Surface machining
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This document introduces Mastercam's surface machining capabilities and provides instructions for creating various surface toolpaths on a sample part. It describes how to create ruled, loft, and Coons surfaces on the part geometry. It then provides step-by-step instructions for creating rough parallel, finish parallel, finish leftover, and finish pencil toolpaths to machine the surfaces. It emphasizes selecting appropriate tools and parameters and verifying that the toolpaths correctly machine the desired material.
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Chapter13
2
3
1
4. Select at position 3.
5. Choose Do it.
6. Choose Backup.
7. Press [Alt + S] to see a shaded view of the surfaces. The surfaces
should look like the following picture.
Note: Shading the surfaces makes selection easier when creating
surface fillets.
Creating surface fillets between the loft and Coons
surfaces
1. Choose Main Menu, Create, Surface, Fillet, Surf/surf.
2. Select the loft surface.
3. Choose Done.](https://image.slidesharecdn.com/surfacemachining-130529100817-phpapp02/85/Surface-machining-6-320.jpg)
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4. Choose End here, Do it.
5. When you see the following message, choose Yes.
6. Choose Manual, and repeat steps 2 through 5 for the two ends of
the loft surface. The part should look like the following picture.
7. Press [Alt + A] to save the file.](https://image.slidesharecdn.com/surfacemachining-130529100817-phpapp02/85/Surface-machining-10-320.jpg)
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Exercise 2 - Creating a rough parallel toolpath
The rough parallel toolpath removes the bulk of the material quickly.
Using a flat endmill instead of a ball endmill also speeds up the material
removal. This cutting method does not work well on parts with multiple bosses
because the toolpath involves too much plunging. Parallel roughing is the most
efficient roughing toolpath for this particular part. The
completed toolpath should look like the following picture.
Note: The surfaces do not have to be trimmed in order to be machined.
Mastercam automatically cuts only the highest surfaces.
This exercise shows you the following skills:
Creating a rough parallel toolpath
Using cutting direction
Using cutting depths
Defining the stock boundaries
1. Press [Alt + S] to turn off the shading on the part.
2. Choose Main Menu, Toolpaths, Job Setup.
3. Choose the Select corners button.](https://image.slidesharecdn.com/surfacemachining-130529100817-phpapp02/85/Surface-machining-11-320.jpg)
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7. Press [Alt + T] to clear the toolpath display from the screen.
Exercise 3 - Creating a finish parallel toolpath
Using a finish parallel toolpath allows Mastercam to machine over all the
surfaces of this part. Parallel finishing is the most efficient choice for this
part. The completed toolpath should look like the following picture.
This exercise shows you the following skills:
Creating a finish parallel toolpath
Setting filter and tolerance values
Using gap settings to reduce processing time](https://image.slidesharecdn.com/surfacemachining-130529100817-phpapp02/85/Surface-machining-18-320.jpg)
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Notice how long this toolpath takes to process. The next procedure
shows you how to reduce the processing time by adjusting the gap
settings.
Changing the gap settings
1. Press [Alt + O] to open the Operations Manager.
2. Choose the Parameters icon for the Surface Finish Parallel
toolpath.
3. Choose the Finish parallel parameters tab.
4. Choose the Gap settings button.
5. Change the Motion to
Smooth.
6. Clear the Check gap
motion for gouge check
box.
Tip: Setting the gap motion to
Smooth creates smooth tool motion
between passes. And since the tool
motion between passes is on a flat
plane, there is no need to check the
gap motion for gouges. This setting
reduces the time needed to process
the toolpath.
7. Choose OK twice.
8. Choose Regen Path.
Mastercam regenerates the toolpath, which should look like the
following picture. You should notice a reduction in the processing
speed and smooth motion between the passes of the toolpath.](https://image.slidesharecdn.com/surfacemachining-130529100817-phpapp02/85/Surface-machining-22-320.jpg)
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Verifying all the surface toolpaths
You can verify the toolpaths to see the stock removal. Verifying all the
toolpaths can take a number of minutes, depending on the speed of your
computer.
1. If necessary, press [Alt + O] to return to the Operations Manager.
2. Choose Select All, Verify.
3. Choose the Configure button on the Verify toolbar.
4. Enter the values shown on the following dialog box and choose
OK.
5. Choose the Machine button on the Verify toolbar.
Mastercam runs through the toolpaths and displays the
verification results, which should look like the following picture.](https://image.slidesharecdn.com/surfacemachining-130529100817-phpapp02/85/Surface-machining-30-320.jpg)
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6. Choose the Close button on the Verify toolbar to return to the
Operations Manager.
7. Choose OK to close the Operations Manager.
8. Press [Alt + A] to save the file.
Now that you have experience with creating surface toolpaths, the next two
chapters will show you more types of surface toolpaths and their
applications.](https://image.slidesharecdn.com/surfacemachining-130529100817-phpapp02/85/Surface-machining-31-320.jpg)
Surface machining
- 1. 1 lab cnc compiled by paryono 13 Creating and Machining Surfaces This chapter introduces you to Mastercam's surface machining capabilities. First, you will create several different kinds of surfaces. Then, you will create a number of different roughing and finishing surface toolpaths. In this chapter, you will work with the following types of surfaces: Ruled surfaces are created by a linear blend between several chains. Loft surfaces are created by a curved blend between several chains. Coons surfaces are created from grids of chains or curves. Exercise 1 - Creating surfaces In this exercise, you will open a part file that already has some wireframe geometry and add surfaces to it. The following pictures show the wireframe geometry and completed surfaces.
- 2. 2 lab cnc compiled by paryono In this exercise, you will learn the following skills: Defining surface attributes with the Entity Attributes Manager Creating a ruled surface Creating a loft surface Creating a Coons surface Creating surface fillets Setting the level and color for the new surfaces Organizing your work with levels can make working on complicated parts much easier. In this exercise, the wireframe geometry is on level 2, and you will create the surface geometry on level 3. Use the Entity Attributes Manager to set default properties for surfaces so that when you create surfaces, they are automatically created in the proper color and placed on the proper level. 1. Buka gambar wire frame diatas 2. Choose Attributes from the Secondary Menu. 3. Choose the EA Mgr check box and button.
- 3. 3 lab cnc compiled by paryono 4. Find the line for Surfaces. Select the Level check box and enter 3. This means that every time you create a surface, Mastercam will place it on level 3, regardless of what the current level is. 5. Select the Color check box. You want the surfaces to be green (color 10), which is the default color, so you do not need to change it. Your values should match the following picture.
- 4. 4 lab cnc compiled by paryono Tip: To change the default color when you don't know the number, right-click in the number field and choose Select from dialog. This will show you the same dialog box as when you choose the Color button from the Secondary Menu. 6. Choose OK twice. Creating the ruled surfaces 1. Choose Main Menu, Create, Surface, Ruled, Single. 2. Select the lines at position 1 and position 2. 2 4 1 6 3 5 Tip: If you used the Chain option instead of Single, only one ruled surface with rounded corners would be created. This would not follow the shape of the part. 3. Choose Done, Do it. 4. Repeat steps 2 and 3 for positions 3 and 4. (Before selecting the lines, choose Single to make sure you are using Single chaining.) 5. Repeat for positions 5 and 6. This creates a total of three ruled surfaces.
- 5. 5 lab cnc compiled by paryono Creating the loft surface 1. Choose Backup, Loft. 2. Select the arcs at positions 1, 2, and 3 in that order. 2 3 1 Tip: A ruled surface would not work for this geometry because it would create sharp corners in the middle of the surface. A Coons surface would not work because the sections are not connected. 3. Choose Done, Do it. Creating the Coons surface 1. Choose Backup, Coons. 2. Choose Yes when you see the following message: 3. Select at positions 1 and 2.
- 6. 6 lab cnc compiled by paryono Chapter13 2 3 1 4. Select at position 3. 5. Choose Do it. 6. Choose Backup. 7. Press [Alt + S] to see a shaded view of the surfaces. The surfaces should look like the following picture. Note: Shading the surfaces makes selection easier when creating surface fillets. Creating surface fillets between the loft and Coons surfaces 1. Choose Main Menu, Create, Surface, Fillet, Surf/surf. 2. Select the loft surface. 3. Choose Done.
- 7. 7 lab cnc compiled by paryono CreatingandMachiningSurfaces 4. Select the Coons surface. 5. Choose Done. 6. Enter a radius of 6 7. Choose Check norms, Cycle. 8. The surface normal (represented by the arrow) should point out as shown in the following picture. If it does not, choose Flip from the menu. When it is correct, choose OK. 9. Repeat step 8 for the next normal. 10. Choose Do it. The fillets should look like the following picture.
- 8. 8 lab cnc compiled by paryono Chapter13 Creating surface fillets on two of the ruled surfaces 1. Choose Surfaces. 2. Select the top ruled surface. 3. Choose Done. 4. Select the next ruled surface. 5. Choose Done. 6. Enter a radius of 6. Top ruled surface Next ruled surface 7. Set the Trim option to Y. Tip: The surface normals must point inside the part. The arrows for the normals should match the following picture. 8. Choose Check norms Cycle Flip OK Flip OK Do it 9. Choose Main Menu, File, Save and save the file in your working folder as surfaces1.mc9. The part should look like the following picture.
- 9. 9 lab cnc compiled by paryono Note: The next procedure is optional—capping the surfaces only makes the part look better. It does not change the toolpath. Capping the ends of the surfaces 1. Choose Main Menu Create Surface Trim/extend Flat bndy Manual 2. Select the Coons surface. 3. Drag the arrow cursor to the edge of the surface and click once as shown in the following picture.
- 10. 10 lab cnc compiled by paryono 4. Choose End here, Do it. 5. When you see the following message, choose Yes. 6. Choose Manual, and repeat steps 2 through 5 for the two ends of the loft surface. The part should look like the following picture. 7. Press [Alt + A] to save the file.
- 11. 11 lab cnc compiled by paryono Exercise 2 - Creating a rough parallel toolpath The rough parallel toolpath removes the bulk of the material quickly. Using a flat endmill instead of a ball endmill also speeds up the material removal. This cutting method does not work well on parts with multiple bosses because the toolpath involves too much plunging. Parallel roughing is the most efficient roughing toolpath for this particular part. The completed toolpath should look like the following picture. Note: The surfaces do not have to be trimmed in order to be machined. Mastercam automatically cuts only the highest surfaces. This exercise shows you the following skills: Creating a rough parallel toolpath Using cutting direction Using cutting depths Defining the stock boundaries 1. Press [Alt + S] to turn off the shading on the part. 2. Choose Main Menu, Toolpaths, Job Setup. 3. Choose the Select corners button.
- 12. 12 lab cnc compiled by paryono 4. Select the geometry at position 1 and position 2. 1 2 Tip: Setting the stock limits is not necessary, but allows for more accurate toolpath verification. 5. Select the Display stock check box.
- 13. 13 lab cnc compiled by paryono 6. Choose OK. Selecting the surfaces and surface parameters 1. Choose Surface. 2. Toggle the Drive setting to A. This tells Mastercam you want to machine all the surfaces. 3. Toggle Contain to Y. This tells Mastercam that you want to use a tool containment boundary to limit the tool's motion. Your surface selection menu options should match the following picture.
- 14. 14 lab cnc compiled by paryono Tip: Drive surfaces are surfaces that will be machined. Check surfaces are surfaces that Mastercam will avoid. Tool containment is geometry that serves as a "fence," setting limits for the tool motion. Choose CAD file to create a toolpath based on an external CAD file, instead of geometry in the current Mastercam file. 4. Choose Rough, Parallel, Boss. 5. Select the 12 mm flat endmill. Note: All the tools you will need in this chapter have been saved with the part. You do not need to get them from the tool library. 6. Select the Surface parameters tab. 7. Enter the values as shown on the following dialog box. 8. To determine the tool containment boundary, choose the Select button in the Tool containment section.
- 15. 15 lab cnc compiled by paryono CreatingandMachiningSurfaces 9. Choose Chain, Options. 10. Select the Plane mask option and choose OK. 11. Select the bottom of the part as shown in the following picture. 12. Choose Done to return to the Surface parameters dialog box. 13. Choose the Direction check box and button. 14. Enter the values shown on the following dialog box. Tip: Setting a plunge length in the Direction dialog box allows the tool to plunge off the part. 15. Choose OK.
- 16. 16 lab cnc compiled by paryono Entering the roughing parameters 1. Select the Rough parallel parameters tab. 2. Enter the values shown on the following dialog box. Note: Selecting only the Allow positive Z motion along surface option limits the tool motion and prevents the tool from plunging into the material. 3. Choose the Cut depths button. 4. Enter the values shown on the following dialog box.
- 17. 17 lab cnc compiled by paryono CreatingandMachiningSurf Tip: The adjustment to top cut option sets how far below the top of the surface the first cut lies. The adjustment to other cuts option sets how far above the bottom the last cut lies. 5. Choose OK twice. 6. Mastercam prompts you to select the starting point. Select near the front corner of the part as shown in the following picture. Mastercam generates the toolpath, which should look like the following picture.
- 18. 18 lab cnc compiled by paryono 7. Press [Alt + T] to clear the toolpath display from the screen. Exercise 3 - Creating a finish parallel toolpath Using a finish parallel toolpath allows Mastercam to machine over all the surfaces of this part. Parallel finishing is the most efficient choice for this part. The completed toolpath should look like the following picture. This exercise shows you the following skills: Creating a finish parallel toolpath Setting filter and tolerance values Using gap settings to reduce processing time
- 19. 19 lab cnc compiled by paryono Selecting the surface parameters 1. Choose Main Menu, Toolpaths, Surface, Finish, Parallel. 2. Select the 12 mm ball endmill. 3. Select the Surface parameters tab. 4. Enter the values as shown on the following dialog box. 5. Choose the Select button in the Tool containment section. 6. Select the bottom of the part as shown in the following picture.
- 20. 20 lab cnc compiled by paryono 7. Choose Done. 8. Select the Finish parallel parameters tab. 9. Enter the values shown on the following dialog box.
- 21. 21 lab cnc compiled by paryono 10. Choose the Total tolerance button. 11. Choose a Filter ratio of 2:1. 12. Set the Total tolerance to 0.025. Your other values should match the following dialog box. Z-plane arcs Some controls aren't capable of machining arcs in the XZ or YZ planes. Check the documentation for your control before selecting these options. Also, verify that your post- processor is configured to handle XZ and YZ arcs. Tip: The filter settings can reduce the size of the NC program. Collinear and nearly collinear moves (within the specified tolerance) are removed and arcs are inserted when possible to reduce the toolpath size. Tip: The filter tolerance should be set to at least twice the cut tolerance. The filter ratio does this automatically. 13. Choose OK twice. Mastercam generates the toolpath, which should look like the following picture.
- 22. 22 lab cnc compiled by paryono Notice how long this toolpath takes to process. The next procedure shows you how to reduce the processing time by adjusting the gap settings. Changing the gap settings 1. Press [Alt + O] to open the Operations Manager. 2. Choose the Parameters icon for the Surface Finish Parallel toolpath. 3. Choose the Finish parallel parameters tab. 4. Choose the Gap settings button. 5. Change the Motion to Smooth. 6. Clear the Check gap motion for gouge check box. Tip: Setting the gap motion to Smooth creates smooth tool motion between passes. And since the tool motion between passes is on a flat plane, there is no need to check the gap motion for gouges. This setting reduces the time needed to process the toolpath. 7. Choose OK twice. 8. Choose Regen Path. Mastercam regenerates the toolpath, which should look like the following picture. You should notice a reduction in the processing speed and smooth motion between the passes of the toolpath.
- 23. 23 lab cnc compiled by paryono Exercise 4 - Creating a finish leftover toolpath The finish leftover toolpath removes material left behind by the larger tool of the finish parallel toolpath. It also adjusts to different Z depths, unlike a restmill toolpath, which makes planar cuts at constant Z depths and is more appropriate for roughing operations. In this exercise, you will learn the following skill: Creating a finish leftover toolpath Creating the finish leftover toolpath 1. Right-click in the Operations Manager and choose Toolpaths, Surface finish, Leftover. 2. Select the 5 mm ball endmill. 3. Select the Surface parameters tab. 4. Enter the values shown on the following dialog box.
- 24. 24 lab cnc compiled by paryono 5. Choose the Select button in the Tool containment section. 6. Select the bottom of the part as shown in the following picture. 7. Choose Done. 8. Select the Finish leftover parameters tab.
- 25. 25 lab cnc compiled by paryono 9. Enter the values shown on the following dialog box. 10. Select the Leftover material parameters tab. 11. Enter the values shown on the following dialog box.
- 26. 26 lab cnc compiled by paryono 12. Choose OK. Mastercam generates the toolpath, which should look like the following picture. It can take several minutes to generate the toolpath.
- 27. 27 lab cnc compiled by paryono Note: If you receive an error message stating that the toolpath allocation is too low, choose Main Menu, Screen, Configure and select the Allocations tab. Increase the value for the Toolpath allocation in Kbytes option and choose OK. Finally, regenerate the operation. This increases the amount of RAM designated for toolpath functions. Exercise 5 - Creating a finish pencil toolpath On this geometry, the finish pencil toolpath cleans up more of the material by driving the cutter tangent to two surfaces at a time. This exercise shows you the following skills: Creating a finish pencil toolpath Verifying the toolpath Creating the finish pencil toolpath 1. Right-click in the Operations Manager and choose Toolpaths, Surface finish, Pencil. 2. Select the 2 mm ball endmill. 3. Select the Surface parameters tab. 4. Enter the values shown on the following dialog box.
- 28. 28 lab cnc compiled by paryono 5. Choose the Select button in the Tool containment section. 6. Select the bottom of the part as shown in the following picture. 7. Choose Done. 8. Select the Finish pencil parameters tab.
- 29. 29 lab cnc compiled by paryono 9. Enter the values shown on the following dialog box. . Choose OK. Mastercam generates the toolpath, which should look like the following picture.
- 30. 30 lab cnc compiled by paryono Verifying all the surface toolpaths You can verify the toolpaths to see the stock removal. Verifying all the toolpaths can take a number of minutes, depending on the speed of your computer. 1. If necessary, press [Alt + O] to return to the Operations Manager. 2. Choose Select All, Verify. 3. Choose the Configure button on the Verify toolbar. 4. Enter the values shown on the following dialog box and choose OK. 5. Choose the Machine button on the Verify toolbar. Mastercam runs through the toolpaths and displays the verification results, which should look like the following picture.
- 31. 31 lab cnc compiled by paryono 6. Choose the Close button on the Verify toolbar to return to the Operations Manager. 7. Choose OK to close the Operations Manager. 8. Press [Alt + A] to save the file. Now that you have experience with creating surface toolpaths, the next two chapters will show you more types of surface toolpaths and their applications.