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IHS Mill 2D Advanced User Mastercam 2023 Professional Courseware - IHS Mill 2D Advanced User Copyright: 1998 - 2023 In-House Solutions Inc All rights reserved Software: Mastercam 2023 Date: July 22, 2022 Notice In-House Solutions Inc reserves the right to make improvements to this manual at any time and without notice Disclaimer Of All Warranties And Liability In-House Solutions Inc makes no warranties, either express or implied, with respect to this manual or with respect to the software described in this manual, its quality, performance, merchantability, or fitness for any particular purpose In-House Solutions Inc manual is sold or licensed "as is." The entire risk as to its quality and performance is with the buyer Should the manual prove defective following its purchase, the buyer (and not In-House Solutions Inc., its distributer, or its retailer) assumes the entire cost of all necessary servicing, repair, of correction and any incidental or consequential damages In no event will In-House Solutions Inc be liable for direct, indirect, or consequential damages resulting from any defect in the manual, even if In-House Solutions Inc has been advised of the possibility of such damages Some jurisdictions not allow the exclusion or limitation of implied warranties or liability for incidental or consequential damages, so the above limitation or exclusion may not apply to you Copyrights This manual is protected under International copyright laws All rights are reserved This document may not, in whole or part, be copied, photographed, reproduced, translated or reduced to any electronic medium or machine readable form without prior consent, in writing, from In-House Solutions Inc Trademarks Mastercam is a registered trademark of CNC Software, Inc Table Of Contents IHS Mill 2D Advanced User Getting Started 20 Mastercam® User Interface: 22 Setting The Grid 23 Conventions Used In This Book: 23 Installing MPMASTER Post 24 Customize Ribbon Bars 25 Introduction 26 Create A New Tab 27 Configuration Backup & Restore 33 Introduction 34 Setup Mastercam Interface 35 Customize Right Mouse Menu 43 Introduction 44 Customize The Right Mouse Button Menu 45 Add Analyze Functions To The Right Mouse Button Menu 45 Toolpath Defaults 50 Introduction 51 Instructor Demonstration: 52 Step 1: Open The File 53 Step 2: Set The Default Tool 53 Step 3: Set The Cut Parameters Defaults 55 Step 4: Linking Parameters 56 Step 5: Save The Parameters As Defaults 56 Step 6: Backplot The Toolpath 57 Step 7: Reload The Part 57 Step 8: Create The Face Toolpath 57 Step 9: Check The Cut Parameters Defaults 58 Step 10: Check The Linking Parameters 59 Setup Sheets 60 Introduction 61 Instructor Demonstration: 62 Step 1: Open The File 63 Step 2: Setup Sheet 63 Multiple WCS 70 Introduction 71 Instructor Demonstration: 72 Dynamic Transform Reference Information 73 Step 1: Open The File 73 Step 2: Dynamic Align The Pocket Top Face To The Top Plane 74 Step 3: Create A Viewsheet 79 Step 4: Select A Machine And Set The Stock 80 Step 5: Machine The Pocket Using Dynamic Mill 85 Step 6: Export The Toolpath For Later Use 89 Step 7: Define A Plane Using The Gnomon 90 Step 8: Circle Mill The 1" Diameter Holes 96 Step 9: Using Toolpath Groups 100 Step 10: Define A New Plane Using Plane Manager 103 Step 11: Import The Operation To The New Plane 107 Step 12: Face And Drill The 3/8" Holes Of The Beveled Face 111 Step 13: Machine The Third Pocket 114 Step 14: Face And Drill The 1/4" Holes Of The Beveled Face 116 Step 15: Change The NC File Names 118 Step 16: Post Process The Toolpaths To Generate The G-Code 119 Step 17: Save Your File 121 Exercise 122 Plane Creation & Indexing 124 Introduction 125 Instructor Demonstration: 126 Step 1: Open The File 127 Step 2: Set The Origin At The Center Bottom Of The Part 127 Step 3: Define A Plane From Geometry 131 Step 4: Select A Machine 137 Step 5: Circle Mill The Hole 139 Step 6: Create A Plane Using From Entity Normal 142 Step 7: Drill The Hole 145 Step 8: Post Process The Toolpaths To Generate The G-Code 148 Step 9: Save Your File 149 Exercise 151 Levels & Viewsheets 152 Introduction 153 Instructor Demonstration Preview: 155 Step 1: Open The File 156 Step 2: Working With Levels 156 Step 3: Working With Viewsheets 167 Step 4: Save Your Mastercam File 180 Exercise 181 Advanced Drilling Toolpath 183 Introduction 184 Instructor Demonstration: 185 Step 1: Open The File 186 Step 2: Advanced Drilling For Deep Holes 186 Step 3: Advanced Drill For Holes With Air Region 195 Step 4: Save Your File 202 Step 5: Post Process The Toolpaths To Generate The G-Code 202 Dynamic Toolpaths 204 Introduction 205 Step 1: Dynamic Mill Radial Chip Thinning (RCT) 205 Step 2: Dynamic Motion Power Cutting 206 2D High Speed Toolpaths (HST) Information 207 2D High Speed Part - Instructor Demonstration: 208 Step 3: Prepare And Orient Model For Machining 209 Step 4: Using The Classic Tool Manager To Create The Tools 209 Step 5: Create The Job Setup 218 Step 6: Use Dynamic Mill With RCT 219 Step 7: Dynamic Mill Power Cutting 228 Step 8: Machine The Left Side Step Using Blend Mill 230 Step 9: Dynamic Mill Using Air Regions 235 Step 10: Machine The Open Pocket Using Automatic Regions 241 Step 11: Machine The Slot Using Slot Mill Toolpath 244 Step 12: Dynamic Mill The Open Step 248 Step 13: Machine The Circular Boss 254 Step 14: Dynamic Mill The Closed Pocket With The Island 258 Step 15: Dynamic Rest Mill The Inside Corners 264 Step 16: Finish The Open Pocket Walls Using Contour 270 Step 17: Finish The Closed Chain Walls Using Contour 275 Step 18: Save Your File 278 2D High Speed Part - Instructor Demonstration 280 Step 19: Open The File 281 Step 20: Set The Stock In The Stock Setup: 281 Step 21: Machine Half Of The Outside Profile 281 Step 22: Machine The Top Of The Outside Profile 284 Step 23: Machine The Right Side Open Step 284 Step 24: Machine The Left Side Open Step 285 Step 25: Machine The Top Open Step 285 Step 26: Machine The Open Step At An Angle 286 Step 27: Machine The Pocket With The Island 287 Step 28: Machine The Walls 288 Step 29: Backplot And Verify The Toolpaths 288 2D HST Toolpaths 289 Introduction 290 Instructor Demonstration: 291 Part Drawing 292 2D High Speed Toolpaths (HST) Information 293 Step 1: Create The Stock Using Bounding Box 294 Step 2: Create A Point At The Top Center Of The Part 296 Step 3: Save The Part 297 Step 4: Open The Vise And Merge The Part 297 Step 5: Move The Origin To The Point 303 Step 6: Save Your File 304 Step 7: Create The Job Setup 304 Step 8: Facing Toolpath 306 Step 9: Dynamic Mill To Machine The Outside 309 Step 10: Dynamic Mill To Remove The Inside Material 318 Step 11: Dynamic Mill The Closed Pocket 323 Step 12: Peel Mill To Machine The Inside Center Boss 327 Step 13: Dynamic Rest Mill The Inside Corners 333 Step 14: Finish The Walls Using Contour 339 Step 15: Chamfer The Sharp Edges - Model Chamfer 344 Step 16: Post Process The Toolpaths To Generate The G-Code 349 Step 17: Save Your File 350 Exercise #1 352 352 Horizontal Machining 353 Introduction 354 Instructor Demonstration 356 Step 1: Setup Multiple Stock Using Stock Model 357 Step 2: Set The Stock In The Stock Model 357 Step 3: Setup The Machining Plane At B0 361 Step 4: Rough Out The Part Using High Speed Dynamic Mill 363 Step 5: Chamfer Drill & Drill The 3/8" Diameter Holes 367 Step 6: Circle Mill The Large Diameter Hole 369 Step 7: Contour The 0.0625 Radius Channel 371 Step 8: Setup The Machining Plane At B90 372 Step 9: Chamfer Drill & Drill The 31/64" Diameter Hole 374 Step 10: Setup The Machining Plane At B270 375 Step 11: Spot Drill & Drill The 31/64" Diameter Hole 377 Step 12: Machine The Rest Of The Parts - Transform Rotate 382 Step 13: Post Process The Toolpaths 385 Step 14: Save The Mastercam File 388 Exercise #1 389 Axis - Axis Substitution 390 Introduction 391 Axis -Axis Substitution - Instructor Demonstration: 395 Step 1: Create The Job Setup 396 Step 2: Dynamic Mill - Axis Substitution 396 Step 3: Create Another Toolpath Group 404 Step 4: Finish The Teeth - Rolldie Toolpath 405 Step 5: Create Another Toolpath Group 410 Step 6: Drill The Holes 411 Step 7: Define A New Tool Plane To Machine One Slot 418 Step 8: Machine The Slot In The New Plane 423 Step 9: Transform - Rotate To Machine The Other Slots 430 Step 10: Contour The Letters 435 Step 11: Post The File To Generate The NC Code 440 Step 12: Save The Updated MCAM File 440 Surface Machining 441 Introduction 442 Mastercam® Surface Toolpath Work Flow: 444 Toolpath Descriptions 449 Instructor Demonstration 452 Geometry Creation Tips 453 Part - Single Surface Machining 454 Step 1: Plane Settings 454 Step 2: Spline From Curves 454 Step 3: Revolved Surface 455 Step 4: Move The Wireframe On Level 100 457 Step 5: Prepare The Part For Machining 457 Step 6: Setup The Stock 460 Step 7: Surface Rough Pocket 461 Step 8: Finish The Part Using Surface Finish Scallop 466 Part - Multiple Surface Model 469 Step 9: Setup The Stock 470 Step 10: Surface Rough Pocket 471 Step 11: Surface Finish Parallel 476 Step 12: Create A Loft/Ruled Surface 479 Step 13: Finish The Surface Using Finish Flowline 483 Step 14: Create A Sweep Surface 487 Step 15: Finish The Sweep Surface - Finish Flowline 494 OptiRough Toolpath 500 Introduction 501 Instructor Demonstration: 502 Part Drawing 503 Toolpath Information 504 Step 1: Create The Job Setup 505 Step 2: Stock Model 506 Step 3: Dynamic OptiRough Toolpath 507 Step 4: 2D HS Area Mill Automatic Regions 514 Step 5: Finish The Walls Using Contour 517 Step 6: Post Process The Toolpaths 521 Step 7: Save Your File 521 Exercise #1 522 Exercise #2 523 Trim Toolpath 524 Introduction 525 Instructor Demonstration: 526 Step 1: Open The File 527 Step 2: Make Level Invisible 527 Step 3: Set The Stock 527 Step 4: Machine The Open Pocket Using Facing 530 Step 5: Trim Toolpath 534 Step 6: Save Your File 537 Wireframe Toolpaths 538 Introduction 539 Instructor Demonstration: 540 Step 1: Create The 2D Swept Wireframe 541 Step 2: Wireframe Toolpath - 2D Swept 545 Step 3: Backplot The 2D Swept Toolpath 549 Step 4: Verify The 2D Swept Toolpath 549 Step 5: Post Process The Toolpaths 550 Step 6: Save Your File 550 Step 7: Create The Ruled Wireframe 551 Step 8: Wireframe Toolpath - Ruled 554 Step 9: Post Process The Toolpaths 563 Step 10: Save Your File 563 Solids Model Prep 564 Introduction: 565 Instructor Demonstration: 566 Solids Model Prep Drawing 567 10 Undercut & Custom Tool n Step 3: Undercut Machining -Contour Toolpath The Render Imported Tool geometry should look as shown Note: You can display the Render Imported Tool used for Backplot or the Render Mastercam Tool that will be used to calculate the toolpath You can Zoom in and Zoom out to check the tool geometry in either state 695 Undercut & Custom Tool n n n n n Step 3: Undercut Machining -Contour Toolpath Change the thickness to 0.25 as shown Select the Next button In the Finalize Properties set the SFM to 100 and press Enter The Feed rate, Plunge rate, Retract rate should be changed as needed Select the Finish button Note: These are just suggested feeds and speeds They depend on the machine, tool material and part material Change them as needed 696 Undercut & Custom Tool Step 3: Undercut Machining -Contour Toolpath 3.2 Cut Parameters n In the Cut Parameters, change the Compensation type to Wear 3.3 Depth Cuts n n Enable Depth cuts Set the Max rough step to 0.125 as shown 697 Undercut & Custom Tool Step 3: Undercut Machining -Contour Toolpath 3.4 Lead In/Out n Set the Lead In/Out parameters as shown 3.5 Linking n Set the parameters as shown 698 Undercut & Custom Tool n Step 3: Undercut Machining -Contour Toolpath Select the OK button to exit 2D Toolpath - Contour 3.6 Backplot the toolpath n The toolpath should look as shown 3.7 Verify the toolpath n n Rotate the part as needed The part should appear as shown 699 Undercut & Custom Tool Step 3: Undercut Machining -Contour Toolpath 3.8 Compare n In the Verify tab, click on the Compare icon n Click on the Refresh button to run the compare n The part should look as shown 700 Undercut & Custom Tool Step 4: Create A Tool Library STEP 4: CREATE A TOOL LIBRARY 4.1 Tool Manager Toolpaths n In the Utilities group, select the Tool Manager as shown n The Slot Mill will be listed in the part section as shown 701 Undercut & Custom Tool Step 4: Create A Tool Library n To create a new library, in the Library section, select Create a new library button as shown n Enter the library name MyCustomTool and select the Save button 702 Undercut & Custom Tool n Step 4: Create A Tool Library To add the tool to the new library, select it first and then click on the down arrow as shown Note: The tool is added under the Assemblies tab Any other tool that you add from Mastercam existing libraries will be listed under Tools n Select the OK button and Yes to Save changes to your current library 703 Undercut & Custom Tool Step 5: Find The Tool In The New Library STEP 5: FIND THE TOOL IN THE NEW LIBRARY 5.1 Open the Part Resources - Download the file from www.EMASTERCAM.COM/TRAININGFILES/ n Find and open the UndercutExercise.mcam file STEP 6: UNDERCUT MACHINING -CONTOUR TOOLPATH Toolpaths n From the 2D group, select Contour n In the Solid Chaining, select the Edges button as shown Hold down the Shift key and select the edge on the solid as shown Select the OK button to finish the n n selection 704 Undercut & Custom Tool Step 6: Undercut Machining -Contour Toolpath 6.1 Tool n Click on the Select library tool button n Select the New Library button to open the MyCustomTool n Find MyCustomTool.TOOLDB and select the Open button 705 Undercut & Custom Tool n n n Step 6: Undercut Machining -Contour Toolpath Disable Filter Active and make sure that in the Display mode Both is enabled Select the tool as shown Select the OK button to continue 6.2 Tool n The Tool page parameters should look as shown 706 Undercut & Custom Tool Step 6: Undercut Machining -Contour Toolpath 6.3 Cut Parameters n In the Cut Parameters, change the Compensation type to Wear 6.4 Depth Cuts n n Enable Depth cuts Set the Max rough step to 0.125 as shown 707 Undercut & Custom Tool Step 6: Undercut Machining -Contour Toolpath 6.5 Lead In/Out n Set the Lead In/Out parameters as shown 6.6 Linking n Set the parameters as shown 708 Undercut & Custom Tool n Step 7: Save Your File Select the OK button to exit 2D Toolpath - Contour 6.7 Backplot the toolpath n The toolpath should look as shown 6.8 Verify the toolpath n n Rotate the part as needed The part should appear as shown STEP 7: SAVE YOUR FILE n Your file will be saved with the Mastercam toolpath data stored inside the file SUMMARY: In this lesson, you learn how to machine an undercut You will learn how to create in Mastercam a Slot Mill tool from a STP file that was downloaded from www.machiningcloud.com You will save the custom tool as an assembly in a new tool library created in the Classic Tool Manager After completing this tutorial and the practice exercises that follow you should be able to: n n n n Create an undercut toolpath using Contour toolpath Create a custom tool from a STP file Save the tool into a new library Find the tool from the new library and use it for another part 709