ENGI 7962 Mastercam Lab Mill 1 Starting a Mastercam file: Once the SolidWorks models is complete (all sketches are Fully Defined), start up Mastercam and select File, Open, Files of Type, SolidWorks Files, your SolidWorks drawing (License Plate 1) The part should be shown with the origin in the lower left bottom corner (hold down Alt S to shade part). Select Isometric & Fit Select Machine Type, Mill, Default
Setting up Machine Group Properties: Expand Properties in the Operations Manager and set up Files, Tool Settings, & Stock Set up Type in you group number ie 79621, 79622, 79623 etc (to be assigned) 2
Pick Select, Source Mill Library, to change material to Aluminum 6061 Change the following settings then use the mouse to pick the lower left hand corner of the stock envelop to set up the Stock Origin 3
Operation 1: Facing the top of part Tool Number: 1 Tool Type: Carbide, 2 Ø, 6 Tooth, Face Mill Save As: Your assigned Group number Select Isometric View Select C-plane Select the outside upper rectangular profile of the part using Chain 4
Do not change any values yet, Select Library Tool then pick Filter 5
Select None under Tool Types to disable all tool selections then select Face Mill, OK Select 2 Face Mill, OK 6
Change the Feed rate, Spindle speed and Plunge rate as shown Change Style to Zigzag, the Across overlap, Along overlap and check all values are as shown 7
Activate depth cuts and check all values Check all values are exactly as shown 8
Coolant on After each operation use Verify to check the part is being machined using the correct tool, toolpath direction, to appropriate depth cuts, rough cuts, & finish cuts as required. Select all operations, Verify Select the Simulate Tool, adjust for Quality & Speed 9
Operation 2: Contour 2 ¾ diameter island Tool Number: 2 Tool Type: HSS, ¾ Ø, 4 Flute, Flat End Mill C-plane Chain Select the lower circular profile of the 2.75Ø island Ensure the arrow direction is pointing in a clockwise direction (climb milling) Select Reverse arrow direction if required, OK 10
Tool, Select Library Tool, Filter, Tool Types None, End Mill Flat, OK, ¾ Flat End Mill, OK Set Feeds and Speeds and Plunge rate as shown, select Rapid Retract 11
Activate Lead In/Out, set Entry Length to 25 and Arc Radius to 25 use the double arrow to copy new values to Exit side 12
Activate Multi Passes and change the settings as shown Set up Linking Parameters and select Use clearance only at start & end of operation 13
Turn on Flood coolant After each operation use Verify to check the part is being machined using the correct tool, toolpath direction, to appropriate depth cuts, rough cuts, finish cuts as required. Select all operations, Verify Select the Simulate Tool, adjust Quality & Speed 14
Operation 3: Contour star shape island Tool Number: 2 Tool Type: HSS, ¾ Ø, 4 Flute Flat End Mill C-Plane, Chain Select the bottom contour of the star shape Chain direction in clockwise direction, OK 15
The tool selected is the ¾ end mill with speeds and feeds remaining the same as used the previous operation, select Rapid Retract 16
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Activate Lead In/Out and change the values as shown Disable Break Through and Multi Passes and set the following values for Linking Parameters 18
Coolant On After each operation use Verify to check the part is being machined using the correct tool, toolpath direction, to appropriate depth cuts, rough cuts, finish cuts as required. Select all operations, Verify Select the Simulate Tool, adjust Quality & Speed 19
Operation 4: Contour 1.4 Ø Tool Number: 2 Tool Type: HSS, ¾ Ø, 4 Flute, Flat End Mill C-Plane Chain, select 1.4 diameter lower profile Chain direction in Clockwise direction 20
Accept the same feeds and speeds as used in the previous operation and select Rapid Retract 21
Disable depth cuts and for Lead In/Out change the values as shown 22
Activate Multi Passes and change the values as shown In Linking Parameter change the values as shown 23
Coolant On After each operation use Verify to check the part is being machined using the correct tool, toolpath direction, to appropriate depth cuts, rough cuts, finish cuts as required. Select all operations, Verify Select the Simulate Tool, adjust Quality & Speed 24
Operation 5: Pocket.28 Ø slots x 4 Tool Number: 3 Tool Type: HSS, ¼ Ø, 2 Flute, Flat End Mill C-plane, chain, select the bottom of all 4 pockets making sure each chain will machine in a counter clockwise direction 25
Tool, Select library tool, Filter Tool Type- None, Flat End Mill, OK, ¼ Flat End Mill, OK Change the Speeds, Feeds, Plunge, Retract as shown and select Rapid Retract 26
Cutting method Parallel Spiral and change the values as shown 27
Entry Off Set Finish values as shown 28
Disable Lead In/Out & Depth Cuts and set the Linking parameters as shown Coolant On Verify, Select all operations and check this operation 29
Operation 6: Drill - centre drill & break sharp edges x 4 Tool Number: 4 Tool Type: Carbide, 1/2 Ø, 2 Flute, 90 Spot Drill Select Top View from the Graphics View toolbar, Fit Select the centre point of each of the four holes, OK 30
Select Tool, Select Library Tool, Filter, Tool Type- None, Spot Drill, OK, ½ Spot Drill, OK 31
Change the Feed & Speed as shown Cut Parameters Drill/Counterbore 32
Change the settings below then pick the Depth calculator icon to the right of the Depth value box Change Finish Diameter to.22 which will break the sharp edge for each the.191 Ø drill Select Overwrite depth 33
Note the depth Mastercam has calculated for the counter sink (Depth.19) Turn on coolant After each operation use Verify to check the part is being machined using the correct tool, toolpath direction, to appropriate depth cuts, rough cuts, finish cuts as required. Select all operations, Verify Select the Simulate Tool, adjust Quality & Speed 34
Operation 7: Drill - drill thru.191 Ø (drill #11) x 4 thru Tool Number: 5 Tool Type: HSS,.191 Ø, 2 Flute Drill Select Top View from the Graphics View toolbar, Fit Select the centre point of each of the four holes, OK 35
Select Tool, Select Library Tool, Filter, Tool Type- None Select Drill icon, OK, No. 11 Drill, OK 36
Change Feed rate & Spindle speed For Cycle select Peck Drill (this will break the chips while drilling through) 37
Change the values as shown for Linking Parameters Select Tip Compensation and break through.030 38
Coolant On After each operation use Verify to check the part is being machined using the correct tool, tool path direction, to appropriate depth cuts, rough cuts, finish cuts as required. Select all operations, Verify Select the Simulate Tool, adjust Quality & Speed Now use Backplot, view iso metric, fit, select all operations, adjust the speed control and backplot, check each operation carefully, try a front or right side view, fit and backplot again. 39
Operation 8: Contour- break sharp edge on 2.75 Ø Tool Number: 4 Tool Type: Carbide, ½ Ø, 2 Flute, 90 Spot Drill 40
Select the upper 2 ¾ Ø contour Ensure the chaining direction will be in the clockwise direction Select the ½ Spot Drill and change Feed rate & Spindle speed as shown below, select Rapid Retract 41
2D Chamfer, Width.015, Tip Offest.015 Disable Depth Cuts, Lead In/Out, Break Through & Multi Passes and change settings as shown Turn Coolant On and Verify this Operation 42
Operation 9: Contour (Engrave Engineering logo) Tool Number: 6 Tool Type: HSS, 1/8 Ø, 2 Flute, Centre Drill File, File Merge/Patterns Find the logo in the 7962 folder, select ENG_LOGO_CAE_FINAL, OK. Select Top View, Fit, zoom in on the logo, select the logo path with a Window selection box 43
3D Select Window and draw a window around the logo only Sketch approximate start point on the logo path, OK 44
Tool, Select library tool, Filter, Tool types- none, select Centre Drill, OK, select 1/8 Centre Drill, OK Modify the Feed rate & Spindle speed, Plunge & Retract speeds 45
Compensation type Off as the tool will run on center to engrave Change Linking Parameters as shown Coolant On and Verify 46
Generating a Tool List: First set up the type of tool list- Settings, Configuration, Toolpath, Setup Sheet program, GUI, OK Then select all operations in the Operations Manager To view Tool List, right click in the Operations Manager and pick Set Up Sheet Select Internal, Auto-read operations & toggle tools image on left, print the Tool List & the Set up sheet Check all tools, tool numbers, feeds & speeds are correct as per the tutorial settings 47
Print Tool List Print Set Up sheet 48
Posting a file: Before Posting a file check your work. Verify, Backplot and check all tool settings Select all operations, Backplot, pick the Info tab and check the total cycle time (under 20 minutes) Select all operations in the Operations Manager & Post Selected Operations 49
Save your file, Save As: the group number you were given (i.e. 79621, 79622 etc.) 50
Verify your code and print the first page of code The Work Set offset for the Hass Super Mini Mill is set up at G55. In the Mastercam editor Find & Replace G54 with G55. Replace all and check that this has been done for each tool. Save the new NC file Congratulations - you have completed the Mastercam Mill 1 tutorial! Now on to the Haas Super Mini Mill tutorial where you will make the part! 51