level To 2 223

Step 11: Create The Solid Body 224

Step 12: Create Two Holes 227

Step 13: Using Solids Manager To Modify The Holes 231

Step 14: Add A Boss 233

Step 15: Chamfer The Top Of The Boss 235

Step 16: Save The File 237

Solid Fillet 237

Step 17: Solid Chamfer 240

Solid Extrude - Exercise #1 244

Solid Extrude - Exercise #2 245

Solids & Pocket Toolpaths 247

Introduction 248

Instructor Demonstration 249

Part Drawing 250

Solid Terms 251

Pocket Toolpath - Basic Steps 252

Step 1: Save Machine Group Setup Future Jobs 253

Step 2: Create And Locate Part Geometry 257

Step 3: Select A Machine And Set The Job Setup 261

Step 4: Facing Toolpath 262

Step 5: Machine The Closed Pocket 267

Step 6: Open Pocket Toolpath 273

Step 7: Remachine The Pockets 279

Step 8: Option 2 - Slot Mill The Closed Pocket 285

Step 9: Post Process The Toolpaths 289

Step 10: Save The File 289

8
 Exercise #1 290

Exercise #2 291

Drilling Toolpaths 292

Introduction 293

Instructor Demonstration: 294

Part Drawing 295

Step 1: Open The Soft Jaw Vise 296

Step 2: Merge The Part 296

Step 3: Add Holes To The Part Solid 301

Step 4: Move The Points On Level 1001 303

Step 5: Save The File 303

Step 6: Set The Part Origin 304

Step 7: Create The Job Setup 305

Step 8: Drill The Holes 308

Step 9: Chamfer Drill The 4 Holes 312

Step 10: Tapping The Four Holes 315

Step 11: Verify The Part With The Fixture 318

Step 12: Drill The 1/2" Through Holes 320

Step 13: Circle Mill The Large Holes 322

Step 14: Create A 5/8" Thread Mill 327

Step 15: Set The Thread Mill Cut Parameters 330

Step 16: Post Process The Toolpaths 332

Step 17: Save Your File 332

Exercise #1 334

Advanced Pocket - Dynamic Mill 335

Introduction 336

Instructor Demonstration: 337

Dynamic Toolpaths Information 337

Step 1: Make Visible The Vise 338

Step 2: Set The Stock 340

9
 Step 3: Facing Toolpath 343

Step 4: Dynamic Toolpath To Machine The Bosses 347

Step 5: Machine The Outside Profile Using Dynamic 354

Step 6: Machine The Slot With Contour Ramp 357

Step 7: Slot Mill The Bigger Slot 361

Step 8: Pockets With Different Depths & An Island 365

Step 9: Machine The Two Open Pockets 369

Step 10: Drill The Holes 372

Step 11: Circle Mill The Large Holes 375

Step 12: Remachine The Pockets With Rest Mill 380

Step 13: Remachine The Contour 385

Step 14: Finish The Walls 388

Step 15: Post Process The Toolpaths 393

Step 16: Save Your File 393

Exercise #1 394

Exercise #2 395

Exercise #3 396

2D HST Toolpaths 397

Introduction 398

Instructor Demonstration: 398

Part Drawing 399

2D High Speed Toolpaths (HST) Information 400

Step 1: Create The Stock Using Bounding Box 401

Step 2: Create A Point At The Top Center Of The Part 403

Step 3: Save The Part 404

Step 4: Merge The Vise 404

Step 5: Change The Cplane To Top 406

Step 6: Move The Origin To The Point 406

Step 7: Create The Job Setup 407

Step 8: Facing Toolpath 410

10
 Step 9: Dynamic Mill Toolpath The Outside Shape 413

Step 10: Dynamic Mill To Remove The Inside Material 421

Step 11: Dynamic Mill The Closed Pocket 427

Step 12: Peel Mill To Machine The Inside Center Boss 431

Step 13: Dynamic Rest Mill The Inside Corners 436

Step 14: Finish The Walls Using Contour 441

Step 15: Chamfer The Sharp Edges - Model Chamfer 446

Step 16: Post Process The Toolpaths 451

Step 17: Save Your File 451

Exercise #1 452

Exercise #2 453

2D Blend & Chamfer Drill 454

Introduction 455

Instructor Demonstration: 455

Toolpaths Information 456

Step 1: Create The Job Setup 457

Step 2: Dynamic Mill Toolpath Review 458

Step 3: Stock Model 474

Step 4: Blend Mill - Finish The Floors 476

Step 5: Finish The Walls Using Contour 484

Step 6: Chamfer Drill Toolpath 487

Step 7: Drill The 3/8" Holes 491

Step 8: Model Chamfer Toolpath 493

Step 9: Post Process The Toolpaths 497

Step 10: Save Your File. 497

Review - High Speed Toolpaths 498

Introduction 499

Instructor Demonstration: 500

Step 1: Rename The Toolpath Group 501

Step 2: Contour Toolpath 504

11
 Step 3: Dynamic Toolpath To Rough The Open Pockets 510

Step 4: Rough Out The Inside Pockets Using Dynamic 515

Step 5: Circle Mill The Larger Holes 518

Step 6: Verify The Toolpath 523

Step 7: Compare To Model 523

Step 8: Expand Air Regions 525

Step 9: Stock Model 527

Step 10: Create A Toolpath Group 529

Step 11: Finish Open Pocket Floors - Area Mill 530

Step 12: Finish The Inside Pocket Using Area Mill 535

Step 13: Finish The Left Side Pocket - HS Blend 537

Step 14: Finish The Walls Using Contour 540

Step 15: Finish The Large Holes 544

Step 16: Simulator Options 547

Step 17: Verify The Finish Toolpath 548

Step 18: Create The Stock Model After Finish 549

Step 19: Create Another Toolpath Group 550

Step 20: Spot Drill The Holes -Chamfer Drill 551

Step 21: Drill The Holes 555

Step 22: Create Another Toolpath Group 562

Step 23: Deburr The Sharp Edges - Model Chamfer 563

Step 24: Post Process The Toolpaths 568

Step 25: Save Your File 568

Nesting 570

Introduction 571

Instructor Demonstration: 572

Guidelines And Procedures When Nesting Geometry 573

Geometry Nesting 575

Step 1: Change The Color Of The Holes 576

Step 2: Nesting The Geometry 577

12
 Step 3: Move The Vertical Cut Off 582

Step 4: Create Rectangular Points For The Tabs 583

Machine Nested Parts 586

Step 5: Machine Type 587

Step 6: Drill The 10MM Diameter Through Holes 589

Step 7: Drill The 12MM Diameter Through Holes 593

Step 8: Contour The Outside Profiles 596

Step 9: Machine The Cut Off 601

Toolpath Nesting 606

Step 10: Contour The Left Part 607

Step 11: Contour The Right Part 610

Step 12: Nesting The Toolpaths 614

2D Skills Test 624

Required Skills 625

Skills Test #1 626

Job Description: 626

Skills Test #2 627

Job Description: 627

Appendix - Drawings 628

Contour Part 1 629

Contour Part 1 - Exercise 1 630

Contour Part 1 - Exercise 2 631

Contour Part 2 632

Contour Part 2 - Exercise 1 633

Contour Part 2 - Exercise 2 634

Contour Part 2 - Exercise 3 635

Basic Drill 636

Basic Drill Exercise 1 637

Pocket 638

Pocket - Exercise 1 639

13
Pocket - Exercise 2 640

Advanced Pocket -Exercise 1 641

Advanced Pocket -Exercise 2 642

Advanced Pocket -Exercise 3 643

Manual Drill 644

Manual Drill _ Exercise 1 645

2D HST 646

2D HST - Exercise 1 647

2D HST - Exercise 2 648

Extra Drawings 649

Drawing #1 649

Drawing #2 650

Drawing #3 651

Drawing #4 652

Drawing #5 653

Drawing #6 654

Drawing #7 655

Drawing #8 656

Drawing #9 657

Drawing #10 658

Drawing #11 659

Drawing #12 660

Drawing #13 661

Drawing #14 662

Drawing #15 663

Drawing #16 664

Drawing #17 665

Drawing #18 666

Drawing #19 667

Drawing #20 668

14
Drawing #21 669

Drawing #22 670

Drawing #23 671

Drawing #24 672

Drawing #25 673

Drawing #26 674

Drawing #27 675

Drawing #28 676

Drawing #29 677

Drawing #30 678

Drawing #31 679

15
 Mill 2D Projects
Workspace: Getting Started Topics Covered
n Starting Mastercam.
n Graphical User Interface (GUI).
n Navigate through Mastercam.
n Setting the Attributes.
n Manager Panels.
n Setting Mastercam Unit.
n Setting the Grid.

Exercise 1: Geometry Tools - Part 1 Topics Covered

n The important components of the
Mastercam Interface.
n Important Function Key shortcuts.
n Cartesian Coordinate System.
n How to create a Point knowing its
Position.
n Line Creation - Several line creation
methods with emphasis on Endpoints
and Parallel.
n How to Trim and Extend Lines.
n How to Create Rectangles and
Rectangular Shapes.

Exercise 2: Contour Toolpaths Part 1 Topics Covered

n How to create and locate geometry in
correct orientation for machining.
n How to create the job setup prior to
machining.
n How to select the portions of the model
to machine.
n Contour toolpath parameter selection.
n Verifying the results of the toolpath.
n Making changes to completed
toolpaths.
n Creating programming code to send to
the CNC Machine.

16
Exercise 3: Geometry Tools Part 2 Topics Covered
n Create Circles
n Create Arcs
n Create Fillets
n Create Chamfers
n Break and Join entities
n Delete Duplicate entities
n Create Tangent Lines and Arcs
n Create Letters
n Overview of remaining Wireframe tab Items.

Exercise 4: Contour Toolpath Part 2 Topics Covered

n 2D Geometry Review.
n Locate geometry and Job Setup.
n Facing rough stock.
n 2D High Speed Area Mill to cut an open
pocket shape.
n Removing excess stock.
n Chamfer contour toolpath.
n Multiple techniques for contour chain
selection.
n Chain Manager options.
n Review of basic Mastercam general workflow
procedures.

Exercise 5: Geometry Manipulation Topics Covered

n Transform commands such as Mirror,

Translate, Offset and Rotate.
n Analyze geometry and measurement values.
n Setting and changing attributes of geometry.
n The Mastercam Levels manager.
n Geometry selection techniques.
n The Chaining dialog box.
n Analyzing and fixing problems in chaining.
n Importing 2D geometry.

17
Exercise 6: Basic Drilling Topics Covered

n Bolt Circle command to create the holes.

n Set a cylindrical stock.
n Drilling parameter settings options.
n Verify the toolpaths .
n Post processing Drill operations.

Exercise 7: Import CAD Files Topics Covered

n Importing 2D geometry.
n Set the Origin.
n Scale the geometry.
n Organize the geometry on levels.

Exercise 8: Solids Extrude Topics Covered

n Extrude Create Solid.

n Extrude Cut Solid.
n Extrude Add Boss.
n Solid Hole.
n Solid Fillet.
n Solid Chamfer.

18
Exercise 9: Pocket Toolpath Topics Covered

n Saving Job Setup settings for future usage.

n Extrude Create Solid.
n Extrude Cut Solid.
n Closed Pocket toolpath.
n Open Pocket toolpath.
n Remachining Pocket toolpath.
n Remachining Contour toolpath.
n Slot Mill toolpath.

Exercise 10: Drilling Toolpaths Topics Covered

n Merge / Import a SolidWorks file.

n Align the part in the vise.
n Create the holes using Add History
command.
n Set a stock from a solid.
n Drilling parameter settings options.
n Spot Drilling holes.
n Tapping holes.
n Circle mill operations on large holes with
Flat Endmills.
n Thread Mill toolpath and Thread mill tool.
n Verify the toolpaths with the part and the
fixture displayed.
n Using the Section view option for better
visualization of toolpaths.
n Post processing Drill operations.

19
Exercise 11: Dynamic Mill Topics Covered
n Open the file and check the fixture.
n Setup the part origin.
n Machine the standing bosses using Dynamic
toolpath.
n Cutting the slot shapes using Ramp Contour
toolpath and Slot Mill toolpath.
n Machine open pocket areas, closed pocket
areas and pocket area with Island facing
using a Dynamic toolpath. Machine multiple
pockets at different depths.
n Remachine the pockets using Dynamic
toolpath with Rest Mill option.
n Extracting depth values from the model while
completing parameters.
n Finish the walls using Contour toolpath.
n Machine the outside profile using Dynamic
toolpath.
n Finish the outside profile using Contour
toolpath.

Exercise 12: 2D HST Toolpaths Topics Covered

n Imported a Parasolid model.

n Create the stock using Bounding box
command.
n Merge the vise.
n 2D HST Geometry / boundary selection
rules.
n Setting the 2D HST cut parameters.
n Dynamic Milling toolpaths.
n Dynamic Rest Mill toolpaths.
n Model Chamfer toolpath.

Exercise 13: 2D Blend & Chamfer Drill Topics Covered

n Create a Stock Model.

n High Speed Blend Mill to finish the floors.
n Chamfer Drill toolpath.
n Review of Model Chamfer toolpath.

20
Exercise 14: Review & Compare Topics Covered

n Using Toolpath Groups.

n Review Contour.
n Review High Speed Dynamic Mill.
n Review High Speed Area Mill.
n Compare the machined part to Workpiece.
n Review Stock Model.
n Review High Speed Blend.
n Review Circle Mill.
n Review Chamfer Drill.
n Review Drill.
n Review Model Chamfer.

Exercise 15: Nesting (For router users) Topics Covered

n Geometry Nesting.
n Tabs.
n Toolpath Nesting

21
Getting Started

22
 Getting Started Introduction “What Is “Mastercam“?

INTRODUCTION “WHAT IS “MASTERCAM“?

Mastercam® is the world’s most widely-used CAM software from CNC Software, Inc.
Machine tool programmers can program parts graphically in Mastercam, using the innovative, time tested,
proven toolpaths and machining strategies preferred the most by shops around the world. This book is a
step-by-step “hands-on” book of examples to have you programming quickly without knowing NC Machine
programming languages.

WHO THIS BOOK IS FOR:

This book is for the machine tool programming student who wants to learn how to program parts using
Mastercam. This book is intended to be used as reinforcement exercises as part of classroom training. While
a student can learn from books or videos if they are highly motivated, there is no substitution for the
interaction with a “live” instructor.
This book covers Mastercam Mill (2D toolpaths) and assumes you are new to the Mastercam programming
environment. This book also assumes that the student using this book is familiar with machining processes,
tools and how Numerical Control (NC) machines operate. This book is intended to teach you how to get your
job done using Mastercam.

PROGRAMMING TECHNIQUES USED IN EXAMPLES:

The example exercises in this book can be programmed an infinite number of ways. In fact, any two
programmers would likely approach each part a different way and probably use different tools or toolpaths.
For the exercises in this book, we used settings that were the personal preference or that came from the
experience of multiple Mastercam authorized instructors. All of the examples and exercises have options that
can be set or changed to suit your experiences or company standards.
We chose one method rather than clutter the book with all of the possible options and disrupting the workflow
of the exercises. Utilize the Mastercam Help that is accessible from most dialog boxes whenever you need
more information about options.

23
 Getting Started The Mastercam® User Interface:

THE MASTERCAM® USER INTERFACE:

Mastercam is a complete graphic programming interface that includes built in CAD tools. You will find the
interface to be very streamlined and find it easy to access all of the toolpath generating commands. There
are several places you need to know to access all of the Mastercam commands. The locations for the
Mastercam commands and tools are shown in the screen display below.

Quick Access Toolbar (QAT) allows you to quickly access the most
Quick Access Toolbar
commonly used functions.
Ribbon Tabs Access to all Mastercam commands, features and functions.
Expanded Gallery and Tooltips Additional icons to start toolpaths and hints on the toolpath.
General Selection Bar Used to access AutoCursor settings and selection options.
Mini Toolbar Quick access to attributes.
Quick access to commands relevant to the graphics view and analyze
Right Mouse Click Menu
commands.
Quick Mask Toolbar Used to control entity masking for easier selection.
This is where all toolpath operations you create are stored. They can
Mastercam Toolpath Manager be accessed here for editing the Parameters, Tools, and the
Geometry of the toolpaths.
Toolpath Manager Right
Special commands for working with the operations you have created.
Mouse Click Menu
Managers Tabs Tabs to control which panel is displayed in the Manager panel.
Displays the current WCS, Tool and Construction plane info and
Status bar
current cursor location and also displays the Section View.
The cube hasmany interactive features that let you control the cube
Gview Cube
and thus the on-screen representation of your part.

24
 Getting Started Setting The Grid

SETTING THE GRID

Before starting the geometry enable the Grid. It will show you where the origin of the part is.

File

n Configuration.
n Select Screen from the
configuration Topics.
n Select the plus sign (+) beside
screen as shown.
n Spacing
n X = 0.25.
n Y = 0.25.
n Origin
n X = 0.0.
n Y = 0.0.
n Size = 1.0.
n Select the OK button to exit.

n Select the Yes button to save the

settings in the System
Configuration.

n To see the Grid in

the graphics
window, from the
View ribbon enable
Show Grid as
shown.

25
 Getting Started Conventions Used In This Book:

CONVENTIONS USED IN THIS BOOK:

We have attempted to make this manual as uncluttered as possible and provide you with reference
information when it is appropriate. It is not intended to be a Reference Guide or all-encompassing user
manual.
The text styles used are the following:

Bold Text - Represents menu commands, dialog box settings or other similar items from the screen

Standard Text - Represents normal wording needed to provide you the instruction.

STEP 1: STEP TITLES

1.1 Sub step titles
Information about the current step or terms or parameter definitions describing the parameters.

Note: Represents information about the process step that is important or may require an explanation.

n Bulleted text is step by step instructions that have to be followed.

TUTORIALS FILES:
The training files are Mastercam parts, SolidWorks parts, assemblies or drawing files. These files are
available for download at http://www.emastercam.com/files/.

26
 Getting Started Mastercam® Parameter Dialog Boxes:

MASTERCAM® PARAMETER DIALOG BOXES:

When you begin creating toolpaths with Mastercam® you will be required to supply information so you can
create the toolpath exactly the way you want it. Mastercam® utilizes a tree-style dialog box interface that is
made up of several distinct areas as shown.

Tree View Area Displays a list of all of the available dialog box pages.
Changes with each new Tree Menu item selected. Each page has
Page View Area
selections to be made.
Shows a quick summary of key selections you have made on various
Quick View Settings Area
pages.
Area to Accept and Close, Cancel, Apply or get Help about the
Confirmation Area
displayed page.

27
 Getting Started Mastercam® Work Flow:

MASTERCAM® WORK FLOW:

The process to generate a toolpath will be repeated over and over through the tutorials in this book. You will
find the process simple and straightforward once you have programmed a few parts. Following is an outline
of the process we will follow to create programs:

1. Create the Geometry or Open the CAD file

and select the Machine if it is different than
Default.

2. Transform the Geometry if needed,

identify the work face/view.

3. (Optional) Add extra stock for the fixture.

28
 Getting Started Mastercam® Work Flow:

4. (Optional) Open the fixture.

5. (Optional) Merge the part and align it

into the fixture.

6. Set the part origin using Move to Origin

command.

29
 Getting Started Mastercam® Work Flow:

7. Machine Group Setup to define

the stock size that your part will be
cut from and set tool information.

8. Select a toolpath operation type such as Contour,

Drilling or 2D High Speed Dynamic.

9. Select the geometry of the part you

will cut with the selected operation
using geometry selection tools.

30
 Getting Started Mastercam® Work Flow:

10. Confirm or adjust the Chain direction, Start Point, End Point, etc., if
needed.

11. Fill in the necessary information on

the Parameters pages of the dialog box
that appears for the toolpath type you
choose.

12. Verify the toolpath on your computer

screen to confirm the results are as you
expected, using Backplot and/or Solid
Verify.

31
 Getting Started Mastercam® Work Flow:

13. Make any changes as required by

changing parameters.

14. Regenerate the “Dirty” operation to update the

parameter changes.

Note: To skip this step enable Generate toolpath in the

toolpath parameters before exit it.

15. Verify again to make sure the

toolpath is correct.

16. Convert the graphical toolpath

information into machine code by Post
Processing and sending it to the CNC
machine.

32
Geometry Tools - Part 1

33
Geometry Tools - Part 1 Introduction:

INTRODUCTION:
This lesson will introduce the Mastercam user interface in detail and will also teach you the first geometry
creation tools that you will need for creating your own geometry to define toolpaths or for creating
supplemental geometry to graphically control the toolpath motions in Mastercam. The main goal of the
geometry lessons is to give you the basic understanding of how to create geometry in Mastercam so that you
can practice to become as proficient as your job requires.

OVERVIEW OF EXERCISE:
In this lesson we will become familiar with the Mastercam screen components and learn tools and shortcuts
to begin creating basic geometry shapes.

NEW CONCEPTS COVERED IN THIS LESSON:

n The important components of the Mastercam Interface.
n Important Function Key shortcuts.
n Cartesian Coordinate System.
n How to create a Point knowing its Position.
n Line Creation - Several line creation methods with emphasis on Endpoints and Parallel.
n How to Trim and Extend Lines.
n How to Create Rectangles and Rectangular Shapes.

34
Geometry Tools - Part 1 Instructor Demonstration Preview:

INSTRUCTOR DEMONSTRATION PREVIEW:

Note: This entire lesson is a joint Instructor / Student exercise. No instructor demo for this lesson.

Topics

GEOMETRY TOOLS PART 1: BASIC STEPS REFERENCE

In this first lesson the students and instructor will work through the topics as a group.

STEP 1: EXPLORE MASTERCAM INTERFACE

MASTERCAM INTERFACE VIDEO

1.1 Load the part: MCAM

INTERFACE.MCAM
We will do a “Preview” of some of the different
components of the Mastercam screen. The goal is
just to see where things are, not to master their
usage yet.

35
Geometry Tools - Part 1 Step 1: Explore Mastercam Interface

1.2 Tabs - Buttons -

Submenus - Tooltips
Like many Windows programs,
many have submenus or options.
We will not go through any uses at
this point, just review how they
work.

1.3 Quick Access Toolbar

User can customize it to add often used functions by right-
clicking beside the toolbar or selecting the drop down menu.

1.4 The Esc (Escape) Key

(Master key for ending most functions)

1.5 The View Tab

Provides access to many
of the options to control
the Mastercam layout.

1.6 Zoom Commands

(Since these commands are used extensively, it may be useful to memorize
the keyboard shortcut keys)

n Fit (Alt+F1)
n Zoom Window (F1)
n Un-Zoom 80% (Alt+F2)
n Un-Zoom Previous / 50% (F2)
n Repaint (F3)

36
Geometry Tools - Part 1 Step 1: Explore Mastercam Interface

1.7 Graphic Views

Standard View Choices RMB (Right Mouse Button
options) Free Spin rotation with middle mouse button
Zoom in and out with middle mouse wheel

1.8 Appearance
n Wireframe Choices
n Shaded Choices
n Appearance
n Stock Display options

Shaded and Wireframe Display of Solid Alt+S

1.9 Axis and Gnomon Display

n F9
n Alt+F9

1.10 The Managers Panel

(Preview of the location and purpose only. Functions to
be covered when needed.)

1.11 MRU (Most Recently Used) Panel Preview

37
Geometry Tools - Part 1 Step 2: About The Cartesian Coordinate System

1.12 Quick Mask Preview

1.13 Status Bar

1.14 Wireframe Tab preview

STEP 2: ABOUT THE CARTESIAN COORDINATE SYSTEM

Cartesian Coordinate System

For Mastercam to display a part, you must define its exact shape, size, and location. You can do this by
drawing lines, arcs, points, solids, surfaces and other geometric entities that precisely describe the part.
These geometric entities exist in a Cartesian Coordinate System.
A Cartesian Coordinate System consists of two or three perpendicular number lines (coordinate axis). A
number line is a line divided into equal segments. The point on the line designated as zero is called the
Origin.
The Cartesian Coordinate System allows you to define each point uniquely in a plane using a pair of
numerical coordinates, which are the signed distances to the point from the origin, measured in the same unit
of length.

38
Geometry Tools - Part 1 Step 2: About The Cartesian Coordinate System

A two-dimensional Cartesian Coordinate System consists of two

number lines set at a 90-degree angle to each other. One line is
horizontal (left to right) and is labeled as the X-axis. The other is
vertical (up and down) and labeled as the Y-axis. The point where the
axes cross is the Origin as shown.
All points in this space, also called a Plane, or Construction Plane,
are precisely defined given its axes label, sign, and value.
Cartesian coordinates may be written in two different ways. One
uses the axis label, sign and value. For example: X3 Y2.
The other writes coordinates as an Ordered Pair. Numbers are
written in a specific order (X, Y) separated by commas. For example:
3,2.
If the point is defined in 3D, the coordinate of the Z value should
follow the Y value.

Absolute coordinates are always in reference to the Origin,

regardless of the previous position. Starting at the Origin, the diagram
shows a move to N1 and then to N2, written in absolute coordinates

Incremental coordinates (sometimes called Delta or Rectangular

coordinates) are always in reference to the current position. This
example, shows a move to N1 starting at the Origin, and then to N2,
written in incremental coordinates.

39
Geometry Tools - Part 1 Step 2: About The Cartesian Coordinate System

Polar Coordinates are always in reference to a position (called the

Anchor Point), a Distance and an Angle. Starting at the position (X2,
Y1), this figure shows a move to N2, written in polar coordinates.

A plane can be divided along its axes into four

quadrants. Starting in the upper-right corner and
moving Counterclockwise, the quadrants are labeled: I,
II, III, IV. It's important to know which quadrant the part
is in because the sign of the coordinates changes
based on the quadrant.

40
Geometry Tools - Part 1 Step 3: Create Point Position Command

STEP 3: CREATE POINT POSITION COMMAND

Note: The following instructor led training exercises cover different basic geometry creation commands.
The student has to complete the right side geometry based on the left side geometry and dimensions.

Create Point Position

3.1 Open CREATE_POINT_

POS.MCAM

n From the QAT, select the Open icon.

n Select CREATE_POINT_POS.MCAM.

3.2 Set Auto Cursor in the

Selection Bar
Instructor recommended settings.
n From the General Selection
Toolbar select the AutoCursor
Configuration icon.
n Set the settings as shown.
n Select the OK button to accept the
changes.

3.3 Wireframe / Point Position

41
Geometry Tools - Part 1 Step 3: Create Point Position Command

n Create the points on the right side to match the left side.
n Use the AutoCursor options to insert the points at the Endpoint,
Midpoint, Intersection, Quadrant, Origin and Center locations.
As Mastercam detects and snaps to the points, it displays a
temporary square over the point and the corresponding cursor icon.

n Enter the coordinate values for the first point as shown.

n Press Enter from the keyboard to see the point created.
n Press Enter again to finish.

n Enter the coordinate values for the second point as

shown.
n Press Enter from the keyboard to see the point created.
n Select the OK button to exit the command.

Note: Mastercam can perform simple math operations

such as addition, subtraction, multiplication and division.
The instructor can also demonstrate how to change to
Relative when entering the coordinates.

42
Geometry Tools - Part 1 Step 4: Create Line Endpoints & Parallel Commands

STEP 4: CREATE LINE ENDPOINTS & PARALLEL COMMANDS

Create Lines

4.1 Open CREATE_LINES.MCAM

n From the QAT, select the Open icon.

n Select CREATE_LINES.MCAM.

4.2 Wireframe / Line Endpoints

n Enable the Horizontal option in the Line

Endpoints panel.
n Sketch the endpoints of the horizontal line
approximately at the same location from the X
and Y axes as per the left side drawing.
n In the Axis Offset box enter 1.5 as the
Y coordinate.
n Press the Enter key to position the line.
n Press Enter again to finish the line or select
the OK and Create New Operation button

to continue in the same command.

n Enable the Vertical option in the Line

Endpoints panel.
n Sketch the endpoints of the vertical line
approximately at the same location from the X
and Y axes as per the left side drawing.
n In the Axis Offset box enter 1.0 as the
X coordinate.
n Press the Enter key to position the line.
n Press Enter again to finish the line or select the
OK and Create New Operation button to
continue in the same command.

43
Geometry Tools - Part 1 Step 4: Create Line Endpoints & Parallel Commands

n Select the Freeform button in the Line

Endpoints panel.
n Type the coordinate values for the first point
(-1.25,-0.5) and press Enter.

Note: Select the AutoCursor Fast Point

icon if needed to open the coordinates’ field.

n Type the coordinate values for the second

point (-2.5,-1.75) and press Enter.
n Select the OK and Create New Operation
button to continue in the same command.

n In the Line Endpoints panel, input a

Length of 3.0 and an Angle of -
25.0.
n Pick the Origin (center of the Grid)
as the first endpoint.
n Select the OK button to exit the
command.

REFERENCE INFORMATION - Angle Measurement

Mastercam measures positive angles in a Counter Clock Wise (CCW) direction as shown in the following
picture. It also creates the arcs in a CCW direction.

Note: The same angle can be given as a positive angle 335 degrees or as a negative value -25 degrees.

44
Geometry Tools - Part 1 Step 5: Create Rectangle Commands

4.3 Wireframe / Line Parallel

n Select the existing line and indicate the offset direction by

clicking below the existing line
n In the Line Parallel panel, enter an Offset Distance of 0.5.
Press Enter.
n Select the OK button to exit the command.

STEP 5: CREATE RECTANGLE COMMANDS

Create Rectangle

5.1 Open CREATE_RECTANGLE.MCAM

n From the QAT, select the Open icon.

n Select CREATE_RECTANGLE.MCAM.

5.2 Wireframe / Rectangle

45
Geometry Tools - Part 1 Step 5: Create Rectangle Commands

n In the Rectangle panel, enter the

Width 2.0 and the Height 1.0.
Press Enter.
n Enable Anchor to the center.
n Use AutoCursor Fast point icon
and enter the coordinates
(2.0,2.5).
n Press Enter to locate the
rectangle.
n Press Enter again to finish the
rectangle.

n In the Rectangle panel, enter the Width 1.0 and the Height
1.0. Press Enter.
n Disable Anchor to the center.
n Use AutoCursorFast point icon and enter the coordinates
(3.0,0.75).
n Press Enter to locate the rectangle.
n Press Enter again to finish the rectangle.

5.3 Wireframe / Rectangular

Shapes

46
Geometry Tools - Part 1 Step 6: Trim Commands

n In the Rectangle panel, select the Obround shape.

n Enter the Width 2.0 and the Height 1.0. Press
Enter.
n For Origin select the left lower corner.
n Use AutoCursor Fast point icon and enter the
coordinates (0.5,0.5).
n Press Enter to locate the Obround.
n Select the OK button to exit the command.

STEP 6: TRIM COMMANDS

Trim

6.1 Open TRIM.MCAM

n From the QAT, select the Open icon.

n Select TRIM.MCAM.

6.2 Wireframe / Dynamic

Trim

47
Geometry Tools - Part 1 Step 6: Trim Commands

Trim 1 entity

Trim 1 entity: trims or extends one entity

to its intersection with a second entity
without modifying the second entity.

n In the Dynamic Trim panel, make sure

that the Type is set to Trim.
n As Method, enable Trim 1 entity.
n Select the entity you wish to trim/extend
and the entity you want to trim/extend
the selected entity to. When you
choose the entity to trim/extend and
hover over the entity you wish to
trim/extend it to, a lighter color line will
appear showing you what the result of
the trim/extend will be.

Note: You can also click outside of the line to be extended, hold down
the mouse and drag the cursor over the line and up to the line to trim to
as shown. Some times this method might be harder to use. Both
methods are valid.

Trim 2 entities

Trim 2 entities: trims or extends both entities to their

intersection.

n In the Dynamic Trim panel, enable Trim 2

entities.
n Select the first entity you wish to trim and then
move the cursor over to the second entity.
n When you move the cursor over the second entity
you should see some hidden lines. These lines
represent what will be trimmed as shown. Ensure
that you select the end of the entity you intend to
keep.

Note: You can also click outside of the corner, hold down the
mouse and drag the cursor around the corner in the area to keep
the lines after trimming as shown.

48
Geometry Tools - Part 1 Step 6: Trim Commands

Trim 3 entities

Trim 3 entities: trims or extends all three entities. The

first two entities that you select are trimmed to the third
selected entity, which acts as a trimming curve. The
third entity is then trimmed to the first two entities.

n In the Dynamic Trim panel, enable Trim 3 entities.

n Select the entities to trim on the side that you want to
keep after trimming as shown. Ensure that you select
the entities in the order shown.

Note: You can also click outside of one of the parallel line, hold the
mouse down and drag the cursor above the other parallel line and to
the line up to which both parallel line are trimmed as shown.

Divide

Divide: trims a line or an arc into two disjointed segments by removing

the segment that lies between two dividing entities. When you move
your mouse cursor over the point where you wish to divide the entities
a hidden line should appear showing you the entities which will be
removed. Divide will delete isolated entities with no intersections.
Entities with a single point of intersection at an endpoint will also be
deleted.

n Click on the Divide icon.

n Select the parts of the entity to be removed as shown.

Note: You can also, hold the mouse down and drag the cursor
above the areas that need to be removed creating a path as
shown.

49
Geometry Tools - Part 1 Step 6: Trim Commands

Trim to point

Trim to point: trims or extends a curve to a point or

any defined position in the graphics window. If the
point that you enter does not lie on the selected
entity, Mastercam calculates the closest position on
the entity and trims the entity to that point.

n In the Dynamic Trim panel, enable Trim to point.

n Select the line and then pick the point. The line will
be extended to be perpendicular to the point.
n Select the OK button to exit the command.

SUMMARY:
In this first hands-on lesson, you were introduced to several of the basic procedures you will soon learn to
use over and over again to create geometry as needed so you can generate toolpaths accurately. After
completing this lesson and some of the practice exercises that follow you should be able to:
n Have an understanding of where to find items in Mastercam.
n Create Point Position.
n Create Line Endpoints.
n Create Parallel Lines from an existing line.
n Delete Entities and Undelete Entities (Lines)
n Create Rectangles and Rectangular Shapes.
n Divide.
n Trim and Extend Lines.
n Use the Windows “Undo and Redo” functions.

50
Geometry Tools - Part 1 Exercise #1

EXERCISE #1

Job Description:

Create the geometry as described in the part file with the following requirements:
n Open the Mastercam part: GEOMETRY TOOLS PART - LAB 1.
n Follow the file instructions to complete the 5 Exercises.
n Save your part and have the Instructor confirm your results.

51
Geometry Tools - Part 1 Exercise #2

EXERCISE #2

Job Description:

Create the geometry required to as shown above with the following requirements:
n Open the Mastercam part: GEOMETRY TOOLS PART - LAB2
n Create Exercises # 1 through #5 as time allows.
n Save your part and have the Instructor confirm your results.

52
Contour Toolpath Part 1

53
 Contour Toolpath Part 1 Introduction

INTRODUCTION
This lesson will introduce the basic procedures for generating a toolpath with Mastercam. The toolpath will
consist of simple open contours. The main goal of these tutorials is to introduce you to the procedures that
will be followed to program most parts in Mastercam. The process steps used in this lesson will be followed
on all exercises in this book (as needed).

CONTOUR STYLE TOOLPATHS:

Contour toolpaths remove material along a path defined by a chain of edges . Contour toolpaths only follow a
chain; they do not clean out an enclosed area.

OVERVIEW OF EXERCISE:
In this lesson we will machine the two steps shown by using 2D contour cuts with a Flat Endmill.

NEW CONCEPTS COVERED IN THIS LESSON:

n How to create and locate geometry in correct orientation for machining.
n How to create the job setup prior to machining.
n How to select the portions of the model to machine.
n Contour toolpath parameter selection.
n Verifying the results of the toolpath.
n Making changes to completed toolpaths.
n Creating programming code to send to the CNC Machine.

54
Contour Toolpath Part 1 Part Drawing

PART DRAWING

55
 Contour Toolpath Part 1 Contour Toolpath Information:

CONTOUR TOOLPATH INFORMATION:

The following are brief descriptions of the toolpath types available for Contour Cut Parameters. (For more detailed
information, see the Mastercam Help while on the parameter page of the Contour Toolpath dialog box.)

Contour Types

2D Contours are used to rough and finish part walls. Multiple

depths and passes can be applied to control stock removal and
finish quality.

3D Contours are used for simple ramps and trimming cuts.

Cutter moves in X, Y, and Z direction simultaneously.

2D Chamfers are used to bevel the edge of a 2D contour.

Ramp Contours allows you to transition smoothly between

depth cuts instead of individual plunge cuts.

Remachining Contours are 2D contours that remove material

only in areas where stock remains from previous finishing
operations.

Oscillate Contours move the cutter up and down in the Z

direction while
following the 2D path. This allows more of the cutting tool to be
used and can reduce wear. It is also useful for cutting thinner
materials.

56
 Contour Toolpath Part 1 Instructor Demonstration Preview:

INSTRUCTOR DEMONSTRATION PREVIEW:

Note: This entire lesson is a joint Instructor / Student exercise. No instructor demo for this lesson.

Topics

n Create 2D Geometry
n Job Setup
n Single Chain Contour
n Contour Parameters
n Verify Toolpaths
n Changes

CONTOUR TOOLPATH PART 1: BASIC STEPS REFERENCE

STEP 1: CREATE AND LOCATE PART GEOMETRY

In this step you will create the geometry using the following commands: rectangle, line parallel, line
endpoints and delete.

Step Preview:

1.1 Start a new file and save it as CONTOUR-1.MCAM

n To start a new file, from the Quick Access Toolbar (QAT) select New
icon, or press Ctrl + N

n To save the file as CONTOUR-1, from the QAT, select Save as icon
or press Ctrl + Shift + S.

57
 Contour Toolpath Part 1 Step 1: Create And Locate Part Geometry

1.2 Set the Grid

The Grid allows you to visualize where
the origin is.

n From File
n Select Configuration.
n In the Topics, expand the Screen and
select the Grid.
n Leave the defaults in the Spacing and
the Origin and change the Size to 1.0.
n Select the OK button and accept to
save the settings to the configuration
file.
n In the View tab, make sure that Show
Grid is selected.

1.3 Create a Rectangle

n Use Wireframe / Rectangle.
n Set the Width to 5.0 and the Height to 3.5.
n Anchor to center disabled.
n Set the Origin to the lower left corner.
n Select the OK button to exit the command.

1.4 Create Parallel Lines

(For construction purpose only)
n Use Wireframe / Line Parallel.
n Set the Distance to 1.0 and lock it.

58
Contour Toolpath Part 1 Step 1: Create And Locate Part Geometry

n Select the top horizontal line.

n Click below the line to indicate the offset
direction.
n Select the bottom horizontal line.
n Click above the line to indicate the offset
direction.
n Select the OK button to exit the command.

n The geometry should look as shown.

1.5 Create Line Endpoints

n Use Wireframe / Line Endpoints.
n Make sure Freeform and Two endpoints are enabled
in the Line Endpoints panel.

n Select the endpoints as shown.

59
 Contour Toolpath Part 1 Step 2: Create The Job Setup

1.6 Delete the construction lines

n Select the lines.
n Press Delete key.

1.7 Save your part

STEP 2: CREATE THE JOB SETUP

In this step you will supply Mastercam with information about tool settings and stock size before starting to
create the toolpaths.

Step Preview:

2.1 Load the Mill Default if needed

n From the Machine tab, select Mill and

Default.

n Expend the Machine Group Properties.

n Select the Stock setup as shown.

60
Contour Toolpath Part 1 Step 2: Create The Job Setup

2.2 Set the Stock

n Make sure that Show wireframe entities is enable as

shown.
n Select the Create rectangular stock button.

61
Contour Toolpath Part 1 Step 2: Create The Job Setup

n Press Ctrl + A to select all the entities from the screen.

n Set the Origin as shown.
n Enter Z = 1.5. (Value obtained from the 2D Drawing)

Note: The check mark should be in front of the Rectangular 1. Otherwise,

Right mouse click on the Rectangular 1 and select Set as active stock.

n Right mouse click in the graphics window and select the

Isometric view.
n The stock should look as shown.

n Select the OK to accept and close Bounding Box.

62
Contour Toolpath Part 1 Step 2: Create The Job Setup

2.3 Set the Tools page

n Select the Tools and change the parameters as shown.

n Feed Calculation set to From Tool.
n Enable Assign tool numbers sequentially.
n Expand the panel, and enable Override defaults with
modal value and check all options.
n Select the OK to accept and close the Machine

Group Properties.

n To check the stock, in the Toolpaths ribbon you

can enable Stock display.

n The stock should look as shown.

63
 Contour Toolpath Part 1 Step 3: Toolpath Selection

STEP 3: TOOLPATH SELECTION

This is the most involved portion of the Mastercam programming process. During this section you will
select the portions of the geometry that the CNC tool will cut. You will also set the Contour toolpath
parameters.

3.1 Wireframe Chaining Wireframe Chaining

REFERENCE INFORMATION
C-Plane - allows you to select geometry in the current construction plane.
3D - allows you to select 3D geometry.
Options - lets you refine the way Mastercam chains entities.
Chain - allows you to select entities that form a chain.
Partial - creates an open chain by selecting the first entity and the last entity of the
chain. Other controls let you manage the selection process.
Window - allows you to select entities by drawing a rectangle around them.
Polygon - to select entities inside of a multi sided irregular window that you draw
around the entities.
Point - allows you to select a point that can be used as starting point.
Area - allows you to select closed boundaries around a point where you click the
mouse.
Single - allows you to select one entity.
Vector - creates chains from entities that intersect a vector line.
Last - reselects entities chained during the previous operation.
End Chain - forces the end of the chain.
Chain Similar- instructs Mastercam to add chains based on criteria set in the
Options.
Chain Similar Option - allows you to set the way Mastercam can recognize
related chains.
Unselect.
Display all selection arrows.
Previous - used to move the end of the chain back to the end of the previous entity in
the chain.
Adjust - used to guide the chaining when a branch point has been reached and allows
you to select a different direction or entity.
Next-used to guide the chaining when a branch point has been reached and allows you
to continue in the direction of the red arrow.
Start point Back
Start point Forward
Dynamic - moves the start or end of a selected chain to any position along an
entity, without restricting the start/end to an entity endpoint.
Reverse - swaps the chain direction.
End point Back
End point Forward

64
 Contour Toolpath Part 1 Step 3: Toolpath Selection

3.2 Select the Contour toolpath

n From the Toolpaths tab

select the Contour icon.

n Select the Single button from the Chaining dialog box.

n Make sure the Single button is enabled in the

Chaining dialog box and select the Contour
Chain 1 by selecting this line near the end you
want the cutter to start.
(Make sure the Green start arrow is at this end. We
want the cut direction as shown so the tool cuts with
a “Climb Cut” direction.)

65
 Contour Toolpath Part 1 Step 4: Set The 2D Toolpath Parameters

n Select the Contour Chain 2 by selecting this line near

the end you want the cutter to start.
n In the Wireframe Chaining dialog box, click on the
Display all selection arrows to see the arrows
on the first selected chain as well.
n Select the OK button to end the selection.

STEP 4: SET THE 2D TOOLPATH PARAMETERS

Step Preview:

n Contour dialog box appears on the screen as shown.

REFERENCE INFORMATION
All Mastercam toolpaths utilize the Tree
View List. Mastercam Help provides a
complete description of each parameter
available. For purposes of each tutorial,
only the parameters used will be
discussed. As you click each item in the
Tree View List, you will be provided
options to change settings relevant to that
main setting title. The Quick View
Settings gives you a quick look at several
settings as they are currently are set.

Note: In the following steps you will be setting the parameters to generate the Contour toolpath.

66
 Contour Toolpath Part 1 Step 4: Set The 2D Toolpath Parameters

4.1 Toolpath Type

n The Contour icon is already selected. If needed,

you can reselect the 2 chains in the Chain
geometry area.

4.2 Tool
In the following steps you will choose a ¾” Flat Endmill from the Library of tools provided by Mastercam.
You will use the Filter option to search through the tool library for a specific tool type which makes it easier
and quicker to find the desired tool.

n From the Tree View List,

select Tool and click on the
Select library tool button as
shown.

n Select the
Filter button
as shown.

(The Filter button

will allow searching
through the tool
library for a specific
tool type to make it
easier and quicker
to find the desired
tool)

67
Contour Toolpath Part 1 Step 4: Set The 2D Toolpath Parameters

n Select the None button to

de-select all tool types and
clear the filter.
n Select the Flat Endmill tool
type.

Note: You can hover your

cursor over the icons to see
what tool type is represented
by each icon.

n Confirm that the rest of your

settings match the
screenshot as shown.
n Select the OK button to exit
the Tool List Filter dialog
box.

n Select the ¾" Flat

Endmill from the
filtered list and click the
OK button.

68
 Contour Toolpath Part 1 Step 4: Set The 2D Toolpath Parameters

n Enable Rapid Retract to force the tool to retract from the part at the rapid feed rate set at the machine.
n In the Comment area, enter a description of what the toolpath does. This will be part of the program to
assist the operator of the machine to identify what this part of the program does. In this example enter
“Contour the two ledges” as shown.

Note: The Feed rate, Plunge rate and Spindle speed are based on the tool definition. You can change
them as needed.

69
 Contour Toolpath Part 1 Step 4: Set The 2D Toolpath Parameters

4.3 Cut Parameter

Cut Parameters page allows you to set the Contour parameters such as cutter compensation type and
direction.

Compensation Type

n From the Tree View

List, select the Cut
Parameters and set the
Compensation type to
Wear as shown.
n The rest of the settings
should match the default
values as shown.

Note: Using Wear allows you to output Control codes for compensation as well as calculating the
compensation in Mastercam. Using this method, the operator can add compensation as the tool wears.

4.4 Lead In/Out

Lead In/Out page allows you to set the entry and/or exit movements as a combination of a line and an arc.

LeadInOut

n From the Tree View List, select Lead

In/Out and make sure that Lead In/Out
is enabled.
n In the Entry area set the rest of the
parameters as shown.
n Select the Double Arrow to copy all
values to the Exit values.

Note: By setting the Radii to 0 the arc

moves are eliminated. The Lines set to
Tangent and 100% of the tool diameter,
will extend both ends of the contour by
0.75".

70
 Contour Toolpath Part 1 Step 4: Set The 2D Toolpath Parameters

4.5 Linking Parameters

Linking Parameters page allows you to define the Clearance, Retract, Feed plane, Top of stock and
Depth heights.

Linking

n From the Tree View List, select

Linking Parameters and set the
values as shown. Make sure to
enable Absolute or Increment
settings as shown.

REFERENCE INFORMATION
Absolute values are always measured from the origin (0,0,0).
Incremental values are measured relative to chained geometry or other parameter values.
Associative values are measured relative to a selected point on the feature. Use Select point to choose the
point from which the associative value will be measured.
Arc fit maximum radius attempts to fit 90 degrees arc moves into rapid and clearance moves. If not
possible it creates 180 degrees arcs.
Output feed move outputs the rapid moves between passes as feed rate moves.
Clearance sets the height at which the tool moves to and from the part. If it is not selected, the Retract value
is used as the clearance plane. You can set a point on the geometry or manually enter a value.
Retract sets the height that the tool moves up to before the next tool pass.
Top of Stock sets the height of the material in the Z axis. To set absolute values, click the button and select
a point on the geometry or manually enter a value. Incremental values are measured from the chained
geometry.
Depth determines the final lowest machining depth. To change absolute depth, choose the Depth button
and select a point on the geometry or enter a value manually. Incremental values are relative to the
chained geometry – not the top of the stock.

71
 Contour Toolpath Part 1 Step 5: Verify The Toolpath Using Backplot

4.6 Coolant

n From the Tree View List, select

Coolant and turn the Flood on
as shown.

n Select the OK button to exit

2D Toolpaths - Contour.

n The toolpath should look as shown.

STEP 5: VERIFY THE TOOLPATH USING BACKPLOT

Backplot shows the path the tools take to cut the part. This display lets you spot errors in the program before you
machine the part. As you backplot toolpaths, Mastercam displays additional information such as the X, Y, and Z
coordinates, the path length, the minimum and maximum coordinates, and the cycle time.
Backplotting is the quickest way to confirm the toolpath. With backplot, you do not see material being removed,
you only see tool motion compared to the finished part.

n Make sure the toolpath is selected as shown.

n Select the Backplot selected operations button.

72
 Contour Toolpath Part 1 Step 5: Verify The Toolpath Using Backplot

n The Backplot dialog box opens as shown.

BACKPLOT REFERENCE INFORMATION

Display with color codes displays the toolpath with different colors when a feed rate or rapid
movement is being completed.
Display tool shows the tool, as defined in the Define Tool dialog boxes. Any tool shape can be
displayed. You can draw form cutters and Mastercam will display them during backplot and verification.
Display holder shows the holder, as defined in the Define Tool dialog.

Display rapid moves shows rapid moves; usually moves between cuts. By default, rapid moves are
yellow, but this can be changed in the Options, Appearance dialog box.
Displays endpoints draws a small white dot at the end of every arc and line move.
Quick verify shows a colored path where the tool cuts. This is useful for making sure the tool cleans
up an area.
Options allows you to set the Backplot display options.
Restrict drawing removes all plotted toolpaths from the screen, so only those next backplotted
toolpaths will be displayed.
Remove restrict drawing reverts back to displaying all of the toolpaths.
Save tool geometry allows you to save the profile of the tool as geometry.

n You can step through the Backplot by

using the Step forward or Step back
buttons.
n You can adjust the speed of the backplot.

n Select the Play button to run Backplot.

n The toolpath should look as shown.

n From the Backplot panel, select the OK
button to exit Backplot.

73
 Contour Toolpath Part 1 Step 6: Simulate The Toolpath In Verify

STEP 6: SIMULATE THE TOOLPATH IN VERIFY

Verify Mode shows the path the tools take to cut the part with material removal. This display lets you spot
errors in the program before you machine the part. As you verify toolpaths, Mastercam displays additional
information such as the X, Y, and Z coordinates, the path length, the minimum and maximum coordinates,
and the cycle time. It also shows any collision between the workpiece and the tool.

n From the Toolpaths Manager, select Verify

selected operations icon as shown.

Note: Mastercam launches a new window that

allows you to check the part using Verify.

n In Mastercam
Simulator, Visibility
group, enable only Tool,
Stock, Wireframe and
Fixtures.

VERIFY REFERENCE INFORMATION

6.1 Home Tab:

Mode toggles between Backplot and Solid Verify.

Playback provides settings for display during the verify playback.
Visibility sets the options for tool, workpiece, stock and other components to display.
Defaults sets and reads settings as user likes them.

74
 Contour Toolpath Part 1 Step 6: Simulate The Toolpath In Verify

6.2 View Tab:

3D View controls the view similar to those in the Mastercam screen.

Focus determines the center of focus during playback.
Viewports allows viewing simulation from multiple directions simultaneously.
Show determines whether to display tool motion movements or Collisions during playback.
Utilities allows you to select a motion controller rotation position and to synchronize the views between
Mastercam and Simulator.
Verify Tab:

Provides multiple options to control display of the part during backplotting or verification.
(See the Mastercam Simulator Help for further information.)

n Select the Play button

to run Verify.

n The part should appear as shown.

75
Contour Toolpath Part 1 Step 6: Simulate The Toolpath In Verify

n In the Visibility group disable Wireframe to remove it from

the graphics window.

n Select the Verify tab and enable Color

Loop, Collision Checking and Show
Edges.

Note: To rotate the part, move the cursor to the center of the part and click and hold the mouse wheel
and slowly move it in one direction. To zoom in or out, scroll up or down the mouse wheel as needed.
To see the part in Isometric view, right mouse click in the graphics window and select Isometric.
To fit the part on the screen, right mouse click and select Fit.
To check the part step-by-step, click on the Step Forward to see the tool moving one step at a time.

n When finished verifying, Minimize the Mastercam Simulator Window to leave it

open or move it on a separate monitor.

76
 Contour Toolpath Part 1 Step 7: Editing The Toolpath Parameters

STEP 7: EDITING THE TOOLPATH PARAMETERS

Mastercam allows you to make changes to your geometry and any parameters or settings without requiring
you to start over. In this example, we will modify the toolpath parameters to add multiple passes to remove
the remaining material we discovered during Verify.

n To re-open the Contour parameters dialog box, select the

Parameters icon from the Toolpaths Manager as
shown.

7.1 Multi Passes

Multi Passes

n From the Tree View

List, select Multi
Passes and enable the
page as shown.
n Set the Rough
parameters as shown:
n Number = 3.
n Spacing = 0.375.

n Set the Finish

parameters as shown:
n Number = 1.
n Spacing = 0.05.
n Select the OK button to
exit
2D Toolpaths -
Contour.

Note: Since we changed parameters, Mastercam recognizes the toolpath needs to be regenerated and
marks it as “Dirty” (red X) in the Toolpaths Manager.

7.2 Regenerate the Dirty Operation

n Select the icon to Regenerate all Dirty Operations as

shown.

77
 Contour Toolpath Part 1 Step 8: Post Process The Toolpaths

7.3 Repeat the Backplot procedure

n The toolpath should look as shown.

7.4 Repeat the Solid Verify procedure

n The part after being verified in Mastercam

Simulator should look as shown.
n When finished verifying, Close Mastercam
Simulator.

STEP 8: POST PROCESS THE TOOLPATHS

We now will take the toolpath information we have created and convert it to a language that the machine
tool can read. This process is called Post Processing.

n Select the Post selected operations icon from the

Toolpaths Manager as shown.

Note: The HLE/Demo version of Mastercam does not support post processing. The G1 button does not
work and no G-code can be created in the HLE/Demo version.

78
 Contour Toolpath Part 1 Step 9: Save Your Mastercam File

n In the Post processing window, make necessary changes as

shown.

REFERENCE INFORMATION
Output part file descriptor includes the descriptor as a comment in the NC
program.
NC file saves the file as an NC machine code file.
Overwrite / Ask sets whether to automatically overwrite or ask for permission
to overwrite if NC file with same name already exists.
Edit automatically launches the text editor so you can review or modify the
NC code.
Send to Machine automatically transmits the NC program to your machine
tool control.
Communications will open the Communications dialog box so you can set or
edit the serial communication parameters.

n Select the OK button to continue.

n Give the program a name.

(CONTOUR-1.NC is used in this
example.)
n Select Save button to continue.
n Mastercam Code Expert
window will be launched and the
G-code should look as shown.
n Close Mastercam Code Expert
window.

STEP 9: SAVE YOUR MASTERCAM FILE

n Your file will be saved with the Mastercam toolpath data stored inside the file.

SUMMARY:

After completing this lesson and some of the practice exercises that follow you should be able to:
n Create basic Mastercam geometry.
n Locate the Mastercam part with Origin at the correct location.
n Create the Job setup and Stock setup to begin programming.
n Select Single entities to generate the Contour toolpath.
n Select a tool and supply the basic Contour parameters to create contour toolpaths.
n Verify using Backplot and Verify the Contour toolpath.
n Modify the parameters and have the toolpath updated.
n Create NC code to send to the machine.

79
 Contour Toolpath Part 1 Exercise #1

EXERCISE #1

Job Description:

Create the geometry required to program the part above with the following requirements:
n Create the geometry in the Top view and locate the origin at the lower left corner.

Job Setup Notes/Tips:

n Stock Size = All Entities.
n Z size = 1.75
Contour Parameters:
n Tool = 3/4 Flat Endmill.
n Use Multi-passes to remove all required material.
n Run Backplot and Solid Verify to confirm results.
n Generate the G-code for the CNC machine.

80
 Contour Toolpath Part 1 Exercise #2

EXERCISE #2

Job Description:

Create the geometry required to program the part above with the following requirements:
n Create the geometry in the Top view and locate the origin at the lower left corner.

Job Setup Notes/Tips:

n Stock Size = All Entities.
n Z size = 1.5
Contour Parameters:
n Tool = 0.75 Flat Endmill.
n Use Multi-passes to remove all required material.
n Run Backplot and Solid Verify to confirm results.
n Generate the G-code for the CNC machine.

81
Geometry Tools - Part 2

82
Geometry Tools - Part 2 Introduction:

INTRODUCTION:
This lesson will further your knowledge of the geometry creation tools that you will need for creating your
own geometry to define toolpaths or for creating supplemental geometry to graphically control the toolpath
motions in Mastercam. The main goal of the geometry lessons is to give you the basic understanding of how
to create geometry in Mastercam so that you can practice to become as proficient as your job requires.
While Mastercam offers a large number of geometry creation tools, this workbook focuses on fundamental
tools for most shapes. Other geometry tools work in a similar manner to the ones shown in this lesson and
can be used as needed for unique constructions. We have selected what we consider to be the most useful
tools.

OVERVIEW OF EXERCISE:
In this lesson we will continue to become familiar with the Mastercam screen components and learn tools
and shortcuts to begin creating basic curved 2D geometry shapes. We will also be introduced to some
specialty geometry tools that are useful for preparing geometry for toolpaths.

NEW CONCEPTS COVERED IN THIS LESSON:

n Circle and Arc Creation.
n Chamfer and Fillet Creation.
n How to Delete Duplicate Geometry.
n How to Break and Join Geometry.
n How to Create Letters in Mastercam for Engraving toolpaths.

INSTRUCTOR DEMONSTRATION PREVIEW:

Note: This entire lesson is a joint Instructor / Student exercise. No instructor demo for this lesson.

Topics:

n Create Circles
n Create Arcs
n Create Fillets
n Create Chamfers
n Break and Join entities
n Delete Duplicate entities
n Create Tangent Lines and Arcs
n Create Letters
n Overview of remaining Wireframe tab
Items

83
Geometry Tools - Part 2 Geometry Tools Part 2: Basic Steps Reference

GEOMETRY TOOLS PART 2: BASIC STEPS REFERENCE

Note: In this lesson the students and instructor will work through the topics as a group.

STEP 1: CREATE CIRCLES AND ARCS COMMAND

Create Arcs

1.1 Open CREATE_ARC.MCAM

n From the QAT, select the Open icon.

n Select CREATE_ARC.MCAM.

1.2 Wireframe / Circle

Center Point

n In the Circle Center Point panel, enter a Radius of

1.0 and select the point as the center location.
n Select the OK and Create New Operation button to

continue in the same command.

n Enter a Diameter of 1.0 and select the point as the

center location.
n Select the OK and Create New Operation button to

continue in the same command.

84
Geometry Tools - Part 2 Step 1: Create Circles And Arcs Command

n Enter a Diameter of
0.5 and lock it by
selecting the icon.
n Select the point as the
center location.
n Select the OK button
to exit.

1.3 Wireframe / Arc

Endpoints

n From the Arcs group, click on

the drop down arrow on Circle
Edge Point and select Arc
Endpoints.
n Enter a Radius of 0.25 (you
can lock the value). Select the
first point, then the second
point. The system gives all
possible results. Select the arc
that you want to keep.
n Choose the OK and Create
New Operation button to
continue in the same command.

n Following the same steps create the other arc.

n Select the OK button to exit Arc Endpoints panel.

85
Geometry Tools - Part 2 Step 2: Create Tangent Arcs

1.4 Look at other options in the Arcs group

Note: No live exercises. These tools work similar to the ones used
and are for specialized purposes. For more information see the
Mastercam Help.

STEP 2: CREATE TANGENT ARCS

Create Arc Tangent

2.1 Open CREATE_ARC_

TANGENT.MCAM

n From the QAT, select the Open icon.

n Select CREATE_ARC_
TANGENT.NT.MCAM.

2.2 Wireframe / Arc Tangent

86
Geometry Tools - Part 2 Step 2: Create Tangent Arcs

n From the Wireframe tab, in the

Arcs group, select Arc
Tangent.

Note: In the Arc Tangent panel

are 7 methods that allow you to
create a tangent arc. Hover
above the method to see an
explanation about all of the
methods available.

2.3 Arc Tangent 1 Entity

n In the Arc Tangent panel, in the Method, select the Arc
one entity.
n Input a Radius of 0.5. Select the entity that the arc is to be
tangent to, then select the top quadrant point of the circle.
Mastercam will create 4 separate arcs.
n Select the arc you wish to keep.
n Select the OK and Create New Operation button to

continue in the same command.

2.4 Arc Tangent to 3 Entities

n Select the Arc three entities in the Arc Tangent panel.
n Select the three entities at the approximate tangent points.

2.5 Arc Tangent to 2 Entities

n Select the Arc two entities in the Arc Tangent panel.
n Input a Radius of 1.5. Select the two circles and pick the
arc you wish to keep. This will create an arc which is
tangent between the two circles.
n Pick the OK button to exit the command.

87
Geometry Tools - Part 2 Step 3: Create Tangent Lines

STEP 3: CREATE TANGENT LINES

Create Line Tangent

3.1 Open CREATE_LINE_

TANGENT.MCAM

n From the QAT, select the Open icon.

n Select CREATE_LINE_
TANGENT.MCAM.

3.2 Wireframe / Line Endpoints

n From the Wireframe tab, in the Lines group, select Line

Endpoints.
n In the Line Endpoints panel, ensure that Freeform and
Tangent are enabled.

3.3 Tangent Line At an Angle

n Enter a line Length of 2.0 and an Angle of 10.0.
n Select the arc close to where you want to create the tangent line.

Note: When you are selecting the arc, make sure that you are not
selecting a Quadrant point, Midpoint, or Endpoint.

n Multiple solutions may be possible.

n Select the line to keep.
n Press Enter key to continue in the same command.

88
Geometry Tools - Part 2 Step 4: Create Fillet Commands

3.4 Tangent Line Through a Point

n Select the arc and move the cursor to select the point for the
tangent line to pass through (the Origin).
n Press Enter key to continue in the same command.

3.5 Tangent Line to Two Arcs

n Select the two arcs close to where you want to create the
tangent line.
n Select the OK button to exit the command.

Note: When you are selecting the arc, make sure that you
are not selecting a Quadrant point, Midpoint, or Endpoint.

STEP 4: CREATE FILLET COMMANDS

Fillet

4.1 Open FILLET.MCAM

n From the QAT, select the Open icon.

n Select FILLET.MCAM.

4.2 Wireframe / Fillet

Entities

89
Geometry Tools - Part 2 Step 4: Create Fillet Commands

Normal
n In the Fillet Entities panel make
sure that the Method is set to
Normal and input a fillet Radius of
0.25.
n The Trim entities option should be
enabled.

Note: The Fillet command

creates an arc of a defined
radius tangent to the lines. By
default Trim entities is
enabled and Mastercam trims
the curves to the fillet;
although you have the option
to turn off trimming. Always
select the entities on the side
you want to keep after filleting.

n Select the lines between which you

need to insert the fillet.
n Press Enter to continue in the same
command.

Inverse
n The upper right corner settings should be as follows:
n Enable the fillet method Inverse and keep Trim entities enabled.
n Press Enter to continue in the same command.

Clearance
n The lower right corner settings should be as follows:
n Enable the fillet method Clearance and keep Trim entities
enabled.
n Press Enter to continue in the same command.

Relief
n The lower left corner settings should be as follows:
n Enable the fillet method Relief and keep Trim entities enabled.
n Select the OK button to exit the command.

90
Geometry Tools - Part 2 Step 4: Create Fillet Commands

4.3 Wireframe / Fillet Chains

Note: For the

second rectangle,
the Fillet Chains
command lets you
create fillets at the
sharp corners along
the selected chain.

n Click the drop down arrow

on the Fillet Entities icon
and select Fillet Chains
n When the Chaining dialog
box appears, enable the
Chain button and select
the rectangle.
n Choose the OK button to
exit the chaining dialog
box.
n In the Fillet Chains panel
enter a Radius of 0.375.
n Make sure that the
Method is set to Normal
and Trim entities is
enabled.
n Select the OK button to
exit the command.

91
Geometry Tools - Part 2 Step 5: Create Chamfer Commands

STEP 5: CREATE CHAMFER COMMANDS

Chamfer

5.1 Open CHAMFER.MCAM

n From the QAT, select the Open icon.

n Select CHAMFER.MCAM.

5.2 Wireframe / Chamfer Entities

1 Distance
n The upper left corner settings should be as follows:
n In the Chamfer Entities panel make sure that the
Method is set to 1 Distance and input a Distance
1 of 0.25.
n The Trim entities option should be enabled.
n Select the lines between which you need to insert
the chamfer.
n Press Enter to continue in the same command.

2 Distances
n The upper right corner settings should be as follows:
n Set the method to 2 Distances and keep Trim entities enabled.
n Set Distance 1 of 0.25.
n Set Distance 2 of 0.125.
n Select first the horizontal line and then the vertical line of the upper right corner.
n Press Enter to continue in the same command.

92
Geometry Tools - Part 2 Step 5: Create Chamfer Commands

Distance And Angle

n The lower right corner settings should be as follows:
n Set the method to Distance and angle and keep Trim entities enabled.
n Set the Distance 1 to 0.375 and the Angle to 30 degrees.
n Select the vertical line first and then the horizontal line on the lower right
corner.
n Press Enter to continue in the same command.

Width
n The lower left corner settings should be as follows:
n Set the method to Width and keep Trim entities enabled.
n Set the Width to 0.5.
n Select the vertical line and the horizontal line of the lower left corner.
n Select the OK button to exit the command.

5.3 Wireframe / Chamfer

Chains

Note: For the second rectangle, the Chamfer

Chains command lets you create chamfers at the
sharp corners along the selected chain.

n Click on the drop down arrow on the Chamfer

Entities icon and select Chamfer Chains.
n When the Chaining dialog box appears, leave the
default settings and select the rectangle.
n Choose the OK button to exit the chaining dialog
box.
n In the Chamfer Entities panel make sure that the
Method is set to Distance.
n Set the Distance to 0.25.
n The Trim entities option should be enabled.
n Select the OK button to exit the command.

93
Geometry Tools - Part 2 Step 6: Break

STEP 6: BREAK

The Break, Join and Delete Duplicate functions are specialty editing functions to prepare geometry for
making efficient toolpaths.

Break Modify Length

6.1 Open BREAK.MCAM

n From the QAT, select the Open

icon.
n Select BREAK.MCAM.

6.2 Wireframe / Break Two

Pieces

n Select the entity to break, then select the

midpoint where you want to break the
selected entity.

94
Geometry Tools - Part 2 Step 6: Break

6.3 Wireframe /
Modify Length

Break At A Given Length

n In the Modify Length panel, set
the Type to Shorten and enable
Break.
n To break the line by the specified
amount, enter in the Distance of
0.25.
n Select the line above the midpoint
and the line will be broken from
the closest endpoint.
n Choose the OK and Create New
Operation button to stay in the
command.
Extend A Line With Another Line
n To create another line that is an
extension, enable Lengthen and
set the Distance to 0.5.
n Select the line above the midpoint
and another line will be created
with the length 0.5 starting at the
original line endpoint and having
the same orientation.
n Choose the OK button to exit the
command.

95
Geometry Tools - Part 2 Step 7: Delete Duplicates & Join

STEP 7: DELETE DUPLICATES & JOIN

Delete Duplicates Join

7.1 Open JOIN.MCAM

n From the QAT, select the Open icon.

n Select JOIN.MCAM.

7.2 Statistics
n From the Home tab, in the Analyze group, select
Statistics.
n Mastercam automatically lists the number of different
entities that the file contains.

Note: The number of lines and arcs does not match

what you can see on the screen. This indicates that
duplicate entities are likely.

7.3 Delete Duplicates

n From the Home tab, Delete group, select
Duplicates.
n The pop-up dialog displays the results of the
deletion.

Note: Often you may accidentally create entities on

top of each other, or you may import a file from
another CAD system that has duplicate geometry.
These need to be removed to make the toolpath
selection easier.

n Right mouse click in the graphics window and

select the Clear Colors icon.

Note: Clear colors removes the group and resultant colors. When performing a transform function or the
Delete Duplicates, Mastercam creates a temporary group from the originals (indicated in red color) and a
result (magenta color) for the resulted entities.

96
Geometry Tools - Part 2 Step 7: Delete Duplicates & Join

7.4 Duplicates - Advanced

n Advanced options allow masking
on specific criteria to determine
what a duplicate is.

7.5 Wireframe / Join

Entities

Use this function to join collinear lines, arcs that have the same
center and radius, or splines that were originally created as the
same entity.

Hover the cursor above the left vertical line and notice that there are 2
lines.
n Select the two lines. Press Enter to finish the selection.
n Select the OK button in the Join Entities panel.

Results of the Join Entities command.

7.6 Other Trim to Entities commands

n Experiment with the other Trim to
Entities drop down options.

(Instructor will explain uses of Break

Functions)

97
Geometry Tools - Part 2 Step 8: Create Letters

STEP 8: CREATE LETTERS

The Create Letters command creates alphanumeric characters comprised of lines, arcs, and NURBS
splines. Mastercam fonts contain pre-defined letter files in four fonts: Block, Box, Roman, and Slant. Each
file contains a letter or character comprised of lines, arcs, and splines. You can customize any Mastercam
font by opening the file for each letter. True Type® fonts: Mastercam can create letters from any True Type
font on your system.

Create Letters

8.1 Use the same JOIN.MCAM file.

8.2 Create Letters

n From the Wireframe tab, Shapes group,
select Create Letters.

Note: We will create Letters that can be used

for engraving on a machined part.

8.3 Experiment with Create - Letters

n Style = Mastercam (Box) Font

n Enter the letters.
n Height = 0.75.
n Spacing = 0.15
n Pick a point o position the letters.

STEP 9: OTHER GEOMETRY CREATION TOOLS

The other Mastercam Wireframe tools are similar in functionality. Once you understand the basic tools, you
should be able to use the specialty tools when required.

98
Geometry Tools - Part 2 Step 9: Other Geometry Creation Tools

SUMMARY:
In this second hands-on lesson, you were introduced to several of the basic procedures you will soon learn to
use over and over again to create geometry as needed so you can generate toolpaths accurately. After
completing this lesson and some of the practice exercises that follow you should be able to:
n Have a more thorough understanding of how to create geometric shapes in Mastercam.
n Create Circles and Arcs to draw most shapes.
n Create Lines and Arc Tangent.
n Add Fillets and Chamfers to corners of geometry.
n Delete Duplicate Geometry.
n Break and Join Geometry.
n Create Letters in Mastercam for Engraving toolpaths.

99
Geometry Tools - Part 2 Exercise #1

EXERCISE #1

100
Geometry Tools - Part 2 Step 10: Lab 1 Suggested Steps

Job Description:

Create the geometry as shown above following the next steps:

STEP 10: LAB 1 SUGGESTED STEPS

10.1 Start a new Mastercam part
n Select New button from the QAT.

n Display the Axis with Shortcut

key Alt+F9. (Or just use the Grid).

Scroll down the mouse wheel to
zoom out to have more room to
draw.

10.2 Create a Rectangle 8.5 by 2.5

n Width = 8.5.
n Height = 2.5.
n Press Enter.
n Make sure Anchor to center is disabled.
n Select the Origin.
n Un-zoom more if needed to see the entire
rectangle

10.3 Parallel Lines

n Draw a line parallel at a distance of 1.5" from
the lower horizontal line as shown.

10.4 Create four 0.75 diameter circles

n Use Circle Center Point command.
n Diameter = 0.75.
n Lock the Diameter Value to keep all the same.
n Press Enter to finish the last circle.

101
Geometry Tools - Part 2 Step 10: Lab 1 Suggested Steps

10.5 Create two 0.75 radius circles

n Use Circle Center Point command.
n Radius = 0.75.
n Lock the Radius Value to keep all the same.

10.6 Create line tangents

n Use Line Endpoint command with the Freeform
and
Tangent options enabled.
n Create the 2 vertical lines that are tangent to the
circles.
n When selecting the circle make sure that you do not
select Midpoints, Quadrants or Endpoints.
n The length of lines is not important.

10.7 Delete the construction lines

n Select the lines and press Delete key.
n Fit and unzoom the geometry as needed.

10.8 Create the chamfers

n Use Chamfer Entities command.
n 1 Distance = 0.5
n Trim enabled.
n Select the entities between which you create the
fillets.

10.9 Trim the geometry using Divide

n Select the arcs to be removed.

10.10 Create the fillets with radius of 0.375"

n Use Fillet Entities command.
n Radius = 0.375.
n Trim enabled.
n Select the entities between which you create the
fillets.

102
Geometry Tools - Part 2 Exercise #2

EXERCISE #2

Job Description:

Create the geometry required as shown above with the following requirements:
n Start a new Mastercam Part for each drawing.
n Create Exercise # 2 if the time allows.
n Save your part and have the Instructor confirm your results.

103
Contour Toolpath Part 2

104
Contour Toolpath Part 2 Introduction

INTRODUCTION
This tutorial builds on the basic procedures you were introduced to in the first Contour tutorial. You will gain
experience in additional geometry selection (Chaining) techniques that will allow you to cut most Contour
shapes you come across. The toolpaths will consist of several new types of contours.

You are also introduced to the 2D High Speed Area Mill toolpath that allows you to machine pockets,
material that other toolpaths left behind, and standing bosses or cores.

OVERVIEW OF EXERCISE:
In this lesson you will machine the part shown by first Facing the 5.0 X 8.0 stock, then machining the outside
profile shown by using several different types of 2D contour toolpaths and tools.
You will machine the open pocket using the 2D High Speed Area Mill.

NEW CONCEPTS COVERED IN THIS TUTORIAL:

n Facing rough stock
n 2D High Speed Area Mill to cut an open pocket shape
n Removing excess stock
n Chamfer contour toolpath
n Multiple techniques for contour chain selection
n Chain Manager options
n Review of basic Mastercam general workflow procedures

105
Contour Toolpath Part 2 Instructor Demonstration

INSTRUCTOR DEMONSTRATION
Topics:

n 2D Geometry Review
n Locate geometry and Job Setup
n Facing operation
n 2D Area Mill
n Contour entire Chain
n Chamfer Operation

AREA MILL TOOLPATHS INFORMATION

The following are brief descriptions of the toolpath types available for Area Mill toolpaths.

Area Mill - Stay Inside Strategy machines pockets

using one or more chains to drive the toolpath.

Area Mill - From Outside Strategy machines open

pockets or standing core shapes using the outmost chain
as the stock boundary. The toolpath starts from the
outside and works its way towards the inner boundary.

Area Mill Rest Mill machines areas that previous

tool could not machine. Mastercam analyzes the
pocket to find areas where stock remains.

106
Contour Toolpath Part 2 Part Drawing

PART DRAWING

107
Contour Toolpath Part 2 2D Geometry Selection Reference Information:

2D GEOMETRY SELECTION REFERENCE INFORMATION:

STEP 1: CREATE AND LOCATE PART GEOMETRY

In this step you will create the geometry shown in the Top View from the Contour 2 Drawing. Locate the
Origin as shown. See the following steps as reference. Use the following commands: rectangle, line
parallel, trim, chamfer entities, fillet entities and offset chains.

1.1 Start a new file and save it as CONTOUR-2.MCAM

1.2 Create a Rectangle

n Use Wireframe/Rectangular Shapes.
n Set the Width to 8.0 and the Height to 5.0.
n Anchor the upper right corner in the Origin.

1.3 Create Parallel Lines

(For construction purpose only)
n Use Wireframe / Line Parallel.
n Set the Distance to 1.75 .
n Select the top horizontal line.
n Select a point below the line. Press Enter.
n Set the Distance to 3.0 and select the left vertical
line. Select a point to the right of the line. Press
Enter.
n Set the Distance to 2.0 and select the last parallel
line. Select a point to the right of the line. Press
Enter.

1.4 Trim the geometry

n Use Divide command.
n Use Trim to Entity command.
n Method set to Trim 2 entities.

108
Contour Toolpath Part 2 Step 1: Create And Locate Part Geometry

1.5 Create 1” X 45° Chamfer on 4 corners

n Set the Method to 1 Distance.
n Distance 1 = 1.0.
n Select the lines.

1.6 Create 0.375 Radius Fillets at the corners

n Fillet the 8 outside corners and 2 inside corners as
shown.

Note: There are 2 sharp corners at the top of the open

slot.

1.7 Offset the outside profile with a 0.06

distance

Note: This step is showing the Offset

command, it is not needed to machine the
part.

n From Transform tab select the Offset Chains.

n Select the entire chain.

n Click inside the geometry to indicate the offset

direction.
n Set the Method to Copy and the Distance to
0.06.
n Right mouse click and select Clear colors icon.

1.8 Save your part as "Contour-2.MCAM"

109
Contour Toolpath Part 2 Step 2: Create The Job Setup

STEP 2: CREATE THE JOB SETUP

In this step you will supply Mastercam with information about tool settings and stock size before starting to
create the toolpaths.

2.1 Load the Mill Default if needed

n From the Machine tab, select

Mill and Default.

2.2 Set the Tool settings

n Select the Files icon.

n Set the Program Number as shown.

110
Contour Toolpath Part 2 Step 2: Create The Job Setup

n Select the Stock Setup tab.

n Make sure that Show wireframe entities is enabled.

n Select the Create rectangular stock icon as shown.

111
Contour Toolpath Part 2 Step 2: Create The Job Setup

n Press Ctrl + A to select all the entities.

n Set the Origin to the center of the top face.
n Change the Z to 0.5". Press Enter.

n To add an extra 0.05 to the top of the stock for facing, add the
0.05 to the Z value of the Origin as shown.

112
Contour Toolpath Part 2 Step 2: Create The Job Setup

n The stock, in the Isometric view, should look as

shown.

n Select the Tool and enable Assign tool numbers

sequentially.
n Expand the panel, and enable Override defaults with modal
value and check all options.

n Select the OK button to exit Machine Group Setup.

113
Contour Toolpath Part 2 Step 3: Facing Toolpath

STEP 3: FACING TOOLPATH

A Facing toolpath quickly removes material from the top of the part to create an even surface and prepare
for subsequent operations.

STEP 4: SET THE FACING PARAMETERS

Step Preview:

n From the Toolpaths

tab, select the Face
icon as shown.

n The Wireframe Chaining dialog box appears on the screen.

n To use the defined stock select the OK button.

Note: This is an option for Face operations. Otherwise we would need to

create additional geometry to represent the stock shape.

n The Facing dialog box appears on the screen.

Note: In the following steps you will be setting the parameters to generate the Facing toolpath.

114
Contour Toolpath Part 2 Step 4: Set The Facing Parameters

4.1 Toolpath Type

n The Facing icon is already

selected. No chains are
selected in the Chain
geometry area.

4.2 Tool
In the following steps you will choose a 2” Face Mill from the Library of tools provided by Mastercam. You
will use the Filter option to search through the tool library for a specific tool type which makes it easier and
quicker to find the desired tool.

n From the Tree View List, select

Tool and click on the Select
library tool button as shown.

n Select the Filter button

as shown.
(The Filter button will allow
searching through the tool
library for a specific tool
type to make it easier and
quicker to find the desired
tool)

115
Contour Toolpath Part 2 Step 4: Set The Facing Parameters

n Select the None button to de-

select all tool types to clear the
filter.
n Select the Face Mill tool type.

Note: You can hover your cursor

over the icons to see what tool
type is represented by each icon.

n Confirm that the rest of your

settings match the screenshot as
shown.
n Select the OK button to exit the
Tool List Filter dialog box.

n Select the 2.0" Face Mill from

the filtered list and click the OK

button.
n You can also double click on the
tool to open it in the Tool page.

n Enable Rapid Retract

to force the tool to
retract from the part at
the rapid feed rate set at
the machine.
n In the Comment area,
enter a description of
what the toolpath does
as shown.

Note: The Tool numbers were automatically assigned due to Job Setup settings.
The Feed rate, Plunge rate, Retract rate and Spindle speed are based on the tool definition as set in the
Tool Settings. You may change these values as per your part material and tools.

116
Contour Toolpath Part 2 Step 4: Set The Facing Parameters

4.3 Cut Parameters

Cut Parameters page allows you to set the Facing parameters such as Type, Stock to leave, and Move
between passes.

n From the Tree View List,

select the Cut Parameters.
n Set the Style to Zigzag and
Move between cuts to
High speed loops.
n Set the Stock to leave on
floors to 0.0 as shown.

REFERENCE INFORMATION
The Style (facing cutting method) Zigzag creates a back and forth cutting motion.
Auto angle determines the angle to machine along the larger side of the stock.
Move between cuts determines how the tool moves between each cut. This is only available if you select
the zigzag cutting method.
High speed loops creates 180 degrees arcs between each cut.
Roll in adds an arc move at the beginning of the toolpath.

Note: You can save the Cut Parameters to the defaults to save time next time when you need to
generate another Facing toolpath.

4.4 Save the Facing parameters to defaults

n Click on the Save parameters to defaults icon.

117
Contour Toolpath Part 2 Step 4: Set The Facing Parameters

4.5 Linking Parameters

Linking Parameters page allows you to define the Clearance, Retract, Feed plane, Top of stock and Depth
heights.

n From the Tree View List,

select Linking Parameters
and set the values as shown.

4.6 Coolant

n From the Tree View List,

select Coolant and turn
the Flood on as shown.
n Select the OK button to
exit 2D Toolpaths -
Facing.

n The toolpath should look as shown.

118
Contour Toolpath Part 2 Step 4: Set The Facing Parameters

4.7 Backplot the toolpath

n Select the Backplot selected operations

button.

n Select the Play button to run Backplot.

n The toolpath should look as shown.

n From the Backplot dialog box, select
the OK button to exit Backplot.

4.8 Simulate the toolpath in Verify

n From the Toolpaths Manager, select Verify selected

operations icon as shown.

Note: Mastercam launches a new window that allows you to check the part using Backplot or Verify.

n Select the Play button to run

Verify.

n The part should appear as shown.

n When finished verifying, Minimize the Mastercam Simulator Window to leave it

open or move it on a separate monitor.

119
Contour Toolpath Part 2 Step 5: Machine The Open Pocket - Area Mill

STEP 5: MACHINE THE OPEN POCKET - AREA MILL

In this operation we will remove the cutout area using 2D High Speed Area Mill toolpath with the
strategy set to From outside.

Step Preview:

n Before starting the next operation, turn off the

toolpath display for the Facing operation.

Note: This will remove selected toolpaths to make it easier to view and select the model edges for the
next operation. You can also press Alt +T.

n In the Toolpaths ribbon, 2D group, click on the Expand

gallery arrow and select the Area Mill icon.

n Enable From outside and click on the Select button in the Machining
regions.

120
Contour Toolpath Part 2 Step 5: Machine The Open Pocket - Area Mill

n In the Wireframe Chaining Mode,

enable Partial Chain button.
n Select the first and the last entity of
the chain as shown.

n Click on the Preview chains

button to check the chaining.
n Select the OK button to
continue.

121
Contour Toolpath Part 2 Step 5: Machine The Open Pocket - Area Mill

5.1 Tool

n Click on the Select library tool button and using the Filter options select the 1/2" Flat Endmill.
n Rapid Retract enabled.
n Comment: “Machine the open pocket”.

5.2 Cut Parameters

n Machining direction
is set to Climb.
n XY Stepover
distance = 75%.
n Stock to leave on
walls = 0.005.
n Stock to leave on
floors = 0.0.

REFERENCE INFORMATION
Cutting method set to Climb cuts in one direction with the tool rotating in the opposite direction of the
tool motion.
XY stepover sets the distance between cutting passes in the X and Y axes.
% of tool diameter expresses the maximum XY stepover as a percentage of the tool diameter. The Max.
XY stepover field will update automatically when you enter a value in this field. The actual stepover is
calculated by Mastercam between the Min. and Max. values.
Corner rounding activates toolpath corner rounding, which replaces sharp corners with arcs for faster
and smoother transitions in tool direction.
Profile tolerance represents the maximum distance that the outermost profile of a toolpath created with
corner rounding can deviate from the original toolpath.
Offset tolerance represents the maximum distance that a profile of a toolpath created with corner
rounding can deviate from the original toolpath. This is the same measurement as the profile tolerance but
is applied to all the profiles except the outermost one.

122
Contour Toolpath Part 2 Step 5: Machine The Open Pocket - Area Mill

5.3 Depth Cuts

n Enable Depth cuts.

n Max rough step =0.3.

5.4 Transitions

Note: Strategy is set from outside and the entry method does not matter.

5.5 Break Through disabled

5.6 Linking Parameters

n Clearance = 2.0
(Absolute).
n Retract = 0.25
(Absolute).
n Feed Plane = 0.2
(Incremental).
n Top of Stock = 0.0
(Absolute).
n Depth = -0.55
(Absolute).

123
Contour Toolpath Part 2 Step 5: Machine The Open Pocket - Area Mill

5.7 HST Leads

n Set the Vertical arc

entry to 0.0.

n Select the OK button to exit 2D Toolpaths - Pocket.

5.8 Repeat the Backplot procedure

n The toolpath should look as

shown.

5.9 Repeat the Verify procedure

n In the Toolpaths Manager, click on the

drop down next to Verify selected
operations and select Add to current
verification icon.

124
Contour Toolpath Part 2 Step 6: Machine The 4 Corners Using Contour

n The part after being verified in Mastercam

Simulator should look as shown.

n When finished verifying, Minimize the

Mastercam Simulator Window to leave it
open or move it on a separate monitor.

STEP 6: MACHINE THE 4 CORNERS USING CONTOUR

In this step you will learn how to use Partial chaining to machine the four corners of the part.

Step Preview:

n Press Alt + T to remove the toolpath display.

n From the Toolpaths tab, and select the Contour icon

as shown.

125
Contour Toolpath Part 2 Step 6: Machine The 4 Corners Using Contour

n Rotate and zoom in on the geometry as

shown.
n In the Chaining dialog box, enable Partial
button.
n Select the First entity (arc)and the Last
entity (arc)as shown.

Note: Make sure the chaining direction is

as
shown. Otherwise, select Reverse button
when selecting the first entity.

n In the Wireframe Chaining

dialog box, click on the
Chain Similar button as
shown.
n All the corners will be
selected as shown.

Note: In the Wireframe Chaining enable

Display all selection arrows to see
the arrows on the chains.

n Select the OK button to exit the Chaining

dialog box.

126
Contour Toolpath Part 2 Step 6: Machine The 4 Corners Using Contour

6.1 Toolpath Type

n The 2D Toolpaths - Contour dialog box

appears on the screen.
n The Contour icon is already selected. If
needed, you can reselect the 4 chains in
the Chain geometry area.

6.2 Tool
In the following steps you will select the 1/2” Flat Endmill from the list.

n From the Tree

View List, select
Tool.
n Make sure that the
1/2" Flat Endmill
and enter a
comment as
shown.

127
Contour Toolpath Part 2 Step 6: Machine The 4 Corners Using Contour

6.3 Cut Parameters

n From the Tree View List, select

the Cut Parameters and set the
Compensation type to Wear and
the Stock to leave on walls as
shown. The rest of the settings
should match the default values as
shown.

Note: Using Wear allows you to output Control codes for compensation as well as calculating the
compensation in Mastercam. Using this method, the operator can add compensation as the tool wears.

6.4 Lead In/Out

n From the Tree View List,

select Lead In/Out and make
sure the parameters are set as
shown.

128
Contour Toolpath Part 2 Step 6: Machine The 4 Corners Using Contour

6.5 Break Through

n Make sure that the Break Through is

enabled and set as shown.

6.6 Multi Passes

n From the Tree View List,

select Multi Passes and
enable the page as shown.
Set the rest of the
parameters as shown.

Note: In this case, we must turn off Keep tool down to avoid the tool cutting through the part as it
moves to the next corner. Enable One way to ensure Climb cutting on all passes.

129
Contour Toolpath Part 2 Step 6: Machine The 4 Corners Using Contour

6.7 Linking Parameters

n From the Tree View List, select Linking

Parameters and set the values as shown.

6.8 Coolant

n From the Tree View List, select Coolant and turn the
Flood on as shown.
n Select the OK button to exit 2D Toolpaths - Contour.

n The toolpath should look as shown.

130
Contour Toolpath Part 2 Step 7: Contour The Outside Profile

6.9 Repeat the Verify procedure

n The part after being verified in

Mastercam Simulator should look as
shown.
n When finished verifying, minimize
Mastercam Simulator.

STEP 7: CONTOUR THE OUTSIDE PROFILE

In this Contour operation we will run a clean-up contour around the entire outside edge of the part.

Step Preview:

n Press Alt + T to remove the toolpath display.

n From the Toolpaths tab, and select the Contour

icon as shown.

131
Contour Toolpath Part 2 Step 7: Contour The Outside Profile

n Holding down the mouse wheel, click on the part

and rotate it as shown.
n The cut direction should be CW to ensure climb
milling, the side of the cutter should be outside of
the contour and the starting position should be
as shown.
n Select the OK button to accept the Chain
settings.

n The 2D Toolpaths - Contour dialog box appears on the screen.

Note: Most settings should remain the same as in the previous contour operation.

7.1 Cut Parameters

n In the Cut Parameters page set the Stock to leave on walls to 0.

7.2 Lead In/Out

n Enable Enter/exit at midpoint in

closed contours.

7.3 Multi Passes

n From the Tree View List, select Multi

Passes and disable the page as shown.

132
Contour Toolpath Part 2 Step 7: Contour The Outside Profile

7.4 Linking Parameters

n From the Tree View List, select Linking

Parameters and set the values as shown.

n Select the OK button to exit 2D Toolpaths

- Contour.

n The toolpath should look as shown.

7.5 Repeat the Verify procedure

n The part after being verified in Mastercam Simulator

should look as shown.

Note: There is not material removal on the sides of the

part as in the stock setup you did not add any extra stock.

n When finished verifying, minimize Mastercam

Simulator.

133
Contour Toolpath Part 2 Step 8: Chamfer The Top Of The Part

STEP 8: CHAMFER THE TOP OF THE PART

In this step you will use the Contour toolpath to make a chamfer around the entire top of the part.

Step Preview:

n Press Alt + T to remove the toolpath display.

Note: You might need to click twice on the icon to remove all toolpath displays.

n From the Toolpaths tab, and select the Contour icon as

shown.

n Click on the Last button to select

the same chain selected in the
previous contour.
n Select the OK button to exit
Wireframe Chaining.

134
Contour Toolpath Part 2 Step 8: Chamfer The Top Of The Part

8.1 Tool

n From the Tool

Library, using the
Filter options,
select the 1/2"
Chamfer Mill as
shown.

8.2 Cut Parameters

In this step you will set the parameters to machine a 45 degrees chamfer with the width of 0.05". To
machine a chamfer, in the Contour type you have to select the 2D Chamfer.

n From the Tree View List,

select Cut Parameters and
select the 2D chamfer as
Contour type and set the
parameters as shown.

135
Contour Toolpath Part 2 Step 8: Chamfer The Top Of The Part

8.3 Disable Break Through

n From the Tree View List, select Break

Through and disable the page as shown.

8.4 Linking Parameters

Linking Parameters page allows you to define the Clearance, Retract, Feed plane, Top of stock and Depth
heights. The 2D Chamfer toolpath is a special type of contour that compensates for the chamfer size. It has
been designed to calculate from a Depth of 0.0.

n From the Tree View List, select

Linking Parameters and set the
values as shown.

n Select the OK button to exit 2D

Toolpaths - Contour.

n The toolpath should look as shown.

136
Contour Toolpath Part 2 Step 9: Post Process The Toolpaths

8.5 Repeat the Verify procedure

n The part after being verified in Mastercam

Simulator should look as shown.

Note: To see the part with different colors after

verification, in the Verify ribbon enable
Color Loop icon.

n When finished verifying, minimize Mastercam

Simulator.

STEP 9: POST PROCESS THE TOOLPATHS

STEP 10: SAVE THE MASTERCAM FILE

SUMMARY:

In this tutorial, you added to your experience in the basic procedures of cutting contour shapes with
Mastercam. You experienced multiple new ways to select geometry to identify chains to cut and created a
program with multiple operations. After completing this tutorial and the practice exercises that follow you
should be able to:
n Select multiple sets of individual edges to create Chains to generate Contour toolpaths.
n Select Partial Chains.
n Select full Chains.
n Face extra stock from the top of a part.
n Cut an open pocket area with 2D High Speed Area Mill.
n Remove areas that have additional stock with multiple contour passes.
n Create a cleanup contour pass around the outside of a part.
n Chamfer the top of a part using Contour toolpath.
n Verify using Backplot and Solid Verify multiple operations.
n Create NC code to send to the machine.

137
Contour Toolpath Part 2 Exercise #1

EXERCISE #1

Job Description:

Create the geometry and program the part above with the following requirements:
n Locate the origin at appropriate place.
Job Setup Notes/Tips:
n Stock Size = Stock Entities; Z = 0.75.
n Locate Origin at Corner of Stock.
Toolpaths:
n Remove excess material from the angled corners (Tool = 1” Flat Endmill).
n Contour the entire outside periphery (Tool = 1” Flat Endmill).
n Chamfer the top edge to remove sharp corners (Tool = 1/2” Chamfer Mill).
n Run Backplot and Solid Verify to confirm results.
n Create G-code for NC machine.

138
Contour Toolpath Part 2 Exercise #2

EXERCISE #2

Job Description:

Create the geometry and program the part above with the following requirements:
n Create the Geometry in the Top view to be able to program the part as shown above.
n Follow the Mastercam Work Flow to Setup the job and create toolpaths.
Job Setup Notes/Tips:
n Stock Size = All Entities
n Locate Origin at Corner of Stock.
Toolpaths:
n Multi-pass Contour to remove the material from the two flat relieved areas. (Tool = 1” Flat Endmill).
n Contour the entire outside periphery (Tool = 1” Flat Endmill).
n Chamfer the top edge to remove sharp corners (Tool = 1/2” Chamfer Mill).
n Run Backplot and Solid Verify to confirm results.
n Create G-code for NC machine.

139
Contour Toolpath Part 2 Exercise #3

EXERCISE #3

Job Description:

Create the geometry and program the part above with the following requirements:
n Create the Geometry in the Top view to be able to program the part.

Job Setup Notes/Tips:

n Stock Size = Bounding Box.
n Locate Origin at Corner of Stock.
Toolpaths:
n Multi-pass Contour to remove the material from the two open areas. (Tool = 1” Flat Endmill).
n Contour the entire outside periphery (Tool = 3/4” Flat Endmill).
n Chamfer the top edge to remove sharp corners (Tool = 1/2” Chamfer Mill).
n Run Backplot and Solid Verify to confirm results.
n Create G-code for NC machine.

140
Geometry Manipulation

141
Geometry Manipulation Introduction:

INTRODUCTION:
This lesson will introduce you to some of the geometry manipulation tools that are useful for extracting
information and organizing or preparing your geometry for toolpaths. You will also learn how to utilize and
prepare geometry that has been imported from other CAD systems to make your programming job easier.
This lesson will focus on what we consider to be the most useful and necessary tools for your daily use.

OVERVIEW OF EXERCISE:
In this lesson you will become more familiar with the Mastercam interface and how to make changes or
extract information from geometry to make it easy to program.

NEW CONCEPTS COVERED IN THIS LESSON:

n Transform commands such as Mirror, Translate, Offset and Rotate.
n Analyze geometry and measurement values.
n Setting and changing attributes of geometry.
n The Mastercam Levels manager.
n Geometry selection techniques.
n The Chaining dialog box.
n Analyzing and fixing problems in chaining.
n Importing 2D geometry.

142
Geometry Manipulation Instructor Demonstration Preview:

INSTRUCTOR DEMONSTRATION PREVIEW:

Note: This entire lesson is a joint Instructor / Student exercise. No instructor demo for this lesson.

Topics:

n Analyze
n Levels Manager
n Geometry Attributes
n Move To Origin
n Translate
n Mirror
n Rotate
n Overview of remaining Transform
tab items

143
Geometry Manipulation Step 1: Selection Method For Design

TRANSFORM GEOMETRY

Note: In this lesson the students and instructor will work through the topics as a group.

STEP 1: SELECTION METHOD FOR DESIGN

1.1 Open CHAINING.MCAM

n From the QAT, select the Open icon.

n Select CHAINING.MCAM.

When in Mastercam, the Single selection method is always active.

n You can single click all the entities you want to select.
n Notice that selected entities are highlighted while selected. To deselect
any one of the entities you have to click it again.
n Press Esc key to unselect all.

n To select multiple entities using

the Window selection method, click an area of the graphics
window that is not directly on an entity.
n Hold down the mouse button, and start to drag the mouse to
anchor the first point.
n Release the button.

Note: There are several methods to select the

geometry using window that can be set in the
Selection bar as shown.

n To select entities using the Chain selection method, hold down the
Shift key and select a single entity that is part of a chain of other
entities.

144
Geometry Manipulation Step 1: Selection Method For Design

n For Partial Chaining, hold down the Shift key and select the
first entity that is part of a chain in the proper direction.
n Notice that the entire chain is selected.
n Hold down the shift key again and select the last entity of the
chain.

n To select multiple entities using the Area selection method,

hold down the Shift key and click inside the outermost
entity, but outside the inside entities.

n To select entities using the Vector selection method, hold down the
Alt key, click the first point of the intended vector, and continue
clicking points to draw lines through each of the entities you want to
select.

n Alternatively, if you do not remember the

short keys, you can choose any of the
selection methods from
the Selection methods drop-down list and
select the entities you want to select.

To see a video on the different methods available to select the geometry in Mastercam while creating the part
geometry, check the Selection Methods in Design video.

145
Geometry Manipulation Step 2: Transform Mirror Command

STEP 2: TRANSFORM MIRROR COMMAND

Mirroring is the process of creating reverse images of entities by reflecting them symmetrically with
respect to a defined axis. You have the option to move, copy or join the original entities within the drawing.

Mirror

2.1 Open MIRROR.MCAM

n From the QAT, select the Open icon.

n Select MIRROR.MCAM.

n From the Transform tab, in the

Position group, select Mirror
icon.

2.2 The upper shape

n Select the entities to mirror using window selection. To use a
Window selection, hold down the Ctrl key and the left mouse
button and drag a box around the entities.
n Press Enter or select the End Selection button to finish the
selection.
n In the Mirror panel, enable X and Y axes to mirror the geometry
about both X and Y axes.

146
Geometry Manipulation Step 3: Transform Translate Command

2.3 The middle shape

n Select both contours to mirror using the chain selection. To enable Chain
Selection, hold down the Shift key and select one entity of the contour.
n Press Enter to finish the selection.
n Enable the Vector option in the Mirror panel and click on the Select
Vector icon.
n Select the hidden style line in the graphic area.

2.4 The lower shape

n Select both contours to mirror using Chain Selection.
n Enable Vector option in the Mirror panel and click on the Select Vector
icon.
n Select any two endpoints of the existing contour chains.

STEP 3: TRANSFORM TRANSLATE COMMAND

Translate copies, moves or joins selected entities to a new position without altering the orientation, size or
shape of the entities.

Translate

3.1 Open TRANSLATE.MCAM

n From the QAT, select the Open icon.

n Select TRANSLATE.MCAM.

n From the Transform tab, in

the Position group, select
Translate icon.

147
Geometry Manipulation Step 3: Transform Translate Command

3.2 Upper shape

n Select the entities to translate, then select the End Selection
button or press Enter.
n In the Translate panel enable Copy, enter the Number 2, and
enter the values for Delta X and Y.

n Select the OK and Create New Operation button to continue

in the same command.

3.3 Middle shape

n Select the entities to translate, then select the End
Selection button to end the selection.
n In the Translate panel, enable Move; set the Number to 1.
n Click on Reselect button in the Vector From/To area and
select the point to translate from the lower left corner of the
rectangle.
n Choose the point as the position to translate the rectangle to.
n Select the OK and Create New Operation button to

continue.

3.4 Lower shapes

n Select the entities to translate, then press Enter to end the
selection.
n In the Translate panel, enable Copy; set the Number to 2,
enter an Angle of 35 and a Length of 2.0 in the Polar
settings.
n Pick the OK button to exit the command.

148
Geometry Manipulation Step 4: Transform Offset Commands

STEP 4: TRANSFORM OFFSET COMMANDS

The Offset command offsets a single entity - moves or copies the entity at the defined distance and direction. The
direction is perpendicular to the curve at every point along the curve relative to the current construction plane.

The Offset Chain command offsets chains of curves by displacing them with a defined distance, direction and
optionally with a depth. The offset is perpendicular to the chains of curves at every position along the curves relative
to the current construction plane.

Offset

4.1 Open OFFSET.MCAM

n From the QAT, select the Open

icon.
n Select OFFSET.MCAM.

n From the Transform tab, in the

Offset group, select Entity.

4.2 Offset Entity

n Select the line and indicate the offset direction.
n Set the Method to Copy.
n In the Instances area, set the Number to 2, and the Distance to 0.25
.
n Select the OK and Create New Operation button to continue.

n Change the Offset parameters and select the arc.

n Pick the side to indicate the offset direction.
n Select the OK button to close the panel.

149
Geometry Manipulation Step 4: Transform Offset Commands

n From the
Transform tab, in
the Offset group,
select Chains.

4.3 Offset Chains

n When the chaining dialog box appears select the contour then
pick the OK button to exit the chaining dialog box.
n Indicate the offset direction picking a point outside of the chain.
n Enable Copy, input a Distance of 0.225 .
n In the graphics window, the resulting contour will be displayed in
magenta color.
n Make sure that it is outside the original contour (in red).
n Otherwise enable the Opposite side option.
n Select the OK button to exit the Offset Chains panel.

4.4 The third exercise

n Open chain with the same settings as the Offset Chains.

4.5 The last exercise demonstrates how

Mastercam deals with sharp corners along a
contour.
n Select the chain and indicate the offset direction.
n Set the Distance to 0.375.
n Enable Modify Fillet Corners and Sharp in the
Offset Chains panel for the first rectangle. This will
apply fillets to the corners of the offset rectangle.
n Disable Modify Fillet Corners in the Offset
Chains panel for the second rectangle.

150
Geometry Manipulation Step 5: Transform Rotate Commands

STEP 5: TRANSFORM ROTATE COMMANDS

Rotate moves selected entities or creates one or more copies of the entities around a point by a defining
angle. A positive angle results in a counter clockwise rotation and a negative angle results in a clockwise
rotation.

Rotate

5.1 Open ROTATE.MCAM

n From the QAT, select the Open

icon.
n Select ROTATE.MCAM.

n From the Transform tab, in

the Position group, select
Rotate.

n Select the entities to rotate, then select the

End Selection button.
n Enable Copy, set the number of steps to 5
and input an Angle of 60.0.
n Select the Rotation Center Point Reselect
button and select the point to rotate the
entities about.
n Choose the OK and Create New
Operation button to continue using the

command.
n Repeat the step for the arcs below, but
change the Angle to 25 degrees.

151
Geometry Manipulation Step 6: Analyze Commands

STEP 6: ANALYZE COMMANDS

Analyze

6.1 Open ANALYZE.MCAM

n From the QAT, select the Open

icon.
n Select ANALYZE.MCAM.

6.2 Analyze Position

Analyze Position allows you to select a
point in the graphics window and
Mastercam will display the coordinates of
the point.

n Select the Home ribbon tab.

n From the Analyze group, select the drop
down arrow next to Dynamic and click
on Position.
n Select point P1.
n Choose the OK button to close the dialog
box.

152
Geometry Manipulation Step 6: Analyze Commands

6.3 Analyze Entity

Analyze Entity displays all relevant information
about a point, line, arc, spline, surface or
dimensions and in some cases allows you to
edit the data.

n From the Analyze group, select the

Analyze Entity icon.
n Select the entity to analyze from the graphics
window and check the dialog box where
Mastercam displays all information about the
entity.
n Choose the OK button to close the dialog
box.

6.4 Analyze Distance

Analyze Distance allows you to analyze the

distance between the following:
Two entities.
Two point positions.
An entity and a point.

n From the Analyze group, select the

Analyze Distance icon.
n To analyze the distance, select the two
points in the graphics window. In the dialog
box, Mastercam displays the coordinates of
the point and the distance (2D and 3D) and
the angle between the points.
n Choose the OK button to close the dialog
box.

153
Geometry Manipulation Step 6: Analyze Commands

6.5 Analyze Angle

Analyze Angle analyzes the angle between two
lines or three points that you select in the graphics
window.

n From the Analyze group, select Angle.

n Select the lines. Mastercam displays the value
of the angle between the lines.
n Choose the OK button to close the dialog box.

6.6 Analyze Contour

Analyze Contour allows you to analyze all the entities
in one or more chained curves. The curves can
contain lines, arcs, or points (no splines).

n From the Analyze group, select the drop down

arrow next to Chain and click on Contour.

Note: You will use this command to analyze chains

for coordinate data.

n Select the chain, then choose the OK button to exit

the Chaining dialog box.
n Set the Contour type to 2D, set Offset direction to
Off and ignore all other options in the Analyze
Contour dialog box.
n Choose the OK button to close the dialog box.

The file with all the entities and their coordinates and
specific parameters will be displayed. You will also get
the total length of the contour.

154
Geometry Manipulation Step 7: Managing Attributes & Levels

STEP 7: MANAGING ATTRIBUTES & LEVELS

The Attributes allow you to set the color, level, line style, width and point style used to create the entities.

Attributes

7.1 Open ATTRIBUTES.MCAM

n From the QAT, select the Open icon.

n Select ATTRIBUTES.MCAM.

ATTRIBUTES
REFERENCE INFORMATION
Level sets the level of the selected entity. Enter a level number or choose the button to select a level from the
Levels Manager panel.
Color sets the color of the selected entity. Enter a color number or choose a color from the color palette.
Style determines the line style for the entity’s display curves.
Width determines the line width for the entity’s display curves.
Point Style sets a point type from the drop down list.

The Point Style, Line Style, Line Width and Color

attributes can be set or modified in the Home tab
Attributes group.

The Current Level can be set in the Organize

group as shown.

You can also set or modify the attributes in the Mini Toolbar.

To open the Mini Toolbar, right mouse click in the graphics

window.

Note: Before you set any attributes, make sure that no entities are selected. From the Quick
Mask buttons, click on the Clear selection left side button to unselect all entities.

155
Geometry Manipulation Attributes

7.2 Set Attributes and create the Rectangles

Green Rectangles Attributes Settings

n In the Home tab Attributes group, set the
attributes based on the notes shown on the
left side of the exercise.

Create The Green Rectangle

n Create a 2.0 by 1.0 rectangle.
n Enable Anchor to center and lock the values.
n Select the point in the right column.
n Press Enter to finish the rectangle and stay in the same command.

Red Rectangle Attributes Settings

n In the Home tab Attributes group set the
attributes based on the notes shown on the
left side of the exercise as shown.

Create The Red Rectangle

n Create the rectangle by selecting the point in the right column.
n Press Enter to finish the rectangle and stay in the same command.

Blue Rectangle Attributes Settings

n In the Home tab Attributes group set the
attributes based on the notes shown on the
left side of the exercise as shown.

Create The Blue Rectangle

n Create the rectangle by selecting the point in the right column.
n Select the OK button to exit the command.

156
Geometry Manipulation Levels

LEVELS
A Mastercam file can contain separate levels for wireframe, surfaces and drafting entities. By organizing
your drawings into levels, you can easily control which areas of your drawing are visible at any time. You
are always drawing on the Main Level. Mastercam also allows copying or moving of geometry from level to
level, lets you hide levels from view, provides level naming utilities and allows you to organize several
levels into sets.

7.3 How to name levels to better manage them

n Make sure that Levels is enabled in the View tab,
Managers group.

n Select the Levels panel if needed.

n New levels can be created by selecting the green addition icon
near the top left corner of the Levels panel.
n In the Levels panel change the Number to 1 and in the Name
field type "Green Rectangles" as shown.

n In the same Levels panel, change the Number to 2 and in

the Name field type "Red Rectangles" as shown.

n Repeat the steps described above for Level 3 inputting the

Name of "Blue Rectangles".

n Make Level 4 the Main Levelby clicking on it in the Levels

panel, and name it "Notes" as shown.

157
Geometry Manipulation Levels

Note: There is no association between levels and colors. Level 4 has no entities. You will learn how to
move the notes onto level 4.

7.4 How to hide levels to control what is visible

n To hide Level 2 click on the "X" in the Visible column
next to the level that you want to hide. The "X" will be
removed as shown in the following picture.
n The Red colored rectangle should not be visible on your
screen.

n To make Level 2 visible again, select Level 2 and click in the

Visible column next to Level 2 as shown.

7.5 Move entities onto different levels

Move All Notes Onto Level 4

Note: All notes were done using the Drafting Notes command. To select them quickly you can
use Quick Mask Drafting button. The button is divided into two sides. The left side of the
button selects all the drafting entities, while the right side of the button allows you to select only
drafting entities.

n Click on the left side of the Quick Mask button to Select all drafting entities.

n From Home tab, in the Organize

group click on the Change Levels icon
as shown.

n In the Change Levels dialog box, leave Move and Use Active Level
enabled as shown.
n Select the OK button to exit the Change Levels dialog box.

158
Geometry Manipulation Levels

n The Levels Manager panel should look as shown.

n To make only Level 4 visible, click

the Turn all levels off button.
n You should only see the notes on
the screen.

Note: Make sure that you always have Active (Main)

level visible which can be found by clicking the Display
options icon.

n To make all levels visible, click on Turn all levels on

button.

Move the table center lines on Level 5

n From the Quick Mask buttons, click on the right side of the Select all advanced button.

159
Geometry Manipulation Levels

n Enable and click on the Style button, then enable Center lines.
n Enable and click on the Color button, then enable color red no. 12.

Note: All entities that meet the criteria should be selected.

n Right mouse click in the graphics window and in the Mini Toolbar,
click on the Change Levels icon.
n In the Change Levels dialog box, leave Move and disable Use
Active Level as shown. In the Number field enter 5.
n In the Name field enter Table.

Move the points on Level 6

n From the Quick Mask buttons, click on the left side of the QM Points to Select all points
button.

160
Geometry Manipulation Levels

n Right mouse click in the graphics window and in the Mini

Toolbar, click on the Change Levels icon as shown.
n In the Change Levels dialog box, leave Move and disable Use
Active Level as shown. In the Number enter 6.
n In the Name field enter Points.

n The Levels Manager should look as shown.

7.6 Change the color, the line style and the line width

n From the Quick Mask buttons, click on the Select all advanced
button and enable the Table level.

n In the
Attributes
group, click on
the Set All
icon.

161
Geometry Manipulation Levels

n Enable color orange 138, break style and select the thickest line as line width.
n Once you select the OK button to exit the Attributes dialog box.

n The lines should look as

shown.

162
Geometry Manipulation Step 8: Chaining - Wireframe Mode

STEP 8: CHAINING - WIREFRAME MODE

Chaining is used to select a number of entities when modifying or transforming existing entities or when
creating a toolpath. The entities form a chain when the distance between two consecutive entity endpoints
is less than the chaining tolerance (0.0001 in the system configuration). The chaining dialog box operates
in two modes: Wireframe (default) and Solids. Two buttons at the top let you switch between modes if both
wireframe and solid entities are in the geometry.

Wireframe Chaining

8.1 Open
CHAINING.MCAM
n From the QAT, select

the Open icon.

n Select
CHAINING.MCAM.

Note: In this exercise the instructor uses Analyze Chain command to be able to see the Chaining
dialog box and the options to be explained.

163
Geometry Manipulation Step 8: Chaining - Wireframe Mode

8.2 Chaining Dialog Box and Chain Selection

Chain options lets you create a chain by clicking on an entity. This default chaining method is active when
the Chaining dialog box first opens (in Wireframe mode).

n In the Levels Manager, make only Level 1 visible.

n From the Home tab, Analyze group, select Chains.

Note: The chain starts with the entity that you select,
from its closest endpoint. Also take note that the
entire contour is selected.

n In the Chaining dialog box, the Chain

button should be enabled.
n Select the chain close to the endpoint of
the entity where you want the chain to
start.
n Choose the Reverse button to change
the chaining direction.

n You can change the starting location using the Forward, Backward or Dynamic
buttons.
n Choose the Forward or Back button. The chaining arrow will move along the
chain one entity at a time. Continue moving the chaining arrow until the point is in
the desired position.
n Choose the Dynamic button and move the mouse along the contour to move the
chaining arrow. When the arrow is in the desired position click to select the point.
n Choose Unselect to unselect the chain.
n Press the Esc key to exit the command.

164
Geometry Manipulation Step 8: Chaining - Wireframe Mode

8.3 Chaining - Window Selection

Window option selects multiple chains by drawing a rectangle around them. Mastercam orders the chains
based on the position of the first corner of the window, which defines the search point. By default, Window
chains all entities inside the chaining window. To modify this behavior choose another option on the inside
drop-down list.

n From the Home tab, Analyze group, select

Chains.
n In the Chaining dialog box, enable
Window button as shown.
n Make a window around the two inside
chains.

n Sketch approximate start point. Pick a point

close to where you want the chain to start from.

n The selected geometry should look as

shown.

165
Geometry Manipulation Step 8: Chaining - Wireframe Mode

8.4 Chaining - Area Selection

Area option selects all chains within a closed boundary with a single mouse click. .

n From the Home tab, Analyze group,

select Chains.
n In the Chaining dialog box, enable Area
button as shown.
n Click inside of the left red chain.
n The geometry selected should look as
shown.

n Click on the Unselect button.

n Click close to the middle of the geometry to
select all the chains with one click.

8.5 Chaining - Single Selection

Single option creates a chain out of a single line, arc, or spline.

n Click on the Unselect button.

n In the Chaining dialog box, enable

Single button as shown.
n Click on the chain as shown.
n The selected geometry should look
as shown.

166
Geometry Manipulation Step 8: Chaining - Wireframe Mode

8.6 Chaining - Vector Selection

Vector option creates chains from entities that intersect a vector line, extending chains in both directions
until a branch point is encountered.

n Click on the Unselect button.

n In the Chaining dialog box, enable Vector button as
shown.
n Create a line as shown.

n Press Enter.
n The selected geometry should look as shown.

8.7 Chaining - Partial Selection

Partial option creates an open chain with two mouse clicks. In the graphics window, click on the entity
where you want to start the chain, then click where you want to end the chain. Mastercam creates an open
chain consisting of all adjacent entities between these two points.

n Click on the Unselect button.

n In the Chaining dialog box, enable Partial button as
shown.
n Select the first entity as shown.

n Select the last entity.

n The selected geometry should look as shown.

167
Geometry Manipulation Step 8: Chaining - Wireframe Mode

8.8 Chain with Branches

A Branch Point is the position where the endpoints of two or more entities meet. Branch points indicate
where there are different paths that the chain can take. When Mastercam encounters a branch point
during chaining, it prompts you to choose the path for the chain to follow. You can also end the chain at the
branch point by choosing Apply or pressing [E].

n In the Levels Manager , make only

Level 3 visible.
n From the Home tab, Analyze group,
select Chains.
n Select the chain as shown. The start of
the chain is symbolized by the green
arrow .
n The end of the chain is symbolized by
the red arrow. You need to guide the
red arrow to the next branch.

n Select the Next button if the red arrow points

towards the desired branch.

n Continue to select the Next button if the red

arrow points towards the desired branch. Otherwise,
select the Adjust button.
n You can also use keyboard shortcuts to do this: X for
Next, and J for Adjust.
n Complete the chaining as shown.
n Select the End chain button to finish the chaining.

n Press Esc button.

168
Geometry Manipulation Step 8: Chaining - Wireframe Mode

8.9 Chaining Options - Mask on Color

Chaining Options -Mask

Use Chaining Options dialog box to set default values for a number of choices that affect how you work
with chains.
Mask on Color opens the Color Mask dialog box, where you can set a color mask. A color mask excludes
from chaining all entities except those whose color(s) match the color(s) you select.

n In the Levels Manager , make only Level 4 visible.

n From the Home tab, Analyze group, select Chains.
n In the Chaining dialog box, click on the Options button.

n The Chaining Options appear as shown.

n Enable Color and click on the Color button.
n In the Color Mask dialog box, click on Clear All button to remove
the selections.
n Select the dark blue color number 9.
n Select the OK button to exit Color Mask dialog box.
n Select the OK button to exit Chaining Options dialog box.

Note: The Options button, in the Chaining dialog box, changes to

reflect that an option is enabled in the Chaining.

Chain option selection

n Leave the Chain button enabled and

hover the cursor above the chain. The
selection color appears only when the
cursor is above the dark blue entities.
n Select the chain as shown

Note: Although the full chain option is

enabled, only the dark blue color entities
that can form a chain are selected.

169
Geometry Manipulation Step 9: Analyze Chains And Fix Their Problems

Window option selection

n Click on the Unselect button.

n Enable the Window button and make
a window around the entire geometry.
n Click somewhere inside of the window
for the approximate sketch point.
n The geometry should be selected as
shown.

Note: Although the window was

around the entire geometry, only the
dark blue color entities that can form a
chain are selected.

For other Chaining Options available in the Wireframe Chaining, such as Ignore depths (in 3D mode),
Start chain at point and Break entities Dynamic check this video:

Wireframe Chaining Options - Start at point -Ignore Depths - Break entities in Dynamic

STEP 9: ANALYZE CHAINS AND FIX THEIR PROBLEMS

Chaining is a process to select multiple entities (lines, arcs, point, splines etc.). Chaining is used when
modifying or transforming existing entities or when creating a toolpath. The entities form a chain when the
distance between two consecutive entities is less than the chaining tolerance (0.001 as stated in the
system configuration).

Analyze Chain

9.1 Open ANALYZE CHAIN.mcam

n From the QAT, select the Open icon.

n Select ANALYZE CHAIN.mcam.

REFERENCE INFORMATION
When selecting geometry to create a toolpath it is important in certain circumstances to chain the geometry
in the proper direction as it will determine the direction the cutter travels when machining the part. Below is
an example of how to select geometry using the chaining method.

170
Geometry Manipulation Step 9: Analyze Chains And Fix Their Problems

To change the direction of the arrows just click on Reverse from the Chaining dialog box.

Chaining Problem Diagnostic

Description Check Fix

Chain stops: Lines do not
touch

Zoom in to inspect Trim lines together using trim 1 entity

Chain stops: Lines cross

Zoom in to inspect Trim lines using trim 2 entities

Lines do not touch

Look at geometry in ISO Gview Use Transform Project.

171
Geometry Manipulation Step 9: Analyze Chains And Fix Their Problems

Description Check Fix

Duplicate entities: Identical entities
on top of each other

Zoom into the area and you will notice a Delete

thicker line Duplicates

Overlapping entities: Entities of

different lengths on top of each
other

Use
Zoom the area, use Analyze menu and
Findoverlap.dll
move the cursor on the top of the entities
C-hook

9.2 Use Delete Duplicates to clean the geometry

n Hold down the Shift key and select each chain.

n You will notice the chains do not start or end at the beginning or end of the curves.
n To unselect the entities, from the Quick Mask buttons click on the Clear selection.

n From the Home tab, Delete

group, select Duplicates to
remove all identical entities from
the screen.
n The system will display how
many duplicate entities were
erased as shown.
n This will fix the upper right
contour.

172
Geometry Manipulation Step 9: Analyze Chains And Fix Their Problems

9.3 Use FindOverlap Chook to remove overlapping entities

Note: The HLE/Demo version of Mastercam does not support C-Hooks.

n To unselect the entities, from the Quick Mask buttons click on the Clear selection.
n The upper left contour has entities of different lengths on top of each other. To fix the geometry use
FindOverlap.dll.
n To use this open the Chooks folder, enter the Alt + C keys or, from the Home tab, select the Run

Add-In icon.
n From the Chooks folder, select FindOverlap.dll and choose the Open button.
n Make a window around all entities and press Enter to finish the selection.

n If overlap entities are present in the geometry the FindOverlap C-Hook

dialog box appears.
n Select the Cleanup button in the FindOverlap C-Hook dialog box.
n Choose OK when the warning dialog box appears.

n Select the OK button.

n This will fix the upper left contour.

9.4 Entities created at different depths

n Right mouse click in the graphics window and

select the Isometric graphics view.
n You can see the arc and the line that are not at
the same Z depth with the rest of the geometry.

173
Geometry Manipulation Step 9: Analyze Chains And Fix Their Problems

n Use Transform Project to move entities to the same Z depth

The Transform Project command is used to move all the entities to

the same depth in the current construction plane (Top).

n From Transform tab, the Position group, select the Project

icon.
n When prompted to select the geometry, choose the Select all
advanced button to select all entities.
n Ensure Move is enabled in the Project panel. Select the option
to project the entities to the current construction plane and set
the depth to zero, as shown.
n Right mouse click and from the Mini Toolbar, select the Clear
Colors icon.

9.5 Use Trim 2 entities command to extend or trim entities to their intersection point

n From the Wireframe tab, the Modify group, select the Trim To Entities icon.
n In the Trim To Entities panel, enable Trim 2 entities.
n Zoom in to the point where the chain stops and trim the entities. Make sure you select the entities on
the side that you want to keep.

174
Basic Drilling

175
Basic Drilling Introduction

INTRODUCTION
This lesson introduces the Drilling toolpath. Hole making is likely the most fundamental and widely used
machining operation. In this tutorial you will learn techniques for manually selecting holes from the wireframe
geometry for drilling and the parameters and methods to create efficient operations.

NEW CONCEPTS COVERED IN THIS TUTORIAL:

n Bolt Circle command to create the holes.
n Set a cylindrical stock.
n Drilling parameter settings options.
n Verify the toolpaths .
n Post processing Drill operations.

INSTRUCTOR DEMONSTRATION:
Topics:

n Bolt Circle command.

n Set a cylindrical stock.
n Point selection and mask on arc
selection for drilling
n Drill the 1/2" holes
n Drill the 1/2" counterbore holes

176
Basic Drilling Point/Circle Toolpaths Information

POINT/CIRCLE TOOLPATHS INFORMATION

Drill/Counterbore toolpaths are for drilling holes with depths of

less than three times the tool diameter. This toolpath drills to
full depth in one motion.

Peck Drill toolpaths are for drilling holes with depths of more than three
times the tool diameter. The tool retracts fully out of the hole to remove
material chips.

Chip Break toolpaths are for holes with depths more than three
times the tool diameter. The tool retracts partially out of the
drilled hole to break material chips.

Tap toolpaths are used to create right hand and left hand
internal threaded holes.

Bore 1, Bore 2 and Fine bore toolpaths are for holes requiring a
smooth surface.

Customizable drill cycle toolpaths drill holes using customized

parameters. (For more information, see “Customizing drill
parameters” in Mastercam Help.)

Circle Mill toolpaths allow creating large holes during drill

cycles with a milling operation.

Helix Bore toolpaths allow creating large holes during drill

cycles with a specialized operation. The helix bore toolpath
uses a boring tool cutting down in a helical motion, then
performs a finish pass in a helical upward motion.

Thread Mill toolpaths are used for machining a thread with a

thread mill or other suitable tool. For internal threads, you must
drill a hole first.

177
Basic Drilling Part Drawing

PART DRAWING

178
Basic Drilling Step 1: Create The 2D Geometry

STEP 1: CREATE THE 2D GEOMETRY

In this step you will use the Circle Center and the Bolt Circle commands to create the circles.

1.1 Use Circle Center Point command to create

the 5.5" diameter circle and the 1.75" diameter
circle.
n From the Wireframe ribbon, Arcs group select
Circle Center Point icon.
n Select the Origin as the center point and in the
Circle Center Point panel enter the Diameter 5.5.
n Press Enter twice to finish the circle and remain in
the same command.
n Select the Origin again as the center point and in the
Circle Center Point panel enter the Diameter 1.75
n Click on the OK button to exit the command.

n From the Wireframe

ribbon, Point Position
group, select Bolt Circle
icon.

179
Basic Drilling Step 1: Create The 2D Geometry

1.2 Bolt Circle

n Select as the base point the Origin (or Center of the

arcs).
n In the Bolt Circle panel, make sure the Method is set to
Full circle.
n Number = 4.
n Diameter = 3.5.
n Start Angle = 0.0.
n Arc diameter = 0.625.
n Select the OK and Create new Operation button.

n The geometry should look as shown.

180
Basic Drilling Step 1: Create The 2D Geometry

n Select as the base point the Origin (or Center of

the arcs).
n In the Bolt Circle panel, make sure the Method is
set to Full circle.
n Number = 4.
n Diameter = 3.5.
n Start Angle = 45.0.
n Arc diameter = 0.5.
n Select the OK and Create new Operation

button.

n The geometry should look as shown.

n Save your part as "Basic Drilling.Mcam"

181
Basic Drilling Step 2: Create The Job Setup

STEP 2: CREATE THE JOB SETUP

In this step you will supply Mastercam with information about tool settings and stock size before starting to
create the toolpaths.

2.1 Load the Mill Default

n Open Toolpaths Manager.

n From the Machine tab, select Mill and Default.

2.2 Set the Files

n Click on the Toolpaths tab to open Toolpaths

Manager.
n Expand the Properties and select the Files icon.
n Set the Default program number to 1003.

182
Basic Drilling Step 2: Create The Job Setup

2.3 Set the Stock

n Select the Stock Setup tab.

n Make sure that Show wireframe entities is

enabled.
n Select the Create cylindrical stock icon as
shown.

183
Basic Drilling Step 2: Create The Job Setup

n Press Ctrl + A to
select all entities.
n Set the Origin to the
center of the top
face.
n Z = 0.75.
n Axis set to Z Axis.
n Right mouse click on
the Cylindrical 1
and select Set as
active stock.

2.4 Tool

n Select the Tool and enable Assign tool numbers

sequentially.

n Select the OK button to exit Machine Group Setup.

184
Basic Drilling Step 3: Drill The Holes

n To check the stock, in the Toolpaths ribbon you

can enable Stock display.

n The stock should look as shown.

We will generate 2 separate operations to drill the 8 holes. These will include:

n Drill through the four 1/2" holes

n Drill through the 5/8" holes

STEP 3: DRILL THE HOLES

In this toolpath you will use a 1/2” Drill to drill the holes. To select the holes you will pick the center
locations.

n In the 2D group, select the Drill icon.

185
Basic Drilling Step 3: Drill The Holes

n Select the edge of each hole as

shown making sure the Center
Point is highlighted when selecting.

Note: You will learn in the next steps

other ways of selecting the holes.

TOOLPATH HOLE DEFINITION REFERENCE INFORMATION

Mask On Arc picks arcs by matching a selected arc diameter. Diameter
shows the value to match. This is set by clicking on an arc in the graphic
area.
Tolerance sets the arc machining tolerance.
Copy Previous Points reuses the last set of geometry selected for a
toolpath operation. This is useful for re-selecting holes for multiple
operations.
Subprograms lets you select a previously created drill toolpath and apply
the new operation to its points.
Reverse reverses the point order.
Reset to Original Order resets the selected points back to their original
order.
Change Parameters at Point displays the Change Parameters at Point
panel.
Move Up moves the selected points up in the Features list.
Move Down moves the selected points down in the Features list.

186
Basic Drilling Step 3: Drill The Holes

n In the Toolpath Hole Definition select the OK button.

3.1 Tool

n Use Select tool

from library and the
Filter to select the
1/2" Drill as shown.
n In the Comment
area enter "Drill the
four 1/2" diameter
holes".

3.2 Cut Parameter

n Set the Cycle to Drill/Counterbore

as shown.
n Set the rest of the parameters as
shown.

3.3 Tool Axis Control

n In the Tool Axis Control page make sure that the Output format is set to 3 axis.

187
Basic Drilling Step 3: Drill The Holes

3.4 Linking Parameters

n Clearance = 2.0
(Absolute).
n Enable Only at the
start and end of
operation.
n Retract = 0.25
(Absolute).
n Top of stock =
0.0 (Absolute).
n Depth = -1.0
(Absolute).
n Enable Tip Comp
as shown. Set the
Amount to 0.05.

REFERENCE INFORMATION
Absolute values are always measured from the origin (0,0,0).
Incremental values are measured relative to chained geometry or other parameter values.
Clearance sets the height at which the tool moves to and from the part. If it is not selected, the Retract value
is used as the clearance plane. You can set a point on the geometry or manually enter a value.
Retract sets the height that the tool moves up to before the next tool pass.
Top of Stock sets the height of the material in Z axis. To set absolute values, click the button and select a
point on the geometry or manually enter a value. Incremental values are measured from the chained
geometry.
Depth determines the final lowest machining depth. To change Absolute depth, choose the Depth button
and select a point on the geometry or enter a value manually. Incremental values are relative to the
chained geometry and not the top of the stock.
Depth Calculator button opens the Depth Calculator so you can calculate proper drilling depth.

188
Basic Drilling Step 3: Drill The Holes

3.5 Plane Display Settings

n To see the Planes displayed in the graphics window, enable Display

graphical elements button as shown.

n Select the Hide dialog button as shown.

n The planes should look as shown.

n Press Esc when done.

3.6 Coolant

n From the Tree View List, select Coolant and turn the
Flood on as shown.
n Select the OK button to exit 2D Toolpaths - Drill
Simple drill - no peck.

3.7 Repeat the Backplot procedure

n Rotate the part and check if the tool breaks

through as shown.

189
Basic Drilling Step 4: Drill The 5/8" 4 Holes

STEP 4: DRILL THE 5/8" 4 HOLES

In this step you will learn how to use Mask on arc option to select the 5/8 " diameter holes.
Mask On Arc picks arcs by matching a selected arc diameter.
Diameter shows the value to match. This is set by clicking on an arc in the graphic area.
Tolerance sets the arc machining tolerance.

n Before starting the next operation, turn off the toolpath display
for the Drilling operation you just completed as shown.

n In the 2D group, select the Drill icon.

n In the Toolpath Hole Definition panel enable Mask on arc.

n Select as the arc to match the 5/8".

190
Basic Drilling Step 4: Drill The 5/8" 4 Holes

n Make a Window around the entire part.

n The 5/8" holes are selected only as shown.

n In the Toolpath Hole Definition select the OK button.

4.1 Tool

n Use the Filter to

select the 5/8" Drill
as shown.
n Enter in the
Comment area "Drill
the four 5/8" holes".

191
Basic Drilling Step 4: Drill The 5/8" 4 Holes

4.2 Cut Parameter

n Set the Cycle to Drill/Counterbore.

4.3 Linking Parameters

n Clearance = 2.0 (Absolute).

n Enable Use Clearance only at the start and end of operation.
n Retract = 0.25 (Absolute).
n Top of stock = 0.0 (Absolute).
n Depth = -1.0 (Absolute).
n Tip Comp enabled.

4.4 Plane Display Settings

n To see the Planes displayed in the graphics window, enable Display

graphical elements button as shown.

n Select the Hide dialog button as shown.

n The planes should look as

shown.
n Press Esc when done.

n Select the OK button to exit 2D Toolpaths - Drill/Circles

Simple drill - no peck.
n The results of the drilling should look as shown.

192
Basic Drilling Step 5: Verify The Part With The Fixture

STEP 5: VERIFY THE PART WITH THE FIXTURE

5.1 Repeat the Solid Verify procedure

n From the Toolpaths Manager, click on the

Select all operations icon as shown.
n Select Verify selected operations icon.

n In the Verify graphics window, right mouse click and select Fit.
n Right mouse click and select Isometric.
n Click in the Visibility group on the Stock to make it
translucent.

Note: The center hole can be machined with a Circle Mill

toolpath that will be explained later in the book.

STEP 6: POST PROCESS THE TOOLPATHS

STEP 7: SAVE YOUR FILE
n Save the file as Basic Drill.MCAM.

SUMMARY:

In this lesson, you further added to your toolpath skill set by learning how to create a soft jaw vise that allows
you to verify the toolpaths. You learned how to merge the part and align it in the vise. You learned how to
create counterbore holes using the Solids Hole command.
You machined the hole shapes using both milling techniques as well as multiple types of drill operations. You
also learned the Toolpath Hole Definition options for sorting and applying special parameters to hole
locations. After completing this lesson and some of the practice exercises that follow you should be able to:
n Bolt Circle command.
n Set a cylindrical stock.
n Point selection and mask on arc selection for drilling.
n Create standard Drill cycles.

193
Basic Drilling Exercise

EXERCISE

Job Description:

Program the part above with the following requirements:

n Create the 2D Geometry.
n Select tools and create the Drill toolpaths to Drill all holes shown in the print.
n Run Backplot and Solid Verify to confirm results.
n Create G-code for NC machine.

194
Import CAD Files

195
Import CAD Files Introduction:

INTRODUCTION:
This lesson will introduce you to how to utilize and prepare geometry that has been imported from other CAD
systems to make your programming job easier.
This lesson will focus on what we consider to be the most useful and necessary tools when importing a file
from a different CAD software.

OVERVIEW OF EXERCISE:
In this lesson you will become familiar with importing files from AutoCAD. You will learn how to prepare the
imported geometry for machining.

NEW CONCEPTS COVERED IN THIS LESSON:

n Importing 2D geometry.
n Set the Origin.
n Scale the geometry.
n Organize the geometry on levels.

INSTRUCTOR DEMONSTRATION PREVIEW:

Note: This entire lesson is a joint Instructor / Student exercise.

Topics:

n Import AutoCAD files

n Prepare the file for machining.

196
Import CAD Files Step 1: Import A Cad File

IMPORT 2D PART1
STEP 1: IMPORT A CAD FILE

Mastercam lets you read (import) a variety of CAD file types into the Mastercam database. You can also
write (export) Mastercam files to a variety of different file formats. To convert files from other CAD
packages you need to use File Open command and set the file extension to the extension of the software you are
importing from.

Resources - Download the file from www.EMASTERCAM.COM/TRAININGFILES/

1.1 Open 2D Part1.DWG

n From the QAT, select the

Open icon.
n Change the File type to
AutoCAD Files
(*.dwg;*.dxf;*.dwf;*.dwfx)
n Select 2D Part1.DWG. and
choose Open button.

n Select the entire geometry and change the wireframe color

from the attributes tab if needed.

n Fit (Alt+F1) the geometry to the screen,

then using the mouse wheel, unzoom the
geometry.

197
Import CAD Files Step 2: Transform Move To Origin

n If you do not have the Grid

displayed, you can display the origin
by pressing F9.

STEP 2: TRANSFORM MOVE TO ORIGIN

Move to Origin quickly moves all visible geometry to the current WCS origin based on a point that you
select with the AutoCursor. Move to Origin respects the 2D/3D construction mode.

n From the Transform tab,

Position group, select Move to
Origin icon.

n Select the lower left corner to translate the geometry

from this point to the Origin.

n Fit the geometry to the screen.

n The geometry should look as shown.

n Right mouse click in the graphics window and select the Clear colors icon to reset the color.
n Save the file.

198
Import CAD Files Step 3: Prepare Imported Geometry - Suggested Steps

IMPORT 2D PART2
Resources - Download the file from www.EMASTERCAM.COM/TRAININGFILES/

STEP 3: PREPARE IMPORTED GEOMETRY - SUGGESTED STEPS

3.1 Start a new Mastercam part
n Select New button from the QAT.

n Display the Axis with Shortcut key

Alt+F9. (Or just use the Grid). Scroll
down on the mouse wheel to zoom out to
have more room to draw.

3.2 Open the AutoCAD file

n Select Open button from the QAT.

n Open the DWG file called: 2D Part2.DWG

Note: A warning message might appear that

the TXT TrueType (R) font cannot be found
on this computer. The font will be replaced
with Mastercam default font. Select the
OK button to accept it.

n Fit the geometry to the screen (Alt+F1).

n Make a window around the entire geometry

(including the dimensions) and change the
wireframe color from the attributes tab if needed.

199
Import CAD Files Step 3: Prepare Imported Geometry - Suggested Steps

n Use the keystroke shortcut F2 to zoom out until

you see the geometry and the Origin Axis or
Grid.

3.3 Move To Origin

n Select the lower left corner as the Point to
translate from as shown.

n Right mouse click and select Clear Colors icon

to return geometry to the original color.
n Right mouse click again and select Fit icon.
n Use the mouse wheel to scroll down to unzoom
the geometry as shown.

n Right mouse click in the graphics window

and ensure that the construction mode is set
to 3D.

200
Import CAD Files Step 3: Prepare Imported Geometry - Suggested Steps

3.4 Statistics
n Select the Home tab and select Statistics button in the
Analyze group to confirm what type of geometry is on the
screen.

Note: We will move the four dimensions to a new level

soon since they will not be needed for Toolpath creation.

3.5 Analyze an
Entity
n Use Analyze
Entity command
(F4) and select
one of the
horizontal lines.

Note: The dimension reads 7.50 but the entity is only 3.75 long. This means the geometry imported is
not to scale. We will need to Scale the geometry to the appropriate value before applying the toolpaths.

3.6 Scale the entire geometry

n From the Transform ribbon, in the Size group, select
Scale icon.
n Make a window around the entire geometry as
shown.

201
Import CAD Files Step 3: Prepare Imported Geometry - Suggested Steps

n Press Enter to finish the selection.

n In the Scale panel enable Move
n Disable Auto center and for Style ensure that Factor is
enabled.
n Click on the Calculate icon.

n In the Scale Calculator enter the values as shown.

n The Scale factor will be automatically calculated.
n Select the OK button to exit Scale Calculator panel.

n Select the OK button to exit Scale panel.

n Fit the geometry to the screen.

n The geometry should look as shown.

202
Import CAD Files Step 3: Prepare Imported Geometry - Suggested Steps

n Use Analyze Entity command and

check the horizontal line again.

Note: Line length should now be 7.5

which matches the dimension.

3.7 Move the dimensions on a different level

n Access the Levels Manager by selecting the tab.

n Name Level 1 "Geometry".
n Create a new level to put the dimensions on.
n Number = 50.
n Name = "Dimensions".

n Click on the left side of the Quick Mask button to Select all drafting entities.

n From Home tab, in the

Organize group click on the
Change Levels icon as
shown.

203
Import CAD Files Step 3: Prepare Imported Geometry - Suggested Steps

n In the Change Levels dialog box, leave Move and Use

Active Level enabled as shown.
n Select the OK button to exit the Change Levels dialog box.

n In the Levels Manager set the Active Level to 1

and make Level 2 invisible as shown.

n The geometry should look as shown.

204
Import CAD Files Step 3: Prepare Imported Geometry - Suggested Steps

3.8 Change the color and the line thickness

n Right mouse click in the graphics window and

from the Mini Toolbar, select the Set All
button.
n When prompted, window select all of the
geometry in the graphics screen and select
End Selection or press Enter.

n In the Attributes dialog box, set the Color to blue and the Line Width to the
fourth thickest line
n Select the OK button to finish the command.

n The completed geometry should look as

shown.

205
Import CAD Files Step 3: Prepare Imported Geometry - Suggested Steps

SUMMARY:
After completing this lesson and some of the practice exercises that follow you should be able to:
n Import geometry from other CAD formats.
n Move geometry to the origin.
n Use Statistics command to confirm the type of the geometry that is imported.
n Use Analyze entity to check the geometry size
n Scale the geometry to the proper size.
n Organize the geometry on different levels.
n Change the geometry color.
n Change the geometry line thickness.

206
Import CAD Files Exercise #1

EXERCISE #1

Job Description:

Import the geometry and prepare it for machining following these steps:
n Start a new Mastercam file.
n Open the AutoCad file Exercise1-Import.dwg.
n Use Move to Origin command and select the center of the left circle as the Origin.
n Use Analyze Entity to check the part.
n Scale the entire geometry to the proper size.
n Move the dimensions on a different level.
n Change the color and the line thickness.
n Save your part and have the Instructor confirm your results.

207
Import CAD Files Exercise #2

EXERCISE #2

Job Description:

Import the geometry and prepare it for machining following these steps:
n Start a new Mastercam file.
n Open the AutoCad file Exercise2-Import.dwg.
n Use Move to Origin command and select the center of the left circle as the Origin.
n Use Analyze Entity to check the part.
n Scale the entire geometry to the proper size.
n Move the dimensions on a different level.
n Change the color and the line thickness.
n Save your part and have the Instructor confirm your results.

208
Solids Extrude

209
Solids Extrude Introduction

INTRODUCTION
Until now, you have used wireframe geometry to model parts. Wireframe entities work well for relatively
simple parts, but they are limited since they contain no information about the faces or interior of the model
and cannot be shaded. 3D wireframe models can be difficult to create and change.
Solid models use a completely different type of geometry that includes information about the faces and
interior of the part. Solids can be shaded, making it much easier to interpret the designer's intent. They often
require less work to create and are easier to modify than other geometry types.
Starting with a basic shape, called a Base Feature, you progressively apply operations like Cut, Add Boss,
Fillet, and Chamfer, to form the finished part.
Nowadays, most mechanical engineering design is done using solids. Given the advantages of solid
modeling for mechanical design, analysis, and machining, this trend will continue. Therefore, it’s important
for you to understand solid geometry concepts, and how to create and work with them.

OVERVIEW OF EXERCISE:
In this lesson you will become familiar with how to create and modify solids.

NEW CONCEPTS COVERED IN THIS LESSON:

n Extrude Create Solid.
n Extrude Cut Solid.
n Extrude Add Boss.
n Solid Hole.
n Solid Fillet.
n Solid Chamfer.

210
Solids Extrude Part Drawing

PART DRAWING

211
Solids Extrude Instructor Demonstration Preview

INSTRUCTOR DEMONSTRATION PREVIEW

Note: This entire lesson is a joint Instructor / Student exercise.

Topics:

n Extrude Create Solid

n Extrude Cut Solid
n Extrude Add Boss
n Solid Hole
n Solid Fillet
n Solid Chamfer

CREATE THE 2D GEOMETRY

STEP 1: SETTING UP THE GRAPHICAL USER INTERFACE

Please refer to the Getting Started section for more info on how to set up the graphical user interface. In
this step, you will learn how to hide the manager panels to gain more space in the graphics window.

n Use Auto Hide icon to hide all Manager panels.

n The panels will be hidden to the left of the graphics window

as shown.

Note: To un-hide them temporally, you can click on one of the Managers tab to open it.
While creating the geometry, keep the Manager panels hidden. This ensures more space in the graphics
window for the geometry.

212
Solids Extrude Step 2: Set The Planes Follow Rules

STEP 2: SET THE PLANES FOLLOW RULES

Tplane follows Cplane - aligns the Tplane with the Cplane when the construction plane has been
changed by the user, or as the result of another follow rule. The Tplane can still be changed independent
of Cplane.
Cplane = Top in Isometric Gview - aligns the construction plane to the Top plane when the graphics
view has been set to Isometric.

n Click on the Planes tab to open

Planes Manager.
n Click on the Follow rules arrow and
enable only Tplane follows Cplane
and Cplane = Top in Isometric
Gview.
n Disable Cplane follows Gview.

STEP 3: SET THE CONSTRUCTION PLANE AND CHANGE WIREFRAME COLOR

In this step you will learn how to set the Construction Plane to create the flat geometry. By setting the Graphic
View to Top the Construction Plane will be automatically set to Top too.

n Right mouse click in the graphics window and select the Top
(WCS) icon as shown.

Note: You may skip this step if the wireframe color is already set to Blue #9.

213
Solids Extrude Step 4: Create Rectangles Given The Size And Anchor

n Right mouse click in the graphics window and

from the Mini Toolbar, left click on the arrow
next to the Wireframe Color icon and select
the color Blue #9 as shown.

STEP 4: CREATE RECTANGLES GIVEN THE SIZE AND ANCHOR

In this step you will learn how to create two rectangles given the width, height, and anchor point.

Step Preview:

4.1 Create the 8.0" X 4.0" Rectangle

Wireframe

n From the Shapes

group, select
Rectangle.

214
Solids Extrude Step 4: Create Rectangles Given The Size And Anchor

n In the Rectangle panel, enter the Width 8.0 and Height

4.0.
n Enable Anchor to center as shown.
n Press Enter after typing the values to see a preview of the
rectangle.

Anchor to center sets the base point of the rectangle to its center and draws the rectangle outward from the center.
Create surface creates a surface inside of the rectangle. Surface creation and Surface toolpath are covered in Mill
Advanced. A surface can be described as the skin on the top of a 3D wireframe. If the Create surface option is on, in
addition to the four lines of the rectangle, you will also see extra lines which represent the surface display while it is
not shaded.

n [Select a base point]: Select the Origin as shown.

n Make sure that when selecting the origin, the

visual cue of the cursor changes as shown.

n Select the OK and Create New Operation

button to stay in the same command.

n To fit the drawing to the screen, press Alt + F1.
n To zoom in and out, hover the cursor
approximately above the center of the part and
scroll the mouse wheel up and down.

Note: While creating geometry for this tutorial, if you make a mistake, you can undo the last step using
the Undo icon. You can undo as many steps as needed. If you delete or undo a step by mistake, just
use the Redo icon. To delete unwanted geometry, select the geometry first and then press Delete
from the keyboard. To zoom or un-zoom, move the cursor in the center of the geometry and scroll up or
down the mouse wheel.

215
Solids Extrude Step 4: Create Rectangles Given The Size And Anchor

4.2 Create the 5.0" X 1.25" Rectangle

n Enter the Width, the Height and leave Anchor to center

enabled as shown.
n Make sure that the Create surface button is not selected.

n [Select a base point]: Select the Origin as

shown.
n Select the OK button to exit the command.

n The drawing should look as shown.

216
Solids Extrude Step 5: Create The Parallel Lines

STEP 5: CREATE THE PARALLEL LINES

In this step you will learn how to create parallel lines to existing lines given the distance between the lines.
We are creating the lines to use them as part of the geometry as well as construction lines.

Step Preview:

Wireframe

n From the Lines group, select Line Parallel as shown.

n [Select a line]: Select Entity A as

shown.

n [Select the point to place a parallel line through]:

Select a point to the right of the selected line.

217
Solids Extrude Step 5: Create The Parallel Lines

n In the Line Parallel panel, enter an Offset Distance of

1.0 as shown.
n Select the OK and Create New Operation button to stay
within the command.

n [Select a line]: Select Entity A again.

n [Select the point to place a parallel line through]: Select a
point to the right of the selected line.
n In the Line Parallel panel, enter an Offset Distance of 7.0
as shown.
n Select the OK and Create New Operation button to stay

within the command.

n [Select a line]: Select Entity B as shown.

n [Select the point to place a parallel line through]:
Select a point above the selected line.

218
Solids Extrude Step 5: Create The Parallel Lines

n In the Line Parallel panel, enter an Offset Distance of

1.0 as shown.

n Select the OK and Create New Operation button to

stay within the command.

n [Select a line]: Select Entity B again.

n [Select the point to place a parallel line through]: Select a
point above the selected line.
n In the Line Parallel panel, enter an Offset Distance of 3.0
as shown.
n Select the OK button to exit the command.

n The geometry should look as shown.

219
Solids Extrude Step 6: Clean Up The Geometry Using Divide

STEP 6: CLEAN UP THE GEOMETRY USING DIVIDE

Divide allows you to select the segment of an entity you wish to remove.

Step Preview:

Wireframe

n From the Modify group, select

the Divide icon as shown.

n In the Divide panel, make sure the Trim is enabled.

n [Select the curve to divide / delete]:

Select the segments as shown as
shown.
n Select the OK icon to exit the
command.

n The drawing will appear as shown.

220
Solids Extrude Step 7: Remove The Leftover Lines Using Divide

STEP 7: REMOVE THE LEFTOVER LINES USING DIVIDE

Step Preview:

n From the Modify

group, select the
Divide icon as
shown.

n Select the lines as shown.

n Select the OK button to finish

the command.

n The geometry will appear as

shown.

221
Solids Extrude Step 8: Chamfer The Inside Rectangle

STEP 8: CHAMFER THE INSIDE RECTANGLE

In this step we will use the Chamfer Chain command to apply chamfers to all the corners of the inside
profile.

Step Preview:

Wireframe

n From the Modify

group, click on the
down arrow next to
Chamfer Entities
and select
Chamfer Chains.

n Select the chain as shown.

n Select the OK button to exit Wireframe
Chaining.

n Set the Distance to 0.25 and make sure Trim entities is

enabled in the panel as shown.

222
Solids Extrude Create The Solid

n Select the OK button to exit the command.

n The geometry should look as shown.

CREATE THE SOLID

A Solid is a geometric entity that occupies a region of space and consists of one or more faces, which
define the closed boundary of the solid. A solid operation requires closed boundary geometry.

STEP 9: CHANGE THE SOLID COLOR TO RED

n Right mouse click in the graphics window and from

the Mini Toolbar, left click on the arrow next to the
Solid Color icon and select the color red as
shown.

STEP 10: CHANGE THE MAIN LEVEL TO 2

Levels are a primary organizational tool in Mastercam. A Mastercam file can contain separate levels for wireframe,
surfaces, drafting entities, solids, and toolpaths. By organizing your files into levels, you can easily control which
areas of the drawing are visible at any time and which parts are selectable. By doing so, you will not inadvertently
make changes to areas of the drawing you do not want to change.
In this step we will change the Main Level to 2 to create the solid on Level 2.

n Right mouse click in the graphics area

and in the Mini Toolbar, change the
Level number to 2 as shown.

n Press the Enter key on your keyboard.

223
Solids Extrude Step 11: Create The Solid Body

STEP 11: CREATE THE SOLID BODY

Solid Extrude performs an operation that results in the creation of one or more new solids. Mastercam
extrudes entities by driving the shapes of the entity along a linear path using a specified direction, distance,
and other parameters that further define the results.

Step Preview:

n Right mouse click in the graphics window and select

Isometric view as shown.

n Press Alt + F1 to fit the geometry to the screen.

Note: The construction plane or the graphics view does not affect the way in which the solid is generated.

224
Solids Extrude Step 11: Create The Solid Body

Solids

n From the Create area,

select the Extrude icon
as shown.

n The Chaining dialog box appears as shown.

Chaining is the process of selecting and linking geometry entities such that they
form the foundation of a toolpath, a surface, or a solid. When you chain the
geometry, you can select one or more sets of curves (lines, arcs, and splines) that have
adjoining endpoints.
Chaining differs from other selection methods because it assigns order and
direction to the selected curves. Chaining order and direction determine how
surfaces, solids, and toolpaths are generated.

n Leave the default settings in the Chaining dialog box and select the outside
rectangle as shown.

n [Select chain(s) to extrude 1]: Select the outer

chain as shown.

Note: If you did not select the chain correctly, from

the Chaining dialog box, click on the Unselect
button to undo the previous selection. If you
need to change the chain direction, click on the
Reverse button.

n Select the OK button to exit the Chaining dialog

box.

225
Solids Extrude Step 11: Create The Solid Body

n Press Alt + F1 to fit the geometry inside the graphics

window if needed.
n The Solid Extrude panel will display. An arrow will
appear on the geometry. This arrow indicates the
direction of the extrusion. The arrow should point
downwards.
n Otherwise, in the Solid Extrude panel, click on the
Reverse All icon as shown to flip the direction.

n Press Alt + S to see the solid shaded if needed.

Note: The Type can only be set to Create body as this is

the first solid operation.

n Ensure other parameters are set as shown in the figure.

Extrusion Operation is used to create a solid body, cut a

solid body, or add a boss to another solid.

Reverse Direction extrudes the solid in the opposite

direction from the arrow on the chain indicating the extrusion
direction.

Distance allows you to control the length of extrusion, by

specifying a Distance, extending Through all, extending in
Both directions, or trimming to selected faces.

Both Directions allows you to extrude in both directions

from the chain.

n Select the OK button to exit the command.

226
Solids Extrude Step 12: Create Two Holes

n Press Alt + F1 to fit the geometry.

n The solid should look as shown.

Note: To view the part shaded or unshaded at any time, you can press Alt + S on the keyboard or select
the Wireframe or Shaded icons from the Status Bar.

You can also select the Outline Shaded for a crisp look of the solid.

STEP 12: CREATE TWO HOLES

This step shows you how to create the holes using the Hole command.

Step Preview:

227
Solids Extrude Step 12: Create Two Holes

Solids

n From the Create

group, select Hole.

n Click the drop down arrow beside Template.

n In the Filter enable U.S..
n In the Category section, select the Fractional/Decimal
as shown.

n From the Presets scroll down and select 1/2 - .5.

228
Solids Extrude Step 12: Create Two Holes

n To enter the coordinates of the holes, in the Position area, click on

the Add AutoCursor Position as shown.

n [Select top of hole locations. Press Enter when done]: -Begin

typing the coordinates -3.5, 0. The coordinates field will open in
the upper left corner as shown.
n Press the Enter key on your keyboard.

n Begin typing the coordinates 3.5, 0 as shown.

n Press the Enter key on your keyboard.
n Press Enter again to finish the selection.

n Set the depth to Through all as shown.

229
Solids Extrude Step 12: Create Two Holes

n To add the 0.1 X 45 degrees chamfer at the top of the holes,

enable Top Edge Treatment.
n Make sure that the Chamfer is enabled and change the
Distance to 0.1.
n Leave the Angle set to 90 degrees.
n Select the OK button to exit the command.

n The solid should look as shown.

230
Solids Extrude Step 13: Using Solids Manager To Modify The Holes

STEP 13: USING SOLIDS MANAGER TO MODIFY THE HOLES

In this step you will re-size the 0.5" diameter holes to 0.75" diameter holes with a 0.05 X 45 degree chamfer.
You will use the Solids Manager to modify the diameter.

Step Preview:

n Click on the Solids tab to open the Solids Manager panel.

n In the Solids Manager, you should see only one Solid as

shown.

n To see the solid history with all the operations listed, click on the
plus sign (+) in front of the Solid.

Note: To modify any of the solids operations, double click on the operation. The corresponding dialog
box will appear on the screen, and hence the parameters can be modified. To update the solid after
modifying the parameters, click on the Regen selected button from the Solids Manager.

You can also regenerate all the operations that were modified, using the Regen button.

231
Solids Extrude Step 13: Using Solids Manager To Modify The Holes

n To open the Hole panel, double click on it in the Solids

Manager as shown.

Note: If the panel does not appear, move your mouse outside of the Solid Panel. The Hole panel
should appear.

n In the Hole panel, make sure that the Category is set to

Fractional / Decimal and the Filter is set to Inch.
n From the Presets select 3/4- .75- Drill as shown.

n Enable Top Edge Treatment.

n Make sure that the Chamfer is enabled and change the Distance
to 0.05.
n Leave the Angle set to 90 degrees.

n The preview should look as shown.

n Select the OK button to exit the command.

232
Solids Extrude Step 14: Add A Boss

n The Solids Manager should look as shown.

n Click on the Regen button to update the solid.

n The solid should look as shown.

STEP 14: ADD A BOSS

In this step, another extrusion operation will be performed to add a boss to the part.

Step Preview:

Solids

n From the Create

area, select Extrude
as shown.

233
Solids Extrude Step 14: Add A Boss

n Leave the default settings in the Chaining

dialog box and select the inside shape as
shown.
n Select the OK button to exit the Chaining
dialog box.
n Press Alt + F1 to fit the geometry inside the
graphics window if needed.

n In the Solid Extrude panel set the Type to Add boss and make sure the Distance is set to 0.25 as
shown. The arrow indicating the direction of the extrusion should point upwards as shown.
n Otherwise, in the Solid Extrude panel, click on the Reverse All icon as shown to flip the
direction.
n Select the OK button to exit the command.

n The solid should look as shown.

234
Solids Extrude Step 15: Chamfer The Top Of The Boss

Note: In the Solids Manager, you should only see one solid.
Otherwise, delete the second solid and redo the last step
making sure that Add boss option is enabled in the Solid
Extrude panel.

STEP 15: CHAMFER THE TOP OF THE BOSS

One Distance Chamfer uses edge blending to create a symmetrical beveled edge with the same chamfer distance
for both edge faces. In this step we will apply a 0.1" X 45° chamfer to the top of the boss.

Step Preview:

Note: To be able to see the solid edges better, you will make the wireframe invisible using Levels
Manager.

n Select the Levels tab as shown.

n To make Level 1 invisible, click on the X under Visible

column next to Level 1 as shown. (The X indicates the
selected level is visible.)

Solids

n From the Modify group, select One Distance

Chamfer as shown.

235
Solids Extrude Step 15: Chamfer The Top Of The Boss

n In the Solid Selection dialog box, enable only the Face button, and make
sure that the Edge, Body, and other buttons are disabled, as shown in the
figure (click on the buttons to disable them).

n [Select one or more entities to

chamfer]: Select the top of the
boss.
n Select the OK button to exit
Solid Selection dialog box.

n The One Distance Chamfer panel will appear. Make

sure the Distance is set to 0.1 as shown.

Distance sets the distance of the chamfer from the

selected edge on the adjacent faces.

Mitered corners: Mastercam will extend each chamfer to the

extent of the edge. Use this feature where three or more
chamfered edges meet at a vertex. With this
option disabled, a smooth face at the vertex where the
chamfers meet will be created.

Propagate along tangencies extends the chamfer along all

tangent edges until a non-tangent edge is reached.

n Select the OK button to exit the command.

236
Solids Extrude Step 16: Save The File

n The geometry should look as shown.

STEP 16: SAVE THE FILE

n Click on the Save As icon from the Quick Access Toolbar at

the upper left corner to save the file.
n Find a location on the computer to save your file.
n File name: "Solid Extrude Part_1".

Note: It is highly recommended to save the file from time to time when going through the tutorial.
Click on the Save icon from the Quick Access Toolbar at the upper left corner to save the file.

SOLID FILLET
Solid Fillet commands allow you to create fillets along solid edges. One advantage of solid geometry is its ability to
easily model fillets that are difficult to model using other methods. The following commands are available:
Constant Fillet can fillet a solid edge, face, or body.
Face to Face Fillet prompts you to select a first and then a second face (or set of faces) to fillet.
Variable Fillet allows you to insert different radius values along a solid edge.

Solid Fillet

n From the QAT, select the Open icon.

n Select Solid_Fillet.MCAM.

237
Solids Extrude Solid Fillet

16.1 Fillet Solid R 0.25

n From the Solids tab,
in the Modify group,
select Constant
Fillet icon.

n In the Solid Selection enable only the

Body button.
n Select the solid as shown.
n Select the OK button to exit Solid
Selection dialog box.

n In the Constant Radius Fillet panel

set the Radius to 0.25.
n Press Enter.
n The solid should look as shown.
n In the Constant Radius Fillet panel,
select the OK and Create New
Operation button to continue in the

operation.

n In the Solid Selection enable only the

Body button.
n Select the solid as shown.
n Select the OK button to exit Solid
Selection dialog box.

238
Solids Extrude Solid Fillet

n In the Constant Radius

Fillet panel set the
Radius to 0.25.
n Press Enter.
n Disable Propagate along
tangencies.
n Enable Mitered corners.
n The solid should look as
shown.
n In the Constant Radius
Fillet panel, select the
OK and Create New
Operation button to
continue in the operation.

n In the Solid Selection enable only the Edge

button.
n Select the edge as shown.
n Select the OK button to exit Solid Selection
dialog box.

n In the Constant Radius

Fillet panel enable
Propagate along
tangencies.
n Disable Mitered corners.
n Radius = 0.125.
n Press Enter.
n The solid should look as
shown.
n In the Constant Radius
Fillet panel, select the
OK button to exit.

239
Solids Extrude Step 17: Solid Chamfer

STEP 17: SOLID CHAMFER

Solid Chamfer commands allow you to create a chamfer along the solid edges. The following commands are
available:
One Distance Chamfer creates a 45 degree chamfer with both distances equal to the specified amount.
Two Distance Chamfer creates a chamfer by specifying a value for each distance.
Distance and Angle Chamfer creates a chamfer by specifying one distance and an angle.

Solid Chamfer

n From the QAT, select the Open icon.

n Select SOLID_CHAMFER.MCAM.

17.1 One Distance Chamfer

n From the Solids tab, in the
Modify group, select One
Distance Chamfer icon.

n In the Solid Selection enable only the

Edge button.
n Select the edge as shown.
n Select the OK button to exit Solid
Selection dialog box.

240
Solids Extrude Step 17: Solid Chamfer

n In the One Distance Chamfer

panel set the Distance to 0.35.
n Press Enter.
n The edge should look as shown.
n In the One Distance Chamfer
panel, select the OK button to exit.

17.2 Two Distance Chamfer

n From the Solids tab, in the Modify group,
click on the arrow next to One Distance
Chamfer icon.
n Select the Two Distance Chamfer.

n In the Solid Selection enable only

the Edge button.
n Select the edge as shown.

241
Solids Extrude Step 17: Solid Chamfer

n The vertical face should be selected as shown.

n If not, in the Pick Reference Face dialog box,
click on the Other face.
n In the Pick Reference Face dialog box, select
the OK button to continue.
n Select the OK button to exit Solid Selection
dialog box.

n In the Two Distance Chamfer panel

set the following:
n Distance 1 = 0.35. (Measured from
the edge along the selected face).
n Distance 2 = 0.125.
n Press Enter.
n The edge should look as shown.
n In the Two Distance Chamfer
panel, select the OK button to exit.

17.3 Distance and Angle Chamfer

n From the Solids tab, in the Modify group, click on the arrow
next to One Distance Chamfer icon.
n Select the Distance and Angle.

n In the Solid Selection

enable only the Edge
button.
n Select the edge as shown.

242
Solids Extrude Step 17: Solid Chamfer

n The vertical face should be selected as shown.

n If not, in the Pick Reference Face dialog box,
click on the Other face.
n In the Pick Reference Face dialog box, select
the OK button to continue.
n Select the OK button to exit Solid Selection
dialog box.

n In the Two Distance

Chamfer panel set the
following:
n Distance = 0.5.
(Measured from the edge
along the selected face).
n Angle = 30.
n Press Enter.
n The edge should look as
shown.
n In the Distance and
Angle Chamfer panel,
select the OK button to
exit.

SUMMARY:
In this instructor led lesson, you were introduced to several ways to create a solid. After completing this
lesson and some of the practice exercises that follow you should be able to:
n Know how to use Solid Extrude to create a body.
n Know how to use Solid Extrude to add a boss or cut a pocket.
n Using Solid Hole command to create holes.
n Create fillets at the edges of solids.
n Create chamfers at the edges of solids.
n Modify the solids using Solids Manager.

243
Solids Extrude Solid Extrude - Exercise #1

SOLID EXTRUDE - EXERCISE #1

Job Description:

Note: Create 1/4 of the entire drawing and use the Rotate command to complete it.

Use the following commands to create the 2D geometry:

n Line Endpoints.
n Line Parallel.
n Circle Center Point.
n Divide.
n Fillet Entity.
n Delete construction lines.
n Rotate.

244
Solids Extrude Solid Extrude - Exercise #2

Use the following commands to

create the solid:

n Solid Extrude - Create body.

n Set the arrow direction
downward.
n Distance = 0.5.
n Solid Extrude - Cut body.

n Set the arrow direction

downward.
n Distance = 0.25.

Save the exercise file.

SOLID EXTRUDE - EXERCISE #2

245
Solids Extrude Solid Extrude - Exercise #2

Job Description:

Use the following commands to create the 2D geometry

n Rectangular Shapes.
n Circle Center Point.
n Arc Tangent.
n Fillet Entities.
n Trim 1 entity.
n Arc Polar.
n Trim 2 entities.
n Trim - Divide/delete.
n Break at Intersection.

Note: To create the geometry follow these instructions:

Create the obround shapes using the create rectangular shapes. Use as the Anchor the bottom middle
point and select the origin.
Create the circles using the known center points and the radii/diameters.
Create the arcs with the radii 6.0", 4.2" and 1.0" tangent to 2 entities. The arc with the radius 4.2" is
tangent to the 0.75" diameter circle.
Trim divide the 6.0" radius and use the fillet command to create the arcs with the radius 0.38".
Trim 1 entity to clean the geometry.
Window the entire geometry and use Break at Intersection command to break the geometry. This
ensures that you can select the closed chains that define the solid operations.

Use the following commands to create the solid:

n Solid Extrude - Create body.

n Set the arrow direction downward.
n Distance = 1.

n Solid Extrude - Cut Body.

n Set the arrow direction downward.

n Distance = 0.25.

n Solid Extrude - Cut body.

n Set the arrow direction downward.

n Through all enabled.

Save the exercise file.

246
Solids & Pocket Toolpaths

247
Solids & Pocket Toolpaths Introduction

INTRODUCTION
Until now, you have used wireframe geometry to model parts. Wireframe entities work well for relatively
simple parts, but they are limited since they contain no information about the faces or interior of the model
and cannot be shaded. 3D wireframe models can be difficult to create and change.
Solid models use a completely different type of geometry that includes information about the faces and
interior of the part. Solids can be shaded, making it much easier to interpret the designer's intent. They often
require less work to create and are easier to modify than other geometry types.
Starting with a basic shape, called a Base Feature, you progressively apply operations like Cut, Add Boss,
Fillet, and Chamfer, to form the finished part.
Nowadays, most mechanical engineering design is done using solids. Given the advantages of solid
modeling for mechanical design, analysis, and machining, this trend will continue. Therefore, it’s important
for you to understand solid geometry concepts, and how to create and work with them.
This lesson introduces the pocket style toolpaths. Pocket operations are generally used to remove excess
material on the interior of the part. With Mastercam, the pocket operations can include rough and finish
paths. The finish path in a pocket operation is basically the same as the Contour operations we have already
experienced. The rough paths are to remove large amounts of material as quickly and efficiently as possible.
There are multiple options of cut styles to choose from when pocketing. For this lesson, we will explore a few,
but any of the exercises can be modified to use most of the pocketing styles.
You will also use the Slot Mill toolpath to machine a closed pocket. Starting with Mastercam 2023 you can
use Slot mill to machine pockets that have a different shape that the Obround shape. Slot Mill toolpaths
automatically calculate plunge, entry, and exit points appropriate for the pocket shape.

248
Solids & Pocket Toolpaths Instructor Demonstration

OVERVIEW OF TUTORIAL:
In this tutorial you will learn Extrude command to create solids and will face and machine the areas shown by
using Pocket style toolpaths. In Mastercam 2023 you can also use Slot Mill toolpath to machine a closed
pocket with a shape that is not an Obround shape.

NEW CONCEPTS COVERED IN THIS TUTORIAL:

n Saving Job Setup settings for future usage.
n Extrude Create Solid.
n Extrude Cut Solid.
n Closed Pocket toolpath.
n Open Pocket toolpath.
n Remachining Pocket toolpath.
n Remachining Contour toolpath.
n Slot Mill.

INSTRUCTOR DEMONSTRATION
Topics:

n Solid Extrude command to create the

solid body
n Locate Geometry and Job Setup
n Saving the Job Setup Defaults
n Closed Pocket Toolpath
n Open Pocket Toolpath
n Copy and Paste Operations
n Re-Machining Toolpaths
n Slot Mill Toolpath

249
Solids & Pocket Toolpaths Part Drawing

PART DRAWING

250
Solids & Pocket Toolpaths Solid Terms

SOLID TERMS
The following illustration shows a simple solid model and some common terms associated with solids.

Any continuous surface on the outside shell of the part. It can be both
Face
flat or curved.
Edge Any seam where two faces intersect.
Solid Body The entire solid with all features.
A closed wireframe boundary that is extruded and removed from the
Cut
solid body.
A closed wireframe boundary that is extruded and added to the solid
Boss
body.

Solid Options

The following terms are used in solid modeling. Those common for modeling prismatic shapes are covered in
this chapter. More advanced solid functions, like Revolve and Sweep, are used mostly for modeling complex
3D parts like molds and are detailed in the Mill Advanced Professional Courseware.

251
Solids & Pocket Toolpaths Pocket Toolpath - Basic Steps

POCKET TOOLPATH - BASIC STEPS

Following are brief descriptions of the toolpath types available for Pocket Cut Parameters.

Standard Pocket toolpaths are completely closed shapes. They

may have standing islands or bosses to avoid. Mastercam will
machine the largest closed boundary and consider other
smaller boundaries non-machinable.

Facing Pocket toolpaths are used to face a part with islands. This
allows the tool to overlap the edges of the part but still avoid island
areas.

Island Facing Pocket toolpaths are used to machine pocket

areas as well as the tops of islands that are different heights.
When selecting the geometry, you must chain the bottom of the
pocket and the tops of the islands.

Remachining Pocket toolpaths work identical to Contour

remachining. Mastercam analyzes the pocket to find areas
where stock remains.

Open Pocket toolpaths are for pockets that have one open end.
The tool removes all of the inner material and overlaps the
open boundary to ensure a clean edge.

252
Solids & Pocket Toolpaths Step 1: Save Machine Group Setup Future Jobs

POCKET TOOLPATHS - BASIC STEP REFERENCE

STEP 1: SAVE MACHINE GROUP SETUP FUTURE JOBS

We have set the Tool settings for each toolpath so far. Now that we know how we would like them to
appear, we will set them to Default to the settings we want to use most of the time.

n Open any part or start a New part.

n Set the Machine type to Mill Default.
n Expand the Properties in the Toolpaths Manager.
Click the plus (+) sign if the Files, Tool Settings and
Stock Setup are not visible as shown.

ADDITIONAL TOOLPATH MANAGER REFERENCE INFORMATION

Delete all operations, groups and tools in the toolpath manager. You will NOT be able to undo
this deletion.
Lock/Unlock selected operations prevents you from regenerating the toolpath operation.
Toggle Display on selected operations displays and hides selected operations in the graphics
window.
Toggle posting on selected operations enables and disables post processing on selected
operations.
Operations arrow position icons allow the user to locate where new operations will be
placed in the order of machining. The user can move the operations up, down, position after a selected
operation or scroll so arrow is visible in the toolpaths manager.
Only display selected toolpaths icon displays only the operations selected.
Highfeed icon optimizes feedrate for selected operations.

1.1 Set the Operations defaults

n Select Files as shown.

253
Solids & Pocket Toolpaths Step 1: Save Machine Group Setup Future Jobs

n Expand the Libraries.

n In the Operations Defaults, select the Edit
Operations Defaults button.

254
Solids & Pocket Toolpaths Step 1: Save Machine Group Setup Future Jobs

n In the Edit Operation Defaults dialog, scroll up and

expand Properties as shown.
n Select Tool settings as shown.

n Set the parameters as shown.

255
Solids & Pocket Toolpaths Step 1: Save Machine Group Setup Future Jobs

1.2 Set the Stock Setup

n Select the Stock Setup icon and enable Show wireframe

entities enabled.

n Click OK once again to close the Machine Group Setup dialog

box.
n Click OK to close the Edit Operation Defaults dialog box.
n Click OK once again to close the Machine Group Setup dialog

box.

n From the Operations Manager, select Delete all

operations, groups and tools.

Note: This will make sure that any parameters, views or settings are returned back to the default values
in case this file has already been saved.

n From the Operations Manager, select the Tool Settings from

the Properties.

256
Solids & Pocket Toolpaths Step 2: Create And Locate Part Geometry

n Confirm that our preferred settings are pre-set as shown.

Note: These are the settings that will be used

most of the time. Change them as needed.

STEP 2: CREATE AND LOCATE PART GEOMETRY

In this task you will create the Top plane geometry shape and then use Solid Extrude command to create
the solid for easier selection and confirmation of toolpaths.

n Start a new part and save as POCKET-1.MCAM

n Using the POCKET-1 DRAWING for

dimensions, create the geometry as shown in
the Top plane with the origin located as
shown.

Note: Solids require closed chains. To be able to create the open pocket you will need to create an extra
line or break the left vertical line where it intersects with the horizontal lines.

257
Solids & Pocket Toolpaths Step 2: Create And Locate Part Geometry

n Switch the Gview to Isometric (Alt + 7) and

then Fit to the screen (Alt+ F1).

2.1 Create the solid base using the outside profile

n From the Solids tab, in the Create

group, select the Extrude icon.

n Select the outer periphery

(as highlighted).
n Use the Next button to
continue the selection at
the branches if you broke
the right side vertical line.
n Select the End Selection
button or press Enter. You
can also double-click to end
the selection.

n A solid will appear. The

arrow has to point
downwards as shown.
n If not, in the Solid
Extrude panel clik on
the reverse if needed.

258
Solids & Pocket Toolpaths Step 2: Create And Locate Part Geometry

n In the Distance
field enter 1.5.
Press Enter for the
solid size to be
updated.
n Select the OK and
Create New
Operation button.

2.2 Cut the inside pocket

n Select the inside pocket.

n Make sure the arrow is

pointing downwards.
n In the Solid Extrude
enable Cut body.
n Distance = 1.0.
n Select the OK and
Create New Operation

button.

259
Solids & Pocket Toolpaths Step 2: Create And Locate Part Geometry

2.3 Cut the open pocket

n Select the open pocket.

n Make sure that Cut body

is enabled.
n Distance = 1.125.
n Select the OK button to
exit the command.

n The geometry should look as shown.

Note: To view the part shaded or unshaded at any time, you can press Alt + S on the keyboard or select
the Wireframe or Shaded icons from the Status Bar.
You can also select the Outline Shaded for a crisp look of the solid.

260
Solids & Pocket Toolpaths Step 3: Select A Machine And Set The Job Setup

STEP 3: SELECT A MACHINE AND SET THE JOB SETUP

n Set the Machine type to Mill Default.

n Expand the Properties in the Toolpaths Manager and
confirm the Tool Settings.

n Select the Stock Setup and click on the Add from bounding
box button.

n Enable All
shown.
n The Size values
should look as
shown.

261
Solids & Pocket Toolpaths Step 4: Facing Toolpath

n Set the Origin to

the middle top face
as shown and
change the Origin
Z to 0.1 to increase
the stock on the top
of the stock.
n Change the Height
to 1.6.
n Select the
OK button to exit
Bounding Box.

n The stock should look as shown.

Note: The extra stock above the part will be removed with a Facing operation.

STEP 4: FACING TOOLPATH

A Facing toolpath quickly removes material from the top of the part to create an even surface and prepare
for subsequent operations.

Toolpaths

n From the 2D group, select

the Facing icon as shown.

262
Solids & Pocket Toolpaths Step 4: Facing Toolpath

n In the Chaining dialog box, select the OK button to use the stock as the
toolpath geometry.

n The 2D Toolpaths -
Facing dialog box
appears on the screen as
shown.

Note: In the following steps you will be setting the parameters to generate the Facing toolpath.

263
Solids & Pocket Toolpaths Step 4: Facing Toolpath

4.1 Tool
In the following steps you will choose a 2.0” Face Mill from the Library of tools provided by Mastercam. You
will use the Filter option to search through the tool library for a specific tool type which makes it easier and
quicker to find the desired tool.

n From the Tree View List, select

Tool and click on the Select
library tool button as shown.

n Using the Filter, select the 2"

Face Mill as shown in previous
tutorials.
n Enable Rapid Retract to force the
tool to retract from the part at the
rapid feed rate set at the machine.
n In the Comment area, enter a
description of what the toolpath
does as shown.

Note: The Tool numbers were

automatically assigned due to Job
Setup settings.
The Feed rate, Plunge rate, Retract
rate and Spindle speed are based
on the tool definition as set in the
Tool Setting. You may change
these values as per your part
material and tools.

264
Solids & Pocket Toolpaths Step 4: Facing Toolpath

4.2 Cut Parameters

Cut Parameters page allows you to set the Facing parameters such as Style, Stock to leave, and
Move between passes.

n From the Tree View List,

select the Cut Parameters
and set the Style to Zigzag
and Move between cuts to
High speed loops. Set the
Stock to leave on floors to
0.0 as shown.

4.3 Depth Cuts disabled

4.4 Linking Parameters

Linking Parameters page allows you to define the Clearance, Retract, Feed plane, Top of stock and
Depth heights.

n From the Tree View List, select Linking

Parameters and set the values as shown.

Note: Depth value is set from the top of the

finish part. In this case the depth is at Z =
0.0.

265
Solids & Pocket Toolpaths Step 4: Facing Toolpath

4.5 Coolant

n From the Tree View List,

select Coolant and turn the
Flood on as shown.

n Select the OK button to exit

2D Toolpaths - Facing.

n The toolpath should look as

shown.

4.6 Simulate the toolpath in Verify

n The part should appear as

shown.

266
Solids & Pocket Toolpaths Step 5: Machine The Closed Pocket

STEP 5: MACHINE THE CLOSED POCKET

In this operation you will remove the closed cavity area in the middle of the top face.

n Before starting the next operation, turn off the toolpath display for the Facing operation. (Alt+T)

Toolpaths

n From the 2D group, click

on the expand gallery
arrow, and select the
Pocket icon as shown.

n In the Chaining dialog box, select

Solid Mode.
n In the Selection Method, enable only
the Face button.
n Select the bottom of the pocket as
shown.

Note: Chaining direction does not

matter for a Pocket toolpath. By
selecting at the cut depth, the value will
be extracted by Mastercam.

n Select the OK button to continue.

5.1 Toolpath Type

n Make sure that the Pocket

icon is selected as shown.

267
Solids & Pocket Toolpaths Step 5: Machine The Closed Pocket

5.2 Tool
In the following steps you will choose a 3/4” Flat Endmill from the Library of tools provided by Mastercam.

n From the Tree View List,

select Tool and click on the
Select library tool button.
n Use the filter options and
select a 3/4" Flat Endmill.
Set the rest of the
parameters as shown.

Note: The corner radii of the

pocket area are actually 1/4”
which this tool cannot finish.
You will create another
operation to clean out the
corners later.

5.3 Cut Parameter

Cut Parameters page allows you to set the Pocket parameters such as machining direction and pocket
type.

n From the Tree View List,

select the Cut Parameters
and make sure that the
Machining direction is
set to Climb and the
Pocket type is set to
Standard as shown. The
rest of the settings should
match the default values as
shown.

268
Solids & Pocket Toolpaths Step 5: Machine The Closed Pocket

5.4 Roughing

Roughing page allows you to set the Pocket parameters such as Cutting method and Stepover
percentage.

n From the Tree View List, select

Roughing and set the Cutting
method to Constant Overlap
Spiral and set the Stepover
percentage to 75%.

Note: There are multiple cutting

methods available. You can
choose the type as desired on
future parts.

5.5 Entry motion

These settings will allow the tool to enter with a safe helical entry.

n Set the
parameters as
shown.

269
Solids & Pocket Toolpaths Step 5: Machine The Closed Pocket

5.6 Finishing
A Pocket finish pass is actually a Contour cut. These settings will leave 0.01 material for a final contour
clean-up pass. The clean-up pass will only cut at the final depth.

n Set the Finishing

parameters:
n # Passes = 1.
n Spacing = 0.01.
n Finish outer boundary
enabled.
n Cutter compensation set to
Wear.
n Machine finish passes only
at final depth enabled.

5.7 Lead In/Out

Lead In/Out page allows you to set the entry and/or exit movements as a combination of a line and an arc.

n From the Tree View List, select

Lead In/Out and make sure that
Lead In/Out is enabled.
n Select the Arrow to copy all
values to the Exit values.

Note: These are the same

recommended settings that were
used on Contour toolpaths.

270
Solids & Pocket Toolpaths Step 5: Machine The Closed Pocket

5.8 Depth Cuts

Depth Cuts

n Max rough step =

0.375.

5.9 Break Through disabled

5.10 Linking Parameters

n From the Tree View List, select

Linking Parameters and set the
values as shown.

271
Solids & Pocket Toolpaths Step 5: Machine The Closed Pocket

5.11 Arc Filter / Tolerance

Arc Filter/ Tolerance

The option to Output 3D arcs will create the entry helix move with arc moves when possible.

n From the Tree View List,

select Arc Filter /
Tolerance and make sure
that Output 3D arc entry
motion is enabled as
shown.

5.12 Coolant

n From the Tree View List, select Coolant and turn the Flood
on as shown.
n Select the OK button to exit 2D Toolpaths - Pocket.

5.13 Repeat the Backplot procedure

n The toolpath should look as

shown.

272
Solids & Pocket Toolpaths Step 6: Open Pocket Toolpath

5.14 Verify the last toolpath

n The part after being verified in Mastercam Simulator should look as

shown.

Note: If the verified part does not look like this result, click the
Parameters icon under the Pocket toolpath in the Mastercam
Toolpaths Manager and confirm your settings are correct. Then
Regenerate the toolpath.

STEP 6: OPEN POCKET TOOLPATH

In this Pocket operation you will use a special type of Pocket style toolpath to remove the open area with a
3/4" Flat Endmill. The Open Pocket toolpath allows using pocket parameters even if the pocket is not a
completely enclosed boundary.

Toolpaths

n From the 2D select the Pocket from the

list as shown.

Note: You may need to rotate the geometry to select the chain.

n In the Solid
Chaining dialog
box, enable Outer
shared edges
button.
n [Select faces, edges,
and/or loops]: Select
the bottom face as
shown.

273
Solids & Pocket Toolpaths Step 6: Open Pocket Toolpath

n The open chain will be automatically

selected.
n In the Chaining dialog box, select the
OK button.

6.1 Toolpath Type

n Make sure that the Pocket icon

is selected as shown.

6.2 Tool

n From the Tree View

List, select the Tool
page and select the
3/4" Flat Endmill as
shown.
n Set the rest of the
parameters as shown.

Note: The corner radii

of the pocket area are
actually 1/4” which this
tool cannot finish. You
will create another
operation to clean out
the corners later.

274
Solids & Pocket Toolpaths Step 6: Open Pocket Toolpath

6.3 Cut Parameter

n From the Tree View List,

select the Cut Parameters
and make sure that the
Machining direction is set
to Climb and the Pocket
type is set to Open as
shown. Enable Use open
pocket cutting method
and set the rest of the
settings as shown.

These settings will allow the cutter to overlap the open area by 0.9375 ".
With Use open pocket cutting method enabled, the entry motion is automatically outside of the part.

6.4 Roughing

n From the Tree View List,

select Roughing and make
sure the Stepover
percentage is set as shown.

Note: The cutting methods

are not available since we
previously selected to use
the Open pocket cutting
method.

6.5 Entry motion

The settings on this page are NOT USED because we selected to use the Open pocket cutting method.

275
Solids & Pocket Toolpaths Step 6: Open Pocket Toolpath

6.6 Finishing
A Pocket finish pass is actually a contour cut. These settings will leave 0.01 in of material for a final contour
clean-up pass. The clean-up pass will only cut at the final depth.

n From the Tree View List,

select Finishing.
n Leave the settings as shown.

6.7 Lead In/Out

Lead In/Out page allows you to set the entry and/or exit movements as a combination of a line and an arc.

n From the Tree View List,

select Lead In/Out and make
sure that Lead In/Out is
enabled.
n Use the same settings as the
previous pocket operation as
shown.

276
Solids & Pocket Toolpaths Step 6: Open Pocket Toolpath

6.8 Depth Cuts

n From the Tree View List, select Depth

Cuts and use the same settings as the
previous pocket toolpath as shown.

6.9 Linking Parameters

Linking Parameters page allows you to define the Clearance, Retract, Feed plane, Top of stock and
Depth heights.

n From the Tree View List, select

Linking Parameters and set the
values as shown in the previous
pocket toolpath.
n Select the OK button to exit 2D
Toolpaths - Pocket.

277
Solids & Pocket Toolpaths Step 6: Open Pocket Toolpath

6.10 Repeat the Backplot procedure

n The toolpath should look as shown.

n From the Backplot panel, select the OK button to exit
Backplot.

6.11 Verify the last toolpath

n The part after being verified in Mastercam

Simulator should look as shown.
n When finished verifying, minimize
Mastercam Simulator.

Note: If the verified part does not look like this result, click the Parameters icon under the second Pocket
toolpath in the Mastercam Toolpaths Manager and confirm your settings are correct. Then regenerate the
toolpath.

278
Solids & Pocket Toolpaths Step 7: Remachine The Pockets

STEP 7: REMACHINE THE POCKETS

In this toolpath we will use a 3/8” Flat Endmill to machine the corners of the pocket that the ¾” tool could
not cut. Since the Pocket geometry has already been selected and since we have most of the parameters
set the way we like them for the pocket toolpaths, we will Copy and Paste the toolpath to simplify the work.

n Before starting the next operation, turn off the toolpath

display for the Pocket operation you just completed as
shown.
n In the Toolpaths Manager, select the first pocket as
shown.

n Right mouse click on the selected pocket and select

Copy.

279
Solids & Pocket Toolpaths Step 7: Remachine The Pockets

n Make sure that the insert arrow is below the last toolpath and
then right mouse click on it and select Paste.

n The Toolpaths Manager should look as shown.

Note: To remachine both the closed and open pocket in one

toolpath, you need to add the geometry (chain) of the open
pocket in the Geometry of the last pocket.

280
Solids & Pocket Toolpaths Step 7: Remachine The Pockets

n In the Toolpaths Manager, click on the Pocket (Open)

Geometry and drag it above the last Pocket Geometry as
shown.
n Once you release the mouse above the last Pocket Geometry
the chain will be added to the last pocket.

Note: You should have 2 chains in the last Pocket toolpath Geometry as shown.

n Select the Parameters in the last Pocket toolpath as

shown.

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Solids & Pocket Toolpaths Step 7: Remachine The Pockets

7.1 Tool
In the following steps you will choose a 3/8” Flat Endmill from Mastercam library.

n From the Tree

View List, select
Tool and click on
the Select
library tool
button.
n Using the Filter
options select the
3/8" Flat
Endmill.
n Enable Rapid
Retract and
enter a comment
as shown.

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Solids & Pocket Toolpaths Step 7: Remachine The Pockets

7.2 Cut Parameters

Cut Parameters page allows you to set the Pocket type to Remachining and set the parameters.

n From the Tree View

List, select the Cut
Parameters and set the
Pocket type to
Remachining and set
the parameters as
shown.

REFERENCE INFORMATION
Roughing tool diameter calculates areas where the previous tool could not machine the stock based on
the previous tool diameter.
Clearance extends the area to be remachined to overlap the already machined areas.
Display stock previews how much stock is removed during the roughing toolpath and the remachining or
finishing toolpath, and how much stock is left after remachining.

Note: As we copied the toolpath, most of the parameters are already set.

283
Solids & Pocket Toolpaths Step 7: Remachine The Pockets

7.3 Linking Parameters

Linking Parameters page allows you to define the Clearance, Retract, Feed plane, Top of stock and Depth
heights.

n From the Tree View

List, select Linking
Parameters and
make sure the
parameters are set as
shown.
n Select the OK button
to exit 2D Toolpaths
- Pocket.

n Enable Generate toolpath as shown to avoid

regenerate the toolpath in the Toolpath Manager.

7.4 Repeat the Backplot procedure

n Run backplot to check the last toolpath.

n Press Ctrl + T to see the solid translucent as shown.

284
Solids & Pocket Toolpaths Step 8: Option 2 - Slot Mill The Closed Pocket

7.5 Repeat the Solid Verify procedure

n From the Toolpaths Manager, click on the Select all

operations icon as shown.

n The part after being verified in Mastercam Simulator

should look as shown.

Note: To see the part with different colors after verification, in the Verify ribbon enable Color Loop icon.

STEP 8: OPTION 2 - SLOT MILL THE CLOSED POCKET

Starting with Mastercam 2023, you can use Slot Milling toolpath to machine the closed pocket. Slot Mill
toolpaths automatically calculate plunge, entry, and exit points. This operation can be used instead of the
Closed pocket operation.

n Before starting the next operation, turn off the toolpaths. Press Al + T.

n Select the drop down arrow below

the 2D Toolpaths and select the
Slot Mill from the list.

285
Solids & Pocket Toolpaths Step 8: Option 2 - Slot Mill The Closed Pocket

n Enable only Loop button.

n Holding down the mouse wheel
click on the part and rotate the
model and Zoom in.
n Select an edge at the bottom of
the pocket to select the entire
Loop as shown.
n Make sure the chain direction is
CCW as shown.

8.1 Tool

n Select the 3/4" Flat Endmill.

n Rapid Retract enabled.
n Comment: “Machine the pocket using Slot Mill toolpath”.

8.2 Cut Parameters

n Machining direction
is set to Left.
n Stock to leave on
walls = 0.0.
n Stock to leave on
floors = 0.0.

REFERENCE INFORMATION
Entry/exit arc sweep sets the included angle of each entry and exit arc.
Perpendicular entry enters the toolpath perpendicular to the first tool move. Useful when using
Compensation type in Control.
Overlap how far the tool goes past the end of the toolpath before exiting for a cleaner finish.

286
Solids & Pocket Toolpaths Step 8: Option 2 - Slot Mill The Closed Pocket

8.3 Rough/Finish

n Plunge angle = 2 degrees.

n Enable Keep tool down.

Note: While machining the slot

there is no need for the tool to
retract. Keep tool down is safe
and saves some machining
time.

8.4 Depth Cuts

n Depth cuts enabled.

n Max rough step =
0.07.
n Enable Keep tool down.

8.5 Break Through disabled

We do not want the cutter to cut beyond the bottom of the slot, so we need this setting to be off.

287
Solids & Pocket Toolpaths Step 8: Option 2 - Slot Mill The Closed Pocket

8.6 Linking Parameters

n Clearance = 2.0 (Absolute).

n Retract = 0.25 (Absolute).
n Feed Plane = 0.2 (Incremental).
n Top of Stock = 0.0 (Absolute).
n Depth = 0.0 (Incremental).

Note: Depth value is set from the value of the

chained edges. Incremental values should
almost always be set to 0.0.

n Select the OK button to exit 2D Toolpaths - Slot mill.

8.7 Repeat the Backplot procedure

n The toolpath should look as shown.

8.8 Verify the first and last toolpaths

n The part should appear

as shown.

288
Solids & Pocket Toolpaths Step 9: Post Process The Toolpaths

STEP 9: POST PROCESS THE TOOLPATHS

STEP 10: SAVE THE FILE

Note: The file will be saved with the Mastercam toolpath data stored inside the file.

SUMMARY:

In this tutorial, you learned how to create a solid using the Extrude command and added to your toolpath skill
set by learning the basics of pocket style toolpaths. You also learned how to set default values for Tool and
Stock setup parameters so they suit your everyday preferences. This will save you time daily. You also
learned the techniques for selecting the geometry you want to cut.
After completing this tutorial and some of the practice exercises that follow you should be able to:
n Create a solid using Solids Extrude command.
n Use the Pocket toolpath type to create Closed and Open pocket shapes.
n Understand the common pocket parameters.
n Understand how to utilize the Mastercam Help file as a reference for additional information.
n Understand how to save Tool and Stock setup settings.
n Understand how to use Copy and Paste to quickly create new toolpaths with the same geometry.
n Use the Contour and Pocket Remachining toolpaths.
n Use Slot Mill to rough and finish a closed pocket.

289
Solids & Pocket Toolpaths Exercise #1

EXERCISE #1

Job Description:

Create the solid geometry and program the part above with the following requirements:
n Use Mastercam design tools to create the solid model of the drawing shown above.
n Job Setup Notes/Tips:
n Stock Size = All Entities.
n Select suitable tools to:
n Face the top of the Stock with 2” Face Mill
n Pocket the closed cavity area.
n Pocket the open cavity area.
n Remachine small corners.
n Run Backplot and Solid Verify to confirm results.
n Create G-code for NC machine.

290
Solids & Pocket Toolpaths Exercise #2

EXERCISE #2

Job Description:

Create the solid geometry and program the part above with the following requirements:
n Use Mastercam design tools to create the 3D Wireframe of the drawing shown above.
n Job Setup Notes/Tips:
n Stock Size = All Entities.
n Face the top of the Stock with 2” Face Mill.
n Contour the outside periphery with a 1” Flat Endmill.
n Machine most of the material from the 3 pocket areas with a 1” Flat Endmill.
n A. Through Closed Pocket
n B. Blind Closed Pocket (1” Deep)
n C. Open Blind Pocket (1.50” Deep)
n Remachine the inside radii with appropriate Flat Endmills.
n Run Backplot and Solid Verify to confirm results.
n Create G-code for NC machine.

291
Drilling Toolpaths

292
Drilling Toolpaths Introduction

INTRODUCTION
This lesson introduces fixtures and the Drilling toolpaths. Hole making is likely the most fundamental and
widely used machining operation. In this tutorial you will learn techniques for manually selecting holes from
the model for drilling and the parameters and methods to create efficient operations.

NEW CONCEPTS COVERED IN THIS TUTORIAL:

n Merge / Import a SolidWorks file.
n Align the part in the vise.
n Create the holes using Add History command.
n Set a stock from a solid.
n Drilling parameter settings options.
n Spot Drilling holes.
n Tapping holes.
n Circle mill operations on large holes with Flat Endmills.
n Thread Mill toolpath and Thread mill tool.
n Verify the toolpaths with the part and the fixture displayed.
n Using the Section view option for better visualization of toolpaths.
n Post processing Drill operations.

293
Drilling Toolpaths Instructor Demonstration:

INSTRUCTOR DEMONSTRATION:
Topics:

n Merge/Import a Solid model (SolidWorks).

n Align the part in the vise.
n Move the part and the vise in the Origin.
n Use Add History to create hole operations
shown in the Solids Manager.
n Set the stock from a solid.
n Point selection and face selection for
drilling
n Peck Drill, Spot Drill and Tap the 3/8-16
holes
n Drill the 1/2" counterbore holes
n Circle Mill the counterbore holes
n Thread mill the center tap hole

294
Drilling Toolpaths Part Drawing

PART DRAWING

295
Drilling Toolpaths Step 1: Open The Soft Jaw Vise

STEP 1: OPEN THE SOFT JAW VISE

In this step you will open the soft jaw vise made especially for this part.

n Find and Open SOFT_JAW_VISE.MCAM

n The solid, in Isometric view should look as
shown.

STEP 2: MERGE THE PART

In this step you will merge the part and align it in the vise.

File

n From the Backstage select Merge.

296
Drilling Toolpaths Step 2: Merge The Part

2.1 Merge/open the part

n In the Open dialog box change the File

extension to SOLIDWORKS Files (*.sldprt,
*.sldasm,*.slddrw).
n Find and open the part MANUAL
DRILL.SLDPRT.

Note: There are Options when opening a

SolidWorks file. For this class we will import
just the solid model without the Edge
Curves.

n Alt + F1 to fit the screen.

Note: The part is not oriented as

needed to machine the features so
we will rotate it to the correct side to
face the Top plane. We will use
Align Coincident option to achieve
this. It is important to follow the
steps in the correct order as follows.

297
Drilling Toolpaths Step 2: Merge The Part

2.2 Align the part

n In the Merge Pattern panel enable Active level.

n From the Merge Pattern panel, select Align button.

298
Drilling Toolpaths Step 2: Merge The Part

n In the Align to Face panel the Method should be set to Move.

n Mode = Coincident.

n Select the outside face of the part to be moved.

n Press Enter to accept the reference point at the center of the

face where the gnomon is automatically located.

n Select the cylindrical face on the vise as shown.

299
Drilling Toolpaths Step 2: Merge The Part

n Rotate the geometry and press

Ctrl + T to make the solids
translucent.
n Click on the gnomon center and
drag it to the point.

Note: The part should be already

at the proper location.

n Press Enter to continue.

n Rotate and remove the translucent mode (Ctrl + T).
n The part should look as shown.
n Select the OK button to exit Align.
n Select the OK button to exit Merge.

n Select and delete any extra geometry that was imported

with the part.

300
Drilling Toolpaths Step 3: Add Holes To The Part Solid

STEP 3: ADD HOLES TO THE PART SOLID

In this step you will learn how to add the holes on one solid body with no history. This will be helpful to quick
select the holes that you want to machine.

Find Holes detects complex holes when you select the Hole operations option. Hole operations finds all
holes with the radius dimensions that you enter. Mastercam creates an operation in the Solids Manager for
each detected hole.

n Open the Solids Manager and rename the imported solid

Part.

n Open the Solids Manager and rename the imported solid

Part.
n Expand the Part history as shown.

Note: The part is just a body no feature holes are listed.

n From the Model

Prep, Modify group,
select Find Holes.
icon.

301
Drilling Toolpaths Step 3: Add Holes To The Part Solid

n Select the part solid.

n Press Enter to finish the selection.

n In the Find Holes panel, enable Hole operations and

Create a single operation.
n In the Radius set Maximum to 5.0.
n Select the OK button.

302
Drilling Toolpaths Step 4: Move The Points On Level 1001

n A message that 9 holes were detected will appear.

n Select the OK button to continue.
n The Solids manager should look as shown.

Note: The Find Holes creates center points. You will

move them on a different level to have only the solid
visible when machining.

STEP 4: MOVE THE POINTS ON LEVEL 1001

n From the Quick Mask Toolbar, click on Select all point entities.

n Right mouse click in the graphics window

and select Change levels icon.

n In the Change Levels dialog box, enable Move.

n Disable Use Active Level.
n Number set to1001.
n Name set to Points.
n Force visibility and Off enabled.

STEP 5: SAVE THE FILE

n Save the file as Drill-1.MCAM.

303
Drilling Toolpaths Step 6: Set The Part Origin

STEP 6: SET THE PART ORIGIN

Move to Origin

In this step you will move the part and the vise and set the Origin at the top center of the part using Move to
Origin command.

n From the
Transform ribbon,
select Move to
Origin icon.

n Select the center of the hole.

n Right mouse click in the graphics window and

from the Mini Toolbar, select Clear colors icon.

n Right mouse click and select the Isometric

view.
n Right mouse click and select the Fit .
n Press F9 to see the Origin.
n Press F9 again to remove the coordinate axes.

Note: The part is oriented as needed to machine the features. Next, you will hide the vise using Levels
Manager.

304
Drilling Toolpaths Step 7: Create The Job Setup

n Open Levels Manager .

n Make the Active Level, Level 1 and rename it Part.
n Make invisible the rest of the levels by removing the Xs
in the Visible column.

n Right mouse click in the graphics window and

select Fit.
n The geometry should look as shown.

STEP 7: CREATE THE JOB SETUP

In this step you will supply Mastercam with information about tool settings and stock size before starting to
create the toolpaths.

7.1 Load the Mill Default

n Open Toolpaths Manager.

n From the Machine tab, select Mill and Default.

7.2 Set the Machine Group Setup

n Click on the Toolpaths tab to open Toolpaths

Manager.
n Expand the Properties and select the Files icon.

305
Drilling Toolpaths Step 7: Create The Job Setup

Files

n Program number set to 1008.

Note: The default Mill is a 5-Axis Trunnion rotary table.

Master Model

n Click on Add from selection icon to

select the part.
n Press Enter.

Stock Setup

n Open Levels Manager and make the Active Level,

Level 1000 and make invisible the rest of the levels by
removing the Xs in the Visible column.

n Select the Stock Setup tab.

n Select the Add from selection icon as shown.

306
Drilling Toolpaths Step 7: Create The Job Setup

n Select the solid as shown.

n Press Enter to continue.
n Make sure that the check mark is in front of the Manual
Drill selection.

Workholding

n Enable Fixtures.
n Click on Add from a
level button.
n In the Select Level
dialog box, select Level
100, 101 and 102.
n Select the OK button.

307
Drilling Toolpaths Step 8: Drill The Holes

Tools

n Make sure that Assign tool numbers sequentially is enabled.

Note: All of this setting should be pre-set from the saved Operations defaults we setup in a
previous lesson.

n Select OK to exit the Machine Group Setup.

n The stock should look as shown.

We will generate 5 separate operations to machine the part in this process step. These will include:

n Drill through the four 3/8" tap holes

n Spot Drill the four 3/8" tap holes
n Tap the four 3/8" holes
n Drill through the 1/2" counterbore holes
n Circle Mill the counterbore holes with 1/2” Flat Endmill
n Thread Mill the center hole 1"-12 UNC

STEP 8: DRILL THE HOLES

In the following toolpaths you will go through the required steps to generate tapped holes. We will select
the holes to be drilled and then we will use Copy and Paste to simplify your work.
In this toolpath you will use a 5/16” Drill to drill the Tap Hole before the actual Tap operation.

n In the 2D group, select the Drill icon.

308
Drilling Toolpaths Step 8: Drill The Holes

n Select the edge of each hole as shown making sure the

Center Point is highlighted when selecting.

Note: You will learn in the next steps other ways of selecting
the holes.

n In the Toolpath Hole Definition select the OK button.

8.1 Tool

n Use the Filter to select

the 5/16" Drill as
shown.
n In the Comment area
enter "Drill the four 3/8"
tap holes".

309
Drilling Toolpaths Step 8: Drill The Holes

8.2 Cut Parameter

n Set the Cycle to Peck Drill

as shown.
n Set the rest of the
parameters as shown.

8.3 Tool Axis Control

n In the Tool Axis Control page make sure that the Output format is set to 3 axis.

8.4 Linking Parameters

n Clearance = 2.0
(Absolute).
n Only at the start and
end of operation
disabled.
n Retract = 0.1
(Incremental).
n Top of stock = 0.0
(Incremental).
n Depth = -1.0
(Incremental).
n Enable Tip Comp as
shown. Change the
parameters to match
the following
screenshot.

Note: The tool has to

retract to clearance
height between each
hole to ensure there is
not a collision with the
standing boss. The
Depth can be extracted
by clicking the Depth
button and selecting the
geometry at the bottom
surface of the hole as
shown.

310
Drilling Toolpaths Step 8: Drill The Holes

8.5 Plane Display Settings

n To see the Planes displayed in the graphics window, enable Display

graphical elements button as shown.

n Select the Hide dialog button as shown.

n The planes should look as shown.

n Press Esc when done.

n Hover the cursor above one plane the height value

appears on the screen as shown.
n Select the OK button to exit 2D Toolpaths - Drill.

8.6 Coolant

n From the Tree View List, select Coolant and turn the
Flood on as shown.

311
Drilling Toolpaths Step 9: Chamfer Drill The 4 Holes

8.7 Repeat the Backplot procedure

n Rotate the part and check if the tool breaks

through as shown.

STEP 9: CHAMFER DRILL THE 4 HOLES

Chamfer Drill allows you to quickly create chamfered edges around your holes. Chamfer Drill toolpath
main advantage is that you can select holes of different diameter or size that can lie in different z depths
and machine them in a single operation with a single tool. You can use any tool with a tapered tip, not just a
drill.

n Before starting the next operation, turn off the

toolpath display for the Drilling operation you just
completed as shown.

9.1 Chamfer Drill selection

n From the Toolpaths ribbon, 2D group, select the expand

gallery arrow and select Chamfer Drill icon.

n To select the holes, Hold down Ctrl key and select the inside face
of on of the hole. The rest of the holes with the same diameter will
be automatically selected.

Note: That all the other holes that match the criteria were
automatically selected. Make sure the arrows are all pointing
upwards, otherwise click on them to change the direction.

312
Drilling Toolpaths Step 9: Chamfer Drill The 4 Holes

9.2 Tool

n Use the Filter to

select the 1/2"
Spot Drill as
shown.
n Enter in the
Comment area
"Chamfer the tap
holes".

9.3 Cut Parameter

n Set the Width to 0.05 as shown.

n Press Enter.

REFERENCE INFORMATION
Width allows you to define the chamfer by its width.
Depth allows you to define the chamfer by its depth.
Dwell allows you to enter a dwell after machining the chamfer in seconds.
Maintain SFM/CS varies the spindle speed for each hole to maintain the cutting speed (CS) in surface feet
per minute (SFM) which helps when machining different size holes.

313
Drilling Toolpaths Step 9: Chamfer Drill The 4 Holes

9.4 Linking Parameters

n Set the values as

shown making sure
that the Top of stock
is set to 0.0.
n Make sure that Only
at the start and end
of operation is
disabled as shown.

Note: Mastercam automatically calculates the depth based on the width entered in the Cut Parameters.

n Select the OK button to exit

Chamfer Drill.
n The results of the chamfer drill
toolpath should look as
shown.

314
Drilling Toolpaths Step 10: Tapping The Four Holes

STEP 10: TAPPING THE FOUR HOLES

In this operation we will use a 3/8” Tap to thread the 4 holes that have been Spot Drilled and Peck Drilled. You
will use Copy and Paste to simplify our work. The other option would be to re-select the hole location geometry.

n Before starting the next operation, turn off the toolpath display.
n In the Toolpaths Manager, select the Peck Drill operation as
shown.
n Right mouse click on the selected drill operation and select
Copy as shown.

n Make sure that the insert arrow is below the last toolpath
and then right mouse click on it and select Paste.

315
Drilling Toolpaths Step 10: Tapping The Four Holes

n Select the Parameters in the last Drill toolpath

as shown.

Note: In the next steps you will modify the existing parameters to change the drilling operation to a tap
operation.

10.1 Tool

n Use the Filter to

select the 3/8"-16
TapRH as shown.
n Enter the Spindle
speed and the Feed
rate field will be
automatically updated
based on the tap
selected. Set the rest
of the parameters as
shown.

316
Drilling Toolpaths Step 10: Tapping The Four Holes

10.2 Cut Parameters

n Set the Cycle to Tap as

shown.

10.3 Linking Parameters

n Clearance = 2.0
(Absolute).
n Use Clearance only at
the start and end of
operation disabled.
n Retract = 0.1
(Incremental).
n Top of stock = 0.0
(Incremental).
n Depth = -1.0
(Incremental).
n Disable Tip Comp.

n Enable Generate
toolpath.
n Select the OK button to exit
2D Toolpaths - Drill /
Circles Tapping.

317
Drilling Toolpaths Step 11: Verify The Part With The Fixture

STEP 11: VERIFY THE PART WITH THE FIXTURE

In this step you will instruct Mastercam Verify to display the vise while the toolpaths are checked. You will
enable the fixture display in the Simulator Options.

11.1 Repeat the Solid Verify procedure

n From the Toolpaths Manager, click on the Select all

operations icon as shown.
n Select Verify selected operations icon.

n In the Toolpaths Manager, select Verify selected operations.

n In the Verify graphics window, right mouse click

and select Fit.
n Right mouse click and select Isometric.
n The part with the vise should look as shown.

318
Drilling Toolpaths Step 11: Verify The Part With The Fixture

n The part after being verified in Mastercam

Simulator should look as shown.

Note: To see the part with different colors after verification, in the Verify ribbon enable Color Loop icon.
You can see a section through the part if in the Verify ribbon you select the ZX Clipping Plane and
select Clip Front.

To remove the section, in the ZX Clipping Plane select Off.

n When finished verifying, minimize Mastercam Simulator.

319
Drilling Toolpaths Step 12: Drill The 1/2" Through Holes

STEP 12: DRILL THE 1/2" THROUGH HOLES

In this toolpath you will use a 1/2” Drill to drill the counterbore holes. To select the holes you will use a
different method of selection; you will select the inside faces of the holes.

n In the 2D group, select the Drill icon.

n Holding down Ctrl key (to select all matching

radius solid features), select the inside face of
one of the 1/2" Counterbore holes.

Note: That all the other holes that match the

criteria were automatically selected.
Make sure the arrows are all pointing upwards,
otherwise click on them to change the direction.

12.1 Tool

n Use the Filter to select

the 1/2" Drill as
shown.
n In the Comment area
enter "Drill the four 1/2"
holes".

320
Drilling Toolpaths Step 12: Drill The 1/2" Through Holes

12.2 Stock

n In the Stock enable Use Stock and

Stock Setup as shown.
n In the Use stock definition for enable
Both.

Note: The Stock page is used to trim a

multiaxis or hole-making toolpath based
on a stock model. This reduces the
amount of time the tool is not in contact
with the material. Absolute and
Associative values are not accepted.

12.3 Cut Parameter

n Set the Cycle to Drill Counterbore as shown.

n Set the rest of the parameters as shown.

12.4 Linking Parameters

n Clearance = 2.0
(Absolute).
n Only at the start and
end of operation
disabled.
n Retract = 0.1
(Incremental).
n Top of stock = 0.0.
n Depth = -1.0.
n Enable Calculate depth
from top of stock.

Note:Calculate depth from

top of stock is available
only when the Use Stock is
enabled. The Depth value
is measured from the top
of the stock that was
defined in Stock setup.

n Tip Comp enabled.

n Amount = 0.05.

321
Drilling Toolpaths Step 13: Circle Mill The Large Holes

12.5 Repeat the Backplot procedure

n Rotate the part and check if the tool breaks through as

shown.

STEP 13: CIRCLE MILL THE LARGE HOLES

Circle mill toolpath allows you to machine large holes using a milling type toolpath. You will machine the
large 1” counterbore hole using a ½” Flat Endmill.
As selection method you will select the hole feature from the Solids Manager. This is mainly used when
you have a part with many hole features that have same diameter and you do not want to select them all
based on diameter.

n In the Toolpaths Manger, select Toggle display on

selected operations to remove the toolpath display.

n In the 2D group, select the drop down arrow and select the
Circle Mill from the Hole making gallery.

322
Drilling Toolpaths Step 13: Circle Mill The Large Holes

n Open Solids Manager and expand Part

click on the Counterbore.

Note: The entire feature is selected. In the

Hole Segments you can specify which
area will be machined.

13.1 Toolpath Type

n The Circle Mill icon is selected

as shown.

13.2 Tool

n Select the 1/2 "

Flat Endmill as
shown.
n Enter the
Comment: "Circle
mill the counterbore
holes".

323
Drilling Toolpaths Step 13: Circle Mill The Large Holes

13.3 Stock Disabled

13.4 Cut Parameters

n Set the
Compensation
type to Wear as
shown.
n No stock to leave.

13.5 Roughing disabled

13.6 Finishing disabled
13.7 Transitions

n From the Tree View list, expend

Finishing and click on the
Transitions.
n Enable Lead In/Out.
n Enable Start at center.
n Enable End at center.

324
Drilling Toolpaths Step 13: Circle Mill The Large Holes

13.8 Depth Cuts

n Enable Depth Cuts.

n Max rough step = 0.25.
n Enable Keep tool down.

13.9 Hole Segments

n In the Hole Segments page, click on

the Counterbore to selected as
shown. In the graphics, only the top
counterbore area will be selected
and displayed in red color as
shown.

Note: Hole segments help drive

the linking parameters for the Hole
making toolpath. Selecting a single
segment or multiple segments
modifies the parameters on the
Linking Parameters page to
machine those exact features.

325
Drilling Toolpaths Step 13: Circle Mill The Large Holes

13.10 Linking Parameters

n Clearance = 2.0
(Absolute).
n Retract = 0.25
(Incremental).
n Feed Plane = 0.1
(Incremental).
n Depth = 0.0
(Incremental).
n Break Through
disabled.

13.11 Repeat the Backplot procedure

n Rotate the part back.

n From the Status Bar, lower left corner, select the
Translucency icon.
n The toolpath should look as shown.

13.12 Verify all the toolpaths

n From the Toolpaths Manager, click on the Select all operations icon as shown.

n From the Toolpaths Manager, select Verify selected operations icon as shown.

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Drilling Toolpaths Step 14: Create A 5/8" Thread Mill

n Select the Play button to run Verify.

n The part should appear as shown.

STEP 14: CREATE A 5/8" THREAD MILL

In this step you will use Thread mill toolpath to machine the thread. You will first create the 5/8" Thread mill tool and
then set the Thread mill cut parameters.

Step Preview:

Toolpaths

n Expand the 2D group Toolpath gallery and select the Thread Mill icon
as shown.

n Select the inside face of the hole as shown.

n Select the OK button to exit the Toolpath Hole Definition

dialog box.

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Drilling Toolpaths Step 14: Create A 5/8" Thread Mill

14.1 Create a 5/8"Thread Mill

n Select Tool from the Tree view list.

n Right mouse click in the Tool list
window and select Create tool as
shown.

n Under Select Tool Types, select the Thread mill button as shown.
n Select the Next button.

328
Drilling Toolpaths Step 14: Create A 5/8" Thread Mill

14.2 Define Thread mill

n Change the tool overall dimensions and the non cutting geometry to create a single point 5/8" Thread
mill, then click Next.

Note: To create a Single Point Thread Mill, the Cutting length was calculated as 1/Thread per inch (in
our case 1/12).

329
Drilling Toolpaths Step 15: Set The Thread Mill Cut Parameters

14.3 Finalize Properties

n In the Finalize miscellaneous properties change the parameters as shown.

n Select the Finish button to exit.

STEP 15: SET THE THREAD MILL CUT PARAMETERS

n Select Cut Parameters, and

change the parameters as
shown.

330
Drilling Toolpaths Step 15: Set The Thread Mill Cut Parameters

15.1 Set the Linking Parameters

n Select Linking Parameters

and input a Depth value of
as shown.

n To quickly check how the toolpath will be generated, select the

Hide dialog icon as shown.

n Press Ctrl + T to see the part in the translucent

mode.
n The toolpath should look as shown.

n Press Esc key to exit the preview.

Note: If the toolpath does not look as shown in the preview, check your parameters again.

331
Drilling Toolpaths Step 16: Post Process The Toolpaths

15.2 Repeat the Backplot procedure

n Rotate the part back.

n From the Status Bar, lower left corner, select
the Translucency icon.
n The toolpath should look as shown.

15.3 Verify the last toolpath

n In the Toolpaths Manager, click on the

drop down next to Verify selected
operations and select Add to current
verification icon.

n The part should appear as

shown.

STEP 16: POST PROCESS THE TOOLPATHS

STEP 17: SAVE YOUR FILE
n Save the file as Drill-1.MCAM.

332
Drilling Toolpaths Step 17: Save Your File

SUMMARY:

In this lesson, you further added to your toolpath skill set by learning how to create a soft jaw vise that allows
you to verify the toolpaths. You learned how to merge the part and align it in the vise. You learned how to
create counterbore holes using the Solids Hole command.
You machined the hole shapes using both milling techniques as well as multiple types of drill operations. You
also learned the Toolpath Hole Definition options for sorting and applying special parameters to hole
locations. After completing this lesson and some of the practice exercises that follow you should be able to:
n Merge the part and align it on the vise.
n Create holes using Solids Hole command.
n Work with round part shapes and set up round stock.
n Create Circle Mill operations on large holes with Endmills.
n Efficiently enter drilling parameter settings.
n Create standard Drill cycles.
n Spot Drill the holes in preparation for tapping.
n Tap holes.
n Thread Mill an inside hole.

333
Drilling Toolpaths Exercise #1

EXERCISE #1

Job Description:

Program the part above (MANUAL DRILL EXERCISE-1.SLDPRT) with the following requirements:

n Open the Vise.

n Merge import the SolidWorks file.
n Align the part in the Vise.
n Use Move to Origin command to locate the origin.
n Create the 1/2 Counterbore holes using Solids Hole command.
n Select tools and create Drill toolpaths to Drill, Spot Drill, Ream and Tap all holes shown in the print.
n Run Backplot and Solid Verify to confirm results.
n Create G-code for NC machine.

334
Advanced Pocket - Dynamic Mill

335
Advanced Pocket - Dynamic Mill Introduction

INTRODUCTION
Mastercam high speed toolpaths are specially designed to produce the smoothest, most
efficient tool motions, optimized for high speed and hard milling. These high speed toolpaths can help make
the processes we have learned so far more efficient and automated, minimizing programming and cycle
times.

Dynamic Mill Toolpath machines pockets, material that other toolpaths left behind, and standing bosses or
cores using the entire flute length. The toolpath supports many powerful entry methods, including a custom
entry method. Entry methods and micro lifts support custom feeds and speeds to optimize and generate safe
tool motion.

The toolpath depends on the Machining strategy that you choose in the Chain Options. If the strategy
chosen is From outside, the toolpath starts at the outmost chain and works its way in taking on the final
shape of the part as it approaches the final pass. You can also machine pockets in which case the strategy
selected is Stay inside which keeps the tool inside of the machining regions. The main difference between
the Dynamic Mill and Area Mill is that the cutting method of the first one allows you to use the entire flute of
the tool while with Area Mill, small depth of cuts are recommended.

OVERVIEW OF TUTORIAL:
In this lesson we will learn to locate and machine Solid Models. We will Face the top of the part and then
machine the highlighted areas shown by using Dynamic toolpaths.

NEW CONCEPTS COVERED IN THIS TUTORIAL:

n Open the file and check the fixture.
n Setup the part origin.
n Machine the standing bosses using Dynamic toolpath.
n Machine the outside profile using Dynamic toolpath.
n Cutting the slot shapes using Ramp Contour toolpath and Slot Mill toolpath.
n Machine open pocket areas, closed pocket areas and pocket area with Island facing using a Dynamic
toolpath. Machine multiple pockets at different depths.
n Remachine the pockets using Dynamic toolpath with Rest Mill option.
n Extracting depth values from the model while completing parameters.
n Finish the walls using Contour toolpath.
n Finish the outside profile using Contour toolpath.

336
Advanced Pocket - Dynamic Mill Instructor Demonstration:

INSTRUCTOR DEMONSTRATION:
Topics:

n Setup the Origin

n Set the stock in Job Setup
n Selecting Solid Model edges and
faces to machine
n Dynamic toolpath to machine
multiple pockets at different depths
n Dynamic toolpath to machine
pockets with islands of different
heights
n Copy and Paste Operations
n Dynamic toolpath to Re-Machining
the pockets
n Contour Ramp toolpath to cut
Obround shape
n Contour Remachining toolpath
n Contour toolpath

DYNAMIC TOOLPATHS INFORMATION

The following are brief descriptions of the toolpath types available for Dynamic toolpaths.

Dynamic Mill - Stay Inside Strategy machines pockets using

one or more chains to drive the toolpath.

Dynamic Mill - From Outside Strategy machines open pockets or

standing core shapes using the outmost chain as the stock boundary.
The toolpath starts from the outside and works its way towards the
inner boundary.

Dynamic Rest Mill machines areas that previous tool could not
machine. Mastercam analyzes the pocket to find areas where
stock remains.

Dynamic Contour - Efficient milling of material off walls.

Supports both closed or open chains.

337
Advanced Pocket - Dynamic Mill Step 1: Make Visible The Vise

STEP 1: MAKE VISIBLE THE VISE

In this step you will use Levels Manager to make visible the vise.

n Find and Open ADVANCED POCKET.MCAM

n The solid, in Isometric view should look as
shown.

n In the Status bar set the

mode to 3D and the solid
display to Outline Shaded.

n Open Levels Manager, and click in

the Visible columns next to Level
100, Level 101 and Level 102 as
shown.

n Press Alt + F1 or right mouse click in the

graphics window and select Fit to fit the
geometry in the graphics view.
n The part inside the fixture should look as
shown.

338
Advanced Pocket - Dynamic Mill Step 1: Make Visible The Vise

n Right mouse click in the

graphics and change the
Gview to Right.

Note: Zoom in at the corner and notice that the part is above the top highest part of the movable jaw.
When you created the stock box, you gave 0.125 extra stock at the bottom. The movable jaw step height
is 0.1. There is an extra 0.025 stock that allows you to completely machine the outside profile. After you
machine all the features in this setup, you will have to flip the part and face it, removing the extra 0.125.

1.1 Use Levels Manager to make invisible the vise

n Open Levels Manager and make the Active Level, Level 1.

n Make invisible the vise levels by removing the Xs in the
Visible column as shown.

Note: Removing the vise from display makes it easier to

select the geometry required to generate the toolpaths .

n Change the Cplane and Gview to

Top.
n The geometry should look as
shown.

339
Advanced Pocket - Dynamic Mill Step 2: Set The Stock

STEP 2: SET THE STOCK

In this step you will supply Mastercam with information about tool settings and stock size before starting to
create the toolpaths.

2.1 Load the Mill Default if needed

n From the Machine tab, select Mill and Default.

2.2 Machine

n Expand the Properties and select the Files icon.

n Set the Default program number to 1004.

Master Model

n Click on Add from

selection icon to
select the part.
n Press Enter.

Stock

n Enable Show wireframe entities if needed.

n Select the Stock Setup and click on the Add from a
bounding box button.

340
Advanced Pocket - Dynamic Mill Step 2: Set The Stock

n Enable All shown.

n Change the Origin location to the center of the box.
n Change the Size values should look as shown.

n Select the OK button to exit Bounding Box.

341
Advanced Pocket - Dynamic Mill Step 2: Set The Stock

Workholding

n In the Workholding, enable Fixtures and select Add

from a level icon.

Note: Make sure that all levels that contain the fixture
bodies are selected Level 100,101,102.

n Select the OK button to exit Select Level dialog.

n The Fixtures should be listed as shown.
n Change the fixture color to green (no 65) as shown.
n Select the OK button to exit Machine Group Setup.

n To check the stock, in the Toolpaths ribbon you

can enable Stock display.

n The stock should look as shown.

342
Advanced Pocket - Dynamic Mill Step 3: Facing Toolpath

We will generate 13 separate operations to machine the part in the next steps. These will include:

n Facing the top of the stock

n Pocket toolpath with Facing option to machine the top bosses
n Cutting the thin slots using a Ramp Contour Toolpath
n Slot Mill toolpath to machine the larger slot
n Dynamic toolpath with Island Facing option
n Dynamic toolpath with Open option
n Dynamic Rest Material toolpath to clean up smaller fillets for multiple pockets
n Drill the two large holes
n Circle Mill the two large holes
n Dynamic toolpath to machine the outside profile
n Contour Remachining the outside profile
n Contour the walls

STEP 3: FACING TOOLPATH

A Facing toolpath quickly removes material from the top of the part to create an even surface and prepare
for subsequent operations.

n In the Toolpaths tab, from the 2D group, select the

Facing icon as shown.

n The Chaining dialog box appears on the screen.

n To use the defined stock select the OK button.

Note: This is an option for Face operations.

n The 2D Toolpaths - Facing dialog box appears on the screen.

3.1 Toolpath Type

n The Facing icon is already selected. No

chains are selected in the Chain geometry
area.

343
Advanced Pocket - Dynamic Mill Step 3: Facing Toolpath

3.2 Tool

n Click on the Select

library tool button
and using the Filter
options select a 2.0"
Face Mill as shown.

n Enable Rapid
Retract to force the
tool to retract from
the part at the rapid
feed rate set at the
machine.
n In the Comment
area, enter a
description of what
the toolpath does as
shown.

3.3 Cut Parameters

n Set the Style to Zigzag.

n Across Overlap = 25%.
n Along Overlap = 110%.
n Approach distance = 0.
n Exit Distance = 0.
n Max stepover = 75%.
n Move between cuts to
High speed loops.
n Set the Stock to leave on
floors to 0.0 .

344
Advanced Pocket - Dynamic Mill Step 3: Facing Toolpath

3.4 Linking Parameters

n Clearance = 2.0
(Absolute).
n Retract = 0.25
(Absolute).
n Feed Plane = 0.1
(Incremental).
n Top of Stock = 0.0625
(Absolute).
n Depth = 0.0 (Absolute).

n The toolpath should look as

shown.

345
Advanced Pocket - Dynamic Mill Step 3: Facing Toolpath

3.5 Verify the toolpath

n In the Toolpaths Manager, click on the t Verify

selected operation button.

3.6 Repeat the Verify procedure

n When finished verifying,

Minimize the Mastercam
Simulator Window to leave it
open or move it on a separate
monitor.

346
Advanced Pocket - Dynamic Mill Step 4: Dynamic Toolpath To Machine The Bosses

STEP 4: DYNAMIC TOOLPATH TO MACHINE THE BOSSES

In this step you will use the Dynamic toolpath with the strategy set to From outside to machine around the
standing bosses.

n Before starting the next operation, turn off the toolpath

display for the Facing operation.

n In the 2D Toolpaths group, select the Dynamic icon from the list.

n Enable From outside and click to select the Machining regions.

n In the Wireframe Chaining Mode,

enable Cplane and Chain button.
n Select the top rectangle as shown.

Note: This is the boundary from where

the tool starts machining. In our case,
this step is not needed as Mastercam
will consider the stock set in the setup
and start machining from the stock
edges.

n In the Avoidance regions, make sure that the Clearance is set

to 0.0 and click on the Select button.

347
Advanced Pocket - Dynamic Mill Step 4: Dynamic Toolpath To Machine The Bosses

n Switch to Solid Chaining Mode

and enable only Loop button.
n Select the two bosses as shown.

Note: These bosses are going to

be islands that the tool will avoid
machining.

n Select the OK button to continue.

n Click on the Preview

chains button to
check the chaining.

348
Advanced Pocket - Dynamic Mill Step 4: Dynamic Toolpath To Machine The Bosses

Face when selecting a loop, Mastercam

will use the same reference face used in
the previously selected loop.
3D when selecting a loop, Mastercam
will display the Pick reference face
dialog box, prompting the user to select
a new reference face.
Edge toggles edge selection on or off.
Linked edges allows for contiguous
SOLIDS CHAINING REFERENCE INFORMATION chaining of edges across multiple solid
faces.
Face toggles face selection on or off.
Last re-selects entities selected during
the previous chaining operation.
Loop toggles solid loop chaining on or
off. You can create a closed chain (with
no branch points) — in which you select
an edge, a reference face, a resulting
loop, and a start point on a solid model.
Partial loop toggles partial loop
chaining on or off. You can create an
open chain — in which you select a
starting edge, a reference face, and an
ending edge on a solid model.
From back toggles "from back"
selection on or off. You can select solid
edges or faces only on the back of a
model.
End chain ends the chain, as when
creating a partial chain, so you can
extend the current chain or start a new
one.
Unselect un-selects the active chain.
Display all selection arrows shows
all the arrows of the chains you
selected.
Reverse swaps the chaining direction.
Back / Forward allows you to move the
start of a chain from one entity endpoint
to another.

349
Advanced Pocket - Dynamic Mill Step 4: Dynamic Toolpath To Machine The Bosses

4.1 Tool

n Click on the Select library tool button and using the Filter options select the 1/2" Flat Endmill.
n Rapid Retract enabled.
n Comment: “Machine the two bosses.”

4.2 Cut Parameters

n Machining direction is set

to Climb.
n Approach distance = 0.
n Stepover distance = 25%.
n Minimum toolpath radius
= 10.0%.
n Keep tool down within %
of tool diameter = 100.
n Micro lift distance = 0.01.
n Stock to leave on walls =
0.02.
n Stock to leave on floors =
0.0.

REFERENCE INFORMATION
Stepover sets the distance between cutting passes in the X and Y axes.
Toolpath radius reduces sharp corner motion between cut passes.
Micro lift distance enters the distance the tool lifts off the part on the back moves. Microlifts are slight lifts
that help clear chips and minimize excessive tool heating.
Back feedrate controls the speed of the backfeed movement of the tool.
Motion > Gap Size, retract controls retracts in the toolpath when making a non-cutting move within an
area where the tool can be kept down or microlifted.
Cut order optimization defines the cut order Mastercam applies to different cutting passes in the
dynamic mill toolpath.
Stock to leave on walls sets the stock left on the walls that has to be removed by another operation.

350
Advanced Pocket - Dynamic Mill Step 4: Dynamic Toolpath To Machine The Bosses

4.3 Corner Pretreatment disabled

4.4 Depth Cuts

n Enable Island facing.

n Overlap = 50%.
n Stock above islands = 0.0.

The Island facing parameters

allows you to face the island
and overlap its edges.

4.5 Break Through disabled

4.6 Linking Parameters

n Clearance = 2.0 (Absolute).

n Retract = 0.25 (Absolute).
n Feed Plane = 0.1 (Incremental).
n Top of Stock = 0.0 (Absolute).
n Depth = -0.3125 (Absolute).

Note: To establish the Depth value, after set it

to Absolute, click on the Depth button to return
in the graphics window and select a point at the
bottom of one of the bosses.

4.7 Entry motion

Note: Strategy is set from outside and the entry motion does not matter.

351
Advanced Pocket - Dynamic Mill Step 4: Dynamic Toolpath To Machine The Bosses

4.8 Arc Filter / Tolerance

The option to Output 3D arcs will create the entry helix move with arc moves when possible.

n From the Tree View List, select

Arc Filter / Tolerance.
n Set the Line/ arc tolerance to
70% to ensure that the filter will
remove some of the lines and
arcs move in the given tolerance.
n Enable Line/Arc Filtering
Settings and make sure that
Output 3D arc entry motion is
enabled as shown.

4.9 Preview the toolpath

n Click on the Apply button as shown.

n Click on the Hide dialog icon as shown to hide

the toolpath parameters.
n Press Esc.

n The toolpath should look as shown.

n Press Esc button when done.
n Select the OK button to exit 2D High Speed
Toolpaths - Dynamic Mill.

n Select the OK button to exit 2D Toolpaths - Dynamic.

352
Advanced Pocket - Dynamic Mill Step 4: Dynamic Toolpath To Machine The Bosses

4.10 Repeat the Backplot procedure

n The toolpath should look as

shown.

Note: The top of the right side

boss is faced with the settings in
the Depth cuts. The right side
boss is not faced because the
Top of stock is set to the height
of the boss (in our case 0).

4.11 Verify all the toolpaths

n From the Toolpaths Manager, click on the Select all

operations icon as shown.

n From the Toolpaths Manager, select Verify

selected operations icon as shown.

n Select the Play button to run Verify.

n The part should appear as shown.

Note: If your verify does not look like this result, click the Parameters icon under the Pocket toolpath in
the Mastercam Toolpaths Manager and confirm your settings are correct. Then Regenerate the
toolpath.

353
Advanced Pocket - Dynamic Mill Step 5: Machine The Outside Profile Using Dynamic

STEP 5: MACHINE THE OUTSIDE PROFILE USING DYNAMIC

In this step you will use the Dynamic toolpath with the From outside option to machine the outside
profile.

n Before starting the next operation, turn off the

toolpath display for the Facing operation.

n Select the the Dynamic icon in the 2D Toolpaths.

n In the Chain Options enable From outside.

Note: You do not need to select any geometry as Machining regions.

Mastercam will automatically calculate the toolpath from the edge of
the defined stock.

n In the Avoidance regions, click

on the Select button.
n Switch to Solid Chaining Mode
and enable only Loop button.
n Select the bottom of the outside
profile as shown.

Note: The chain direction does

not matter for a pocket toolpath.

n Select the OK button to

continue.
n Set the Clearance to 0.0.

5.1 Tool

n Select the 1/2" Flat Endmill.

n Rapid Retract enabled.
n Comment: “Machine the outside profile”.

5.2 Stock
n Make sure Rest material is disabled.

354
Advanced Pocket - Dynamic Mill Step 5: Machine The Outside Profile Using Dynamic

5.3 Cut Parameters

n Leave the parameters as

set before.

5.4 Depth Cuts

n Disable Island facing.

355
Advanced Pocket - Dynamic Mill Step 5: Machine The Outside Profile Using Dynamic

5.5 Linking Parameters

n Clearance = 2.0 (Absolute).

n Retract = 0.25 (Absolute).
n Feed Plane = 0.1
(Incremental).
n Top of Stock = -0.3125
(Absolute).
n Depth = -1.0625 (Absolute).

n Select the OK button to exit 2D Toolpaths - Pocket.

5.6 Repeat the Backplot procedure

n The toolpath should look as shown.

356
Advanced Pocket - Dynamic Mill Step 6: Machine The Slot With Contour Ramp

5.7 Verify the last toolpath

n In the Toolpaths Manager, click on the drop

down next to Verify selected operations and
select Add to current verification icon.

n The part should appear as shown.

Note: There are 0.2 radius fillets around

the outside profile that cannot be
machined with the 1/2" Flat Endmill. A
contour remachining is necessary to
machine them. You will do that latter on.

STEP 6: MACHINE THE SLOT WITH CONTOUR RAMP

In this example, you will machine the two narrow slots using a Contour operation with a constant ramp
motion. You will cut the 0.15” wide slot with a 1/8” Flat Endmill.

n Before starting the next operation, turn off the toolpath display.
n From the 2D Toolpaths select Contour.

n In the Solid Chaining dialog box

enable selection of Loops only.
n Ctrl + T to make the solid
translucent.
n Select the chain on the bottom
faces as shown.
n Make sure the chain direction is
CCW and starts as shown.
Otherwise, select the Reverse
button.
n Enable Display all selection arrows
to see the arrow display for both
chains.
n Select the OK button to exit the
Chaining dialog box.

357
Advanced Pocket - Dynamic Mill Step 6: Machine The Slot With Contour Ramp

6.1 Tool

n Select the 1/8" Flat Endmill from the library.

n Enable Rapid Retract to force the tool to retract from the part at the rapid feed rate set at the
machine.
n In the Comment area, enter "Ramp cut the slot shapes" as shown.

6.2 Cut Parameters

Cut Parameters page allows you to set the Contour parameters such as cutter compensation type,
direction and Contour Type.

n Set the Compensation type to

Wear as shown.
n Set the Contour type to Ramp
and the rest of the parameters as
shown.
n Ramp motion set to Depth.
n Ramp Depth = 0.05.
n Make pass at final depth
enabled.

Note: This setting tells the

program to ramp continuously
during depth cuts by descending
by a specified depth during each
full ramp motion.

6.3 Depth Cuts disabled

358
Advanced Pocket - Dynamic Mill Step 6: Machine The Slot With Contour Ramp

6.4 Lead In/Out

Lead In/Out page allows you to set the entry and/or exit movements as a combination of a line and an arc.

n Make sure that Lead In/Out is

enabled.
n Enable Enter/exit at midpoint
n In the Entry area set the line to
Perpendicular.
n Length = 10%.
n Select the Double Arrow to copy
all values to the Exit values.

6.5 Break Through disabled

6.6 Multi Passes disabled
6.7 Tab disabled
6.8 Linking Parameters

n Clearance = 2.0 (Absolute).

n Retract = 0.25 (Absolute).
n Feed plane = 0.1 (Incremental).
n Top of Stock = 0.0 (Absolute).
n Depth = 0.0 (Incremental).

Note: The two slots have different

depths. It is important that you chained
them at the bottom. This allows you to
set the Depth Incremental and 0
instructing Mastercam to machine
each slot at the z value of the chained
geometry.

359
Advanced Pocket - Dynamic Mill Step 6: Machine The Slot With Contour Ramp

6.9 Repeat the Backplot procedure

n The toolpath should look as

shown.

6.10 Verify the last toolpath

n The part after being verified in

Mastercam Simulator should look as
shown.

Note: To see the part with different colors after verification, in the Verify ribbon enable Color Loop icon.

360
Advanced Pocket - Dynamic Mill Step 7: Slot Mill The Bigger Slot

STEP 7: SLOT MILL THE BIGGER SLOT

In this step you will machine the bigger slot using Slot Mill toolpath. The Slot Mill toolpath is designed
specifically for the obround shapes. The slots must be closed and include two parallel, straight sides.

n Before starting the next operation, turn off the toolpaths. Press Al + T.

n Select the drop down arrow below

the 2D Toolpaths and select the
Slot Mill from the list.

n Enable only Loop button.

n Holding down the mouse wheel click on the part
and rotate the model and Zoom in.
n Select an edge at the bottom of the pocket to
select the entire Loop as shown.
n Make sure the chain direction is CCW as shown.

361
Advanced Pocket - Dynamic Mill Step 7: Slot Mill The Bigger Slot

7.1 Tool

n Select the 1/8" Flat Endmill.

n Rapid Retract enabled.
n Comment: “Machine the slot using Slot Mill toolpath”.

7.2 Cut Parameters

n Machining direction is
set to Left.
n Stock to leave on walls
= 0.0.
n Stock to leave on
floors = 0.0.

REFERENCE INFORMATION
Entry/exit arc sweep sets the included angle of each entry and exit arc.
Perpendicular entry enters the toolpath perpendicular to the first tool move. Useful when using
Compensation type in Control.
Overlap how far the tool goes past the end of the toolpath before exiting for a cleaner finish.

362
Advanced Pocket - Dynamic Mill Step 7: Slot Mill The Bigger Slot

7.3 Rough/Finish

n Plunge angle = 2 degrees.

n Enable Keep tool down.

Note: While machining the slot

there is no need for the tool to
retract. Keep tool down is safe
and saves some machining
time.

7.4 Depth Cuts

n Depth cuts enabled.

n Max rough step =
0.07.
n Enable Keep tool down.

7.5 Break Through disabled

We do not want the cutter to cut beyond the bottom of the slot, so we need this setting to be off.

363
Advanced Pocket - Dynamic Mill Step 7: Slot Mill The Bigger Slot

7.6 Linking Parameters

n Clearance = 2.0 (Absolute).

n Retract = 0.25 (Absolute).
n Feed Plane = 0.1 (Incremental).
n Top of Stock = -0.3125 (Absolute).
n Depth = 0.0 (Incremental).

Note: Depth value is set from the value of the

chained edges. Incremental values should
almost always be set to 0.0.

n Select the OK button to exit 2D Toolpaths - Slot mill.

7.7 Repeat the Backplot procedure

n The toolpath should look as shown.

7.8 Verify last toolpath

n The part should appear

as shown.

364
Advanced Pocket - Dynamic Mill Step 8: Pockets With Different Depths & An Island

STEP 8: POCKETS WITH DIFFERENT DEPTHS & AN ISLAND

In this step you will machine all the closed cavities including the one with a standing island. Note the
selection method that will be needed to let Mastercam know where is the top of the island that needs to be
faced.

n Before starting the next operation, turn off the

toolpath display for the last operation.

n From the 2D Toolpaths select the Dynamic from the gallery.

n In the Machining region strategy enable Stay inside and click on the Machining regions
select button.

n Enable only the Face button.

n Select the bottom of the two similar pockets
as shown.

n Change the selection method to

loop and select the bottom of the
pocket with the island.
n Select the OK button to exit the
Chaining dialog box.

365
Advanced Pocket - Dynamic Mill Step 8: Pockets With Different Depths & An Island

n In the Avoidance regions click on the Select button.

n Select the top of the island.

8.1 Tool

n Select the 3/8" Flat Endmill.

n Rapid Retract enabled.
n Comment: “Machine the closed area pockets and face the island”.

8.2 Cut Parameters

n Machining direction is set to Climb.

n Stepover Distance = 15% of Tool
Diameter.
n Enable Maximize engagement.
n Minimum toolpath radius = 10%.
n Stock to leave on walls = 0.02.
n Stock to leave on floors = 0.0.

8.3 Depth Cuts

n Make sure that Island facing

is enabled.
n Overlap = 50%.
n Stock above islands = 0.0.

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Advanced Pocket - Dynamic Mill Step 8: Pockets With Different Depths & An Island

8.4 Break Through disabled

8.5 Linking Parameters

n Clearance = 2.0 (Absolute).

n Retract = .25 (Absolute).
n Feed Plane = 0.1 (Incremental).
n Top of Stock = -0.3125 (Absolute).
n Depth = 0.0 (Incremental).

Note: Depth value is set from the value of the

chained edges. Incremental value is used in
this case because there are multiple geometry
selections that are at different depths.
Incremental values should always be set to
0.0.

8.6 Entry motion

n Helix only enabled.

n Helix radius = 0.16875.
n Z clearance = 0.125.
n Plunge angle = 2.0.

Note: These settings will allow the tool to

enter with a safe helical entry.

n Select the OK button to exit 2D Toolpaths - Pocket.

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Advanced Pocket - Dynamic Mill Step 8: Pockets With Different Depths & An Island

8.7 Repeat the Backplot procedure

n The toolpath should look as shown.

8.8 Verify the toolpath

n The part should appear as

shown.

Note: The 3/8 Flat Endmill could not remove all the material. The corner radius of the pocket shapes is
only 0.125 Radius. You will need to come back with another operation to clean out the corners, because
we do not want to cut away all of the pocket material with the small 0.125 tool.

368
Advanced Pocket - Dynamic Mill Step 9: Machine The Two Open Pockets

STEP 9: MACHINE THE TWO OPEN POCKETS

In this Pocket operation you will machine the open pockets, using the Dynamic toolpath and Air regions
options. You will use a ½” Flat Endmill. The corner radius of the pocket shapes is only 0.125 Radius. You
will need to come back with another operation to clean out the corners, because we do not want to cut
away all of the pocket material with the small 0.125 radius tool.

n In the Toolpaths Manger, select Toggle display on selected operations to remove the
toolpath display.

n Select the Dynamic icon.

n In the Machining region

strategy enable From
outside.
n Click on the Machining
regions Select button.
n In the Solid Chaining
dialog box enable only the
Outer shared edges
button.
n Select the bottom face of the
two open pockets as shown.
n Select the OK button to exit
the Chaining dialog box.

n In the Air regions click

on the Select button.
n In the Solid Chaining
dialog box enable only
the Outer open edges
button.
n Select the bottom face
of the two open pockets
as shown.
n Select the OK button to
exit the Chaining
dialog box.

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Advanced Pocket - Dynamic Mill Step 9: Machine The Two Open Pockets

n The Preview chains should look as

shown.

9.1 Tool

n Select the 1/2 " Flat Endmill.

n In the Comment area enter "Machine the open pockets".

Note: The corner radii of the pocket area are actually 1/16” which this tool cannot finish. You will
create another operation to clean out the corners later.

9.2 Cut Parameters

n Make sure the settings

are as shown.

9.3 Corner Pretreatment disabled

9.4 Depth Cuts and Island facing disabled

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Advanced Pocket - Dynamic Mill Step 9: Machine The Two Open Pockets

9.5 Break Through disabled

9.6 Linking Parameters

n Top of stock = -0.3125. (Absolute).

n Depth = 0.0 (Incremental).

9.7 Entry motion

The toolpath starts from outside and does not take the entry motion settings in account.

n Select the OK button to exit 2D Toolpaths - Pocket.

9.8 Repeat the Backplot procedure

n The toolpath should look as

shown.

9.9 Repeat the Verify procedure

n The part after being verified in

Mastercam Simulator should look as
shown.

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Advanced Pocket - Dynamic Mill Step 10: Drill The Holes

STEP 10: DRILL THE HOLES

In the following toolpaths you will create two pilot holes in the large holes using a 3/4 Drill. You can use the
holes created to plunge the 1/2 Flat Endmill to finish the holes with a Circle Mill toolpath.

n In the 2D group, select the Drill icon.

n Select the inside faces of the holes as shown.

n Make sure that both arrows are pointing
upwards. Otherwise, click on the arrow to change
the direction.

n In the Toolpath Hole Definition select

the OK button.

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Advanced Pocket - Dynamic Mill Step 10: Drill The Holes

10.1 Tool

n Use the Filter to

select the 3/4" Drill
as shown.
n In the Comment
area enter "Drill the
four tap holes".

10.2 Cut Parameter

n Set the Cycle to Peck Drill as shown.

n Set the rest of the parameters as
shown.

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Advanced Pocket - Dynamic Mill Step 10: Drill The Holes

10.3 Linking Parameters

Linking Parameters page allows you to define the Clearance, Retract, Feed plane, Top of stock and
Depth heights.

n Enable Calculate
incremental values
from holes/lines.
n Retract = 0.5
(Incremental).
n Top of stock = 0.0
(Incremental).
n Depth = 0.0
(Incremental).

Note: When Calculate

incremental values
from holes/lines is
enabled, the Depth
value is based on the
inside face of the hole.

n Enable Tip Comp as

shown. Change the
parameters to match
the following
screenshot.
n Select the OK button
to exit 2D Toolpaths -
Drill.

Note: The
Breakthrough amount
has to be bigger than
0.125 which is the
amount of the extra
stock at the bottom.

10.4 Coolant

n From the Tree View List, select Coolant and turn the
Flood on as shown.

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Advanced Pocket - Dynamic Mill Step 11: Circle Mill The Large Holes

10.5 Repeat the Backplot procedure

n Rotate the part and check

if the tool breaks through
as shown.
n From the Status Bar,
lower left corner, select
the Translucency icon.

STEP 11: CIRCLE MILL THE LARGE HOLES

Circle mill toolpath allows you to machine large holes using a milling type toolpath. You will machine the
large 1” counterbore hole using a ½” Flat Endmill.

n In the Toolpaths Manger, select Toggle display on selected operations to remove the
toolpath display.

n In the 2D group, select the drop down arrow and select the Circle
Mill from the Hole making gallery.

n With Ctrl key hold down, select the inside face

of the hole as shown.
n Make sure the arrows are pointing upwards.
n Select the OK button to continue.

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Advanced Pocket - Dynamic Mill Step 11: Circle Mill The Large Holes

11.1 Toolpath Type

n The Circle Mill icon is selected

as shown.

11.2 Tool

n Select the 1/2 " Flat Endmill as shown.

n Enter the Comment: "Circle mill the holes".

11.3 Cut Parameters

n Set the Compensation

type to Wear as
shown.
n No stock to leave.

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Advanced Pocket - Dynamic Mill Step 11: Circle Mill The Large Holes

11.4 Roughing enabled

n Enable Roughing and

disable Helical Entry.

11.5 Finishing enabled

n Enable Finishing and Finish.

n Number =1.
n Spacing = 0.05.
n Enable Keep tool down.
n In the Finish passes enable
Final depth.

11.6 Transitions

n From the Tree View list, expend

Finishing and click on the
Transitions.
n Enable Lead In/Out.
n Enable Start at center.
n Enable End at center.
n Overlap = 0.05.

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Advanced Pocket - Dynamic Mill Step 11: Circle Mill The Large Holes

11.7 Depth Cuts

n Enable Depth Cuts.

n Max rough step = 0.25.
n Enable Keep tooldown.

11.8 Tool Axis Control

n Make sure that the Output format is set to 3 axis

as shown.

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Advanced Pocket - Dynamic Mill Step 11: Circle Mill The Large Holes

11.9 Linking Parameters

n Make sure Calculate

depth from top of stock
is enabled.
n Clearance = 2.0
(Absolute).
n Retract = 0.25
(Absolute).
n Feed Plane = 0.2
(Incremental).
n Top of Stock = 0.0
(Incremental).
n Depth Type = -1.0625
(Incremental).

Note: When Calculate

incremental values
from holes/lines is
enabled, the Depth value
is based on the inside face
of the hole.

n Enable Break through.

n Break through amount
= 0.13.

11.10 Repeat the Backplot procedure

n Rotate the part back.

n The toolpath should look as
shown.

379
Advanced Pocket - Dynamic Mill Step 12: Remachine The Pockets With Rest Mill

11.11 Verify all the toolpaths

n The part after verifying should look as

shown.

STEP 12: REMACHINE THE POCKETS WITH REST MILL

In this toolpath you will use a 1/8” Flat Endmill to machine the corners of the pocket that the 1/2” and 3/8 "
tools could not cut. The toolpath used is Dynamic toolpath with Rest Mill option.

n Select the Dynamic icon.

n In the Machining region

strategy enable Stay inside.
n Click on the Machining
regions Select button.
n In the Solid Chaining dialog
box enable only the Face
button.
n Select the bottom face of the
pockets as shown.

380
Advanced Pocket - Dynamic Mill Step 12: Remachine The Pockets With Rest Mill

n In the Solid Chaining

dialog box enable only the
Loop button.
n Select the bottom face of the
two open pockets as shown.

n In the Solid Chaining

dialog box enable only the
Face button.
n Select the bottom face of the
pockets as shown.
n Select the OK button to exit
the Chaining dialog box.

n In the Avoidance regions,

click on the Select button.
n With the Face button
enabled select the top of
the island.
n Select the OK button to exit
the Chaining dialog box.

n Set Clearance to 0.0.

381
Advanced Pocket - Dynamic Mill Step 12: Remachine The Pockets With Rest Mill

n In the Air regions click on

the Select button.
n In the Solid Chaining
dialog box enable only the
Outer open edges
button.
n Select the bottom face of
the two open pockets as
shown.
n Select the OK button to
exit the Chaining dialog
box.

n The Preview chains should look as

shown.
n Select the OK button to exit the
Chaining Options dialog box.

12.1 Tool

n Select the 1/8" Flat Endmill.

n Enter a comment: "Remachine all pockets".

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Advanced Pocket - Dynamic Mill Step 12: Remachine The Pockets With Rest Mill

12.2 Stock

Rest Material parameters are located in the Stock page and allow you to target the material left behind
by a previous toolpath. You have to define how Mastercam calculates the remaining stock for a 2D High
Speed Dynamic Mill or Area Mill toolpath. There are two main approaches:

1. You can choose to calculate the stock remaining from one or more source operations. If the part file
includes a Mastercam stock model operation, you can select it for use as the stock model. Or select one or
more other operations from the list in the window. The source operation does not have to be another high
speed toolpath.
2. You can also just enter the dimensions of a roughing tool. Mastercam calculates a stock model based on
the areas of your part that could not be cut or accessed by such a tool.

n Enable Rest material.

n Enable Roughing Tool.
n Diameter = 0.5.

12.3 Cut Parameters

n The Cut parameters should be set

as shown.

383
Advanced Pocket - Dynamic Mill Step 12: Remachine The Pockets With Rest Mill

12.4 Depth Cuts Disabled

12.5 Linking Parameters

n Top of stock = -0.3125. (Absolute).

n Depth = 0.0 (Incremental).

n Select the OK button to exit 2D Toolpaths - Dynamic Mill.

12.6 Repeat the Backplot procedure

n The toolpath should look as shown.

12.7 Repeat the Verify procedure

n The part after being verified in

Mastercam Simulator should look as
shown.

384
Advanced Pocket - Dynamic Mill Step 13: Remachine The Contour

STEP 13: REMACHINE THE CONTOUR

In this step you will learn how to remachine the outside profile using Contour toolpath.

n Press Alt + T to remove the toolpath display.

Note: You might need to click twice on the icon to remove all toolpath displays.

n From the Toolpaths tab, and select the Contour icon as

shown.

n Select the outside contour as shown.

n The cut direction should be CW to ensure
climb milling, the side of the cutter should be
outside of the contour and the starting position
should be as shown.
n Select the OK button to accept the Chain
settings.

13.1 Tool

n Select the 1/8" Flat Endmill.

n Enter in the Comment: "Remachine the outside profile".

13.2 Cut Parameters

n Select the Remachine as

Contour type and set the
parameters as shown.

385
Advanced Pocket - Dynamic Mill Step 13: Remachine The Contour

13.3 Depth Cuts

n Enable Depth cuts.

n Max rough step = 0.1.

13.4 Lead In/Out

n Set the Line to Tangent

with the Length set to
30%.
n Set the Arc Radius to
30% and Sweep angle to
90.

13.5 Break Through disabled

386
Advanced Pocket - Dynamic Mill Step 13: Remachine The Contour

13.6 Linking Parameters

n From the Tree View List,

select Linking Parameters
and set the values as shown.
n Select the OK button to exit
2D Toolpaths - Contour.

n The toolpath should look as shown.

13.7 Repeat the Verify procedure

n The part after being verified in Mastercam

Simulator should look as shown.

387
Advanced Pocket - Dynamic Mill Step 14: Finish The Walls

STEP 14: FINISH THE WALLS

In this step you are going to finish the pockets walls using Contour toolpath. The Dynamic toolpath does
not have a finish option and you will need to use a different toolpath to remove the 0.02 stock on the walls.

n Press Alt + T to remove the toolpath display.

14.1 Finish the outside walls of the bosses using Contour toolpath

n Select the top of the bosses in CW

direction.

n Use the 3/8 Flat Endmill.

n Enter in the Comment: "Finish the two boss walls".

388
Advanced Pocket - Dynamic Mill Step 14: Finish The Walls

14.2 Cut Parameters

n Select the 2D as Contour

type and set the parameters
as shown.

14.3 Depth Cuts disabled

14.4 Lead In/Out

n In the Entry Line enable

Tangent.
n Length = 60%.
n Radius = 60%.
n Sweep = 35.0.
n Set the same parameters
in the Exit.

389
Advanced Pocket - Dynamic Mill Step 14: Finish The Walls

14.5 Break Through disabled

14.6 Linking Parameters

n Top of stock = 0
(Absolute).
n Depth = -0.3125.
(Absolute).

n Make sure Generate toolpath is enabled and select the

Apply button to preview the toolpath.
n To hide the dialog box click on the Hide dialog button.

n The toolpath should look as shown.

n Press Esc to go back to the parameters.
n Select the OK button to exit 2D Toolpaths - Contour.

390
Advanced Pocket - Dynamic Mill Step 14: Finish The Walls

14.7 Finish the pocket walls using Contour toolpath

n From the Toolpaths tab, and select the Contour icon.

n Select the pockets as

shown.
n The cut direction should
be CCW to ensure climb
milling, the side of the
cutter should be inside of
the contour and the
starting position should be
as shown.
n For the island chain the
direction should be CW.
n To see the arrows click on
the Display all selection
arrows button.

n For the open pockets enable

Outer shared edges button.
n Select the bottom of the open
pockets and make sure the
chains are selected in CCW
direction.
n You can reverse chain direction
if needed and move the starting
location to match the selection
shown.
n Select the OK button to accept
the Chain settings.

14.8 Tool

n Select the 1/8" Flat Endmill.

n Enter in the Comment: "Finish the walls".

391
Advanced Pocket - Dynamic Mill Step 14: Finish The Walls

14.9 Linking Parameters

n Top of stock = -0.3125

(Absolute).
n Depth = 0.0.
(Incremental).

n Select the Apply button and check the preview.

n The toolpath should look as shown.

n Select the OK button to exit 2D Toolpaths -
Contour.

392
Advanced Pocket - Dynamic Mill Step 15: Post Process The Toolpaths

14.10 Finish the outside profile using Contour toolpath

n Select the bottom of the outside profile.

n Use the 3/8 Flat Endmill.
n Top of stock = 0.0 Absolute.
n Depth to 0.0 (Incremental).

14.11 Verify the toolpaths.

Note: You will learn how to machine the bottom of the part in a later lesson that covers multiple setups.

STEP 15: POST PROCESS THE TOOLPATHS

STEP 16: SAVE YOUR FILE
SUMMARY:

In this lesson, you learned how to generate more complicated, specialized pocket type toolpaths, including
the special rules for selecting the geometry to machine for these toolpath types. After completing this lesson
and some of the practice exercises that follow you should be able to:
n Setup the origin using Move to Origin command.
n Face the top of the part.
n Use Dynamic toolpath to machine standing bosses.
n Cut narrow slots with the Ramp Contour toolpath.
n Cut a slot using Slot Mill toolpath.
n Use the Dynamic toolpath type to machine pockets with different depths.
n Use the Dynamic toolpath to face the tops of islands.
n Reinforce the Copy and Paste technique to quickly create new similar operations.
n Dynamic Rest Mill to remachine the pockets to remove leftover material from previous operations.
n Pre drill holes and use Circle Mill toolpath to finish them.
n Remachine the outside profile using Contour toolpath.
n Finish the walls using Contour toolpath.

393
Advanced Pocket - Dynamic Mill Exercise #1

EXERCISE #1

Job Description:

Program the part above (Advanced Pocket Exercise 1.SLDPRT) with the following requirements:

n Open the SolidWorks file and use Dynamic Transform command to orient the solid so pockets face the
Top view and locate the solid at the origin.
n Create the stock wireframe giving extra stock on Z axis 0.125 at top and at bottom.
n Open the vise and merge and align the pa rt.
n Face the top of the stock with 2” Face Mill.
n Machine using Dynamic Mill toolpaththe 1.0" Deep pocket area using Island facing to clean the top of the
standing boss using 0.75" Flat Endmill.
n Use Dynamic Mill to machine the other 4 pocket areas (note the different depths) using 0.75" Flat
Endmill.
n Use Dynamic Mill with the Rest Material option to remachine the corner areas with a 0.25" Flat Endmill.
n Finish the walls using Contour toolpath.
n Run Backplot and Solid Verify to confirm results.
n Create G-code for NC machine.

394
Advanced Pocket - Dynamic Mill Exercise #2

EXERCISE #2

Job Description:

Program the part above (Advanced Pocket Exercise 2.SLDPRT) with the following requirements:

n Open the SolidWorks file and use Dynamic Transform command to orient the solid and locate the origin.
n Create the stock wireframe giving extra stock on Z axis 0.125 at top and at bottom.
n Program the entire part completely including:
n Open the vise and merge and align the part.
n Face the top of the Stock.
n Contour the outside periphery.
n Rough out all of the pocket areas using Dynamic Mill toolpath with Flat Endmill tools that will fit in the
areas.
n Finish the walls of the pocket and islands using Contour toolpath.
n Run Backplot and Solid Verify to confirm results.
n Create G-code for NC machine.

395
Advanced Pocket - Dynamic Mill Exercise #3

EXERCISE #3

Job Description:

n Program the part above (Advanced Pocket Exercise 3.SLDPRT) with the following requirements:
n Open the SolidWorks file and use Dynamic Transform command to orient the solid and locate the origin.
n Create the stock wireframe giving extra stock on Z axis 0.125 at top and at bottom.
n Program the entire part including:
n Open the vice and merge and align the part.
n Face the top of the stock.
n Contour the outside periphery.
n Rough out all of the pocket areas using Dynamic Mill toolpath with Flat Endmill tools that will fit in the
areas.
n Finish the walls of the pocket and islands using Contour toolpath.
n Run Backplot and Solid Verify to confirm results.
n Create G-code for NC machine.

396
2D HST Toolpaths

397
2D HST Toolpaths Introduction

INTRODUCTION
This lesson will build on the High Speed toolpaths you learned in the previous tutorial. This lesson will
enforce your knowledge on how to use the different strategies the Dynamic Mill toolpath provides as you
program more complicated and realistic parts. You will learn new parameter settings to achieve the desired
results.

NEW CONCEPTS COVERED IN THIS TUTORIAL:

n Imported a Parasolid model.
n Create the stock using Bounding box command.
n Merge the vise.
n 2D HST Geometry / boundary selection rules.
n Setting the 2D HST cut parameters.
n Dynamic Milling toolpaths.
n Dynamic Rest Mill toolpaths.
n Model Chamfer toolpath.

INSTRUCTOR DEMONSTRATION:
Topics:

n Import a Parasolid
n Create the stock
n Merge the vise
n Job Setup
n Face Toolpath
n Dynamic Mill From Outside Toolpath
n Dynamic Mill From Inside Toolpath
n Rest Mill Toolpaths
n Peel Mill Toolpath
n Contour Toolpath
n Model Chamfer Toolpath

398
2D HST Toolpaths Part Drawing

PART DRAWING

399
2D HST Toolpaths 2D High Speed Toolpaths (HST) Information

2D HIGH SPEED TOOLPATHS (HST) INFORMATION

2D High Speed Dynamic toolpaths utilize the entire flute length of their cutting tools to achieve efficiency in
milling. They are designed to maximize material removal while minimizing tool wear.
The dynamic mill toolpaths are all designed to simplify the programming of complex pocket and core shapes.
Benefits include:
n Tool burial avoidance
n Minimum heat buildup
n Better chip evacuation

Dynamic Mill - Stay Inside Strategy machines pockets using

one or more chains to drive the toolpath.

Dynamic Mill - From Outside Strategy machines open pockets or

standing core shapes using the outmost chain as the stock boundary.
The toolpath starts from the outside and works its way towards the
inner boundary.

Dynamic Contour - Efficient milling of material off walls.

Supports both closed or open chains.

2D High Speed Area Mill toolpaths machine pockets using a

smooth clean motion. Helical entries and tangent stepovers
create efficient motion for tools. Cut parameters allow
controlled smoothing to avoid sharp corners or direction
changes.
2D HST Peel Mill toolpath generates an efficient climb mill cut
between two selected contours or along a single contour. It
uses a dynamic style motion with accelerated “back” feed
moves when the tool is not engaged in material. For single
chains, user defines the width of cut, otherwise the width is
defined by the area between the 2 boundary chains.

2D HST Blend Mill toolpath morphs smoothly between two

open boundary chains. The toolpath supports the full depth of
the cutting tool, utilizing more of the cutter’s flute length
resulting in less cycle time and wear.

400
2D HST Toolpaths Step 1: Create The Stock Using Bounding Box

STEP 1: CREATE THE STOCK USING BOUNDING BOX

In this step you will use Bounding Box command to create the stock necessary to machine part.

n Find and open the part 2DHST.x_t.

n Change to the Isometric View and display the axes
(F9 and Alt+F9) to determine the model orientation.

n Press F9 and Alt + F9 to remove the axes display.

n From the Status bar, to

set the mode to display
the solid, select the
Outline Shaded icon.
n Make sure that the
construction mode is set
to 3D as shown.

n Select the Bounding Box

icon from the Wireframe
tab.
n Select the entire solid and
select End Selection
button.

401
2D HST Toolpaths Step 1: Create The Stock Using Bounding Box

n Leave the Origin location as shown.

n Change the X to 10.25.
n Y = 9.25.

n To ensure that we have an extra 0.125 at the bottom

of the stock, change the Origin location at the top
center face as shown.
n Add to the current Z value 0.125.

n Change the Origin location at the bottom center

face and set Z to 1.0. (The 0.075 extra stock will be
added at the top of the part).

402
2D HST Toolpaths Step 2: Create A Point At The Top Center Of The Part

n In the Create Geometry enable Lines and

arcs only.
n The geometry should look as shown.

STEP 2: CREATE A POINT AT THE TOP CENTER OF THE PART

In this step you will use Temporary points to create a point at the top center of the part.

n From the Wireframe ribbon select Point Position

icon.

n Hover the cursor above the midpoint of the edge

until the temporary green point appears.

Note: Make sure that you do not click to select the

point.

n Hover the cursor above the midpoint of the edge

until the temporary green point appears.
n Select the red point located at the midpoint between
the two green temporary points.
n Select the OK button to exit the command.

403
2D HST Toolpaths Step 3: Save The Part

n The geometry should look as shown.

STEP 3: SAVE THE PART

n From the QAT select the Save As button and save the file to a desired location.

STEP 4: MERGE THE VISE

In this step you will learn how to merge the vise that will be used when verifying the toolpath.

File

n From the Backstage select

Merge.
n Find the 2DHST_VISE.MCAM

n In the Merge Pattern panel, make sure Merged file levels is

enabled.

n Select the OK button to exit Merge Pattern command.

404
2D HST Toolpaths Step 4: Merge The Vise

n Right mouse click in the graphics

window and select Fit.
n The part in the vise should look as
shown.

n Right mouse click in the graphics window and

select the Right view.
n The part inside the fixture should look as
shown.

Note: Zoom in at the corner and notice that the part is above the top highest part of the movable jaw.
When you created the stock box, you gave 0.125 extra stock at the bottom. The movable jaw step height
is 0.1. There is an extra 0.025 stock that allows you to completely machine the outside profile. After you
machine all the features in this setup, you will have to flip the part and face it to remove the extra 0.125.

n Right mouse click in the graphics window and

select Isometric.

405
2D HST Toolpaths Step 5: Change The Cplane To Top

STEP 5: CHANGE THE CPLANE TO TOP

n In the Status Bar change the Cplane to Top.

n The Cplane and the Tplane will be set to Top as

shown.
n The Construction mode is set to 3D.

STEP 6: MOVE THE ORIGIN TO THE POINT

In this step you will use Move to Origin command to set the part origin at the top center of the finish part.
You will use the point created with the Bounding Box command.

n From Transform ribbon select the Move to

Origin icon.
n Select the point as shown.

n Right mouse click in the graphics window and select

Clear Colors icon.

406
2D HST Toolpaths Step 7: Create The Job Setup

6.1 Use Levels Manager to make invisible the vise

n Open Levels Manager and make the Active Level, Level 1.

n Make invisible the vise levels by removing the Xs in the
Visible column as shown.

Note: Removing the vise from display makes it easier to

select the geometry required to generate the toolpaths .

n The geometry should look as shown.

STEP 7: CREATE THE JOB SETUP

In this step you will supply Mastercam with information about tool settings and stock size before starting to
create the toolpaths.

7.1 Load the Mill Default if needed

n From the Machine tab, select Mill and Default.

n Expand Machine Group and select Files.

7.2 Machine

n Set the Default program number to 1006.

407
2D HST Toolpaths Step 7: Create The Job Setup

Master Model

n Click on Add
from
selection icon
to select the
part.
n Press Enter.

Stock Setup

n Enable Show wireframe entities if needed.

n Select the Stock Setup and click on the Add from a two
corners button.

n Select the left lower corner

n Select the opposite corner.

408
2D HST Toolpaths Step 7: Create The Job Setup

n The Size values should look as shown.

n Select the OK button to exit Bounding Box.

Workholding

n In the Workholding, enable Fixtures and select Add

from a level icon.

Note: Make sure that all levels that contain the fixture
bodies are selected. You might need to select one at a time.

n Select the OK button to exit Select Level dialog.

n The Fixtures should be listed as shown.
n Select the OK button to exit Machine Group Setup.

409
2D HST Toolpaths Step 8: Facing Toolpath

n To check the stock, in the Toolpaths ribbon you can

enable Stock display.

n The stock should look as shown.

Note: In this lesson, you will generate several separate operations to machine the part. These operations
are the latest technology in Mastercam. The operations include: Facing, Dynamic Mill - From Outside
Dynamic Mill to remove inner material, 2D HST Peel Mill and Dynamic Rest Mill.

STEP 8: FACING TOOLPATH

A Facing toolpath quickly removes material from the top of the part to create an even surface and prepare
for subsequent operations.

n In the Toolpaths tab, from the 2D group, select the

Facing icon as shown.

n The Chaining dialog box appears on the screen.

n To use the defined stock select the OK button.

Note: This is an option for Face operations.

n The 2D Toolpaths - Facing dialog box appears on the screen.

Note: In the following steps you will be setting the parameters to generate the Facing toolpath.

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2D HST Toolpaths Step 8: Facing Toolpath

8.1 Toolpath Type

n The Facing icon is

already selected. No
chains are selected in the
Chain geometry area.

8.2 Tool

n Click on the Select

library tool button and
using the Filter options
select a 2.0" Face Mill
as shown.
n Enable Rapid Retract
to force the tool to retract
from the part at the rapid
feed rate set at the
machine.
n In the Comment area,
enter a description of
what the toolpath does
as shown.

411
2D HST Toolpaths Step 8: Facing Toolpath

8.3 Cut Parameters

n Set the Style to Zigzag.

n Across Overlap =
25%.
n Along Overlap =
110%.
n Approach distance =
0.
n Exit Distance = 0.
n Max stepover = 75%.
n Move between cuts to
High speed loops.
n Set the Stock to leave
on floors to 0.0 .

8.4 Linking Parameters

n Clearance = 2.0 (Absolute).

n Retract = 0.25 (Absolute).
n Feed Plane = 0.1
(Incremental).
n Top of Stock = 0.05
(Absolute).
n Depth = 0.0 (Absolute).

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2D HST Toolpaths Step 9: Dynamic Mill Toolpath The Outside Shape

n Select the Apply button to preview the toolpath.

n The toolpath should look as shown.

STEP 9: DYNAMIC MILL TOOLPATH THE OUTSIDE SHAPE

Dynamic Mill toolpath machines cores or pockets using the entire flute length. The toolpath supports many
powerful entry methods, including a customized entry method. Entry methods and micro lifts support custom feeds
and speeds to optimize and generate safe tool motion. The toolpath depends on the Machining strategy that you
choose in the Chain Options. If the strategy chosen is From outside, the toolpath starts at the outmost chain and
works its way in, taking on the final shape of the part as it approaches the final pass. You can also machine pockets,
in which case the strategy selected is Start inside, which keeps the tool inside the machining regions.

n From the Toolpaths ribbon, in the 2D group, select the Dynamic

Mill icon.

2D HST CHAIN REFERENCE INFORMATION

For further information on settings, see the Mastercam Help file.

Automatic regions: Automatically determines the regions based on the

selection made.

Machining regions: Allows selecting areas where the tool will remove
material. If no machining region is selected, the area to be machined defaults to
the stock size defined in Stock Setup.

Machining region Strategy:

Stay inside: keeps the toolpath inside the selected machining region.

From outside: Causes the toolpath to start from outside and work toward the
machining region.

Open chain extension to stock: defines the option to cut open chains to the
stock defined in stock setup.

Avoidance regions: defines areas to be avoided during machining.

Air regions: allows defining areas where there is no material so tool can travel
through it when machining.

Containment regions: defines an area where the tool cannot travel outside of.

Entry chain: defines a chain of geometry or point where the tool enters the part
to begin machining.

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2D HST Toolpaths Step 9: Dynamic Mill Toolpath The Outside Shape

n The Chain Options dialog box appears as shown.

n For our toolpath, no Machining regions need to be selected.

Note: When no geometry is selected, the area to be machined defaults

to the Stock Size from the Stock Setup that we completed previously.

n In the Avoidance Regions, click on the Select button.

n In the Chaining dialog box

leave the Loop button
selected.
n Click on the edge of the
bottom of the part to select
the outside profile.
n Select the OK button to
accept.

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2D HST Toolpaths Step 9: Dynamic Mill Toolpath The Outside Shape

Note: There will be no chains under Machining Regions and one under
Avoidance Regions. With this type of toolpath, we do not need to set
Direction since the machining occurs between the two boundaries
selected.

n Enable From outside.

n Click on the Preview chains button to check your selection.

n Press Esc button when

done.
n Click again on the Preview
chains button to remove the
display.
n Select the OK button to exit
the Chain Options dialog
box.

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2D HST Toolpaths Step 9: Dynamic Mill Toolpath The Outside Shape

n The 2D Toolpaths - Dynamic Mill dialog

box appears on the screen as shown.

Note: The Avoidance regions selected

shows as (1).
Changes to any of the chaining areas can
be made from this dialog box.

Note: In the following steps you will be setting the parameters to generate the Dynamic Mill toolpath.

9.1 Tool
In the following steps you will choose a 1.0” Flat Endmill from the tool library provided by Mastercam. You
will use the Filter option to search through the tool library for a specific tool type which makes it easier and
quicker to find the desired tool. The model drawing indicates that the smallest inside radius on the outer
contour is 2.00 which can be machined with the 1.0" Flat Endmill.

n Click on the Select

library tool button
and using the Filter
options select the
1.0" Flat Endmill.
n Rapid Retract
enabled.
n Comment: “Use
Dynamic mill to
remove the outside
material”.

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2D HST Toolpaths Step 9: Dynamic Mill Toolpath The Outside Shape

9.2 Stock

n In the Stock page make

sure Rest material is
disabled as shown.

9.3 Cut Parameters

Cut Parameters page allows you to set the Dynamic Mill parameters such as Cutting method and
Stepover.

n Cutting method set to

Climb.
n Stepover = 15%.
n Stock to leave on
walls = 0.01.
n Stock to leave on
floor = 0.0.
n (Set the rest of settings
as desired or leave as
default.)

Stepover sets the distance between cutting passes in the X and Y axes.
Approach distance adds the specified absolute distance to the beginning of the toolpath’s first cut.
First pass offset offsets out the machining region with a user defined distance for the tool to safely engage
from the outside of the material.
First pass feed reduction allows you to slow the feed for the first pass on machining region material
approached from the outside.
Min toolpath radius reduces sharp corner motion between cut passes.
Micro lift distance enters the distance the tool lifts off the part on the back moves. Microlifts are slight lifts
that help clear chips and minimize excessive tool heating.
Back feedrate controls the speed of the backfeed movement of the tool.
Motion > Gap size, retract controls retracts in the toolpath when making a non-cutting move within an area
where the tool can be kept down or microlifted.

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2D HST Toolpaths Step 9: Dynamic Mill Toolpath The Outside Shape

9.4 Corner Pretreatment disabled

Corner pretreatment page sets machining parameters for corners in the selected Machining regions before
machining the rest of the part for a Dynamic Mill toolpath. No need for this shape.

9.5 Depth Cuts disabled

In the Dynamic Mill toolpath the recommended depth is two times to three times the tool diameter. In this
example, the depth cuts should be disabled.

9.6 Break Through disabled

9.7 Linking Parameters

Linking Parameters page allows you to define the Clearance, Retract, Feed plane, Top of stock and
Depth heights.

n Clearance = 2.0
(Absolute).
n Retract = 0.25
(Absolute).
n Feed Plane = 0.1
(Incremental).
n Top of Stock = 0.0
(Absolute).
n Depth = -0.8
(Absolute).

Note: The Depth can be extracted by selecting the Depth button and selecting a vertex at the bottom of
the solid model.

9.8 Entry Motion

Note: These settings will have no impact when machining from outside. You can enable Plunge only.

418
2D HST Toolpaths Step 9: Dynamic Mill Toolpath The Outside Shape

9.9 Arc Filter / Tolerances

n Enable Line/Arc Filtering

Settings.
n Enable XY (G17).
n Set the Cut tolerance = 30%.
n Make sure that Output 3D arc
entry motion is enabled.

9.10 Coolant

n Select Coolant and turn the

Flood on as shown.

9.11 Preview the toolpath

n Click on the Apply button as shown.

n Click on the Hide dialog icon as shown to hide

the toolpath parameters.

419
2D HST Toolpaths Step 9: Dynamic Mill Toolpath The Outside Shape

n The toolpath should look as shown.

n Press Esc button when done.
n Select the OK button to exit 2D High Speed
Toolpaths - Dynamic Mill.

9.12 Verify the last toolpath

n In the Toolpaths Manager, click on the

drop down next to Verify selected
operations and select Add to current
verification icon.

n Select the Play button to run Verify.

n The part should appear as shown.

n When finished verifying, Minimize the Mastercam
Simulator Window to leave it open or move it on a
separate monitor.

Note: If your verify does not look like this result, click the Parameters icon under the Dynamic Mill
toolpath in the Mastercam Toolpaths Manager and confirm your settings are correct.

Then Regenerate the toolpath.

420
2D HST Toolpaths Step 10: Dynamic Mill To Remove The Inside Material

STEP 10: DYNAMIC MILL TO REMOVE THE INSIDE MATERIAL

In this step you will machine the inside area that has one standing island.

n Before starting the next operation, turn off the

toolpath display.

n From the Toolpaths ribbon, in the 2D group, select the

Dynamic Mill icon.

n The Chain Options dialog box appears as shown.

n In the Automatic regions, click on the Select button.

Note: Automatic regions selection instructs Mastercam to

automatically create the Machining, Air and Avoidance regions
based on the selected geometry.

n In the Chaining
dialog box
enable only
Face button.
n Select the large
face.
n Select the
OK button.

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2D HST Toolpaths Step 10: Dynamic Mill To Remove The Inside Material

n Enable From outside.

n Click on the Preview

chains button to check
your selection.
n Press Esc button
when done.
n Click again on the
Preview chains
button to remove the
display.

Note: Mastercam
creates the regions
based on the selection
provided. It
automatically
determined the
Avoidance and Air
regions.

n Select the OK button to exit the Chain Options dialog box.

422
2D HST Toolpaths Step 10: Dynamic Mill To Remove The Inside Material

10.1 Toolpath type

n The 2D Toolpaths -
Dynamic Mill dialog box
appears on the screen as
shown.

10.2 Tool

n Select the existing

1.0" tool as shown.
n In the Comment
area enter
"Remove the
inside material".

423
2D HST Toolpaths Step 10: Dynamic Mill To Remove The Inside Material

10.3 Cut Parameters

n Use the same

settings as in the
previous toolpath.
n Ensure that the
Keep tool down
within is set to % of
tool diameter =
100.
n In the Motion > Gap
size, retract set to
When avoiding a
boundary.

Note: The gap

setting and the
retract will allow the
tool to retract at the
avoidance regions.

10.4 Corner Pretreatment disabled

10.5 Depth Cuts disabled
10.6 Break Through disabled

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2D HST Toolpaths Step 10: Dynamic Mill To Remove The Inside Material

10.7 Linking Parameters

n From the Tree View List, select Linking Parameters and set the values as shown.

n Clearance = 2.0
(Absolute).
n Retract = 0.25
(Absolute).
n Feed Plane = 0.1
(Incremental).
n Top of Stock = 0.0
(Absolute).
n Depth = -0.7
(Absolute).

Note: In Dynamic Mill, the Depth value is set from the value of the chained edges of the Machining
regions. In this example the Absolute value of the depth of the large machining region area is -0.7.

10.8 Entry Motion not needed

10.9 Preview the toolpath

n The toolpath should look as shown.

n Press Esc button when done.
n Select the OK button to exit 2D
High Speed Toolpaths -

Dynamic Mill.

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2D HST Toolpaths Step 10: Dynamic Mill To Remove The Inside Material

10.10 Backplot the toolpath

n Select the Backplot selected operations button.

n Select the Play button to run Backplot.

n The toolpath should look as shown.

n From the Backplot panel, select the OK button
to exit Backplot.

10.11 Verify all the last toolpath

n In the Toolpaths Manager, click on the

drop down next to Verify selected
operations and select Add to current
verification icon.

n Select the Play button to run Verify.

n The part should appear as shown.

n When finished verifying, Minimize Mastercam
Simulator Window.

426
2D HST Toolpaths Step 11: Dynamic Mill The Closed Pocket

STEP 11: DYNAMIC MILL THE CLOSED POCKET

In this operation you will machine the closed pocket using Dynamic Mill toolpath with Stay inside option
enabled to keep the tool inside of the pocket.

n Before starting the next operation, turn off the toolpath display by
pressing Alt + T.
n From the Toolpaths ribbon, in the 2D group, select the Dynamic
Mill icon.

n The Chain Options appears as shown.

n In the Machining regions, click on the Select button.

n In the Chaining dialog box enable

only Face button.
n Select the pocket bottom face.
n Select the OK button to exit the
Chaining dialog box.

n In the Chain Options enable Stay inside as shown.

n Select the OK button to exit the Chain Options dialog box.

427
2D HST Toolpaths Step 11: Dynamic Mill The Closed Pocket

11.1 Tool

n Select the existing

1.0" tool as shown.
n In the Comment
area enter "Machine
the closed pocket".

11.2 Cut Parameters

n Use the same

settings as in the
previous
toolpath.
n Set the Motion
> Gap size,
retract to
Never to keep
the tool down.

428
2D HST Toolpaths Step 11: Dynamic Mill The Closed Pocket

11.3 Depth Cuts disabled

11.4 Break Through disabled
11.5 Linking Parameters
n From the Tree View List, select Linking Parameters and set the values as shown.

n Clearance = 2.0
(Absolute).
n Retract = 0.25
(Absolute).
n Feed Plane = 0.1
(Incremental).
n Top of Stock = 0.0
(Absolute).
n Depth = 0.0
(Incremental).

Note: In Dynamic Mill,

the Depth value is set
from the value of the
chained edges of the
Machining regions.

11.6 Entry Motion

n Entry method set to Helix only.

n Helix radius = 0.45. (Any value less than tool
diameter).

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2D HST Toolpaths Step 11: Dynamic Mill The Closed Pocket

11.7 Preview the toolpath

n Click on the Apply button.

n Click on the Hide dialog button to hide the toolpath parameters.

n The toolpath should look as shown.

Note: The Helix entry is not performed because

the Helix radius is to big.

n Press Esc button when done.

11.8 Change the Entry to Helix

n In the Entry motion, set the Helix radius to 0.375.

11.9 Preview the toolpath

n The toolpath should look as shown.

n Press Esc button when done.
n Select the OK button to exit 2D High Speed
Toolpaths - Dynamic Mill.

11.10 Verify the last toolpath

n Select the Play button to run Verify.

n The part should appear as shown.

n When finished verifying, Minimize the Mastercam
Simulator Window.

430
2D HST Toolpaths Step 12: Peel Mill To Machine The Inside Center Boss

STEP 12: PEEL MILL TO MACHINE THE INSIDE CENTER BOSS

In this step you will remove the material inside the slot in the center boss.

n Before starting the next operation, turn off the toolpath

display for the Facing operation.

n In the Toolpaths ribbon, 2D group, select the Expand gallery arrow

and select the Peel Mill icon as shown.

n Click on the Translucency icon to make the solid transparent.

n In the Chaining dialog box,

enable 3D mode and only
the Edges button.
n Select the 2 individual
edges as shown. Make
sure that both chains are in
the same direction as
shown, otherwise select
the Reverse button.
n Enable Display all
selection arrows button to
see both chain arrows.

n In the Chaining dialog box,

select the OK button to
accept the chain and
continue.

Note: For Peel Mill toolpaths to be defined, the two chains must point in the same direction, so they must
be selected near the same endpoints. The chain direction also determines lead in side.

431
2D HST Toolpaths Step 12: Peel Mill To Machine The Inside Center Boss

12.1 Toolpath type

n In the Toolpath Type

you should have the
parameters set as shown.

12.2 Tool

n Click on the Select

library tool button
and using the Filter
options select the
1/2" Flat Endmill.
n In the Comment
area enter “Machine
the slot inside of the
boss”.

432
2D HST Toolpaths Step 12: Peel Mill To Machine The Inside Center Boss

12.3 Cut Parameters

n Cutting style set to

Dynamic peel.
n Cutting method set to
Climb.
n Tip comp set to Tip.
n Approach distance =
0.25.
n Stepover = 25%.
n Min toolpath radius =
10%.
n Back feederate = 400.
n Extend Entry = 0.3.
n Extend Exit = 0.3.
n No Stock to leave.

REFERENCE INFORMATION

Stepover sets the distance between adjacent cuts of the toolpath.

Min toolpath radius defines the radius of the arc that the tool follows along its semi-circular path. This value must
be greater than the stepover amount.
Micro lift distance is the distance the tool lifts off of the part on back moves. Micro lifts are slight lifts that help clear
chips and minimize excessive tool heating.
Back feedrate controls the speed (inches per minute or millimeters per minute) of the backfeed movement of the
tool. This allows 3D arcs between cuts to have a different feed rate than the rest of the toolpath, which can help
reduce cycle time.
Extend Entry/Exit allows you to adjust the initial and final tool engagement with the material.

12.4 Depth Cuts disabled

12.5 Finish Passes

n Enable the Finish Passes as

shown.
n Number of passes = 1.
n Spacing = 0.01.
n Cutting method set to Climb.
n Compensation type set to Wear.

433
2D HST Toolpaths Step 12: Peel Mill To Machine The Inside Center Boss

12.6 Break Through disabled

12.7 Linking Parameters

n Clearance = 2.0 (Absolute)

n Retract = 0.25 (Absolute)
n Feed plane = 0.1
(Incremental)
n Top of Stock = 0.0 (Absolute)

n Depth = 0.0 (Incremental)

(Depth is extracted from the Z
value of the selected edges.)

12.8 Arc Filter / Tolerance

n Total tolerance = 0.001

n Cut tolerance = 30.0%
n Line/Arc Filtering Settings
enabled.
n Create arcs in XY enabled.
n Output 3D arc entry motion
enabled.

Note: This page is used to control toolpath tolerances. Since this toolpath will have several arc
moves, we want to ensure that arcs are created instead of a large number of linear moves. For
more detailed information on these options, see Mastercam Help.

434
2D HST Toolpaths Step 12: Peel Mill To Machine The Inside Center Boss

12.9 Preview the toolpath

n Click on the Translucency

icon to remove the
transparency.

n The toolpath should look as

shown.
n Press Esc button when done.
n Select the OK button to exit 2D
High Speed Toolpaths - Peel
Mill.

12.10 Verify the last toolpath

n Select all the operations.

n The part after running the simulation
should appear as shown.

n When finished verifying, minimize

Mastercam Simulator Window.

Note: As we can see from this verify, the part is completely cut except for the inside corners. We need to
use a smaller tool to remove the corner material.

435
2D HST Toolpaths Step 13: Dynamic Rest Mill The Inside Corners

STEP 13: DYNAMIC REST MILL THE INSIDE CORNERS

In this operation we will use a smaller tool to remove only the small amount of stock that is leftover from the
previous Dynamic Mill toolpaths.

n Before starting the next operation, turn off the toolpath display for the Peel Mill operation you just
completed. Press Alt + T.

13.1 Copy the third Dynamic Mill toolpath

n In the Toolpaths Manager, select only the third Dynamic Mill

toolpath as shown.

n Right mouse click on the selected Dynamic Mill toolpath, holding

down the mouse drag the cursor below the last toolpath as shown.

436
2D HST Toolpaths Step 13: Dynamic Rest Mill The Inside Corners

n Release the mouse wheel and select Copy after as

shown.

n Make sure that the insert arrow is below the last toolpath.

n Left click on the Geometry of the Operation 4 and drag it

above the Operation 6 Geometry to copy the geometry of
the closed pocket.

437
2D HST Toolpaths Step 13: Dynamic Rest Mill The Inside Corners

n Release the mouse. Select Add if needed.

n You should have 2 chains in the Operation 6
geometry.

n Select the Parameters in the last Dynamic Mill toolpath as

shown.

13.2 Toolpath Type

n In the Toolpath Type, enable

Stay inside as shown to ensure
the tools machine only the inside
corners.

438
2D HST Toolpaths Step 13: Dynamic Rest Mill The Inside Corners

13.3 Tool
In the following steps you will select the 3/16” Flat Endmill. The 1/8" radius of the Flat Endmill will fit inside
of the 1/8" corner radii of the inside pocket and 3/8" corner radii from the larger pocket corners.

n Select the 3/16" Flat

Endmill from the library as
shown.
n In the Comment area enter
“Remachine the corners”.

13.4 Stock
High Speed Dynamic Mill toolpath with Rest material options enabled, targets material left behind by the
previous toolpaths.

n Enable Rest material.

n Enable Roughing Tool and set the
Diameter to 1.0.

The Rest material page allows you to set how Mastercam calculates the remaining stock.
All previous operations calculates the remaining stock from all operations.
Roughing tool calculates the remaining stock from the tool diameter of the previous operation that machined the
area.

439
2D HST Toolpaths Step 13: Dynamic Rest Mill The Inside Corners

13.5 Cut Parameters

n In the Cut
Parameters page,
change the Gap
size to 500%.
n Set the Motion >
Gap size, retract
to When
avoiding a
boundary OR
exceeding a
distance.
n Make sure that
Generate toolpath
is enabled.

n The rest of the parameters can be left as they are.

n Select the OK button to exit 2D High Speed Toolpaths - Dynamic Mill.

13.6 Repeat the Backplot procedure

n The toolpath should look as shown.

440
2D HST Toolpaths Step 14: Finish The Walls Using Contour

13.7 Verify the toolpath

n The part after being verified in

Mastercam Simulator should look
as shown.
n When finished verifying, minimize
Mastercam Simulator.

STEP 14: FINISH THE WALLS USING CONTOUR

In this operation we will use a smaller tool to finish the walls using the Contour toolpath to remove the 0.01
stock.

n Before starting the next operation, turn off the toolpath display for the operation you just completed.
Press Alt + T.

14.1 Select the Contour toolpath

n From the Toolpaths tab, select the Contour icon as shown.

n Select the two chains in the

directions shown.

Note: Confirm arrows are

pointing correctly to do a
“Climb Mill” cut.

441
2D HST Toolpaths Step 14: Finish The Walls Using Contour

n Enable Outer shared edges button

as shown.
n Select the face as shown and make
sure the chains direction is CCW
as shown.

n In the Chaining dialog box,

make sure that only the Loop
button is enabled.
n Select the outside profile at the
bottom in CW direction as
shown.
n Select the OK button to exit
Chaining.

442
2D HST Toolpaths Step 14: Finish The Walls Using Contour

14.2 Tool

n Select the 3/16"

Flat Endmill.
n Enable Rapid
Retract.
n In the Comment
area, enter
“Finish the walls”
as shown.

14.3 Cut Parameters

n Set the
Compensation
type to Wear as
shown.
n The rest of the
settings should
match the default
values as shown.

443
2D HST Toolpaths Step 14: Finish The Walls Using Contour

14.4 Lead In/Out

n Length = 30%.
n Radius = 30%.
n Sweep = 90.

14.5 Break Through disabled

14.6 Multi Passes disabled

444
2D HST Toolpaths Step 14: Finish The Walls Using Contour

14.7 Linking Parameters

Linking Parameters page allows you to define the Clearance, Retract, Feed plane, Top of stock and
Depth heights.

n From the Tree View List,

select Linking Parameters
and set the values as
shown.

14.8 Coolant
n From the Tree View List, select Coolant and turn the Flood on.
n Select the OK button to exit 2D Toolpaths - Contour.

14.9 Repeat the Backplot procedure

n The toolpath should look as shown.

445
2D HST Toolpaths Step 15: Chamfer The Sharp Edges - Model Chamfer

14.10 Repeat the Verify procedure

n From the Toolpaths Manager, click on the

Select all operations icon as shown.

n The part after being verified in

Mastercam Simulator should look as
shown.
n When finished verifying, Minimize
the Mastercam Simulator
Window to leave it open or move it
on a separate monitor.

STEP 15: CHAMFER THE SHARP EDGES - MODEL CHAMFER

In this operation you will machine all the sharp edges using Model Chamfer toolpath and a Chamfer mill
tool.
Model Chamfer toolpath allows you to machine safe horizontal chamfers on solid models. This toolpath
allows you to enter a side clearance to further protect your part.

Step Preview:

n Before starting the next operation, turn off the

toolpath display by pressing Alt + T.

Toolpaths

n From the 2D group, click on the Expand

Gallery arrow and select the Model Chamfer
icon.

446
2D HST Toolpaths Step 15: Chamfer The Sharp Edges - Model Chamfer

n In the Toolpath Type page, in the Chain geometry, click on the

Select button.

n In the Chaining, enable

only Outer open
edges button.
n Select the faces as
shown.

Note: Only the outer

edges of the faces were
selected. The chain is
automatically selected in
the CW direction to
ensure climb milling.

n In the Solid Chaining

dialog box, enable Open
edges button and select
the faces as shown.
n Rotate the part as
needed.

Note: Once you click on a

face only the open edges
will be automatically
selected. The chaining
direction will be CW to
ensure climb milling.

447
2D HST Toolpaths Step 15: Chamfer The Sharp Edges - Model Chamfer

n In the Solid Chaining

dialog box, enable
Cavities button and
select the face as shown.

Note: Once you click on a

face only the pocket will
be automatically
selected. The chaining
direction will be CCW to
ensure climb milling.

n Move the start point back

one entity.
n Select the OK button to
exit Solid Chaining
dialog box.

15.1 Tool

n Select the
existing 1/2"
Chamfer Mill as
shown.
n In the Comment
area enter
"Chamfer the
sharp edges."

448
2D HST Toolpaths Step 15: Chamfer The Sharp Edges - Model Chamfer

15.2 Cut Parameters

n Chamfer width = 0.03.

n Bottom offset = 0.03.
n Make sure that the rest of the
parameters are set as
shown.

15.3 Depth Cuts disabled

15.4 Lead In/Out

n Make sure that just the

Arc is enabled.
n Enable Enter /exit at
midpoint in closed
contours.
n Radius = 100%.
n Fitting distance =
0.3. (smaller sized tool
will gouge at the open
edge walls).

Fitting distance allows you to enter a distance to trim the Model Chamfer back to avoid gouging.

15.5 Multi Passes disabled

449
2D HST Toolpaths Step 15: Chamfer The Sharp Edges - Model Chamfer

15.6 Linking Parameters

n From the Tree View List, select Linking Parameters and set the values as shown.

n Clearance = 2.0.
n Retract = 0.25.
n Feed Plane = 0.1.
n Select the OK button to exit 2D Toolpaths -
Model Chamfer.

Note: The Clearance, Retract and Feed

Plane values are measured from the
selected chains.

15.7 Backplot the last toolpath

n The toolpath should look as

shown.

450
2D HST Toolpaths Step 16: Post Process The Toolpaths

15.8 Verify the toolpath

n The part should appear as

shown.

Note: To completely finish the part, another setup is required. You will need to create a new plane at the
bottom of the part with a new Origin. You will set the WCS, Cplane and Tplane to the new plane and
then, face the part to remove the extra material.

STEP 16: POST PROCESS THE TOOLPATHS

STEP 17: SAVE YOUR FILE
n Your file will be saved with the Mastercam toolpath data stored inside the file.

SUMMARY:

In this lesson, you were introduced to the newest Mastercam 2D toolpath technologies that utilize the high
speed capabilities and are specially designed to produce the smoothest, most efficient tool motions. As you
should have noticed, the cut styles are more efficient, but are similar to other toolpaths such as the standard
pockets. These high speed toolpaths can help make the processes we have learned so far more efficient and
automated, minimizing programming and cycle times.
After completing this tutorial and the practice exercises that follow you should be able to:
n Use Stock Setup and Bounding box to create a stock to be used in toolpaths and Verify.
n Understand the 2D HST boundary selection rules and be able to select the appropriate boundary for
each toolpath type.
n Effectively set the 2D HST cut parameters.
n Generate Dynamic Milling toolpaths to machine cores or bosses.
n Generate Dynamic Milling toolpaths to machine pockets.
n Change an existing Dynamic Milling toolpath to a new type.
n Generate Peel Mill toolpaths.
n Generate Rest Mill toolpaths.
n Finish the walls with Contour toolpath.
n Machine the sharp edges using Model Chamfer toolpath.

451
2D HST Toolpaths Exercise #1

EXERCISE #1

Job Description:

Program the part above (2D HST Exercise-1.x_t) with the following requirements:

n Setup the machining plane and locate the origin.

n Create a bounding box for the stock and add 0.125 extra stock on both top and bottom of the part.
n Open the vise and merge the part.
n Use 2D HST Dynamic Mill toolpath to remove the material outside the island.
n Use 2D HST Dynamic to remove the inside pocket area.
n Use Model chamfer to chamfer the sharp edges.
n Select tools and any additional operations needed to remove any remaining stock.
n Run Backplot and Solid Verify to confirm results.
n Create G-code for NC machine.

452
2D HST Toolpaths Exercise #2

EXERCISE #2

Job Description:

Program the part above (2D HST Exercise-2.x_t) with the following requirements:

n Use Planes Manager to create and setup the machining view and locate the origin.
n Create a bounding box for the stock and add 0.125 extra stock on both top and bottom of the part.
n Open the vise and merge the part.
n Use 2D HST Dynamic Mill toolpath to remove the material outside the part with 3/4” Flat Endmill.
n Use 2D HST Dynamic Mill to remove the inside relieved area with 3/4” Flat Endmill.

Note: You will need to select multiple machining and avoidance areas.

n Use 2D HST Dynamic Mill to remove the through slot area with a 1/2” Flat Endmill.
n Use Contour toolpath to finish the walls with a 3/8" Flat Endmill.
n Use Circle Mill to cut the large holes with a 1/2” Flat Endmill.
n Use Model chamfer to chamfer the sharp edges.
n Run Backplot and Solid Verify to confirm results.
n Create G-code for NC machine.

453
2D Blend & Chamfer Drill

454
2D Blend & Chamfer Drill Introduction

INTRODUCTION
In this exercise you will learn how to finish the part floors using Blend Mill Toolpath toolpath. The toolpath
morphs between two open chains. This toolpath generates fewer retract moves on these difficult to machine
features.
This toolpath is used to machine areas which are difficult to machine and blends the toolpath so the cutter is
constantly engaged in the material.
You will also learn how to chamfer the holes in a solid using Chamfer drill toolpath.
Model Chamfer will be also reviewed.

NEW CONCEPTS COVERED IN THIS TUTORIAL:

n Review of 2D High Speed Dynamic Mill
n Create a Stock Model.
n 2D High Speed Blend Mill to finish the floors.
n Chamfer Drill toolpath.
n Review of Model Chamfer toolpath.

INSTRUCTOR DEMONSTRATION:
Topics:

n Job Setup - Adding additional stock

n 2D High Speed Dynamic Mill Review.
n Blend Mill toolpath selection and
parameters.
n Chamfer Drill parameters.
n Model Chamfer parameters.

455
2D Blend & Chamfer Drill Toolpaths Information

TOOLPATHS INFORMATION
2D High Speed Toolpath Backplot Result
Dynamic Mill - From Outside Strategy machines
open pockets or standing core shapes using the
outmost chain as the stock boundary. The toolpath
starts from the outside and works its way towards the
inner boundary.

2D High Speed Blend Mill morphs between two

open chains. This toolpath generates fewer retract
moves on these difficult to machine features. The
Blend mill uses the tool's full depth and more of the
flute length, resulting in less cycle time and tool wear.
n Morphs between two open chains generating the
optimum toolpath.
n The toolpath strategy supports cutting with the full
depth of the tool.

You can cut along the chains using the Along option
or perpendicular to the chains using the Across
options.

Drilling Toolpath Verify Result

Chamfer Drill toolpath creates chamfered edges
around a solid holes. The advantage of the
Chamfer Drill toolpath is that you can select holes
of different diameter and that could lie in different
planes and machine them in a single operation
with a single tool. You can use any tool with a
tapered tip, not just a drill.

456
2D Blend & Chamfer Drill Step 1: Create The Job Setup

STEP 1: CREATE THE JOB SETUP

In this step you will supply Mastercam with information about tool settings and stock size before starting to
create the toolpaths.

1.1 Open the Blend_ChamferDril.MCAM

1.2 Load the Mill Default if needed

n From the Machine tab, select Mill and Default.

1.3 Set the Tool settings

n Click on the Toolpaths tab to open Toolpaths Manager.

n Expand the Properties and select the Files icon.

n Set the Default program number to 1007.

n Select the Stock

Setup.
n Click on the
Rectangular Stock
icon and select the
solid.
n The stock size
values should look
as shown.

n In the Tools, enable Assign tool numbers

sequentially and all of the Advanced options.
n Enable Feed Calculation From tool.

Note: All of these settings should be pre-set from the

saved Operations defaults we setup in previous lesson.

n The stock will look as shown.

457
2D Blend & Chamfer Drill Step 2: Dynamic Mill Toolpath Review

STEP 2: DYNAMIC MILL TOOLPATH REVIEW

2.1 Machine the outside profile
Toolpath Preview:

n From Toolpaths ribbon, 2D group, select the Dynamic Mill

icon.

n Enable From outside and click to select the Avoidance regions Select
button as shown.

n In the Solid Chaining Mode,

the Loop button should be
enabled.
n Select the outer edge as
shown.
n Select the OK button to exit

Chaining.

458
2D Blend & Chamfer Drill Step 2: Dynamic Mill Toolpath Review

n Leave the rest of the regions settings as they are.

n Select the Preview chains button as shown.

n The preview should look as shown.

2.2 Tool

n Click on the Select library tool button and using the Filter options select the 1/2" Flat Endmill.
n Rapid Retract enabled.
n Comment: “Machine the outside profile”.

459
2D Blend & Chamfer Drill Step 2: Dynamic Mill Toolpath Review

2.3 Cut Parameters

n Machining direction is
set to Climb.
n Approach distance = 0.
n Stepover distance =
25%.
n Minimum toolpath
radius = 10.0%.
n Keep tool down within
% of tool diameter =
100.
n Micro lift distance =
0.01.
n Stock to leave on walls
= 0.02.
n Stock to leave on
floors = 0.0.

REFERENCE INFORMATION
Stepover sets the distance between cutting passes in the X and Y axes.
Toolpath radius reduces sharp corner motion between cut passes.
Micro lift distance enters the distance the tool lifts off the part on the back moves. Microlifts are slight lifts
that help clear chips and minimize excessive tool heating.
Back feedrate controls the speed of the backfeed movement of the tool.
Motion > Gap Size, retract controls retracts in the toolpath when making a non-cutting move within an
area where the tool can be kept down or microlifted.
Cut order optimization defines the cut order Mastercam applies to different cutting passes in the
dynamic mill toolpath.
Stock to leave on walls/floors sets the stock left on the walls/floors that has to be removed by another
operation.

460
2D Blend & Chamfer Drill Step 2: Dynamic Mill Toolpath Review

2.4 Corner Pretreatment disabled

2.5 Depth Cuts

n Enable Depth cuts.

n Max rough step = 1.0.

Maximum rough step is set to

two times the tool diameter
which is a common depth cut
for dynamic toolpath.

2.6 Entry motion

Note: Strategy is set from outside and the entry motion does not matter.

2.7 Break Through

n Enable Break Through.

n Set the Break through amount to 0.05.

2.8 Linking Parameters

n Clearance = 2.0
(Absolute).
n Retract = 0.25
(Absolute).
n Feed Plane = 0.1
(Incremental).
n Top of Stock = 0.0
(Absolute).
n Depth =0.0
(Absolute).
n Click on the Depth
button to return to the
graphics window.

461
2D Blend & Chamfer Drill Step 2: Dynamic Mill Toolpath Review

n Select an Endpoint at the bottom edge of the

part as shown.

n The Depth value should be as shown.

2.9 Arc Filter / Tolerance

The option to Output 3D arcs will create the entry helix move with arc moves when possible.

n From the Tree View List,

select Arc Filter / Tolerance.
n Set the Line/ arc tolerance to
70% to ensure that the filter
will remove some of the lines
and arcs move in the given
tolerance.
n Enable Line/Arc Filtering
Settings and make sure that
Output 3D arc entry motion
is enabled as shown.

n Select the OK button to exit 2D High Speed Toolpaths - Dynamic Mill.

462
2D Blend & Chamfer Drill Step 2: Dynamic Mill Toolpath Review

2.10 Backplot the toolpath

n The toolpath should look as

shown.

2.11 Verify the toolpath

n The part should appear as shown.

463
2D Blend & Chamfer Drill Step 2: Dynamic Mill Toolpath Review

2.12 Machine the bottom pocket

Toolpath Preview:

n From Toolpaths ribbon, 2D group, select the Dynamic Mill

icon.

n Enable From outside and click to select the Automatic

regions.

n In the Solid Chaining Mode, the Face

button is enabled.
n Select the bottom face as shown.
n Select the OK button to exit Chaining.

464
2D Blend & Chamfer Drill Step 2: Dynamic Mill Toolpath Review

n Leave the rest of the regions settings as they are.

n Select the Preview chains button as shown.

n The preview should look as shown.

2.13 Tool

n Select the 1/2" Flat Endmill.

n Comment: “Machine the bottom pocket”.

465
2D Blend & Chamfer Drill Step 2: Dynamic Mill Toolpath Review

2.14 Cut Parameters

n Machining direction
is set to Climb.
n Approach distance
= 0.
n Stepover distance =
25%.
n Minimum toolpath
radius = 10.0%.
n Keep tool down
within % of tool
diameter = 100.
n Micro lift distance =
0.01.
n Stock to leave on
walls = 0.02.
n Stock to leave on
floors = 0.02.

2.15 Corner Pretreatment disabled

2.16 Depth Cuts

n Enable Depth cuts.

n Max rough step = 1.0.

Maximum rough step is set to

two times the tool diameter
which is a common depth cut
for dynamic toolpath.

2.17 Entry motion

Note: Strategy is set from outside and the entry motion does not matter.

466
2D Blend & Chamfer Drill Step 2: Dynamic Mill Toolpath Review

2.18 Break Through disabled

2.19 Linking Parameters

n Clearance = 2.0 (Absolute).

n Retract = 0.25 (Absolute).
n Feed Plane = 0.1
(Incremental).
n Top of Stock = 0.0
(Absolute).
n Depth =0.0 (Incremental).

n Select the OK button to exit 2D High Speed Toolpaths - Dynamic Mill.

2.20 Backplot the toolpath

n The toolpath should look as shown.

467
2D Blend & Chamfer Drill Step 2: Dynamic Mill Toolpath Review

2.21 Verify the toolpaths

n The part should appear as shown.

2.22 Machine the slot

Toolpath Preview:

n From Toolpaths ribbon, 2D group, select the Dynamic Mill

icon.

n Make sure From outside is enabled and click to select the

Automatic regions.

468
2D Blend & Chamfer Drill Step 2: Dynamic Mill Toolpath Review

n Select the slot as shown.

n Select the OK button to exit Chaining.

n Leave the rest of the regions settings as they are.

n Select the Preview chains button.

n The preview should look as shown.

n Press Esc to exit the preview.

2.23 Tool

n Select the 1/2" Flat Endmill.

n Comment: “Machine the slot”.

2.24 The rest of the parameters are the same as in the previous toolpath

n Select the OK button to exit 2D High Speed Toolpaths - Dynamic Mill.

2.25 Backplot the toolpath

n The toolpath should look as shown.

469
2D Blend & Chamfer Drill Step 2: Dynamic Mill Toolpath Review

2.26 Verify the toolpaths

n The part should look as shown.

2.27 Machine the two steps

Toolpath Preview:

n From Toolpaths ribbon, 2D group, select the Dynamic Mill

icon.

n Make sure From outside is enabled and click to select the

Automatic regions.

470
2D Blend & Chamfer Drill Step 2: Dynamic Mill Toolpath Review

n Select the two faces as shown.

n Select the OK button to exit
Solid Chaining.

n Leave the rest of the regions settings as they are.

n Select the Preview chains button.

n The preview should look as shown.

Note: The air region on the right goes

through the part. You need to set an
avoidance region.

n In the Avoidance regions click on the Select button.

471
2D Blend & Chamfer Drill Step 2: Dynamic Mill Toolpath Review

n Select the right side face as shown.

n Select the OK button to exit Solid
Chaining.

n Select the Preview chains button.

n Select the OK button to exit Chain Options.

2.28 Tool

n Select the 1/2" Flat Endmill.

n Comment: “Machine the two steps”.

2.29 The rest of the parameters are the same as in the previous toolpath

n Select the OK button to exit 2D High Speed Toolpaths - Dynamic Mill.

472
2D Blend & Chamfer Drill Step 2: Dynamic Mill Toolpath Review

2.30 Backplot the toolpath

n The toolpath should look as shown.

2.31 Verify the toolpaths

n The part should appear as shown.

473
2D Blend & Chamfer Drill Step 3: Stock Model

STEP 3: STOCK MODEL

Stock Model allows you to create and manage stock models in the Toolpaths Manager in the same
manner as other types of toolpath operations. This includes using the toolpath display option to turn the
display on and off. The Stock models are used to verify the toolpath, to define stock for rest machining, to
visualize the stock and to compared the stock to the part model.

n From the Toolpaths tab, Stock

group, select Stock Model.

n In the Name enter

"Stock after
roughing".
n Click on the Stock
Setup button to
define the stock size
used in this
operation based on
the one set in the
Stock setup.

474
2D Blend & Chamfer Drill Step 3: Stock Model

n In the Source Operations

enabled the 2D High Speed
(Dynamic Mill) toolpaths.
n Select the OK button to exit
Stock model.

n The stock model should look as

shown.
n Press Alt +T to remove the stock
model display.

475
2D Blend & Chamfer Drill Step 4: Blend Mill - Finish The Floors

STEP 4: BLEND MILL - FINISH THE FLOORS

In this step you will use multiple Blend Mill toolpaths to finish the floors. Blend Mill morphs between two
open chains.

n Press Alt + T to remove the toolpath display.

4.1 Machine the left step

n From the Toolpaths tab, 2D group, expand the Toolpath

gallery and select the Blend Mill icon.

n Click on the Options button.

n Set the Sync mode to None.

n In the Solid
Chaining, enable
Outer shared edges
button.
n Select the bottom of
the step and make
sure the chains are
selected in CCW
direction.

476
2D Blend & Chamfer Drill Step 4: Blend Mill - Finish The Floors

n In the Solid Chaining,

enable Partial loop
button only.
n Select the first edge as
shown.

Note: The chain direction

should be CW as shown.

n Select the last edge as shown.

n To see the arrows click on the
Display all selection arrows
button.

Note: Both chains had to point

in the same direction as shown.

n Select the OK button to exit the

Solid Chaining dialog box.

4.2 Tool

n Select the 1/2" Flat Endmill.

477
2D Blend & Chamfer Drill Step 4: Blend Mill - Finish The Floors

4.3 Cut Parameters

n Cutting method set to Zigzag.

n Comp direction set to Left.
n First pass feed =100%.
n Max. stepover = 50%.
n Enable Along.
n Distance = 0.025.
n Extend Entry = 0.25.
n Extend Exit = 0.25.
n Stock to leave on wall = 0.02.
n Stock to leave of floors = 0.0.

Cutting method set to Zigzag moves the tool back and forth across the part.
Comp direction set to Left set the tool to travel to the left of the selected chains.
Along cuts in the along direction.
Distance sets the spacing between the temporary across moves. These moves are used to generate final
along cuts. This value can be entered as a percentage or absolute value.
Max Stepover sets the distance between adjacent passes in the toolpath.
Extend Entry/Exit allows you to adjust the initial and final tool engagement with the material. When
activated Mastercam adds the additional amount you specify to the beginning/end of the cut.

478
2D Blend & Chamfer Drill Step 4: Blend Mill - Finish The Floors

4.4 Depth Cuts disabled

4.5 Finish Passes disabled
4.6 Break Through
4.7 Linking

n Clearance = 2.0
(Absolute).
n Retract = 0.25
(Incremental).
n Feed plane = 0.1
(Incremental).
n Top of stock = 0.1
(Incremental).
n Depth = 0.0
(Incremental).

n The toolpath should look as shown.

479
2D Blend & Chamfer Drill Step 4: Blend Mill - Finish The Floors

4.8 Verify the Toolpaths

n To use the stock model as the stock in Verify, select the

Simulator Options icon from the Toolpaths Manager.

n Enable Sock Override and click on the Add from a Stock

Model button.

n Select the Stock after roughing.

4.9 Verify only the 2D Blend Mill toolpath

n The part should look as shown.

480
2D Blend & Chamfer Drill Step 4: Blend Mill - Finish The Floors

4.10 Machine the center channel

n From the Toolpaths tab, 2D group, select the Blend Mill icon.

n In the Solid Chaining, enable

Partial loop button.
n Press Ctrl + T to make the part
translucent.
n Click on the edge twice in the shown
direction. (First click for the start of the
loop and the second click for the end
of the loop.)

Note: Blend toolpath require both

chains to point in the same direction.

n Rotate the part and select the other edge the same way.

n Select the OK button to exit Solid Chaining.

4.11 Cut Parameters

n In the Comp direction enable Inside.

Note: The rest of the toolpath parameters are already set.

481
2D Blend & Chamfer Drill Step 4: Blend Mill - Finish The Floors

n The toolpath should look as shown.

4.12 Verify only the 2D Blend Mill toolpaths

n The part should look as shown.

482
2D Blend & Chamfer Drill Step 4: Blend Mill - Finish The Floors

4.13 Machine the larger step

n From the Toolpaths tab, 2D group, select the Blend Mill icon.

n In the Solid
Chaining, enable
Outer shared edges
button.
n Click on the bottom
face.

n In the Solid
Chaining, enable
Outer open edges
button.
n Click on the bottom
face.
n Select the OK button
to exit Solid
Chaining.

4.14 Cut Parameters

n In the Comp direction enable Left.

n Disable Extend Entry and Extend
Exit.

Note: The rest of the toolpath parameters are already set.

483
2D Blend & Chamfer Drill Step 5: Finish The Walls Using Contour

n The toolpath should look as shown.

4.15 Verify only the 2D Blend Mill toolpaths

n The part should look as shown.

STEP 5: FINISH THE WALLS USING CONTOUR

In this step you will use Contour toolpath to finish all the walls and remove the 0.02 stock on the walls.

n Press Alt + T to remove the toolpath display.

n From the Toolpaths ribbon, and select the Contour icon.

n Enable Outer shared edges

button.
n Select the bottom of the open
pocket and make sure the direction
of the chains is as shown.
n You can reverse chain direction if
needed and move the starting
location to match the selection
shown.
n To see the arrows click on the
Display all selection arrows button.

n Select the OK button to accept the

Chain settings.

484
2D Blend & Chamfer Drill Step 5: Finish The Walls Using Contour

5.1 Tool

n Select the 1/2" Flat Endmill.

n Enter in the Comment: "Finish the walls".

5.2 Cut Parameters

n Select the 2D as
Contour type and
set the parameters
as shown.

5.3 Depth Cuts disabled

5.4 Lead In/Out

n In the Entry Line enable Tangent.

n Length = 60%.
n Radius = 60%.
n Sweep = 45.0.
n Set the same parameters in the Exit.

485
2D Blend & Chamfer Drill Step 5: Finish The Walls Using Contour

5.5 Break Through disabled

5.6 Linking Parameters

n Retract = 0.25 (Absolute).

n Top of stock = 0.01
(Incremental).
n Depth = 0.0.
(Incremental).

n Select the OK button to exit

2D Toolpaths - Contour.

n The toolpath should look as shown.

486
2D Blend & Chamfer Drill Step 6: Chamfer Drill Toolpath

5.7 Verify the Toolpaths

n The part should look as shown.

STEP 6: CHAMFER DRILL TOOLPATH

Chamfer Drill toolpath creates chamfered edges around the holes. The advantage of the Chamfer Drill
toolpath is that you can select holes of different diameter or size and that could lie in different planes and
machine them in a single operation with a single tool.

n In the 2D group, click on the Expand gallery and select

the Chamfer Drill icon.

n Hold down the Ctrl key

and click inside of one of
the 3/8" diameter hole.

487
2D Blend & Chamfer Drill Step 6: Chamfer Drill Toolpath

n Select the 5/16 hole inside face.

n In the Toolpath Hole Definition select the OK button.

6.1 Sort the hole order

n To sort the holes, for a more efficient path, click in the Toolpath
Hole Definition, in the Sort area, click on the Select Order and
select the Point to Point option.

n Select the starting hole.

488
2D Blend & Chamfer Drill Step 6: Chamfer Drill Toolpath

The holes will be machined as shown.

6.2 Tool

n Use the Filter to

select the 3/4"
Spot Drill as
shown.
n In the Comment
area enter
"Chamfer the
holes".

489
2D Blend & Chamfer Drill Step 6: Chamfer Drill Toolpath

6.3 Cut Parameter

n Set the parameters as shown.

Note: The holes selected are already chamfered. The

chamfer size is automatically determined based on the
geometry selected.

6.4 Tool Axis Control

n In the Tool Axis Control page make sure that the Output formatis set to 3 axis.

6.5 Linking Parameters

n Enable Automatic linking.

Note: Automatic linking

modifies the Clearance,
Retract, Top of stock, and
the Depth parameters to avoid
collisions with the solid model
or the selected avoidance
geometry.

n Clearance = 2.0.
n Retract = 0.1.
n Top of stock = 0.0.

6.6 Coolant

n From the Tree View List, select Coolant and turn the
Flood on as shown.
n Select the OK button to exit 2D Toolpaths -
Chamfer Drill.

490
2D Blend & Chamfer Drill Step 7: Drill The 3/8" Holes

6.7 Repeat the

Backplot procedure

STEP 7: DRILL THE 3/8" HOLES

n In the Toolpaths ribbon, from the

2D group select the Drill icon.
n Hold down the Ctrl key and click on
the inside face of one of the 3/8"
diameter holes to select them all.

n Repeat the sorting selections.

7.1 Tool

n Use the Filter to select the 3/8" Drill.

n Enter in the Comment area "Drill the 3/8" holes".

7.2 Cut Parameter

n Set the Cycle to Peck Drill.

n Peck = 0.1.

491
2D Blend & Chamfer Drill Step 7: Drill The 3/8" Holes

7.3 Linking Parameters

n Clearance = 2.0
(Absolute).
n Enable Only at start
and end of
operation.
n Top of stock = 0.0
(Incremental).
n Depth = 0.0
(Incremental).
n Enable Calculate
incremental values
from holes/lines.

n Enable Tip Comp.

n Breakthrough
amount = 0.01.
n Select the OK button
to exit 2D Toolpaths
- Drill/Circles Peck
drill.

n The results of the drilling should look as

shown.

7.4 Drill the 9/16 " hole

Follow the same steps and drill the 9/16" diameter hole.

492
2D Blend & Chamfer Drill Step 8: Model Chamfer Toolpath

7.5 Verify the toolpaths

n The part should look as shown.

STEP 8: MODEL CHAMFER TOOLPATH

In this step you will review the Model Chamfer toolpath and machine the sharp edges.

Toolpaths

n From the 2D group, click on the Expand Gallery arrow and select the Model Chamfer icon.

n In the Toolpath Type page, in the Chain geometry, click on the

Select button.

n In the Solid Chaining, enable only Loop

button.
n Select the top face edges as shown.

Note: The chains should be selected in the

proper direction to ensure the tool
compensation to the Left.

493
2D Blend & Chamfer Drill Step 8: Model Chamfer Toolpath

n In the Chaining, enable only

Outer open edges button.
n Select the rest of the faces as
shown.

Note: Only the outer edges of

the faces were selected. The
chains should be selected in
the proper direction to ensure
the tool compensation to the
Left.

n Side clearance = 0.02.

8.1 Tool

n Select the existing 1/4" Chamfer Mill.

n In the Comment area enter "Chamfer the sharp edges."

494
2D Blend & Chamfer Drill Step 8: Model Chamfer Toolpath

8.2 Cut Parameters

n Chamfer width =
0.01.
n Bottom offset =
0.03.
n Make sure that the
rest of the
parameters are set
as shown.

8.3 Depth Cuts disabled

8.4 Lead In/Out

n Make sure that just the

Arc is enabled.
n Length = 50%.
n Radius = 50%.
n Fitting distance =
0.1. (smaller sized tool
will gouge at the open
edge walls).

Fitting distance allows you to enter a distance to trim the Model Chamfer back to avoid gouging.

495
2D Blend & Chamfer Drill Step 8: Model Chamfer Toolpath

8.5 Multi Passes disabled

8.6 Linking Parameters
n From the Tree View List, select Linking Parameters and set the values as shown.

n Clearance = 2.0.
n Retract = 0.25.
n Feed Plane = 0.1.
n Select the OK button to exit 2D
Toolpaths - Model Chamfer.

Note: The Clearance, Retract

and Feed Plane values are
measured from the selected
chains.

8.7 Backplot the last toolpath

n The toolpath should look as

shown.

496
2D Blend & Chamfer Drill Step 9: Post Process The Toolpaths

8.8 Verify all the toolpaths

n The part should appear as

shown.

STEP 9: POST PROCESS THE TOOLPATHS

STEP 10: SAVE YOUR FILE.
n Your file will be saved with the Mastercam toolpath data stored inside the file.

SUMMARY:

After completing this tutorial you should be able to:

n Create a stock model.
n Create a 2D Blend Mill toolpath.
n Create a Chamfer Drill toolpath.
n Create a Model Chamfer toolpath.

497
Review - High Speed Toolpaths

498
Review - High Speed toolpaths Introduction

INTRODUCTION
This lesson will build on the Dynamic toolpath you learned in the previous lessons. This lesson will enforce
your knowledge on how to use the different strategies the Dynamic Mill toolpath provides as you program
more complicated and realistic parts. You will also learn how to group the roughing toolpaths and the finish
toolpaths and of the type of operations.

OVERVIEW OF TUTORIAL:
In this lesson you will learn how to organize the toolpaths in groups. You will use High Speed toolpaths and
Circle Mill toolpath to rough out the part. A Stock Model toolpath will be generated from the roughing
toolpaths. To finish the part you will use another set of High Speed toolpaths, Contour and Circle Mill
toolpath. You will deburr the part using Model Chamfer toolpath.

NEW CONCEPTS COVERED IN THIS TUTORIAL:

n Using Toolpath Groups.
n Review Contour.
n Review High Speed Dynamic Mill.
n Review Circle Mill.
n Review High Speed Area Mill.
n Compare the machined part to the model.
n Review Stock Model.
n Review High Speed Blend.
n Review Chamfer Drill.
n Review Drill.
n Review Model Chamfer.

499
Review - High Speed toolpaths Instructor Demonstration:

INSTRUCTOR DEMONSTRATION:
Topics:

n Roughing Toolpath Group.

n Contour the outside profile.
n High Speed Dynamic Mill to rough out
the part.
n Circle Mill to rough out the bigger
holes.
n Verify Compare the machined part to
the Workpiece checking the accuracy of
the toolpaths.
n Stock Model after roughing to be used
in Verify.
n Create the Finishing Toolpath Group.
n High Speed Area Mill to finish the
floors.
n High Speed Blend to finish a circular
shape floor.
n Contour toolpath to finish the walls.
n Circle Mill to finish the bigger holes.
n Stock Model after finishing to be used
in Verify.
n Chamfer Drill the holes.
n Drill the holes.
n Create the Deburr Toolpath Group.
n Model Chamfer.

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Review - High Speed toolpaths Step 1: Rename The Toolpath Group

STEP 1: RENAME THE TOOLPATH GROUP

In this step you will rename the Toolpath Group "Roughing".

n Find and Open Review_2DHST.mcam

n The solid, in Isometric view should look as
shown.

Note: The Stock is already set. In this exercise

you will concentrate on the toolpaths only. There
is no extra stock on the top of the part. Facing is
not needed. There is extra stock in the XY
plane.

n In the Toolpaths Manager, set click on the Toolpath

Group to highlight the name and enter Roughing to
rename it.

1.1 Machine

n Expand the Properties and select the Files icon.

n Set the Default program number to 1008.

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Review - High Speed toolpaths Step 1: Rename The Toolpath Group

Master Model

n Click on Add from

selection icon to select the
part.
n Press Enter.

Stock

n Select the Stock Setup and click on the Add from a

bounding box button.

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Review - High Speed toolpaths Step 1: Rename The Toolpath Group

n Enable Manual and select the part.

n Change the Origin as shown to add the extra sock in both directions.
n Change the Size values as shown.

n Select the OK button to exit Bounding Box.

Workholding

n In the Workholding, enable

Fixtures and select Add from

selection icon.
n Make a window around the entire
part and click on the part to
unselect it. Press Enter.

n The Fixtures should be listed .

n Select the OK button to exit

Machine Group Setup.

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Review - High Speed toolpaths Step 2: Contour Toolpath

n To check the stock, in the Toolpaths ribbon you can

enable Stock display.

n The stock should look as shown.

STEP 2: CONTOUR TOOLPATH

A Contour toolpath is created to remove the extra stock in XY plane. You will generate a roughing pass
with depth cuts and one finishing step at the final depth.

n In the Toolpaths tab, from the 2D group, select the Contour icon.

n In the Solid Chaining dialog box, enable

Loop only and select the bottom edge in
CW direction as shown.

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Review - High Speed toolpaths Step 2: Contour Toolpath

2.1 Tool

n Click on the
Select library
tool button
and using the
Filter options
select a 1/2"
Flat Endmill
as shown.

2.2 Holder

n In the Holder page select the

B2E4-0500.
n Change the Projection to 2.0.
Press Enter.

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Review - High Speed toolpaths Step 2: Contour Toolpath

2.3 Cut Parameters

n In the Compensation type

select Wear.

n In the Depth Cuts, set the

Maximum rough step to 0.25.

506
Review - High Speed toolpaths Step 2: Contour Toolpath

n In the Multipasses set the

Finish Number to 1 and
the Spacing to 0.01.
n Enable the Final depth.

2.4 Linking Parameters

n Retract = 0.25
(Incremental).
n Feed Plane = 0.125
(Incremental).
n Top of Stock = 0.0
(Absolute).
n Depth = -0.02
(Incremental).

Note: Depth set to -0.02

ensures the tool breaks
through.

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Review - High Speed toolpaths Step 2: Contour Toolpath

2.5 Preview the toolpath

n Make sure Generate toolpath is

enabled and select the Apply
button to preview the toolpath.

n To hide the dialog box click on the

Hide dialog button.

n The toolpath should look as shown.

Note: The lead in/out are too big

and there are to many retract
movements.

n Press Esc to exit Toolpath

preview.

2.6 Enable Keep tool down in the Depth cuts and Multipasses

n In the Depth Cuts, enable

Keep tool down.

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Review - High Speed toolpaths Step 2: Contour Toolpath

n In the Lead In/Out page,

change the Length of
the line to 30% and the
Radius to 60% for both
Entry and Exit.
n Sweep = 45.0.
n Add an Overlap of 0.05
to avoid leaving tool
marks on the part at the
entry/exit .

2.7 Backplot the toolpath

n The toolpath should look as shown.

Note: The lead in/out are smaller and

there is one rapid motion at start of
the toolpath and one exit rapid motion
at the end of the toolpath.

n Press Esc to exit Toolpath

preview.

2.8 Verify the toolpath

n The part should look as shown.

509
Review - High Speed toolpaths Step 3: Dynamic Toolpath To Rough The Open Pockets

STEP 3: DYNAMIC TOOLPATH TO ROUGH THE OPEN POCKETS

In this step you will use the Dynamic toolpath with the strategy set to From outside to machine the open
pockets. As selection method you will use Automatic.

n Before starting the next operation, turn off the

toolpath display for the Contour operation.

n In the 2D toolpaths and select the Dynamic icon.

n Enable From outside and click to select the Automatic regions.

n Select the open

pocket faces as
shown.
n Select the OK button
to continue.

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Review - High Speed toolpaths Step 3: Dynamic Toolpath To Rough The Open Pockets

n Click on the
Preview
chains button
to check the
chaining.
n Select the
OK button to
continue.

3.1 Tool

n Select the 1/2" Flat Endmill.

3.2 Cut Parameters

n Machining direction is set

to Climb.
n Approach distance = 0.
n Stepover distance = 15%.
n Minimum toolpath radius
= 10.0%.
n Keep tool down within %
of tool diameter = 100.
n Micro lift distance = 0.01.
n Stock to leave on walls =
0.01.
n Stock to leave on floors =
0.01.

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Review - High Speed toolpaths Step 3: Dynamic Toolpath To Rough The Open Pockets

3.3 Corner Pretreatment disabled

3.4 Depth Cuts disabled
3.5 Break Through disabled
3.6 Linking Parameters

n Retract = 0.25 (Absolute).

n Feed Plane = 0.1
(Incremental).
n Top of Stock = 0.0
(Absolute).
n Depth =0.0 (Incremental).

3.7 Entry motion

Note: Strategy is set from outside and the entry motion does not matter.

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Review - High Speed toolpaths Step 3: Dynamic Toolpath To Rough The Open Pockets

3.8 Arc Filter / Tolerance

The option to Output 3D arcs will create the entry helix move with arc moves when possible.

n From the Tree View List,

select Arc Filter /
Tolerance.
n Set the Line/ arc
tolerance to 70% to
ensure that the filter will
remove some of the lines
and arcs move in the
given tolerance.
n Enable Line/Arc
Filtering Settings and
make sure that Output
3D arc entry motion is
enabled as shown.

n Select the OK button to exit 2D Toolpaths - Pocket.

3.9 Preview the

toolpath

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Review - High Speed toolpaths Step 3: Dynamic Toolpath To Rough The Open Pockets

3.10 Repeat the Backplot procedure

n The toolpath should look as shown.

3.11 Verify the toolpaths

n In the Toolpaths Manager, click on the

drop down arrow next to Verify all
selected operations and select Add to
current verification.

514
Review - High Speed toolpaths Step 4: Rough Out The Inside Pockets Using Dynamic

STEP 4: ROUGH OUT THE INSIDE POCKETS USING DYNAMIC

In this step you will use the Dynamic toolpath with the Stay inside option to machine the inside pockets.

n Before starting the next operation, turn off the

toolpath display for the Dynamic Mill operation.

n Select the Dynamic icon in the 2D Toolpaths.

n In the Chain Options enable Stay inside.

n In the Automatic regions, click on the Select button.

n Select the bottom of the

pockets as shown.

Note: The chain direction

does not matter for a pocket
toolpath.

n Select the OK button to

continue.

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Review - High Speed toolpaths Step 4: Rough Out The Inside Pockets Using Dynamic

n Click on the
Preview chains
button to check
the chaining.
n Select the
OK button to
continue.

4.1 Tool

n Select the 1/2" Flat Endmill.

4.2 Cut Parameters

n Leave the parameters as set before.

4.3 Linking Parameters

n Linking parameters are already set from the previous Dynamic toolpath.

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Review - High Speed toolpaths Step 4: Rough Out The Inside Pockets Using Dynamic

4.4 Entry Motion

n In the Entry Motion,

leave the Entry method
set to Helix only.
n Change the Z clearance
to 0.05 to avoid wasting
time.

n Select the OK button to exit 2D Toolpaths - Pocket.

4.5 Repeat the Backplot procedure

n The toolpath
should look as
shown.

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Review - High Speed toolpaths Step 5: Circle Mill The Larger Holes

STEP 5: CIRCLE MILL THE LARGER HOLES

In this example, you will rough out the larger holes using Circle Mill toolpath.

n Before starting the next operation, turn off the toolpath display.
n From the 2D Toolpaths select the Expand gallery arrow and select Circle Mill.

n Select the inside faces of

the holes.
n Select the OK button to
exit the Toolpath Hole
Definition panel.

5.1 Tool

n Select the 1/2" Flat Endmill .

5.2 Cut Parameters

n Leave the
Compensation type
to Computer as this
is just a roughing
toolpath.
n Stock to leave on
walls = 0.01.
n Stock to leave on
floors = 0.0.

Note: The holes are

through.

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Review - High Speed toolpaths Step 5: Circle Mill The Larger Holes

5.3 Roughing

n Enable
Roughing and
change the Z
clearance to
0.05 and the
Plunge angle to
2.

5.4 Depth Cuts

n Enable Depth cuts and

set the Max rough step
to 0.25.
n In the Finish area set the
Number of cuts to 0. No
finish cuts needed as the
holes are through.

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Review - High Speed toolpaths Step 5: Circle Mill The Larger Holes

5.5 Linking Parameters

n Make sure that

Calculate incremental
values from
holes/lines is enabled
to calculate the values
from the top of the
holes.

n Enable Automatic
linking and select the
OK button to accept the
warning. This modifies
the values to avoid
collisions.
n Change the
Clearance = 2.0
n Retract = 0.25.
n Feed plane = 0.1.
n Top of Stock = 0.0
(Incremental).
n Depth = -0.02
(Incremental).

Note: You can set the

Break Through amount
to 0.02 or set the Depth
to -0.02 to cut through.

520
Review - High Speed toolpaths Step 5: Circle Mill The Larger Holes

5.6 Repeat the Toolpath preview procedure

n The toolpath should look as

shown.

Note: There are too many

retract movements between
the depth cuts. We also want to
start and exit from the center of
the holes to not leave marks on
the part.

5.7 Depth cuts

n From the Toolpaths Manager, click on the Parameters of the Circle Mill toolpath.

n In the Depth cuts

enable Keep tool
down.

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Review - High Speed toolpaths Step 5: Circle Mill The Larger Holes

5.8 Transitions

n In the Transitions,
enable Lead In/Out.
n Enable Start at center
and End at center.

n Make sure that Generate toolpath is enabled.

n Select the OK button to finish the toolpath.

5.9 Backplot the toolpath

n The toolpath should

look as shown.

522
Review - High Speed toolpaths Step 6: Verify The Toolpath

STEP 6: VERIFY THE TOOLPATH

n Select Add to current verification.

n Run Verify.
n The part should appear as shown.

STEP 7: COMPARE TO MODEL

In this step you will compare the verify results against the model by using Compare in Verify. When using
Compare, Mastercam Simulator colors the part model according to the amount of stock left on the model
beyond the tolerances you specify in the Compare dialog box.

n From the
Verify tab
select
Compare.

n In the Compare dialog box select Compare options icon. This

allows us to change the tolerance as the default 0.01 is too high.

523
Review - High Speed toolpaths Step 7: Compare To Model

n Change the Tolerance to 0.005.

n Select the OK button.

n The rest of the values should be updated.

n The finished part should be all green according to the compare color
map.

n To run Compare, click on the Refresh icon.

524
Review - High Speed toolpaths Step 8: Expand Air Regions

n The part should look as shown.

Note: The dark blue color reflects

the 0.01 stock that you left on the
floors and on the walls. The finish
toolpaths will remove that stock.

n Right mouse click in the Verify window and select the

Top view.
n Zoom in and slightly rotate the part to see the open
corners of the right side pocket.

Note: The extra material at the corners. The

automatic selection used in the second toolpath did
the best it could to machine the open pockets. To fix
the issue, the selected regions need to be adjusted.

STEP 8: EXPAND AIR REGIONS

n In the Toolpaths Manager, click on the Geometry of the

second toolpath.
n In the Toolpath Type click on the Preview chains button.

525
Review - High Speed toolpaths Step 8: Expand Air Regions

n Change the graphics view to Top.

n The tool disengage from the material
straight out.
n Click on the Preview chains button to
exit the preview.

n In the Air regions, enable

Expand region.
n Click on the Preview
chains button.

Note: The Expand

regions in the selected Air
regions improves the
amount of reachable
material on the open
pocket shapes.

n Select the OK button to

exit Chain Options.
n Rgenerate the toolpath.

526
Review - High Speed toolpaths Step 9: Stock Model

8.1 Verify and Compare again

n The corners should be

machined.

STEP 9: STOCK MODEL

In this step you will create a Stock Model that will be used to verify the finish toolpaths.

n From the Toolpaths tab, Stock

group, select Stock Model.

n In the Name enter "Stock after

roughing".
n Click on the Stock Setup
button to define the stock size
used in this operation based on
the one set in the Stock setup.

527
Review - High Speed toolpaths Step 9: Stock Model

n In the Source Operations click on the

Roughing group to select all toolpaths.
n Select the OK button to exit Stock
model.

n The stock model should look as

shown.
n Press Alt +T to remove the stock
model display.

528
Review - High Speed toolpaths Step 10: Create A Toolpath Group

STEP 10: CREATE A TOOLPATH GROUP

In this step you will learn how to create a new toolpath group under which you are going to create all the
finish toolpaths.

n In the Toolpaths
Manager, right mouse
click on the Machine
Group -1.
n Select Groups and then
New Toolpath group.

n Rename the Toolpath Group Finishing.

n Press Alt +T to remove the toolpath display.

529
Review - High Speed toolpaths Step 11: Finish Open Pocket Floors - Area Mill

STEP 11: FINISH OPEN POCKET FLOORS - AREA MILL

In this step you will finish the open pockets floors using Area Milll toolpath.

n In the 2D toolpaths and select the Expand Gallery arrow

and then select the Area Mill icon.

n Enable From outside and click to select the Automatic

regions.

n Select the open

pocket faces as
shown.
n Select the OK button
to continue.

530
Review - High Speed toolpaths Step 11: Finish Open Pocket Floors - Area Mill

n Click on the
Preview
chains button
to check the
chaining.
n Select the
OK button to
continue.

11.1 Tool
n From the Tool page, click on the Select library tool button and using the Filter options select the 3/8"
Flat Endmill.

11.2 Holder

n In the Holder page select the

B2C4 -0032 and change the
Tool Projection to 1.875
(0.375* 5).

531
Review - High Speed toolpaths Step 11: Finish Open Pocket Floors - Area Mill

11.3 Cut Parameters

n Stock to leave
on walls = 0.015.
n Stock to leave
on floors = 0.0.

11.4 Depth Cuts disabled

11.5 Break Through disabled
11.6 Linking Parameters

n Retract = 0.25 (Absolute).

n Feed Plane = 0.1 (Incremental).
n Top of Stock = 0.0 (Absolute).
n Depth = 0.0 (Incremental).

Note: Depth value is set from the value of the

selected faces. Incremental values should
almost always be set to 0.0.

532
Review - High Speed toolpaths Step 11: Finish Open Pocket Floors - Area Mill

11.7 HST Leads

n Set both Vertical arc entry and exit to 0.0.

n Select the OK button to exit 2D Toolpaths - Area Mill.

11.8 Repeat the Toolpath preview procedure

n The toolpath should look as shown.

Note: The big rapid out and the big

feed down motions. They can be
made smaller by changing the Top of
stock value which currently is just
0.01. Also the stepover can be
increased for less passes.

n In the Toolpaths Manager, select

the Parameters of the 2D High
Speed (2D Area Mill).
n In the Linking parameters,
change:
n Top of stock = Incremental 0.01.
n Feed plane = 0.125.
n Retract = 0.5 (Incremental).
n Enable Clearance = 2.0
(Absolute).

Note: With Clearance enabled and

set to Absolute, the tool will retract
above the top of the part when
moving to the next pocket. This
ensures the tool does not rapid into
the part.

533
Review - High Speed toolpaths Step 11: Finish Open Pocket Floors - Area Mill

11.9 Repeat the Toolpath Preview procedure

n The toolpath should look as

shown.

Note: The smaller feed ins and

retract motions as well as the
rapid to the clearance height to
move from one pocket to another
pocket.

11.10 Change the stepover

n In the Toolpaths
Manager, select the
Parameters of the 2D
High Speed (2D Area
Mill).
n In the Cut parameters,
set the XY stepover to
70%.

11.11 Repeat the Toolpath Preview procedure

n The toolpath should look as shown.

534
Review - High Speed toolpaths Step 12: Finish The Inside Pocket Using Area Mill

STEP 12: FINISH THE INSIDE POCKET USING AREA MILL

In this step you will use the Area Mill toolpath with the Stay inside option to finish the right side closed
pocket.

n Select the Area Mill icon in the 2D Toolpaths.

n In the Chain Options enable Stay inside.

n In the Automatic regions, click on the Select button.

n Select the bottom of the right side pocket

as shown.

n Select the OK button to continue.

n Click on the Preview chains

button to check the chaining.
n Select the OK button to
continue.

Note: The inside hole is

already machined. We need to
add the air regions for this
toolpath.

535
Review - High Speed toolpaths Step 12: Finish The Inside Pocket Using Area Mill

n Click on the Convert automatic regions icon in the Automatic

regions.

n In the Air regions, click on the

select button.
n Enable Cavities button and select
the pocket face as shown.

n Click on the Preview

chains button to check the
chaining.

Note: With the Air regions

set to the hole, the tool can
engage into material from
the hole.

n Select the OK button to

continue.

12.1 Tool

n Select the 3/8" Flat Endmill.

12.2 Cut Parameters

n Leave the parameters as set before.

536
Review - High Speed toolpaths Step 13: Finish The Left Side Pocket - HS Blend

12.3 Repeat the Backplot procedure

n The toolpath should look as

shown.

Note: The tool starts in the hole.

STEP 13: FINISH THE LEFT SIDE POCKET - HS BLEND

In this step you will finish the left side closed pocket using the High Speed Blend Mill toolpath.

n From the 2D Toolpaths, select the Expand gallery arrow and select the Blend Mill icon.

n Enable only the Loop button.

n Select first the inside hole and then
larger hole edge at the bottom of
the pocket as shown.
n Make sure the chains are selected
in CCW direction.

13.1 Tool

n Select the 3/8" Flat Endmill.

537
Review - High Speed toolpaths Step 13: Finish The Left Side Pocket - HS Blend

13.2 Cut Parameters

n Cutting method is set to Spiral.

n Comp direction set to Left.
n Max stepover = 50% of Tool
Diameter.
n Make sure that Along is enabled.
n Distance = 0.25.
n Stock to leave on walls = 0.015.
n Stock to leave on floors = 0.0.

13.3 No Depth Cuts

13.4 No Finish Passes
13.5 Break Through disabled
13.6 Linking Parameters

n Retract = 0.25 (Absolute).

n Feed Plane = 0.1 (Incremental).
n Top of Stock = 0.0 (Absolute).
n Depth = 0.0 (Incremental).

n Select the OK button to exit 2D Toolpaths - Blend Mill.

538
Review - High Speed toolpaths Step 13: Finish The Left Side Pocket - HS Blend

13.7 Repeat the Backplot procedure

n In Backplot dialog box,

enable Show end
points.
n The toolpath should look
as shown.

Note: The feed in is big.

To address this in the
Linking parameters
change the Top of the
stock to 0.10 and
Incremental. Remember
you left in the roughing
operation 0.01 stock on
the floor.

13.8 Linking Parameters

n In the Linking
parameters change
the Top of the stock
to 0.10 and
Incremental as
shown.

539
Review - High Speed toolpaths Step 14: Finish The Walls Using Contour

STEP 14: FINISH THE WALLS USING CONTOUR

In this step you will finish the walls using Contour toolpath.

n Press Alt + T to remove the toolpath display.

Note: You might need to click twice on the icon to remove all toolpath displays.

n From the Toolpaths tab, and select the Contour icon.

n To select the open

pockets, enable Outer
shared edges button
as shown.
n Select the edges CCW
to ensure climb milling.
n Select the OK button to
accept the Chain
settings.

n Enable Loop button as

shown.
n Select the inside pockets
walls.

14.1 Tool

n Select the 3/8" Flat Endmill.

540
Review - High Speed toolpaths Step 14: Finish The Walls Using Contour

14.2 Cut Parameters

n Make sure that

Compensation type is
set to Wear.
n Compensation
direction set to Left
as shown.
n Stock to leave on
walls and floors =
0.0.

14.3 Depth Cuts

n Max rough step = 0.375.

541
Review - High Speed toolpaths Step 14: Finish The Walls Using Contour

14.4 Lead In/Out

n Leave the settings as

they were set in the
previous Contour
toolpath.
n Set the Line to Tangent
with the Length set to
30%.
n Set the Arc Radius to
30% and Sweep angle
to 45.

14.5 Break Through disabled

14.6 Multi Passes disabled
14.7 Linking Parameters

n From the Tree View List, select

Linking Parameters and set the
values as shown.
n Select the OK button to exit 2D
Toolpaths - Contour.

542
Review - High Speed toolpaths Step 14: Finish The Walls Using Contour

n The toolpath should look as

shown.

Note: The tool stays down

where we do not need that.
For safety purpose the
Retract should be set to
Absolute. Otherwise,
enable Clearance to move
from one pocket to another
pocket safe.

n In the Toolpaths Manager select the last operation Parameters and in the Depth Cuts disable
Keep tool down.
n In the Linking parameters page, set the Retract to Absolute.

n The toolpath should look as

shown.

543
Review - High Speed toolpaths Step 15: Finish The Large Holes

STEP 15: FINISH THE LARGE HOLES

In this step you will use Circle Mill toopath to finish the large holes.

n In the Toolpaths Manger, select Toggle display on selected operations to remove the
toolpath display.

n Select the Circle Mill toolpath.

n Select the inside faces of

the holes.
n Select the OK button to
exit the Toolpath Hole
Definition panel.

15.1 Tool

n Select the 3/8" Flat Endmill from the library.

15.2 Cut Parameters

n Leave the Compensation type to

Wear as this is the finish toolpath.
n Stock to leave on walls = 0.0.
n Stock to leave on floors = 0.0.

544
Review - High Speed toolpaths Step 15: Finish The Large Holes

15.3 Roughing disabled

15.4 Finishing

n Finishing enabled as
shown.

15.5 Transitions

n The Transitions parameters should be already set.

545
Review - High Speed toolpaths Step 15: Finish The Large Holes

15.6 Depth Cuts

n Set the Max rough step to 0.375.

15.7 Linking Parameters

n Make sure that Calculate

incremental values from
holes/lines is enabled to
calculate the values from the top
of the holes.

n The Automatic linking should

be already enabled.
n Change the Clearance = 2.0
n Retract = 0.25 (Absolute).
n Feed plane = 0.1
(Incremental).
n Top of Stock = 0.0
(Incremental).
n Depth = -0.2 (Incremental).

546
Review - High Speed toolpaths Step 16: Simulator Options

15.8 Repeat the Backplot procedure

n The toolpath should look as

shown.

STEP 16: SIMULATOR OPTIONS

n From the Toolpaths Manager, select the

Simulator Options button.

n Enable Sock Override and click on the Add from a Stock

Model button.

n Select the Stock after roughing.

547
Review - High Speed toolpaths Step 17: Verify The Finish Toolpath

STEP 17: VERIFY THE FINISH TOOLPATH

n Select all the Finishing toolpaths.

n The part after being verified in
Mastercam Simulator should look as
shown.

17.1 Compare the toolpath

n In the Verify tab, select the Compare icon.

n In the Compare dialog box click on the Refresh icon.

n The verified part should look

as shown.

Note: The only thing left to do

is to drill the holes.

548
Review - High Speed toolpaths Step 18: Create The Stock Model After Finish

STEP 18: CREATE THE STOCK MODEL AFTER FINISH

In this step you will create a Stock Model that will be used to verify the holes toolpaths.

n From the Toolpaths tab, Stock group, select Stock

Model.

n In the Name enter "Stock after

finishing".
n For the Initial stock shape, enable
Stock model and set it to Stock after
roughing.

n In the Source
Operations click on the
Finishing group to
select all toolpaths.
n Select the OK button to
exit Stock model.

549
Review - High Speed toolpaths Step 19: Create Another Toolpath Group

n The stock model should look

as shown.
n Press Alt +T to remove the
stock model display.

STEP 19: CREATE ANOTHER TOOLPATH GROUP

In this step you will learn how to create another toolpath group under which you are going to create all the
hole toolpaths.

n In the Toolpaths
Manager, right mouse
click on the Machine
Group -1.
n Select Groups and then
New Toolpathgroup.

550
Review - High Speed toolpaths Step 20: Spot Drill The Holes -Chamfer Drill

n Rename the Toolpath Group Holes.

n Press Alt +T to remove the toolpath display.

STEP 20: SPOT DRILL THE HOLES -CHAMFER DRILL

In the following toolpath you will spot drill the 1/4" and 3/8" diameter holes using Chamfer drill toolpath.
Chamfer Drill toolpath creates chamfered edges on holes of different diameter or size that can lie in
different planes and machine them in a single operation with a single tool.

n In the 2D group, select the Expand gallery arrow

and select Chamfer Drill icon.

n Hold down the Ctrl key and select

the inside face of one of the 1/4"
holes as shown. All the other
holes that have the same diameter
will be selected.

551
Review - High Speed toolpaths Step 20: Spot Drill The Holes -Chamfer Drill

n Hold down the Ctrl key and select the

inside face of one of the 3/8" holes as
shown. All the other holes with the same
diameter will be automatically selected.

n To optimize the path, in the Toolpath Hole Definition select the

Sort.
n Select Point to point sorting.

n Select the first hole as shown.

n In the Toolpath Hole Definition

select the OK button.

552
Review - High Speed toolpaths Step 20: Spot Drill The Holes -Chamfer Drill

20.1 Toolpath Type

n The Drill icon is selected as shown.

20.2 Tool

n Use the Filter to

select the 1/2"
Spot Drill as
shown.

20.3 Cut Parameter

n Set the Depth to 0.025 as shown.

Note: You can define the chamfer either by

setting the Width or by setting the Depth. In
both cases this is a 45 degrees chamfer.

553
Review - High Speed toolpaths Step 20: Spot Drill The Holes -Chamfer Drill

20.4 Linking Parameters

n Enable Automatic
linking to avoid collisions
with the solid model.
n Clearance = 2.0.
n Retract = 0.1.
n Top of stock = 0.0
n Select the OK button to
exit 2D Toolpaths -
Drill.

20.5 Repeat the Backplot procedure

n The 0.025 Chamfer is

created on the different
diameter holes.

554
Review - High Speed toolpaths Step 21: Drill The Holes

STEP 21: DRILL THE HOLES

In the following toolpaths you will create the blind 1/4" diameter holes using a 1/4" Drill.

21.1 Drill the 1/4" Holes

n In the 2D group, select the Drill icon.

n Hold down the Ctrl key and select the

inside face of one of the 1/4" holes as
shown. All the other holes that have
the same diameter will be selected.
n In the Toolpath Hole Definition

select the OK button.

21.2 Tool

n Use the Filter to select

the 1/4" Drill as
shown.

555
Review - High Speed toolpaths Step 21: Drill The Holes

21.3 Cut Parameter

n Set the Cycle to Peck Drill as

shown.
n Set the rest of the parameters
as shown.

21.4 Linking Parameters

n Enable Calculate
incremental values
from holes/lines.
n Enable Automatic
linking and accept the
warning.
n Clearance = 2.0.
n Retract = 0.5.
n Top of stock = 0.0
(Incremental).
n Depth = 0.0 (Incremental).

Note: When Calculate

incremental values from
holes/lines is enabled, the
Depth value is based on
the inside face of the hole.

n Enable Tip Comp as

shown. Change the
parameters to match the
following screenshot.
n Select the OK button to
exit 2D Toolpaths - Drill.

556
Review - High Speed toolpaths Step 21: Drill The Holes

21.5 Repeat the Backplot procedure

n Rotate the part and check if the tool breaks

through as shown.
n From the Status Bar, lower left corner, select
the Translucency icon.

Note: The retract moves are too big. In the

last Drill toolpath, Linking parameters
change the Retract to 0.1.

21.6 Repeat the Backplot procedure

n The toolpath should look as shown.

557
Review - High Speed toolpaths Step 21: Drill The Holes

21.7 Drill the 3/8" Holes

n In the 2D group, select the Drill icon.

n Hold down the Ctrl key and select the inside face
of one of the 3/8" holes as shown. All the other
holes that have the same diameter will be
selected.
n In the Toolpath Hole Definition select the OK

button.

n To optimize the path, in the Toolpath Hole Definition select the

Sort.
n Select Point to point sorting.

n Select the first hole as shown.

n In the Toolpath Hole Definition select the OK

button.

558
Review - High Speed toolpaths Step 21: Drill The Holes

21.8 Tool

n Use the
Filter to
select the
3/8" Drill
as shown.

21.9 Cut Parameter

n Set the Cycle to Peck

Drill as shown.
n Set the rest of the
parameters as shown.

559
Review - High Speed toolpaths Step 21: Drill The Holes

21.10 Linking Parameters

n The parameters should

look as shown.
n Select the OK button to
exit 2D Toolpaths - Drill.

560
Review - High Speed toolpaths Step 21: Drill The Holes

21.11 Repeat the Backplot procedure

n The toolpath should look as

shown.

Note: The Retract moves are just

0.1 above the solid model with no
wasting time.

n The drilling breaks

through.

21.12 Verify the hole toolpaths.

n Select the toolpaths in the Holes
group.
n Select the Simulator Options
button.
n Enable Stock Override and select
the "Stock after Finishing".

561
Review - High Speed toolpaths Step 22: Create Another Toolpath Group

STEP 22: CREATE ANOTHER TOOLPATH GROUP

n In the Toolpaths
Manager, right mouse
click on the Machine
Group -1.
n Select Groups and then
New Toolpathgroup.

n Rename the Toolpath Group Deburr.

n Press Alt +T to remove the toolpath display.

562
Review - High Speed toolpaths Step 23: Deburr The Sharp Edges - Model Chamfer

STEP 23: DEBURR THE SHARP EDGES - MODEL CHAMFER

In this operation you will machine all the sharp edges using Model Chamfer toolpath and a Chamfer mill
tool.
Model Chamfer toolpath allows you to machine safe horizontal chamfers on solid models. This toolpath
allows you to enter a side clearance to further protect your part.

n Before starting the next operation, turn off the

toolpath display by pressing Alt + T.

Toolpaths

n From the 2D group, click on the Expand

Gallery arrow and select the Model Chamfer
icon.

n In the Toolpath Type page, in the Chain geometry, click on the

Select button.

n In the Chaining, enable only

Outer open edges button.
n Select the faces as shown.

Note: Only the outer edges of the

faces were selected. The chain is
automatically selected in the CW
direction to ensure climb milling.

563
Review - High Speed toolpaths Step 23: Deburr The Sharp Edges - Model Chamfer

n In the Solid Chaining

dialog box, enable
Cavities button and select
the large holes edges by
selecting the faces as
shown.
n Rotate the part as needed.

Note: Once you click on a

face only the inside cavities
edges will be automatically
selected. The chaining
direction will be CCW to
ensure climb milling.

n In the Solid
Chaining dialog
box, enable Loop
button and select
the edges of the top
of the pockets as
shown.
n Move the start point
back one entity if
needed.
n Select the
OK button to exit
Solid Chaining
dialog box.

564
Review - High Speed toolpaths Step 23: Deburr The Sharp Edges - Model Chamfer

23.1 Toolpath Type

n Set the Side

clearance to 0.01.

23.2 Tool

n Select the existing

1/4" Chamfer Mill
as shown.

565
Review - High Speed toolpaths Step 23: Deburr The Sharp Edges - Model Chamfer

23.3 Cut Parameters

n Set the Compensation type to

Wear.
n Chamfer width = 0.01.
n Bottom offset = 0.05.
n Make sure that the rest of the
parameters are set as shown.

23.4 Depth Cuts disabled

23.5 Lead In/Out

n Enable Enter /exit at

midpoint in closed
contours.
n Length = 25%.
n Radius = 25%.
n Fitting distance =
0.1. (smaller sized
tool will gouge at the
open edge walls).

Fitting distance allows you to enter a distance to trim the Model Chamfer back to avoid gouging.

23.6 Multi Passes disabled

566
Review - High Speed toolpaths Step 23: Deburr The Sharp Edges - Model Chamfer

23.7 Linking Parameters

n From the Tree View List, select Linking Parameters and set the values as shown.

n Clearance = 2.0.
n Retract = 0.25.
n Feed Plane = 0.2.
n Select the OK button to exit 2D
Toolpaths - Model Chamfer.

Note: The Clearance, Retract and

Feed Plane values are measured
from the selected chains.

23.8 Backplot the last toolpath

n The toolpath
should look as
shown.

567
Review - High Speed toolpaths Step 24: Post Process The Toolpaths

n The toolpath is trimmed

when needed to avoid
collision with the solid.

23.9 Verify all the toolpaths

n In the Simulator
Options, enable
Stock Setup to set
the stock to the
original.
n Run all the
toolpaths.
n The part should
appear as shown.

STEP 24: POST PROCESS THE TOOLPATHS

STEP 25: SAVE YOUR FILE

568
Review - High Speed toolpaths Step 25: Save Your File

SUMMARY:

In this lesson, you review how to generate more complicated, specialized pocket type toolpaths, including the
special rules for selecting the geometry to machine these toolpath types. After completing this lesson and
some of the practice exercises that follow you should be able to:
n Setup Toolpath Groups to organize the operations.
n Contour the outside profile.
n Use Dynamic toolpath to rough out the pockets.
n Use Circle Mill toolpath to rough out the large holes.
n Compare toolpaths to part model.
n Create Stock Model.
n Finish the floors using Area Mill toolpath.
n Finish the round shape pocket using Blend Mill.
n Finish the walls using Contour toolpath.
n Use Circle Mill toolpath to finish the walls of the round shape pocket.
n Chamfer Drill the holes.
n Drill the Holes.
n Deburr the part using Model Chamfer toolpath.

569
Nesting

570
Nesting Introduction

INTRODUCTION
This lesson introduces Nesting option in Mastercam that allows you to fit parts onto a sheet of material for
best yield. Nesting operates on geometry or toolpaths.

Geometry Nesting

For Geometry Nesting, you need geometry consisting of a closed boundary. Any open chain or drafting
note selections will be nested along inside of the boundaries that contain them. You can use colors and levels
to organize results by setting options in the Nesting configuration dialog box.

The Nesting library matches parts to sheets by material. If there is only one sheet, material specification is
disabled and all parts are nested on that sheet. If you do not specify a sheet material, Mastercam can nest
any part of any material on that sheet.
You can save common sheet sizes to sheet libraries or in individual part files. Save common parts as
Mastercam part files.
Toolpath Nesting
If you nest the toolpath instead of the geometry, Mastercam can place a single nesting operation in the
Toolpaths Manager, or break the nesting operation into separate operations for each sheet of material.
To nest geometry associated with toolpaths, select Automatically attach geometry in the Nesting
configuration dialog box.
You can save common sheet sizes to sheet libraries or in individual part files, and common parts to operation
libraries or in part files. To read a detailed report about the nesting results, choose Details in the Nesting
Results dialog box.

NEW CONCEPTS COVERED IN THIS TUTORIAL:

n Geometry Nesting.
n Tabs
n Toolpath Nesting

571
Nesting Instructor Demonstration:

INSTRUCTOR DEMONSTRATION:
Topics:

n Geometry Nesting
n Nest the parts
n Prepare the geometry for the toolpaths
n Create rectangular points for tabs
n Machine the parts using Contour
toolpath

n Nest the Toolpath

n Machine each part using Contour
toolpath
n Toolpath Nesting

572
Nesting Guidelines And Procedures When Nesting Geometry

GUIDELINES AND PROCEDURES WHEN NESTING GEOMETRY

Check each individual part to make sure that it

is chainable and that they are closed
boundaries. If not, fix them.

If you preselect the geometry:

In the Sheets dialog box, right mouse click in Sheet

List window and select the type of sheet you want to
add.
If you did not select the geometry:

In the Sheets dialog box a default rectangular sheet

should be displayed.

In the Sheets dialog box set the Parameters

and Common Parameters that you want to use.

573
Nesting Guidelines And Procedures When Nesting Geometry

Setup the Nesting Configuration. Choose

between TrueShape and Rectangular.

In the Parts dialog box, make sure that the

parts are selected, otherwise, right mouse click
in the Part list and choose how you want to add
the geometry.

In the Nesting Results make any required changes.

If you need to go back to the parameter pages, select

the redo button.

574
Nesting Geometry Nesting

GEOMETRY NESTING
Geometry Nesting fits parts onto a sheet of material for best yield. Nesting operates on geometry or toolpaths.
For geometry nesting (Transform, Geometry Nesting), Mastercam can nest geometry consisting of a closed
boundary. Open chains can be selected and will be nested along with the boundary in which they are contained, as
can drafting notes.

Resources - Download the file from www.emastercam.com/files/

n From the Quick Access Toolbar

select the Open icon.

n Select FRAME NESTED.MCAM.

n Accept to change the System
Configuration to metric if needed.

Note: This is a metric file and has holes with two diameter sizes. Change the color of the holes, based on
their diameter. This will help to select them when machining.

575
Nesting Step 1: Change The Color Of The Holes

STEP 1: CHANGE THE COLOR OF THE HOLES

n From the Quick Mask buttons, click on the Select all advanced (left half of the button) as
shown.

n Enable Miscellaneous and select it.

n Filter by Diameter = 12 as shown.
n Select the OK button to exit Select All dialog box.

Note: Mastercam automatically selects all the circles with this

diameter.

n Right mouse click in the graphics window and

click on the arrow next to the Wireframe Color
as shown.
n Change the color to the dark blue as shown.

576
Nesting Step 2: Nesting The Geometry

n Using again the Select all advanced button and filter by

Diameter = 10 select all the circles with this diameter and
change the color to dark green.

STEP 2: NESTING THE GEOMETRY

n Preselect the geometry by dragging a window

around all of the pieces in the graphics window
as shown.

n Once this is done, all of the

geometry should be selected.

n From the Transform

ribbon, in the Layout
group, select
Geometry Nesting.

577
Nesting Step 2: Nesting The Geometry

2.1 Sheets

Mastercam can create geometry to represent the sheets, or you can create your own geometry for the sheet.
Mastercam uses the sheets in the order in which they appear in the list. In our exercises we will add a rectangular
sheet and we will leave a margin between the edge of the sheet and the parts to be able to machine them. Otherwise
if the margin is zero Mastercam nests the parts to the very edge of the sheet.

n Right mouse click in the Sheet List window and

select Add rectangular to establish the sheet
size.

n For our exercise, change the Size

values to 2438 by 1218.
n Change the Sheet Margin to
2mm.
n The parameters should look as
shown.

Grain Direction is used when nesting parts on material with a noticeable surface direction. Set the grain direction to
match the orientation of the grain on the sheet.
Fill Direction determines the direction in which the sheet is filled with nested parts. A sheet's fill direction runs
perpendicular to the part's nesting direction. Choose calculate to have Mastercam apply the most efficient direction.

n Select the Config button.

578
Nesting Step 2: Nesting The Geometry

2.2 Nesting Configuration

Nesting configuration allows you to choose the Nesting Mode between Rectangular or TrueShape.

Rectangular nesting places a bounding box around the part and uses the box as the part boundary for nesting. The
Rectangular nesting mode is available with Mastercam Router and Router Pro. Use this option when the shape of
the parts are close to rectangular shape.

TrueShape nests parts according to each part's actual shape and other parameters. It allows access to sheet and
part libraries and extended functionality beyond Rectangular nesting. TrueShape nesting is a separately-purchased
option for Mastercam Router and Mill.

n Select Delete original chains.

n Change the nesting mode to
TrueShape for a more efficient
nesting.
n Leave the Accuracy to Fine as
shown.

Display Results dialog automatically displays the nesting results dialog box.

Accuracy determines the precision of the nest. The finer the accuracy, the longer the results may take to generate.
Each of the predefined accuracy settings corresponds to a resolution field value, for example, Fine = 2.0. Use a
larger setting such as Coarse for bigger parts. Choosing User Defined enables the resolution field where you can
enter the resolution for the results.

TrueShape nests parts according to each part's actual shape and other parameters. It allows access to sheet and
part libraries and extended functionality beyond Rectangular nesting. TrueShape nesting is a separately-purchased
option for Mastercam Router and Mill.

n Select the OK button to exit Nesting Configuration.

579
Nesting Step 2: Nesting The Geometry

2.3 Parts

Parts page allows you to select the parts from the open Mastercam file or open existing files.
When you add parts as a cluster, Mastercam nests them as a single unit. Both geometry and toolpath operations can
be added as a cluster.

n Select the Parts tab.

Note: All of the parts are listed

in the window.

n Change the Part-Part

Distance to 13mm and leave
the rest of the parameters as
shown.
n Select the OK button to
generate the nesting.

Minimum quantity allows you to enter the number of copies of the selected part. Nesting creates as many copies
as it can up to the minimum quantity. To make extra copies beyond the minimum quantity, use the Fill all sheets or
Filler Qty fields.

Step Angle controls the degree of rotation Nesting can use when fitting parts on a sheet. For example, a 90 degree
step angle allows Nesting to use 0, 90, 180, and 270 degree rotations. A Grain Direction set to Horizontal or
Vertical disables this option.

Part-Part Distance allows you to enter the amount of space between nested parts. When nesting geometry only, be
sure to space the parts far enough apart to accommodate toolpaths. When nesting toolpaths, Mastercam spaces the
parts using this parameter and whether you selected to nest to the tool center or diameter in the Nesting
configuration dialog box.

580
Nesting Step 2: Nesting The Geometry

2.4 Nesting Results

Nesting Results page allows you to view the results from the geometry nesting before Mastercam creates the
nested geometry.
Here you can manually edit your nested results. You have the ability to move and copy parts in an existing nest while
maintaining the "part-to-part distance” setting. With bump nesting, you can also delete or lock in place selected parts
from the sheet.

n Enable Vertical Trim as shown.

Note: If you did not get the same result, to

modify the parameters click on the redo
button.

n Select the OK button to exit Nesting

Results.

n Right mouse click in the graphics window and

select Fit to fit the nested geometry to the screen.

n The geometry should look

as shown.

581
Nesting Step 3: Move The Vertical Cut Off

STEP 3: MOVE THE VERTICAL CUT OFF

Use Transform Offset to Move the vertical cut off 10 mm to the right.

n From the Transform ribbon, in the

Offset group, select the Entity
icon.

n In the Offset panel enable Move and set the distance to 10.

n Select the hidden line and

indicate the offset direction to
the right of the line.
n Select the OK button.

582
Nesting Step 4: Create Rectangular Points For The Tabs

STEP 4: CREATE RECTANGULAR POINTS FOR THE TABS

Tabs are uncut areas of a toolpath that assist in holding down a part. While the tool is cutting the contour, it retracts a
small amount at the tab location to leave a small amount of stock, then plunges back to the normal cutting depth.
Tabs are especially useful when you are cutting out small parts, multiple parts or nested parts. The rectangular style
points are used to define the tab location in the toolpath.
To create the points, use Point Dynamic command. Make sure that you aligned the points on two adjacent entities
by snapping to the already created points.

n Right mouse in graphics window and in the Mini

Toolbar and change the Point Style to rectangle.

n Right mouse in graphics window and in the Mini Toolbar and

change the Wireframe Color to brown.

n From the Wireframe ribbon, in the Points group, select the drop down arrow and
click on the Point Dynamic.

n Right mouse click in the graphics window and select Fit or press Alt +
F1.

583
Nesting Step 4: Create Rectangular Points For The Tabs

n Select the line and

move the arrow to
the midpoint as
shown.

n Click to create the

point.
n Press Enter or
select the OK and
Create New
Operation button
to continue in the
same command.
or
press Enter.

n Select the adjacent

line as shown.

n Drag the cursor above the existing point as shown.

n Click to create the new point aligned to the previous
point.

584
Nesting Step 4: Create Rectangular Points For The Tabs

Use Point Dynamic Command To Recreate The Image Below.

Note: Ensure the points positioned on the four large arcs are placed at the midpoints as shown.
The points that define tabs on parts that are not positioned close to other parts, do not have to be created
at midpoints.
For example, the point in the top right hand part of the image below.
Make sure that you align the points on two adjacent entities by snapping to the already created point.

n Select the OK button.

n Save the file as FRAME NESTED_TOOLPATHS.MCAM.

585
Nesting Machine Nested Parts

MACHINE NESTED PARTS

n Open the file that

you saved
previously.
n Delete the text
"Sheet #1
Results" and
keep only the
sheet with the
nested parts as
shown.

n From the Wireframe ribbon, Modify group, select the Combine Views icon.

Note: This ensures that all arcs are moved from the parallel views to the single view. This option is useful
when you translate files from other applications and want to reduce the number of different views. For
example, if you have arcs on the bottom view and top view, Mastercam moves all arcs to top view.

586
Nesting Step 5: Machine Type

n Make the Toolpaths Manager panel visible by selecting the Toolpaths tab.

n Lock the panel by clicking on the pin icon as shown.

Note: If a machine group with the Mill Default is already in the Toolpaths Manager skip the Machine
selection.

STEP 5: MACHINE TYPE

n From the Machine ribbon, the Machine Type, select the Mill Default MM.
n Expand and select Stock Setup.

5.1 Stock Setup

n Enable Show wireframe entities.

n Click on the Create rectangular stock icon.

587
Nesting Step 5: Machine Type

5.2 Establishing the stock size

n Enable All shown.

n Change the Origin point at the center of the top face.
n Enter Z= 16.0.

5.3 Tools

n Select Tools.
n Enable Assign tool numbers sequentially.

588
Nesting Step 6: Drill The 10MM Diameter Through Holes

n Select the OK button to exit Machine Group Setup.

n Right mouse click in the graphics window, and select the Isometric
view.

n The stock should look as shown.

STEP 6: DRILL THE 10MM DIAMETER THROUGH HOLES

Toolpath Preview:

n In the
Toolpaths
ribbon, from the
2D group, select
the Drill icon.

589
Nesting Step 6: Drill The 10MM Diameter Through Holes

n Right mouse click in the graphics window and select the Top view.

n Click on the Mask on Arc button in the Toolpath Hole

Definition dialog box.

n Select one of the dark green colored circles from the

graphics window.

n Make a window around the entire part

and press Enter to finish the selection.
n Select the OK button to exit the
Toolpath Hole Definition dialog box.

590
Nesting Step 6: Drill The 10MM Diameter Through Holes

6.1 Tool

n In the Tool tab click on

the Select library tool
and select the 10mm
Drill.

n Set the Spindle

speed and the
Feed rate as
shown.
n Type in the
comment area
"Drilling the
10mm diameter
holes".

6.2 Cut Parameters

n Set the Cycle to Drill/Counterbore.

591
Nesting Step 6: Drill The 10MM Diameter Through Holes

6.3 Linking Parameters

n Clearance = 50.0
(Absolute).
n Enable Use clearance only
at the start and end of
operation.
n Retract = 5.0 (Absolute).
n Top of stock = 0.0
(Absolute).
n Depth = -19.0 (Absolute).
n Ensure the parameters are
the same as shown.
n Select the OK button to exit
the command.

6.4 Verify the toolpath

n Enable Toolpath and Wireframe in the Visibility area.

Note: The Green #10 colored arcs were created to ensure a better fitting of the parts when they are
assembled. These arcs will be drilled with a 12mm drill. The path could vary depending on how you
select the window.

592
Nesting Step 7: Drill The 12MM Diameter Through Holes

STEP 7: DRILL THE 12MM DIAMETER THROUGH HOLES

Toolpath Preview:

n Press Alt + T to
remove the
toolpath.
n In the Toolpaths
ribbon, from the
2D group, select
the Drill icon.

n From the Quick Mask buttons, click on the Select all entities by color button to filter the
arcs by their color.

n Select color 9 and color 10.

n Select the OK button to continue.

n Select the OK button to exit the Toolpath Hole Definition dialog
box.

593
Nesting Step 7: Drill The 12MM Diameter Through Holes

7.1 Tool

n Using Select library

tool and the filter options
select the 12mm Drill as
shown.

n Enter the Comment and

set the parameters as
shown.

7.2 Cut Parameters

n Set the Cycle to

Drill/Counterbore.

594
Nesting Step 7: Drill The 12MM Diameter Through Holes

7.3 Linking Parameters

n Clearance = 50.0
(Absolute).
n Enable Use clearance
only at the start and
end of operation.
n Retract = 5.0 (Absolute).
n Top of stock = 0.0
(Absolute).
n Depth = -20.0
(Absolute).
n Select the OK button to
exit the command.

Verify The Toolpath

n The part should

look as shown.

595
Nesting Step 8: Contour The Outside Profiles

STEP 8: CONTOUR THE OUTSIDE PROFILES

Toolpath Preview:

n Press Alt +T to remove

the toolpath display.
n In the Toolpaths ribbon,
from the 2D group, select
the Contour icon as
shown.

n Select the Window button and click on the Options button as shown.

596
Nesting Step 8: Contour The Outside Profiles

n Enable CW for Closed chains to ensure climb cut as shown.

n Enable Color, click on the Color button and select only the magenta
color #13 as shown.
n Select the OK button to exit the Color Mask dialog box.
n Select the OK button to exit the Chaining Options dialog box.

597
Nesting Step 8: Contour The Outside Profiles

n Ensure Window
selection is selected in the
Chaining dialog box and
make a window around
the entire part.
n Select the Approximate
sketch point at the lower
left corner of the sheet.
n Select the OK button to
exit Chaining dialog box.

8.1 Tool

n Using Select
library tool and
the filter options
select the 12mm
Straight bit as
shown.

n Enter the
Comment and set
the parameters as
shown.

598
Nesting Step 8: Contour The Outside Profiles

8.2 Cut Parameters

n Set the parameters as

shown.

8.3 Lead In/Out

n Enable Lead In/Out

and set the
parameters as shown.

599
Nesting Step 8: Contour The Outside Profiles

8.4 Tabs

Tabs are uncut areas of a toolpath that assist in holding down a part.
Full tabs are the full stock height; in other words, at each tab location, the tool pulls back all the way to the retract
height. Partial tabs are less than the full stock height; you tell Mastercam how far to pull back from the cut depth.
We add square points along the contour to mark the tab locations.

n Enable Tabs and ensure

the parameters are the
same as shown.

8.5 Linking Parameters

n Set the parameters as shown.

n Input these parameters and select
the OK button to generate the
Contour -2D toolpath.

600
Nesting Step 9: Machine The Cut Off

8.6 Verify the last toolpath.

n The part should look as

shown.

Note: Make sure that the cutter

compensation is correct. You
might need to change the cutter
compensation to the Right.

STEP 9: MACHINE THE CUT OFF

Toolpath Preview:

n Press Alt +T to remove the toolpath

display.
n In the Toolpaths ribbon, from the 2D
group, select the Contour icon as
shown.

n Make sure that the Color mask is disabled

601
Nesting Step 9: Machine The Cut Off

n Use Single selection and make sure that the Color mask is disabled.

n Select the line in the upward direction.

n Select the OK button to exit the
Chaining dialog box.

9.1 Tool

n Select the 12mm

Straight Bit
from the previous
operation.
n Insert a
comment:
"Machine the
Cutoff."

602
Nesting Step 9: Machine The Cut Off

9.2 Cut Parameters

n Set the Compensation

Type to Computer and
set the Compensation
Direction to Right. The
rest of the parameters
should look as shown.

9.3 Lead In/Out

n Enable Lead In/Out and set

the parameters as shown.

9.4 Tabs
n Disable Tabs.

603
Nesting Step 9: Machine The Cut Off

9.5 Linking Parameters

n Set the parameters

as shown.
n Select OK to
generate the
Contour toolpath.

604
Nesting Step 9: Machine The Cut Off

9.6 Backplot and Verify the toolpath

n Select Verify selected

operations.

9.7 Verify all toolpaths

n The part should look

as shown.

9.8 Save the file.

605
Nesting Toolpath Nesting

TOOLPATH NESTING

The Nesting option in Mastercam fits parts onto a sheet of material for best yield.

Mastercam can place a single nesting operation in the Toolpath Manager, or break the nesting operation into
separate operations for each sheet of material. You can add operations from the current MCAM file or import
operations from another file. In this exercise you will create two contour toolpaths, one for each part, using the tab
options.

RESOURCES - DOWNLOAD THE FILE FROM WWW.EMASTERCAM.COM/FILES/.

n From the Quick Access Toolbar, located at the upper left

corner of the interface, select Open.

n Select TOOLPATH NESTING .MCAM.

606
Nesting Step 10: Contour The Left Part

STEP 10: CONTOUR THE LEFT PART

Toolpath Preview:

Toolpaths

n From the 2D group,

select the Contour icon
as shown.

n Use Chain selection and chain the part

on the left side in the CW direction.
n Select the OK button to exit the Chaining
dialog box.

607
Nesting Step 10: Contour The Left Part

10.1 Tool

n Select the 1/4"

Straight Bit from
the tool library.
n Insert a comment:
"Contour the left
part."

10.2 Cut Parameters

n Set the
Compensation
Direction to Left. The
rest of the parameters
should look as shown.

608
Nesting Step 10: Contour The Left Part

10.3 Lead In/Out

n Enable Lead In/Out.

n Enable Enter/Exit at
midpoint in closed
contours.
n Leave the default settings.

10.4 Tabs

n Enable Tabs and set the

parameters as shown.

609
Nesting Step 11: Contour The Right Part

10.5 Linking Parameters

n Set the parameters as shown.

n Select OK to generate the Contour

toolpath.

10.6 Backplot the toolpath

n Select Backplot selected operations.

STEP 11: CONTOUR THE RIGHT PART

Toolpath Preview:

n Press Alt +T to remove the

toolpath display.
n In the Toolpaths ribbon, from the
2D group, select the Contour
icon as shown.

610
Nesting Step 11: Contour The Right Part

n Use Chain selection and chain the part on the left side
in the CW direction.
n Select the OK button to exit the Chaining dialog box.

11.1 Tool

n Select the 1/4" Straight Bit from

the previous operation.
n Insert a comment: "Contour the
right part."

11.2 Cut Parameters

n Set the Compensation Direction to Left.

The rest of the parameters should look as
shown.

611
Nesting Step 11: Contour The Right Part

11.3 Lead In/Out

n Enable Lead In/Out.

n Enable Enter/Exit at midpoint in
closed contours.
n Leave the default settings.

11.4 Tabs

n Enable Tabs and set the

parameters as shown.

612
Nesting Step 11: Contour The Right Part

11.5 Linking Parameters

n Set the parameters as

shown.

n Select OK to generate
the Contour toolpath.

11.6 Backplot the toolpath

n Select Backplot selected operations.

613
Nesting Step 12: Nesting The Toolpaths

STEP 12: NESTING THE TOOLPATHS

Toolpath Preview:

n In the
Toolpaths
ribbon, from
the Utilities
group, select
the Nesting
icon.

614
Nesting Step 12: Nesting The Toolpaths

12.1 Nesting Configuration

Nesting Configuration dialog box allows you to set up preferences for Nesting. These options apply to both
geometry and toolpath nesting.

n In the Sheets tab, select

the Config button.

n Enable Load default

sheet to have
Mastercam
automatically load the
rectangular sheet.
n Enable the Display
Results dialog to view
the results of the
toolpath nesting before
Mastercam actually
creates the operations.
n Enable True Shape
and Nest to Tool
center.
n Accuracy set to Fine.
n Set Include rapid
moves to None.
n Disable Nest smaller
parts in the holes of
larger parts.
n Select the OK button to
exit Nesting
Configuration.

615
Nesting Step 12: Nesting The Toolpaths

12.2 Sheets Tab

Use this tab to set up the sheet material for nested parts. Mastercam can create geometry to represent the
sheets, or you can create your own geometry for the sheet.

n Make sure that the

parameters are set
as shown.

616
Nesting Step 12: Nesting The Toolpaths

12.3 Parts Tab

Use this tab to set up part parameters for toolpath nesting. You can enter information about each part,
enter the number of parts and increase the part yield.

n Right-mouse click in the Part List and select

Add operations.

n Click on the Toolpath

Group to select both
contours as shown.
n Select the OK button.

617
Nesting Step 12: Nesting The Toolpaths

n Click on 1-Contour (2D)

- Contour the left part
and set the parameters as
shown.
n Minimum Qty = 35.
n Part-Part Distance =
0.125.

n Click on 2-Contour -
Contour the right part
and set the parameters as
shown.

n Minimum Qty = 45.

n Filter Qty = 19.
n Step Angle = 1.0.
n Part-Part Distance =
0.125

618
Nesting Step 12: Nesting The Toolpaths

12.4 Parameters Tab

Use this tab to set the sorting method, the work offsets and the stop codes parameters.

Maximum vacuum (sorted by area) sorts the operations by size (smallest parts first) and then inside parts before
outside parts to maintain as much vacuum coverage as possible.

Minimum tool change sorts the operations by tool so that all parts that use one tool are cut before changing to the
next tool. This option, when used in conjunction with any of the other sorting options, overrides them.

n Enable Maximum vacuum (sorted by

area) and Minimum tool change.
n Set Stop condition to None.
n Enable One work offset for all
instances of a sheet.
n Select the OK button to generate the
nesting.

n The Nesting Results should look as

shown below, enable Vertical Trim.
n Select the OK button to exit Nesting
Results.

Note: You can manually edit the

results using the Drag icon. The
Bump Nesting dialog box will
appear and you can select one of the
parts, copy it or move it to a desired
location.

Note: This operation is a toolpath nesting and not a geometry nesting. That means that there will not be
wireframe created with this nesting.

619
Nesting Step 12: Nesting The Toolpaths

n Open Properties and select Stock Setup.

12.5 Stock Setup

n Enable Show wireframe entities.

n Click on the Add from a bounding box icon.

620
Nesting Step 12: Nesting The Toolpaths

12.6 Establishing the stock size

n Enable Manual
and click on the
Select Entities
icon.
n Hold down the
Shift key and
select the green
chain.

n Change the Origin point at the center of the top face.

n Enter Z= 0.25.
n Right mouse click on the Rectangular 1 selection.
n Select Set as active stock.

n Select the OK button to exit.

621
Nesting Step 12: Nesting The Toolpaths

12.7 Tools

n Select Tools.
n Enable Assign tool numbers sequentially.

n Select the OK button to exit Machine Group Setup.

n Right mouse click in the graphics window, and select the Isometric
view.

n The stock should look as shown.

622
Nesting Step 12: Nesting The Toolpaths

n Verify the Nesting Toolpath with Color Loop enabled.

Note: In the Visibility group, disable Toolpath and Wireframe.

n Save the file.

623
2D Skills Test

624
2D Skills Test Required Skills

REQUIRED SKILLS
Upon completion of the training lessons presented in this workbook, you should have the basic skills to:
n Create a 2D wireframe geometry.
n Create a solid.
n Import a CAD file from another CAD software.
n Locate the geometry for machining.
n Setup the job.
n Select the appropriate tools.
n Select the toolpaths to machine the part.
n Fill out Mastercam parameters.
n Verify the toolpath on screen.
n Generate the NC code to send to the machine.
The following two skill tests will test your ability to perform these fundamental tasks. The instructor will
provide the files for you to be able to test your skills.

625
2D Skills Test Skills Test #1

SKILLS TEST #1

JOB DESCRIPTION:
Using the Drawing handout from the instructor for Skills Test #1, complete the following tasks:

1. Start a New Mastercam part and save the file as: “Your Name - Skills Test 1”.
2. Draw in the Top view the part to the dimensions shown on the drawing handout.
3. Create the solid.
4. Use Job Setup to prepare the part for machining.
5. Decide on the Tool(s) to use.
6. Face the top of the part.
7. Machine the stand up boss.
8. Machine the circular pocket with the island.
9. Ream the 1/2 hole.
10. Tap the 1/4 -20 UNC holes.
11. Drill and circle mill the counterbores.
12. Machine the outer profile of the part.
13. Chamfer all sharp edges.
14. Verify that your toolpath is correct.

626
2D Skills Test Skills Test #2

SKILLS TEST #2

JOB DESCRIPTION:
Complete the following tasks:

1. In Mastercam, open the native STEP part file called: Skills Test 2.STEP.

2. Save the Mastercam file as: “Your Name - Skills Test 2.MCAM”.
3. Use Move to Origin to get the model in the proper location for machining.
4. Use Job Setup to prepare the part for machining.
5. Use 2D High Speed Toolpaths to:
a. Contour the outer shape of the part. (Decide on the Tool(s) to use.)
b. Remove all pocket areas.
6. Circle Mill the holes as per solid model.
7. Verify that your toolpath is correct.

627
Appendix - Drawings

628
Appendix - Drawings Contour Part 1

CONTOUR PART 1

629
Appendix - Drawings Contour Part 1 - Exercise 1

CONTOUR PART 1 - EXERCISE 1

630
Appendix - Drawings Contour Part 1 - Exercise 2

CONTOUR PART 1 - EXERCISE 2

631
Appendix - Drawings Contour Part 2

CONTOUR PART 2

632
Appendix - Drawings Contour Part 2 - Exercise 1

CONTOUR PART 2 - EXERCISE 1

633
Appendix - Drawings Contour Part 2 - Exercise 2

CONTOUR PART 2 - EXERCISE 2

634
Appendix - Drawings Contour Part 2 - Exercise 3

CONTOUR PART 2 - EXERCISE 3

635
Appendix - Drawings Basic Drill

BASIC DRILL

636
Appendix - Drawings Basic Drill Exercise 1

BASIC DRILL EXERCISE 1

637
Appendix - Drawings Pocket

POCKET

638
Appendix - Drawings Pocket - Exercise 1

POCKET - EXERCISE 1

639
Appendix - Drawings Pocket - Exercise 2

POCKET - EXERCISE 2

640
Appendix - Drawings Advanced Pocket -Exercise 1

ADVANCED POCKET -EXERCISE 1

641
Appendix - Drawings Advanced Pocket -Exercise 2

ADVANCED POCKET -EXERCISE 2

642
Appendix - Drawings Advanced Pocket -Exercise 3

ADVANCED POCKET -EXERCISE 3

643
Appendix - Drawings Manual Drill

MANUAL DRILL

644
Appendix - Drawings Manual Drill _ Exercise 1

MANUAL DRILL _ EXERCISE 1

645
Appendix - Drawings 2D HST

2D HST

646
Appendix - Drawings 2D HST - Exercise 1

2D HST - EXERCISE 1

647
Appendix - Drawings 2D HST - Exercise 2

2D HST - EXERCISE 2

648
Appendix - Drawings Extra Drawings

EXTRA DRAWINGS
DRAWING #1

649
Appendix - Drawings Drawing #2

DRAWING #2

650
Appendix - Drawings Drawing #3

DRAWING #3

651
Appendix - Drawings Drawing #4

DRAWING #4

652
Appendix - Drawings Drawing #5

DRAWING #5

653
Appendix - Drawings Drawing #6

DRAWING #6

654
Appendix - Drawings Drawing #7

DRAWING #7

655
Appendix - Drawings Drawing #8

DRAWING #8

656
Appendix - Drawings Drawing #9

DRAWING #9

657
Appendix - Drawings Drawing #10

DRAWING #10

658
Appendix - Drawings Drawing #11

DRAWING #11

659
Appendix - Drawings Drawing #12

DRAWING #12

660
Appendix - Drawings Drawing #13

DRAWING #13

661
Appendix - Drawings Drawing #14

DRAWING #14

662
Appendix - Drawings Drawing #15

DRAWING #15

663
Appendix - Drawings Drawing #16

DRAWING #16

664
Appendix - Drawings Drawing #17

DRAWING #17

665
Appendix - Drawings Drawing #18

DRAWING #18

666
Appendix - Drawings Drawing #19

DRAWING #19

667
Appendix - Drawings Drawing #20

DRAWING #20

668
Appendix - Drawings Drawing #21

DRAWING #21

669
Appendix - Drawings Drawing #22

DRAWING #22

670
Appendix - Drawings Drawing #23

DRAWING #23

671
Appendix - Drawings Drawing #24

DRAWING #24

672
Appendix - Drawings Drawing #25

DRAWING #25

673
Appendix - Drawings Drawing #26

DRAWING #26

674
Appendix - Drawings Drawing #27

DRAWING #27

675
Appendix - Drawings Drawing #28

DRAWING #28

676
Appendix - Drawings Drawing #29

DRAWING #29

677
Appendix - Drawings Drawing #30

DRAWING #30

678
Appendix - Drawings Drawing #31

DRAWING #31

679