multi axis lesson 7

TRAINING

GUIDE

MULTI-AXIS-LESSON-7

TRUNNION-TABLE – FLOW 5 AXIS

Mastercam Training Guide

Multi-Axis-Lesson-7-1

Objectives For Multi-Axis-Lesson-7 you will generate the toolpaths to machine the propeller part shown below on a CNC vertical milling machine with multi-axis capability. The raw material for the propeller is a casting. The part will be initially machined using the Flowline 5-axis toolpath. Following this the Advanced Multiaxis toolpath will be used to finish machine. Finally the Toolpath Transform feature will be used to copy the toolpaths to and machine the remaining two vanes of the propeller. The part is in inch units. The part will be held on a fixture using a socket head cap screw through the centre hole. This setup will be located on a Trunnion table. This Lesson covers the following topics: � Open an existing file containing: Solid geometry for the part � Generate toolpaths consisting of: Flowline 5-axis toolpath Advanced Multiaxis toolpath � Inspect the toolpath using Mastercam’s

Backplot by: Launching the Backplot function to machine the part on the screen Generating the NC- code

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TOOL LIST

MULTI-AXIS-LESSON-7 - THE PROCESS

Toolpath Creation TASK 1: Setting the environment TASK 2: Introduction - Watch the video TASK 3: Open an existing file from the Multimedia CD TASK 4: Identify the entities on each Level TASK 5: Machine first vane – Flowline 5-axis TASK 6: Machine fillet radii between vane and main hub TASK 7: Transform and Rotate toolpaths TASK 8: Backplot the toolpath TASK 9: Verify the toolpath TASK 10: Post and create the CNC code file



Toolpath Creation 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: Size= 1.0, X & Y Spacing= 0.25. This will help identify the location of the

origin. 2. Customize the toolbars to machine a 4-5 Axis part. TASK 2: INTRODUCTION – WATCH THE VIDEO 1. Before you start to work on this Lesson review the Introduction video on the multimedia CD

that came with this text. You will find the video in the “Lesson-7” section, it is entitled Introduction - 10 Minutes.

� The video will review the techniques that will be used to generate the toolpaths to cut this part.

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TASK 3: OPEN EXISTING FILE FROM THE MULTIMEDIA CD � On the multimedia CD that came with this text is a folder called Mastercam-Files. The file

is in inch units and contains the wireframe and surface (solid) geometry of the part. � The part is already setup for a: GENERIC HAAS VF-TR_SERIES 5X MILL. 1. Select File>Open> Multi-Axis-Lesson-7.MCX. 2. If confronted with the System Configuration dialog box activate the radio button for All

settings.

� System Configuration (switch units) dialog box � When you open a part file that uses different units (English or metric) from those currently in

use, Mastercam automatically displays this dialog box, which informs you that Mastercam is switching units and loading an alternate default configuration file. In order to complete the operation, select one of the following options:

� Units: Tells Mastercam to use only the units from the new configuration file. (default) � All settings: Tells Mastercam to load all settings from the new configuration file.

3. Select the OK button to exit the System Configuration dialog box. 4. Activate a shaded view by selecting the icon at the top of the screen. The file should appear

as below. The Stock setup has already been setup.

5. Display the Operations Manager. Selecting Alt-O will Show/hide the Operations Manager

pane.



TASK 4: IDENTIFY THE ENTITIES ON EACH LEVEL � Before you start to work on the two toolpaths lets first identify the entities on each Level. � Levels are a primary organizational tool in Mastercam. A Mastercam file can contain

separate levels for wireframe, surfaces, drafting entities, and toolpaths. � By organizing your files into levels, you can more easily control which areas of the drawing

are visible at any time and which parts are selectable so that you do not inadvertently make changes to areas of the drawing you do not want to change.

1. From the Status bar at the bottom of the screen select Level. � Note that the Z depth is set to 0.575

� The Level Manager dialog window will now appear. � As you can see in the picture below there is only one Level in this part Level 1. � Level 1 contains the part geometry � Level 1 is visible as noted by the X in the Visible column.

2. Select the OK button to exit the Level Manager dialog box.

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TASK 5: MACHINE FIRST VANE – FLOWLINE 5-AXIS � In this task you will use a 0.5 diameter ball end mil to machine the first vane using Flowline

5-axis. � Flow 5-axis toolpaths allow either precise control of the scallops left on the part or constant

distance stepovers, creating an exact, smooth finish. � The 5-axis output provides 2 degrees of freedom for the tool vectors. You can use flow 5-

axis toolpaths on a row of adjacent drive surfaces or on a single surface. � Flow 5-axis toolpaths can use ball, bull, flat, or tapered tools.

1. Before you start to work on this Task review the Lesson-7 Task 5 video on the multimedia CD that came with this text. You will find the video in the “Lesson-7” section; there is some tricky selection of surfaces in this task so please check out the video before you proceed.

2. Activate a wireframe view by selecting the icon at the top of the screen. 3. Set the graphics view to Isometric View and then select the Screen Fit icon. 4. From the menu bar select Toolpaths> Multiaxis>Flowline 5-axis… 5. When prompted to Enter new NC name Input Multi-Axis-Lesson-7 and then select the OK

button . 6. At the Flow 5-axis dialog box activate the 5-axis radio button and the remaining radio

buttons shown below.

� Cut Pattern – Surfaces Select surfaces to define the drive surfaces for the operation. Multiple surfaces can be selected provided that surfaces form a contiguous row, or where the surface directions are not in conflict with one another. � Tool Axis Control – Pattern

Surface Keeps the tool axis vector normal to a selected surface. For Multisurface 5-axis toolpaths, keeps the tool axis vectors normal to the surfaces selected for the cut pattern. The cut pattern is a set of surfaces that best defines the general machining area for the operation and defines the general flow of tool motion.

7. Now click on the Surfaces button in the Cut Pattern section.



8. On the graphics screen you will be prompted Select Tool Pattern Surface(s). Before you select the surfaces you need to set up the appropriate selection options on the General Selection Toolbar.

9. On the General Selection toolbar select the icon to toggle Activate solid selection. Do this by clicking on the Activate solid selection icon shown below so it is greyed out.

10. After picking the Activate solid selection icon it should be greyed out as shown below.

Now click on the Select Face icon so it is greyed out. Ensure your General Selection Toolbar is setup as below:

� Activate solid selection This activates solid selection functions appropriate for the current solid and operation. In cases where you initiate a Mastercam function that might apply to solids in addition to other types of entities, you can use this button to switch from the default Standard Selection mode to the Solid Selection mode.

� Select face Toggles face selection on or off. When chosen, you can select solid faces on a model. When not chosen, you exclude solid face selection.

� Select edge Toggles edge selection on or off. When chosen, you can select solid edges on a model. When not chosen, you exclude solid edge selection.

� Select body Toggles whole solid body selection on or off. When chosen, you can select whole solids on a model. When not chosen, you exclude whole solid body selection.

� From back Toggles "from back" selection on or off. When chosen, you can select solid edges or faces only on the back of a model. When not chosen, you can select solid edges or faces only on the front of a model.

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11. Now select the surface on the propeller vane shown below.

12. Click on the End Selection icon. . 13. The Flowline data dialog box appears and the graphic screen displays as below. Nothing

to change here, select the OK button to exit the Flowline data dialog box.

� Use this dialog box to change the direction, offset, tolerance, or step direction for Flowline

geometry.



14. Now back at the Flowline data dialog box click on the Check Surfaces button.

15. The Toolpath/surface selection dialog box will appear now select the selection arrow

shown below left:

16. On the graphics screen you will be prompted Select Check Surfaces. Before you select

the surfaces you need to set up the appropriate selection options on the General Selection Toolbar.




19. Activate a shaded view by selecting the icon at the top of the screen.

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20. The prompt now changes to Select Solid Body of Face. Select the four check surfaces shown below. For the four check surfaces, pick the 3 fillets – 1, 2 and 3 from the vane to the hub, then the hub - 4 (conical). Zoom as required.

21. After selecting the check surfaces click on the End Selection icon. . 22. At the Toolpath/surface selection dialog box take note that it indicates (4) check surfaces

as shown below. Select the OK button to exit the Toolpath/surface selection dialog box.

23. Select the OK button to exit the Flow 5-axis dialog box.



24. Select the 1/2” ball end mill and make changes to this page as shown below.

25. Select the Multiaxis parameters page and set the values as shown below:

� Stock to leave on check surfaces For check surfaces, the stock to leave parameter provides an additional margin of clearance. Check surfaces are surfaces that are not cut, but are selected to identify areas for Mastercam to avoid when creating motion that could gouge these surfaces. Stock to leave on check surfaces can be entered as a positive or negative amount. A positive amount leaves stock on the normal side of the surface. A negative amount is applied to the opposite side of the surface and allows cutting into the check surface.

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26. Select the Flowline 5ax Parameters page and set the values as shown below:

� Flowline 5ax Parameters Use this dialog box to: Refine the tool axis vectors. Set the cut tolerance, the size of the stepover and step along. Set flowline parameters for the cut surfaces. Set the gap settings to control retract motion between surfaces in the toolpaths.

27. Select the Edges page and set the values as shown below:

Edges Use this tab to control blending between surface edges on the first and last passes. Edge Blend Options Choose one from the list. Normal Surface Edge: No edge modification (default). Skip Pass: Removes the selected cutting pass or passes from the toolpath. Apply Blend: Adds the selected blending pass or passes to the toolpath, using the Blend Parameters you specify.



28. Select the Axis limits page and set the values as shown below:

� Axis limits Axis limits set a range of tool motion for a rotary axis that limits the amount of head tilt relative to the tool position. Using axis limits provides protection against axis over-travel, and lets you select the action to take were axis over-travel to occur. Note: Axis limits are not available for Rotary 4-axis toolpaths.

29. Select the Point Generator page and set the values as shown below:

� Point Generators Add additional tool positions for a more accurate final toolpath and improved surface finish. Mastercam supports two point generators for multiaxis toolpaths: � Angle Mastercam evaluates the tool moves using an angle measurement. When the tool axis angle between any two vectors in the toolpath exceeds the value entered, Mastercam inserts one or more additional vectors. Can be used concurrently with Distance. � Distance Mastercam evaluates the tool moves using a linear distance measurement. When the distance between any two vectors in the toolpath exceeds the value entered, Mastercam inserts one or more additional vectors. Can be used concurrently with Angle.

30. Select the OK button to exit Flow 5-axis.

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31. Activate a wireframe view by selecting the icon at the top of the screen. 32. If required set the graphics view to Isometric View and then select the Screen Fit icon. 33. Save your file. 34. Backplot the toolpath you have just created. Your backplot should be similar to the image

shown below. 35. Backplot the toolpath you have just created. Your backplot should be similar to the image

shown below.

36. Now verify the toolpath. Your verified part should be similar to the image shown below.



TASK 6: MACHINE FILLET RADII BETWEEN VANE AND MAIN HUB � In this task you will use a 0.5 diameter ball end mil to machine the fillet radii between the

vane and the main hub using the Advanced Multiaxis option.

� The Advanced Multiaxis option on the Toolpaths menu provides enhanced 5-axis

multisurface machining strategies. You can choose to work with the advanced multiaxis toolpaths in either of two ways:

Option 1. You can choose to work with the full interface that gives you access to all the available parameters and options. These are organized in several tabs as shown in the following picture.

� Setting Up: To access the full interface, select Toolpaths, Advanced Multiaxis from the Mastercam menu. In the Select User Interface dialog box, click the 5 ax Multi Surface button

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� Option 2. You can choose from a number of simplified interfaces that have been customized for specific applications and machining strategies. In this case, Mastercam only shows you a small subset of the options, organized in a customized, easy-to-use tab: All the options that are hidden have been preset to values appropriate for the selected application. The following picture below left shows the custom interface for the Impeller application and Floor Surface - Without tilt curve machining application.

� Setting Up: To access a customized interface, select the appropriate application and machining strategy buttons in the Select User Interface dialog box. Once you become familiar with parameters in the advanced interface, you will find the customized interface easy to learn. You can switch from a customized interface to the advanced interface by clicking the Switch to advanced interface button on the Misc tab. However, once you switch from the customized interface to the advanced interface, you cannot return to the customized interface for that operation.



1. Before you start to work on this Task review the Lesson-7 Task 6 video on the multimedia CD that came with this text. You will find the video in the “Lesson-7” section; there is some tricky selection of surfaces in this task so please check out the video before you proceed.

2. If required activate a wireframe view by selecting the icon at the top of the screen.

3. Set the graphics view to Isometric View and then select the Screen Fit icon. 4. Turn off the display of toolpaths by selecting Alt-T on your keyboard.

5. From the menu bar select Toolpaths>Advanced Multiaxis 6. At the Select User Interface dialog box select the 5 Ax Multi Surface tool box icon

� Setting Up: As you will be using the full interface for Advanced Multiaxis the 5 ax Multi Surface button will enable access to the flowing options:

7. After selecting the toolbox icon on the left pick the toolbox icon on the right.

8. Select the 1/2” ball end mill and make changes to this page as shown below.

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9. Select the Surface paths page and set the Pattern to Parallel to curve. Set the remaining values as shown below:

� Parallel to curve The Parallel to curve toolpath pattern will align the cut direction with a leading curve. Adjacent cuts are parallel to each other. It is important to note that the cuts will not simply be copied next to each other. Every new cut is created at an offset from the previous cut. There are special options for the first and last cut. You can define a margin to get the exact position where the tool is located at the edge within a certain distance. � Settings: The distance between two neighboring cuts is the maximum stepover. Define the area to be machined in the Area section. � Note: The curve must be located exactly on the surface edge, so the best curve would be the edge itself. This is very important for toolpath generation. If you don't have a proper curve, an incorrect toolpath can be generated. You can use only ONE curve. If you select multiple curves, only the first curve selected will be used. For more complex face models, this means that the curve cannot be intermitted.



10. Click on the Single edge button in the Edit cures section

11. In the chaining box set to single chain.

12. Activate a shaded view by selecting the icon at the top of the screen.

13. In the graphics window you will now be prompted to Add Chain: 1. Zoom as required and

select the curve shown below. If the arrow is not pointing to the right select the arrow from

the Chaining dialog box to reverse the direction:

14. Select the OK button to exit chaining.

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15. Back at the Surfaces paths parameter pace click on the Drive surfaces button.

16. On the graphics screen you will be prompted Select surface for machining (watch your

surface normals. Before you select the surfaces you need to set up the appropriate selection options on the General Selection Toolbar.




19. In the graphics window you will now be prompted to Select Solid Body or face: Pick the

surface shown below. The fillet between the main body and vane.

20. Click on the End Selection icon. .

21. Click on the Done button ,



22. Select the Tool axis control page and set the values as shown below:

� Maximum angle step The Maximum angle step value sets the maximum allowed angle change between two consecutive toolpath positions. The calculation engine outputs 5-axis toolpath data that contains the tool tip position and the direction vector of the tool. The direction vectors are not allowed to have an angle change larger than the value specified here. � Tool axis will be tilted

relative to cutting direction With this strategy you can assign a lead/lag angle to the cutting direction and a tilt angle at the side of the cutting direction.

23. Select the Gouge check page and set the values as shown below:

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24. Select the Link page and set the values as shown below:

� First entry First entry is the first approach of the tool towards the part. You can specify from where the tool should approach (enter) the part and whether there will be a lead-in move when entering the part. The default setting is From clearance area. In this entry method, the tool comes from the clearance area, moves to the rapid distance, and enters the surface to the feed distance. If you select Use rapid distance or Use feed distance, your tool will start closer to your part.

25. Select the Roughing page and set the values as shown below:



26. Select the Utility page and set the values as shown below:

27. Select the Machine definition page and set the values as shown below:

� Machine definition tab The machine information entered into this tab is used only if you have the machine simulation module (available separately). These values are not read from Mastercam's Machine Definition Manager. See your Mastercam Reseller for more information about machine simulation.

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28. Select the Misc page and set the values as shown below:

� Simulation Select the Save toolpath as geometry (delete: undo) to save the toolpath as geometry in your part file. Click the (…) button to open the Options to create geometry dialog box. � Tip comp Use this option to control whether the locations that are output to the NCI file will be the tool center or tool tip coordinates.

29. Select the OK button to exit 5-Axis Multi Surface.

30. Activate a wireframe view by selecting the icon at the top of the screen. 31. If required set the graphics view to Isometric View and then select the Screen Fit icon. 32. Save your file. 33. Backplot the toolpath you have just created. Your backplot should be similar to the image

shown below left.

34. Verify the toolpath you have just created. Your verified toolpath should be similar to the

image shown above right.



TASK 7: TRANSFORM AND ROTATE TOOLPATHS � In this task you will use Transform Toolpath to rotate the initial two toolpaths to complete the

machining of the remaining two vanes on the propeller. 1. Before you start to work on this Task review the Lesson-7 Task 7 video on the multimedia

CD that came with this text. You will find the video in the “Lesson-7” section. 2. If required set the graphics view to Isometric View and then select the Screen Fit icon. 3. If required turn off the display of toolpaths by selecting Alt-T on your keyboard. 4. From the menu bar select Toolpaths>Transform… 5. On the Types and Methods page set the following. Ensure there is a check for both

operations in the Source operations list, both operations should be selcted.. To select both operation hold the CTRL key down on your keyboard and select both folders in the Source operations list.

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6. Now click on the Rotate tab and set the following:

7. Select the OK button to exit the Transform Operations Parameters dialog box. 8. Save your file.



TASK 8: BACKPLOT THE TOOLPATHS � In this task you will use Mastercam’s Backplot function to view the path the tools take to cut

this part. 1. Set the graphics view to Isometric View and then select the Screen Fit icon. 2. Un-zoom .8 3. Activate a shaded view by selecting the icon at the top of the screen.

4. In the Toolpath Manager only select the third operation to Plot, the transformed toolpaths. 5. The next step is to select the Backplot selected operations icon shown below:

6. After reviewing the backplot of the toolpaths select the OK button to exit Backplot.

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TASK 9: VERIFY THE TOOLPATHS � In this task you will verify all the toolpaths. 1. In the Toolpath Manager only select the third operation to verify, the transformed toolpaths. 2. Select the Verify selected operations button circled below and hit the play button:

3. At the Verify dialog window activate Simulate Tool.

4. Next click on the Verify options icon as shown below:

5. At the Verify Options dialog window set the Miscellaneous options as shown below:

� Stock Shape - Solid Choose this option to use a solid model in the current part file as the stock. Then click the Select button to return to the graphics window and select the solid. This part is already setup to use a solid as the stock.

6. Select the OK button to exit Verify options.



7. Select the play button to verify the toolpath.

8. Select the OK button to exit Verify.

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TASK 10: POST AND CREATE THE CNC CODE FILE 1. In the Toolpath Manager only select the third operation to post.

2. Select the Post selected operations button from the Toolpath manager. 3. Please Note: If you cannot see G1 click on the right pane of the Toolpath manger window

and expand the window to the right.

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

5. Select the OK button to continue.



6. Enter the same name as your Mastercam part file name in the NC File name field MULTI-AXIS-LESSON-7 and select the Save button

7. Select the Save button and review the CNC code.

8. Select the in the top right corner to exit the CNC editor. 9. This completes Multi-Axis-Lesson-7.

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MULTI-AXIS-LESSON-7 EXERCISE #1: THREE-BLADE PROPELLER MULTI-AXIS-LESSON-7-EX-1.MCX

MULTI-AXIS-LESSON-7 EXERCISE #2: TWO-BLADE PROPELLER MULTI-AXIS-LESSON-7-EX-2.MCX

multi axis lesson 7

Documents

general selection toolbar

mastercam training guide

solid body selection

end selection icon

source operations list

maximum angle step

screen fit icon

select solid body