Mastercam Version 9 SolidsTutorial - Part 4 doc

Designing a Connecting Rod Mastercam Version 9 Solids Tutorial 71 4 Designing a Connecting Rod In this chapter, you will use existing wireframe geometry consisting of lines and arcs to generate the following solid model of a connecting rod for a lawnmower. You will build on skills that you learned in previous chapters and learn new skills, such as:  Splitting the draft angle at the center line of the part  Creating a 180-degree revolved boss  Combining operations involving multiple chains  Chamfering solid edges  Analyzing solid properties Exercise 1 – Creating the connecting rod body In this exercise, you will perform a base operation to define the body of the connecting rod. To do so, you will extrude a chain of curves in both the positive direction (indicated by the direction arrow) and the opposite, or negative, direction. In the same operation, you will apply a 5-degree draft angle inward in both directions from the mid-plane of the part (defined by the chain of curves). Chapter 4 72 Mastercam Version 9 Solids Tutorial Chaining the geometry 1. Open rod-wireframe-mm.mc9 from your working folder. 2. Choose the Color button in the Secondary Menu. 3. Set Current color to 7 (light gray) then choose OK to close the Color dialog box. 4. Choose Main Menu, Solids, Extrude. 5. Select the red geometry at the position shown in the following picture. 6. Choose Done to end the selection. 7. Choose Done to accept the default extrusion direction. The Extrude Chain dialog box opens. Note: The extrusion direction does not matter because you will extrude the selected chain in both directions. Setting extrusion parameters When you extrude a solid in both directions and apply draft to the walls of the solid, you have the option to apply the draft in one continuous direction or to split the draft at the defining curves. In this example, you will split the draft angle inward from the defining curves. 1. Enter Con Rod Body for the operation name. 2. Select the Draft check box. 3. Clear the Outward check box. The draft angle will be applied inward along the extrusion direction. 4. Enter 5.0 for Angle. Designing a Connecting Rod Mastercam Version 9 Solids Tutorial 73 5. In the Distance field, type 10.5 and press [Enter]. 6. Select Both directions. 7. Select Split draft. The following pictures show the difference in results with split draft turned on and off. Split Draft On Split Draft Off 8. Check your settings against the following picture. Make any necessary adjustments. 9. Choose OK to create the solid. 10. Press [Alt+S] to turn on shading. Your part should look like the following picture. Chapter 4 74 Mastercam Version 9 Solids Tutorial 11. Save the file as rod-solid-mm.mc9 in your working folder. Exercise 2 – Creating the ends of the connecting rod In this exercise, you will add material to the ends of the connecting rod. You will do this by revolving chains of curves to form a boss at each end. One boss will be a full circle; the other will be 180 degrees. Creating a 360-degree revolved boss 1. Press [Alt+S] to turn off shading. 2. Choose Main Menu, Solids, Revolve. 3. Select the magenta geometry to revolve at the position shown in the following picture. 4. Choose Done to end the selection. Designing a Connecting Rod Mastercam Version 9 Solids Tutorial 75 5. To define the rotation axis, select the dark gray dashed line shown in the following picture. 6. Choose Done to accept the rotation direction. The Revolve Chain dialog box opens. Note: The rotation direction does not matter since you are revolving the chain 360 degrees. 7. Enter Revolve Boss 360 for the operation name. 8. Choose Add Boss to Body. 9. Check your settings against the following picture. Make any necessary adjustments. Chapter 4 76 Mastercam Version 9 Solids Tutorial 10. Choose OK to create the boss. 11. Turn on shading. Your part should look like the following picture. Designing a Connecting Rod Mastercam Version 9 Solids Tutorial 77 Creating a 180-degree revolved boss 1. Turn off shading. 2. From the Solids menu, choose Revolve. 3. Select the magenta geometry to revolve at the position shown in the following picture. 4. Choose Done to end the selection. 5. To define the rotation axis, select the bottom of the dark gray dashed line shown in the following picture. Note: Where you select the line affects the rotation direction. 6. The direction arrow indicates the sweep of the arc that the revolved boss will make. It should point toward the body of the connecting rod. If it does not, choose Reverse. Chapter 4 78 Mastercam Version 9 Solids Tutorial Note: If the sweep arc does not intersect the body of the connecting rod, the following error message displays. This message indicates that you are attempting to create a separate solid body, which is not allowed for an Add Boss operation. 7. Choose Done. The Revolve Chain dialog box opens. 8. Enter Revolve Boss 180 for the operation name. 9. Enter 180.0 for End angle. 10. Check your settings against the following picture. Make any necessary adjustments. Designing a Connecting Rod Mastercam Version 9 Solids Tutorial 79 11. Choose OK to create the boss. 12. Turn on shading. Your part should look like the following picture. Exercise 3 – Creating connecting tabs When you perform a boss or cut operation (Extrude, Revolve, or Sweep) on multiple chains of curves that are not nested within one another, you have the option to define a separate operation for each chain of curves or to combine the resulting operations into one. In general, you want to combine operations for features that will be treated the same; for example, a group of cuts that will always be the same depth. If the features may require different parameters at some point during the design process, you should leave them as separate operations. Note: The selection of nested chains results in one operation, in which the nested chain defines an island. In this exercise, you will create connecting tabs at the ends of the 180- degree boss. To do so, you will extrude two chains of curves as 24 millimeter bosses on the solid. The tabs will use the same parameters; therefore, you will combine the resulting operations into one. Chaining the geometry 1. Turn off shading. 2. Zoom in on the 180-degree boss. Chapter 4 80 Mastercam Version 9 Solids Tutorial 3. From the Solids menu, choose Extrude. 4. Select the brown geometry at the two positions shown in the following picture. 5. Choose Done. 6. Look at the direction arrow on each chain to be sure it points toward the body of the connecting rod. If both arrows point in the correct direction, continue with step 7. Otherwise, take one of the following actions:  If both arrows point in the wrong direction, choose Reverse It.  If one arrow points in the wrong direction, choose Reverse One, then select the chain whose direction arrow points in the wrong direction. 7. When both direction arrows point in the correct direction, choose Done. The Extrude Chain dialog box opens. Setting extrusion parameters 1. Enter Con Tabs for the operation name. 2. Select Add Boss. 3. Select Combine Ops. 4. Clear the Draft check box. 5. Enter 24 for Distance. 6. Clear the Both directions check box. [...]... selection 6 Enter Fillet 2 4- millimeter for the operation name Mastercam Version 9 Solids Tutorial 99 Chapter 4 7 Enter 24 for Radius 8 Select Propagate along tangencies 9 Check your settings against the following picture Make any necessary adjustments 10 Choose OK to fillet the selected edges Mastercam propagates the fillets to tangent edges 11 Unzoom and turn on shading Your part should look like the... Angle 4 Choose Extend by specified distance 5 Enter 3.6 for Distance 6 Check your settings against the following picture Make any necessary adjustments 88 Mastercam Version 9 Solids Tutorial Designing a Connecting Rod 7 Choose OK to cut the body of the connecting rod 8 Your part should look like the following picture 9 Unzoom the screen display 10 Save the part Mastercam Version 9 Solids Tutorial 89 Chapter... following picture Mastercam Version 9 Solids Tutorial 103 Chapter 4 9 8 7 10 12 11 8 Unzoom and check your selections When all twelve edges are selected, choose Done The Fillet Parameters dialog box opens 9 Enter Fillet 3-millimeter for the operation name 10 Enter 3 for Radius 11 Check your settings against the following picture Make any necessary adjustments 1 04 Mastercam Version 9 Solids Tutorial... following picture 1 2 4 3 6 Toggle FromBack to Y on the Pick Solid Entity menu Mastercam Version 9 Solids Tutorial 105 Chapter 4 7 Select the faces shown at positions 3 and 4 in the previous picture 8 Choose Done to end the selection The Fillet Parameters dialog box opens 9 Enter Fillet 1 .44 -millimeter for the operation name 10 Enter 1 .44 for Radius 11 Check your settings against the following picture Make... the selected edges 98 Mastercam Version 9 Solids Tutorial Designing a Connecting Rod 14 Turn on shading Your part should look like the following picture Notice that the center line of the part is now rounded Filleting edges using a 2 4- millimeter radius 1 Turn off shading 2 Zoom in on the intersection of the body of the rod and the 360degree boss 3 Choose Fillet from the Solids menu 4 Select the two edges... chamfer the edges of the internal cylinder of the 180-degree boss You will chamfer the edges using one distance, which refers to the length of the 45 -degree chamfer The chamfer will be positioned an equal distance from the selected edge on the adjacent faces Distance 1 Distance 1 Mastercam Version 9 Solids Tutorial 91 Chapter 4 1 Zoom in on the 180-degree boss 2 Choose Main Menu, Solids, Chamfer The... name 8 Enter 0.72 for Distance 1 9 Enter 2 .4 for Distance 2 10 Check your settings against the following picture Make any necessary adjustments 94 Mastercam Version 9 Solids Tutorial Designing a Connecting Rod 11 Choose OK to chamfer the edges of the selected faces 12 Turn on shading Your part should look like the following picture 13 Fit the geometry to the screen 14 Save the file Exercise 7 – Creating... 2 Toggle Edges to Y and all other Yes/No options to N 96 Mastercam Version 9 Solids Tutorial Designing a Connecting Rod 3 Zoom in on the 180-degree boss 4 Select the edges shown at positions 1 through 4 in the following picture Note: In the picture, a segment of each edge has been thickened to help you identify the correct edge to select 2 1 3 4 5 Unzoom from the boss, and zoom in on the body of the... picture 5 6 7 Unzoom from the body of the rod, and zoom in on the 360-degree boss 8 Select the edge shown at position 7 in the following picture Mastercam Version 9 Solids Tutorial 97 Chapter 4 7 9 Unzoom and check your selections When all seven edges are selected, choose Done The Fillet Parameters dialog box opens 10 Enter Fillet 12-millimeter for the operation name 11 Enter 12 for Radius 12 Check your... to chamfer Distance 2 is calculated with respect to the non-selected adjacent face Selected (reference) face Dist 1 Distance 2 1 Turn off shading Mastercam Version 9 Solids Tutorial 93 Chapter 4 2 Unzoom from the 180-degree boss, then zoom in on the 360degree boss 3 Choose 2 Distances from the Chamfer menu The Pick Solid Entity menu displays 4 Toggle Faces to Y and all other Yes/No options to N 5 Select . operation, you will apply a 5-degree draft angle inward in both directions from the mid-plane of the part (defined by the chain of curves). Chapter 4 72 Mastercam Version 9 Solids Tutorial Chaining. necessary adjustments. 9. Choose OK to create the solid. 10. Press [Alt+S] to turn on shading. Your part should look like the following picture. Chapter 4 74 Mastercam Version 9 Solids Tutorial. Turn off shading. 2. Zoom in on the 180-degree boss. Chapter 4 80 Mastercam Version 9 Solids Tutorial 3. From the Solids menu, choose Extrude. 4. Select the brown geometry at the two positions