Mastercam 2017 Mill Advanced Training Tutorial SAMPLE

IMPERIAL
TRAINING TUTORIAL SERIES
MILL
ADVANCED
Mill Advanced Training Tutorial
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Mastercam 2017 Mill Advanced Training Tutorial

Copyright: 1998 - 2017 In-House Solutions Inc. All rights reserved
Software: Mastercam 2017
Author: Mariana Lendel
ISBN: 978-1-77146-528-1
Date: June 29, 2016
Notice
In-House Solutions Inc. reserves the right to make improvements to this manual at any time and without
notice.
Disclaimer Of All Warranties And Liability
In-House Solutions Inc. makes no warranties, either express or implied, with respect to this manual or
with respect to the software described in this manual, its quality, performance, merchantability, or
fitness for any particular purpose. In-House Solutions Inc. manual is sold or licensed "as is." The entire risk
as to its quality and performance is with the buyer. Should the manual prove defective following its
purchase, the buyer (and not In-House Solutions Inc., its distributer, or its retailer) assumes the entire
cost of all necessary servicing, repair, of correction and any incidental or consequential damages. In no
event will In-House Solutions Inc. be liable for direct, indirect, or consequential damages resulting from
any defect in the manual, even if In-House Solutions Inc. has been advised of the possibility of such
damages. Some jurisdictions do not allow the exclusion or limitation of implied warranties or liability for
incidental or consequential damages, so the above limitation or exclusion may not apply to you.
Copyrights
This manual is protected under International copyright laws. All rights are reserved. This document may
not, in whole or part, be copied, photographed, reproduced, translated or reduced to any electronic
medium or machine readable form without prior consent, in writing, from In-House Solutions Inc.
Trademarks
Mastercam is a registered trademark of CNC Software, Inc.
Microsoft, the Microsoft logo, MS, and MS-DOS are registered trademarks of Microsoft Corporation;
Windows 7 and Windows 8 are registered trademarks of Microsoft Corporation.
MASTERCAM SHORTCUTS
MASTERCAM QUICK REFERENCE CARD
MASTERCAM SHORTCUTS
Function
Keyboard
Shortcut
Function
Keyboard Shortcut
Analyze entities
F4
Mastercam version, SIM serial number
Alt+V
AutoSave
Alt+A
Motion controller rotation point
Alt+F12
C-Hook or user app
Alt+C
Pan
Arrow keys
Configure Mastercam
Alt+F8
Paste from clipboard
Ctrl+V
Copy to clipboard
Ctrl+C
Redo an event that has been undone
Ctrl+Y
Cut to clipboard
Ctrl+X
Repaint
F3
Delete entities
F5
Rotate
Alt+Arrow keys
Drafting global options
Alt+D
Select all
Ctrl+A
Exit Mastercam
Alt+F4
Selection grid parameters
Alt+G
Fit geometry to screen
Alt+F1
Shading on/off
Alt+S
GviewBack
Alt+3
Show/hide all axes (WCS, Cplane, Tplane) Alt+F9
GviewBottom
Alt+4
Show/hide coordinate axes
F9
GviewFront
Alt+2
Show/hide displayed toolpaths
Alt+T
GviewIsometric
Alt+7
Show/hide Toolpaths Manager panel
Alt+O
GviewLeft
Alt+6
Undo the last creation or event
Ctrl+U, Ctrl+Z
Previous Plane
Alt+P
Unzoom to 80% of original
Alt+F2
GviewRight
Alt+5
Unzoom to previous or 50% of original
F2
GviewTop
Alt+1
Zoom around target point
Ctrl+F1
Help
Alt+H
Zoom with window selection
F1
Hide entities
Alt+E
Zoom/unzoom by 5%
Page Up/Page
Down
Level Manager
Alt+Z
Main attributes, set from entity
Alt+X
MASTERCAM QUICK REFERENCE CARD
CUSTOMIZE MASTERCAM
CUSTOMIZE MASTERCAM
Create Your Own Keyboard Shortcuts
Customize the Ribbon
Right mouse click in the Ribbon.

Customize the Ribbon.
Keyboard shortcuts, select the Customize button.
Select the Category.
Select a command and under Press new shortcut
key enter the key combinations you want to assign
to it.

Select Customize the Ribbon.
Select a Mastercam command.
Select a Tab or create a New Tab.
Press Add button.
Customize Quick Access Toolbar

Select Customize the Ribbon.
Select Context Menu.
Select the Category and then the command that
you want to add.
Once you click on the Add button the function will
be added to the Right mouse button menu.
Right mouse click on a command in the Ribbon.

Select Add to Quick Access Toolbar.
Customize the right click menu
WAYS TO GET THE MOST FROM MASTERCAM

Mastercam Training
In-House Solutions offers unsurpassed industrial training for Mastercam and Octopuz. We have training facilities
in a number of cities across Canada and some of our courses can also be offered onsite, depending on trainer
availability. Learn more at eMastercam.com/store.
Our library of Mastercam Training Solutions consists of several product lines that cater to any learning style.
Learn Mastercam at your own pace with our Training Tutorials, teach your students with the help of our
Instructor Kits, learn the theory behind Mastercam with our Handbooks, get projects -la-carte with our Single
Projects, let our instructors show you best practices with our Video Training or go digital with our eBooks.
Mastercam Community
eMastercam is the one-stop web resource for Mastercam users. People from all over the world visit the site
whether they are teaching, learning or working with Mastercam daily. Members can post questions, comments
or share projects and success stories. Visit eMastercam.com and sign up for your free account today!
For downloaded pdf please visit

www.emastercam.com/qrc
MILL ADVANCED TRAINING TUTORIAL PROJECTS
Tutorial
Geometry Functions
Surface and Toolpath Creation
Solid Extrude Create Body

Solid Extrude Cut Body
Solid Extrude Add Body
Solid Fillet
Surface Rough Pocket

High Speed Surface Scallop
High Speed Surface Scallop With
Trim to Stock
Revolved Surface
Transform Project Arc
Trim To Curve
Net Surface
Fillet Surface
Flat Boundary Surface
High Speed Surface OptiRough

High Speed Surface Raster
High Speed Surface Pencil
Swept Surface
Solid Extrude
Solid Trim To Surface
Solid Boolean Add
Use Levels
High Speed Surface Area

Roughing Rest Material
High Speed Surface Radial
Surface Finish Blend
Transform - Rotate By Coordinate
#1
#2
#3
Tutorial
Geometry Functions
Wireframe for Solid

Solid Extrude
Solid Revolved
Swept Surface
Solid Trim to Face
Solid Fillet
Solid Draft Face
Boolean Remove
Boolean Add
High Speed Surface Dynamic

OptiRough
OptiRough with Rest Material
High Speed Surface Hybrid
Edit Projection
Revolved Surface
Project Curve Onto Surface
Ruled Surface
Draft Surface
Curve At Intersection
Trim Surface To Curves
Surface Fillet
Fillet Blend Surface
High Speed Surface Area Roughing

High Speed Surface Spiral
High Speed Surface Scallop
Transform-Rotate
High Speed Surface Waterline
Draft Surface
Swept Surface
Fillet Surface
Rectangle with Surface

OptiRough
High Speed Surface Horizontal
High Speed Surface Waterline
High Speed Surface Raster
High Speed Surface Pencil
#4
#5
#6
Tutorial
Geometry Functions
Lofted Surface
Net Surface (Window
Selection)
Surface Net (Chain Selection)
Fillet Surface
Ruled Surface
Offset Surface
Trim Surface To Curves
Silhouette Boundary

OptiRough
Surface High Speed Area Roughing
with Rest Material
Surface High Speed Scallop
Surface High Speed Scallop with
Trim to Stock
Pocket Standard
Surface Rough Project NCI file
#7
TABLE OF CONTENTS
Table of Contents
Getting Started ........................................................................................................... 1
Tutorials:
Tutorial #1 - Surface Rough Pocket & Surface High Speed Scallop ...................................................11
Tutorial #2 - Surface High Speed Dynamic OptiRough, Raster & Pencil ............................................99
GETTING
Material &STARTED
Radial &
Tutorial #3 - Stock Model, Surface HS Area Roughing - Rest
Surface Finish Blend ...............................................................................................185
Tutorial #4 - Surface HS Dynamic OptiRough, Surface HS OptiRough - Rest Material, Stock
Model & Surface HS Hybrid .....................................................................................303
Tutorial #5 - Surface HS Area Roughing, Scallop, Spiral & Waterline ..............................................429
Tutorial #6 - Surface HS Dynamic OptiRough, Horizontal, Waterline, Raster & Pencil .....................611
Tutorial #7 - Surface HS Dynamic OptiRough, Area Roughing - Rest Material, Surface HS Scallop,
& Surface Rough Project..........................................................................................697
Quiz Answers ......................................................................................................... 831
TUTORIAL #1
Page|11
TUTORIAL #11
OVERVIEW OF STEPS TAKEN TO CREATE THE FINAL PART:

From Drawing to CAD Model:
The student should examine the drawing on the following page to understand what part is being created in this
tutorial.
From the drawing we can decide how to create the geometry in Mastercam.
Create the 3D CAD Model used to generate Toolpaths:

The student will create the wireframe needed to create the solid.
Solid creation commands such as Extrude Create Body, Extrude Cut Body, Extrude Add Boss and Fillet will be
used.
Create the necessary Toolpaths to machine the part:

The student will set up the stock size and the clamping method to be used.
A Surface Rough Pocket toolpath will be created to rough out the part.
A Surface High Speed Scallop toolpath will be created to machine the floors.
A Surface High Speed Scallop toolpath with Trim to Stock options will be created to machine the fillets.
Backplot and Verify the file:

The Backplot will be used to simulate a step-by-step process of the tools movements.
The Verify will be used to watch a tool machine the part out of a solid model.
Post Process the file to generate the G-code:

The student will then post process the file to obtain an NC file containing the necessary code for the machine.
This tutorial takes approximately two hours to complete.
Page |12
TUTORIAL #11
Page|13
TUTORIAL #11
SETTING UP THE GRAPHIC USER INTERFACE
GEOMETRY CREATION
STEP 1: SETTING UP THE GRAPHIC USER INTERFACE

Please refer to the Getting Started section to set up the graphical user interface. In this step you will learn how to hide the
manager panels to gain more space in the graphics window.
Use the Auto Hide icon to hide all Manager panels as shown.
The panels will be hidden to the left of the graphics window.
To un-hide them temporally, click on one of the managers to open it as shown.
Page |14
CREATE RECTANGLES
TUTORIAL #11
STEP 2: CREATE RECTANGLES

In this step you will learn how to create rectangles given the width, the height, and the anchor position.
Step Preview:
2.1 Create the 5.0" by 5.0" rectangle

WIREFRAME
From the Shapes group, select Rectangle.
Enter the Width, the Height and enable Anchor to center as shown. Make sure that Create surface is not
selected.
NOTE: Anchor to center sets the base point of the rectangle

to its center and draws the rectangle outward from the
center.
Create surface creates a surface inside of the rectangle. A
surface can be described as the skin on the top of a 3D
wireframe. If the surface option is on, instead of the four lines
of the rectangle, you will see extra lines which represent the
surface display while it is not shaded. You do not need to
create a surface at this time.
Page|15
TUTORIAL #11
CREATE RECTANGLES
Press Enter after typing the values to see a preview of the rectangle.
[Select position of base point]: Select the Origin as shown in Figure: 2.1.1.
Figure: 2.1.1
Make sure that when selecting the Origin, the visual cue of the cursor changes as shown.
Select the OK and Create New Operation button to stay in the same command.
To fit the drawing to the screen, press Alt + F1.
NOTE: While creating the geometry for this tutorial, if you make a mistake, you can undo the last step using
the Undo icon.
You can undo as many steps as needed. If you delete or undo a step by mistake, just use
the Redo icon.

keyboard.
To delete unwanted geometry, select the geometry first and then press Delete from the
Page |16
CREATE RECTANGLES
TUTORIAL #11
2.2 Create the 4.0" by 4.0" rectangle

Enter the Width, the Height and leave Anchor to center enabled as shown.
Make sure that the Create surface button is not selected (not highlighted).
[Select position of base point]: Select the Origin as shown in Figure: 2.1.1.
The drawing should look as shown below.
Select the OK and Create New Operation button to stay in the same command.
Page|17
TUTORIAL #11
CREATE RECTANGLES
2.3 Create the 2.5" by 2.5"rectangle

Select the HOME tab and set the construction mode to 3D as shown.
NOTE: The construction mode can be toggled between 2D and 3D.

In 2D mode, all the geometry is created parallel to the current construction plane and at the current Z depth
setting. However, you can override the Z depth setting by typing coordinate values that include a Z depth value
different from the current Z depth setting.
In 3D mode, the X, Y, and Z coordinates are all read from AutoCursor when sketching dynamically. The Z depth
setting in the HOME ribbon is not used. When working in a 3D environment, you can create entities whose
points lie in different planes, or create entities (such as arcs or 2D splines) in planes other than the predefined
planes.
Enter the Width and the Height as shown.
Press Enter.
Press the Space bar and enter the coordinates for the Rectangle as shown.
NOTE: When you enter the coordinates of a point in Mastercam, the first value is the X coordinate value
followed by a comma. The second value is the Y coordinate value followed by a comma and the third value is
the Z coordinate value. If you enter the values in this order you do not need to enter the coordinates labels (X,
Y or Z) in front of the values.
Page |18
CREATE FILLETS FOR THE TWO RECTANGLES
TUTORIAL #11
Select the OK button to exit the Rectangle command.

Right mouse click in the graphics window and set the graphics view to Isometric.
The geometry should appear as shown.
STEP 3: CREATE FILLETS FOR THE TWO RECTANGLES

In this step you will learn how to create fillets to all corners of the inside rectangle using the Fillet chain command.
Step Preview:
Page|19
TUTORIAL #11
WIREFRAME
From the Modify area, select the drop down arrow next to Fillet Entities and select Fillet Chains as shown.
Right mouse click in the graphics window and change the graphics view to the Top.
Press Alt + F1 if needed to fit the geometry to the graphics window.

Make sure that in the Chaining dialog box, the Chain button is enabled as shown.
Page |20
TUTORIAL #11
[Select chain 1]: Select the rectangle as shown in Figure: 3.0.1.

Figure: 3.0.1
Select the OK button to exit the Chaining dialog box.
NOTE: Mastercam will automatically insert fillets at all four corners with the radius to be the default value or
the last value used during this Mastercam session.
Change the Radius to 1.0 and make sure the rest of the parameters are set as shown (press Enter).
Select the OK and Create New Operation button to stay within the command.
Page|21
TUTORIAL #11
SUGGESTED FIXTURE:
TOOLPATH CREATION
SUGGESTED FIXTURE:
SETUP SHEET:
Page |48
SELECT THE MACHINE AND SET UP THE STOCK
TUTORIAL #11
STEP 14: SELECT THE MACHINE AND SET UP THE STOCK

In Mastercam, you select a Machine Definition before creating any toolpaths. The Machine Definition is a model of your
machine tool's capabilities and features and acts like a template for setting up machining jobs. The machine definition ties
together three main components: the schematic model of your machine tools components, the control definition that
models your control units capabilities, and the post processor that will generate the required machine code (G-code). For
a Mill Advanced exercise (3D toolpaths), you need only a basic machine definition.
Step Preview:
NOTE: For the purpose of this tutorial, we will be using the Mill Default machine.
Press Alt + F1 to fit the drawing to the screen.
14.1 Unhide the Toolpaths Manager and lock it

The Toolpaths Manager will be hidden to the left of the graphics window as shown.
Page|49
TUTORIAL #11
To lock it, click on the Toolpaths tab and then click on the Auto Hide icon a shown.
The Manager panels will be translated to the lower left corner of the graphics window.
NOTE: If a Machine Group already exist in the Toolpaths

Manager, skip the next step.
MACHINE
From the Machine Type group, select the drop down arrow below Mill.
Select Default.
Page |50
TUTORIAL #11
Select the plus sign in front of Properties in the Toolpaths Manager to expand the Toolpaths Group Properties.
Select Tool settings to set the tool parameters.
Change the parameters to match Figure: 14.1.1.

Figure: 14.1.1
Program # is used to enter a number

if your machine requires a number for
a program name.
Assign tool numbers sequentially
allows you to overwrite the tool
number from the library with the next
available tool number. (First
operation tool number 1; Second
operation tool number 2, etc.)
Warn of duplicate tool numbers
allows you to get a warning if you
enter two tools with the same
number.
Override defaults with modal values
enables the system to keep the values
that you enter.
Feed Calculation set to From tool
uses the feed rate, plunge rate,
retract rate and spindle speed from
the tool definition.
Page|51
TUTORIAL #11
Select the Stock Setup tab to define the stock.

Select the All Entities button to allow Mastercam to establish the necessary stock based on the existing
geometry as shown.
Page |52
TUTORIAL #11
Round the values if needed and change the Z value for the stock to 1.5 as shown in Figure: 14.1.2.
Figure: 14.1.2
The Stock Origin values adjust the

positioning of the stock, ensuring
that you have an equal amount of
extra stock around the finished part.
Display options allow you to set the
stock as Wireframe and to fit the
stock to the screen. (Fit Screen)
NOTE: The extra 0.5" added to the stock thickness is for fixture purposes.
Select the OK button to exit the Machine Group Properties dialog box.
Press Alt + F1 to fit the drawing to the screen.
Page|53
TUTORIAL #11
ROUGH OUT THE PART USING SURFACE ROUGH POCKET
The stock should look as shown.
NOTE: Remember that the stock is not geometry

and thus cannot be selected.
This tutorial utilizes a set of legacy surface toolpaths to machine the part. We begin by showing you legacy
toolpaths as they still have some value in certain situations and the parameters for these toolpaths are easier
to understand for someone just getting started with 3D machining.
That being said, there are more efficient toolpaths that can be used to machine the same part. If you will
actually machine this part, we suggest you use the Surface High Speed OptiArea toolpath as your roughing
toolpath of choice.
STEP 15: ROUGH OUT THE PART USING SURFACE ROUGH POCKET
Surface Rough Pocket toolpath is used to remove a lot of stock quickly by creating a series of planar cuts (constant Z). It is
used to machine both bosses or cavities on surfaces or solid models.
Toolpath Preview:
Page |54
TUTORIAL #11
15.1 Surfaces and Containment selections

TOOLPATHS
From the 3D group, select the Pocket icon.
If a prompt appears to Enter new NC name, select the OK button to accept the default as shown.
[Select Drive Surfaces]: Select the solid as shown.
Click on the End Selection button or press Enter to finish the selection.
Page|55
TUTORIAL #11
To limit the tool motion inside of the boundary, in the Toolpath/surface selection dialog box, click on the
Select button to select a Containment as shown.
From the Chaining dialog box, click on the Solids button as shown.
In the Chaining dialog box, make sure that the Loop button is the only one selected as shown.
Page |56
TUTORIAL #11
[Select faces, edges, and /or loops]: Select the edge as shown.
The chain selected should look as shown.
The Pick Reference Face dialog box will appear on your screen as shown.
Select the OK button to exit the Pick Reference Face dialog box.
Select the OK button to exit the Chaining dialog box.
Select the OK button to exit the Toolpath/surface selection dialog box.
Page|57
TUTORIAL #11
15.2 Set the Toolpath parameters page

The Toolpath parameters page allows you to select a tool, set the feeds and speeds, enter a comment about the
operation, and set other general toolpath parameters.
To select the tool, click on the Select library tool button as shown.
Disable Filter Active and click on the # to list the tools based on their numbers.
Page |58
INDEX
Numerics
2D / 3D Construction ........................................ 6
Graphic Area ..................................................... 3

GUI - Graphical User Interface .......................... 3
Analyze A Spline ........................................... 544

Assign tool numbers sequentially ................... 56
L
Level .................................................................. 6
Backplot The Toolpath .................................... 72

Backplotting .................................................... 72
Boolean Remove ...................................410, 424
Bounding Box .................................................. 57
Break the fillet at the midpoint .................... 571
Machine Definition ......................................... 53

Material Mode .............................................. 291
Maximum step-down ..................................... 69
Mirror ........................................................... 352
Mirror about a line ....................................... 568
Mirror the profile about the Y axis ............... 534
Mitered Corners ........................................... 435
C
Change The Main Level ................................... 30
Clearance ........................................................ 68
Color ................................................................. 6
Constant Radius ............................................ 435
Control Definition ........................................... 53
Create A Net Surface .................................... 157
Create Arc Endpoints .................................... 383
Create Circle Center Point .............................. 27
Create Circle Center point .............................. 27
Create Curve At Intersection ........................ 576
Create Fillets ................................................... 23
Create Fillets For The Two Rectangles ............ 23
Create Parallel Lines ..................................... 110
Create Polar Lines ......................................... 116
Create Rectangles ........................................... 19
Create Revolved Surfaces ............................. 135
Create Silhouette Boundary ......................... 441
Create The Draft Surfaces ............................... 30
Create The Fillet Surface ............................... 558
Create The obround rectangular shape ........ 135
Create The Parallel Lines .............................. 110
Create The Pocket Floor Surface .................. 552
Create The Revolved Surface ........................ 135
D
Delete Entities .............................................. 382
Display ............................................................ 58
Divide ............................................................ 310
Draft Surfaces ........................ 30, 34, 36, 43, 46
Drive surfaces ................................................. 68
E
Extrusion Operation ................................32, 399
F
Feed Calculation set From tool ....................... 56
Feed plane ...................................................... 68
N
Net Surface ................................................... 157
O
Offset Contour .............................................. 370
Offset Surface ............................................... 802
Override defaults with modal values .............. 56
P
Pocket parameters page ................................. 71
Post Process The File ...................................... 98
Post Processing ............................................... 98
Post Processor ................................................ 53
Program # ....................................................... 56
Project .......................................................... 138
Propagate Along Tangencies ........................ 435
R
Reorganizing The Toolbars ............................... 4
Retract ............................................................ 68
Rotate - Copy The Surfaces ........................... 606
Rough parameters page ................................. 69
S
Scale .................................................................. 3
Select The Machine And Set Up The Stock ..... 53
Setting Mastercam To Metric ......................... 10
Setup the stock model .................................. 274
Shaded .......................................................... 244
Simulate the toolpath in Verify ...................... 74
Solid Revolve ................................................ 400
Steep/shallow ............................................... 288
Stock Models ................................................ 274
Stock Origin .................................................... 58
Stock to leave on drive ................................... 68
Surface Finish Blend ..................................... 305
Surface Finish Leftover ................................. 880
Page|839
INDEX
Surface Finish Parallel ................................... 191
Surface Finish Pencil ..................................... 200
Surface Finish Scallop ................................... 869
Surface High Speed Scallop ....................77, 632
Surface High Speed Core Roughing ......277, 616
Surface High Speed Finish Horizontal ........... 740
Surface High Speed Finish Spiral ................... 655
Surface High Speed Hybrid ........................... 482
Surface High Speed OptiArea .......180, 448, 847
Surface High Speed OptiCore ....................... 725
Surface High Speed Pencil ............................ 762
Surface High Speed Radial ............................ 294
Surface High Speed Raster ............................ 755
Surface High Speed Rest Roughing ............... 858
Surface High Speed Restmill ......................... 463
Surface High Speed Waterline ...................... 668
Surface Rough Pocket ..................................... 59
Surface Rough Project .................................. 892
Swept Surface .......................................233, 387
T
Toolpath parameters page ............................. 63
Toolpaths/Solid Manager ................................. 3
Total tolerance ............................................... 69
Transform Toolpaths .................................... 319
Transitions .................................................... 287
Trim 1 Entity ........................ 116, 348, 357, 377
Trim 2 Entities ............................................... 116
Trim the draft surfaces to the curve ............. 578
Trim The Geometry ...................................... 116
Trim The Surfaces ......................................... 576
V
Variable Radius ............................................. 435
View Port XYZ Axes ........................................... 4
W
Warn of duplicate tool numbers .................... 56
Wireframe ..............................................58, 244
Z
Z Depth ............................................................. 6
Page |840

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Mill Advanced Training Tutorial

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