1. Welcome Mill Lesson 15 – Part-2 Computer Aided Manufacturing Using Mastercam

2. Mill Lesson 15 The Process Toolpath Creation Toolpath Creation TASK 1: Setting the environment TASK 1: Setting the environment TASK 2: Open existing file from the multimedia CD TASK 2: Open existing file from the multimedia CD TASK 3: Define the rough stock using stock setup TASK 3: Define the rough stock using stock setup TASK 4: Rough mold core using surface high speed (core roughing) TASK 4: Rough mold core using surface high speed (core roughing) TASK 5: Finish profile surfaces using surface high speed (waterline) TASK 5: Finish profile surfaces using surface high speed (waterline) TASK 6: Finish all remaining stock using surface finish leftover TASK 6: Finish all remaining stock using surface finish leftover TASK 7: Verify the toolpath and compare to STL file TASK 7: Verify the toolpath and compare to STL file TASK 8: Save the updated MCX file TASK 8: Save the updated MCX file TASK 9:Post and create the CNC code file TASK 9:Post and create the CNC code file TASK 10:Create ActiveReport TASK 10:Create ActiveReport

3. Demonstration of Mastercam? 1.Verify Lesson 15

4. Toolpaths>Surface High Speed… In this task you will use a 1.0 diameter end mill with a 0 corner radius to rough the part In this task you will use a 1.0 diameter end mill with a 0 corner radius to rough the part Stock to leave on drive is set to 0.010 Stock to leave on drive is set to 0.010 Rough Out Mold Core Using Surface High Speed

5. The Surface High Speed Toolpaths are a set of machining strategies that are specially designed to produce the smoothest, most efficient tool motions when machining surface models or solid faces. Mastercam uses two main techniques to achieve this: The Surface High Speed Toolpaths are a set of machining strategies that are specially designed to produce the smoothest, most efficient tool motions when machining surface models or solid faces. Mastercam uses two main techniques to achieve this: Each cutting pass can be configured with advanced smoothing techniques to reduce the impact of corners, sharp angles, and other discontinuities so that you can maintain a constant load on the tool. Each cutting pass can be configured with advanced smoothing techniques to reduce the impact of corners, sharp angles, and other discontinuities so that you can maintain a constant load on the tool. An advanced suite of linking tools lets you optimize the transitions between cutting passes and the lead in/out to each cutting pass. An advanced suite of linking tools lets you optimize the transitions between cutting passes and the lead in/out to each cutting pass. Rough Out Mold Core Using Surface High Speed

6. Core Roughing Toolpaths are designed for machining cores which can be approached from the outside. Core Roughing Toolpaths are designed for machining cores which can be approached from the outside. They minimize the need for helical ramp moves or full-width cutting. They minimize the need for helical ramp moves or full-width cutting. Core roughing toolpaths are generated from a set of surface profiles that describe the shape of your surfaces at different Z heights, plus a set of offset profiles that let you rough out stock as you approach the part from the outside. Core roughing toolpaths are generated from a set of surface profiles that describe the shape of your surfaces at different Z heights, plus a set of offset profiles that let you rough out stock as you approach the part from the outside. Rough Out Mold Core Using Surface High Speed

7. Rough Out Mold Core - Drive Surfaces The surfaces, solid faces, solid bodies, or CAD files that will be cut. You are first prompted to Select Drive surfaces, select all of the entities on the screen.You are first prompted to Select Drive surfaces, select all of the entities on the screen.

8. Rough Out Mold Core Containment Curve Cplane - Chains only entities that are parallel to the current construction plane and at the same Z depth as the first entity you chain. Cplane - Chains only entities that are parallel to the current construction plane and at the same Z depth as the first entity you chain.

9. Tool Parameters By clicking on the tool on this page, you will automatically load the values for FPT (feed per tooth) and SFM (surface feet per minute). By clicking on the tool on this page, you will automatically load the values for FPT (feed per tooth) and SFM (surface feet per minute). This is because we selected From Material on the Tool Settings tab of the Machine Group Properties. This is because we selected From Material on the Tool Settings tab of the Machine Group Properties.

10. Tool Parameters Right Click on the tool, select Edit Tool. Then go to the Parameters tab. Right Click on the tool, select Edit Tool. Then go to the Parameters tab. % of matl cutting speed allows the user a further adjustment of SFM based on the particular tool. % of matl cutting speed allows the user a further adjustment of SFM based on the particular tool. % of matl feed per tooth allows the user a further adjustment of FPT based on the particular tool. % of matl feed per tooth allows the user a further adjustment of FPT based on the particular tool.

11. Smoothing activates the toolpath smoothing feature, which replaces sharp corners with arcs for faster and smoother transitions in tool direction. Smoothing activates the toolpath smoothing feature, which replaces sharp corners with arcs for faster and smoother transitions in tool direction. Max radius Enter the radius of the largest arc that you will allow Mastercam to insert to replace a corner. Larger arcs will result in a smoother toolpath, but with greater deviation from the originally programmed toolpath. Max radius Enter the radius of the largest arc that you will allow Mastercam to insert to replace a corner. Larger arcs will result in a smoother toolpath, but with greater deviation from the originally programmed toolpath. Cut Parameters

12. Use this page to configure the entry move that the tool will make as it transitions to new Z levels. Use this page to configure the entry move that the tool will make as it transitions to new Z levels. You can choose to create either a ramp entry, or helical entry move. The entry ramp will be a profile ramp that follows the contour of the cutting pass for a smoother transition into the cut. You can choose to create either a ramp entry, or helical entry move. The entry ramp will be a profile ramp that follows the contour of the cutting pass for a smoother transition into the cut. Radius Enter the radius of the entry helix. If the profile is too small for a helix ramp of this diameter, Mastercam will create a profile ramp instead. Radius Enter the radius of the entry helix. If the profile is too small for a helix ramp of this diameter, Mastercam will create a profile ramp instead. Transitions

13. On the Steep/Shallow page set the Minimum Depth of the cut to 0.1 this is the top of stock. On the Steep/Shallow page set the Minimum Depth of the cut to 0.1 this is the top of stock. Right click in the Maximum Depth then select Z = Z coordinate of a point. Select the Z at the top of the mold base as shown below left: Right click in the Maximum Depth then select Z = Z coordinate of a point. Select the Z at the top of the mold base as shown below left: Steep/Shallow

14. Arc Filter Tolerance The Profile tolerance represents the maximum distance that the outermost profile of the smoothed toolpath will deviate from the original toolpath. The Profile tolerance represents the maximum distance that the outermost profile of the smoothed toolpath will deviate from the original toolpath. The Offset tolerance represents the maximum distance that any other profile of the smoothed toolpath will deviate from the original toolpath. The Offset tolerance represents the maximum distance that any other profile of the smoothed toolpath will deviate from the original toolpath. Total tolerance displays the sum of the filter tolerance and cut tolerance. Total tolerance displays the sum of the filter tolerance and cut tolerance.

15. Arc Filter Tolerance - Refine Toolpath Use this dialog box to refine Mastercam's 3D surface and high speed surface toolpaths, reducing machining time and improving machined surface quality. Use this dialog box to refine Mastercam's 3D surface and high speed surface toolpaths, reducing machining time and improving machined surface quality. Mastercam uses the values you enter here to convert the toolpath— originally created using G1, G2, G3 motions—to a refined set of "smoothed" G1 motions wherever possible, and within the tolerances you specify. Mastercam uses the values you enter here to convert the toolpath— originally created using G1, G2, G3 motions—to a refined set of "smoothed" G1 motions wherever possible, and within the tolerances you specify.

16. Demonstration of Mastercam? 1.Verify Lesson 15 – First Operation