user manual mayka v6 - picasoft
TRANSCRIPT
User Manual
Mayka v6
Innovative tools to compliment the Creative
Beauzy – Route de Châtres sur Cher – 41300 THEILLAY
email : info@ picasoft.com – web : www.picasoft.com
Copyright © 2001-2003 PICASOFT sa ® - All rights reserved
The content of this manual and software describe is protected by the international laws of the author’s right.Neither the software nor the manual can be reproduced, saved or transmitted or otherwise, without prior writtenpermission of PICASOFT sa (11 March 1957 law and 3 of July 1985 law on the author’s right).
Limitation of guarantee and responsibility
Even if the programme described in this manual, being well tested, neither PICASOFT nor its suppliers canoffer a guarantee, implicit or clear, on its qualities, its performances or its capacity in satisfying the user needs.The user assumes the risks of the utilisation and its possible consequences. In any case, PICASOFT or itssuppliers cannot be responsible for some direct or indirect consequences, from whatever nature it can be,resulting from a defect of the programme or in the manual, or from the utilisation, even if they were or were nottold about the possibility of that sort of injuries. However the buyer has the right to the legal guarantee, only inthe case and in the measure we can apply the legal guarantee, not withstanding all exclusions or limitations.
More, PICASOFT keeps the right to modify the product characteristics or the content of its documentationwithout telling the users.
By the use of that product you accept the above clauses.
PICASOFT®, the logo PICASOFT, and the names and the logo’s Mayka™, Maquette Volume™ , Stenza™are trade marks of PICASOFT sa.
Apple®, logo Apple, Macintosh®, logo Macintosh™, Mac™OS are trademarks of © Apple Computer, Inc.
Microsoft™, Windows™, logo Windows™, are trademarks of Microsoft Corporation.
All the other products quoted in the manual are trademarks:
AutoCAD & DXF are trademarks of Autodesk.
CAMM-2, CAMM-3, Modela, Picza & PIX are trademarks of Roland Digital Group Corp.
IGN © BDALTI ® is a trademark of the National Geographic Institute.
Photoshop & Illustrator are trademarks of Adobe Systems Incorporated.
Canvas is a trademark of Deneba Systems.
Corel Draw & Corel Paint are trademarks of Corel Corporation.
HPGL is a trademark of Hewlett Packard Inc
Vellum is a trademark of © Ashlar.
AMAPI is a trademark of © YONOWAT.
MicroScribe is a trademark of Immersion Corporation.
All the other products or trademarks quoted in this manual are acknowledged trademarks of their respectiveowners.
Compiled by Patrick Thorn. January 2004. E&OE
Contents1 Definitions............................................................................................................................................. 9
1.1 CAD .............................................................................................................................................. 9
1.2 CAM ............................................................................................................................................. 9
1.3 CAD: Polyhedral models ........................................................................................................... 9
1.4 CAD: Surface models.................................................................................................................. 9
1.5 CAD : Solid models ..................................................................................................................... 9
1.6 CAD : BITMAP images .............................................................................................................. 9
1.7 CAM 2D _................................................................................................................................... 10
1.8 CAM 3 axis................................................................................................................................. 10
1.9 CAM 4 axis................................................................................................................................. 10
1.10 CAM 5 axis................................................................................................................................. 10
2 Installation of Mayka ......................................................................................................................... 11
2.1 Hardware requirements............................................................................................................ 11Suggested computer configuration Windows...................................................................................... 11
2.2 Installing the software............................................................................................................... 11
2.3 Installing the software protection ............................................................................................ 122.3.1 Windows Dongles ............................................................................................................... 122.3.2 Macintosh Dongle .............................................................................................................. 122.3.3 Both Computers................................................................................................................... 13
2.4 Enter your user licence ............................................................................................................. 132.4.1 Education version................................................................................................................ 152.4.2 Contract OEM versions ....................................................................................................... 152.4.3 Demonstration mode ........................................................................................................... 152.4.4 Evaluation Mode ................................................................................................................. 15
3 Mayka Toolbar.................................................................................................................................... 16
3.1 Cursor icon................................................................................................................................. 16
3.2 Rotate view icon......................................................................................................................... 16
3.3 Pan Screen icon.......................................................................................................................... 16
3.4 Zoom icon................................................................................................................................... 17
3.5 Measure icon.............................................................................................................................. 17
3.6 Fit to view................................................................................................................................... 17
3.7 Shading view .............................................................................................................................. 18
3.8 Shading with transparency....................................................................................................... 18
3.9 Wireframe view ......................................................................................................................... 18
3.10 Contour view.............................................................................................................................. 19
3.11 Isometric view............................................................................................................................ 19
3.12 Orthogonal views .......................................................................................................................193.12.1 Front face .............................................................................................................................193.12.2 Top face ...............................................................................................................................193.12.3 Right view............................................................................................................................20
3.13 Align objects icon .......................................................................................................................20
3.14 Align to machine origin icon .....................................................................................................20
3.15 Create cutting method icon.......................................................................................................21
3.16 Cutting icon ................................................................................................................................21
3.17 Animation / Simulation icon .....................................................................................................213.17.1 Animation ............................................................................................................................213.17.2 Simulation............................................................................................................................21
3.18 Process icon ...............................................................................................................................21
3.19 Information icon ........................................................................................................................22
4 Objects in Mayka.................................................................................................................................23
4.1 List of objects .............................................................................................................................23
4.2 Displaying the objects................................................................................................................23
4.3 Selection of objects.....................................................................................................................244.3.1 Object sub-menus ................................................................................................................244.3.2 Multiple selection ................................................................................................................274.3.3 Order of the objects in the list..............................................................................................27
4.4 Screen icons ................................................................................................................................284.4.1 Datum point X0, Y0, Z0 ......................................................................................................284.4.2 Screen orientation ................................................................................................................28
5 Menus of Mayka .................................................................................................................................29
5.1 File ...............................................................................................................................................295.1.1 New......................................................................................................................................295.1.2 Open.....................................................................................................................................305.1.3 Save a scene .........................................................................................................................355.1.4 Save as… .............................................................................................................................355.1.5 Transmit ...............................................................................................................................375.1.6 Machine Configuration ........................................................................................................385.1.7 Quit ......................................................................................................................................40
5.2 Edit ..............................................................................................................................................415.2.1 Undo Ctrl+Z.......................................................................................................................415.2.2 Redo Ctrl+L .......................................................................................................................415.2.3 Free memory Ctrl+L ..........................................................................................................415.2.4 Select all Ctrl+A ................................................................................................................415.2.5 Unselect all Shift+D............................................................................................................415.2.6 Inverse selection Shift +I .....................................................................................................415.2.7 Hide selection ......................................................................................................................415.2.8 Hide all.................................................................................................................................415.2.9 Show all ...............................................................................................................................415.2.10 Copy Ctrl+C......................................................................................................................425.2.11 Delete Del ..........................................................................................................................425.2.12 Selection Zone .....................................................................................................................42
5.2.13 Redraw Crtl+R .................................................................................................................. 435.2.14 Quit Process Esc................................................................................................................ 435.2.15 Preferences .......................................................................................................................... 43
5.3 Display ........................................................................................................................................ 475.3.1 ZOOM ................................................................................................................................. 475.3.2 View .................................................................................................................................... 475.3.3 Sectional view ..................................................................................................................... 485.3.4 Normal................................................................................................................................. 495.3.5 Undercut .............................................................................................................................. 495.3.6 Horizontal facets.................................................................................................................. 505.3.7 Animation............................................................................................................................ 515.3.8 Simulation ........................................................................................................................... 525.3.9 Shading................................................................................................................................ 54
5.4 Transformation.......................................................................................................................... 545.4.1 Translation........................................................................................................................... 545.4.2 Rotation ............................................................................................................................... 565.4.3 Scale .................................................................................................................................... 585.4.4 Symmetry ............................................................................................................................ 585.4.5 Invert ................................................................................................................................... 605.4.6 Offset ................................................................................................................................... 615.4.7 Array.................................................................................................................................... 625.4.8 Rotate according to view..................................................................................................... 625.4.9 Convert ................................................................................................................................ 625.4.10 Projection/Mapping (available with the option MAYKA Projective) ............................... 675.4.11 Align objects........................................................................................................................ 745.4.12 Align to origin ..................................................................................................................... 755.4.13 Group................................................................................................................................... 755.4.14 Ungroup............................................................................................................................... 76
5.5 Modelling.................................................................................................................................... 765.5.1 Create a method................................................................................................................... 765.5.2 Raised angles....................................................................................................................... 795.5.3 3 axis drilling....................................................................................................................... 835.5.4 5 axis drilling....................................................................................................................... 835.5.5 Process cutting..................................................................................................................... 845.5.6 Configure …........................................................................................................................ 88
5.6 Model menu................................................................................................................................ 885.6.1 Define attachment................................................................................................................ 895.6.2 Define block ........................................................................................................................ 915.6.3 Split a model........................................................................................................................ 925.6.4 Close Model ........................................................................................................................ 945.6.5 Merge surfaces .................................................................................................................... 945.6.6 Separate surfaces ................................................................................................................. 945.6.7 Unify normals...................................................................................................................... 955.6.8 Simplify a model ................................................................................................................. 95
5.7 Contour menu............................................................................................................................ 955.7.1 Extract contours…............................................................................................................... 955.7.2 Edit contours….................................................................................................................... 975.7.3 Convert contour to tool path................................................................................................ 995.7.4 Contour offsetting…............................................................................................................ 995.7.5 Tesselate contours… ........................................................................................................... 99
5.7.6 Text… ................................................................................................................................100
5.8 Window.....................................................................................................................................1015.8.1 Toolbar...............................................................................................................................1015.8.2 Object list ...........................................................................................................................1015.8.3 Cutting process ..................................................................................................................1015.8.4 Information. .......................................................................................................................102
5.9 ? menu.......................................................................................................................................1045.9.1 Personnal code ...................................................................................................................1045.9.2 Getting started....................................................................................................................1045.9.3 www.picasoft.com .............................................................................................................1045.9.4 About .................................................................................................................................104
6 Types of cutting methods ..................................................................................................................106
6.1 Sweeping method .....................................................................................................................1066.1.1 Objects ...............................................................................................................................1076.1.2 Zone ...................................................................................................................................107
6.2 Horizontal facets ......................................................................................................................1366.2.1 Cutting parameters.............................................................................................................1376.2.2 Plunge strategy...................................................................................................................1386.2.3 Entry / Exit.........................................................................................................................139
6.3 Z-constant .................................................................................................................................1406.3.1 Roughing............................................................................................................................1416.3.2 Finishing ............................................................................................................................143
6.4 Profiling ....................................................................................................................................1436.4.1 Roughing............................................................................................................................1446.4.2 Finishing ............................................................................................................................1466.4.3 Limitation of the zone........................................................................................................146
6.5 Surfacing...................................................................................................................................1476.5.1 Roughing............................................................................................................................1476.5.2 Finishing ............................................................................................................................1486.5.3 Limitation of the zone........................................................................................................148
6.6 Slicing........................................................................................................................................1496.6.1 Method zone ......................................................................................................................1496.6.2 Roughing............................................................................................................................1506.6.3 Finishing ............................................................................................................................151
6.7 Contours (contouring, pocketing, projection on model) ......................................................1526.7.2 2D cutting without model (2.5D).......................................................................................1536.7.3 2D cutting with model (3D)...............................................................................................156
6.8 5 axis tool path projection .......................................................................................................158
7 Post processing..................................................................................................................................162
7.1 Saving........................................................................................................................................162
7.2 Security Plane...........................................................................................................................1637.2.1 Post processing of 3 and 4 axis tool paths .........................................................................1647.2.2 Post processing of 5 axis tool paths ...................................................................................165
8 Basic concepts ...................................................................................................................................170
8.1 Basics to getting started with models .....................................................................................170
8.1.1 Launch the software .......................................................................................................... 1708.1.2 Open a model object.......................................................................................................... 1708.1.3 Prepare the method (Roughing) ........................................................................................ 1728.1.4 Start the roughing cutting process ..................................................................................... 1738.1.5 Prepare the method and cut (Finishing) ............................................................................ 1758.1.6 Saving the NC tool paths................................................................................................... 1768.1.7 Setting the Machine tool.................................................................................................... 177
8.2 Basics to getting started with a BMP image......................................................................... 1798.2.1 Open a BMP file................................................................................................................ 1798.2.2 Cutting the grid.................................................................................................................. 1808.2.3 Save the tool path .............................................................................................................. 182
8.3 Cutting techniques................................................................................................................... 1838.3.1 Multiplane cutting ............................................................................................................. 1838.3.2 Cutting using inversion ..................................................................................................... 186
Welcome to Mayka™
Congratulations on your purchase of this Mayka™ (phonetic:- Make ah) software, that allowsyou to easily cut 3D models from all 3D CAD/Design software’s that can produce 3D-DXF andSTL files. Mayka™ also provides unique tools and options related to cutting point cloud andbitmap (picture) data.
We hope that this software will be the answer to your needs. It is important for you to fullyunderstand Mayka™’s functions to exploit your creativity.
Read carefully this general reference manual and contact your supplier for any further trainingand specific information. Please note that this manual has been produced to outline the facilitiesand due to software developments, the documentation may have possible discrepancies, soplease contact your supplier if anything is unclear. This handbook refers to Mayka version 6.0. Ifyou have a later version, contact us for further information.
If you have any suggestions or remarks concerning the Mayka™ software, we will be pleased toreceive them, via your supplier.
The PicaSoft Team
Innovative tools to compliment the Creative
Beauzy – Route de Châtres sur Cher – 41300 THEILLAY
email : info@ picasoft.com – web : www.picasoft.com
1 Definitions
1.1 CADComputer software that assists with the conveying of designs. Many geometrical entity typesdescribe the designs and models drawn with these software products. (see below)
1.2 CAMComputer software that allows the generation of numerical data to pilot computer numericallycontrolled machine tools utilising CAD data.
1.3 CAD: Polyhedral modelsWe speak about a polyhedral model when the geometrical definition of the surface of the CADmodel is composed by lots of small faces. Each face is defined by points linked together by a lineor series of lines, that makes the model look like a net. The true mathematic description of asurface does not normally exist in this kind of model.
This type of modelling is often used in the sotwares which create synthetic images. The outputformats used are usually DXF and STL.
Mayka™ is designed to allow you to reproduce these kind of model’s on a various CNC machinetools. Mayka™ can also generate certain types of polyhedral models from picture and point data.
1.4 CAD: Surface modelsWe speak about surface models when the geometrical definition of the CAD model surface iscomposed by mathematical surfaces. They can be; plane surfaces, surfaces of revolution, coonspatch, beziers, splines, parametric or NURBS surfaces, etc.
These types of modelling software’s are often used in mould production, calculation of theflowing of fluids or materials stress analysys etc.
The standard exchange format used is usually the IGES format. This format cannot be read orprocessed by Mayka™. Most softwares allow the conversion to STL and 3D-DXF polyhedraldata before exporting.
1.5 CAD : Solid modelsSolid models geometry elements are normally based on CAD volumes to define the shape of thepart.
Programmes using this type of solid data usually can export to rapid prototyping format STL,which is compatible with all systems and recommended for Mayka.
1.6 CAD : BITMAP images
Images or photographs stored on a computer are termed as Bitmap files.
This format defines the number and the colour of all the pixels that compose the image. A screenshot copy of your PC's screen is saved as a bitmap. In Windows this is BMP, in Macintosh it isPICT.
Software like Photoshop, Paint, etc. utilise these formats and can be used to convert and saveimages to the correct format.
Many BITMAP formats exist, such as: BMP, JPEG, PICT, PIX, TIFF, EPS, etc
Mayka™ recognises the format BMP(on Windows) & PICT(on Macintosh).
1.7 CAM 2D _The CAM 2-1/2 D softwares calculate the tool paths parallel to the machine axis planes byworking with the geometrical contours of the CAD model. This is the case for the software’swhich are often used for general machining of mechanical parts. The tool is placed on the Z axiswith a given height and then works on two axis at the same time.
The Z height is defined by the operator for a CAD 2D model, where as the Z height isautomatically defined for a 3D CAD model.
1.8 CAM 3 axisThe 3 axis CAM softwares calculate the 3D tool paths by working with 3D surfaces andgeometrical contours. The 3 axis of the machine X, Y & Z can move at the same time to go froma point to another one of the tool path. This is the case for the 3D mould fabrication softwares.
1.9 CAM 4 axisThe CAM softwares that produce 4 axis tool paths usually offer 2 distinct options. 4th axis wherethe actually rotary axis is the 4th axis of the machine and is based on a rotary indexer sitedparallel to one of the main XYZ axis. Either the software facilitates the movement of the 4th axisin conjuction with 3 other axis to product continuous movement, or the software can only indexthe 4th axis and cut in 3 axis in that plane.
1.10 CAM 5 axisThe CAM 5 axis softwares calculate the 3D or surfaces tool paths by working with geometricalcontours. The tool inclination in comparison with the model is taken into consideration in its toolpath calculation and the software allows for all 5 axis movement and or indexing of the rotaryaxis to position the 3 axis cutting plane.
2 Installation of Mayka
2.1 Hardware requirements
Suggested computer configuration Windows
Intel Pentium PC with Windows XP or 2000 Professional, 256 Mb RAM, 10Mb of hard diskspace, 19" Colour Screen, keyboard and mouse. OpenGL graphics card eg NVIDIA GeForce2.
The software mayl run with some other makes of processors, running Windows 98, NT-4 andXP with 128Mb RAM and 15" Colour Screen.
2.2 Installing the softwareYou are provided with a CD that contains the software installer application, examples anddocumentation.
• A dongle to protect the software licence.
• The software operates with Microsoft Windows 98, NT, 2000, XP.
Insert the CD to the drive in your computer. It contains:-
• Installer for different Picasoft applications
• Installer for the protection drivers for the dongle
• Installer for example files
• Installer for documentation.
Click the icon to suit your choice and follow the instructions to make the installation.
So you can utilise MAYKA fully you must perform the following steps:
1. Run the MAYKA installer and the installer application will guide you through the steps,similar to any other application.
2. Install the drivers for the protection key (Dongle)
3. Turn off your PC and connect for the protection key (Dongle) to your PC
4. Turn on your PC, run MAYKA and enter your user code.
5. Exit MAYKA, the start again MAYKA to activate your authorization
During the installation data will need to be added to the preferences, therefore, the user will needfull access to the computers operating system so these files can be saved to the computer. It istherefore important that all restrictive software is disabled. ie Administrator access is required.
Note: If you have install, then re-install an updated version of Mayka, it is usually not necessaryto re-install drivers for the protection key.
2.3 Installing the software protectionMayka ™ is protected against illegal copies. When you have purchased a user licence, to use thesoftware, you will be supplied a protection key. This key, called Dongle, must be connected toeither the PARALLEL port (LPT1 Printer port) of your computer, or the USB port ( if you aresupplied or request an optional USB dongle at the time of ordering.) Note you can exchangeyour dongle at a later date, which is chargable. Macintosh users are provided with a USB dongle.Note that the UBS dongle is different internally for Windows and Macintosh, it is not a dualsystem dongle.
2.3.1 Windows Dongles
The above shows a typical connection to your Windows based computer.
2.3.2 Macintosh Dongle
The above shows a typical connection to your Macintosh computers keyboard USB port
2.3.3 Both Computers
You must turn off your computer to connect the dongle, please be carefull to make theconnections correctly and do not damage the connectors. It is important to switch off yourcomputer before connecting or disconnecting the dongle so as not to damage the dongleselectronic’s or your computer.
IMPORTANT : Turn off your computer before connecting or disconnecting a dongle. Donot connect the parallel dongle to any other port than the parallel port of the computer.Some other ports look similar in shape. The dongle authorises the licence to use thesoftware it is your responsibility to look after it and insure it for the software value againstloss.
2.4 Enter your user licence
From the Windows Start menu select the Programs folder, then the Picasoft folder, then theMayka™ software icon.
On Macintosh, just double click the Mayka™ application.
When you first start Mayka™, with the dongle connected, a dialog box appears. If you cannotsee this dialog, then select Personel Code from the ? menu.
Enter your personal code, which is written on your licence notice, then click on OK to validateyour personal code.
Then click on Yes to confirm your choice, then Quit Mayka™, this will authorise your code.
Should you need to change your code, or enter it at a later date, then select “Personal Code”from the ? menu.
If the software started in “demonstration” mode and you have entered a code, you will need toquit the application and re-launch for the code to take effect.
2.4.1 Education version
There is a software version for National Education School users. Which has some limitations.
2.4.2 Contract OEM versions
The OEM versions is a contract for distribution of Mayka ™ passed on with a machine toolmanufacturer, possibly under another trade name. There are particular versions of the software,limited to functions and to the type of machines tools which are sold by various OEM’s
2.4.3 Demonstration mode
The demonstration mode allows you to use all the functions of the software. But you cannot saveyour work.
Mayka™ works in the demonstration mode when:
• your dongle is not connected or recognised.
• your personal code is not correct.
• you have entered your personal code and you clicked on Cancel.
Note: Drivers for protection key (dongle) are not needed in demonstration mode.
2.4.4 Evaluation Mode
An evaluation version of Mayka ™ is available. It allows you to get access to all the functionsand to save your work, but the number of savings is limited. After the limited saves the programwill only work in demonstration mode.
3 Mayka Toolbar
This tool pallet is the same in all versions of the software, however within Microsoft Windows,dragging the pallet within the main application window will change the pallets appearance. Ifyou cannot see it select toolbar in the Window menu.
3.1 Cursor icon
This icon allows you to use the cusor arrow to select and modify objects with the left mousebutton in the main graphic window. In addition there are other options available with the rightmouse button in other windows and dialogs like the object list window. If you have a 2 buttonmouse with a wheel button, some other features such as zoom +/- with the wheel are available.
3.2 Rotate view icon
This icon allows to display the object from different angles on the screen.
To use this function :
• Click on the rotation icon with the left mouse button once.
• Position the cursor on the working screen then click and drag the mouse withoutreleasing the button.
The rotation is performed around the centre of gravity of the selected object, and not around thereference point. This only modifies the screen display of the objects, it will not modify theposition of the objects in the reference system.
You have this same function available to rotate the screen by using the right mouse buttonwithout selecting using this icon.
Note: When rotating a large model in shades mode the performance of the screen display isrelated to the power and memory of the OpenGL support your PC is using. You canadjust the performance within Mayka's preferences so as to reduce the number of polygonsdisplayed during movement of the screen. This performance value is only related to thedisplay of your model and does not effect the quality of the machining calculations.
3.3 Pan Screen icon
This icon will move the view of the object both horizontally and vertically on the screen. To usethis function :
• Click on the direction icon.
• Move the cursor on the working screen.
• Click and hold the mouse without releasing, then drag the screen.
• Release the mouse to stop.
Important : Only the view of the object on the screen changes, not the position of the objectin the coordinate reference system.
3.4 Zoom icon
This icon will move the view of the object both horizontally and vertically on the screen.
• Click once on the main screen and the display scale is multiplied by 2.
• Hold down the CTRL key and click once on the main screen and the display scale isdivided by 2.
• Click and drag over the display screen and this will enlarge the selected area to fit thescreen.
Note a Windows mouse scroll wheel will perform Zoom +/-, even without this icn beingactive.
3.5 Measure icon
This tool allows you to measure: the position of a point, the distance between two points, theangle between 3 points. The points can be points on the CAD object or points the tool path.
To use this feature click on geometrical points whose you wish to measure. This tool worksequally in shaded and wireframe display modes. The tool remembers upto 3 points in memory,information is displayed at the bottom of the screen.
3.6 Fit to view
This icon adapt the screen dimensions to display all of the visible objects on the screen.
3.7 Shading view
Clicking this icon displays the screen in OpenGL mode to show a realistic representation of yourparts, methods, grids and tool paths
3.8 Shading with transparency
Clicking this icon displays the screen in OpenGL mode to show the parts transparently.
3.9 Wireframe view
Displays an exact representation of your geometry.
3.10 Contour view
This displays the models outline contours.
3.11 Isometric view
Positions the screen to view the objects in a perspective view.
3.12 Orthogonal views
3.12.1 Front face
Clicking the icon positions the screen view so your object viewed from the front face.
Clicking on the small arrow to the right of the icon allows you to display other related viewsdepending on the working zone and the axis configuration.
3.12.2 Top face
Clicking the icon positions the screen view so your object viewed from the top face.
Clicking on the small arrow to the right of the icon allows you to display other related viewsdepending on the working zone and the axis configuration.
3.12.3 Right view
Clicking the icon positions the screen view so your object viewed from the right face.
Clicking on the small arrow to the right of the icon allows you to display other related viewsdepending on the working zone and the axis configuration.
3.13 Align objects icon
Aligns at least two or more selected objects to the first object selected in the list from the top.
The type of alignment is defined by the next window where you have to indicate position criteriaof the objects in all three directions XYZ.
None: means that nothing is displaced in this axis.
3.14 Align to machine origin icon
This icon allows, an object or several selected objects to be aligned on the last defined machineorigin.
3.15 Create cutting method icon
Selecting this icon creates a new method in the object list. It is equivalent to create method in themodelling menu.
3.16 Cutting icon
This icon allows the cutting of the model or the grid of points selected. It is equivalent to processcutting of the Modelling menu. To activate this function, a cutting method has to be selected inthe object list first. When it is activated it calculates the cutting parameters of the method.
3.17 Animation / Simulation icon
This icon allows the selection of either the animation or simulation of the selected tool path inthe object list. It is equivalent to animation or simulation of the Display menu. To activate thisfunction, a tool path has to be selected in the object list first. When it is activated, it opens acontrol window which allows you to navigate the tool path, forward, back, pause, stop etc.
3.17.1 Animation
This activates the animation mode as described in the menu section. Basically with a tool pathselected, you can view the tool movements over the part.
3.17.2 Simulation
This activates the simulation mode as earlier in the menu section. Simulation shows the partbeing machined from a block.
3.18 Process icon
This tool starts the calculations of the deferred cutting processes that are selected in the cuttingprocess list.
3.19 Information icon
This tool displays a window of the relative information relating to objects selected. To access theinformation on a given object, select it in the list and click this icon or choose the functionInformation from the Window menu.
Information displayed depends on the type of object or objects selected. You can simultaneouslyselect several objects in the list and see them in this window.
4 Objects in Mayka
4.1 List of objectsSeveral types of objects can exist in Mayka:
• Models,
• Point clouds,
• Grid of points,
• Tool paths,
• Methods of cutting,
• Attatchments,
• Blocks,
• Selection zones,
• Contours.
The list of the objects appears in the object list in order of their creation.
4.2 Displaying the objectsThe small icons adjacent to the objects in the list can be made visible or invisible :
• Blue icon: object visible
• Red icon: object invisible.
To change the visibility, click the mouse pointer on the blue or red icon.
4.3 Selection of objects
To select a visible object, just left click on its name: it appears highlighted. You cannot select aninvisible object, so make it visible first by clicking its red icon first.
Each object can undergo a certain number of functions (transformations, conversions, etc..). Theformer differ depending on the type of entity selected (model, grid, tool path etc) and areauthorised, or not, automatically by Mayka. If the function of the menu is greyed then thefunction you are selecting is not available for the object that you have selected.
4.3.1 Object sub-menus
With the right mouse button clicked on an object in the list a pop down menu appears. It isdifferent depending on the type of object selected.
In the case of a grid, for example, one can modify the number from points displayed on thescreen using the right mouse button. This affects the speed of screen functions, but not theprecision of the grid.
Options vary when you right click on the objects, as shown in the list as shown below:-
4.3.1.1 Colour
You have here the possibility to modify the color of the object selected. If you wish to permantlychange the color of all objects, you can modify the values of these parameters in the preference/display menu.
4.3.1.2 Rename
You can change the name of the object. Edit the name and click OK.
4.3.1.3 Hide
You can hide this object, which makes its icon go red.
4.3.1.4 Copy
This copies the object, making a duplicate in the object list. Methods hold all the sameparameters so you only need to change the ones you want. eg Roughing to Finishing.
4.3.1.5 Delete
This deletes the object from the list. Edit > Undo or Ctrl+Z with reverse this.
4.3.1.6 Ungroup
When a object consists on more than one object grouped together, you can ungroup it.
4.3.1.7 Properties
You can change various propeties of the object. Double clicking shows properties.
4.3.1.8 Show Normals
It effects the vector orienting the tool. In the case of 3 axis tool paths, this vector is parallel to theaxis Z.
4.3.1.9 Opposite direction
You can invert the direction of the normal.
4.3.1.10 Top side view
This changes the current view to be looking at the local top view of this object.
4.3.1.11 Front side view
This changes the current view to be looking at the local front view of this object.
4.3.1.12 Right side view
This changes the current view to be looking at the local right view of this object.
4.3.1.13 Length of normal
You can change the length of the vector. This function has no influence on the tool path.
You can visualise only a selection of the normals by using the next values:
4.3.1.14 Offset
This function creates a parallel path offset from the selected path of the value that you indicate.Note this value can deform the path.
You do not have to use this function to offset the tool for normal cutting.
4.3.1.15 Save as…
To reduce your mouse movements up to the file menu, here you have the File > Save as.. optionto save your selected NC file.
4.3.2 Multiple selection
To select several objects simultaneously, you have three possibilities:
• Click on the object name whilst holding "Shift" key on the keyboard.
• Click on the object name whilst holding "CTRL" key on the keyboard, this allowsdifferent objects to be selected with unselected ojects in between.
• Click and drag the mouse over several objects in the list.
To deselect specific objects in a selected list, hold the CTRL key and click on those objects.
4.3.3 Order of the objects in the list
The order of objects is defined by their place in the list of objects from the top to the bottom.
This order is important for some functions (for example: to align) and can be easily modified:
• Click the name of the object that you want to move.
• Drag the object to the new place in the list.
The order of tool paths in the list will be the way that they are cut on the machine tool. If yougroup them together you will generate a combined cutting program. ie Group Roughing andFinishing to equal your total process.
4.4 Screen iconsWhen working with object, you will want to orientate, scale, move etc in relation to the axis andthe datum point. The following icons are displayed to help you.
4.4.1 Datum point X0, Y0, Z0
This icon represents the Datum point where the axis are X0, Y0 and Z0. This corresponds to theaxis of your machine tool in absolute coordinates. It is important to align your parts in relationto this point.
Datum in shaded mode Datum in wireframe mode
4.4.2 Screen orientation
This icon is permanently displayed in the bottom left corner of your Mayka window to show youthe orientation of the screen you are viewing. This orientation is displayed as a visual guidebased on a standard geometrical format.
X related items are in Red
Y related items are in Green
Z related items are in Blue
This indicates + rotation around Z is anticlockwise.
This indicates + rotation around Y is clockwise.
This indicates + rotation around X is anticlockwise.
In a lot of the dialogs, the Red, Green and Blue is used to help you.
5 Menus of Mayka
5.1 File
5.1.1 New
This function allows opening of a new window in Mayka™ after the closing of the previous onewithout being forced to quit the application.
Note: Opening of a new working window will erase the previous one and all the files in thelist make sure you save your work first.
5.1.2 Open
This function allows you to open and process files in the following formats :
• DXF 3D face
• DXF Polyline
• STL ASCII & Binary
• BMP
• File of Points
• PIX (format of Roland)
• BDalti (format de IGN)
• Tool path ISO G-Code (G00 & G01) by Mayka
• EPS & AI Contour paths
• Mayka Scene format
5.1.2.1 DXF file format
File extension : .DXF
DXF is a CAD file format that is defined by and, is the property of Autodesk Inc.
It allows the exchange of data between different CAD ans CAM.
This format describes several geometrical entity types such that lines, arcs, polylines, etc... Itdoes not normally allow a mathematical surface definition. In file DXF, surfaces of models arenormally described by a quantity of facets that form a mesh that is commonly known as apolyhedral mesh. Mayka processes facets on the mesh in DXF files and ignores all other entities:
Format DXF 3D Faces: facets of 3 or 4 points.
Format DXF polylines: from a number of points to describe each facet.
Note: A binary DXF format exists, but this is not interpreted by Mayka.
5.1.2.2 STL file format
File extension : .STL
It is a format of CAD file used for the manufacture of models with stereolithography machines.
It is the format it most used in rapid prototyping and, consequently, most CAD software cangenerate the STL file format.
The CAD file description of the model is a polyhedral type that describes the skin of the modelin a multitude of facets. In this format the facets are all triangular with 3 points describing thecorners.
There exists two types of STL formats: Binary and ASCII.
Mayka processes the two formats indifferently. The binary format is more compact and thereforeopens more rapidly than ASCII files. Concerning the cutting process, there is no difference in thetime or the precision of calculation.
Note:
The name of the stereolithography file has to have the suffix .STL in order that it isrecognised by Mayka (Examples: motorbike.stl or motorbike.STL are both valid).
5.1.2.3 Point file format 1
File extension: .pts
There is no standard in formats of 3D point cloud files.
The object generated in MAYKA is called "cloud of points"
It is necessary therefore to insert in the head of point files the words "POINT MAYKA" toindicate it is a points file, then put the file extension .pts. The values of XYZ should bepreceeded with the letters X Y Z and the seperators between values can be space characters,commas, semi-colons, etc.. Each point must be on a separate line, decimal point is assumed if notentered.
example 1 (Comma) :
POINTS MAYKA
X20.1274867, Y10.922, Z45.356
X22.68, Y43.784574, Z25.77856
...
...
example 2 (Space) :
POINTS MAYKA
X20 Y10 Z45
X22 Y43 Z25
...
...
example 3 (Semi-colon) :
POINTS MAYKA
X20; Y10; Z45
X22; Y43; Z25
5.1.2.4 Point file format 2
File extension : .rlf
Use this extension when point files describe a form as a rectangular set points in lines andcolumns. If the interval of these lines and columns is constant, Mayka will try to translate themand will convert the file from ASCII points into Mayka's Grid of point format.
Specific developments to make other point formats compatible with Mayka are available to orderfrom Picasoft. Contact your dealer or PICASOFT for a quotation.
5.1.2.5 Grid format
File extension: .MVGrid
This is a specific internal format of Mayka.
It is a file from points, written in binary, that contains a number of points on X and on Y, with alist of values in Z.
The number of points in X and Y can be different.
The grid file is created from:
• The conversion of a bitmap (BMP) image.
• The projection of grid on a model.
• The opening of a file from points.
• The conversion of a model to grid.
The grid format offers several advantages over the standard CLOUD OF POINTS:
• File compression of important data.
• Rapid cutting calculations.
• Conversion to image.
• Display in OpenGL.
• Conversion to model.
Application developers can ask to licence the description of the GRID format from PICASOFT.
There are several types of grid formats:
• Cartesian, Cylindrical, Polar and Spherical
5.1.2.6 Bitmap file BMP
File extension: .bmp
This is the most common image format used on the PC.
Mayka reads these bitmap files in and converts the pixels of the image into XY coordinate pointswith altitude Z proportional to the level of grey. BMP 16 bit is the prefered format.
Mayka therefore transforms the image into a cloud of orderly points into a grid.
Note on Macintosh this format is substuted by PICT format.
5.1.2.7 File format PIX
The PIX format is produced by digitisers made by Roland DG.(PICZA)
Roland uses PIX variants on different equipment that maybe invalid.
(Models Picza PIX-3, PIX-4 and PIX-30 all work)
MAYKA converts this into its grid format. File extension: .pix
5.1.2.8 File format Bdalti
A proprietary format of Géographique National Français (IGN).
MAYKA converts this into its grid format. File extension : . DIS
5.1.2.9 File format EPS
Format EPS is the format for postscript printers and contains 2 entity types. Points (Raster) andcurves (vectorial). Mayka can only read the curved entities in the file. This format can begenerated by Adobe Illustrator, Corel Draw, Vellum, Concept and Autocad for example?
MAYKA opens this as Contours. File extension : . EPS or .AI
5.1.2.10 File format Scene
The proprietary internal format of MAYKA. File extension: . MVSCN
This format includes the total job you are working on including objects, models, methods,attachments, blocks, methods, tool paths and defered processes. To create a scene file, you mustdo this insde Mayka.
5.1.2.11 File format Tool path
Mayka knows how to read NC cutting files, typically these are CM3, Mimaki, HPGL and ISO(G code).
The CAMM-3 and HPGL are special formats, all other ISO cutting files are initially detectedwith begining % character.
Mayka does not interpret the ISO codes: G2, G3, G41, G42, G43.
You can open and import cutting files described with codes G0 and G1, or any file internallygenerated by one of Mayka's built in post processors.
The plot file format HPGL™ of Hewlett Packard, that consists of PU (Pen Up) and PD (PenDown) commands followed by linear step moves on separate lines, can be read by Mayka, as atool path. No other commands are recognised. ie
PU0,0;
PD100,0;
PU...........etc
Utilisation of files after opening:
During the export of CAD files in the format DXF, the parameters of the scale may have beenlost. (to change this see Scale function of the Transform menu ).
To have a quick idea of the size of the model that you have openned, the size of the X0,Y0, Z0axis origin marker shown on Mayka's screen is defined in the Preference option under display.The default value of 10 mm is initially entered:
Note:
The display of the model to the screen can be interrupted if it takes too long to redraw. Todo this press the ESC key or click the mouse. The amount of model displayed will not effectthe amount of model processed. Pressing the ESC key when a calculation is beingperformed will stop the calculation.
The indicator at the bottom of Mayka's screen indicates to time to open the file.
5.1.3 Save a scene
This function allows you to save all the features of the total job you are working on includingobjects, models, methods, attachments, contours, blocks, methods, tool path’s and deferredprocesses.
5.1.4 Save as…
The format you save depends on the object you have selected in the object list.
5.1.4.1 Save a model
The default saved format is binary STL.
To choose an other format to save, click on the arrow or on the name.
A choice of valid file formats are displayed in the list:
• DXF 3DFACE
• DXF POLYLINE
• STL ASCII Text
• STL Binary
Drag the cursor to the format you require, when it is highlited, click the format and the list willdisappear leaving your choice displayed. Enter the filename you require and then click the Savebutton.
STL formats can only contain 3 points per face, so if the file does not conform to this the formatswill be greyed out in the list.
You may require to save your model when :
• You have change the position or size (translate, scale, rotate, duplicate etc.)
• You have created a model from a grid from points.
Note:
The format you save depends on the object you have selected in the object list.
5.1.4.2 Save a grid
To save a grid first select this in the object list.
You can choose one of the formats to save :
• Image BMP : Mayka converts the grid into a BMP image where the pixels of the imagerepresent the XY coordinate points with altitude in Z proportional to the level of gray inthe image.
• Mayka Grid, the internal Mayka grid format.
• Point Cloud, in text format.
Note:
The format you save depends on the grid object you have selected in the object list.
5.1.4.3 Saving a tool path
When saving the cutting tool path, the atributes and file extension will be configured dependingon the post processor selected.
The available post processor format take into account the configuration of the machine that youhave initially chosen.
Note:
The format you save depends on the tool path object you have selected in the object list.The save process makes the final calculation to generate the tool path in the correct post-processor format.
5.1.5 Transmit
This function is used for sending a cutting file to the CNC machine via a serial port of your PC(Normally COM1 or COM2, LPT1 is available for some machines).
The interface cable is specific for each type of CNC machine and the parameters ofcommunication.
In case of possible communication problems, contact your machine supplier. Some machines donot support standard communication setting and need their own transfer software.
It is not necessary to open the file on the Mayka screen to use the Transmit command. Transmitalso works in demonstration mode.
To control the parameters of this function, choose Preferences/Communications from the Editmenu.
When the Transmit function is selected, the next dialogue window appears:
When the Transmit dialog is displayed, choose the cutting tool path file and open it , you willthen be asked to confirm the transmission.
Make sure your machine is ready to receive the data before clicking OK.
Note :
A % appears in tthe bottom right side of the screen to give you the progress of thecommunication.
You can select Stop transmission from the File menu to terminate the communicationprocess
5.1.6 Machine Configuration
Mayka has the options to drive multi axis machines.
You have to begin by defining the type of machine that you wish to drive before doing any work.The machine configuration sets parameters so that you can only work within your machine toolsaxis.
Choose the configuration schematic corresponding to axis of the machine that you are using.
The cutting functions and the display of the software will be adapted to the capacity of thechosen machine to realise these functions for you. Similarly the valid post processors will bedisplayed. Some machine configurations have limitations such as rotational limits, these will bedisplayed here. This important point for most 5 axis machines is the distance from spindle to thecentre or rotation or pivot point. Consult your supplier to enter these values correctly.
If the post processor for your machine does not exist, contact your retailer for a quotation.
5.1.7 Quit
This is a function of the software which allows you to exit the Mayka™ application when youhave finished and return to Windows™.
Mayka™ does not automatically save your work when you quit the software. It will ask ifyou wish to save the scene. If you choose not to save all work is lost unless previously saved.
5.2 Edit
5.2.1 Undo Ctrl+Z
This function cancels or reverts the effect of your last single operation.
5.2.2 Redo Ctrl+L
This reverses the Undo function.
5.2.3 Free memory Ctrl+L
In some cases when many manipulations have taken place the internal memory can needclearing. You can free up the memory used by Mayka with this function. You will lose thepossibility to undo any preceding functions, but the files you have open will not be effected. Werecommend you save your work regularly.
5.2.4 Select all Ctrl+A
This function selects all the objects in the object list.
5.2.5 Unselect all Shift+D
This function deselects all the objects in the object list.
5.2.6 Inverse selection Shift +I
This function select unselected objects and deselects objects in the object list and vise versa.
5.2.7 Hide selection
Renders invisible all objects selected in the object list.
5.2.8 Hide all
Hides all objects.
5.2.9 Show all
Shows all objects.
5.2.10 Copy Ctrl+C
Duplicate the object selected in the object list.
5.2.11 Delete Del
Delete all objects selected in the object list.
5.2.12 Selection Zone
The selection zone allows you to select a geometrical zone of a model object in Mayka.
In the case of the projection of an image onto a model, the selection zone will allow you todefine the exact place or you wish to place the image.
In the case of dividing a model, the selection zone defines the position of the dividing plane.
Several geometrical forms are available: Rectangular, Polar, Cylindrical, Spherical. Theutilisation is very similar to that of methods.
The configure menu allows you edit the selected zone. It can also be accessed by double clickingon a zone in the list of objects.
With the right click of the mouse can change the attributes of the selection zone.
You can reposition the selection zone using the translation and rotation features. The zone canalso be manipulated using the mouse pointer in the same way as a method zone.
Transformation
With the method selected in the object list and using the transformation menu, you can changethe position and orientation on the method.
Translation by mouse
Using the mouse button with the CTRL key you can move the zone in the view by clicking on ahandle or corner and dragging. The eight corners of the zone of selection are not displayed so asto not to overload the screen, they are never the less all active. The function only works with thecursor arrow selected in the toolbar.
Rotation by mouse
Using the mouse button with the SHIFT key you can rotate the zone in the view by clicking on ahandle or corner and dragging. The eight corners of the zone of selection are not displayed so asto not to overload the screen, they are never the less all active. The function only works with thecursor arrow selected in the toolbar.
Edit sizes
To move a control point (centre on each side) of the zone with the mouse, click these points anddrag. Selecting between shaded and wireframe view makes these features easier to use.
Placement
You can place a zone in any selected view:
• Define your view point (Display >View, or with the mouse),
• Select the zone in the list of objects.
• Use the transformation menu > Rotate according to view.
5.2.13 Redraw Crtl+R
Redraws all the visible objects on the screen.
5.2.14 Quit Process Esc
This function interupts the cutting process calculations.
5.2.15 Preferences
These are general adjustments that can be made to the software and the way it works.
5.2.15.1 Display
Origin length
In order to have a rough idea of the model length, you can give a dimension to the origin(Mayka™ defaults to 10 mm automatically).
Objects colour
This allows you to choose the object types in Mayka and their default colour
Performance
Simplify the model when moving it, allows you to change the number of polygons displayed,during screen manipulation and in shading mode so as to make the display faster. Varying thisvalue will depend on the level of your OpenGL graphics support within your computer. Thiswill not effect the finish of the cutting process, just the display you see on the screen.
You can the level of transparency in shading transparent mode and you can change thickness oflines in the display contours mode.
5.2.15.2 Units
Mayka™ offers you the possibility of choosing your units of length (mm, cm, inch), angle (degree, radian), feedrate (mm/s, mm/mn, m/mn, inch/s, inch/mn ). Click and drag the pop-up tothe unit you want.
Note: Do not change units in the middle of a process, otherwise your results will beincorrect.
5.2.15.3 Files
Mayka™ offers you the possibility of closing the open polylines found in some DXF files. Alsoyou determine the scale factor which Mayka opens your files. This is sometimes needed whenyour CAD outputs different units to Mayka. It is prefered to set this value rather than use thescale function every time you open a part.
5.2.15.4 Communication
This dialog box allows you to define the different communication parameters between yourcomputer and the modelling/cutting machine. The transfer of the cutting tool path programme toyour CNC will be achieved by way of a interface cable connected to a serial port.
Your PC usually has two serial ports (DIN 9 pins) situated behind the central unit (COM1 orCOM2). There is an option for Parallel interface (LPT1), but this only works with certainmachines.
You must define the following to match your machine tool :
• Baudrate of transfer,
• Parity,
• Transmission protocol,
• Communication (COM1 or COM2, etc..),
• End of Block seperator (This is saved in the tool path file)
Note :
The different machine tool parameter should be obtained from your machine tool suplier.Mayka cannot perform special protocols that do not conform to the Microsoftcommunications ports. Other 3rd party software maybe needed to transmit data to yourmachine tool.
5.2.15.5 Modelling
The value of the optimisation parameter is taken in account when the software calculates the toolpath. It affects the length of each block segment and corresponds to the Maximum error that youwill tolerate as compared to the exact path.
This value compromises between the capacity of the CNC controller of your machine to executethe small segments of program at a constant speed and at the precision that you wish. He defaultis 0.010mm.
The default boarder value is the value displayed when setting a working zone.
Create a method is the default when opening your first model object.
Align the method to the origin is useful, if you always do this for your parts.
5.3 Display
5.3.1 ZOOM
All the functions of the menu do not affect the real dimension of the model, but only the visibledimensions of the screen.
- Zoom Out : decrease the view.
- Zoom In : increase the view.
- Fit screen : adjusts the size of the model so that it just fits in the current window.
Note: a Windows mouse scroll wheel will perform Zoom +/-.
Note: Each function of the zoom commands a new display of the screen. If the time of thenew display seems too long, you can stop it by clicking on the ESC key of the keyboard.The shortcut keys relate to the keypad on extended keyboards when « Number lock » ispressed on.
5.3.2 View
You can select the views from this menu the same as clicking on the view buttons : Perspective,Top, Front, Right.
Along a vector allows you to select two points on an object. The view of the object will beoriented to follow this vector.
Normal to a plane allows you to define a plane by 3 points. The view of the object will thenorientate to this view.
5.3.3 Sectional view
This function uses the shading OpenGL mode and functions only in the two next modes:
5.3.3.1 Activate
Cuts the part with a selection zone only showing the rear of the part. The cut plane is parallel tothe view of the screen.
5.3.3.2 Move away
Steps away the cut plane of the selection zone.
You can use the central wheel of the mouse if you have one.
5.3.3.3 Bring nearer
Steps forward the cut plane of the selection zone.
5.3.3.4 Move more away
Steps away a larger step.
5.3.3.5 Bring nearer more
Steps forward a larger step.
5.3.3.6 Reset
Replaces the cut plane in the middle of the selected object.
To exit the function to reselect the activate menu to remove the selection tick.
5.3.4 Normal
This is the mode of normal display. Choose this to cancel Undercut and Horizontal facets displaymodes.
5.3.5 Undercut
This mode displays as follows:-
Red for the surfaces inaccessible to the cutter.
Yellow for the surfaces parallel to the cutter axis,
Green for the surfaces that the cutter can reach, pending the length of tool.
If no method is selected in the object list, the cutter axis is considered vertical.
.
If a method is selected then the display is according to the orientation of the selected method.This feature is very helpful in multi axis set ups.
5.3.6 Horizontal facets
This mode displays all the horizontal facets on the selected model
5.3.7 Animation
Animation allows you to display the tool path movements over the actual model. Changing toolpaths by clicking on then in the object list, view rotation, zoom, pan etc are all active with themouse. Control of the tool path movements can be animated forwards and backward, step by stepetc., via the animation control dialog. This is similar to a movie player apart from the stepsprocessed. This feature displays between 1 and 200 steps of tool path per movement of the tooldisplayed.
Clicking the end button returns you to the normal view.
5.3.8 Simulation
Simulation copies the selected view port to a new display, where you can see the actualmachining movements from a solid graphical block. The tool paths are representative of youractual part and the surface finish. You are prompted to choose a tool path to simulate and ablock. The block can either be the limitation of the tool path movements or a block you havedefined previously.
The control of tool path movements is similar to animation although you casn only play the toolpaths in a forward direction. The Bloc size represents the number of tool path blocks of data thatwill be processed before a piece of the graphic simulation is updated. If the display tool is turnedoff the simulation will be slightly quicker.
In simulation you cannot change the view, this should be selected before using this function.Simulation relies on the graphic processing power of you computer, therefore, on slowercomputers, animation is quicker to view than simulation. If you reduce the window size and theview of your part, simulation will be quicker than on a high resolution large screen.
Clicking the end button returns you to the normal view. If the simulation is only in standard 3axis control, then the “Display Result” button is shown. Clicking this will exit the simulation andthen Mayka will calculate a grid of the tool path, which is a true representation of the cuttingresult.
If you colour your tool paths differently in the object list, then group them together as one object,you will see the different colours in the simulation.
5.3.9 Shading
This function activates the OpenGL shading display. The « Enter key » toggles this mode onand off.
The corresponding icon is:
5.4 Transformation
Mayka allows you to undertake various geometrical transformations on your objects.
Functions of the Transformation menu work on the objects selected in the object list.
All selected objects can undergo geometrical transformations. Mayka controls the coherence ofthe transformation within the possibilities of the selected machine and zone configurations.
For example it will be forbidden to rotate a tool path other than in the Z axis if the machine islimited to 3 axis.
Note :
More than one object can be multiply selected to be moved.
5.4.1 Translation
Transformation applies to everything you have selected in the object list. Do the translation byentering the value of the movement of each axis. If you enter a number greater than 0 in theNumber of copies dialog box, the translation will produce this number of copies in addition toyour original object.
Example of a translation of 10 mm on X and Y and 20 mm on Z, without duplication:
with duplication:
Note :
The duplication keeps the initial object and calculates other objects according to thetransformation and the number of objects you have to duplicate.
5.4.2 Rotation
The model, adaptive grid and tool path objects can undergo rotation.
Choose the rotation axis (X, Y or Z) and indicate the rotation angle. It can be either positive ornegative. You can make rotations with or without duplications.
Example of rotation around the X axis -90°.
The rotation axis can also be arbitary. In that case, define the axis of rotation by giving thecoordinates of two points. For that, click on Two points then on OK, the following windowappears:
Enter the coordinates of the first point and click OK, a second window will appear for the secondpoint enter this and click OK.
Do not forget that the transformation applies to all the objects you have selected.
5.4.3 Scale
The dialog displays the original “previous” dimension of your selected object and allow you toeither enter a “new” dimension or “scale” factor. If the keeep aspect is selected all axis arescaled together ortherwise the scale factor applies to each axis separately, so you can distort yourobjects with this tool.
In most of the numerical fields Mayka accepts formula for calculation with the operators: + - X /.etc for plus, minus, multiply and divide. Pressing the TAB key will calculate the expression.
For example a scale factor can be written: 127.5/ 25.4
Note:
The scale factor modifies the dimensions of the objects selected.
5.4.4 Symmetry
Choose the plane of symmetry to reflect the selected object in. Otherwise known as mirror.
Example :Example of a symmetry according to the XZ plane situated at y = 0
Example of a symmetry according to the XZ plane situated at the middle of the object
If the plane of symmetry is out of the ordinary, give it’s coordinates of three points of that makea plane (enter the coordinates in the same way as the rotation, but with three points).
If the duplication option was selected a copy of the object is made symetrically across the plane,else the object is moved symetrically.
5.4.5 Invert
This function is most often used in the case when you wish to manufacture the two sides of amodel. (see example section)
This function faciltates the inversion of the part and all its block and attatchment objects so thattooling paths will be aligned correctly to the machine tool and the part.
This corresponds to a 180 rotation of the model around an axis. The inversion can made on the Xaxis or Y axis.
Selecting this function displays the following dialog:
Inversion without a block works from to the centre of gravity of the selected model.
Inversion with a block and model, works from to the centre of gravity of the block.
Example of an inversion according to the Y axis
5.4.6 Offset
This function transforms the selected grid by the offset amount specified and creates a new gridthat is proportionally offset from the original.
The offset value can be positive or negative.
5.4.7 Array
This function allows you to make multiple copies of a selected object in the object list.
Number of objects specifies how many total objects you require.
Vector is the size of the selected object.
Offset is the space you require between objects.
In this example a tool path object has been copied with 3 sets in X and 2 sets inY. This is a fasterway to make 6 identical tool paths, rather than processing 6 copies of the model. The tool pathscan be grouped together as one file.
5.4.8 Rotate according to view
You can place a zone perpendicular to any selected view:
- Define your view point (Display >View, or with the mouse),
- Select the zone in the list of objects.
- Use the menu transformation > Rotate according to view.
5.4.9 Convert
The function Convert is used to transform :
• a grid into a DXF or STL model (function Convert to model)
• a model into a grid (function Convert to grid)
• a tool path or points file (function Convert to grid).
The function Convert applies automatically to the type of the selected object, the conversionswhich are not authorized will be in grey.
Mayka can equally convert an image into a grid. This operation is undertaken automaticallyduring the opening of a BMP file.
5.4.9.1 Convert a grid to model
Mayka converts a model (composing of facets) to a grid of points :
• Select a model
• Use the function Convert a model
3D Model created from the grid of the Flower image.
This model can be saved in DXF and STL (see Save as).
Important : the files created can be very large in size.
The precision of the net grid is the one which is displayed and can be set by right mouse-clickingon the name of the selected grid in the object list.
5.4.9.2 Convert a grid to an image
Mayka can convert a 3D grid points file into a image in levels of grey. The shade of grey of eachpoint is linked with each points height.
• Click the grid in the object list with the right mouse button to choose the level of pointsdisplayed.
• With the grid selected choose save in the file menu.
• Select the option for Bitmap Image: BMP
• Click Save.
Note:
Values by default are the black for the low and the white for the high points of the model.Some zones are not definited (outside the object for example) will be coloured red.
5.4.9.3 Convert an image to a grid
From the File menu select open and then choose the BMP files you wish to open, click the openbutton and the following dialog will be displayed :
The result obtained in shading view is the following grid:
System
Select the working system you want
Length and width of the model
Enter the dimensions you want to give to the model
Keep aspect ratio
This option allows you to deform or not the model.
When the button is not activated, the length and the width are not linked. You can enter twovalues of your choice.
When the button is activated, the length and the width are linked to keep the proportions of theimage.
Suggested Precision display
The distance between the points of the 3D grid are displayed which depends on the resolutionand size of the image.
Height of the white
Stipulate the height of the white pixels of the image
Height of the black
Stipulate the height of the black pixels of the image.
Control of grey
This factor allows you to make the corresponding curve vary between the levels of grey and theirheight.
Factor = 1 that means that the heights are exactly proportional to the levels of grey.
Example factor = 1Proportional heights
Example factor = 20
Example factor = 0.01
5.4.9.4 Convert a tool path into a grid
Select the tool path in the object list.
Define the tool geometery you want from the Modelling, Configure menu, or right click on thetool path in the object list and select Properties from the pop down menu. Then click OK.
Select Convert to a Grid from the Transformation menu
The following window appears :
It is necessary to stipulate the precision so that Mayka™ can calculate the data points filecorresponding to the tool path of the currently selected tool definition.
5.4.9.5 Convert a model to grid
When a model is selected, you can convert it entirely or partially in a grid of points.
To convert a part of model to grid, use a selection zone to define the part to be converted. Theselection zone can be polar, cylindrical or spherical.
You can fix the height of the grid using the selection zone. This height is fixed as the base of thecartesian zone. Also you can set the precision of the grid.
5.4.10 Projection/Mapping (available with the option MAYKA Projective)
This function allows a 3D grid of points to merge with a 3D model; by direct projection (withoutdeformation in the axis of projection); or by mapping it along the curve of the model.
Either projection or mapping drapes grid on the model, preserving the aspect in Cartesian, polar,cylindrical and spherical zones.
The diagram below shows the difference between projection and mapping.
Directional mapping is processed on the axis X in this version of MAYKA.
One can see the principle of projection and mapping.
In the two next images, look at the difference between a direct projection on a cylindricalselection zone and mapping on the same selection zone
The next images show the area using a cylindrical selection zone for projection.
5.4.10.1 Projection
These projections can use selection zones of the object (zone selection menu) or the zone can bedefined by the positioning of the grid over the model. The dimension of the projection and thegeometrical type of projection (Cartesian, polar, cylindrical, spherical) can be set by the user
Projection type: means that the size and the position of the image or the grid remainsidentical before and after projection. Choose the direction of the projection.
Warping: means that the size of the image or grid will adapt to the dimensions of thedefined selection zone or to the size of the option that is chosen.
Add or subtract: you can choose to add or to subtract the engraving on the model.
Offset: allows you to raise or lower the total projection.
Alignement: allows you to define where the projection is in relation to the model.
Parameters: allows you to adjust the precision, equally or seperately, also you candiscard the points outside the model.
5.4.10.2 Mapping
In the case of the mapping the parameters are simplified, because mapping has been selected.
Parameters have the same meaning as the direct projection.
The mapping is directional. In this version of MAYKA it is fixed on the X axis.
If you need mapping in an other direction, then to turn the model beforehand.
5.4.10.3 Cartessian projection :
The grid
The model with projection zone
Cartessian projection
5.4.10.4 Cartessian mapping :
The model
The grid
Cartessian Mapping
5.4.10.5 Polar projection :
The grid The model with projection zone
Final result
5.4.10.6 Cylindrical projection :
The grid
The model with projection zone
Final result
5.4.10.7 Spherical projection:
The grid
The model with projection zone
Final result
5.4.11 Align objects
This function permits the alignment of several objects to in relation to each other.
When several objects are selected in the object list, this function aligns each object based on thefirst in the list (nearest the top). Options to agin the ojects either end to end or stacked on eachother are also available. Alignment parameters can be selected for each axis in the followingwindow.
When the end to end option, or stacked option is selected, you have the choice to enter an offsetbetween the selected objects. The default is a zero offset.
You can choose if you want attachments to be included or not.
5.4.12 Align to origin
This function allows you to align objects selected in the object list with respect to the absoluteorigin, which normally corresponds to the machine tool origin for cutting.
Note:
It is usually necessary to make this setting because it determines the origin of your modelon the machine tool. Placing the object so as the origin corresponds to your millingmachine is the easiest and the fastest method to use.
5.4.13 Group
The Group function is available only with model objects, grids and tool paths.
A group is one object containing multiple objects of the same type.
To group several objects:
Select several objects in the object list.
Choose the Group function.
The list of the selected objects disappears to display the resulting object, which has the name ofthe first object of the list. You can change that name by clicking on it in the object list.
5.4.14 Ungroup
This is the reverse function to group.
5.5 Modelling
5.5.1 Create a method
5.5.1.1 Definition of a method
The method is a principal object of MAYKA and contains all the parameters which are needed tocontrol the cutting process. This object is stored in the object list.
The method defines:
The objects that will be process with its specific actions.
The working zone on the model.
The cutting strategies.
All the parameters for the tool definition and cutting attributes.
The method is orientated in 3D space with its own local coordinates.
In shading mode a tool is displayed to exact scale at the top of the method.
In other display modes the method top is outlined with a thicker line.
5.5.1.2 Creating a method
Selecting this menu item in the modelling menu or this icon,
creates a new method in the object list and presents a method dialog on the screen.
If the method dialog is not displayed, select the method in the object list and either:- right clickthe mouse and select properties, double click the method name, or select configure from themodelling menu
5.5.1.3 Manipulating a method in 3D
Several geometrical forms are available: Rectangular, Polar, Cylindrical, Spherical. Theutilisation each manipulation is very similar in each method.
You can reposition the method using the translation and rotation features. The zone can also bemanipulated using the mouse pointer in the same way as a selection zone.
Transformation
With the method selected in the object list and using the transformation menu, you can changethe position and orientation on the method.
Translation by mouse
Using the mouse button with the CTRL key you can move the method in the view by clicking ona handle or corner and dragging. The eight corners of the zone of the method are not displayedso as to not to overload the screen, they are never the less all active. The function only workswith the cursor arrow selected in the toolbar.
Rotation by mouse
Using the mouse button with the SHIFT key you can rotate the zone in the view by clicking on ahandle or corner and dragging. The eight corners of the zone of the method are not displayed soas to not to overload the screen, they are never the less all active. The function only works withthe cursor arrow selected in the toolbar.
Edit sizes
To move a control point (centre on each side) of the zone with the mouse, click these points anddrag. Selecting between shaded and wireframe view makes these features easier to use.
Placement
You can place a method in any selected view:
• Define your view point (Display >View, or with the mouse),
• Select the zone in the list of objects.
Use the transformation menu > Rotate according to view.
5.5.1.4 Editing a method
The configure menu under the modelling menu allows you edit the selected method. Doubleclicking on a method in the list of objects can also access it.
With the right click of the mouse can change the properties of the method.
When the method parameters dialog is displayed, there are several tabs shown across the top toallow you to access the necessary information help in the method you are working on. These tabsvary depending on the type of method.
5.5.1.5 Defer Calculation
This button allows you defer the calculation.
As calculations can take some time to process, you may wish to prepare other cutting methodsand therefore defer all the calculations until later.
In this case the calculations are stored in the cutting process list.
You have the choice to modify the method already used so as to create another cutting processfor MAYKA to memorise if you wish.
You can therefore prepare a multitude of cutting process operations without waiting for eachcalculation to be processed separately.
To launch all the calculations in the cutting process list, click the cutting process icon.
All the calculations will be generated and placed in the object list.
Do not forget to save the tool paths or the entire scene at the end of the calculations.
You can rename or delete files with the right mouse button in the object list or in the cuttingprocess list.
Attention: the cutting process list is memorised when you save a scene.
5.5.1.6 Calculate now
This button allows you start the calculation immediately.
The dialog will be closed and the process will begin. Pressing the ESC key will terminate thecalculation.
5.5.2 Raised angles
This type of cutting makes it possible to cut out sharp interior angled corners and is very usefulin the case cutting quality lettering. It is necessary to use a conical tool (or ball) for this functionto perform correctly.
If one uses a standard pocket cutting routine, then the internal corners are left with a radius equalto the cutters radius, plus certain parts of contours are not reached. This feature will help correctthis problem.
5.5.2.1 The raised angle cutting parameters
Select the contours in the object list and then choose Raised angles from the Modelling menu.The following dialog appears:
For this example we have pre selected a 6mm conical tool with a 15 degree angle and a 0.5mmradius, then selected finishing and indicate the same depth that would be used for pocket cuttingof the contours. Tool definition and Machine parameters are the same as in other methods.
The conical tool will rise up in the corners and at the constricted places that the cutter cannotpass. The trajectory of the cutter is a 3D curve.
The tool path is calculated where the cutter goes up in the angled and constricted places.
5.5.2.2 Complete carving
If the depth of required cutting is rather deep or if the cutter is wide enough and of sufficientdiameter, it is possible that the tool paths and raised angles will be continuous and pocketing willnot be required.
5.5.2.3 Incomplete carving
Depending on the contours and the cutter sizes, in some cases small islands of material are leftbehind.
Use the option "Build pocket contour" to create contours where residual material is left behind.You can then mill this contour with the contouring and pocketing method using the same tool oranother one.
5.5.2.4 Raised angle example to full depth
Plan Side
5.5.2.5 Raised angle example insufficient depth
Here its shape and the contour sizes have restricted the tool depth.
With the option "Build pocket contour" a new contour is created for the residual area.
The resulting contours can be machined with the pocket contour method.
The two tool paths can be grouped together if required to machine a complete part.
5.5.3 3 axis drilling
This tool enables you to drill holes on a model in 3 axis. It is an easy way to drill holes on yourmodel when being used for vacuum forming moulds.
Drilling is executed according to the Z axis. To launch this function first select a model model inthe object list, then select the 3 axis drilling from the modelling menu.
Enter the tool definition and machine parameters for the drill you want to use.
Using the mouse, click on the model on the screen where you wish to drill. The positioning ofthe hole is permanently placed on the face of the model when you click and move the mouseover it. The X, Y, Z values of the point are displayed in the position dialog in real time. If youwish to indicate a precise value, then type the values in fields X, Y, the "on model" model buttonand automatically the Z value will be found.
When you have selected the position you want to drill, enter the cutting parameter, then click the“make a drilling” button. A tool path will be created in the object list for each click of the “makea drilling” button.
When you click the “end” button, all the tool paths will be grouped together for a continuous toolfile. You have the option to ungroup these if you wish.
5.5.4 5 axis drilling
This function is similar to the preceding one, but requires a 5 axis machine. You have twopossibilities: Multiplane drilling and normal drilling on the model.
5.5.4.1 Multiplane 5 axis drilling
You can choose a plane like XY, XZ and YZ, or the plane of view in which you are lookingdirectly at the model. In this case you can choose the position on that plane with the mouse, andthen fixing the height value of the model by clicking the "altitude" button. Checking the “invert”option inverts the direction of the tool normal.
5.5.4.2 5 axis drilling on model
This function is similar to the 3 axis drilling on a model, however, the difference is that thedrilling normal (vector) will be perpendicular to the models surface at all times.
5.5.5 Process cutting
5.5.5.1 Cutting a block
Select the block in the object list.
In the Modelling menu choose Block cutting, the following window appears.
Diameter of cylindrical tool: enter the size of the cylindrical tool to use.
Depending on your selection the following options exist to surface, contour the edges or drilllocation holes. You can select each tool path in the object list and group them together to makeone file if you wish.
Surfacing
This operation is necessary if you want to be sure the top of the block is flat for use wheninverting a part.
Contour edges
This operation is necessary if you want to be sure the block is square. If you drill location holesyou do not normally need to contour the block.
Drilling
This allows you to drill the location holes on the centreline of the block to aid the inversion ofyour part. Using this technique of location holes and locating pins requires you to have a fixtureboard on which to locate the part. The fixture board should not be securely attached to themachine so as to keep the same reference points. You can use this drilling feature to drill theblock and the fixture board. The depth of block denotes the drilling depth.
5.5.5.2 Processing a method
Selecting a method in the object list, followed by this menu item, will process the tool path of themethod immediately.
5.5.5.3 Roughing a tool path
A tool path displayed with shading on.
You can easily make multiple roughing cuts from an existing tool path:
• Select the tool path in the object list.
• Select the roughing a tool path from the modelling menu or click on the cutting icon inthe toolbar, the following will be displayed.
Selecting the minimum and maximum cut heights, plus the depth of each cut and the desiredrapid plane followed by the machine parameters, Mayka will calculate the new roughing toolpaths.
5.5.6 Configure …
This menu changes depending on the object type selected in the object list.
5.5.6.1 Configure a method
The menu "configure a method" appears when a method is selected. When you activate thisfunction, you display the parameters window to adjust the values in the method. This function isequivalent to double clicking on the method in the object.list.
5.5.6.2 Configure a block
The menu "configure a block" appears when a block is selected. When you activate thisfunction, you display the parameters window to adjust the values of the block. This function isequivalent to double clicking on the block in the object.list.
5.5.6.3 Configure a attachment
The menu "configure a attachment" appears when a attachment is selected. When you activatethis function, you display the parameters window to adjust the values of the attachment. Thisfunction is equivalent to double clicking on the attachment in the object.list.
5.6 Model menu
5.6.1 Define attachment
Attachments are small rectangular CAD block models.
They generally used when inversion cutting is used when modelling both sides of an object.They allow you to fix the model so as to avoid it falling away during cutting. (the model ormachine could be damaged if the part comes loose). Therefore, creating attachment’s to tie themodel to the material block is a feature Mayka can help you with.
Images above illustrate the placement of attachments in the software as well as on the finishedobject.
Mayka facilitates the interactive placement and the dimensions of these attachments. Oncedefined it is also easy to orientate these attachments.
To easily see their positions they are displayed semi-transparent in the shaded view.
They can be used equally to block a hole or to create a zone you do not want to be cut.
Operations to create an attachment
Display the model and view from the top in X and Yaxis (other orthographic views can be used).
Select Define Attachment in the model menu.
The mouse cursor changes to a cross.
In the main screen window, click and drag the mouse so as to draw a rectangle where you requireit. Ideally make sure the attachment is intersecting the model and the block.
Holding down the CTRL key will allow you to click and drag several attachments. Release theCTRL key before drawing the last attachment.
Selecting your attachments in the object list allows your edit the values. In any view you candrag any of the eight corners to easily change its size. In shaded mode you can also use the sixmarker points.
Enter the attachments coordinates and click OK.
If you are in shaded mode or perspective view, you will be prompted to enter its dimensions inthe preceding window.
You can select attachments in the object list, or if you are in a shaded mode you can click onthem.
Using the SHIFT key will allow you to rotate the attachment by draging one of its corners. Usingthe CTRL key will allow you to drag it to a new position.
In some views the control points are not easily visible, but they are still active if the attachmentis selected in the object list.
5.6.2 Define block
The block feature in Mayka is a rectangular CAD model specifically created to help represent theblock of material you are going to make your model from. It is most commonly used whencutting two sides of the model using the invert feature.
Note :
It is not necessary to define a block to make your model.
Click Define block in the modelling menu and the following dialog is displayed:
You can define the size of the block numerically by entering the values you require, ordepending on the objects you want selected you can define a border around these. Clicking thecompute button will calculate the block sizes required.
If you want to align the block to the origin, use the “align to origin” button.
Clicking Ok will create the block on the screen and show it in the object list.
Modifying a block :
- Select the block object on the list and the choose configure block from the modelling menu, thelist of values will be displayed.
- Or double click the block in the object list.
5.6.3 Split a model
First begin by defining a rectangular selection zone from the edit menu. This zone can be placedand orientated to the place required. To edit the selection zone sizes, double click its name in theobject list.
This function allows you to split / slice a model in several pieces. The split planes are defined bya rectangular selection zone, not the cutting method zone.
5.6.3.1 Object to split
Choose the model you want to split in this pop up list. Models in the object list are displayedhere.
5.6.3.2 Splitting zone
Choose the selection zone you want to use to split your selected model in this pop up list.Selection zones in the object list are displayed here.
5.6.3.3 Split a model once
The splitting of the model uses the rectangular selection zone you have selected. The split can bemade on any of the 8 sides of the selection zone using the X,Y, Z selections.
Here we used the top face of the selection zone as the face for defining the split. The option splitonce at the Z+ cutting face was used with the option close selected.
In shading display mode, use the control points to move the selection zone to see its intersectionwith the model.
5.6.3.4 Close model
When the model is split Mayka can close the open faces by constructing intermediate meshesacross the open faces.
The new split model is displayed in the object list, select this object and then ungroup it to see allthe split parts. Note this function only works correctly if the model is a clean stl file.
5.6.3.5 Cut into many parts.
These parameters give you the option to split the model in respect to the top and bottom faces ofthe selection zone, parallel to an axis of the zone. To split the total model into many equal parts,make the selection zone so it contains all the model.
5.6.4 Close Model
This function detects open facet in your STL model and attempts to close the openings. If onlyworks correctly if the model is a clean STL file, like those produced in a solid based CADsoftware. Open surfaces or scanned data models saved as STL may produce incorrect results.
5.6.5 Merge surfaces
When in a model there are several sets of surfaces, jointed or not, this function amalgamatesthem into a single object. This function is equivalent to grouping surfaces without preserving theoriginal hierarchy.
5.6.6 Separate surfaces
When a models surfaces are not jointed, Mayka allows you to separate them. They are placed ina group, in the object list, which you can ungrouped later on.
5.6.7 Unify normals
Certain models contain badly orientated facet normals (direction of the faces). These sometimescan cause errors in contouring the model. Using this function, Mayka enables you to rectify theproblem by making all the normals face the same direction.
5.6.8 Simplify a model
In the case of very dense STL files, such as those files from 3D scanning systems. This functionallows you to decrease the number of facets without deteriorating the model too much. When amodel contains many horizontal faces, the algorithms can sometimes generate slight aberrations.
5.7 Contour menu
5.7.1 Extract contours…
This function allows you to generate particular contours from a faceted model. These contoursmaybe useful to you when making a clearance path around the model, or pocketing or finishing amodel.
5.7.1.1 Silhouette
The silhouette is contour wrapped around the model in the Z direction that is projected onto theXY plane.
5.7.1.2 Horizontal faces
This function allows you to extract the contours of the models horizontal faces.
You can display the horizontal faces on the model with the aid of the display/faces horizontalmenu. The horizontal faces of the model are shown in red, whilst in shaded mode.
Extraction of the horizontal faces creates the contours of the red faces. You do not need thedisplay/horizontal faces active for this function to work. The extracted contours are closedcontours.
5.7.1.3 Vertical faces
This function allows you to extract the contours of the models vertical faces.
The extracted contours will not necessarily be closed contours.
You can use the Contour / Edit contours function to modify these.
5.7.2 Edit contours…
This function gives you certain numbers editing tools to draw, clean, erase and modify curves.The curves can be either imported EPS vectors or contours extracted from a model.
The selection of the curves is done with the mouse. Multi-selection can be made with the SHIFTkey presses whilst clicking the contours. Selected curves are displayed in red. Although the editmenu is not displayed, the keyboard function Control+Z will undo most of these editing actions.
5.7.2.1 Delete
Deletes the selected curves.
5.7.2.2 Extract
Extracts the selected curves from the selected contours in the object list and makes a new set ofcontours in the list.
5.7.2.3 Duplicate
Duplicates the selected curves and makes them as a new set of contours in the list.
5.7.2.4 Invert winding
Inverts the direction of the selected curves. This is indicated with a small arrow head on thecurve.
5.7.2.5 Cut
Cuts a curve at a designated position. With a curve selected, click this button and then the placeto cut the curve.
5.7.2.6 Chain
This function enables you to connect two curves and to amalgamate them into one.
You must:
Check that the direction of the arrows of each curve is in a good direction.
To select the first curve with the mouse, then with the shift key pressed select the second curve.
Click the chain button to connect them.
5.7.2.7 Close
An open curve has a green round point at the starting point of the curve with an arrow at theother end. The close function connects the arrow to the green point by creating a segment ofcurve.
5.7.2.8 Draw
This function allows you to draw a curve with the mouse. Select Top view, click the draw buttonthen click on the screen for your first point. The next place you click will draw the first segmentof your curve, the click the next point and so on. When you have drawn the last point, right clickthe mouse and drawing will stop, then a contour will be added to the object list. To close thecurve, use the “close” button.
Holding the SHIFT key whilst drawing will constrain the curve to horizontal and verticalpositions.
5.7.2.9 Entry point
The entry point of a complete curve can be changed. Click the change button then click theselected curve where you want the new entry point to be.
5.7.2.10 End
End will close the editing function dialog.
5.7.3 Convert contour to tool path..
This function is equivalent to cutting a contour with the centre of a tool. You must enter theparameters for:- the tool, the Z heights and machine. A tool path will be placed in the object list.
5.7.4 Contour offsetting…
Select a contour in the object list and check the direction of contour by looking at the orientationof the arrow. Choose the function contour offsetting from the contour menu. The followingwindow appears:
The offset side is determined by the direction of the curve from the start point (green point) tothe end point (arrow). On closed curves a counter clockwise direction will work as inside andoutside by convention. Pocket will determine the number of offset counts when it works to theinside of a closed curve until it reaches the centre. Choose the option and set the offset distance.
Clicking Ok will create the new contours.
5.7.5 Tesselate contours…
This function makes it possible to create faces by filling a contour and generate a model entity.In the example we want to seal the hole.
A hole to be sealed Extract the vertical contour
Select your contour in the object list. The function tesselate contour, creates the facets of theinterior of a selected contour (shown blue here) and places it in the object list. You canamalgamate this with your model, if you wish to by using function model /merge surfaces. Tomachine this as part of your model you do not have to merge it. You can add it in the objects tabof the method.
5.7.6 Text…
This function allows you to create text contours based on Truetype fonts.
When you first select this function there will be a small delay whilst Mayka reads you systemfonts. In the dialog the left-hand column displays all the Truetype fonts installed on your PC, onthe right are the font styles. You can indicate the approximate height of the letters, but this willvary slightly with different font styles. Type your text in the box provided. By clicking Ok thetext is generated as contours at the origin point and added to the object list. You can apply all theediting and cutting functions like other contours.
5.8 WindowThis menu allows you to select windows that you are using by bringing them to the front of thescreen display.
5.8.1 Toolbar
This displays the screen tool pallet.
5.8.2 Object list
This displays the Object List to handle the different types of objects (models, methods, grids andtool paths).
5.8.3 Cutting process
This displays the Cutting process list with the deferred cutting processes.
5.8.4 Information.
The Information window gives you all the instructions (dimensions, number of points, numberof faces, modelling time, …) on the selected object or multiple objects:
Information concerning:
5.8.4.1 The model:
Data relating to the number of points, faces, groups, dimensions and their differences aredisplayed.
5.8.4.2 The grid:
Data relating to the number of points in X and Y, the precision and the distance between them.
5.8.4.3 The tool path:
Data relating to the maximum sizes, the cutting time, tool used and tooling parameters.
The saving on the cutting file adds the parameters of the post processor that has been selectedand calculates the correct tooling sequences.
5.8.4.4 Information print
If you have a printer connected to your computer, you can print the information. A basic reportsheet will be made with a picture of your screen part and the text.
If you do not have a printer, you can drag your mouse over the text and use Control + C keys tocopy the information, then paste it in another text application.
5.9 ? menu
5.9.1 Personnal code
The function displays the following:
Enter your personal code, which is written on your licence notice, then click on OK to validateyour personal code.
Then click on Yes to confirm your choice, then quit Mayka for the setting to take effect. Shouldyou need to change or update your code, or enter it at a later date, then select “Personal Code”from the ? menu.
If the software started in “demonstration” mode and you have entered a code, you will need toquit the application and relaunch for the code to take effect.
5.9.2 Getting started
This item will launch a basic help in Internet Explorer.
5.9.3 www.picasoft.com
This item will launch Internet Explorer and link to the Picasoft web site.
5.9.4 About
When the software starts a window displaying the software name placed on the screen for a fewseconds. Selecting this option displays that window with other information. The modes ofoperation of Mayka are:
• Normal commercial licence information
• Demonstration (saving is disabled)
• NFR (Not for Resale, available only to authorised dealers for support)
• Education licence information
• The build version. For upgrades and support you will be asked for this information.
6 Types of cutting methods
The different types of method enable you to choose the best cutting strategy that adapts to thetopology of the model you wish to manufacture. Each type of method requires slightly differentattributes. The tabs for objects, zone, tool definition, cutting parameters, machine parametershold different information according to the selected type of cutting method. You can enter theinformation in these tabs in any order you wish, although they do follow a logical order from leftto right to help you process your part. Changing the type of cutting tab will change the other tabsinformation.
Each type of method creates a specific object of Mayka that holds all the information on thecutting zone, tools and parameters linked to a model to perform a process.
To create a method click the method icon:
or select the modelling menu : " Create a method "
Mayka displays the method parameters.
6.1 Sweeping methodThis cutting method machines models based on an assembly of facets, by successive passes backand forth across the defined cutting zone. This strategy can be applied with all types of 3Dmodels. This method can generate long cutting times, but the algorithms of sweeping willsupport the cutting of bad quality CAD models such as scanned 3D data. This method is used
when the other strategies are not suitable or for models that may fail due to geometrical errors.This method is available for 3, 4 and 5 axis machining.
6.1.1 Objects
Defines the objects you wish to include in the method.
In the left-hand side list are the objects, which can be taken into account by this method. In thelist on the right-hand side you place the objects of your choice. Only, the models placed in theright-hand list "Objects to cut" will be taken into account for cutting with this method. You canselect all the objects of the scene if you wish by clicking the check box "cut whole scene". Un-check the check box "cut whole scene" will move all objects to the right-hand side list. Select anobject in the list and use the buttons "add", "remove", “add all” and “remove all” to move objectsfrom list to lists. You can also double click on an object to transfer it from one side to theopposite list.
Note:- If you are working on a scene with models you want to cut separately, it is best to un-check the check box "cut whole scene" and select the items you want to work on.
6.1.2 Zone
Zones define the volume to manufacture and the geometrical shape of the cutting zone. Severalcutting zones are proposed depending on the machine axis configuration options.
On a linear 3-axis machine: Cartesian, Polar
On a 3-axis machine with 2 linear and 1 rotary axis: Cylindrical.
On a 4-axis machine with 3 linear and 1 rotary axis: Cartesian, Polar, Cylindrical.
On a 4-axis machine with manually inclined spindle: Cartesian, Polar, Cylindrical, Conical.
On a 5-axis machine: Cartesian, Polar, Cylindrical, Conical and Spherical.
Zone dimensions are displayed according to the shape and size of the zone. In many cases it iseasier to position and resize the zone using the mouse on the main screen.
Border around the object will allow you to add a border around the objects selected. Enteringa value and pressing set will compute a new zone area.
Tool path direction relates to the way the cutter will travel in the zone. According to the type ofselected zone various cutting strategies are proposed. They can be parallel to the axis of themethod, crossing, angled, spiral or helical.
Opposite end starts the cutting from opposite side of the defined zone.
Reverse changes the direction of cutting when using helical or spiral directions.
Min Radius using cylindrical, conical and spherical zones, you can limit the minimum radiusfrom the centre to stop over cutting.
Inside using cylindrical, conical and spherical zones, allow the cutting inside the zone. You needto check the tool collision for yourself with this option.
6.1.2.1 Cartesian zone
It is the most commonly used feature to drive 3 and 5 axis machines.
You can indicate dimensions of the method numerically either manually or by using the borderset feature. Click the Set button to update the values.
In shading mode you can change the zone using the mouse in any view. You can drag any of theeight corners or six marker points to easily change its size. The six maker points are show in red,green and blue to relate to the axis.
Tool path direction
With the aid of selecting different tool path cutting directions, you can achieve varying resultsthat may benefit your particular part of machine tool. For example when cutting detailed reliefwork like medals and jewellery, then the spiral tool paths generally give a better looking
machine finish to the eye of the viewer. On large 5 axis machines, changing from one directionto another can be faster and more beneficial for the machines structure.
Choose a direction for cutting:
Some of the cutting directions are drawn on the top surface of the selected method to help youvisualise the process. These are schematic and do not represent the actual tool paths that will becalculated by the method.
An example of inclined sweeping display
in X
When cutting in X, Y and X plus Y directions, you can select to start cutting from the oppositeside of the zone.
in Y
in X & Y
Cutting in X and Y first cuts all in the X direction and then follows with cuts all in Y direction.This choice of cutting will be twice as long as working in one axis, however, the finest finish canbe obtained with this option.
Incline
This incline cutting strategy is interesting for parts whose sides are vertical or are relativelyparallel to an axis. Enter an angle greater than 0 and less than 90.
Spiral
You can choose a cutting path in round spiral or square spiral. This option produces a smoothpart where the tooling lines on the part are less obvious to the eye.
You can limit the spiral by the minimum radius.
In all cases the spiral adapts to the X and Y dimensions of the method. Square becomesrectangular and round becomes eliptical.
Spiral round cutting
Spiral square cutting
Normally cutting starts in the centre unless you select the opposite end function. You can alsospecify the minimum radius to cut from the centre.
Zone polar
This is used to drive 3, 4 and 5 axis machines where the part is cylindrical or round in shape.Ideal for curved corner sections of models.
In shading mode you can change the zone using the mouse in any view. You can drag any of theeight marker points to easily change its size.
in C in R
in C then R
Placement of circular based methods
During the initial creation of a circular zone: polar, cylindrical, conical or spherical, the centralaxis is placed on the origin X0 and Y0.
Object and origin
Created default Polar method
Polar method with 10mm border based around origin X0, Y0
To place the method around the object correctly, its axis should be moved. Using the control keyand mouse pointer, click on a coloured point of the method then drag the method to look like this
To place the method accurately you can adjust the values in the method zone dimensions.
Then you can relocate it by using the transformation/translation menu. You can also use thealign objects tool to position you zone correctly.
Zone cylindrical
This method cannot be used on a machine that does not have a rotary table (normally a 4th axis)or full 5-axis movement. With a 3-axis machine configuration you will not be allowed access tothis method.
The definition is similar to the polar zone, but in this case the tool is perpendicular to the axis ofthe method.
In shading mode you can change the zone using the mouse in any view. You can drag any of theeight marker points to easily change its size.
Following the rotary axis:
Following the linear axis:
Rotary and linear:
This cutting strategy improves the general surface finish of the part. However the cutting time islonger.
In Helical:
Surface finish is better
Interior cutting:
The axis of revolution of the part is independent of axis of revolution of the machine. Mayka canmake interior cutting non coaxial, if the machine limitations allow it. Making a good zone willmake an effective tool path.
Zone conical
This zone is similar to the cylindrical zone, but the tool can be inclined. The angle required is theangle the tool makes with the axis of the cylinder.
A machine with 5-axis or 4-axis can utilise this feature, as well as a machine with a manuallyinclinable spindle (optional). The user will have to manually set the machine to the inclinedangle they have entered in the method before cutting.
In shading mode you can change the zone using the mouse in any view. You can drag any of themarker points to easily change its size.
In linear axis
In rotary axis
Rotary plus linear
In helical
Zone spherical
This zone is only supported on simultaneous 5 axis machines.
The spherical zone keeps the tool axis normal to the surface of the zone.
Theta and Radius work identically to preceding methods to change the zone.
The angle Phi represents the angle the tool with respect to the XY plane.
In shading mode you can change the zone using the mouse in any view. You can drag any of themarker points to easily change its size.
When aligning this zone, remember it is the centere of the sphere that is related to the objects.
These cutting strategies can be external or internal.
Direction Theta Direction Phi
Theta plus Phi In Helical
Tool Definition
Select the shape and sizes of tool that you wish to use. Each tool form is accompanied by agraphical representation allowing you to easily identify the parameters required.
Make sure you use the same tool description in MAYKA as intend to use on your millingmachine otherwise the cutting will not be a true representation of your model.
The tool length value is not important on 3 axis machines with tool length compensation. If yourmachine needs the tool length to be added to the calculation, such as in 5 axis cutting, then enterthe tool length correctly here with the other values required.
Hemispherical (ball end)
Enter the tool diameter.
Cylindrical (end mill)
Enter the tool diameter
Conical
Enter the tool diameter, the tool angle and the radius on the end of the tool.
Conical flat
Enter the tool diameter, the tool angle and the flat on the end of the tool.
Bullnose
Enter the tool diameter and the radius on the corner of the tool..
Flat disk
Enter the tool diameter and the thickness of the tool.
Attention: this type of cutter is usually used in specialist application such as stone carving with a5 axis robotic arm. The tool is defined, for example in 3 axis, with the disk diameter beingparallel to the X axis and the cutters shaft inclined by 90 degrees, ie in Y direction.
Bullnose disk
Enter the tool diameter, the thickness and the radius on the corner of the tool.
Attention : this type of cutter is usually used in specialist application such as stone carving with a5 axis robotic arm. The tool is defined, for example in 3 axis, with the disk diameter beingparallel to the X axis and the cutters shaft inclined by 90 degrees, ie in Y direction.
Cutting parameters
Tool path type.
There are 3 main types of cutting :
• Finishing,
• Roughing,
• Plunge cutting.
Finishing
Clearance
You can specify a clearance value over your part. This therefore leaves an amount on the part forfine finishing later, if required.
Surface quality Ridge value
The quality of the surface obtained is defined by the ridge value that you specify.
The ridge is the height of the waves generated by sweep cutting and the shape of the tool used.
This value corresponds to the surface finish of your part and is represented by the height of theridges left by the cutting tool on each sweep. Some users relate to this as the scallop height. Youcan either select one of the suggested values from the pop-up arrow, or enter your own numericvalue.
- Excellent:
Corresponds to a ridge value of 0.005 mm
- Good:
Corresponds to a ridge value of 0.015 mm
- Medium:
Corresponds to a ridge value of 0.03 mm
- Rough:
Corresponds to a ridge value of 0.05 mm
The choice of the ridge value, calculates the increment value of the chosen tool.
The increment is the distance between each sweeping pass over the model.
You can change the increment value to one you prefer, but note the ridge value parameter is usedin a calculation algorithm and fixes the precision of cutting calculations. It is not a good idea toforce the increment too different from that which the ridge value generates automatically. If youwish to decrease the increment it is strongly advised to also decrease the ridge value in the sameproportion.
Some parameters that are not editable on this screen are displayed to remind you of theircurrent value:
Optimisation:
This parameter influences the optimisation of the distance and the number of cutting points. Youcan access to this parameter in the preference menu.
End of block:
This parameter fixes the type of line end character that will be written in the tool path file. Youcan access to this parameter in the preference menu
Tool:
This reminds you of the tool you selected in the previous window.
Remark
With constant increment, the ridge value is not the same everywhere on the model.
The ridge value of sweeping is calculated with reference to the orientation of the models faces.
The nearer the trajectory of the tool path is perpendicular to the faces, better the ridge. The opposite issuch when the tool is cutting parallel with the faces.
You should choose the sweeping direction in the zone "tool path direction" according to this criterion. Incertain cases you will have to carry out several sweeping procedures.
With a rectangular zone, angled sweeping is adapted to avoid most of the crossing the trajectories.
Roughing
You can specify a clearance value over your part, this therefore leaves an amount on the part forfinishing.
Specify the increment of each roughing pass.
This value corresponds to the step of each pass of the tool across of your part. You can eitherselect one of the suggested values from the pop-up arrow, or enter your own numeric value.
- Small:
Correspond to 0.25 x the diameter of the tool
- Medium:
Correspond to 0.50 x the diameter of the tool
- Course:
Correspond to 0.75 x the diameter of the tool
Specify the depth cut pass of each cut in depth. You will need to change this value dependingon the material you are cutting.
depth cut pass
Optimised tool path
This function reorganises the tool path trajectories so as to reduce the number of tool retractionmoves and therefore, produce a faster cutting cycle. As this is a new feature, you have the choiceto unselect it to be compatible with earlier versions on Mayka.
Normal non-optimised tool path
Optimised tool path
Another example:
Plunge cutting
This function allows you to remove most of the material using successive plunge drilling /cutting feature, which is preferred by some users, especially with soft materials. The valuesentered are the same as in roughing.
You can equally use this function to drill with a conical tool on a grid of points. This featureproduces a pleasing effect when drilling a grid produced from a BMP photographic image.
When applying this method to a photographic image grid, the depth of drilling will be equal tothe Z level of the grid.
Diameters of the holes are proportional to their depth and the generated shade reflects the levelof grey of the original image.
Example: Drilling a BMP image
Image Christofe.BMP
Open the image and convert to grid.
Define the depth (Height of the white and Height of the black) so that conical tool you chooserealises coherent hole diameters.
Ex: Depth= 1.1 mm. You have to calculate the depth according to the angle of the conical toolthat you are going to use. (in the example angle = 30).
The result:
Note:
If the tool is too large, or the angle to great, or the increment between each hole is too closetogether, then the results will be poor.
Limits of Cutting:
Mayka offers several possibilities to limit the area of cutting:
• Cutting zone.
• Strictly object.
• Object.
• Partition line.
Cutting Zone:
Cutting is performed to the limits of the defined cutting zone. Depending on where you place thezone, all of your model and the surrounding area within the zone will be cut.
Strictly object:
The cutting is performed strictly within the maximum limits of the models perimeter as viewedfrom the top of the working zone.
This function allows is ideal when cutting a part where you do not want to cut outside its limits.Also when cutting a grid that has been inverted and you do not want to cut over the edge. Thetool will not go outside these limits.
Object:
Cutting is limited to the models silhouette plus the radius of the tool. The depth of cut will be thebottom limit of the working zone.
Partition line:
Cutting is limited to the models silhouette plus the radius of the tool. The depth of cut is limitedto the position that would be the widest point of the model in the view of the zone, normallyreferred to as the partition line or seam line.
Using the menu, display / undercut will show a coloured view of the visible parts where thepartition line is.
Non-horizontal faces:
You can use the menu, display / horizontal faces to show a coloured view of these faces in yourselected model. Generally the horizontal faces of a model can be cut with the horizontal facecutting method using a cylindrical tool. This option allows you to cut only the non-horizontalfaces of your model. Choose this option only if the horizontal faces represent a sufficientlysignificant part of the model and have been cut with the horizontal face cutting method.
Rapid plane
The Rapid plane is the level that the cutter will raise up to at the end of the cutting sequence orbetween cutting different model areas. The indicate amount will be a height that will be relativeto the top of the selected working zone. This value is always relative to the zone, so in the caseof 5 axis cutting it is a retract value only when cutting in that particular zone. The direction of
retracting the tool is normal to the method. In the case of Spherical and Cylindrical methods thetool retracts along the tool normal at the point of retraction.
When using a zone that is lower that your part, make sure to enter a rapid plane distance that willbe clear of the top of your model and any fixed items such as a vice or clamping device.
Security plane
This fixes an absolute position value from your origin (not the working zones local origins). Thecutter lifts to this position between cutting several methods.
This value is indispensable in 5-axis multi-plane cutting and is used by the post processor incalculating the final NC too path. You will be prompted for this value when post processing thecutting tool paths.
Machine parameters
This window of machine tool related parameters offers options to enter parameters that somemachine tools require. When saving your tool paths the post processor will ignore values that arenot related to your specific machine.
Programme number
• Indicate the programme number.
Tool number
• Indicate the tool number of your machine to use. (Manual or Automatic)
Tool Length corrector
• Indicate the tool corrector number of your machine with tool offset tables.
Tool Length value
• Indicate the actual tool length value in certain machines without tool offset tables.
Option M-Function
• Indicate a number which can be entered as an M function in your specific post processor.Ask your supplier about this.
Spindle speed
• Indicate the numeric rotation speed of the spindle in rpm.
Feedrate
• Indicate the side feed velocity of the cutter in the material in the displayed units (eg mm/s),in the respective axis.
Note:
This feedrate depends on the material, on the diameter of the chosen cutter, the cuttingdepth and the spindle power and feedrate
Plunge feedrate
• Indicate the feed velocity of the cutter in the axis parallel to the cutter (Z axis in 3 axiscutting) into the material in the displayed units (eg mm/s selectable in preferences). Dependingon the cutter form and material, this feed usually is much slower that the side feed. Somethinglike 20% or 30% of the side feed would be a guide.
6.2 Horizontal facetsThe cutter machines faces of the model that are parallel with the Cartesian zone. In the case of a3 axis machining centre, they are the horizontal faces. In general you will use a cylindrical cutter.The detection of the horizontal faces in a model requires the model to be a clean and coherentCAD file. This method can be applied in a Cartesian zone, which can be in 3 axis or in 5 axismulti planes.
The tabs for "objects", "zone" and "tool definition" are the same ones as in the sweeping method.Display the horizontal faces of your model using the menu display/ horizontal faces. The zonelimits are used to limit this machining area.
The red faces are horizontal and can therefore be machined using this method.
6.2.1 Cutting parameters
6.2.1.1 Finishing:
Calculate the tool path on the horizontal faces directly and do not take into account any materiallocated above the faces. I.e. always perform roughing first if there is material to be removed.
6.2.1.2 Roughing:
You can specify a clearance value over your part, this will leave an amount on the part forfinishing. Specify the depth cut pass of each roughing pass.
6.2.1.3 Rapid plane:
This is the level that the cutter will raise up to at the end of the cutting sequence or betweencutting different model areas. The indicate amount will be a height that will be relative to the topof the selected working zone
6.2.1.4 Milling direction:
The direction of the cutting paths will influence the surface finish and the quality of the chipsand the life of the cutter.
Conventional Climb
Conventional cutting has been the most commonly used method of milling as it is working inopposition to the machines axis, therefore, any limitations in the machines rigidity will not drawthe cutter forward and break it. Machines that have virtually no mechanical backlash and arerigid will allow climb cutting and the results of finish can be much better. Materials hardness,angles of cut of the cutter, numbers teeth of the cutter and other factors will effect your choice ofcutting direction. Generally your own experimentation will be the best solution for yourapplication.
6.2.2 Plunge strategy
These parameters will be used each time the cutter begins a plunging trajectory. Depending onthe tools used it is sometimes not preferred to plunge straight down. In this cutting method therecan be several tool plunges, so Mayka offers 3 options.
Normal plunge: The cutter descends directly down on each trajectory point.
Plunged with pecking: The cutter descends on each trajectory point by successive drilling orpecking movements. These increments of drilling are defined by the "depth cut pass". The“height of retract” defines the distance the tool will stop clear of previous cuts before feedingdown. This makes it possible to limit the volume of cutting chips and to facilitate theirevacuation.
Plunged helical: The descent of the cutter on each trajectory point following a helicalmovement. You must fix the helical diameter and the angle of descent. This strategy is utilisedwhen the cutter used does not have centre cutting, like an end mill, or for very hard materials.
6.2.3 Entry / Exit
These parameters will be used each time the cutter begins a sideways movement towards thestart point of a 2D contour and away from the exit point.
In different applications, the default of plunging at the start point can sometimes make a cuttermark on the part due to the way the cutter works. Mayka has 3 options.
6.2.3.1 Linear
The length parameter specifies the length of the segment before the start point and after the exitpoint of the contour.
6.2.3.2 Circular
The length parameter specifies the length of the segment before the start point and after the exitpoint of the contour. The radius parameter specifies the arc radius before and after the start andexit points.
If you only wish to use an arc, then set the length equal to 0. Note if your zone is not far enoughaway from the entry/exit points then the paths will be truncated by the zones limits.
These parameters can be combined with the plunge parameters if required.
6.3 Z-constant
This method moves in constant Z level movements and removes all the material at that levelbased on the computed contours at successive sections.
Where you use this method against sections of your model with vertical walls, you will need tomake sure your cutter has sufficient flute length to cut at that depth.
The detection of the faces in a model to find each contour requires the model to be a clean andcoherent CAD file. This method can be applied in a Cartesian zone, which can be in 3 axis or in5 axis multi planes.
6.3.1 Roughing
6.3.1.1 XY clearance
In this method you can add different clearances to the XY and Z directions of the zone. In thecase of deep vertical faces, it is possible that you may leave an extra clearance on the walls thatthe finishing cutter may not be able to cut in a single pass due to the limited cutting flute lengthsof the tool. Please check this in each application.
6.3.1.2 Z clearance
With Z-constant cutting, as its name indicates, cuts the model by constant sections like astaircase and it is therefore recommend leaving extra clearance in Z.
6.3.1.3 Increment
This value corresponds to the distance the tool will side step with each pass. Normally the toolneeds to overlap each cutter pass depending on the tool and the material. In general the selectedvalue is the radius of the cutter, for harder materials this maybe 10% to 25% of the cuttersdiameter. This value should not exceed the diameter of tool otherwise not all the material will beremoved.
Increment Depth of cuts
6.3.1.4 Depth of cuts
This value corresponds to the distance that separates each of the layers that will be cut with eachplunge of the tool.
6.3.1.5 Milling direction
See definition § horizontal faces
6.3.1.6 Rapid plane
The Rapid plane is the level that the cutter will raise up to at the end of the cutting sequence orbetween cutting different model areas. The indicate amount will be a height that will be relativeto the top of the selected working zone.
6.3.1.7 Plunge strategy
See definition § horizontal faces
6.3.2 Finishing
In this case finishing has the option for a depth of cut value. If entered the cutter contours thesilhouette at each cut value layer until the bottom of the zone is reached. Note that roughingshould have been performed first.
6.4 Profiling
The cutter circumvents the silhouette of the model.
This type of milling makes it possible to make a models profile edges cleaner than using thesweeping method.
The detection of the horizontal faces in a model requires the model to be a clean and coherentCAD file. This method can be applied in a Cartesian zone, which can be in 3 axis or in 5 axismulti planes.
6.4.1 Roughing
6.4.1.1 Z Clearance
See definition § horizontal faces
6.4.1.2 XY Clearance
See definition § horizontal faces
6.4.1.3 Increment
See definition § horizontal faces
6.4.1.4 Depth cut pass
See definition § horizontal faces
6.4.1.5 Milling direction
See definition § horizontal faces
6.4.1.6 Offset count
This function allows you to specify several offset cuts away from the profile. The default value is1 and the offset amount is based on the radius of the tool being used. Here the offset is 2.
With roughing the offset count is very useful to remove material around the outside of your partto facilitate clearance for other cutting methods.
6.4.1.7 Rapid plane
See definition § horizontal faces
6.4.1.8 Plunge strategy
See definition § horizontal faces
6.4.2 Finishing
The contour profile is only effective for one pass at the bottom level of the methods zone.
6.4.3 Limitation of the zone
The working zone will limit the contour. After each pass the tool will retract to the rapid plane.
6.5 Surfacing
The method detects the silhouette of the model, then will product surfacing limited to thatsilhouette.
The detection of the contour in a model requires the model to be a clean and coherent CAD file.This method can be applied in a Cartesian zone, which can be in 3 axis or in 5 axis multi planes.
6.5.1 Roughing
6.5.1.1 Depth cut pass
It is taken into account starting from the top of the method and defined penetration of the cutterwill be to reach the top of the model.
6.5.2 Finishing
The cutting path will be on the top of the model
6.5.3 Limitation of the zone
The working zone will limit the contour. After each pass the tool will retract to the rapid plane.
6.6 Slicing
This method allows the cutter to carry out a linear trajectory and makes it possible to cut slicesacross the model. One generally uses this method for roughing of blocks of stone with a diskcutter.
When using this method it is up to the user to make sure the depth of cut is such that the spindleand tool holder will not touch the model.
This method can be applied in a Cartesian zone, which can be in 3 axis or in 5 axis multi planes.
6.6.1 Method zone
Unlike the other methods the slicing method can only cut in the Z direction, parallel to the Xdirection of the working zone. It is impossible to make multiple cut passes in the Y direction ofthe zone. Hence the parameters to define the slicing zone are X and Z only.
6.6.2 Roughing
6.6.2.1 Rapid plane:
This is the level that the cutter will raise up to at the end of each cutting sequence. The indicateamount will be a height that will be relative to the top of the selected working zone.
6.6.2.2 Clearance
This will be the value of the distance in Z that will be left on the model.
6.6.2.3 Depth cut pass
Starting from the top of the method this is the step value of each cut in the Z axis direction of thezone.
6.6.3 Finishing
With finishing there is only one single pass of the tool across the zone.
Check that the depth of cut is such that the spindle and tool holder will not touch the model.
6.6.3.1 Direction of slice
To cut in different directions across the model the method can be moved and rotated within thelimitations of the machine configuration.
Translation by mouse
Using the mouse button with the CTRL key you can move the method in the view by clicking ona handle and dragging. The function only works with the cursor arrow selected in the toolbar.
Rotation by mouse
Using the mouse button with the SHIFT key you can rotate the zone in the view by clicking on ahandle and dragging. The function only works with the cursor arrow selected in the toolbar. It isbest to be in a viewpoint where it is easy to rotate around.
6.7 Contours (contouring, pocketing, projection on model)
This method allows the cutting of 2D contours by either following their centreline, or offset totheir sides, or to pocket them or to engrave them.. You have the options to cut the contours in2.5D by defining the Z depth and there are options to project the cutting tool paths of thecontours onto a model making a 3D contoured path. Therefore in this method there is an extratab for selecting the contours to work with.
6.7.1.1 Contour
The contours to be cut with this method are selected with this tab. It displays the contours thatare listed in the object list.
6.7.1.2 Objects
As with all the other methods models can be selected.
If a model is not selected then the contour cutting will be limited to 2.5D
If a model is selected and below the contours in the working zone, then the resulting tool pathfrom the contours will be projected onto the models and thus making a 3D tool path.
6.7.2 2D cutting without model (2.5D)
When the method does not have a model associated to it, then the cutting of the contour is asfollows:
6.7.2.1 Object not selected
6.7.2.2 Total depth
Absolute
The value entered in “Absolute” is the starting position relative to the “origin”. The real Zposition of the contour is not taken into account. If contour is with the actual height Z=0 and youenter 0, then the result is the same in both cases.
“Total depth” is the depth of all cutting in the Z direction of the zone. . Note the working zone isonly used in X and Y to limit the cutting.
“Depth cut pass” is the pecking depth to reach the “Total depth” used in “Roughing”
Relative
“Total depth” is the relative depth of all the cutting in the Z direction of the zone relative to thecontours actual position. Note the working zone is only used in X and Y to limit the cutting.
In “Finishing” no “Depth cut pass” is used.
6.7.2.3 Type of cutting - Contouring
Inside Exterior
Offset count
This function allows you to specify several offset cuts away from the profile. The default value is1 and the offset amount is based on the radius of the tool being used. Here the offset is 2.
XY Clearance
See definition § horizontal faces
Z Clearance
See definition § horizontal faces
Increment
See definition § horizontal faces
Milling direction
See definition § horizontal faces
Plunge strategy
See definition § horizontal faces
Entry/Exit
See definition § horizontal faces
6.7.2.4 Type of cutting - Pocketing
There are 2 types of pocketing. Contouring and Sweeping. Both functions depend on thecontours being in good directions.
If there are multiple contours within each other contour, then each of the inside contours shouldbe in opposing directions.
The increment of step over is based on the radius of the selected tool.
Contouring Sweeping
6.7.2.5 Type of cutting – Tool centre
With this function the tool centre will follow the selected contours. The tool parameters forshape and diameter are not taken into effect.
6.7.3 2D cutting with model (3D)
When the method has a model associated to it, then the cutting of the contour is as follows:
6.7.3.1 Object selected
Depth into the object
When the model is selected with the contour then the depth is determined by the model and thelimits of the working zone.
The following example is with the depth set at 0, so the tool path is only on the models surface.
With the depth set at 1 then the tool path has cut the model surface 1 mm deep as seen in thissimulation.
If contour exceeds the model you can limit the projection of the tool path with the popupaccording to the “Limit of cutting”.
The operation of these limits is the same as for the sweeping method.
6.8 5 axis tool path projectionThis function allows you to place a tool path on a model or on a point cloud.
Tool path can be 2,3,4 or 5 axis or drawn with the contour functions, or from a HPGL file, or animported roughing or finishing tool path.
The projection is normal to the tool path.
The tool path to project
HPGL 2axis tool path
The model to cut on
STL model
Placing the tool path on the model
The tool path can be orientated anywhere in space as long as your machine tool can cut in thatdirection. Projection is in either 3 or 5 axis.
Selecting the tool path to project followed by selecting the menu Project tool path will create anew method in the object list. This method can be edited or manipulated the same as any othermethod.
Enter all the values in the Method parameters and click OK.
All the calculations will be generated for the tool path and placed in the object list.
Do not forget to save the tool paths or the entire scene at the end of the calculations.
You can rename or delete files with the right mouse button in the object list or in the cuttingprocess list.
Projection 3 axis :
Example of projection
Projection Multi plane :
7 Post processing
When that you want to save your tool path for your particular machine tool you will perform thefollowing steps. These will vary slightly depending on the machine tool configuration youselected.
7.1 Saving• Click on the visible tool path object you wish to save in the object.
• Select Save as… from the File menu.
• Select the folder to save your work, then enter a file name, then select the post processorformat you require. Click Save.
• Next you will be prompted to enter the “Security plane” height. This dialog will varydepending on the machine configuration.
• The tool path file will be formatted for your machine and saved to disk so you can takethem to your machine tool.
7.2 Security Plane
This value fixes the height as an absolute value compared to machine origin, where the cutterwill safely retract to between one or several methods.
This value is of the utmost importance in the case of 5 axis multi plane cutting.
This data is used each time your tool path file is post processed, but it is not displayed on thescreen after the calculation of the tool path. The “security plane” is interpreted differentlyaccording to the configuration machine. The following table summarizes the different cases.
Machine Configuration Interpretation of the “Security Height”
XYZ & XY Z on a manual indexer Height according to the Z axis
AXZ Height according to the Z axis
BYZ Height according to the Z axis
CXZ Distance according to the Y axis
AXYZ & AXY Z on a manual indexer Height according to the Z axis
BXYZ & BXY Z on a manual indexer Height according to the Z axis
CXYZ & CXY Z on a manual indexer Distance according to the Y axis
CAXYZ
CBXYZ
CXYZB & CXYZA
XYZCB & XYZCA
XYZIJK
Height according to the Z axis
7.2.1 Post processing of 3 and 4 axis tool paths
The “security height” is requested in the following dialog:
The process of movements are summarised in the following diagram.
1. From the initial start position “T”, the movements of the machine axis are safely made atthe “security plane” at fast traverse speed (G00 by default) with the tool vertical to avoidthe risk of collision between the tool and the work piece.
2. The tool then goes down to the “rapid plane” at fast traverse speed (G00 by default). The“rapid plane” is located at a distance, which corresponds to the value of the safewithdrawal of the tool compared to the top of the method. (The value of the “rapidplane” is defined in the methods cutting parameters.)
3. Cutting within the working zone as defined within the method.
4. When cutting is finished in the method the tool withdraws at rapid speed to the “rapidplane”, local to the zone.
5. The “security plane” is reached.
6. If there is another tool path grouped with the current tool path then the machine willmove to the beginning of the next methods zone. Otherwise the program end sequencewill move the tool away and back to the initial start position “T”.
Key
Ø T Represents to position the machine tool starts from. Sometimes referred to as thetool change position. This is controlled in the post processors tool start up.
Ø S This is the “security height” and is an absolute distance from the origin in Mayka,which is also the part origin (datum), or work offset, set in your machine tool.
Ø R “Rapid plane”, this is the incremental distance above the top each specific methodsworking zone.
Ø Origin (datum).
7.2.2 Post processing of 5 axis tool paths
1. From the initial start position “T”, the movements of the machine axis are safely made at the“security plane” at fast traverse speed (G00 by default) with the tool vertical to avoid the riskof collision between the tool and the work piece.
2. Before plunging the tool, it is rotated according to the direction of the first position of thecutting method. Rotation is made around the tool point. Therefore the point of the toolremains within the safety zone during this phase. Rotation is carried out at fast traversespeed (G00 by default).
3. The tool then goes down to the “rapid plane” of the zone with the same orientation. The“rapid plane” is located at a distance, which corresponds to the value of the safe withdrawalof the tool compared to the top of the method. (The value of the “rapid plane” is defined inthe methods cutting parameters.)
4. Cutting within the working zone as defined within the method.
5. When cutting is finished in the method the tool withdraws at rapid speed to the “rapid plane”,local to the zone.
6. Still at rapid speed the tool retracts with the rotational axis held at their previous angles.When the ““security plane” is reached the rotational axis are rotated around the tool point toreturn to the vertical position.
7. If there is another tool path grouped with the current tool path then the machine will move tothe beginning of the next methods zone. Otherwise the program end sequence will move thetool away and back to the initial start position “T”.
7.2.2.1 Management of the angle in 5 axis
In the case of a machine configuration XYZCB for example, the cutting position can be reachedin different ways.
For example:
When the tool is vertical the C axis can be at an unspecified value.
The orientation of the tool one can choose several B and C axis configurations.
Case 1: B = 45 Degree, C = 70 Degree
Case 2: B = -45 Degree c = 250 Degree
Case 3: B = -45 Degree c = -110 Degree.
These 3 cases represent the same tool orientation.
The choice of the correct pair of values in B and C is done according to the angular limitationsavailable for each axis.
In general:
- B can vary between -90 degrees and 90 degrees.
- C can vary between 0 degrees and 360 degrees.
Mayka proposes to determine the angular behaviours in order to remain within the machine axislimits. For that, at the time of post processing your 5 axis tool path, it is necessary to inform youof the axis in the following dialogue.
Force A/B axis sign
In the case of configuration XYZCB, this parameter allows you to force the B axis to be apositive or negative value.
Leave A/B axis sign free
In the case of configuration XYZCB, this parameter allows you to vary B into being positive ornegative. Subsequently with a case of an indecision (Movement of the tool to vertical forexample) the strategy followed by Mayka is to minimise the axis displacement.
Initial value of C axis
Mayka will choose the nearest to that required by user.
Test
This function makes it possible to check the angular beach used according to the selectedparameters. Press the “test” button.
In this case the linear axis limits and angular limits are displayed:
According to B:
Machine limits are from: -1 to 90 deg
Tool path movements are from: 0 to 84.46 deg
Following C:
Machine limits are from: -320 to 320 deg
Tool path movements are from: 22.5 to 315 deg
You need to physically check these resulting limits are compatible with the machine limitsdisplayed. In the contrary case then it is necessary to adapt the parameters and re-test beforeclicking OK.
Note that you may, change the tool length value of a 5 axis tool path by double clicking the toolpath in the object list. If you do this then you need to re-save the tool path and check the aboveparameters. Only to tool length value and the machine parameters will change. Changing the toolform or diameter will not affect the tool path trajectory; this will need calculating from themethod if required.
8 Basic concepts
8.1 Basics to getting started with modelsThis is a quick overview on using Mayka™ to produce 3D cutting data for your machine tool. Inthis example we show you how to make a finish cut in soft modelling foam. For harder materialsyou will need to us the Rough cutting first.
Note: We are assuming that you have been instructed on the features of the Microsoft Windowsenvironment, which are detailed in the Windows documentation, supplied with your computer.Also you should understand on how to use your machine tool. If you are unsure please contactyour dealer.
8.1.1 Launch the software
• From the Windows Start menu select the Picasoft folder then the Mayka™ software.
8.1.2 Open a model object
• Select Open from the Mayka™ File menu.
• Navigate to Open the Samples folder that came with Mayka™.
• Open from the sample folder the file called “Canard.dxf”.
• Mayka™ will open the file and display it on the screen. The progress of opening isdisplayed at the bottom of the screen window, like this:-
This is what you will see when the sample file is opened. There will be the file Canard.dxf and afile called Method in the object list.
8.1.3 Prepare the method (Roughing)
• Double click on the name Method in the object list.
• Edit the values as shown in the following dialogs.
• Nothing to change in Objects.
• Check the values, making sure to set Z-Max to –25.0
• Choose a 6mm Spherical ball cutter
• Set-up for roughing, then Click OK and the method will close.
8.1.4 Start the roughing cutting process
• With the method still selected in the object list, click the Cutting icon.
• The parameters of the method are redisplayed with the Machine parameters active. Enterthe values shown and click OK.
• The tool path will be calculated, placed in the object list and displayed on the screen overthe model. As the tool path is created you will see red/blue lines that indicate the toolpath. Should you have made a mistake or want to abort the calculations, press the ESCkey.
8.1.5 Prepare the method and cut (Finishing)
• Click on the name Method in the object list.
• Click the Cutting icon.
The Machine parameters are displayed, click the Cutting Parameters tab and enter the valuesshown and click OK. The tool path will be calculated, placed in the object list and displayed onthe screen over the model. All other values on the other tabs will remain the same as in roughing.
• Clicking on the different objects in the list will allow you to see the cutting paths and themodel. Also selecting different view modes will help you to see more clearly.
8.1.6 Saving the NC tool paths
• Clicking on the visible tool path object you wish to save in the object list will allow youto save that file in the format for your NC machine.
• Select a too path object.
• Select Save as… from the File menu.
• Select the folder to save your work then enter a file name followed by the postprocessorformat you require. Click Save.
• Next you will be prompted to enter the “Security Height”. This dialog will varydepending on the machine configuration. Here we have chosen 10mm above the origin.
• The tool path file will be formatted for your machine and saved to disk so you can takethem to your machine tool.
8.1.7 Setting the Machine tool
• Assuming you did not re-align the part datum when in Mayka™, you need to set up youpart on the machine as follows. Each machine tool is different and we cannot anticipatefor that, nor do we take any responsibility for your actions. This is just an illustration soyou understand the principles.
• Fix a piece of modelling foam to your machine with the approximate size of X105mm xY55mm x Z35mm. The working area in Mayka™ is actually X : 103.800 mm x Y :52.900 mm x Z : 25.000 mm
• Securely fit a 6mm ball end cutter into your machine, with approximately 30mm ofcutting flute.
• Using the axis jog controls, set the datum at the front left corner of the block of foam inX and Y with the tool tip Z0 point set to the top.
• When the machine is set as instructed by your machine tool supplier, you can downloadthe Mayka™ NC file you have made either using the Makya File>Transmit function, oryour own NC transfer software.
Then you can make the part for the model sample file, using extreme caution!
8.2 Basics to getting started with a BMP image
8.2.1 Open a BMP file
Open the Fleur.BMP file from the examples.
Fleur.BMP file as seen on a Paint program like Adobe Photoshop™
The following window appears:
Leave the System as Cartesian.
Change the Grid length to 30 mm. Maka™ recalculates automatically the width proportionnalyto the length if the Keep aspect ratio function is checked on.
Maka™ displays distance between points (0.121 mm) which is taken into consideration. In fact,the real precision of the grid depends on the resolution of the image (72 dpi) and its initialheight.
Set height of the white to 0.0 mm , set height of the black to –5.0 mm and the Control of greyto 1.000.
Click on OK to validate.
The grid of points is displayed:
Flower.PICT file convert into a grid of 3D points.
NB: You can interrupt the display or the current function when you want, with the ESCkey of your.
8.2.2 Cutting the grid
Select the method in the object list.
With the method still selected in the object list, click the Cutting icon.
Make the Tool Definition parameters active. Enter the values shown for a 1.0mm ball.
Make the Tool Definition parameters active. Enter the values shown.
Make the Machine parameters active. Enter the values shown and click OK.
Mayka™ calculates the tool path according to all the entered parameters. If you wish, you caninterrupt a calculation in the working screen by pressing the ESC key.
Tool path of the Flower .PICT file.
8.2.3 Save the tool path
When the calculation is over, Select the File - Save as.. Tto save a tool path, you have to give ita name, indicate the folder in which you want to save it and the format of the machine tool whichwill machine this object.
This is this file which will be transmitted to the machine tool.
8.3 Cutting techniques
8.3.1 Multiplane cutting
Some models (as above) can not be easily machined in 3, 4 or 5 axis systems without generatinga lot of seperate surfaces and boundry curves. The best solution is Mayka's 5 axis multiplanecutting.
The principle is to position multiple working zones at different angles around the job and cutthese in 3 axis mode. This will limit the amount of continous 5 axis movement in a part like this.
Arrows represent directions we wish to cut in. These will be chosen as each of multiplane zones.
Here we place cartessian zones.
It is necessary to orientate the zones in order that the tool will manufacture them according to thepreceding diagram.
One can easily verify these by changing between the different shaded views. In wireframe viewthe starting face of each zone is highlited with a thicker boarder.
Generation of cutting
Defining a method for the first zone, then copying this zone will save time as the toolingparameters will be constant. Position the zones, then ideally defer the calculation, then processthe entire list. The software calculates the corresponding tool paths of each zones. With this typeof work we recommend you reguarly save your scene.
You can then manufacture the part and obtain the result below.
8.3.2 Cutting using inversion
Cutting with invertion allows you to manufacture two sides of a part with a 3 axis machine.
Here we look at the basic steps to do this:
Placing the attachments.
Configure a method in 3 axes.
Define a block.
Prepare the block.
Set the invert parameters.
Choose file menu to open the file Retournement.mvscn. A plane with attachment is displayed.
8.3.2.1 Placing the attachments
To be able to turn a part over and cut both sides it is necessary to place attachments so the partwill be supported and will not fall.
Before placing the attachments, it is necessary to make sure the part is correctly positioned.Select the object mustang.stl in the object list and click the align to origin.
Choose center for X and Y, maximum for Z.
Now you are ready to place the attachments.
Set the view to top and the display to wireframe.
From the modelling menu select "define attachment".
Using the mouse click and drag an attachment.
Repeat this operation to obtain the same position shown below.
If you hold down the CTRL key you will keep the function active and can draw severalattachments successively without selecting the menu. Release the CTRL key before drawing thelast attachment.
If you now change to shaded mode and view from a different position you will be able to selecteach attachment in the object list, then use the mouse to adjust their positions.
You can change the dimensions numerically of each attachment by double clicking their name inthe object list. Or you can use the contol points on each attachment.
It is necessary to place the attachments so they just intersect with the model.
Once all the attachments are correctly positioned, select them all in the object list and select themodel. Now group then all together using the transformation menu and choose group.
8.3.2.2 Create the block
Select the new model with grouped attachments in the object list.
Choose "Define block" from the modelling menu.
In the dialog make sure the ignore attachments option is selected, then enter a border of 30mmand click set. Now ajust the thickness of the block by changing the Z values as 0mm maximumand the thickness as 100mm. Click OK to confirm and check visually the block is correct. Youcan always double click the blocks name in the object list to change the values.
Now it is necessary to physically prepare the block for the two sided cutting of the mustang.
8.3.2.3 Prepare the block
Select the block in the object list.
Click the cutting icon.
The following dialogue will appear. You will be able to choose the diameter of the tool that youare going to use to prepare the block. If you require you can choose one or all of the followingoptions; surfacing the top of the block, contouring the edges or drilling location holes. In ourexample, we have have assumed you have a square block, so we have only chose to drill thelocation holes. You can see the tool path on the illustration below.
These drilled location holes will need to be drilled in the block and in the fixture when the blockis inverted to the other side.
8.3.2.4 Configuration of the cutting method
• Select the new model with grouped attachments in the object list.
• Click on the icon to create a method.
• In the zone dimensions select a border of 10mm and click set. Select a 6mm sphericaltool. In the cutting parameters select roughing with 1mm clearance and an increment of3mm. The depth pass will depend on the material and the machine you are using.
Your method should look similar to this.
It is important that the attachments exceed the size of the method. If this is not the case, deletethe method, ungroup the objects and enlarge the attachments, the repeat the steps again.
Reduce the depth of the method so that is is just below the widest point on the models partitionline. (It does not save anytime if you cut lower than the partition line).
In the same manner, create a finishing method (without clearance and with a smaller increment).In configuring this method, choose the limit of cutting to be model only, this will save cuttingtime.
You can then start the cutting calculations by having the model selected in the list of object andclick the cutting button. Save the tool paths for your machine and make the part.
8.3.2.5 Invert the model
• To invert the object and to be able to manufacture on the other side, it is necessary toselect the object containing the grouped plane and attachments in the object list.
• In the transformation menu, select invert.
• The dialog is displayed with the options to invert in X or in Y. In this example select thein X. Select the block and the model.
• The objects are inverted. Now it is necessary to create two more cutting methods(roughing then finishing). Then calculate the tool paths and save them.
All that remains is to drill the location holes in your fixture board and insrt some pins the samesize as the holes, turn the part over and locate it on the pins. Fix the part down with your clampsetc., then manufacture the other side. To remove the finished part you will have to manually cutthrough the attachments.
E&OE
The PicaSoft Team
Innovative tools to compliment the Creative
Beauzy . Route de Châtres . 41300 THEILLAY. France
Phone: 00 33 254 83 32 16 - Fax: 00 33 254 83 35 72 - Email : Info@ Picasoft.com –www.picasoft.com