Mastercam Version 9 SolidsTutorial - Part 5 pdf

Designing a Forging Die Mastercam Version 9 Solids Tutorial 111 5 Designing a Forging Die In this chapter, you will build a solid model of a steel forging die. The shape of the forging die will be defined by the connecting rod that you created in Chapter 4. Note: A backup file containing the connecting rod was provided with the other tutorial parts in case you did not complete Chapter 4. You will build on skills that you learned in previous chapters and learn new skills, such as:  Creating multiple solids in the same file  Creating a primitive solid  Suppressing solid operations  Removing one solid volume from another  Scaling a solid body Chapter 5 112 Mastercam Version 9 Solids Tutorial Exercise 1 – Setting visible levels and display lines 1. Open rod-solid-mm.mc9 from your working folder. Note: If you did not complete Chapter 4, open rod-solid-backup- mm.mc9. 2. Choose the Level button on the Secondary Menu. 3. Click in the Visible column for Level 3 to make it visible. This level contains a reference point, which you will use in a later exercise. Note: Levels 1 and 2 should already be visible. 4. Choose OK to close the Level Manager. 5. Choose Main Menu, Screen, Surf disp, Solids. The Solids Display dialog box opens. 6. To turn off the display of hidden lines, select Hidden and clear the Show Hidden Lines check box, as shown in the following picture. Designing a Forging Die Mastercam Version 9 Solids Tutorial 113 7. Choose OK. Your part should look like the following picture. Notice the reference point located below the forging die. Reference point 8. Save the file as forging die-mm.mc9 in your working folder. Chapter 5 114 Mastercam Version 9 Solids Tutorial Exercise 2 – Creating the die stock In this exercise, you will create a block-shaped solid to represent the die stock for the forging die. You will use the Primitives function to create the solid block. This function lets you quickly create solids in simple, predefined shapes. Unlike the solids that you have created so far, a primitive solid is not defined by curve geometry. Creating a primitive block Before creating the block, you will change the construction color to distinguish the block from the connecting rod, which was constructed using light gray. 1. Choose the Color button on the Secondary Menu. 2. Set Current color to 10 (light green) then choose OK to close the Color dialog box. 3. Choose Main Menu, Solids, Next menu, Primitives. The Primitives menu displays. 4. Choose Block. Mastercam creates a green block at the end of the rod with the 180-degree boss. 5. Choose the Cplane-3D toolbar button. 6. Press [Alt+S] to turn on shading. 7. The center of the block’s bottom face is positioned at the system origin. Press [F9] to view the coordinate axes. Your part should look like the following picture. Designing a Forging Die Mastercam Version 9 Solids Tutorial 115 Setting the block’s position 1. Press [Alt+S] to turn off shading and [F9] to clear coordinate axes. 2. Choose Base Point from the Block menu. 3. Choose Point from the Point Entry menu. 4. Select the reference point located below the forging die. The center of the block’s bottom face is now positioned at this point. Chapter 5 116 Mastercam Version 9 Solids Tutorial Setting the block’s dimensions The prompt area reports the block’s dimensions. The height, length, and width are currently set to 20 (millimeters). 1. Choose Height. 2. In the prompt area, type 24 and press [Enter]. 3. Choose Length. 4. In the prompt area, type 150 and press [Enter]. 5. Choose Width. 6. In the prompt area, type 250 and press [Enter]. The connecting rod now fits within the block, as shown in the following picture. 7. Choose the Gview-Front toolbar button. The top face of the die stock bisects the forging die. 8. Return to Isometric view. Designing a Forging Die Mastercam Version 9 Solids Tutorial 117 9. Choose Done to complete the block and exit the Block menu. 10. Press [Alt+Y] to open the Solids Manager. Notice that there are now two solids contained in this file. The first one is the connecting rod, which you created in Chapter 4. The second one is the die stock. Connecting Rod Die Stock Exercise 3 – Removing the connecting rod from the die stock Boolean operations combine multiple solids for the purpose of adding them together, subtracting them from one another, or finding the common, or overlapping, regions between them. In this exercise, you will perform a Boolean Remove operation to cut the shape of the connecting rod from the die stock to form the forging die. Suppressing an operation Before performing the Boolean operation, you will suppress the two cut operations that define the bolt holes and spot faces because these features represent voids, which cannot be forged. Chapter 5 118 Mastercam Version 9 Solids Tutorial 1. Right-click on the Bolt Holes operation listed under the first solid. 2. Choose Suppress. The menu closes, and the operation symbol in the Solids Manager turns gray. 3. Right-click on the Bolt Holes operation again. There is a check mark next to the Suppress option, as shown in the following picture. 4. Click outside the menu to close it. 5. Repeat steps 1 and 2 to suppress the Spot Faces operation. 6. Choose OK to close the Solids Manager. Your part should look like the following picture. Notice that the bolt holes and spot faces no longer display in the model. Designing a Forging Die Mastercam Version 9 Solids Tutorial 119 Performing a Boolean operation When performing a Boolean Remove operation, you must define a target body and one or more tool bodies. The target body is the solid that remains after you perform the operation. The tool bodies are the solids whose material is removed from the target body. 1. Turn on shading. 2. Choose Main Menu, Solids, Boolean, Remove. The Pick Solid Entity menu displays. 3. Toggle Solids to Y and all other Yes/No options to N. 4. The prompt area instructs you to select the target body. Select the green die stock. 5. The prompt area instructs you to select a tool body. Select the gray connecting rod. 6. Choose Done to create the forging die. 7. Make Level 2, which contains the wireframe geometry, invisible. Tip: Choose Level from the Secondary Menu, click in the Visible column for Level 2 to remove the check mark, then choose OK. Chapter 5 120 Mastercam Version 9 Solids Tutorial 8. Choose the Screen-Repaint toolbar button to clean up the display. Your part should look like the following picture. 9. Press [Alt+Y] to open the Solids Manager. 10. Expand the operation history. The list now contains one solid defined by two operations. The Block (die stock) operation is the target body and base operation. The Boolean Remove operation contains the operation history of the tool body (connecting rod). [...]... Cuts operation (if necessary) and doubleclick on Parameters 2 Enter 5 for Distance and choose OK 3 Choose Regen All to incorporate the new distance into the model 4 Choose OK to close the Solids Manager Your part should look like the following picture Mastercam Version 9 Solids Tutorial 121 Chapter 5 This island now stands taller Exercise 5 – Scaling the forging die In this exercise, you will increase... solid model of a forging die for the connecting rod that you created in Chapter 4 In the next chapter, you will create a lofted solid for a windshield on a toy race car Mastercam Version 9 Solids Tutorial 123 Chapter 5 124 Mastercam Version 9 Solids Tutorial ... opens 5 Enter 1.02 for Scale factor 6 Check your settings against the following picture Make any necessary adjustments 122 Mastercam Version 9 Solids Tutorial Designing a Forging Die 7 Choose OK to enlarge the forging die 8 Choose the Screen-Clear Colors toolbar button to return the solid to its construction color Note: You will learn about this function in Exercise 1 of the following chapter 9 Press .  Scaling a solid body Chapter 5 112 Mastercam Version 9 Solids Tutorial Exercise 1 – Setting visible levels and display lines 1. Open rod-solid-mm.mc9 from your working folder. Note:. as forging die-mm.mc9 in your working folder. Chapter 5 114 Mastercam Version 9 Solids Tutorial Exercise 2 – Creating the die stock In this exercise, you will create a block-shaped solid. OK. Chapter 5 120 Mastercam Version 9 Solids Tutorial 8. Choose the Screen-Repaint toolbar button to clean up the display. Your part should look like the following picture. 9. Press [Alt+Y]