ASSIGNMENT

The assignment given to us is as shown in fig 1 we have to generate the CAD model out of
the given Drawing and then will have to generate the Machining toolpaths for same.

Fig. 1
This whole assignment is divided into 3 parts i.e. 1st is generating the CAD model out of 2D
drawing 2nd is generating the tool path for that CAD model and 3rd is verification of
toolpath.
So we will be First concentrating on making the CAD model of above shown part.

EXERCISE

STEPS
1st CAD Model Generation
1.

First thing to make sure is that the unit should be in Metric (mm).

Fig. 2
2.

As it is a turn mill operation we have to work in Right side plane. As in figure

2 you can see by default Mastercam opens in Top plane we will have to change it to
Right Side plane by click on shortcut of Right side plane or we can go to View in that
Standard View and their we can select Right (WCS).

Fig. 3
We can make sure that we are in Right side view by looking in Left bottom corner of
screen as it shows Right Side View.
3.

Now we will start the drawing of CAD model.

4.

We will make a circle of Dia 100mm at a Depth of 120mm from origin, for that we
will have to make some changes in Status Bar at bottom of screen.

Fig. 4
by default we get 3D mode which is to be converted to 2D as shown and required
depth is to be put in column as shown in figure 4. So we put -120 as depth.
5.

We then make a circle of Dia 100mm taking origin as Centre.

Fig. 5

6.

Then we will go to Solids in MENU bar and select Extrude command. It will as us for
Chaining. Chaining is nothing but we have to give the area or the entity to which we
want to apply the command in this case extrude.

Fig. 6
As soon as you click on the Circle it will be selected for chaining. As shown below

Fig. 7
Press OK after selection.
7.

It will take us to Extrude option screen. Where we will put the height of circle i.e. 35
mm and to see the preview correctly we will see Isometric view, we can get to iso
view by pressing Alt+7 or else we have a shortcut key on right side of Right side view
key.

Fig. 8
Once done press on OK. and then get back again to Right Side view.
8.

Next is we have to make a Hexagon with Circumcircle of Dia 70mm. at a depth of 85

mm. So first we have to select the depth of 85 mm as done above.

Fig. 9
after selecting Polygon option making Hexagon of it as below.

Fig. 10
9.

Again extruding it till a distance of 20mm as done above. The output will be as shown
below.

Fig. 11
10.

Now we will Design Blade for that we have to Make upper drawing 1st which will be
at origin i.e. at 0 Depth.

11.

Make 2 point with Co-ordinates (-20,-9) and other one at (30,0). For that select Create
Point position and select fast point option once its active then enter the co-ordinates.

Fig. 12
Similarly make other point at (30,0).

Fig. 13
After creating two points we will have to create circles with these two having these two
points as Centre.
12.

Two circle radius being 6mm and 3.5 mm.

Fig. 14
13.

Now we have to create arc tangent to these two circles which is having radius of
70mm. For that we will have to select option CREATE in Menu bar in that ARC
option and in that we will select ARC TANGENT from drop down menu list as shown
below.

Fig. 15
Once in this option we will have to select Arc tangent 2 entities also enter the radius i.e.
70mm.

Fig. 16
Select the two circles to be tangent. We will get all possibilities of making that circle out of
given inputs as shown below.

Fig. 17
Selecting fillet that has been coloured black and white in above figure.
Then again repeating the same procedure and selecting black and white coloured line in
below figure.

Fig. 18
Once we are done with this we will get following result.

Fig. 19
14.

Next step is to trim two circles.

15.

Select Trim/Break/Extend option as shown below and in that select Divide/Delete

option. Once selected delete the extra or inner part just by clicking on it, of circle to
look like below figure.

Fig. 20
16.

Next step is to draw the lower part of blade.

17.

For that we will have to copy and move upper curve at depth of 65mm.

18.

We will use TRANSLATE option present in XFORM Menu Bar.

Fig. 21

19.

Once selected it will ask us to select the entities to be translated. Select the upper
curve as shown.

Fig. 22
20.

Then in Translate Menu put value -65 mm in Z column and press OK. our entity has
been translated to a depth of 65mm.

21.

Now we have to rotate the lower curve at an angle of 15 degree from centre, before
that we can confirm the same by viewing the isometric view as shown below.

Fig. 23
22.

To rotate select Rotate option from XFORM menu bar and select the Lower curve.
Make sure you have selected lower curve only by going into Isometric view and then
once confirmed again come back to Right side view.

Fig. 24
23.

In rotate option put -15 degree in angle column and make sure you have selected
Move option from top of rotate menu.

Fig. 25
24.

Once done press OK.

25.

Now we have to make a Solid body between these two curves. That will be done by
LOFT option present in SOLIDS option.

26.

Select LOFT option. Also come to Isometric view for same.

27.

It will ask you to select the two curves between which the Loft is to be generated
select the curves as shown below. Then press OK.

Fig. 26
28.

It will take you to Loft Menu here also just press OK after seeing the preview.

Fig. 28
29.

Now we will have to make Slots on Hexagonal faces, for that we will have to Work in
Top view selecting TOP view as we selected Right Side view.

30.

For making slot we will have to first draw a Point at (-75,0) at a distance of 35mm
above origin that will be the centre of slot that we will make.

Fig. 29
31.

For making Slots we will select RECTANGULAR SHAPES from CREATE Menu
bar.

32.

In Rectangular Shapes Menu we will select Anchor point to be Centre point then the
shape would be Slot type Obround shape and then slot height would be 15mm and
width would be 6mm as shown in fig. below.

Fig. 30
33.

Select the centre point Created before to draw the slot as shown above.

34.

Now we have to Cut this slot till a distance of 5 mm.

35.

Go to Extrude option. Select the chain i.e. slot that we created. Go to Iso view. Select
Cut Body option Change the direction and put distance 5mm.

Fig. 31
36.

Now we will have to revolve this Cut pattern into along all faces of Hexagon.

37.

Selecting CIRCULAR PATTER from PATTERN option in SOLIDS option from

Menu bar.

38.

On selecting the CIRCULAR PATTER it asks us the target body which will be
Hexagon so select the hexagon then it will ask us to select the Solid Operations to be
patterned. So now selecting the Slot hole created as shown below.

Fig. 32
39.

Pressing OK after selecting the Operation.

40.

Now go to Right Side view and then in Menu Select Full Circle and instances to be 5
and say OK. Make sure to go in Right Side View as shown below.

Fig. 33
41.

We are done with CAD Model preparation.

Fig. 34

2nd Toolpath Generation

1.

The first thing that we have to select is Machine type i.e. What we call are
Controllers. So we have to go to MACHINE TYPE option in menu bar an then in
LATHE in that it will open a drop down menu which will show all the default
controllers available with Mastercam. We will select Default for our practice.

Fig. 35

2.

Now Next step is to define the RAW Material, we call it STOCK SETUP in
Mastercam.

3.

We will have to double click on Properties Icon as shown below.

Fig. 36
4.

Click on Stock Setup under Properties.

5.

We will get a menu bar where we have to Define the stock and the below that the
chuck.

Fig. 37
6.

Click on Properties in Stock setup to define Raw material.

7.

As we go in properties of stock we have to select Make from 2 point option.

Fig. 38
8.

after selecting that option it will guide you to model where you have to select two
diagonal point covering the maximum part, the point in this case will be as shown
below.

Fig. 39

9.

Then select Use Margin option to make margin for same. Give value 5mm for OD
margin, 5mm for Right margin and 25mm for left margin.

Fig. 40
10.

Press OK when done.

11.

Now again go to properties of CHUCK JAWS. In that turn on from stock option and
give value 15mm in Grip Length.

Fig. 41

12.

Press OK when done. You will see figure as shown below.

Fig. 42
13.
14.

Now you Raw material is ready now we know what we have and what we want to
have.
Facing toolpath generation
Select Face toolpath from Toolpaths menu.
It will ask you to enter NC name enter and proceed.
Then a Lathe Face Properties dialogue box will appear.

Fig. 43

Tool Parameters- Select the tool. We will select T0101 R0.8 OD ROUGH
RIGHT- 80 DEG. We can edit the tool insert by double clicking on tool even
the holder and all the parameters related to tool can be edited. Outside also we
get the parameters like feed rate, finish feed rate, spindle speed, finish spindle
speed, max. spindle speed can be edited.
Face Parameters- It is mainly asking for what is the amount of stock to be
faced. Again we can give it manually (Use stock) or automatically (Select
points) we will go for automatic click on select points shown below.

Fig. 44

In this it asks for the area till which the stock is to be faced. Select the area as
shown below. Edit other parameters such as turn on Rough Stepover option
and let the distance be 2mm and say OK.
Facing is done and we will get following toolpath.

Fig. 45
15.

Next step is to make the turn profile.

16.

Select TURN PROFILE option in CREATE menu and then select the complete Part
and then say OK . We will get a profile which can be used for turning.

17.

Roughing Operation

Select the Rough Operation from Toolpath menu

Select the chain as shown.

Fig. 46

Again lathe rough properties dialogue box will appear having two tabs to
define. Toolpath parameters and Rough parameters.
Toolpath Parameters- Select same tool as before and change the parameters as
required.
Rough Parameters- Main thing to remember here is to select Use stock for
outer boundary in Stock recognition. If this is not done the toolpath will not
be generated according to stock it will be generated according to defined part
which may lead to collision. Rest other parameter can be varied accordingly.
We will use the same as defined. Say Ok.

Fig. 48

We will get following toolpath.

Fig. 49
18.

Facing Toolpath
Select the Finish Operation from Toolpath menu
Select the chain for surface to be finished. For our example we will select
same as before, for this we have one option called LAST in chaining menu
which automatically select the last chain as select by us before click on it.

Fig. 50

Again lathe Finish properties dialogue box will appear having two tabs to
define. Toolpath parameters and Finish parameters.
Toolpath Parameters- We will select T2121 R0.8 OD FINISH RIGHT- 35
DEG. tool and change the parameters as required as shown.

Fig. 51

Finish Parameters- Here the finish parameters Finish Stepover & Number of
finish passes are important. We will give Finish stepover as 0.5 and Number of
finish passes as 2. And say OK.

Fig. 52

We will get following toolpath for finishing operation.

Fig. 53

19.

2D Contour
Select the CONTOUR toolpath in MILL option from TOOLPATH menu.
Come to isometric view for selection.

Fig. 54

Select the chain as shown in figure and say OK.

Fig. 55

As the 2D contour toolpaths Menu opens. Directly go to Planes (WCS) option

in Menu and change Tool plane view to Right View and also
Comp/Construction Plane to Right view.

Fig. 56

Then go to Tool- In this you can either Create new tool by right clicking in the
List screen and selecting Create new tool then selecting proper tool type and
then entering the required values of tool. Else you can select from library by
clicking on Select library Tools.

We will select from library 16.FLAT ENDMILL (dia16)( Keep Overall height
of 110 and cutting Length is 100 as per our part) .
Holder You can edit holder dimensions in there. (default)
Next comes the Cut Parameters which has following options:o Compensation Type- It means what type of tool radius compensation you
want to give, it can be Computer that means computer controlled or
Control that means you have to take care of compensation or Wear which
means you have to give the toll positive tool wear value or Reverse wear
which means you have to give negative tool wear value or you can Off it
also. (We will keep it Computer)
o Compensation Direction- It ask the direction from which the
compensation will be either from left or right it depends on the direction
of chaining you have selected in chaining option i.e clockwise or anticlockwise. (We will keep it Left as our chaining direction is Clockwise)
o Tip Compensation- It ask for tip compensation either from tip or from
centre. (Tip)
o Roll cutter around Corner- You can keep it None, Sharpe or All. (Sharp)
o Internal Corner rounding radius- you can give the corner rounding radius.
(0.0)
o Stock to leave on walls/floors- It asks for stock to leave on wall for finish
cuts.(0.0)
Depth Cuts- It ask for the depth of Cut that means for one cut till what depth it
should cut then it also asks for Finish cuts i.e number of finish cuts you want and
then finally the distance between finish steps (Max Rough step- 5 , Finish cuts-2,
Finish step-0.5).

Note- the depth of cut depends upon the Material of Stock and Tool.

Lead IN/Lead OUT- It is option for Entry and Exit of tool it has many options,
you can control with right from Perpendicular or Tangent Entry and exit to the
Line and Arc of entry and exit. (Default)
Break Through- It is option for tool going pass the edge of the part or not. You can
decide the length of it or you can close it. (Off)
Multi Passes- This option is for no. of passes you want to give on contour face.
You can decide the number of passes the distance between the passes and same for
finish cut. (Off)
Tab- You can define the tab in if required in this option. ( We will keep it off)
Linking Parameter- It has following important options to defineo Clearance- It is the height till which the tool comes from home position in
rapid mode. (We will give of 50.0)
o Retract- It is the height till which the tool Retract after each Depth of Cut
rapidly. (We will give of 25.0)
o Feed Plane- It is the height from which the tool will move in with defined
Feed rate inside the part. ( We will give of 10.0).

o Top of stock- As said you have to define the top of stock (Our top of stock
will be -65).
o Depth- Again you have to give the depth of part (Our depth will be -85).
We have selected both the distances by clicking on the icons and selecting
it from the screen itself.
The generated Toolpath is as shown below.

Fig. 57

20.

Pocket
Select Pocket toolpath from Toolpaths menu in MILL option.
Now it will ask for chaining, select 1st and only slot pockets as shown in figure.

Fig. 58

Then a 2D Toolpaths-Pocket Dialogue box will appear.

Tool Type- Pocket.
Tool- Select the tool as per defined in contour operation.
We will select from library 5 FLAT Endmill Cutter (Dia-5).

Fig. 59

Holder You can edit holder dimensions in there. (default)

Cut Parameterso Machine direction- We need to define the machining direction it
could be Climb or conventional. (We will keep it Climb)
o Pocket type- Standard.
o Tip comp.- Tip

o Roll cutter round corners- Sharp

o Stock to leave on walls - 0
o Stock to leave on floors- 0
Roughing- This will create the rough profile of pocket followed by finish
machining. We can define the tools path. (We will keep Parallel Spiral).
Entry motion (for Roughing)- You can define the entry of the tool and various
parameters related to it. (We will keep it Default)
Finishing- This is the finishing pass of pocket. (We will give Passes-1,
Spacing-0.5, Spring passes-0, Cutter compensation- Computer, rest everything
is default).
Lead IN/Lead OUT- It is option for Entry and Exit of tool it has many options,
you can control with right from Perpendicular or Tangent Entry and exit to the
Line and Arc of entry and exit. (Default)
Depth Cuts:- It ask for the depth of Cut that means for one cut till what depth
it should cut then it also asks for Finish cuts i.e number of finish cuts you want
and then finally the distance between finish steps (Max Rough step- 2 , Finish
cuts-1, Finish step-0.5).
Break Through- It is option for tool going pass the edge of the part or not. You
can decide the length of it or you can close it. (Off)
Linking Parameter- It has following important options to defineo Clearance- It is the height till which the tool comes from home
position in rapid mode. (We will give of 50.0)
o Retract- It is the height till which the tool Retract after each Depth of
Cut rapidly. (We will give of 45.0)
o Feed Plane- It is the height from which the tool will move in with
defined Feed rate inside the part. (we will give of 40).
o Top of Stock- Define the top of stock. (ours is - 35 )
o Depth- Give the depth of part (Our depth will be - 30).
The generated toolpath is as shown below.

Fig. 60

21. Toolpath Transform

Go to TOOLPATH TRANSFORM toolpath in TOOLPATHS menu bar.
Transform Operation Parameter menu will open where we have to define
all the parameters related to to it.
We will first edit TYPE AND METHODS bar.
In Type select ROTATE.
In Method Select TOOL PLANE.
In Source Operation Select POCKET (Standard)

Fig. 61

Now we will edit ROTATE bar.

In INSTANCES- 5 (#).
Both Angles be 60 degree.
In Rotation Plane Right Side
Say OK when done.

Fig. 62

We get following toolpath.

Fig. 63

22. Stock Model

Now what we are going to do is . We will make a Solid of machined part i.e.
till now what what all operation has been performed we will see the cut part of
it. It will also act as reference to next toolpaths.
Select STOCK MODEL toolpath from TOOLPATHS Menu bar.
In STOCK DEFINITION
o Name- ABC
o Initial Stock Shape Stock Setup. It will automatically take the
stock value initially defined in stock setup.
o It will automatically take all the value of initial defined stock

Fig. 64

In SOURCE OPERATION
o Compute Stock Model from Select all the toolpaths by pressing
Ctrl and selecting it one by one.
o Say OK when its done.

Fig. 65

We will get following Model after the above operations.

Fig. 66
23. Dynamic OptiRough Toolpath (TOP)

Before starting this toolpath we need to make a containment boundary which

means the cutter will be inside that boundary only. So we will make a
random rectangle as highlighted in below figure.

TOOLPTHS menu bar we will have to go to MILL in that SURFACE

HIGHSPEED toolpaths and in that OPTIROUGH TOOLPATHS.
As soon as you click on above toolpath it will ask you to select drive
surface. Select complete model as drive surface.

Fig. 67

Tooltype- Roughing ; Dynamic optirough

Tool 8 BULL MILL Cutter 2 RAD.
Holder- Default
Cut Parameter
o Cut Style- Default
o Passes Stepover : 45% ; Steep Down : 10% ; Stetup : 5%
o Rest default

Fig. 68

Rest material Check ON rest material option and select One other
operation option and in that we have to select last option i.e. Stock Model

Fig. 69

Tool Containment inside

Transition Default
Steep/ Shallow Check ON , Z depth , minimum depth : 35mm, maximium
depth : -10mm

Fig. 70

Linking parameter
o Retracts Instead of Full Vertical Retracts make it Minimum
vertical retract
o Fitting Instead of Minimize Trimming make it Machine entire
pass

Fig. 71

Toolpath

Fig. 72
24. Dynamic OptiRough Toolpath (BOTTOM)
Just copy the above toolpath below it. as shown below.

Fig. 73

Go to Parameter option in this copied toolpath.

Go to PLANE (WCS) change Tool plane and Comp/Construction plane to
BOTTOM

Fig. 74

Go to Steep/ Shallow option Change the maximum depth to -1.

Regenerate the toolapth.
Toolpath

Fig. 75
25. MULTIAXIS
Go in TOOLPATHS menu bar in that MILL drop down menu in that
MULTIAXIS.

Fig. 76

Once selected Multiaxis

Select Tool Type - ROTARY

Fig. 77

Tool 9 BALL END MILL

Cut Parameter
o Surface as shown below

Fig. 78

Tool axis control

o Axis Dampening Length 1 mm
o Maximum step 1 mm
Keep rest setting default.
Toolpath

Fig. 79

3rd Verification of toolpath

26. select all the toolpath by clicking on below button

27. Click on verify selected operation by clicking on following button and you can see
the solid simulation of part.

28. Click PLAY on Simulation screen and you will the cut part.