This book is to be distributed freely and may be copied or printed as needed. Copyright © 2007 Masterwork Solutions, Inc. 13875 Creekview Dr SW Port Orchard, WA 98367 http://www.masterworksolutions.com All Rights Reserved The information contained in this document is subject to change without notice and should not be considered commitments by Masterwork Solutions, Inc. No material may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of Masterwork Solutions, Inc. The documents discussed in this document are furnished under license and may be used or copied only in accordance with the terms of this license. All warranties given by Masterwork Solutions, Inc. are set forth in this document and may not be ammended or modified. As a condition to your use of this product, the user agrees to accept the limited warranty, disclaimer, and other terms and conditions set forth. The Masterwork Solutions, Inc. logo is the trademark of Masterwork Solutions, Inc. Other Product and Company names mentioned herein are the trademarks of their respective owners. Mastercam is a registered trademark of CNC. Windows 95,98,2000 and XP are registered trademarks of Microsoft Corporation. Companies, names, and data used in examples herein are fictitious unless otherwise noted. Complying with all applicable copyright laws is the responsibility of the user. All documents are printed in the United States of America.
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Mastercam X2 Surfaces Tutorial
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Contents ■ Shortcut Keys........................................................................................................................................iii ■ Chapter 1: Using Draft Surfaces............................................................................................................1 Section 1: Setup.....................................................................................................................................................................2 Section 2: Geometry.............................................................................................................................................................2 Section 3: Base Flat Boundary Surface...........................................................................................................................2 Section 4: Draft Surface Sides...........................................................................................................................................3 Section 5: Fillet Surfaces.....................................................................................................................................................4 Section 6: Rough Parallel Toolpath.................................................................................................................................7 Section 7: Finish Radial Toolpath..................................................................................................................................10 Section 8: Stock Setup.......................................................................................................................................................13 Section 9: Verify...................................................................................................................................................................14 Section 10: Post Processing.............................................................................................................................................15 ■ Chapter 2: Using Revolved Surfaces..................................................................................................17 Section 1: Setup...................................................................................................................................................................18 Section 2: Geometry..........................................................................................................................................................18 Section 3: Offset the Center Line...................................................................................................................................19 Section 4: Create the Circle.............................................................................................................................................20 Section 5: Fillet.....................................................................................................................................................................21 Section 6: Trimming...........................................................................................................................................................22 Section 7: Chamfer.............................................................................................................................................................24 Section 8: Revolved Surface............................................................................................................................................25 Section 9: Ruled Surface...................................................................................................................................................26 Section 10: Stock Setup....................................................................................................................................................27 Section 11: Rough Toolpath...........................................................................................................................................28 Section 12: Finish Toolpath.............................................................................................................................................31 Section 13: Verify................................................................................................................................................................34 Section 14: Post Processing.............................................................................................................................................35 ■ Chapter 3: Using Swept Surfaces........................................................................................................37 Section 1: Setup...................................................................................................................................................................38 Section 2: Base Rectangle................................................................................................................................................38 Section 3: Wing Spline......................................................................................................................................................39 Section 4: Connecting Geometry..................................................................................................................................39 Section 5: Swept Surface..................................................................................................................................................41 Section 6: Stock Setup.......................................................................................................................................................44 Section 7: Toolpath............................................................................................................................................................45 Section 8: Verify...................................................................................................................................................................48 Section 9: Post Processing...............................................................................................................................................49 This book is to be distributed freely and may be copied or printed as needed. Masterwork Solutions
i
Table Of Contents
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■ Chapter 4: Using Blended Surfaces....................................................................................................51 Section 1: Setup...................................................................................................................................................................52 Section 2: Toolpath Cleanup..........................................................................................................................................52 Section 3: Wing Camber...................................................................................................................................................53 Section 4: Mirror Wing......................................................................................................................................................54 Section 5: Blended Surface..............................................................................................................................................56 Section 6: Scale Wings.......................................................................................................................................................57 Section 7: Translate Wings...............................................................................................................................................58 Section 8: Stock Setup.......................................................................................................................................................59 Section 9: Finish Parallel Toolpath................................................................................................................................60 Section 10: Verify................................................................................................................................................................62 Section 11: Post Processing.............................................................................................................................................63 ■ Chapter 5: Using Loft Surfaces............................................................................................................65 Section 1: Setup...................................................................................................................................................................66 Section 2: Rectangle and Points....................................................................................................................................66 Section 3: Ribs......................................................................................................................................................................68 Section 4: Remove Excess Geometry...........................................................................................................................72 Section 5: Fillet the Ribs....................................................................................................................................................74 Section 6: Mirror the lines................................................................................................................................................75 Section 7: Loft Surface.......................................................................................................................................................76 Section 8: Stock Setup.......................................................................................................................................................77 Section 9: Rough Flowline Toolpath............................................................................................................................78 Section 10: Finish Flowline Toolpath...........................................................................................................................82 Section 11: Verify................................................................................................................................................................85 Section 12: Post Processing.............................................................................................................................................86 ■ Chapter 6: Using Primitives and Multisurface Toolpaths.................................................................89 Section 1: Setup...................................................................................................................................................................90 Section 2: Blade Geometry..............................................................................................................................................90 Section 3: Trim Circles.......................................................................................................................................................92 Section 4: Break Circles.....................................................................................................................................................93 Section 5: Join Lines...........................................................................................................................................................93 Section 6: Create Blade Surface.....................................................................................................................................94 Section 7: Rotate Surface.................................................................................................................................................95 Section 8: Create Primitive Torus..................................................................................................................................96 Section 9: Create Surface to Surface Fillet.................................................................................................................97 Section 10: Create Blades.................................................................................................................................................98 Section 11: Translate..........................................................................................................................................................99 Section 12: Stock Setup..................................................................................................................................................100 Section 13: Rough Parallel Toolpath.........................................................................................................................100 Section 14: Finish Radial Toolpath.............................................................................................................................103 Section 15: Verify..............................................................................................................................................................105 Section 16: Post Processing..........................................................................................................................................106 This book is to be distributed freely and may be copied or printed as needed.
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Masterwork Solutions
Mastercam X2 Surfaces Tutorial
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Shortcut Keys About Mastercam X2 Analyze
ALT + V F4
Auto Save Parameters
ALT + A
Copy
CTRL + C
Cut
CTRL + X
Delete
F5
Drafting Settings
ALT + D
Exit
ALT + F4
Fit Screen
ALT + F1
Grid Settings
ALT + G
Gview Top
ALT + 1
Gview Front
ALT + 2
Gview Back
ALT + 3
Gview Bottom
ALT + 4
Gview Right
ALT + 5
Gview Left
ALT + 6
Gview Isometric
ALT + 7
Help
ALT + H
Hide Entities
ALT + E
Level Manager
ALT + Z
Mastercam X2 Configuration Previous Gview Paste
ALT + F8 ALT + P CTRL + V
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iii
Shortcut Keys
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Redo
CTRL + Y
Regenerated On Screen Entities
SHIFT + CTRL + R
Repaint Screen
F3
Run User Application (C-Hook)
ALT + C
Select All
CTRL + A
Set Attributes From Selected Entity
ALT + X
Set Motion Controller Rotation Center Point
ALT + F12
Toggle Axis Display
F9
Toggle WCS Axis Display
ALT + F9
Toggle Toolpath Display
ALT + T
Toggle Shading
ALT + S
Toggle Toolpaths / Solids Tab
ALT + O
Undo
ALT + U
Undo
CTRL + Z
Undo
CTRL + U
Unzoom by 0.8
F2
Zoom Target
CTRL + F1
Zoom Window
F1
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iv
Masterwork Solutions
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Chapter
1 Geometry
Using Draft Surfaces
➤ About this project:
Abstract Introduces basic concepts of creating draft and fillet surfaces.
Toolpath
Description Surfaces are very important in creating real world parts in Mastercam X2. A surface can define complex 3D regions where normal 2D geometry will not suffice. Surfaces can be trimmed, filleted, extended, and blended to create more complex surfaces. Surfaces are created from existing 2D geometry. There are 5 commonly types of surfaces: Ruled, Lofted, Extruded, Revolved and Swept. Each of these surfaces has a different application. Make a mold relief box using draft surfaces. Fillet the surfaces for a smooth corner. Use Rough Parallel and Finish Radial toolpaths to machine the part.
Materials 3"x3"x1.5" Protofoam Block.
Verified
Machines 1/4" Ball Endmill.
Functions Create Flat Boundary Surface, Create Draft Surfaces, Fillet Surfaces to Surfaces, Rough Parallel Toolpath, Finish Radial Toolpath
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Chapter 1: Using Draft Surfaces
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Section 1: Setup Start Mastercam X2. If it is already running, save your document and create a new one: ■ select File -> Save If you have not saved your document yet, Mastercam X2 will prompt for a file name and location. Enter this information as desired. ■ select File -> New Mastercam X2 creates a new drawing. NOTE: If you create a new drawing in this way, then you must also set your machine, as Mastercam X2 does not do this automatically. ■ select Machine Type -> Mill -> Your Machine If you have not created a Mastercam X Machine Definition for your machine, or if no machine is available, choose the default machine: ■ select Machine Type -> Mill -> 3 - Axis VMC.MMD Mastercam X2 creates a new Toolpath Group. You are now ready to begin this exercise.
Section 2: Geometry Set your Z depth to -1.0: In the Z field at the bottom of the screen:
■ type -1.0 press ENTER
Next, create a rectangle that will serve as base geometry: ■ select Create -> Create Rectangle... Mastercam X2 prompts for corner points: ■ press SPACE ■ type 0.5,0.5 press ENTER Enter the second point: ■ press SPACE ■ type 2.5,2.5 press ENTER Mastercam X2 creates the rectangle. ■ select OK ■ press ALT-F1 ■ press F2 You should have a single rectangle on your screen.
Section 3: Base Flat Boundary Surface The base surface will be created as a flat boundary surface using the rectangle geometry. ■ select Create -> Surface -> Create Flat Boundary Surface... Mastercam X2 displays the Chaining window. ■ select anywhere on the rectangle ■ select OK
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Mastercam X2 Surfaces Tutorial
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Mastercam X2 creates a preview of the flat boundary surface. ■ select OK Your drawing should look like Figure 1.3.1. If it is shaded: ■ press ALT-S
Figure 1.3.1: Flat boundary base surface.
Section 4: Draft Surface Sides First, switch to isometric view: ■ press ALT-7 ■ press ALT-F1 ■ press F2 You will now create four draft surfaces that will serve as the sides of the box. ■ select Create -> Surface -> Create Draft Surfaces... Mastercam X2 displays the Chaining window. ■ select Chain ■ select a side of the rectangle ■ select OK Mastercam X2 displays the Draft Surface dialog. In the length field: ■ type 1.0 press ENTER In the angle field: ■ type -10.0 press ENTER
Figure 1.4.1: Draft Surface.
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Chapter 1: Using Draft Surfaces
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Mastercam X2 displays a preview of the four draft surfaces to be created. Your drawing should look like Figure 1.4.2.
Figure 1.4.2: Preview of side draft surfaces. If it does: ■ select OK The four draft surfaces are created. Your drawing should look like Figure 1.4.3.
Figure 1.4.3: Side draft surfaces. Now is a good time to save your drawing: ■ select File -> Save Since you are saving for the first time, Mastercam X2 displays the Save dialog. In the File name field: ■ type DRAFT plus your initials. Example: DRAFTNWT ■ select Save Mastercam X2 saves your drawing.
Section 5: Fillet Surfaces You will now create surface-to-surface fillets to smooth out the joints between the box sides.
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Mastercam X2 Surfaces Tutorial
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■ select Create -> Surface -> Fillet Surface -> Fillet Surfaces to Surfaces... Mastercam X2 prompts for the first set of surfaces. ■ select the four box side surfaces as shown in Figure 1.5.1
Figure 1.5.1: Correct fillet surface selection. ■ select End Selection
in the toolbar
Mastercam X2 prompts for a second set of surfaces. This selection is not important at this time. ■ select End Selection
in the toolbar
Mastercam X2 displays the Fillet Surfaces to Surfaces dialog. Set the average radius to 0.5. In the radius field: ■ type 0.5 press ENTER You will notice that Mastercam X2 uses the same radius for the entire fillet. We want, however, to use a smaller radius at the bottom. ■ select Expand Mastercam X2 expands the dialog to contain options for settings variable fillets. ■ select Variable Fillet Mastercam X2 enables the variable fillet selection buttons. You will use these to modify the fillet size for each of the four fillets. ■ press ALT-F1 ■ select Modify Radius Mastercam X2 prompts for a radius marker. The radius markers are shown as small lines that connect the edge of the fillet to its center.
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Chapter 1: Using Draft Surfaces
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■ select a bottom radius marker as shown in Figure 1.5.2
Figure 1.5.2: Select here for the bottom radius marker. Mastercam X2 prompts for a radius. In the radius field inside the Variable Fillet box: ■ type 0.125 press ENTER Mastercam X2 modifies the radius. Repeat this for the other 3 bottom markers. Do not press the OK button until all 3 are set! ■ select Trim When all of the fillet radii have been modified, your drawing should look like Figure 1.5.3.
Figure 1.5.3: Preview of the fillet surfaces operation. ■ select OK Mastercam X2 creates the fillet surfaces. Turn on shading to see the part better. ■ select Shaded
in the toolbar
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Mastercam X2 Surfaces Tutorial
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Your drawing should look like Figure 1.5.4.
Figure 1.5.4: Surfaces complete.
Section 6: Rough Parallel Toolpath Make sure your Cplane is set to Top: The Planes menu is on the bottom of the screen ■ select Planes -> Top (WCS) at the bottom of the Mastercam X2 window You will use a Rough Parallel Toolpath to remove the bulk of the material. ■ select Toolpaths -> Surface Rough -> Rough Parallel Toolpath... Mastercam X2 displays the Select Boss/Cavity dialog. ■ select Cavity ■ select OK Mastercam X2 prompts you for a NC name.
■ type DraftMC replacing MC with your initials
■ select OK Mastercam X2 prompts for drive surfaces. You will use all of the surfaces as drive surfaces. ■ select All in the toolbar Mastercam X2 displays the Select All window. ■ select surfaces by double clicking on it Mastercam X2 selects all of the surfaces. ■ select End Selection
in the toolbar
Mastercam X2 displays the Toolpath/surface selection. ■ select OK
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Chapter 1: Using Draft Surfaces
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Mastercam X2 displays the Surface Rough Parallel window. ■ select Select library tool...
Mastercam X2 displays the Tool Selection dialog. You may have to change the Filter settings in order for ball endmills to be listed. ■ select #252 Endmill2 Sphere 0.2500" as shown in Figure 1.6.1
Figure 1.6.1: #252 1/4" ball endmill. ■ select OK Set your Toolpath Parameters as shown in Figure 1.6.2.
Figure 1.6.2: Toolpath Parameters.
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Mastercam X2 Surfaces Tutorial
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Set your Surface Parameters as shown in Figure 1.6.3.
Figure 1.6.3: Surface Parameters. Set your Rough Parallel Parameters as shown in Figure 1.6.4.
Figure 1.6.4: Rough Parallel Parameters. ■ select OK
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Chapter 1: Using Draft Surfaces
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Mastercam X2 creates the toolpath. Your drawing should look like Figure 1.6.5.
Figure 1.6.5: Rough Parallel Toolpath. Save your drawing: ■ select File -> Save
Section 7: Finish Radial Toolpath Next, create a finish toolpath to machine the part to a smooth finish: ■ select Toolpaths -> Surface Finish -> Finish Radial Toolpath... Mastercam X2 prompts for drive surfaces. You will use all of the surfaces as drive surfaces. ■ select All in the toolbar Mastercam X2 displays the Select All window. ■ select surfaces by double clicking on it ■ select OK Mastercam X2 selects all of the surfaces. ■ select End Selection
in the toolbar
Mastercam X2 displays the Toolpath/surface selection. ■ select OK Mastercam X2 displays the Surface Finish Radial window. Select a smaller tool for the finish toolpath: ■ select Select library tool... Mastercam X2 displays the Tool Selection dialog.
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Mastercam X2 Surfaces Tutorial
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■ select #249 Endmill2 Sphere 0.1250" as shown in Figure 1.7.1
Figure 1.7.1: #249 1/4" ball endmill. ■ select OK Set your Toolpath Parameters as shown in Figure 1.7.2.
Figure 1.7.2: Toolpath Parameters.
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Chapter 1: Using Draft Surfaces
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Set your Surface Parameters as shown in Figure 1.7.3.
Figure 1.7.3: Surface Parameters. Set your Finish Radial Parameters as shown in Figure 1.7.4.
Figure 1.7.4: Finish Radial Parameters. ■ select OK Mastercam X2 prompts for a radial point. ■ press SPACE ■ type 1.5,1.5 press ENTER
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Mastercam X2 Surfaces Tutorial
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Mastercam X2 creates the toolpath. Your drawing should look like Figure 1.7.5.
Figure 1.7.5: Finish Radial Toolpath. Save your drawing: ■ select File -> Save
Section 8: Stock Setup Before creating the toolpath, tell Mastercam X2 what your stock looks like. In the Toolpaths tab at the left of the screen: ■ select the Plus icon on Properties Properties expands, allowing you to select Stock Setup.
■ select Stock Setup
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Chapter 1: Using Draft Surfaces
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Mastercam X2 displays the Stock Setup dialog. Set your parameters as shown in Figure 1.8.1:
Figure 1.8.1: Stock Setup dialog. ■ select OK ■ press ALT-F1 Save your drawing: ■ select File -> Save
Section 9: Verify Verification allows you to see what your part will look like without actually machining it. ■ select Select All Operations ■ select Verify Selected Operations ■ press ALT-7 ■ press ALT-F1 Mastercam X2 displays the Verify Controller, changes your view to isometric and fits your part to screen. ■ select Simulate Tool ■ select Machine Mastercam X2 machines your part. You can control the speed and quality by adjusting the options in the Verify Controller.
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Mastercam X2 Surfaces Tutorial
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When your part is machined, it should look like Figure 1.9.1.
Figure 1.9.1: Verified draft surface part. If it does: ■ select
on the Verify Controller dialog
Mastercam X2 exits verify mode.
Section 10: Post Processing ■ select Select All Operations ■ select Post Selected Operations Mastercam X2 displays the Post Processing dialog. Your post processor should be selected. Match the settings with those shown in Figure 1.10.1.
Figure 1.10.1: Post Processing. ■ select OK Mastercam X2 displays a Save dialog for you to save your NC file. In the File name field: ■ type DRAFT plus your initials. Example: DRAFTNWT ■ select Save Mastercam X2 saves your NC file. You can use this to machine your part, if you want.
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Chapter 1: Using Draft Surfaces
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Finally, save your file:
■ select File -> Save Since you saved your file before, Mastercam X2 silently saves the changes you have made since then, without prompting again for a file name.
Congratulations! You have completed the Draft Surface Exercise!
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Masterwork Solutions
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Chapter
2 Geometry
Using Revolved Surfaces
➤ About this project:
Toolpath
Abstract Introduces basic concepts of creating revolved and ruled surfaces.
Description In this exercise, you will create a simple Revolved Surface. A revolved surface takes a contour and makes a surface by revolving it around an axis of revolution. This can create radially-symmetric objects such as a vase or light bulb. You will create a light bulb along with a rough and finish toolpath.
Materials 3"x3"x3/4" Protofoam Block.
Machines
Verified
1/8" Flat Endmill.
Functions Create Arc Polar, Fillet Entities, Chamfer Entities, Create Revolved Surfaces, Create Ruled/Lofted Surfaces, Finish Parallel Toolpath
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Chapter 2: Using Revolved Surfaces
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Section 1: Setup Start Mastercam X2. If it is already running, save your document and create a new one: ■ select File -> Save If you have not saved your document yet, Mastercam X2 will prompt for a file name and location. Enter this information as desired. ■ select File -> New Mastercam X2 creates a new drawing. NOTE: If you create a new drawing in this way, then you must also set your machine, as Mastercam X2 does not do this automatically. ■ select Machine Type -> Mill -> Your Machine If you have not created a Mastercam X Machine Definition for your machine, or if no machine is available, choose the default machine: ■ select Machine Type -> Mill -> 3 - Axis VMC.MMD Mastercam X2 creates a new Toolpath Group. You are now ready to begin this exercise.
Section 2: Geometry First, set your Z depth to -0.5 to draw the geometry in the correct place. In the Z: field at the bottom of the screen: ■ type -0.5 press ENTER Now, create a bounding rectangle: ■ select Create -> Create Rectangle... Mastercam X2 enters rectangle creation mode and prompts for two points. Enter the first point: ■ press SPACE ■ type 0.0,0.0press ENTER Mastercam X2 creates the first point. Enter the second: ■ press SPACE ■ type 3.0,3.0press ENTER Mastercam X2 creates the rectangle. ■ select OK Fit the drawing to the screen: ■ press ALT-F1 Next, create a horizontal line in the middle of the rectangle. ■ select Create -> Line -> Create Line Endpoint... Mastercam X2 is ready for you to create the line. You will use the autocursor to select the midpoints on both vertical lines. Move the mouse cursor toward the middle of the leftmost vertical line. The cursor should change to indicate a midpoint when you are close enough for it to snap. When it snaps to the midpoint: ■ select this point (the midpoint) Mastercam X2 now prompts you to select the other point: ■ select the midpoint of the rightmost vertical line Mastercam X2 creates the horizontal line. Exit from line creation mode: ■ select OK
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Mastercam X2 Surfaces Tutorial
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Your drawing should look like Figure 2.2.1.
Figure 2.2.1: Lines.
Section 3: Offset the Center Line ■ select Xform -> Xform Offset... Mastercam X2 displays the Offset dialog. Match your settings with those shown in Figure 2.3.1, but do not select OK.
Figure 2.3.1: Offset parameters. Mastercam X2 is ready offset geometry. Simply select the geometry, then a direction to offset. You select the direction by selecting with the mouse on the side that you'd like the offset to occur. ■ select the horizontal line in the center of the drawing Click the mouse anywhere above this line. Mastercam X2 shows a preview of the offset line. To accept: ■ select OK
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Chapter 2: Using Revolved Surfaces
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Mastercam X2 offsets the center line. Your drawing should look like Figure 2.3.2.
Figure 2.3.2: Offset lines.
Section 4: Create the Circle Now, you can create the circle that will form the rounded portion of the bulb. ■ select Create -> Arc -> Create Arc Polar... Mastercam X2 enters arc creation mode. In the Radius field next to the Radius button ■ type 0.5press ENTER In the Start Angle field next to the Start Angle button ■ type 45press ENTER In the End Angle field next to the End Angle button ■ type 180press ENTER Mastercam X2 is ready to create your arc. ■ select the midpoint of the lower horizontal line (red) using the autocursor Mastercam X2 creates the arc. Exit arc creation mode: ■ select
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Mastercam X2 Surfaces Tutorial
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Your drawing should look like Figure 2.4.1.
Figure 2.4.1: Arc created.
Section 5: Fillet Now that the geometry is complete, create a fillet to smooth the joint between the bulb and the base. ■ select Create -> Fillet -> Fillet Entities... Mastercam X2 enters fillet creation mode. In the radius field in the Ribbon Bar: ■ type 0.25press ENTER Make sure Mastercam X2 will trim the entities when it creates the fillet: ■ select Trim
in the Ribbon Bar
Now, select the geometry to fillet: ■ select the arc and top horizontal line (purple) as shown in Figure 2.5.1
Figure 2.5.1: Select these two locations to fillet the arc. Mastercam X2 creates the fillet. Exit from fillet creation mode:
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Chapter 2: Using Revolved Surfaces
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■ select OK Mastercam X2 exits from the fillet mode. Your drawing should look like Figure 2.5.2.
Figure 2.5.2: Fillets created.
Section 6: Trimming Before you can trim the part, you must create one additional line. ■ select Create -> Line -> Create Line Endpoint... Mastercam X2 enters line creation mode. ■ select Vertical Draw the line: ■ select the midpoint of the horizontal line filleted to the bulb circle ■ select anywhere below the red horizontal line Your drawing should look like Figure 2.6.1.
Figure 2.6.1: Line to be used for trimming.
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Mastercam X2 Surfaces Tutorial
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Exit from line creation mode: ■ select
Mastercam X2 exits line creation mode. You can how begin trimming the bulb. ■ select Edit -> Trim / Break -> Trim / Break / Extend Mastercam X2 enters Trim mode. In the Ribbon Bar: ■ select Trim 2 Entities Mastercam X2 is prompting for geometry to trim. Select as shown in Figure 2.6.2.
Figure 2.6.2: Select geometry to trim. Your drawing should look like Figure 2.6.3.
Figure 2.6.3: Trimmed geometry. Exit from Trim mode: ■ select
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Chapter 2: Using Revolved Surfaces
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Section 7: Chamfer Create a chamfered edge on the end of the bulb: ■ select Create -> Chamfer -> Chamfer Entities... In the Distance 1 field in the Ribbon Bar: ■ type 0.0625press ENTER Mastercam X2 prompts for geometry to chamfer. ■ select as shown in Figure 2.7.1
Figure 2.7.1: Select geometry to chamfer. When chamfered, your drawing should look like Figure 2.7.2.
Figure 2.7.2: Chamfered geometry. Exit from Chamfer mode: ■ select Now is a good time to save your drawing:
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Masterwork Solutions
Mastercam X2 Surfaces Tutorial
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■ select File -> Save
Since you are saving for the first time, Mastercam X2 displays the Save dialog. In the File name field: ■ type REVOLVED plus your initials. Example: REVOLVEDNWT ■ select Save Mastercam X2 saves your drawing.
Section 8: Revolved Surface The geometry being complete, you can now create the revolved surface. ■ select Create -> Surface -> Create Revolved Surfaces... Mastercam X2 displays the Chaining window and prompts for geometry. ■ select Chain ■ select anywhere on the bulb circle Correctly selected geometry is pictured in Figure 2.8.1. The directions of the arrows at the end is not important at this time.
Figure 2.8.1: Correctly selected geometry for Revolved Surface. ■ select
on the Chaining window
Mastercam X2 prompts for an axis of rotation: ■ select the red horizontal line Switch to isometric view to see the surface more clearly: ■ press ALT-7 ■ press ALT-F1 Mastercam X2 creates a preview of the surface. It should look like a full lightbulb. However, the bottom half will not be needed for this exercise. You can choose how far Mastercam X2 will revolve the surface. In the End Angle field next to the End Angle button in the Ribbon Bar: ■ type 180press ENTER Mastercam X2 displays a preview of the surface. It should look like the top half of a lightbulb in Figure 2.8.2. If your surface looks instead like the bottom of a lightbulb, reverse it:
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Chapter 2: Using Revolved Surfaces
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■ select Flip
until the bulb looks like Figure 2.8.2
Figure 2.8.2: Correctly facing bulb surface. Exit surface creation: ■ select
Section 9: Ruled Surface Now, create a flat surface on the base rectangle. This will be used later as a drive surface for the toolpath. Using it as a drive surface means that the tool will cut the area around the bulb, instead of just the bulb itself. ■ select Create -> Surface -> Create Ruled/Lofted Surfaces... Mastercam X2 displays the chaining window. ■ select Single ■ select the two lines as shown in Figure 2.9.1 make sure that both arrows are pointed the same way on the Chaining window ■ select
Figure 2.9.1: Two lines for Ruled Surface.
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Masterwork Solutions
Mastercam X2 Surfaces Tutorial
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Mastercam X2 creates the surface. Your drawing should look like Figure 2.9.2.
Figure 2.9.2: The Ruled Surface will be used to cut out the area around the bulb.
Section 10: Stock Setup Before creating the toolpath, tell Mastercam X2 what your stock looks like. In the Toolpaths tab at the left of the screen: ■ select the Plus icon on Properties Properties expands, allowing you to select Stock Setup.
■ select Stock Setup
Mastercam X2 displays the Stock Setup dialog. Set your parameters as shown in Figure 2.10.1:
Figure 2.10.1: Stock Setup dialog. ■ select File -> Save
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Chapter 2: Using Revolved Surfaces
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Section 11: Rough Toolpath Make sure your Cplane is set to Top: ■ select Planes -> Top (WCS) at the bottom of the Mastercam X2 window The first toolpath you will create is a rough toolpath. Roughing removes the bulk of the material, but leaves jagged edges. To create a Rough toolpath: ■ select Toolpaths -> Surface Rough -> Rough Parallel Toolpath... Mastercam X2 displays the Select Boss/Cavity dialog. You will select Boss because the bulb extends about the rectangular base. ■ select Boss ■ select OK
■ type revelvednwt when prompted for a NC filename.
■ select OK Mastercam X2 prompts for drive surfaces: ■ select All in the toolbar Mastercam X2 displays the Select All window. Make sure only Surfaces is selected as shown in Figure 2.11.1
Figure 2.11.1: Selecting the geometry. ■ select OK
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Masterwork Solutions
Mastercam X2 Surfaces Tutorial
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Mastercam X2 selects the geometry. It should look like Figure 2.11.2.
Figure 2.11.2: Correctly selected geometry for the Rough Toolpath. ■ select End Selection Mastercam X2 displays the Toolpath/surface selection dialog. ■ select OK Mastercam X2 displays the Surface Rough Parallel window. ■ select Select library tool... Mastercam X2 displays the Tool Selection dialog. ■ select #252 Endmill2 Sphere 0.250" as shown in Figure 2.11.3
Figure 2.11.3: #252 1/4" endmill. ■ select OK
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Chapter 2: Using Revolved Surfaces
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Set your Toolpath Parameters as shown in Figure 2.11.4.
Figure 2.11.4: Toolpath Parameters. Match your Surface Parameters with those in Figure 2.11.5.
Figure 2.11.5: Surface Parameters.
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Masterwork Solutions
Mastercam X2 Surfaces Tutorial
This book is to be distributed freely and may be copied or printed as needed.
Match your Rough Parallel Parameters with those shown in Figure 2.11.6.
Figure 2.11.6: Rough Parallel Parameters. ■ select OK Mastercam X2 creates the toolpath. Your drawing should look like Figure 2.11.7.
Figure 2.11.7: Surface Rough Parallel Toolpath created.
Section 12: Finish Toolpath Next, create a finish toolpath to clean up the excess material left by the rough toolpath. ■ select Toolpaths -> Surface Finish -> Finish Parallel Toolpath... Mastercam X2 prompts for drive surfaces: ■ select All in the toolbar
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Chapter 2: Using Revolved Surfaces
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Mastercam X2 displays the Select All window. Make sure only Surfaces is selected as shown in Figure 2.12.1
Figure 2.12.1: Selecting the geometry. ■ select OK Mastercam X2 selects the geometry. ■ select End Selection Mastercam X2 displays the Toolpath/surface selection dialog. ■ select OK Select a new tool for the finish toolpath: ■ select Select library tool... Mastercam X2 displays the Tool Selection dialog. ■ select #249 Endmill2 Sphere 0.125" as shown in Figure 2.12.2
Figure 2.12.2: #249 1/8" endmill.
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Masterwork Solutions
Mastercam X2 Surfaces Tutorial
This book is to be distributed freely and may be copied or printed as needed. ■ select OK Set your Toolpath Parameters as shown in Figure 2.12.3.
Figure 2.12.3: Toolpath Parameters. Match your Surface Parameters with those in Figure 2.12.4.
Figure 2.12.4: Surface Parameters.
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Chapter 2: Using Revolved Surfaces
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Match your Finish Parallel Parameters with those shown in Figure 2.12.5.
Figure 2.12.5: Finish Parallel Parameters. ■ select OK Mastercam X2 creates the toolpath. Your drawing should look like Figure 2.12.6.
Figure 2.12.6: Rough Surface toolpath created.
Section 13: Verify Verification allows you to see what your part will look like without actually machining it. ■ select Select All Operations ■ select Verify Selected Operations ■ press ALT-7 ■ press ALT-F1 Mastercam X2 displays the Verify Controller, changes your view to isometric and fits your part to screen. ■ select Simulate Tool
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Masterwork Solutions
Mastercam X2 Surfaces Tutorial
This book is to be distributed freely and may be copied or printed as needed. ■ select Machine
Mastercam X2 machines your part. You can control the speed and quality by adjusting the options in the Verify Controller. When your part is machined, it should look like Figure 2.13.1.
Figure 2.13.1: Verified revolved bulb surface. If it does: ■ select
on the Verify Controller dialog
Mastercam X2 exits verify mode.
Section 14: Post Processing Now that you have verified your part, it is time to generate NC code so that you can machine a real part. In the Toolpaths tab on the left of the Mastercam X2 window: ■ select Select All Operations ■ select Post Selected Operations Mastercam X2 displays the Post Processing dialog. Your post processor should be selected. Match the settings with those shown in Figure 2.14.1.
Figure 2.14.1: Post Processing. ■ select OK Mastercam X2 displays a Save dialog for you to save your NC file. In the File name field: ■ type REVOLVED plus your initials. Example: REVOLVEDNWT
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Chapter 2: Using Revolved Surfaces
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■ select Save
Mastercam X2 saves your NC file. You can use this to machine your part, if you want. Finally, save your file: ■ select File -> Save Since you saved your file before, Mastercam X2 silently saves the changes you have made since then, without prompting again for a file name.
Congratulations! You have completed the Revolved Surface Exercise!
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Masterwork Solutions
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Chapter
3 Geometry
Using Swept Surfaces
➤ About this project:
Toolpath
Abstract Introduces basic concepts of creating a swept surface.
Description In this exercise, you are creating a simple aircraft wing. You will design a wing frame using splines. A Spline is Mastercam X2's name for a smooth curve. You will then use a swept surface to create a surface on the wing. Finally, you will cut the part out using a flowline toolpath.
Materials 9"x3"x3/4" Protofoam Block.
Verified
Machines 1/4" Ball Endmill.
Functions Create Manual Spline, Create Swept Surfaces, Finish Flowline Toolpath
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Chapter 3: Using Swept Surfaces
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Section 1: Setup Start Mastercam X2. If it is already running, save your document and create a new one: ■ select File -> Save If you have not saved your document yet, Mastercam X2 will prompt for a file name and location. Enter this information as desired. ■ select File -> New Mastercam X2 creates a new drawing. NOTE: If you create a new drawing in this way, then you must also set your machine, as Mastercam X2 does not do this automatically. ■ select Machine Type -> Mill -> Your Machine If you have not created a Mastercam X Machine Definition for your machine, or if no machine is available, choose the default machine: ■ select Machine Type -> Mill -> 3 - Axis VMC.MMD Mastercam X2 creates a new Toolpath Group. You are now ready to begin this exercise.
Section 2: Base Rectangle First, set your Z depth to -9.0. In the Z: field at the bottom of the screen: ■ type -9.0 Mastercam X2 sets your Z depth to -9.0. All entities subsequently drawn will appear at this depth. Next, set your Gview and Cplane to front: ■ select anywhere in the drawing area with your mouse ■ press ALT-2 Mastercam X2 changes your Gview and Cplane to front. Now, draw a simple bounding rectangle: ■ select Create -> Create Rectangle... Mastercam X2 enters rectangle creation mode. Enter the first end point of the rectangle: ■ press SPACE ■ type 0,0 press ENTER Now for the second point: ■ press SPACE ■ type 3.0,-0.75 press ENTER Mastercam X2 creates the rectangle. Exit rectangle creation mode: ■ select OK Your drawing should look like Figure 3.2.1.
Figure 3.2.1: A rectangle.
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Masterwork Solutions
Mastercam X2 Surfaces Tutorial
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Section 3: Wing Spline Now that you have created a base rectangle, you can create the wing shape. You will do so using a spline. A spline smoothly connects a series of points into a single curve without any straight lines. When you make the spline for the wing profile, you will be plotting points manually, by selecting the location using your mouse. A guide of a simple wing shape is presented, but you are free to make your wing look as you desire, provided the first and last points remain the same, and it fits in the bounding box. To begin creating the spline: ■ select Create -> Spline -> Create Manual Spline... Mastercam X2 enters spline creation mode. For the first point: Move the mouse to the middle of the right vertical line on the rectangle. It should snap to the midpoint. When it does: ■ select this midpoint Now, plot the wing points, using Figure 3.3.1 as a guide. Remember, you can make your wing as you want, but it has to fit inside the bounding box.
Figure 3.3.1: Guide for wing points. When you are ready for the last point: ■ select the midpoint of the left vertical line on the rectangle as before When you are done creating your points: ■ press ENTER Mastercam X2 creates a spline through the points you specified. Your drawing should look similar to the one in Figure 3.3.2 NOTE: If you made a customized wing shape, yours may look different, but make sure that the spline was properly created.
Figure 3.3.2: Wing spline. Yours may look different if you customized your wing.
Section 4: Connecting Geometry Next, create the other end of the wing. You have created the first end using the spline, now create a smaller tail end. First, set your Z depth back to 0.0. In the Z: field at the bottom of the screen: ■ type 0.0press ENTER Mastercam X2 will draw all future entities at this depth. Create a rectangle that will form the smaller end of the wing: ■ select Create -> Create Rectangle... Mastercam X2 enters rectangle creation mode. Enter the first point: ■ press SPACE ■ type 1.5,-0.75 press ENTER Enter the second point: ■ press SPACE ■ type 2.25,0.0 press ENTER
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Chapter 3: Using Swept Surfaces
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■ select OK Mastercam X2 creates the rectangle. Next, it will be necessary for you to change your Gview to Isometric in order to correctly draw the next entity: ■ press ALT-7 ■ press ALT-F1 Your drawing should look like Figure 3.4.1.
Figure 3.4.1: Rectangles in Isometric view. Now, create two connecting lines to form the frame of the wing. Although you will not be drawing in a specific plane, Mastercam X2 does not require that you set your Cplane to 3D in order to accomplish this. Do make sure that the Vertical or Horizontal buttons are not presses in the ribbon bar. ■ select Create -> Line -> Create Line Endpoint... in the toolbar Mastercam X2 enters line creation mode. Create two lines by selecting as shown in Figure 3.4.2 NOTE: All four line locations are midpoints; be sure Mastercam X2's autocursor snaps to the midpoint before you select.
Figure 3.4.2: Select to create two lines.
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Mastercam X2 Surfaces Tutorial
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When both lines are created, your drawing should look like Figure 3.4.3.
Figure 3.4.3: Two lines. ■ select OK Finally, clean up your drawing by removing the bounding boxes: ■ select Chain
in the toolbar
■ select either of the rectangles in your drawing ■ select Chain
in the toolbar
■ select the other rectangle in your drawing ■ press F5 OR DELETE Mastercam X2 removes the rectangles. Your drawing should look like Figure 3.4.4, with only the spline and the two wing lines remaining. Return to normal selection mode
Figure 3.4.4: Spline and wing end lines.
Section 5: Swept Surface Now that the geometry for the wing is complete, you can create a swept surface to make it one piece.
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Chapter 3: Using Swept Surfaces
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■ select Create -> Surface -> Create Swept Surfaces...
Mastercam X2 prompts for across contours. The across contours define the part that will be swept. in the Chaining window ■ select Single ■ select the spline as shown in Figure 3.5.1
Figure 3.5.1: Select the spline. Mastercam X2 displays arrows indicating the direction of the selected across contour. These arrows should point to the lower right. If they don't: ■ select Reverse When the arrows are facing to the lower right: ■ select
on the Chaining window
Mastercam X2 prompts for along contours. The along contours define where the geometry will be swept. in the Chaining window ■ select Single ■ select the lower line as shown in Figure 3.5.2
Figure 3.5.2: Select this lower line. Mastercam X2 selects the top line and displays an arrow indicating the direction in which it will sweep. Your arrow should be facing to the lower left. If it is not:
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Masterwork Solutions
Mastercam X2 Surfaces Tutorial
This book is to be distributed freely and may be copied or printed as needed. ■ select Reverse Mastercam X2 reverses the arrow. When the arrows face to the lower left, select the second along contour: ■ select the upper line as shown in Figure 3.5.3
Figure 3.5.3: Select this upper line. Mastercam X2 displays a preview of the swept surface. Your drawing should look like Figure 3.5.4.
Figure 3.5.4: Swept Surface preview. If it does: ■ select OK Turn on shading to see your part as a solid instead of wireframe. ■ select Shaded
in the toolbar
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Chapter 3: Using Swept Surfaces
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Your drawing should look like Figure 3.5.5.
Figure 3.5.5: Shading on. Now, save your drawing: ■ select File -> Save Since you are saving for the first time, Mastercam X2 displays the Save dialog. In the File name field: ■ type SWEPT plus your initials. Example: SWEPTNWT ■ select Save Mastercam X2 saves your drawing.
Section 6: Stock Setup Before creating the toolpath, tell mastercam what your stock looks like. In the Toolpaths tab at the left of the screen: ■ select the Plus icon on Properties Properties expands, allowing you to select Stock Setup.
■ select Stock Setup
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Masterwork Solutions
Mastercam X2 Surfaces Tutorial
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Mastercam X2 displays the Stock Setup dialog. Set your parameters as shown in Figure 3.6.1:
Figure 3.6.1: Stock Setup dialog. ■ select OK Save your drawing: ■ select File -> Save
Section 7: Toolpath Make sure your Cplane is set to Top: ■ select Planes -> Top (WCS) at the bottom of the Mastercam X2 window In order to machine this part, you will use a Flowline toolpath. A Flowline toolpath follows the surface in on direction, but unlike a Parallel toolpath, each pass does not have to be a constant distance from the previous one. ■ select Toolpaths -> Surface Finish -> Finish Flowline Toolpath...
■ type sweptmc
■ select OK Mastercam X2 prompts for drive surfaces: ■ select the wing surface you created in the toolbar ■ select End Selection Mastercam X2 displays the Toolpath/surface selection dialog. ■ select OK
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Chapter 3: Using Swept Surfaces
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Mastercam X2 displays the Surface Finish Flowline window. Select a tool: ■ select Select library tool... Mastercam X2 displays the Tool Selection dialog. ■ select #252 Endmill2 Sphere 0.2500" as shown in Figure 3.7.1
Figure 3.7.1: #252 1/4" ball endmill. ■ select OK Set your Toolpath Parameters as shown in Figure 3.7.2.
Figure 3.7.2: Toolpath Parameters.
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Masterwork Solutions
Mastercam X2 Surfaces Tutorial
This book is to be distributed freely and may be copied or printed as needed.
Set your Surface Parameters as shown in Figure 3.7.3.
Figure 3.7.3: Surface Parameters. Set your Finish Flowline Parameters as shown in Figure 3.7.4.
Figure 3.7.4: Finish Flowline Parameters. ■ select OK Mastercam X2 displays the Flowline Data dialog. ■ select Offset until the grey lines appear above the wing. ■ select Cut Direction until the larger arrow is pointing along the long part of the wing
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Chapter 3: Using Swept Surfaces
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When your drawing looks like Figure 3.7.5.
Figure 3.7.5: Correct Offset and Cut Direction. ■ select OK Mastercam X2 creates the toolpath. Your drawing should look like Figure 3.7.6.
Figure 3.7.6: Flowline Toolpath.
Section 8: Verify Verification allows you to see what your part will look like without actually machining it. ■ select Select All Operations ■ select Verify Selected Operations ■ press ALT-7 ■ press ALT-F1 Mastercam X2 displays the Verify Controller, changes your view to isometric and fits your part to screen. ■ select Simulate Tool ■ select Machine Mastercam X2 machines your part. You can control the speed and quality by adjusting the options in the Verify Controller.
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Masterwork Solutions
Mastercam X2 Surfaces Tutorial
This book is to be distributed freely and may be copied or printed as needed.
When your part is machined, it should look like Figure 3.8.1.
Figure 3.8.1: Verified swept surface. If it does: ■ select
on the Verify Controller dialog
Mastercam X2 exits verify mode.
Section 9: Post Processing Now that you have verified your part, it is time to generate NC code so that you can machine a real part. In the Toolpaths tab on the left of the Mastercam X2 window: ■ select Select All Operations ■ select Post Selected Operations Mastercam X2 displays the Post Processing dialog. Your post processor should be selected. Match the settings with those shown in Figure 3.9.1.
Figure 3.9.1: Post Processing. ■ select OK Mastercam X2 displays a Save dialog for you to save your NC file. In the File name field: ■ type SWEPT plus your initials. Example: SWEPTNWT ■ select Save Mastercam X2 saves your NC file. You can use this to machine your part, if you want. Finally, save your file:
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Chapter 3: Using Swept Surfaces
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■ select File -> Save
Since you saved your file before, Mastercam X2 silently saves the changes you have made since then, without prompting again for a file name.
Congratulations! You have completed the Swept Surface Exercise!
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Masterwork Solutions
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Chapter
4 Geometry
Using Blended Surfaces
➤ About this project:
Toolpath
Abstract Introduces basic concepts of creating a blended surface.
Description This exercise uses the wing from the Swept chapter, duplicates it, and creates a blended surface between the two wings. A single toolpath is then used to cut out the set of wings.
Materials 10"x3"x3/4" Protofoam Block.
Verified
Machines 1/4" Ball Endmill.
Functions Shade Settings, Xform Rotate, Create 2 Surface Blend, Xform Translate
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Chapter 4: Using Blended Surfaces
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Section 1: Setup Start Mastercam X2. You will need to open the drawing you created in the swept chapter. ■ select File -> Open Mastercam X2 prompts for a file to open. ■ select the SWEPT file that you created earlier ■ select Open Mastercam X2 opens the SWEPT chapter. You are now ready to begin this exercise.
Section 2: Toolpath Cleanup Before you begin, remove the old toolpaths: ■ select Select All Operations ■ press DELETE NOTE: If Mastercam X2 does not remove the toolpath the first time, press delete again. Mastercam X2 removes the toolpaths. Turn shading off: ■ select Screen -> Shade Settings... Mastercam X2 displays the Shading Settings window. Match your settings with Figure 4.2.1.
Figure 4.2.1: Turn shading off. Mastercam X2 turns off shading. Turn off stock display: ■ select the Plus icon on Properties Properties expands, allowing you to select Stock Setup.
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Masterwork Solutions
Mastercam X2 Surfaces Tutorial
This book is to be distributed freely and may be copied or printed as needed. ■ select Stock Setup
Mastercam X2 displays the Stock Setup dialog. Set your parameters as shown in Figure 4.2.2:
Figure 4.2.2: Stock Setup dialog. ■ select OK Finally, change your view to right side: ■ press ALT-5 ■ press ALT-F1 ■ press F2 Mastercam X2 sets your Gview and Cplane to right side, fits the part to screen, and zooms out. Your drawing should look like Figure 4.2.3.
Figure 4.2.3: Cleanup complete.
Section 3: Wing Camber Now you will rotate the wing to give it camber. ■ select Xform -> Xform Rotate... Mastercam X2 prompts for geometry to rotate. ■ select the wing by dragging a window around it ■ select End Selection Mastercam X2 displays the Rotate dialog. ■ select Move
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Chapter 4: Using Blended Surfaces
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■ select Define Center (point) of Rotation Mastercam X2 prompts for a center of rotation. ■ select the lower right corner of the wing with the autocursor Finally, set an angle of rotation. In the Angle field in the Rotate window: ■ type -5.0 press ENTER Mastercam X2 rotates the wing. If the left edge moved up, as shown in Figure 4.3.1:
Figure 4.3.1: Rotated wing. ■ select OK
Section 4: Mirror Wing Next, you will mirror the wing you have to create the second wing. First, change your view to top: ■ press ALT-1 ■ press ALT-F1 ■ press F2 Mastercam X2 changes the view to top and fits the geometry to the screen. Change the purple wing back to green: ■ select Screen -> Clear Colors Next, create a line to mirror over: ■ select Create -> Line -> Create Line Endpoint... Mastercam X2 enters create line mode. Enter the first point: ■ press SPACE ■ type 0.0,10.0 press ENTER Enter the second point: ■ press SPACE ■ type 3.0,10.0 press ENTER Mastercam X2 creates a preview of the line. ■ select OK
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Mastercam X2 Surfaces Tutorial
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Your drawing should look like Figure 4.4.1.
Figure 4.4.1: Mirror line. Now, mirror the surface over the line: ■ select Xform -> Xform Mirror... Mastercam X2 prompts for geometry to mirror. You will mirror the entire wing. ■ select the wing by dragging a window around it ■ select End Selection Mastercam X2 displays the Mirror dialog. Make sure the operation is set to "Copy." ■ select Select Line ■ select the horizontal line above the wing ■ press ALT-F1 Mastercam X2 displays a preview of the mirrored geometry. If there is now a matching wing above the original: ■ select OK Mastercam X2 mirrors the geometry. Your drawing should look like Figure 4.4.2.
Figure 4.4.2: Mirrored Wing.
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Chapter 4: Using Blended Surfaces
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Clear the color again:
■ select Screen -> Clear Colors
Section 5: Blended Surface First, delete the mirror line: ■ select the mirror line ■ press DELETE Change your view to isometric: ■ press ALT-7 ■ press ALT-F1 Next, blend the two wings using a blended surface: ■ select Create -> Surface -> Create 2 Surface Blend... Mastercam X2 displays the 2 Surface Blend dialog and prompts for the first surface. ■ select the top right wing Mastercam X2displays a blue arrow that will indicate which part of the surface should blend. Since you want to blend the two surfaces where they are closest to each other, you must move this arrow as far left and down as possible. ■ select using the mouse when the arrow is at the bottom left of the wing Mastercam X2 prompts for the next surface. ■ select the wing on the lower left Mastercam X2 again displays the blue arrow that will indicate which part of the surface to blend. Move the arrow to the bottom right of this wing. When it reaches this location: ■ select using the mouse Mastercam X2 attempts to blend the surface, but does so backwards. To correct this: ■ select Reverse
next to surface 1
■ select Reverse
next to surface 2
Your drawing should look like Figure 4.5.1.
Figure 4.5.1: Preview of the blended surface. If it does not, you can try different combinations of reversing the direction of the two surfaces, or select the Select Surface 1 or Select Surface 2
to redefine the surfaces.
When your figure does look like Figure 4.5.1: ■ select OK
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Mastercam X2 Surfaces Tutorial
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Your drawing should look like Figure 4.5.2:
Figure 4.5.2: The blended surface. Save your drawing. ■ select File -> Save As Since you are saving for the first time, Mastercam X2 displays the Save dialog. In the File name field: ■ type BLEND plus your initials. Example: BLENDNWT ■ select Save Mastercam X2 saves your drawing.
Section 6: Scale Wings Now that the geometry is constructed, scale it so it will fit in the 10" stock. ■ select Xform -> Xform Scale... Mastercam X2 prompts for geometry to scale. ■ select All in the selection toolbar Mastercam X2 displays the Select All window. ■ select All Entities Mastercam X2 selects all of the geometry. ■ select End Selection Mastercam X2 displays the Scale dialog. Make sure the operation is set to "Copy". Under the Uniform field: ■ type .5 press ENTER Next, select a point of reference for the scaling. ■ select Define Scaling Reference Point ■ select Origin
in the toolbar
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Chapter 4: Using Blended Surfaces
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Mastercam X2 displays a preview of the scale operation. Your drawing should look like Figure 4.6.1.
Figure 4.6.1: Scale operation preview. If it does: ■ ■ ■ ■
select Move select OK press ALT-F1 select Screen -> Clear Colors
Your drawing should look like Figure 4.6.2.
Figure 4.6.2: Wings scaled.
Section 7: Translate Wings Make sure your Cplane is set to Top: ■ select Planes -> Top (WCS) at the bottom of the Mastercam X2 window Now, move the geometry below the top of the stock: ■ select Xform -> Xform Translate... Mastercam X2 prompts for geometry ■ select All in the selection toolbar Mastercam X2 displays the Select All window. ■ select All Entities Mastercam X2 selects all of the geometry. ■ select End Selection Mastercam X2 displays the Translate dialog. Make sure the operation is set to "Move".
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Mastercam X2 Surfaces Tutorial
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In the ΔZ field:
■ type -0.25 press ENTER In the ΔX field: ■ type 0.5 press ENTER ■ select OK Mastercam X2 translates the geometry down by 0.25 inches and over by 0.5 inches. Your drawing should look the same ■ select Screen -> Clear Colors
Section 8: Stock Setup Before creating the toolpath, tell Mastercam X2 what your stock looks like. In the Toolpaths tab at the left of the screen: ■ select the Plus icon on Properties Properties expands, allowing you to select Stock Setup.
■ select Stock Setup
Mastercam X2 displays the Stock Setup dialog. Set your parameters as shown in Figure 4.8.1:
Figure 4.8.1: Stock Setup dialog. ■ select OK Save your drawing: ■ select File -> Save
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Chapter 4: Using Blended Surfaces
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Section 9: Finish Parallel Toolpath Make sure your Cplane is set to Top: ■ select Planes -> Top (WCS) at the bottom of the Mastercam X2 window Next, create the finish toolpath. ■ select Toolpaths -> Surface Finish -> Finish Parallel Toolpath...
■ type BLENDNWT
■ select OK Mastercam X2 prompts for drive surfaces. ■ select the two wings ■ select the blended surface between the two wings ■ select End Selection Mastercam X2 displays the Toolpath/surface selection dialog. ■ select OK Mastercam X2 displays the Surface Finish Parallel dialog. Use the same tool that was in the Swept toolpath. Set your Toolpath Parameters as shown in Figure 4.9.1.
Figure 4.9.1: Toolpath Parameters.
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Mastercam X2 Surfaces Tutorial
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Set your Surface Parameters as shown in Figure 4.9.2.
Figure 4.9.2: Surface Parameters. Set your Finish Parallel Parameters as shown in Figure 4.9.3.
Figure 4.9.3: Finish Parallel Parameters. ■ select OK
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Chapter 4: Using Blended Surfaces
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Mastercam X2 creates the toolpath. Your drawing should look like Figure 4.9.4.
Figure 4.9.4: Finish Parallel Toolpath. Save your drawing: ■ select File -> Save
Section 10: Verify Verification allows you to see what your part will look like without actually machining it. ■ select Select All Operations ■ select Verify Selected Operations ■ press ALT-7 ■ press ALT-F1 Mastercam X2 displays the Verify Controller, changes your view to isometric and fits your part to screen. ■ select Simulate Tool ■ select Machine Mastercam X2 machines your part. You can control the speed and quality by adjusting the options in the Verify Controller. When your part is machined, it should look like Figure 4.10.1.
Figure 4.10.1: Verified blended surface. If it does:
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on the Verify Controller dialog
Mastercam X2 exits verify mode.
Section 11: Post Processing Now that you have verified your part, it is time to generate NC code so that you can machine a real part. In the Toolpaths tab on the left of the Mastercam X2 window: ■ select Select All Operations ■ select Post Selected Operations Mastercam X2 displays the Post Processing dialog. Your post processor should be selected. Match the settings with those shown in Figure 4.11.1.
Figure 4.11.1: Post Processing. ■ select OK Mastercam X2 displays a Save dialog for you to save your NC file. In the File name field: ■ type BLEND plus your initials. Example: BLENDNWT ■ select Save Mastercam X2 saves your NC file. You can use this to machine your part, if you want. Finally, save your file: ■ select File -> Save Since you saved your file before, Mastercam X2 silently saves the changes you have made since then, without prompting again for a file name.
Congratulations! You have completed the Blended Surface Exercise!
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Chapter
5 Geometry
Using Loft Surfaces
➤ About this project:
Toolpath Abstract Introduces basic concepts of creating a loft surface.
Description Create a boat using a loft surface and cut it out with a flowline toolpath.
Materials 9"x5"x2.5" Protofoam Block.
Machines 1/4" Flat Endmill.
Functions
Verified
Rough Flowline Toolpath
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Chapter 5: Using Loft Surfaces
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Section 1: Setup Start Mastercam X2. If it is already running, save your document and create a new one: ■ select File -> Save If you have not saved your document yet, Mastercam X2 will prompt for a file name and location. Enter this information as desired. ■ select File -> New Mastercam X2 creates a new drawing. NOTE: If you create a new drawing in this way, then you must also set your machine, as Mastercam X2 does not do this automatically. ■ select Machine Type -> Mill -> Your Machine If you have not created a Mastercam X Machine Definition for your machine, or if no machine is available, choose the default machine: ■ select Machine Type -> Mill -> 3 - Axis VMC.MMD Mastercam X2 creates a new Toolpath Group. You are now ready to begin this exercise.
Section 2: Rectangle and Points Creating the geometry for this part is somewhat indirect, as you have to create base geometry before you can create any part of the boat. Also, it is important that you follow the instructions given here to the letter; miss one step and your entire part could be thrown off. Begin by changing your Gview and Cplane to Front: ■ press ALT-2 Mastercam X2 changes the view to front. Next, create a rectangle: ■ select Create -> Create Rectangle... Mastercam X2 enters create rectangle mode. Enter the first point: ■ press SPACE ■ type 1.0,-0.75 press ENTER Enter the second point: ■ press SPACE ■ type 2.5,-2.25 press ENTER Mastercam X2 creates the rectangle. Exit from rectangle creation mode: ■ select OK ■ press ALT-F1 Next, create a diagonal line: ■ select Create -> Line -> Create Line Endpoint... Mastercam X2 enters create line mode and prompts for the first point. Use the autocursor to snap to the corners of the rectangle. ■ select the upper left corner of the rectangle ■ select the lower right corner of the rectangle Mastercam X2 creates the line. Exit from line creation mode: ■ press ESCAPE
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Your drawing should look like Figure 5.2.1.
Figure 5.2.1: Frame geometry. Now, you will create points along 3 lines -- the diagonal, the vertical line on the right, and the bottom horizontal line. ■ select Create -> Point -> Create Point Segment... Mastercam X2 prompts for a line to create the points along. ■ select the vertical line on the right Mastercam X2 prompts for the number of points to create. In the Number field in the Ribbon Bar: ■ type 14 press ENTER ■ select Apply Mastercam X2 creates 14 points equally spaced along the line. Now for the two other lines: ■ select the diagonal line In the Number field in the Ribbon Bar: ■ type 24 press ENTER ■ select Apply Mastercam X2 creates 24 points equally spaced along the diagonal line. Now for the final line: ■ select the bottom horizontal line In the Number field in the Ribbon Bar: ■ type 21 press ENTER Mastercam X2 creates 21 points along the bottom line. Exit from point creation mode: ■ press ESCAPE
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After all the points have been created, your drawing should look like Figure 5.2.2.
Figure 5.2.2: These points will be used to create the boat ribs.
Section 3: Ribs Now that you have the base geometry complete, you can create the ribs for the boat. The ribs will be used to outline the shell of the boat. You will create 7 ribs by connecting lines using the points you just created. However, you will need to change the Z depth for EACH rib you draw. Forgetting to set the Z depth properly will cause problems in later steps. Mastercam X2 changes the way Mastercam X2 works with drawing in 3D. In the bottom right corner of your screen, you will notice a small button that says "3D." In this mode, Mastercam X2 will draw points where you select them, regardless of your current Z depth. Since you want to create the ribs at a specified depth, you have to change this button to "2D." To do: ■ select 3D at the bottom of the screen The button changes to 2D Rib #1 ■ select Create -> Line -> Create Line Endpoint... Mastercam X2 enters create line mode. Create the first rib:
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■ select the points as shown in Figure 5.3.1
Figure 5.3.1: Points for Rib #1 Rib #2 In the Z: field at the bottom of the screen: ■ type -0.47press ENTER Create the rib: ■ select the points as shown in Figure 5.3.2
Figure 5.3.2: Points for Rib #2 Rib #3 In the Z: field at the bottom of the screen: ■ type -0.95press ENTER Create the rib:
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Chapter 5: Using Loft Surfaces
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■ select the points as shown in Figure 5.3.3
Figure 5.3.3: Points for Rib #3 Rib #4 In the Z: field at the bottom of the screen: ■ type -1.74press ENTER Create the rib: ■ select the points as shown in Figure 5.3.4
Figure 5.3.4: Points for Rib #4 Rib #5 In the Z: field at the bottom of the screen: ■ type -2.53press ENTER Create the rib:
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■ select the points as shown in Figure 5.3.5
Figure 5.3.5: Points for Rib #5 Rib #6 In the Z: field at the bottom of the screen: ■ type -3.00press ENTER Create the rib: ■ select the points as shown in Figure 5.3.6
Figure 5.3.6: Points for Rib #6 Rib #7 In the Z: field at the bottom of the screen: ■ type -9.00press ENTER Create the rib:
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■ select the points as shown in Figure 5.3.7
Figure 5.3.7: Points for Rib #7 ■ select OK When all the ribs are complete, your drawing should look like Figure 5.3.8.
Figure 5.3.8: Completed ribs.
Section 4: Remove Excess Geometry Next, remove the excess geometry that you created to make the ribs for the boat. ■ press F5 Mastercam X2 enters delete mode. Any entities you select now will be deleted. ■ select the four walls of the rectangle ■ select the diagonal line Mastercam X2 highlights the 5 lines you selected. Next, highlight all the points. Instead of selecting each one, you can tell Mastercam X2 to delete all of the points in one step: ■ select All in the Selection toolbar
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Mastercam X2 displays the Select All window. Make sure that Points are the only type selected as shown in Figure 5.4.1.
Figure 5.4.1: Select only and all points. ■ select ■ press ENTER
on the Select All window
Mastercam X2 deletes all of the highlighted items in your drawing. ■ press F3 ■ press ALT-F1 Your drawing should look like Figure 5.4.2
Figure 5.4.2: Extra geometry removed.
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Chapter 5: Using Loft Surfaces
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Section 5: Fillet the Ribs Next, you will fillet the joints of the lines to smooth out the boat geometry. Change your drawing mode to 3D so that Mastercam X2 will create the fillets at the depth of the lines, instead of all at one depth: ■ select 2D at the bottom of the screen The button changes to say 3D Begin creating the fillets: ■ select Create -> Fillet -> Fillet Entities... Mastercam X2 enters fillet creation mode. In the Radius field in the Ribbon Bar: ■ type 0.125press ENTER Mastercam X2 is now ready for you to create the fillets. ■ select the first pair of connected lines as shown in Figure 5.5.1
Figure 5.5.1: Create fillets at these points. Mastercam X2 creates the fillets. Repeat this for the other pairs of connected lines until your drawing looks like Figure 5.5.2.
Figure 5.5.2: Correctly filleted ribs. Exit from fillet creation mode:
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This book is to be distributed freely and may be copied or printed as needed. ■ select Now is a good time to save your drawing: ■ select File -> Save Since you are saving for the first time, Mastercam X2 displays the Save dialog. In the File name field: ■ type LOFTSURFACE plus your initials. Example: LOFTSURFACENWT ■ select Save Mastercam X2 saves your drawing.
Section 6: Mirror the lines Now that the ribs for the boat are complete, you can mirror them to create the other side of the boat. ■ select Xform -> Xform Mirror... Mastercam X2 prompts for geometry to mirror. ■ select All in the selection toolbar ■ select All Entities Mastercam X2 selects all of the ribs you created. ■ select End Selection Mastercam X2 displays the Mirror dialog. Make sure the operation is set to "Copy." ■ select Select Two Points Mastercam X2 prompts for two points. Select any two of the rib endpoints on the right side of the screen. An example of a possible selection is shown in Figure 5.6.1.
Figure 5.6.1: Possible selections ■ select any two of the right endpoints of the ribs Mastercam X2 displays a preview of the mirror operation. If a purple version of your geometry appears to the right of the original: ■ select ■ press ALT-F1
in the Mirror dialog
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Chapter 5: Using Loft Surfaces
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Mastercam X2 Mirrors the geometry. Your drawing should look like Figure 5.6.2.
Figure 5.6.2: Mirrored ribs. You will notice that even after the mirror operation is complete, one half of your drawing is red, and the other purple. Mastercam X2 draws the last entity in red. The last entity is always the entity or group of entities that was last used in a operation. The result is always drawn in purple. When performing subsequent operations, Mastercam X2 allows you to quickly select the last or result groups for quick access. However, since all references to this geometry in the future will reference the entire boat, the last and result groups are not particularly useful. Fortunately, Mastercam X2 provides a way to clear these colors, and return the entities to their standard green color: ■ select Screen -> Clear Colors Mastercam X2 clears the colors. All geometry in your drawing should appear green. Save your drawing: ■ select File -> Save
Section 7: Loft Surface The geometry being complete, it is time to create the loft surface of the boat. ■ select Create -> Surface -> Create Rules/Loft Surfaces Mastercam X2 displays the chaining window and prompts for geometry. You will select the ribs by dragging a window around them. NOTE: You MUST start your window in the lower left and end in the upper right, or the loft surface will not be created correctly! in the Chaining window ■ select Window ■ select all of the ribs by dragging a window around them ■ select with your mouse a point below the lower left corner of the ribs ■ select OK If Mastercam X2 warns about sharp corners: ■ select OK Mastercam X2 creates the Loft surface. Exit from surface creation mode: ■ select Change your view to isometric to see what your boat looks like: ■ press ALT-7 ■ press ALT-F1
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Mastercam X2 displays your view in isometric. Your drawing should look like Figure 5.7.1
Figure 5.7.1: Isometric view. Finally, turn on shading to see the boat as a solid: ■ select Screen -> Shade Settings... Mastercam X2 displays the Shading Settings window. Match your settings with those shown in Figure 5.7.2.
Figure 5.7.2: Turn shading on.
Section 8: Stock Setup Before creating the toolpath, tell Mastercam X2 what your stock looks like. In the Toolpaths tab at the left of the screen: ■ select the Plus icon on Properties Properties expands, allowing you to select Stock Setup.
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Chapter 5: Using Loft Surfaces
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■ select Stock Setup
Mastercam X2 displays the Stock Setup dialog. Set your parameters as shown in Figure 5.8.1:
Figure 5.8.1: Stock Setup dialog. ■ select OK Save your drawing: ■ select File -> Save
Section 9: Rough Flowline Toolpath Make sure your Cplane is set to Top: ■ select Planes -> Top (WCS) at the bottom of the Mastercam X2 window Now, make a toolpath to machine your part. For this part, you will create two toolpaths: a Rough and Finish Flowline. A Flowline Toolpath is better for this part than a Parallel Toolpath because it follows the natural curve of the surface, resulting in less air cutting and faster machining time. First, see your entire drawing: ■ press ALT-F1 Make the toolpath: ■ select Toolpaths -> Surface Rough -> Rough Flowline Toolpath... Mastercam X2 displays the Select Boss/Cavity dialog. ■ select Boss ■ select OK
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■ type loftsurfacemc
■ select OK Mastercam X2 prompts for drive surfaces. ■ select the boat surface ■ select End Selection Mastercam X2 displays the Toolpath/surface selection dialog: ■ select OK Mastercam X2 displays the Surface Rough Flowline dialog. NOTE: There are three tabs of parameters that must be set before you can create the toolpath. Do not press OK until all three have been set. ■ select Select library tool... Mastercam X2 displays the Tool Selection dialog. ■ select #252 Endmill2 Sphere 0.2500" as shown in Figure 5.9.1
Figure 5.9.1: #252 1/4" ball endmill. ■ select OK
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Chapter 5: Using Loft Surfaces
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Set your Toolpath Parameters as shown in Figure 5.9.2.
Figure 5.9.2: Toolpath Parameters. Set your Surface Parameters as shown in Figure 5.9.3.
Figure 5.9.3: Surface Parameters.
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Set your Rough Flowline Parameters as shown in Figure 5.9.4.
Figure 5.9.4: Rough Flowline Parameters. ■ select OK Mastercam X2 displays the Flowline Geometry dialog. ■ select Offset until the grey lines are above the boat surface ■ select Cut Direction until the grey lines follow the length of the boat surface When your drawing looks like Figure 5.9.5:
Figure 5.9.5: Correct Offset and Cut Direction for Flowline Toolpath. ■ select
on the Flowline Geometry window
Mastercam X2 creates the toolpath.
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Chapter 5: Using Loft Surfaces
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Your drawing should look like Figure 5.9.6.
Figure 5.9.6: Flowline Toolpath. Save your drawing: ■ select File -> Save
Section 10: Finish Flowline Toolpath Next, create the finish toolpath. Turn off toolpath display on the first toolpath so that you can see the boat surface: ■ select Select All Operations ■ select Toggle Toolpath Display Mastercam X2 hides display of the first toolpath. ■ select Toolpaths -> Surface Finish -> Finish Flowline Toolpath... Mastercam X2 prompts for drive surfaces. ■ select the boat surface ■ select End Selection Mastercam X2 displays the Toolpath/surface selection dialog. ■ select OK Mastercam X2 displays the Surface Finish Flowline dialog. Use the same tool as before.
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Set your Toolpath Parameters as shown in Figure 5.10.1.
Figure 5.10.1: Toolpath Parameters. Set your Surface Parameters as shown in Figure 5.10.2.
Figure 5.10.2: Surface Parameters.
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Chapter 5: Using Loft Surfaces
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Set your Finish Flowline Parameters as shown in Figure 5.10.3.
Figure 5.10.3: Finish Flowline Parameters. ■ select OK If Mastercam X2 warns about Gauge Check: ■ select OK Again, Mastercam X2 displays the Flowline Geometry dialog. ■ select Offset until the grey lines are above the boat surface ■ select Cut Direction until the grey lines follow the length of the boat surface When your drawing looks like Figure 5.10.4.
Figure 5.10.4: Correct offset and cut direction. ■ select
in the Flowline Geometry window
Mastercam X2 creates the finish toolpath. Turn all toolpath display on: ■ select Select All Operations ■ select Toggle Toolpath Display
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Your drawing should look like Figure 5.10.5.
Figure 5.10.5: Finish Flowline Toolpath. Save your drawing: ■ select File -> Save
Section 11: Verify Verification allows you to see what your part will look like without actually machining it. ■ select Select All Operations ■ select Verify Selected Operations ■ press ALT-7 ■ press ALT-F1 Mastercam X2 displays the Verify Controller, changes your view to isometric and fits your part to screen. ■ select Simulate Tool ■ select Machine Mastercam X2 machines your part. You can control the speed and quality by adjusting the options in the Verify Controller.
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Chapter 5: Using Loft Surfaces
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When your part is machined, it should look like Figure 5.11.1.
Figure 5.11.1: Verified Boat. If it does: ■ select
on the Verify Controller dialog
Mastercam X2 exits verify mode.
Section 12: Post Processing Now that you have verified your part, it is time to generate NC code so that you can machine a real part. In the Toolpaths tab on the left of the Mastercam X2 window: ■ select Select All Operations ■ select Post Selected Operations Mastercam X2 displays the Post Processing dialog. Your post processor should be selected. Match the settings with those shown in Figure 5.12.1.
Figure 5.12.1: Post Processing. ■ select OK Mastercam X2 displays a Save dialog for you to save your NC file. In the File name field:
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■ type LOFTSURFACE plus your initials. Example: LOFTSURFACENWT ■ select Save
Mastercam X2 saves your NC file. You can use this to machine your part, if you want. Finally, save your file: ■ select File -> Save Since you saved your file before, Mastercam X2 silently saves the changes you have made since then, without prompting again for a file name.
Congratulations! You have completed the Loft Surface Exercise!
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Chapter
6 Geometry
Using Primitives and Multisurface Toolpaths Toolpath ➤ About this project:
Abstract Introduces basic concepts of creating a primative, manipulating surfaces and creating multsurface toolpaths
Description Create a surface for the blade of a turbine using a simple ruled surface. Then, create a torus primative to serve as the center of the turbine. Rotate the blade to give it pitch, then copy it around the torus, to create the other 17 blades. Use Rough Parallel and Finish Radial toolpaths to machine the part.
Verified
Materials 4"x4"x.5" Protofoam Block.
Machines 1/4" Ball Endmill.
Functions Break at Intersection, Join entities, Create Torus
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Chapter 6: Using Primitives and Multisurface Toolpaths
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Section 1: Setup Start Mastercam X2. If it is already running, save your document and create a new one: ■ select File -> Save If you have not saved your document yet, Mastercam X2 will prompt for a file name and location. Enter this information as desired. ■ select File -> New Mastercam X2 creates a new drawing. NOTE: If you create a new drawing in this way, then you must also set your machine, as Mastercam X2 does not do this automatically. ■ select Machine Type -> Mill -> Your Machine If you have not created a Mastercam X Machine Definition for your machine, or if no machine is available, choose the default machine: ■ select Machine Type -> Mill -> 3 - Axis VMC.MMD Mastercam X2 creates a new Toolpath Group. You are now ready to begin this exercise.
Section 2: Blade Geometry Begin by creating two circles that will be used to create the blade. ■ select Create -> Arc -> Create Circle Center Point... Mastercam X2 is ready to create the circles. In the radius field: ■ type 2.0 press ENTER ■ select Origin
Mastercam X2 creates the first circle. ■ select Apply Next, create the second circle. In the radius field: ■ type 0.75/2 press ENTER
Mastercam X2 can do math! Mastercam allows you to enter expressions into any field that requires number input. Mastercam will take the "0.75/2" you entered and calculate its value, 0.375. It will use this value when creating the circle. You can use other operators too, "+", "-", "*" and "/" for addition, subtraction, multiplication and division, respectively. Mastercam X2 prompts for a center point for the circle: ■ select the small dot that signifies the center of the larger circle ■ select OK ■ press ALT-F1
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Your drawing should look like Figure 6.2.1.
Figure 6.2.1: Two circles. Next, create the blade edges using two lines: ■ select Create -> Line -> Create Line Endpoint... Mastercam X2 is ready to create a line. Make sure the white window turns RED. ■ select Length ■ type 2.0 press ENTER In the angle field: ■ type 10.0 press ENTER Mastercam X2 prompts for a location to place the line: ■ select the small dot in the center of both circles ■ select Apply Create the second line. In the angle field: ■ type -10.0 press ENTER ■ select the small dot in the center of both circles ■ select OK
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Chapter 6: Using Primitives and Multisurface Toolpaths
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Mastercam X2 creates both lines. Your drawing should look like Figure 6.2.2.
Figure 6.2.2: Lines for the blade.
Section 3: Trim Circles You only need the part of the two lines that is between the two circles. Trimming the lines will remove the excess part inside the smaller circle: ■ select Edit -> Trim / Break -> Trim / Break / Extend ■ select 1 Entity Mastercam X2 prompts for geometry to trim. ■ select as shown in Figure 6.3.1
Figure 6.3.1: Select geometry to trim. Mastercam X2 trims the geometry. ■ select OK
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Your drawing should look like Figure 6.3.2.
Figure 6.3.2: Trimmed lines.
Section 4: Break Circles To create the blades, you want the portion of the circles that is between the two lines. In order to do this, you need to break the circles at the intersection of it and the lines. Then, you can delete the portion of the circle that you don't need. ■ select Edit -> Trim / Break -> Break at Intersection Mastercam X2 prompts for geometry to break. ■ select both circles and both lines ■ select End Selection Mastercam X2 breaks the circles at the intersections of the lines. Your drawing should not change at all. Next, delete the unneeded parts of the circles: ■ select the left side of the small circle ■ select the left side of the large circle ■ press DELETE Mastercam X2 deletes the unneeded parts of the circles. Your drawing should look like Figure 6.4.1.
Figure 6.4.1: Circles deleted.
Section 5: Join Lines The circles have a natural break point on the right side of the circle. The remaining arcs need to be joined into one entity to continue. Using the join command, you can join objects into a single entity. ■ select Edit -> Join entities
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Chapter 6: Using Primitives and Multisurface Toolpaths
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Mastercam X2 prompts for geometry to join.
■ select the two arc sections as shown in Figure 6.5.1
Figure 6.5.1: Join the two arc segments. ■ select End Selection Mastercam X2 joins the two arc segments together. Next, join the other two on the right side of the drawing: ■ select Edit -> Join entities ■ select as shown in Figure 6.5.2
Figure 6.5.2: Join the two large arc segments. ■ select End Selection Mastercam X2 joins the arcs. Your drawing should not look any different. Now is a good time to save your drawing: ■ select File -> Save Since you are saving for the first time, Mastercam X2 displays the Save dialog. In the File name field: ■ type TURBINE plus your initials. Example: TURBINENWT ■ select Save Mastercam X2 saves your drawing.
Section 6: Create Blade Surface Now that the blade geometry is complete, create a ruled surface over the blade. ■ select Create -> Surface -> Create Ruled/Lofted Surfaces... Mastercam X2 displays the Chaining window and prompts for geometry to create the surface from. ■ select Single ■ select the small arc on the left side of the screen Mastercam X2 will display arrows indicating the surface direction when you select the small arc. Memorize the direction of the arrows, as the arrows on the second arc will need to face the same way. ■ select the large arc on the right side of the drawing
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If the arrows do not face the same way as the first arc: ■ select Reverse When the arrows face the same way as the first arc: ■ select OK ■ select Ruled
This is on the left side of the Ribbon Bar.
■ select OK Mastercam X2 creates the ruled surface. Your drawing should look like Figure 6.6.1.
Figure 6.6.1: The blade surface.
Section 7: Rotate Surface Next, rotate the surface to give it pitch. First, change your Gview and Cplane to Right Side: ■ press ALT-5 ■ press ALT-F1 Mastercam X2 displays your drawing from the right side. ■ select Xform -> Xform Rotate... Mastercam X2 prompts for geometry to rotate. ■ select All in the toolbar ■ select All Entities ■ select End Selection Mastercam X2 displays the Rotate dialog: ■ select Move ■ select Define center of rotation Mastercam X2 prompts for a center of rotation. Use the autocursor to select the middle of the horizontal line: ■ select the midpoint of the line using the autocursor Next, set the angle of rotation. In the angle field: ■ type 20.0 press ENTER
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Mastercam X2 displays a preview of the rotated geometry. Your drawing should look like Figure 6.7.1.
Figure 6.7.1: Preview of blade rotation. If it does: ■ select OK ■ select Screen -> Clear Colors ■ press ALT-F1 Your wing should become green.
Section 8: Create Primitive Torus Change your Gview back to top: ■ press ALT-1 ■ press ALT-F1 ■ press F2 Mastercam X2 zooms out on the blade. Create the primative torus: ■ select Create -> Primitives -> Create Torus... In the major radius field, Top Number: ■ type 0.25 press ENTER In the minor radius field, Bottom Number: ■ type 0.125 press ENTER Mastercam X2 prompts for a torus base point: ■ select the small dot signifying the center of the two arcs Mastercam X2 displays a preview of the torus. Your drawing should look like Figure 6.8.1.
Figure 6.8.1: Preview of the torus primative. ■ select OK Display the part in isometric view: ■ press ALT-7 ■ press ALT-F1 Turn shading on: ■ select Screen -> Shade Settings...
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Mastercam X2 displays the Shading Settings dialog. Match your settings with those in Figure 6.8.2 to turn shading on:
Figure 6.8.2: Shading on. ■ select OK Your drawing should look like Figure 6.8.3.
Figure 6.8.3: Shaded blade and torus. Save your drawing: ■ select File -> Save
Section 9: Create Surface to Surface Fillet Next, create a fillet to join the blade to the torus. ■ select Create -> Surface -> Fillet Surface -> Fillet Surfaces to Surfaces... Mastercam X2 prompts for the first set of surfaces: ■ select the torus
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Chapter 6: Using Primitives and Multisurface Toolpaths
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■ select End Selection Mastercam X2 prompts for the second set of surfaces: ■ select the blade surface ■ select End Selection Mastercam X2 warns about no fillets found: ■ select OK Mastercam X2 displays the Fillet Surfaces to Surfaces dialog: ■ select Flip Normal Mastercam X2 prompts for a surface to flip: ■ select the torus ■ press ENTER Mastercam X2 flips the normal on the torus and displays a preview of the fillet. In the radius field: ■ type 0.05 press ENTER Trim the blade surface to the fillet: ■ select Trim so that it is checked. ■ select Join so that it is checked. ■ select OK Your drawing should look like Figure 6.9.1.
Figure 6.9.1: Fillet between blade and torus.
Section 10: Create Blades Now that one blade and fillet are complete, create the other 17 blades that make up the turbine by rotating this one around the torus. ■ press ALT-1 ■ press ALT-F1 ■ select Xform -> Xform Rotate... Mastercam X2 prompts for geometry to rotate: ■ select the blade surface ■ select the fillet surface between the blade and the torus Make sure both surfaces are selected.
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This book is to be distributed freely and may be copied or printed as needed. ■ select End Selection Mastercam X2 displays the Rotate dialog. ■ select Copy In the number field: ■ type 17 press ENTER In the angle field: ■ type 20 press ENTER There should be 18 blades wrapped around the center torus. ■ ■ ■ ■
select OK press ALT-7 press ALT-F1 select Screen -> Clear Colors
Your drawing should look like Figure 6.10.1.
Figure 6.10.1: Completed turbine.
Section 11: Translate Translate all of the geometry so that it will be below the top of the stock. ■ select Xform -> Xform Translate... Mastercam X2 prompts for geometry to translate: ■ select All in the toolbar ■ select All Entities ■ select End Selection Mastercam X2 selects all of the entities and displays the Translate dialog. ■ select Move In the ∆Z field: ■ type -0.2 press ENTER ■ select OK ■ select Screen -> Clear Colors Mastercam X2 translates the geometry. Your drawing should not look any different.
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Section 12: Stock Setup Before creating the toolpaths, tell Mastercam X2 what your stock looks like. In the Toolpaths tab at the left of the screen: ■ select the Plus icon on Properties Properties expands, allowing you to select Stock Setup.
■ select Stock Setup
Mastercam X2 displays the Stock Setup dialog. Set your parameters as shown in Figure 6.12.1:
Figure 6.12.1: Stock Setup dialog. ■ select OK Save your drawing: ■ select File -> Save
Section 13: Rough Parallel Toolpath Make sure your Cplane is set to Top: ■ select Planes -> Top (WCS) at the bottom of the Mastercam X2 window Now, make a toolpath to machine your part. ■ select Toolpaths -> Surface Rough -> Rough Parallel Toolpath... Mastercam X2 displays the Select Boss/Cavity dialog. ■ select Boss ■ select OK
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■ type TurbineNWT
■ select OK Mastercam X2 prompts for drive surfaces. ■ select All in the toolbar Mastercam X2 displays the Select All window. It has automatically selected surfaces, so selecting OK will select all of the surfaces. ■ select OK ■ select End Selection Mastercam X2 displays the Toolpath/surface selection dialog: ■ select OK Mastercam X2 displays the Surface Rough Parallel dialog. NOTE: There are three tabs of parameters that must be set before you can create the toolpath. Do not press OK until all three have been set. ■ select Select library tool... Mastercam X2 displays the Tool Selection dialog. ■ select #252 Endmill2 Sphere 0.2500" as shown in Figure 6.13.1
Figure 6.13.1: #252 1/4" ball endmill. ■ select OK
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Chapter 6: Using Primitives and Multisurface Toolpaths
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Set your Toolpath Parameters as shown in Figure 6.13.2.
Figure 6.13.2: Toolpath Parameters. Set your Surface Parameters as shown in Figure 6.13.3.
Figure 6.13.3: Surface Parameters.
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Set your Rough Parallel Parameters as shown in Figure 6.13.4.
Figure 6.13.4: Rough Parallel Parameters. ■ select OK Mastercam X2 creates the toolpath. Your drawing should look like Figure 6.13.5.
Figure 6.13.5: Parallel Toolpath. Save your drawing: ■ select File -> Save
Section 14: Finish Radial Toolpath Next, create the finish toolpath. Turn off toolpath display on the first toolpath so that you can see the turbine surfaces: ■ select Select All Operations ■ select Toggle Toolpath Display Mastercam X2 hides display of the first toolpath. ■ select Toolpaths -> Surface Finish -> Finish Radial Toolpath... Mastercam X2 prompts for drive surfaces. ■ select All in the toolbar
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Chapter 6: Using Primitives and Multisurface Toolpaths
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Mastercam X2 displays the Select All window. It has automatically selected surfaces, so selecting OK will select all of the surfaces. ■ select OK ■ select End Selection Mastercam X2 displays the Toolpath/surface selection dialog. ■ select OK Mastercam X2 displays the Surface Finish Flowline dialog. Use the same tool as before. Set your Toolpath Parameters as shown in Figure 6.14.1.
Figure 6.14.1: Toolpath Parameters. Set your Surface Parameters as shown in Figure 6.14.2.
Figure 6.14.2: Surface Parameters.
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Set your Finish Radial Parameters as shown in Figure 6.14.3.
Figure 6.14.3: Finish Radial Parameters. ■ select OK Mastercam X2 prompts for a radial center point:
■ select Origin
in the toolbar
Mastercam X2 creates the finish toolpath. Turn all toolpath display on: ■ select Select All Operations ■ select Toggle Toolpath Display Your drawing should look like Figure 6.14.4.
Figure 6.14.4: Finish Radial Toolpath. Save your drawing: ■ select File -> Save
Section 15: Verify Verification allows you to see what your part will look like without actually machining it.
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■ select Select All Operations ■ select Verify Selected Operations ■ press ALT-F1 Mastercam X2 displays the Verify Controller. ■ select Simulate Tool ■ select Machine Mastercam X2 machines your part. You can control the speed and quality by adjusting the options in the Verify Controller. When your part is machined, it should look like Figure 6.15.1.
Figure 6.15.1: Verified Boat. If it does: ■ select
on the Verify Controller dialog
Mastercam X2 exits verify mode.
Section 16: Post Processing Now that you have verified your part, it is time to generate NC code so that you can machine a real part. In the Toolpaths tab on the left of the Mastercam X2 window: ■ select Select All Operations ■ select Post Selected Operations
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Mastercam X2 displays the Post Processing dialog. Match your settings with those shown in Figure 6.16.1.
Figure 6.16.1: Post Processing. ■ select OK Mastercam X2 displays a Save dialog for you to save your NC file. In the File name field: ■ type TURBINE plus your initials. Example: TUBINENWT ■ select Save Mastercam X2 saves your NC file. You can use this to machine your part, if you want. Finally, save your file: ■ select File -> Save Since you saved your file before, Mastercam X2 silently saves the changes you have made since then, without prompting again for a file name.
Congratulations! You have completed the Turbine Exercise!
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Glossary
Glossary
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Glossary
2
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2D 2 Dimensional. When in this mode, Mastercam X2 creates all entities on the specified Cplane, such as Top, Front, or Right Side. Entities are also created at the set Z depth.
A window that appears during operations that require selected geometry. The dialog allows you to select geometry using Chain, Area, Window, Single, Polygon, Vector, or Partial selection modes. It allows allows for the unselecting of geometry, or for the reversal of the direction indicator, should it apply.
Chamfer The trimming of two intersecting lines by a third line of any length. The line is created at an angle equal to half of the angle of the two intersecting lines.
3 3D 3 Dimensional. When in this mode, Mastercam X2 allows you to create entities at any Z depth. The plane setting is still respected when creating new entities not based on existing geometry. When creating entities based off of other entities, however, the Cplane is ignored. This allows you to link other geometry without setting the correct Cplane.
A
Context Menu A menu that appears when right-clicking in the drawing area. By default, it contains functions for setting the Gview and controlling Zoom levels. You can also customize it by adding any function you wish
Contour Usually refers to a toolpath. The toolpath will follow specific geometry, either on the left or right sides, or centered on the geometry. A contour can also be a name for geometry.
Coordinates
Arc A section of a circle, usually created by specifying a radius or diameter and a start and end angle. The 0 angle position is along the positive X axis.
Cartesian coordinates refer to measurements in 2D or 3D using the X, Y, and Z values. The origin is X0 Y0 Z0. Polar coordinates are specified with a radius an an angle.
Cplane
B
Short for construction plane. Refers to the plane on which new geometry will be created, if the 2D/3D mode is set to 2D. This plane is independent of the Gview and Tplane.
Backplot
Cylinder
A function similar to verification that allows you to step though a toolpath's operation. The tool is drawn directly on your existing drawing. As the toolpath progresses, it's path is drawn on the screen.
A primative cylinder can be created either as a solid or a surface. It is made by extruding a circle to a specified height.
Bevel The angle or inclination of a line or surface that meets another at a non-90° angle. Two rules joined together as adjustable arms used to measure or draw angles of any size or to fix a surface at an angle. Also called bevel square.
Block Refers to one of the provided Mastercam fonts for lettering.
Boolean Add A solid modifier that combines two solids by adding their structures.
Boss A boss surface is one that will be machined by cutting up to its outer limits.
D Differential A bevel gear that permits rotation of two shafts at different speeds; used on the rear axle of automobiles to allow wheels to rotate at different speeds on curves.
Draft A surface created from a single geometry entity. Parameters allow you to specify length and angle of the surface.
Drill Toolpath used to drill holes in stock. Parameters allow for multiple drills in a single toolpath, as well as drill hole arrays.
Dynamic
A font provided by Mastercam commonly used for lettering.
A method for rotating your Gview in 3D in real time. Moving the mouse rotates the Gview, so all sides of the part can be seen.
C
E
Cavity
Endpoint
Box
A surface that will be machined by cutting out its insides.
Chain A selection mode that will select all geometry connected to the entity selected with the cursor.
The point corresponding to the end of the a line, arc, or other 2D geometry.
Extrude A method of creating a solid by adding thickness to a closed planar chain.
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F
Geometry made of arcs and lines that forms Roman characters. Used for
Fillet
Line
An arc created at the intersection of two 2D entities. Used primarily to smooth sharp corners cause by two intersecting lines. Similar to a chamfer, but used with
A single linear geometric entity in Mastercam X2, defined by its two endpoints.
Linear
Filter Used in the tool manager to limit the results displayed to a specific tool or tools.
Geometry that is linear can be duplicated by drawing a line through the two endpoints. Linear geometry has a constant slope.
Fit Screen
Loft
A function used to set the zoom exactly as it should be to view all of the geometry in the drawing at its maximum size. This can be accessed in the context menu or by pressing ALT-F1
Flat Boundary A type of surface created from a closed planar chain.
Loft surfaces are created from a set of ribs. The surface follows curvature based on the ribs. Lofted solids are created similarly, but the end result is a solid, not a surface.
M
Flowline A toolpath that cuts along the "grain" of a surface or surfaces. The tool will follow the contours of the part when machining. Both Rough and Finish versions of this toolpath are available.
MCX The file extension of a Mastercam X2 drawing file.
Midpoint A point on a line where the distance from the point to each endpoint is identical.
G
Mirror Gear
To move or copy geometry by reflecting it over a line.
A toothed machine part, such as a wheel or cylinder, than meshes with another toothed part to transmit motion or to change speed or direction.
MRU
Geometry Entities created in Mastercam X2. Usually refers to 2D geometry such as lines, arcs, circles, and splines. Used to create other entities such as surfaces, solids, and toolpaths.
Gview Geometry view. Controls how the part is displayed on the screen. Changing the view changes how you look at the part. Common Gviews include Top, Front, and Right Side. In most parts, you will switch between Gviews often when creating geometry.
Most Recently Used toolbar. Usually appears at the right side of the Mastercam X2 window. Displays icons for recently used functions. Every time you use a new function it is added to this list.
N NC Numerical Code. G&M code created by a post processor. This code is sent to your CNC Mill/Lathe and instructs it how to machine your part..
O
H Horizontal A method for constraining the creation of a line. The Y value of the line remains constant.
Offset To move or copy linear by a delta value. Similar to Translate except translation can only occur in one direction. The Cplane is respected when choosing where to place the offset geometry.
Offset Contour
I Island A area in a pocket toolpath that is excluded from machining. A pocket toolpath can have multiple islands.
Similar to offset. Allows chains of geometry, including arcs and circles to be selected. If the geometry selected is a closed chain, Offset Contour scales the part larger or smaller depending on the offset side chosen.
Origin
Isometric
The point X0 Y0 Z0.
Often referred to as 2.5D. Allows you to see your part in psuedo-3D. (Isometric lacks perspective shown in true 3D)
P
L
Parallel Rough and Finish parallel toolpaths are available for machining surfaces. The tool makes parallel passes over the stock, with
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Glossary
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one or more plunges in each path. Also a method of creating lines by duplicating the slope of an existing line.
Pocket Toolpath allowing an area of your drawing to be cut to a constant depth.
Ruled
A type of surface made from a set of ribs by concatenating planar surfaces. Similar to loft except the resulting surface is not curved.
S
Point Entity representing a single point, such as X3 Y2 Z0.
Polar
Scale
A coordinate system in which points are defined in terms of a radius R and angle θ.
An Xform that transforms geometry by adjusting its size. Geometry is scaled around a point of origin. A scale factor of 1.0 indicates no change, a smaller factor will reduce the size of the part.
Post Processor An interpreter used with Mastercam X2 to generated the correct NC code for your CNC Mill/Lathe. The post processor should be included with the machine. Post processors for V9 will need to be updated to work with VX.
Primative A primative is a solid or surface entity that is complex to create normally. Primitives consist of Cylinders, Cones, Blocks, Spheres and Toruses.
Shading Toggles shading on or off. When shading is on, surfaces and solids are draw as such -- they are opaque. This can be helpful when visualizing your part.
Shell A solid modifier function that "shells" a solid by opening one of it's faces. The solid is then given a thickness.
Side
R
A Gview that views the part from either the left or right side.
Sketch Radial Both Rough and Finish Radial toolpaths are available for machining surfaces. The tool starts from an origin, usually in the center of the part, and proceeds to machine the part by moving around in circles.
Radius A property of an arc or circle that controls its size. The radius is half of the diameter.
Rectangle
A method of entering points by simply clicking the mouse in the drawing area. Without the autocursor, this is usually very imprecise.
Solid An entity created from wireframe geometry. Represents a real world physical entity. The chain it is created from must be closed. Solids can be created as Extrude, Revolve, Sweep or Loft. Solids can also be filleted, chamfered, trimmed and shelled.
An entity consisting of four lines.
Spline
Revolved
A continuous curve that goes through several points.
A chain of geometry can be revolved around an axis of revolution, a line, to create either a solid or surface. For solids, the chain must be closed.
Stock Setup Dialog that allows you to define the size of your stock and display it on the screen.
Rotate
Surface
An Xform method that transforms geometry by rotating it around a single point. The geometry can be either moved or copied. The current Cplane determines how the geometry will be rotated.
Rough
An entity made from wireframe geometry that specifies a 3D contour for machining. Often surfaces indicate actual faces of the final part. Surfaces can be modified using trim, extend, and fillets. Surfaces can be created as Draft, Loft, Ruled, Revolved, Swept, or Flat Boundary surfaces.
A toolpath made for machining the bulk of the stock that needs to be removed. Rough toolpaths are usually done with a moderately large tool, large step over, and a small amount of stock left on the part.
Swept A swept surface is created by "sweeping" a single contour across multiple other contours, usually 2. A swept solid is created similarly, but produces a solid instead of a surface.
N
T
Normal
Toolpath
The surface normal controls which side of the surface is the "front". Changing the normal is sometimes necessary when creating surface to surface fillets.
A toolpath is created to machine a part. It consists of instructions for how to move the tool to machine the part as desired. Many different types of toolpaths are available to cut a wide variety of parts.
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Toolpaths Tab
A tab at the left of the Mastercam X2 window that displays all of the toolpaths used in the drawing. It also displays the machine and stock used. Selecting these items brings up configuration windows.
Torus A type of primative created as either a surface or solid. A torus is a doughnut shaped entity.
Trim / Break A combined function in Mastercam X2 that integrates trim and break functions. Trim functions include Trim 1 Entity, Trim 2 Entities, Trim 3 Entities and Trim Divide. An entity is trimmed to another by either removing excess geometry past the entities' intersection or extending the geometry to the intersection.
V Verification A way to see your part as it would be machined, without machinging it.
Vertical A method for constraining the creation of a line. The X coordinate remains constant.
W Window A selection mode that allows you to drag a selection window around geometry that you want to select.
Z Zoom A function that allows you to view in detail small sections of your geometry. You can zoom in by pressing F1 and dragging a window around the area you want to view in detail. Zoom out by pressing F2
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