TRAINING GUIDE

MILL-LESSON-3 DRILLING

Mastercam Training Guide Objectives You will create the geometry for Mill-Lesson-3, and then generate a toolpath to machine the part on a CNC vertical milling machine. This Lesson covers the following topics:  Create a 2-dimensional drawing by: Creating lines. Creating arcs. Using Xform Translate to copy entities. Using Xform Rotate to copy entities.  Establish Stock Setup settings: Stock size. Material for the part. Feed calculation.  Generate a 2-dimensional milling toolpath consisting of: Drill toolpath.  Inspect the toolpath using Mastercam’’s Verify and Backplot by: Launching the Verify function to machine the part on the screen. Using Backplot to identify the correctness of the toolpaths. Generating the NC- code.

Mill-Lesson-3 - 1

MILL-LESSON-3 DRAWING

Mill-Lesson-3 - 2

Mill-Lesson-3

Mastercam Training Guide TOOL LIST Two cutters will be used to create this part. Â The .5 diameter spot drill to spot drill all the .25 diameter holes. Â The .25 diameter drill to drill all the .25 diameter holes through the part.

MILL-LESSON-3 - THE PROCESS TASK 1: TASK 2: TASK 3: TASK 4: TASK 5: TASK 6: TASK 7:

Geometry Creation Setting the environment Introduction Create the Lines for the 3 x 3 Rectangle Create the .25 Diameter Circle at the Center of the Part Create the First Circle for the Bolt Hole Circles Create the Bolt Hole Circle using Xform Rotate Save the drawing

TASK 8: TASK 9: TASK 10: TASK 11: TASK 12: TASK 13: TASK 14:

Toolpath Creation Define the Rough Stock using Stock Setup Spotdrill all .25 Diameter Holes Drill all .25 Diameter Holes Backplot the Toolpath Verify the Toolpath Save the Updated Mastercam File Post and Create the CNC Code File Mill-Lesson-3 - 3

Mill-Lesson-3 TASK 1: SETTING THE ENVIRONMENT Before starting the geometry creation you should set up the grid, toolbars and machine type as outlined in the Setting the environment section at the beginning of this text: 1. Set up the Grid. This will help identify the location of the origin. 2. Customize the toolbars to machine a 2D part. 3. Set the machine type to a Haas Vertical Spindle CNC machine.

TASK 2: INTRODUCTION Â This task explains how to create the four lines that make up the main body of Mill-Lesson-3. These lines could be created in many different ways, this is just one option. Â Note the location of X0 Y0 and the direction of the X and Y axis as shown below. Â You will start to create line 1 first and then move around in a clockwise direction to create the remaining lines 2,3 and 4 as shown below:

Mill-Lesson-3 - 4

Mastercam Training Guide  To create this series of lines you need to refer to the dimensioned part drawing for MillLesson-3 and determine the absolute values in the X and Y axis for the endpoints of the individual lines.  Absolute means the X and Y coordinate all relate to the Origin - the X0 Y0 position.  For more information on co-ordinate systems see the Tips and Techniques section on the multimedia CD supplied with this text.  The X and Y values for the endpoints of the lines are shown below:

Mill-Lesson-3 - 5

Mill-Lesson-3

Geometry Creation TASK 3: CREATE A SERIES OF LINES USING LINE>ENDPOINT THE CENTER OF THE PART IS AT X0 Y0.  Create Line #1 1. Select from the pull down menu: Create>Line>Endpoint…….

2. On the graphics screen you are prompted: Specify the first endpoint and the Line ribbon bar appears.

3. To satisfy this first prompt click on the FastPoint Icon on the Auto Cursor ribbon bar

.

FastPoint When activated, FastPoint mode opens a long empty field over the existing X, Y, Z entry fields, as shown below:

Whenever a coordinate value is required, you can type the coordinates into the FastPoint field. For example, if Mastercam prompts you to specify an endpoint, you activate FastPoint mode and enter the coordinates directly, and press [Enter]. As long as you separate the values with commas, any of the following types of input for an X6,Y3,Z.5 position will work: 6,3,.5 X6,3,.5 6,Y3,.5 6,3,Z.5

Mill-Lesson-3 - 6

Mastercam Training Guide 4. In the space input -1.5,-1.5 values for the first end point of line 1 and hit enter. Note that there is a comma between the X and Y values, and you do not need to input the Z value for this example.

5. You have now input the coordinates for the start of line 1 and the prompt on the graphic screen changes to Specify the second endpoint. 6. To satisfy this prompt click on the FastPoint Icon again . 7. In the space input -1.5,1.5 values for the second end point of line 1 and hit enter. Note that there is a comma between the X and Y values, and you do not need to input the Z value for this example.

8. On the ribbon bar click on Apply

to fix the entity.

 The first line is complete and the prompt changes to Specify the first endpoint. Before you move onto the second line you need to adjust the display of the geometry on the graphics screen.  What you will do now is Zoom and Pan to adjust the graphic screen display so that when creating the remaining lines you will be able to view all the geometry of the part. The View manipulation toolbar is at the top of the screen and is shown below:

9. Select the Screen Fit icon from the toolbar to fit the part to the screen

.

10. Next Select the Un-Zoom .8 icon from the toolbar to shrink the display 11. Now use the RIGHT arrow key on your keyboard to pan the screen over so the first line moves over to the far left of the screen, close to the left toolbar. This will allow the creation of the remaining lines without any need to perform any Zoom display functions. Unzoom .8: Reduces the size of the displayed geometry to 80% of its current size.

Mill-Lesson-3 - 7

Mill-Lesson-3 Â Your part geometry, the first line, should appear as below:

 Create Line #2 12. For the construction of the remaining three lines you will now activate Multi-line on the Line ribbon bar. Click on the Multi-line icon as shown below:

Multi-lines button Lets you create multiple lines connected at their endpoints. Enter a point for the first endpoint of the first line and then a point for the second endpoint of the line. That second point becomes the first endpoint of the next line that you create. Double-click the last point or press Escape to end this function.

Mill-Lesson-3 - 8

Mastercam Training Guide  On the screen you are prompted to Specify the first endpoint. For the selection of this point you will employ the use of the AutoCursor to select the endpoint of the line you just created. 13.

Move the cursor over the last end point of the first line you just created and as you get close to the end point a visual cue appears. This is the cue that will allow you to snap to the endpoint of this line. With this visual cue highlighted pick the end point of the line.

 You have now input the coordinates for the start of line 2 and the prompt on the graphic screen changes to Specify the second endpoint. 14. To satisfy this prompt click on the FastPoint Icon again In the space input 1.5,1.5 values for the second end point of line 2 and then hit enter. Note that there is a comma between the X and Y values, and you do not need to input the Z value for this example.

Mill-Lesson-3 - 9

Mill-Lesson-3 Â Create Line #3 Â The prompt on the graphic screen changes to Specify the second endpoint. Â For this endpoint for line 3 you will use the Length and Angle option, The length of the line is 3.0 and the angle is -90. 15. Click in the space for Length and enter 3.0. 16. Hit the Tab key to move over to the Angle value, enter a value of -90 and hit enter. This completes the third line.

 17. 18. 19.

Create Line #4 The prompt on the graphic screen changes to Specify the second endpoint. Click in the space for Length and enter 3.0. Hit the Tab key to move over to the Angle value, enter a value of 180 and hit enter. This completes the fourth line.

20. Click on the OK icon

to complete this feature.

21. Select the Screen Fit icon to fit the part to the screen

.

22. Next Select the Un-Zoom .8 icon from the toolbar to shrink the display  The geometry created is shown below.

Mill-Lesson-3 - 10

.

Mastercam Training Guide TASK 4: CREATE THE .25 DIAMETER CIRCLE AT THE CENTER OF THE PART  In this task you will first create the .25 diameter circle, with the center at X0 Y0. 1. Select Create>Arc>Circle Center point……

2. The Circle Center Point ribbon bar appears and you are prompted to Enter the center point.

3. Click in the space for diameter (shown above) and enter a value of .25 and then hit the enter key. 4. To satisfy the prompt Enter the center point click on the drop down to review the selection of overrides in the AutoCursor toolbar and then select Origin (X0 Y0).

5. Click on the OK icon

to complete this feature.

Mill-Lesson-3 - 11

Mill-Lesson-3 TASK 5: CREATE THE FIRST CIRCLE FOR THE BOLT HOLE CIRCLE .25 DIAMETER CIRCLE  In this task you will first create the .25 diameter circle shown with the arrow below.  You will accomplish this by using Xform Translate to make a copy of the first circle and translate it 1.0 along the X axis from the center circle. 1. Select Xform>Translate……

2. You are first prompted to Translate: select entities to translate Select the .25 diameter circle at the center of the part as shown below:

Mill-Lesson-3 - 12

Mastercam Training Guide

3. To move onto the next step you now need to pick the End Selection icon located over in the top right of the screen as shown below:

. This is

4. After selecting End Selection the Translate Dialog Window appears, Set the following values: A: Activate Copy, by ensuring the green dot is visible for the copy radio button. B: The number of items to be copied is 1. C: The Delta X value is 1.0. The distance you need to translate along the X axis. Translate Dialog Window Use this dialog box to move, copy or join entities within the same view (plane), without altering their orientation, size, or shape. You can translate all geometric and drafting entity types using: Rectangular coordinates (X, Y, Z). Polar coordinates (vector and length). For more information on Translating see the Tips and Techniques section on the multimedia CD supplied with this text.

Mill-Lesson-3 - 13

Mill-Lesson-3 5. Click on the OK icon to complete this feature. 6. Click on the Clear Colors at the top right hand corner of the screen. Clear Colors Removes the group and result colors from affected entities and from the database. When performing a transform function (Xform), Mastercam creates a temporary group from the originals (red) and a result (purple) from the transformed entities. These system groups appear in the Groups dialog box. However, they stay in effect only until you use the Screen, Clear Colors function or perform another transform function.

TASK 6: CREATE THE BOLT HOLE CIRCLE USING XFORM ROTATE .25 DIAMETER CIRCLE 10 PLACES EQUI SPACED  In this task you will create the bolt hole circle: .25 diameter circles equally spaced on a 2.0 diameter circle 10 places. Refer to the drawing of the part at the start of this lesson.  The angle between each circle 360°/10 = 36°.  You will accomplish this by using Xform Rotate to make copies of the circles around the bolt hole. 1. Select Xform>Xform Rotate……

2. You are first prompted to Rotate: select entities to rotate Select the .25 diameter circle on the right of the part shown above. 3. To move onto the next step you now need to pick the End Selection icon located over in the top right of the screen as shown below:

Mill-Lesson-3 - 14

, This is

Mastercam Training Guide 4. After selecting End Selection the Rotate Dialog Window appears, Set the following values: A Activate Copy, by ensuring the green dot is visible for the radio button. B Enter the number of items to be copied is 9 and hit Enter. C Activate the Angle between as shown below: D

Denotes the entities will be rotated around the Origin (X0Y0). This is what you will be doing for this example. E Input the Angle between each circle: 36°. F The radio button for Rotate is activated. Â After you have input these values a preview of the rotated entities will be displayed on the screen as shown below: Rotate Dialog Window Use this dialog box to move, copy, or join selected geometric and drafting entities around a center point. You can translate or rotate the entities around the selected center point by a specified angle. For more information on Rotating see the Tips and Techniques section on the multimedia CD supplied with this text.

5. Click on the OK icon

to complete this feature.

6. Click on the Clear Colors at the top right hand corner of the screen

Mill-Lesson-3 - 15

.

Mill-Lesson-3 TASK 7: SAVE THE DRAWING 1. 2. 3. 4.

Select File. Select Save as…… In the File name box, type Mill-Lesson-3. Save to an appropriate location.

5. Select the green check mark button

to save the file and complete this function.

Mill-Lesson-3 - 16

Mastercam Training Guide

Toolpath Creation TASK 8: DEFINING THE ROUGH STOCK USING STOCK SETUP 1. For a better view of the part, use the toolbar at the top of the screen to change the graphics view to Isometric.

. 2. Now select the Fit to screen icon 3. Your screen should look like the image below:

4. Select the plus in front of Properties to expand the Toolpaths Group Properties.

Mill-Lesson-3 - 17

Mill-Lesson-3 5. You may need to extend the toolpaths manager window, if so left mouse button click on the right hand pane hold and extend to the right.

6. Select Stock setup in the Toolpaths manager window.

7. Change the parameters to match the Stock Setup screenshot below:

Mill-Lesson-3 - 18

Mastercam Training Guide 8. Select the Tool Settings tab and change the parameters to match the Tool Settings screenshot below. To change the Material type follow the next set of instructions.

9. To change the Material type to Aluminium 6061 pick the Select button at the bottom of the Tool Settings page.

10. At the Material List dialog box open the Source drop down list and select Mill –– library.

Mill-Lesson-3 - 19

Mill-Lesson-3 11. From the Default Materials list select ALUMINIUM inch - 6061 and then select

12. Select the OK button

.

again to complete this Stock Setup function.

TASK 9: SPOT DRILL ALL THE .25 DIAMETER HOLES Â In this task, you will spot drill all the .25 diameter holes with a .5 spot drill. 1. Change the graphics view to a Top View by using the toolbar at the top of the screen.

2. From the menu bar select Toolpaths>Drill……

3. When prompted to Enter new NC name ensure Mill-Lesson-3 is displayed and then select the OK button

.

Mill-Lesson-3 - 20

Mastercam Training Guide 4. Now you are prompted to:

5. The Drill Point Selection dialog box appears.

6. Your screen will look similar to the screenshot below:

Mill-Lesson-3 - 21

Mill-Lesson-3 7. As you need to spot drill all eleven holes at the center of the .25 diameter circles, click on Entities button in the Drill Point Selection dialog window to activate it as shown below. The Entities icon is pressed down to signal that it is activated and the prompt on the screen changes to Select Entities. Entities Return to the graphics window to select entities. You are prompted to Select Entities. Mastercam will place drill points at the endpoints of the selected entities. If you select closed arcs, the drill points are placed in the center of the arcs. Mastercam sorts the points based on the order that the geometry was created (click Sorting to change the order).

8. To capture the center points of the circles left mouse click approximately at position 1 hold the mouse button down and drag to the right and down and release the mouse button at approximately position 2. Then pick at approximately position 2. What you have done is described a window around the entities you wish to capture.

Mill-Lesson-3 - 22

Mastercam Training Guide 9. Select the OK button in the Drill Point Selection dialog window to complete the selection of points. Â After selecting the OK button, you are confronted with the Drill Toolpath Type page. The first task here will be to select a .5 diameter Spot Drill. 10. Ensure the Toolpath Type is set to Drill as shown below and then select Tool from the list on the left.

11. Click on the Select library tool button in the lower left corner.

Mill-Lesson-3 - 23

Mill-Lesson-3 12. Select the .5 Spot Drill by picking anywhere along its row, as shown below:

to complete the selection of this tool. 13. Select the OK button 14. Make changes to the Tool parameter page as shown below:

Mill-Lesson-3 - 24

Mastercam Training Guide 15. Select Cut Parameters from the list on the left and make changes to this page as shown below. The Cycle should be set to Drill/Counterbore.

16. Select Linking Parameters from the list on the left and make changes to this page as shown below. Input the depth of -0.14 and the other values as shown below. Note all the values are set to Absolute.

Mill-Lesson-3 - 25

Mill-Lesson-3 17. Select Coolant from the list on the left. Open up the drop down menu for Flood and set it to On.

to complete this function. 18. Select the OK button 19. Your part should look like the screenshot below:

Mill-Lesson-3 - 26

Mastercam Training Guide TASK 10: DRILL ALL THE .25 DIAMETER HOLES  In this task you will drill all the.25 diameter holes with a .25 drill. 1. From the menu bar select Toolpaths>Drill……

2. Now you are prompted to:

3. The Drill Point Selection dialog box appears.

Mill-Lesson-3 - 27

Mill-Lesson-3 4. Your screen will look similar to the screenshot below:

5. As you need to drill all eleven holes at the center of the .25 diameter circles, click on Entities icon in the Drill Point Selection dialog window to activate it. As shown below, the Entities icon is pressed down to show it is activated and the prompt on the screen changes to Select Entities.

Mill-Lesson-3 - 28

Mastercam Training Guide 6. To capture the center points of the circles left mouse click approximately at position 1 hold the mouse button down and drag to the right and down and release the mouse button. Pick at approximately position 2. What you have done is described a window around the entities you wish to capture.

7. Select the OK button selection of points.

in the Drill Point Selection dialog window to complete the

 After selecting the OK button, you are confronted with the Drill Toolpath Type page. The first task here will be to select a .25 diameter drill. 8. Ensure the Toolpath Type is set to Drill as shown below and then select Tool from the list on the left.

Mill-Lesson-3 - 29

Mill-Lesson-3 9. Click on the Select library tool button in the lower left corner.

10. Scroll down and select the .25 diameter drill by picking anywhere along its row, as shown below:

11. Select the OK button

to complete the selection of this tool.

Mill-Lesson-3 - 30

Mastercam Training Guide 12. Make changes to the Tool parameter page as shown below:

13. Select Cut Parameters from the list on the left and make changes to this page as shown below. The Cycle should be set to Drill/Counterbore.

Mill-Lesson-3 - 31

Mill-Lesson-3 14. Select Linking Parameters from the list on the left and make changes to this page as shown below. Input the depth of -0.25 and the other values as shown below. Note all the values are set to Absolute.

15. Select the plus sign to the left of Linking Parameters to expand the list and click on Tip Comp.

Mill-Lesson-3 - 32

Mastercam Training Guide 16. Ensure Tip Comp is activated as shown below by the green check mark. Breakthrough amount is set to 0.1

17. Select Coolant from the list on the left. Ensure Flood and set it to On.

18. Select the OK button

to complete this function.

Mill-Lesson-3 - 33

Mill-Lesson-3 Â Your part should look like the screenshot below:

TASK 11: BACKPLOT THE TOOLPATH  In this task you will use Mastercam’’s Backplot function to view the path the tools take to cut this part.  Backplot will enable you to review the cutting motions and identify any problem areas when cutting the part.  When the toolpath is being Backplotted Mastercam displays the current X, Y, and Z coordinates in the left side of the status bar - lower left corner of the screen. 1. To pick all the operations to backplot pick the Select All icon

circled below:

 Another method to Select all the operations is by clicking on the Toolpath Group-1 in the Tool Manager as shown by the arrow above. 2. The next step is to select the Backplot selected operations icon shown below:

Mill-Lesson-3 - 34

Mastercam Training Guide 3. Before you Backplot the toolpath ensure the two buttons shown below are activated. The option on the left will Display Tool and the option on the right will Display rapid moves. These buttons act like a toggle switch, pressed in activates the function.

4. Select the Isometric view from the view toolbar.

5. Select the Screen Fit icon to fit the part to the screen . 6. Set the run speed on the Backplot VCR midway along the sped bar as shown by the arrow below and then select the play button.

7. After reviewing the backplot of the two toolpaths using a .25 center drill and .25 drill select the OK button

to exit Backplot.

Mill-Lesson-3 - 35

Mill-Lesson-3 TASK 12: VERIFY THE TOOLPATH Â Mastercam's Verify utility allows you to use solid models to simulate the machining of a part. The model created by the verification represents the surface finish, and shows collisions, if any exist. Â This allows you to identify and correct program errors before they reach the shop floor. 1. In the Toolpath Manager pick all the operations to verify by picking the Select All icon . 2. Select the Verify selected operations button circled below:

3. Select the Options button

.

Mill-Lesson-3 - 36

Mastercam Training Guide 4. Change the Verify Options to those shown below:

About the Verify Options dialog box: Initial stock size source: Stock Setup: Uses any available stock boundary information from the Job Setup dialog box to determine the stock boundaries. This is the default option. Miscellaneous options Use TrueSolid: Switches between Standard mode and TrueSolid mode. Standard mode is pixel-based, while TrueSolid uses advanced solid modeling technology to create and manipulate complete and accurate solid models for toolpath simulation. TrueSolid also uses OpenGL graphics for dynamic 3D solid rendering and animation. Cutter compensation in control: Allows you to view simulated cutter compensation during the verification process, if you selected cutter compensation in control in the toolpath. Change tool/color: Changes the color of the cut stock to indicate tool changes in the toolpath. You can set these colors by choosing the Set colors button. Once Mastercam has reached the last color, all subsequent tool changes remain in the last cut stock color. 5. Select the OK button to exit Verify Options. 6. Adjust the Verify speed to midway along the speed control bar.

Mill-Lesson-3 - 37

Mill-Lesson-3 7. Select the play button to verify the two toolpaths.

8. The verified toolpaths should appear as in the picture below, with a small countersink on the holes. This countersink was generated by the spot drill.

9. Select the OK button

to exit Verify.

TASK 13: SAVE THE UPDATED MASTERCAM FILE

1. Select the save icon from the toolbar

Mill-Lesson-3 - 38

.

Mastercam Training Guide TASK 14: POST AND CREATE THE CNC CODE FILE 1. Ensure all the operations are selected by picking the Select All icon Toolpath manager.

from the

2. Select the Post selected operations button from the Toolpath manager. Â Please Note: If you cannot see G1 click on the right pane of the Toolpath manger window and expand the window to the right.

3. In the Post processing window, make the necessary changes as shown below:

About NC Processing NC file: Select this option to save the NC file. The file name and extension are stored in the machine group properties for the selected operation. If you are posting operations from different machine groups or Mastercam files, or batch processing, Mastercam will create several files according to the settings for each machine group. Edit: When checked, automatically launches the default text editor with the file displayed so that you can review or modify it. 4. Select the OK button

to continue.

Mill-Lesson-3 - 39

Mill-Lesson-3 5. Ensure the same name as your Mastercam part file name is displayed in the NC File name field as shown below:

6. Select the Save button. 7. The CNC code file opens up in the default editor.

8. Select the in the top right corner to exit the CNC editor. 9. This completes Mill-Lesson-3.

Mill-Lesson-3 - 40

Mastercam Training Guide MILL-LESSON-3 EXERCISES

Mill-Lesson-3 - 41

Mill-Lesson-3 - 42

Mill-Lesson-3

Mastercam Training Guide

Mill-Lesson-3 - 43