MCAMX4 Wire GettingStartedGuide

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mastercam x4
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Mastercam X4 Wire 12
Getting Started 13
Guide
April 2009
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Be sure you have the latest information!
Information might have been changed or added since this document was
published. The latest version of this document is installed with Mastercam or
can be obtained from your local Reseller. The ReadMe file (ReadMe.htm)
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includes the latest information about new features and enhancements.
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Mastercam® X4 Wire Getting Started Guide

Date: April 2009
Copyright © 2009 CNC Software, Inc. — All rights reserved.
First Printing: September 2006
Software: Mastercam X4 Wire
Part Number: X4-PDF-WG
TERMS OF USE Use of this document is subject to the Mastercam End User License
Agreement. A copy of the Mastercam End User License Agreement is
included with the Mastercam product package of which this docu-
ment is part. The Mastercam End User License Agreement can also be
found at:
www.mastercam.com/legal/licenseagreement/
• v
Contents
1. Introduction to Mastercam X4 Wire ...........................1

 Starting Mastercam Wire .....................................................2
 Getting Help ...........................................................................4
Mastercam X4 Documentation ..............................................6
Mastercam Support and Services ...........................................9
2. Wire Part Geometry ...........................................................11

 Basic Requirements for Wire Geometry ...........................12
Contours ...............................................................................12
Points ....................................................................................14
4-axis Wirepath Geometry ....................................................14
 Creating Thread Points .......................................................16
 Creating Cut Points .............................................................18

Creating Thread and Cut Points with Toolbar Buttons........19
Breaking Geometry Perpendicular
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to a Thread Point21
 Chaining Wire Geometry ....................................................24
Window Chaining .................................................................24
Chaining Individual Contours and Points............................25
Setting the Start Position for a Wirepath ..............................26
3. Wire Machine and Control Definitions .....................27

 Wire Machine Definitions ...................................................28
Using Machine Definitions in Mastercam ...........................28
Machine Definition Manager ...............................................28
 Wire Control Definitions .....................................................34
Control Definition Manager .................................................34
vi • MASTERCAM X4 / Wire Getting Started Guide
 Wire Machine Group Properties ........................................46

Files Tab ................................................................................47
Program Settings Tab............................................................49
Stock Setup Tab ....................................................................49
Piece Setup tab (Agievision only)..........................................50
Piece Details tab (Agievision only)........................................53
4. Wirepaths ...............................................................................55
 Wirepath Types ...................................................................56
Contour Wirepaths ...............................................................56
Canned Wirepaths ................................................................69
No Core Wirepaths................................................................71
4-axis Wirepaths....................................................................75
Point Wirepaths ....................................................................86
Transform Wirepaths............................................................86
 Setting Wirepath Parameters.............................................89
Power Settings Libraries .......................................................89
Wire Compensation ..............................................................99
Lead ins and outs ................................................................102
Cuts .....................................................................................104
Thread Positions .................................................................107
 Wirepath Dialog Boxes .....................................................108
Wirepath Dialog Box Layout ...............................................108
Wirepath Dialog Box Descriptions .....................................110
Wirepath Dialog Box Pages.................................................112
• vii
 Agievision Wirepaths........................................................146
Machining page ..................................................................148
Group page .........................................................................150
Cut Parameters page...........................................................151
Collar page ..........................................................................152
Rough page .........................................................................153
Finish page..........................................................................154
Start Point page...................................................................156
Entry page ...........................................................................157
Exit page..............................................................................158
Threading page ...................................................................159
Taper page ..........................................................................160
Corners page .......................................................................161
Attributes page....................................................................162
Technology Database dialog box........................................164
 Backplotting Wirepaths ....................................................165
Backplot Display Options ...................................................165
Backplot Symbols ...............................................................166
5. Editing Wirepaths .............................................................167

 Editing Wirepath Methods ...............................................168 16
 Wirepath Editing Dialog Boxes ........................................169
Edit Wirepath Dialog Box ...................................................169
Edit Point Dialog Box ..........................................................170
Control Settings Dialog Box................................................171
Control Flags Dialog Box ....................................................172
Change At Point Dialog Box................................................173
 Editing Wirepaths Guidelines ...........................................175
Edit Wirepath Dialog Box Guidelines .................................175
Change At Point Dialog Box Guidelines .............................176
viii • MASTERCAM X4 / Wire Getting Started Guide
 Edit Wirepath Dialog Box Procedures .............................178

Adding a Point to a Wirepath ..............................................178
Deleting a Point from a Wirepath .......................................178
Moving a Point in a Wirepath .............................................179
Deleting a Pass from a Wirepath.........................................179
Deleting a Section from a Wirepath....................................180
Changing Control Flags with Edit Point Dialog Box...........180
Changing Control Settings with Edit Point Dialog Box ......181
Editing Points Using the Edit Point Dialog Box (Wire).......182
 Change At Point Dialog Box Procedures .........................184
Assigning Canned Text with Change At Point ....................184
Changing Control Flags with Change At Point ...................185
Changing Control Settings with Change At Point ..............186
Making Associative Changes with Change At Point ...........188
Index ........................................................................................189
chapter 1
Introduction to
Mastercam X4 Wire
Welcome to Mastercam X4 Wire. Mastercam Wire creates toolpaths for
wire EDM machines, offering advanced tapering in both 2-axis and 4-
axis wirepaths, automatic corner filleting and skim cut definition,
advanced synchronization, and efficient tab creation and management.
Mastercam Wire provides graphic land programming, supports
multiple tabs with click-and-drag positioning, and lets you translate
wirepaths for repetition without creating new geometry.
This guide covers the features of Mastercam that are specific to wire
EDM programming.
 Chapter 1: Introduction to Mastercam X4 Wire describes
how to start Mastercam and provides a road map of the
documentation, online help, and support services
Mastercam provides. . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1
 Chapter 2: Wirepath Geometry discusses the geometry
requirements for wirepaths, start, thread, and cut points,
and wirepath chaining. . . . . . . . . . . . . . . . . . . . . . . . . page 11
 Chapter 3: Wire machine and control definitions shows
components used in wire machine definitions, covers wire-
specific pages in the control definition, and provides an
overview of machine group properties.. . . . . . . . . . page 27
 Chapter 4: Wirepaths provides an overview of each wire
machining operation, parameter settings, and
dialog boxes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 55
 Chapter 5: Editing Wirepaths describes how to edit existing
wirepaths through editing the operation parameters or
using point-based editing with either the Change at Point
dialog box or the Edit Wirepath dialog box. . . . . . page 167
2 • MASTERCAM X4 / Wire Getting Started Guide
Starting Mastercam Wire

This guide assumes that you have successfully installed Mastercam
X4, have completed the necessary post-installation procedures, and
are ready to begin using Mastercam X4 to design and machine parts.
 For information on installing Mastercam X4, see the
Mastercam X4 Installation Guide included with your soft-
ware, or contact your local Mastercam Reseller.
 If you have upgraded from a previous Mastercam X version,
see the Mastercam X4 Transition Guide for important infor-
mation on converting Mastercam X4 files, libraries, and post
processors.
 To start Mastercam Wire

1 Double–click the Mastercam X4 icon on your Windows®
Desktop:
Or select Mastercam X4 from the Windows Program menu.

By default, Mastercam X4 starts up in the Design application.
2 To open Mastercam Wire, choose a wire machine definition
from the Machine Type menu.
Once you have selected a wire machine definition,

Mastercam creates a machine group in the Toolpath
Manager. This machine group will hold your wirepaths.
Selecting a machine definition also makes wirepaths avail-
able in the Toolpaths menu.
INTRODUCTION TO MASTERCAM X4 WIRE / Starting Mastercam Wire • 3
 To switch between Mastercam products

Mastercam lets you create toolpaths on the same part from any
product that you have licensed on your HASP. 1
1 From the Machine Type menu, choose a Mill, Lathe, or
Router machine definition. Mastercam creates a new
machine group in the Toolpath Manager.
2 Drag the red arrow between machine groups to change prod-
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ucts.
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In the picture above, dragging the arrow from the Generic
Mill machine group to the Generic Wire EDM machine group
will switch Mastercam from Mill to Wire. The Toolpaths
menu shows the toolpaths available in the current
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Mastercam product.
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Getting Help
Mastercam includes several sources of documentation and support to
help you put it to use quickly and effectively. Because Mastercam is so
widely used in manufacturing, additional resources are available
through your Reseller and on the Internet. The following sections give
you a tour through some of the Mastercam documentation, training,
and technical support resources.
Using Online Help

Each dialog box in Mastercam provides instant access to online help.
Click the button on the dialog box to open a help screen about it.
INTRODUCTION TO MASTERCAM X4 WIRE / Getting Help • 5
The How do I get here link expands into text that provides naviga-
tional information.
1
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13
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The About this dialog box topics provide information about how and
why the dialog boxes are used. Click the Field definitions tab to view
field definitions. The Field definitions tab provides pop-up descrip-
tions of dialog box controls. 15
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Every topic provides an e-mail link you can use to contact CNC Soft-
ware Technical Documentation to send feedback regarding the Help. 18
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Mastercam X4 Documentation
The \Documentation folder in your Mastercam installation includes a
suite of documentation tools, training videos, and other resources you
can use to make the most of your Mastercam experience. These
publications and movies are designed to get you up and running quickly,
and to provide ongoing education and support as you work with basic
and advanced features.
In addition to the Mastercam X4 Wire Getting Started Guide you are
currently reading, here are just some of the materials you will find your
Mastercam X \Documentation folder.
 What’s New in Mastercam X4 (printed document and PDF):
Outlines the new features in each product level of Mastercam X4.
Also includes short tutorials to let you try out some of the new
functionality
 Mastercam X4 Quick Start (printed document and PDF):
Designed to get you up and running—quickly, effectively, and
efficiently. Use the Quick Start to get a basic orientation to the
interface and functions, to customize and configure Mastercam
X4 for optimum efficiency, and to understand the fundamentals
of using Mastercam X4 to design and cut parts.
 Mastercam X4 Installation Guide (printed document and PDF):
Provides instructions for installing Mastercam X.
 Mastercam X4 Quick Reference card (printed document and
PDF): Provides a graphical summary of Mastercam X key
features and functions.
 Mastercam X4 Transition Guide (PDF): Assists Mastercam
Version 9 users with the process of migrating their settings,
libraries, and parts to Mastercam X, and provides guidelines for
Mastercam X users who are updating to Mastercam X4. Includes
PDF checklists to use as migration worksheets.
 Mastercam Version 9 to X Function Map (PDF): Maps all
functions available in Mastercam Version 9 to a Mastercam X
equivalent.
 Mastercam X4 Reference Guide (PDF): Supplements the Help
and other Mastercam product documentation. Includes
comprehensive conceptual information, detailed overviews,
examples, definition of terms, and workflow-related information
on using Mastercam X and its functions. To open, choose Help,
Reference Guide.
Notes:
• You must install Adobe® Reader® (version 6.0 or higher) before
you can view or print PDF documentation.
• All PDF documents are available from the Mastercam X
\Documentation directory.
 To view a PDF document:

1 Use Windows Explorer to navigate to your Mastercam
\Documentation folder, and then double–click a PDF file in the
file list. This automatically opens the Adobe Acrobat Reader to
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display the document.
2 To navigate through the document, use the bookmark list in the
leftmost pane of the Reader window, or use the Search functions.
3 To view information, scroll through the pages using the mouse
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wheel or the scroll bar on the right side of the Reader window.
TIP: For quick access to the Mastercam X4 Reference Guide,

choose Help, Reference Guide from the Mastercam menu. 13
You can view PDF documents in different page layouts. This affects how
some Reader functions work, and also affects links in the PDF document.
To change the layout, choose View, Page Layout and one of the following
options:
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Single Page—Displays all the text on a page of the PDF document (with
the exception of graphics or text that is part of a graphic).
Continuous—Arranges the pages in a continuous vertical column.
Facing—Arranges pages side by side in a one or two page layout.
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Continuous-Facing—Arranges the pages side by side, with the first page
displayed on the right.
PDF Guidelines 16
 Embedded links in the document are indicated when the
hand icon changes to a pointer as you move the cursor
over text that contains a link.
 You can expand and collapse the Bookmark list. To
expand a bookmark (show subtopics), click on its plus symbol
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(+). To collapse it (hide subtopics), click the minus symbol (–).
 If the Reader toolbar does not appear, press the [F8] key to
display it.
 To search for a word or phrase, click the binocular icon
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to begin a search.
Note: For more information on working with PDFs, refer to the

Reader Help. 19
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Additional Training
Additional Mastercam training is available from a variety of sources,
including your Mastercam Reseller and CNC Software, Inc. Two
options are listed below:
 Mastercam University: CNC Software sponsors Mastercam
University, an affordable online learning platform that gives
you 24/7 access to Mastercam training materials. Take
advantage of more than 180 videos to master your skills at
your own pace and help prepare yourself for Mastercam
Certification. For more information on Mastercam Univer-
sity, please contact your Authorized Mastercam Reseller, visit
www.mastercam.com, or email training@mastercam.com.
 Getting Started Tutorial Series: The Getting Started Tutorial
Series is a set of books and videos designed to introduce new
users to Mastercam. The tutorials are best used in sequence,
but they can also be used independently. For more informa-
tion, please contact your Authorized Mastercam Reseller.

Mastercam Support and Services

Use the following websites to find information on Mastercam: 1
www.emastercam.com Mastercam global user forum
www.mastercam.com
www.mastercamedu.com
CNC Software, Inc. corporate website
CNC Software, Inc. Educational Divi-

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sion website
For assistance with installing Mastercam, its SIM HASP or NetHASP,

or to obtain more information on using Mastercam, contact your
local Mastercam Reseller. If your Reseller is unavailable, you can call
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CNC Technical Support Services Monday through Friday, 8:00 a.m.–
5:30 p.m., USA Eastern Standard Time.
When calling CNC Software for technical support, please follow these
guidelines:
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 Be sure you have already tried to contact your Mastercam
Reseller.
 Provide the serial number of your SIM HASP or NetHASP. 15
 Be ready to describe the problem in detail. Write down what
happened, particularly if you cannot call immediately after
the problem occurs.
 Be in front of your computer when you call. 16
 If possible, try to duplicate the problem before calling. Our
Support Services technician may require you to duplicate the
problem while you are on the phone.
 When you call, have ready a complete description of your 17
hardware, including your operating system (OS), central
processing unit (CPU), graphics card and settings, and
memory.
You can also leave a message for CNC Support Services twenty-four
hours a day, seven days a week via our email or website addresses.
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When sending email, please include:
 The serial number of your SIM HASP or NetHASP
 Telephone number and contact information where you can 19
be reached
 Files required to reproduce an issue, such as .MCX and post
files
110
TIP: Use Mastercam’s Zip2Go utility to gather Mastercam part

data into a compressed .Z2G file. This utility makes it easy to
provide your Reseller or CNC Support Services with a file
attachment that contains the information they need. Zip2Go
scans the machine groups in your current part file and captures
information such as your Mastercam configuration, machine
definition, and post files. For more information on using
Zip2Go, please refer to the Mastercam Help.
Important Contact Information
Address CNC Software, Inc.

671 Old Post Road
Tolland, Connecticut, 06084-9970
USA
Phone (860) 875-5006
Fax (860) 872-1565
FTP Address ftp://ftp.mastercam.com
Internet Address http://www.mastercam.com
email support@mastercam.com
chapter 2
Wire Part Geometry
This chapter covers geometry used for wirepaths. It includes the
following discussions:
 Basic Requirements for Wire Geometry . . . . . . . . . . page 12
 Creating Thread Points . . . . . . . . . . . . . . . . . . . . . . . . page 16
 Creating Cut Points . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18
 Breaking Geometry Perpendicular to a Thread Point
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21
 Chaining Wire Geometry . . . . . . . . . . . . . . . . . . . . . . . page 24
For more information on creating geometry, see the Mastercam X4
Quick Start Guide, and the Mastercam X4 Reference Guide provided in
the \Documentation folder of your Mastercam installation.
Basic Requirements for Wire Geometry

Geometry for Mastercam wirepaths has a few requirements that are
simple to satisfy. Most wirepath geometry is created and machined in
the Top plane with WCS also set at Top. The following sections
describe the contours and points that Mastercam needs for wire-
paths.
Contours
Mastercam Wire creates operations using lines, points, arcs, or splines
as its source geometry. This geometry needs to be flat (planar) and lie
in the construction plane. The following picture shows geometry for a
contour wirepath.
If your part is a surface model, you may need to create lines, arcs, or
splines that form a planar contour. Mastercam does not let you chain
surface edges for wirepath geometry. Use Mastercam’s Create, Curve
functions to create the geometry for a wirepath.
WIRE PART GEOMETRY / Basic Requirements for Wire Geometry • 13
The Contour wirepath can act on both closed and open contours.
Open contours can be used for cut off operations like the one shown
in the following picture. 2
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All Mastercam wirepaths require geometry in the XY plane. The XY
plane must be equal to the construction plane when you initiate a
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wirepath. You do not need to create a contour in the upper or UV
plane for contour or no core wirepaths. Mastercam will create the UV
contour automatically. Only the 4-axis wirepath requires geometry in
two planes. The picture below shows the geometry in the XY plane, 26
and the UV contour for a contour wirepath.
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Mastercam creates the
Geometry lies in the XY plane UV contour for the wirepath
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Points
Each contour to be cut requires a thread point. Create thread points
by following one of the following methods:
 Choose Create, Point, Thread Point.
 Choose the Thread point style in the Attributes section of the
Status Bar and then choose Create, Point, Position.
 Use the Lead Distance (overrides thread/cut point) check
box and Lead distance field on the Lead Distance page of
any wirepath dialog box.
See Creating Thread Points on page 16 to learn more.
Cut points need to be created if you want the wire to be cut in a
different position than the thread position. Create the cut points in
the positions where you want the wire cut before moving to another
contour in the operation by following one of the following methods:
 Choose Create, Point, Cut Point.
 Choose the Cut point style in the Attributes section of the
Status Bar and then choose Create, Point, Position.
 Use the Lead Distance (overrides thread/cut point) check
box and Lead distance field on the Lead Distance page of
any wirepath dialog box.
See Creating Cut Points on page 18 to learn more.
4-axis Wirepath Geometry

4-axis wirepaths require two contours instead of one. The lower XY
contour must be planar and lie in the construction plane. An upper
UV contour must also be chained for a 4-axis wirepath. The UV
contour can be different from the XY contour, and lie in a plane that is
not parallel to the XY plane.
Mastercam uses chain synchronization to coordinate the wirepath
between the two chains. Several methods of chain synchronization
are available so that you can get the best results for your geometry
and toolpath.
WIRE PART GEOMETRY / Basic Requirements for Wire Geometry • 15
The following picture shows 4-axis geometry with branch lines for
chain synchronization.
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UV contour
XY contour
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Examples of branch lines
used for synchronization 24
You can select the chain synchronization method in the Chaining
Options dialog box, or in the 4 Axis page of the Wirepath 4 Axis
dialog box.
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Creating Thread Points

Each chain in a wire operation requires a thread point. Mastercam
provides a special attribute that describes a point as a thread point.
Using the Create, Point, Thread Point function, you can place a
thread point in position for each chain in a wire operation. The
following picture shows a thread point entity:
TIP: You can let Mastercam create thread positions by using

the Lead Distance (overrides thread/cut point) check box and
Lead distance field on the Lead Distance page of any wirepath
dialog box.
You will need to create a thread point for each contour in the wire
operation. If you do not create a thread point, Mastercam will show
the following message when you generate a wirepath:
WIRE PART GEOMETRY / Creating Thread Points • 17
Since 0,0 may not be a desirable location for threading the EDM
machine, use the following procedure to create a thread point for your
geometry. 2
 To create a thread point
1 Click the point style menu next to Attributes in the Status
bar.
2 Select the thread point style.
2
3 Choose Create, Point, Position.
4 Click the position for the thread point in the graphics

window, or enter coordinates in the AutoCursor ribbon bar.
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5 Click OK.
Note: You can use any point creation method that you wish. This
procedure is only one way of creating a point. It may be easier to
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choose Create, Point, Thread Point and position the point.
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Creating Cut Points

Setting a cut point is optional for wire operations. When you do not
set a cut point, Mastercam sets the cut point at the same position as
the thread point. If you want the cut point in a different position, use
the following procedure to create a cut point.
 To create a cut point

1 Click the point style menu next to Attributes in the Status bar.
2 Select the cut point style.
3 Choose Create, Point, Position.
4 Click the position for the cut point in the graphics window, or
enter coordinates in the AutoCursor ribbon bar.
5 Click OK.
Note: You can use any point creation method that you wish. This
procedure is only one way of creating a point. It may be easier to
choose Create, Point, Cut Point and position the point.
TIP: You can also select the Auto position cut point check box
on the Leads page of any wirepath dialog box to have
Mastercam Wire automatically set a cut point to the thread
point for each contour.
WIRE PART GEOMETRY / Creating Cut Points • 19
Creating Thread and Cut Points with

Toolbar Buttons 2
Mastercam Wire allows you to add thread and cut point toolbar
buttons to your Mastercam working area.
 To add the thread and cut point toolbar buttons to the

Mastercam working area
2
1 Choose Settings, Customize.
2 Under Category, select Geometry.

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3 Click and drag on the Create Thread Point button and
release it in the desired position outside of the graphics
window.
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4 Click and drag on the Create Cut Point button and release it
in the desired position outside of the graphics window.
5 Choose OK to close the Customize dialog box and save the
toolbar button to their new positions.
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 To automatically create thread or cut points

Use this procedure for either thread or cut points.
1 Click the Create Thread Point or Create Cut Point button.

The Point ribbon bar appears.
2 Move the cursor into the working area and click to position a
thread or cut point. You can also enter position coordinates
into the AutoCursor ribbon bar.
3 Press [Esc] when done.
WIRE PART GEOMETRY / Breaking Geometry Perpendicular to a Thread Point • 21
Breaking Geometry Perpendicular

to a Thread Point 2
Many wire EDM machines require the lead into the part geometry to
be perpendicular to the wirepath. Mastercam Wire starts a wirepath
2
only at an entity endpoint. To satisfy both of the requirements, the
thread position needs to be perpendicular to an entity endpoint. One
way to accomplish this is to break the entity that is closest to the
thread point.
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Mastercam provides a chaining option, Break closest entity to
thread point. When you activate this chaining option and chain
geometry for a wirepath, Mastercam automatically breaks the entity
that is closest to the thread point, at a point perpendicular to the
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thread point.
 To automatically break an entity perpendicular to the thread

point
Before you begin, you will need to have created a thread point
25
entity for the contour. See Creating Thread Points on page 16 for
instructions.
1 Choose an operation from the Toolpaths menu such as
Contour.
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2 Click the Options button on the chaining dialog box.
3 Select the Break closest entity to thread point check box,

and choose OK.
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4 Chain both the geometry and the thread point that you want
to use. Most often, this is done by using the Window chain
method in the Chaining dialog box.
5 Click to enter a search point.
6 Choose OK to exit the Chaining dialog box and open the

Wirepath dialog box.
7 Set all appropriate parameters for the wirepath in the dialog
box pages and choose OK to generate the wirepath. Note that
the wirepath lead in was created perpendicular to the
contour.
If you require more control when breaking entities or placing the
thread point, use the following procedure to manually break an entity,
and then place the thread point perpendicular to the entity end point.
Note: If Mastercam Wire displays the message “cannot break line

or arc past its endpoints,” the entity you are trying to break cannot
be broken perpendicular to the thread point position without
extending the entity. Choose a different entity or move the thread
point position.
WIRE PART GEOMETRY / Breaking Geometry Perpendicular to a Thread Point • 23
 To break an entity and create a perpendicular thread point
TIP: Right-click in the graphics window and choose Auto-

Cursor to open the AutoCursor Settings dialog box. Be sure
2
that Endpoint is selected so that the AutoCursor will present
you with a visual cue as you work.
1 In the Status Bar, Attributes section, set the point style to

2
thread point (as shown below).
23
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2 Choose Edit, Trim/Break, Trim/Break/Extend.
3 On the Trim/Extend/Break ribbon bar, select these two

25
options:
 Trim to Point
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 Break
4 Select the entity to break.
5 Select the midpoint of the entity to break it in half.

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6 Choose OK.
7 Choose Create, Point, Dynamic.
8 Select one of the segments of the entity that was broken in

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step 4.
9 Press [S] for Offset, enter a distance, and press [Enter].
10 Using the dynamic arrow, position the cursor on the side of

the entity where you want the thread point, as close to the
29
entity endpoint as possible so that the AutoCursor highlights
the endpoint. Otherwise, the point will not be perpendicular
to the endpoint.
11 Click to set the position.
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12 Choose OK.
Chaining Wire Geometry

Chaining is the selection method for gathering the part geometry for
machining. Chaining sets the order and direction of the contours that
make up the part. Mastercam uses the order to output the contours,
and the direction to set wire compensation and to position entry and
exit moves and tabs.
Use the techniques in this section to select the wire geometry for an
operation.
Window Chaining
The window chaining method is an efficient method for selecting
thread points, geometry, and cut points for a wire operation. In
window chaining, Mastercam automatically sets the cut order of the
contours.
 To window chain thread points and geometry

1 Choose the Toolpaths menu, and then choose a wire opera-
tion such as Contour.
2 Choose Window in the Chaining dialog box.
3 In the graphics window, click and drag a rectangle around all

the geometry to be included in the operations. Make certain
that the thread points are included in the rectangle.
WIRE PART GEOMETRY / Chaining Wire Geometry • 25
Click and drag a rectangle around the part...

2
2
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...and click to set the second corner
4 Click to set the window. 25

5 Choose OK in the Chaining dialog box to continue creating
the wirepath.
Note: Mastercam automatically puts the contours in a cut order. 26

To change the cut order in a completed operation, click the Geom-
etry icon to open the Chain Manager, and then right-click and
choose Sort options from the menu.
27
Chaining Individual Contours and Points
Because window chaining automatically sets the sort order of
contours for the wire operation, you may have situations where you
28
prefer to chain the thread points, contours, and cut points individu-
ally. Mastercam requires that the geometry be chained in the
following order:
1. Thread
29
2. Chain (or for 4-axis wirepaths, XY chain, then UV chain)
3. Cut
Any of the chaining methods can accomplish the task. See Chaining
210
Wireframe Geometry in the Mastercam X4 Reference Guide to learn
more about chaining.
Setting the Start Position for a Wirepath

Mastercam automatically uses the thread position as the start posi-
tion for an operation. To set the start position to a different point from
the thread position, you must deselect the Set start position to
thread point check box on the Leads page of the wirepath dialog box.
If you uncheck Set start position to thread point, you can use the
Start Position page to set the coordinates for the start position.
Use the Lead Distance (overrides thread/cut point) check box and
the Lead distance field on the Lead Distance page to override the
thread and cut points. Mastercam Wire uses the same lead distance
for each contour in the operation. When lead distance is 0,
Mastercam Wire uses the thread point that you have set.
Lead distance can be used for operations where each thread point is
the same distance from each contour. For example, each thread point
corresponds to a pre-drilled hole in the stock and each is the same
distance from each contour. In this case, using a lead distance can
eliminate the need to create a point entity to serve as the thread point
for each contour.
chapter 3
Wire Machine and
Control Definitions
Mastercam X organizes operations on a part differently from
previous versions of Mastercam. The machine definition
functionality lets you create operations for different machine
tools, all on the same part and saved in the same file.
This chapter looks at wire machine and control definitions, and
discusses the new options for creating these definitions in
Mastercam X Wire.
 Wire Machine Definitions . . . . . . . . . . . . . . . . . . . . . . page 28
 Wire Control Definitions . . . . . . . . . . . . . . . . . . . . . . . page 34
 Wire Machine Group Properties . . . . . . . . . . . . . . . . . page 46
Notes:
• Refer to the Mastercam X4 Reference Guide for more information
on using the Machine Definition Manager, the Control
Definition Manager, and the Toolpath Manager. To access this
document, choose Help, Reference Guide from the Mastercam
menu. The document is also located in the \Documentation
folder of your Mastercam installation.
• Each dialog box also provides help. Open the dialog box
help by clicking the Help button in the dialog box.
Wire Machine Definitions

A Mastercam machine definition is a description of an actual
machine tool that you will use to cut a part. The physical aspects of
the machine, such as axes, feed rates, and flushing, are represented in
the machine definition. The machine definition, along with the
control definition, determine which toolpaths and parameters you
can use when programming parts for a particular machine.
Using Machine Definitions in Mastercam

Mastercam stores the machine definition in a file in the
cnc_machines folder in your local Mastercam install directory. In
Wire, the machine definition file has a .wmd extension.
When you select a machine definition from the Machine Type menu,
Mastercam loads a copy of the machine definition into a machine
group in the Toolpath Manager. This local copy is stored within the
part so that you can move the part to another Mastercam station
without bringing along the separate machine and control definition
files.
IMPORTANT: The post processor does not become part of

the machine definition, and therefore is not stored or trans-
ferred with the part file.
Machine Definition Manager

In Mastercam Wire, the machine definition, control definition, and
post processor together represent a wire EDM machine. These
elements are assembled in the Machine Definition Manager.
The quickest way to become familiar with a wire machine definition is
to select the default wire machine definition so that Mastercam loads
the machine into a machine group in the Toolpath Manager, and then
open the Machine Definition Manager.
Use the following procedure to open the local copy of the machine
definition. When you open the local copy of the machine definition,
any changes you make are saved with the part file, and the master
copy of the machine definition remains unchanged.
WIRE MACHINE AND CONTROL DEFINITIONS / Wire Machine Definitions • 29
 To select a machine definition and open the Machine Definition

Manager
1 Choose Machine Type, Wire, Default. Mastercam creates a
machine group in the Toolpath Manager.
3
2 Expand the Properties icon in the Toolpath Manager.
3 Choose the Files icon.

32
3
34
4 Choose the Edit button on the Files tab to open the Machine
Definition Manager.
35
36
You will see the machine definition in the Machine Configu-
ration tree.
37
38
39
310
Note: The machine definition may be in metric or inch units,

depending on the units you chose when initially installing
Mastercam. If you open the Machine Definition Manager and
load a machine created in the unit system you are not currently
running in, Mastercam will ask you to verify the change in units.
When you exit the Machine Definition Manager, Mastercam will
change back to your original units.
Wire Machine Component Groups

Wire machine definitions consist of three component groups, as
shown in the following Machine Configuration pane graphic below.
The Wire Table group represents the part holding components. The
Upper Wire Guide group supports the U and V axes and represents
the UV plane. The Lower Wire Guide group supports the X and Y axes
and represents the XY plane.
Note: When programming a non-wire EDM machine using

Mastercam Wire, such as a water jet machine, you can make a
machine definition that includes only one set of axes.
Wire Machine Components

Wire machine components are stored in a component library file
called ALL WIRE COMPONENTS.GMD or ALL WIRE COMPONENTS
3
MM.GMD. Component files can be accessed through the Component
File open button in the Machine Definition Manager.
When creating a new machine definition, select one of the wire
component libraries in the Machine Definition Manager to pick only
32
wire components to add to the machine definition. To add compo-
nents to the machine definition, drag and drop them from the
components pane into the Machine Configuration pane.
3
34
35
36
The following components will need to be part of your wire machine
definition. You can edit the properties of each component by double-
37
clicking the component to open its properties dialog box.
 Linear axes You need to enter the positive axis direction and
feed rate limits for the XY and UV axes. The maximum feed
rate limit is used as the rapid feed rate when calculating wire-
38
path times in backplot and the graphical setup sheet. All feed
rate limits for each axis are available to the post. See the
Mastercam X Post Parameter Reference in the \Documenta-
tion folder for more information.
Feed rate limits can be set in units/minute or inverse (time
39
per move). You make this selection in the Feed page of the
control definition. (The units/revolution settings apply only
to Lathe machines.)
When entering feed rates, enter both inch and metric values.
310
The units do not update each other.
To limit feed rates for wirepaths, use the Op. feed rates
limits, axis motion tab of the General Machine Parameters
dialog box.
To access that dialog box, choose the Edit general machine

parameters button from the toolbar in the Machine Defini-
tion Manager.
 Wire guides The machine definition requires that a wire

guide component be the last component at the end of the
component group. No additional information needs to be
entered for the wire guides.
Selecting a Control Definition and Post Processor

The control definition provides the post processor with the informa-
tion it needs to process toolpath data so that it meets the control's
3
requirements. It is assigned to the machine definition. To change the
control definition used with a machine definition, open the machine
definition through the Settings menu (Settings, Machine Definition
Manager). This method allows you to change the master copy of the 32
machine definition which is the only place where you can change the
control definition used with a machine definition.
Since a single control definition can support more than one post, a
drop-down list (highlighted in the graphic below) shows the posts 3
that are available for the selected control definition. You can change
the post processor by selecting it from the list of available posts in the
Machine Definition Manager.
Note: The drop-down list contains posts only if they have been
34
previously loaded through the folder button.
35
36
Setting a Default Machine Definition
Mastercam lets you select a default machine definition in Settings,
37
Configuration, Default Machines. The default machine definition is
used in these situations:
 Choose the Machine Type, Wire, Default to use the default
Wire machine definition.
38
 Open a part file from a previous version of Mastercam. When
Mastercam opens the file, it uses the default machine defini-
tion when it creates a machine group for the operations in
the file.
39
Note: The Machine Definition Manager can only open the
machine types associated with the Mastercam products you have
purchased and that are enabled on your SIM. For purchasing 310
information, contact your local Mastercam Reseller.
Wire Control Definitions

The control definition provides the post processor with the informa-
tion it needs to process wirepath data. In addition to centralizing
machine tool control parameters and settings, the control definition
provides an easy-to-use interface for changing and saving toolpath
defaults.
IMPORTANT: The post processor must be set up to read the

settings that are available to it in the control definition to see
any change in the NC code. For information on post processor
customization, contact your Mastercam Reseller.
TIP: The UpdatePost utility can be used to create a control

definition from your existing post processor. UpdatePost reads
the information it needs for the control definition and saves
you from entering the control definition information by hand.
To learn more, see the Mastercam X4 Transition Guide (avail-
able in the \Documentation folder of your Mastercam installa-
tion), or see the Mastercam online help.
Control Definition Manager

Use one of these methods for opening the Control Definition
Manager:
 Choose Settings, Control Definition Manager. This opens
the master copy of the control definition (.CONTROL file).
 Choose the Files icon from the machine group properties in
the Toolpath Manager. Choose the Edit button to open the
Machine Definition Manager. Choose the Edit the control
definition button on the Machine Definition Manager
toolbar to open the local copy of the of the control definition
that is stored with the part.
WIRE MACHINE AND CONTROL DEFINITIONS / Wire Control Definitions • 35
In addition to common pages in the Control Definition Manager

(Settings, Control Definition Manager), Mastercam Wire uses the
following pages to set wire-specific options. 3
 Files (page 35)  Linear (page 37)
 Feed (page 38)  Start/Leads (page 38)
 Cuts (page 39)s  Corner (page 40) 32

 Reverse Cuts Contour  Reverse Cuts Auxiliary
(page 41) (page 42)
 4 Axis Paths (page 43)  Nocore (page 44) 3

 Subprograms  Text (page 45)
(page 44)
Note: For detailed information on the Mastercam common

34
Control Definition Manager pages, please refer to the Mastercam
Reference Guide (Help, Reference Guide).
35
Files
Use this page to set your default files such as the power settings
library (.POWER file). Mastercam reads this library into the machine
group properties and into a wire operation.
36
37
38
39
310
If you used a previous version of Mastercam, you may have attached

C-Hooks as auxiliary registers and/or miscellaneous/reals integers.
Use the Files page of the Control Definition to make these mappings
for Mastercam. For users of the Agievision controls, you will need to
set data paths for the following C-Hooks:
 Chook from Misc. values button: Set Selected item’s file
name to agie.dll.
 Chook from Aux. register button: Set Selected item’s file
name to Agiereg.dll.
Both of the AgieVision C-Hooks are located in the \chooks folder of
your Mastercam installation.
Use other option groups in the Files page to configure the posting
process. Tell Mastercam how to log errors and other messages, set
Post Processing dialog box defaults, and handle NC parameters.
Wire Control Model

Use this page to select a Wire Machine Model and subsequent Control
Version.
The Machine model field lets you select the desired Wire machine.
The Control version field lets you select the appropriate control
version.
Note: The Control version field is only available when the

machine model is set to an Agie machine model.
Linear
On the Linear page, only the Corner rounding/Exact stop options are
available. These options control how the machine approaches
3
changes in direction by slowing to an exact stop at an entity endpoint
to avoid over-shooting a corner, and how the wire rolls around sharp
corners in the operation.
While many wire EDM machines do not use these options, they are
32
available for other machine types that can be programmed with
Mastercam Wire such as water jets, lasers, and plasma cutters.
3
34
35
36
37
38
39
310
Feed
For Wire machines, you can choose to output a feed rate code in the
NC file. Mastercam will output the feed rate specified in the power
library selected for an operation. You can choose to output rapid
moves as linear moves at the maximum feed rate.
Start/Leads
Use this page to set preferences for lead in and lead out moves for
wire operations. First, select the type of threading supported by the
machine. The Leads section of the page contains options regarding
which type of lead in/out moves are supported by your control.
Mastercam uses the Lead in type and Lead out type selections to set
preferences for Wire operations that support lead in/out moves.
Cuts
Use this page to set two preferences in the wirepath dialog box. 3
32
3
34
35
The Reset pass number on tab cuts option automatically sets the tab
cut to the Starting Pass # setting on the Wire/Power page of the
wirepath dialog box.
36
37
38
Lock the UV height above the XY height tells Mastercam never to
allow the UV height set in the Taper page of the wirepath dialog box to
be equal to or lower than the XY height. If these values were to be
inadvertently reversed, Mastercam would generate an error when
39
creating the wirepath.
310
Corner
Use this page to tell Mastercam what corner types are supported by
the wire control.
The corner type selections also modify the corner choices in the
Corners page of the wirepath dialog box:
For more information on contour corner types, see Corner and Arc
Types on page 58.
Notes:
• Mastercam outputs a code for the fishtail corner type but does
not display this corner type in the backplot or verify functions.
3
• The Other corner type is a custom corner programmed in the
post processor.
Besides the corner types, this page contains selections for two post
32
questions that are used by some controls. See the online help for
more information.
Reverse Cuts Contour

3
This page sets values for the post processor when Reverse is selected
as the cutting method for a contour or 4-axis wirepath. In versions
prior to Mastercam X, these options were parameters set in the post
processor. The auxiliary register codes can be changed on the current
34
point, the current move, or the prior point.
35
36
37
38
39
310
Reverse Cuts Auxiliary

Use this page to tell Mastercam how to output the auxiliary register
codes when Reverse is selected as the cutting method for a contour or
4-axis wirepath. In older versions of Mastercam, these options were
parameters set in the post processor. The auxiliary register codes can
be changed on the current point, the current move, the prior point, or
modally. A code is modal when it stays in effect until the next code is
read.
4 Axis Paths
Use this page to tell which type of 4-axis wirepaths are supported by
the control.
3
Taper wirepaths output wire moves as linear moves, while Direct
wirepaths output wire moves as both linear and arc moves.
The maximum step size is used in a 4-axis operation when the sync 32
method is set to None. Typically some form of chain synchronization
is needed between the XY and UV chains for the wirepath to be
created properly.
3
34
35
36
37
38
39
310
Nocore
Use this page to set preferences for no core wirepaths.
When Add finish contour operation is selected in the Finish page for
a no core wirepath, Mastercam creates the finish operation after it
finishes the no core roughing operation. When this option is dese-
lected, Mastercam will create all the no core roughing passes in the
operation, and then create the finish contour afterward for each
pocket.
You can also select a lead move for a no core wirepath if such a move
is required by the control. This lead is typically required by Agie wire
machines.
Subprograms
The use of Wire subprograms is enabled using a single check box on
the Subprograms page of the Control definition dialog box. This
check box is checked (enabled) by default. Subprograms need to be
supported in the post processor. Subprograms for wirepaths can be
set as a part of each contour or 4-axis wirepath in the Subprograms
page of the wirepath dialog box.
Text
In Wire, the text page shows the system text that is used in a number
of categories. These categories are listed in the topic “tree” in the left
3
side of the window.
32
3
Most of the categories correspond to the standard headers used in the
post processor .TXT files before Mastercam X; the ones that do not are
34
new categories added in Mastercam X.
The entries on the Text pages also appear in the wirepath dialog box
pages. See the table below for the pages in which the text is used. 35
Note: You cannot change the text for the wire canned cycles pages
in this version of Mastercam Wire.
36
Control Definition Dialog box page where the text is
page used
Wire Misc. Int/Real
Wire Canned Cycles
Misc. Values page
Canned Cycle page
37
Wire Custom Canned Cycle Custom Parameters page
Parameters
Wire Canned Cycle Canned Cycle page 38
Descriptions
Canned Text Canned text dialog box
Wire Path Parameters
Auxiliary Registers
Wire/Power page
Aux. Registers page
39
310
Wire Machine Group Properties

The machine definition in the active machine group in the Toolpath
Manager determines which Mastercam product is active in the work-
space. Selecting a wire machine definition activates Mastercam Wire
and makes wirepaths available under the Toolpaths menu.
TIP: To create toolpaths for another type of machine on the

same part, select the machine from the Machine Type menu so
that Mastercam creates a new machine group. Each machine
group can have only a single machine definition.
To open Mastercam Wire, select a wire machine from the Machine

Type menu.
Mastercam loads a wire machine definition into the Toolpath

Manager.
In a Mastercam part file, the machine definition is part of the

machine group properties. The machine definition in the machine
group is actually a copy of the machine definition file. This copy is
stored within the part so that you can move the part file to another
Mastercam station without bringing along the machine and control
definition files.
WIRE MACHINE AND CONTROL DEFINITIONS / Wire Machine Group Properties • 47
Note: A copy of the post processor is not stored with the part file.
You will need to transfer the post processor if you move the part to
another Mastercam station, or select a post processor on the
3
Mastercam station that is compatible with the control definition.
The properties of a Wire machine group are slightly different than

those for Mill, Router, or Lathe machine definitions. Each of the 32
following sections describes the parameters you can set in the
Machine Group Properties dialog box tabs. These are specific to the
machine group properties of Mastercam Wire. Each dialog box tab
can be opened by clicking its icon under the Properties icon in the
Toolpath Manager.
3
34
35
Files Tab
Use the Files tab for the following tasks:
36
 Change the name of the machine group and toolpath, and
enter a group comment.
 Select a machine definition for the machine group. This
machine definition, along with its control definition and post
37
processor, will be used to generate and post the wirepaths.
 Make changes to the machine or control definition used in
the current Mastercam file. When you open the machine
definition using the Edit button, any changes you make will
38
be saved to the copy of the machine definition stored in the
part file. This rule also applies to the control definition when
you open it through a local machine definition.
 Choose the power settings library to be used for opera-
39
tions in the machine group. Mastercam will load this power
settings library into the Wire Parameters tab when you begin
making a wirepath. You can change the settings in the library
by choosing the Edit button next to the library path. 310
 Choose the default operations library and wirepath

defaults. You can also edit the operations library or wirepath
default by choosing the Edit button.
Program Settings Tab

Use the Program Settings tab to set the program number and
sequence numbers to be used when you post process the wirepaths to
3
an NC file.
32
3
34
Mastercam applies the Program # option to any operations created
after you set the program number.
To change the program number of existing operations, select an oper-
ation and right-click in the Toolpath Manager. Choose Edit selected
35
operations, Change Program #.
For sequence numbers, enter the start and increment numbers that
Mastercam assigns to each line in the NC program when you post the
operations. If you change the sequence numbers, Mastercam updates
36
the sequence numbers for any operations in the machine group.
Stock Setup Tab 37

Use this tab to set up a stock model for the wirepaths in the machine
group. You can create a stock model by entering dimensions, or by
using an STL file that contains a pre-defined stock model. Use the
Stock Setup tab for the following tasks:
38
 Set the stock view. The stock view is a plane that the stock
model is aligned to. In Mastercam Wire, the stock view is typi-
cally set to Top.
 Define the stock shape. Mastercam can create rectangular or
39
cylindrical stock. If you choose one of those shapes, continue
to set the dimensions. The other option is Solid. Using a solid
for a stock model lets you use an irregular shape for the stock
model. Make certain that the solid is open in the current file,
310
and then select the solid from the graphics window.
 Choose to display the stock model as either a wireframe or

solid.
Piece Setup tab (Agievision only)

Use the Piece Setup tab to setup stock models to help you visualize
your Agie wirepaths more realistically. The stock model that you
create here can be displayed with the part geometry when viewing the
file or wirepaths, during backplot, or while verifying wirepaths.
In this dialog box tab, you can:
 Set the stock view
 Set the stock display
 Set the stock dimensions
 Set the Stock origin
3
32
3
34
35
36
37
Setting the stock view (Agie)
Select a stock view to properly orient the stock model with respect to
your part. You can align the stock model to any named view saved in
38
your part file. When you choose a stock view, the edges of the stock
model will be parallel with the axes of the selected view.
Select a stock view when you will be creating wirepaths in a work
coordinate system (WCS) other than Top and want to align the stock
39
model to your part. If you have several wirepaths in the machine
group that use more than one WCS, Mastercam will use the stock view
to keep the stock model constant when the WCS for each operation
changes. Mastercam stores the stock view with the stock definition, 310
independent of the WCS.
To select a stock view, click the Stock View button and select the view
from the View Selection dialog box.
Note: If you change the stock view, you might need to reset the
stock origin.
Setting the stock display (Agie)

There are several ways to create stock models depending on your
needs.
 Choose Fit screen to have the stock boundary lines are
included when you use Mastercam's Fit to Screen function
when in the graphics window.
 Choose Wire frame to display the stock model as wire frame
geometry. The geometry isn’t actually added to your part file,
Mastercam simulates it based on the dimensions in this
dialog box.
 Choose Solid to display the stock as a solid model. The solid
isn’t actually added to your part file, Mastercam simulates it
based on the dimensions in this dialog box.
Setting the stock dimensions (Agie)

Mastercam gives you several techniques for setting the stock dimen-
sions. You can type the dimensions directly into the X, Y, and Z fields,
or use the following methods when you don't know the exact dimen-
sions:
 Choose the Select corners button to return to the graphic
window and select the two opposing corners of a 3D rect-
angle.
 Choose the Bounding box button to have Mastercam calcu-
late the furthest points in your part geometry.
 Choose the NCI extents button to have Mastercam calculate
the furthest points in your wirepaths, based on just the
feedrate moves.
Mastercam will automatically enter the stock dimensions in the
fields. You can then edit them as needed.
Setting the stock origin (Agie)

Use the stock origin to locate the stock relative to your part. First, you
need to choose a point on the stock to use for the stock origin. In the
dialog box, the cross shows you where the stock origin is:
The default position is the middle of the stock. Click a corner of the
part to set it as the stock origin.
Then, enter the coordinates of this point in the Distance measure
point - Piece reference X, Y, Z fields, or click the Select button to
3
choose the point from the graphics window.
Piece Details tab (Agievision only) 32

Use this tab to specify the following details:
 A name for the piece
 The material to be used for stock
3
 The wire type (material and diameter)
 The quality of the cut
 The machining strategy to be used 34
Note: Although you are not required to enter a name for the piece, we
recommend that you do. Naming each piece will help you easily store,
sort, and locate pieces for future work.
35
36
37
38
39
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chapter 4
Wirepaths
Mastercam Wire provides specialized wirepaths for EDM machining.
The following sections cover these wirepaths and their dialog boxes,
wire parameters, and backplotting information that you will need to
know.
 Wirepath Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
 Setting Wirepath Parameters . . . . . . . . . . . . . . . . . . . . . . . . 89
 Wirepath Dialog Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
 Agievision Wirepaths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
 Backplotting Wirepaths . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Wirepath Types
Contour Wirepaths
The contour wirepath is used in applications where the same general
shape is required in both the XY plane (the lower contour) and the UV
plane (the upper contour). Contour wirepaths can taper inward or
outward, and you can specify the location of the land (the point at
which the taper begins). You can further change the shape of the
contour wirepath by specifying how Mastercam handles sharp and
smooth corners. A contour wirepath can also be based on an open
boundary and used for cutting off or trimming a part.
Contour wirepaths support associative, point-based editing called

Change at point. This function makes changes on geometry
endpoints, which link the changes to the operation. See Making Asso-
ciative Changes to a Contour Wirepath (Change at point) on page 64
for more information.
Contour Taper Styles

The contour taper styles section of the Taper page allows you to
choose a taper style by selecting the radio button below the icon that
represents the type of part you are creating. Contour wirepaths can
taper inward or outward, and you can specify the location of the land
(the point at which the taper begins). You can also select how to apply
the taper to passes and specify the tilt direction of the taper (left or
right of wirepath).
WIREPATHS / Wirepath Types • 57
Notice that you must check the Taper check box (highlighted below)
to activate the wirepath taper options.
4
42
By default Mastercam Wire assigns the taper direction (right or left)
based on the chaining direction of the part geometry. In the case of
43
multiple contours, Mastercam Wire assigns the taper direction based
on the chaining direction of the first contour chained.
Contour taper tilts the wire by several degrees right or left, toward the
inside or the outside of the part depending on chaining direction.
4
TIP: To find the cutting direction of an existing wirepath, click
the operation’s geometry icon in the Toolpath Manager to open
the Chain Manager. The chaining direction arrows appear on
45
the wirepath geometry. To change the chaining direction, right-
click on a chain in the Chain Manager and choose Reverse
chain.
46
Taper can be applied to all or part of a pass. In the Taper page of the
contour dialog box, taper can be applied in the following ways:
Taper all passes — Applies the taper to all passes in the wirepath.
Cancel taper after pass — Returns the wire upright after completing
47
the specified pass.
Apply taper after pass — Applies the taper after completing the speci-
fied pass. 48
To change taper during a pass, use Change at point to assign point-
based taper changes. Two additional choices are available when
editing taper with Change at point in the Change at point dialog box
(see Making Associative Changes to a Contour Wirepath (Change at
point) on page 64 to learn more).
49
Immediate — Moves the wire to the XY coordinates of the selected
point, and then applies a new taper in two separate lines of NC code
(XY and then T). 410
Gradual — Moves the wire to the XY coordinates of the selected point
and applies a new taper in one line of NC code (XYT).
Corner and Arc Types

Corner and arc types (set on the Corners page of the Contour wire-
path dialog box) control how the wire cuts the corners in the offset
contour (the contour that creates the taper).
When Mastercam encounters a sharp corner (135 degrees or less) in
the geometry, selections made in the Corner type and radius area
define the shape of the tapered contour. When Mastercam encoun-
ters an arc in the geometry, selections made in the Arc type and
radius area define the shape of the tapered contour.
You can set different corner types for clockwise and counterclockwise
corners. Mastercam determines the arc direction by the way the wire
rounds the corner—either clockwise or counterclockwise, based on
the chaining direction—and whether the corner is inside or outside.
The following picture shows a counterclockwise (CCW) wire direction
with clockwise, inside corners.
See Corner on page 40 to make corner selections for your control. The
picture below shows the inside corners.
4
Inside corners have

42
clockwise direction
43
CCW chaining direction
4
Constant
The Constant option keeps the corner or arc in the contour the same 45
size as the corner or arc in the geometry. A constant corner or arc uses
the same radius, length, and diameter as the geometry.
UV (upper) contour
XY (lower) contour
UV (upper) contour
XY (lower) contour
46
Geometry in XY plane
Mastercam Wire creates

Geometry in XY plane
Mastercam Wire creates

47
a Constant arc type in the
a Constant corner type in the
UV contour because of the
UV contour because of the
smooth corner in the geometry
sharp corner in the geometry
48
49
410
Conical
The Conical option creates a cone-shaped move around the corner of
the part. Conical results in a move that is bigger or smaller in the
contour than in the geometry, depending on the direction in the
taper.
UV (upper) contour UV (upper) contour

XY (lower) contour XY (lower) contour
Geometry in the XY plane Geometry in the XY plane

Mastercam Wire creates Mastercam Wire creates
a conical arc in the UV contour a conical corner in the UV contour
because of the smooth corner because of the sharp corner
in the geometry in the geometry
Sharp
The Sharp option creates an angled move around the corner of the
part.

XY (lower) contour
XY (lower) contour
Geometry in the XY plane

Mastercam Wire creates Geometry in the XY plane
a sharp corner in the UV contour Mastercam Wire creates
because of the smooth corner a sharp corner in the UV contour
in the geometry because of the sharp corner
in the geometry
Fishtail
The Fishtail option causes the wire to move slightly off the part, swing
around in a loop, and then reenter the part to create very sharp 4
corners. For Fishtail to appear in the drop-down list, Fishtail corners
must be selected in the control definition.
UV (upper) contour
XY (lower) contour 42
Wire motion
Geometry in the XY plane
Fishtail corner symbol
appears in wirepath
backplot
Geometry
43
4
TIP: To avoid material dropout, the radius for a fishtail corner
should be the diameter of the wire plus overburn.
45
Note: Mastercam does not display fishtail corners when it gener-
ates the wirepath. You can view the corners that are assigned as
fishtails only when you backplot the wirepath. Mastercam places
a fishtail symbol at each corner but does not draw the fishtail wire
46
movement.
47
48
49
410
Fixed
The Fixed option applies the same radius to all corners. For Fixed to
appear in the drop-down list, Fixed corners must be selected in the
control definition.
XY (lower) contour XY (lower) contour
Geometry in the XY plane Geometry in the XY plane
Mastercam Wire creates Mastercam Wire creates

a fixed radius arc type in the a fixed radius corner type in the
UV contour because of the UV contour because of the
smooth corner in the geometry sharp corner in the geometry
Other
The Other option allows you to specify a radius for a custom corner
defined in the post processor. Mastercam draws the corner as a
straight line because it can’t anticipate what type of corner the post
processor will specify.
Guidelines for Contour Wirepaths

Use these guidelines when making selections in the Taper page for
contour wirepaths:
 Choose a taper style by selecting the radio button below the
icon that represents the type of part you are creating.
 When using a taper style, enter the Initial Taper value in

degrees, and then choose when to apply the taper from the
Pass settings drop-down list. Mastercam Wire assigns the
taper direction (right or left) based on the chaining direction
of the part geometry. In the case of multiple contours,
Mastercam Wire assigns the taper direction based on the
chaining direction of the first contour chained.
 Choose one of the Chain height selections to indicate where

the geometry was chained—at the XY or UV height or, if there
is a land, at the land height.
 Use Rapid height to set the Z height of the upper wire guide
4
for rapid moves. Rapid moves are made at the rapid height
and speed whether or not the wire is threaded.
 Use UV trim plane to locate the upper wire guide in relation
to the XY height (if incremental) or Z0 (if absolute). When not
42
using the UV trim plane, enter 0 (if incremental) or the same
value as the UV height (if absolute).
 For UV height, enter the part height, which becomes the
location of the upper contour of the wirepath.
43
 When using a taper, enter the Land height, the point at
which the wire pivots to the taper angle. Available only when
Land up or Land down is selected as the taper style in the
Taper section.
4
Land up Land down
45
 For XY height, enter the Z depth of the XY plane that forms
the lower contour of the wirepath. When using incremental
values, XY height is relative to the Z depth of the XY plane of
the chained geometry. When absolute, XY height is relative to
46
the system origin.
 Use XY trim plane to locate the lower wire guide in relation
to the XY height (if incremental) or Z0 (if absolute). When not
using the XY trim plane, enter 0 (if incremental) or the same
47
value as the XY height (if absolute).
Use these guidelines when making selections in the Corners page for
contour wirepaths:
 Corner type and radius controls the shape of corners in the
48
contour when the geometry contains sharp corners.
 Arc type and radius controls the shape of corners and arcs in
the contour when the geometry contains arcs. 49
410
Making Associative Changes to a Contour Wirepath

(Change at point)
Change at point provides the flexibility to assign taper, corner types,
and wire parameters to entity endpoints on the geometry. Change at
point is available only on contour wirepaths and is associative.
When you first create a contour wirepath, Mastercam prompts you to
select entity endpoints so that you can use the Change at point option
before generating the wirepath. After the wirepath is created, the
Change at point option is available through the Toolpath Manager:
 To use Change at point from the Toolpath Manager

1 Click the geometry icon for an existing contour wirepath.
2 Select a chain from the list in the Chain Manager.
3 Right-click the chain and choose Change at point from the

menu.
Note: Select the point by clicking on the entity next to it, not on the
point itself. Where lines meet, more than one endpoint can exist
at the same location.
Changes made with Change at point remain in effect if you change

the geometry. However, Mastercam erases the point changes if you
rechain the geometry. 4
Note: When selecting entity endpoints, the endpoints of two adja-
cent entities may lie at the same location and appear to be the
same point in the graphics window. However, when using wire
compensation to the outside of the geometry, these two endpoints
42
actually correspond to different locations on the contour because
the wirepath has a corner arc.
Guidelines for Change at Point

43
The following lists are guidelines for using the options available in the
Change At Point dialog box:
Taper
4
 Check Taper and enter a new angle.
 Gradual applies the taper angle gradually over the
length of the wirepath segment. 45
 Immediate applies the taper angle immediately.
 Restore returns taper to original programmed
settings.
 Left and Right control the direction of the tilt.
46
 Cancel after pass returns the taper angle to its original
programmed value after the pass number specified.
Corner and Arc Types

47
 Check Corner Type or Arc Type to change the shape of the
contour when encountering a sharp corner or arc in the XY
contour.
 Enter a radius for Other, Fixed, or Fishtail corner or arc types.
48
Wire Parameters
 Pass specifies the pass number to which the parameter
changes are applied.
49
 Wire Comp specifies a new setting for wire compensation in
control. Left and Right offset the wire to the left or right of the
chained entities. Cancel turns off compensation. *
 Rapid Move creates a non-cutting move at the top speed of
410
the machine. Rapid move is unavailable for arcs. *
 Dwell stops the wire for the number of seconds specified. *

 Feedrate changes the speed at which the wire cuts along the
wirepath, in inches/minute or mm/second. Restore returns
the feed rate to the original programmed speed. *
 Manual Entry enters text to be inserted before, with, or after
the selected point. *
 Canned Text triggers specific events in the post processor.
Using Canned Text through Change at point associates the
command to a selected point in the wirepath. *
 Control Settings generates a G1010 code (wire condition
change) and overrides auxiliary register settings entered in
the wire parameters tab.
 Control Flags outputs a control flag at the selected point to
set machine events such as stops, glue stops, threading the
wire, cutting the wire, or flush.
* Choose All passes to apply the parameter changes to the selected
point for all passes in the wirepath.
Creating Operations with Multiple Contours

The contour wirepath can cut multiple chains in the same operation.
One method of setting up a multiple contour operation follows. This
method requires that you set chaining options and create a point
entity for the thread/cut point for each contour.
 To set up a multiple contour operation

1 Create the contours to be cut. Both closed and open contours
can be part of the same operation.
2 Create a thread point inside or outside of each contour. When
window chaining contours (which you will do later in this
procedure), Mastercam automatically uses each point entity
for the thread position for each contour. See Creating Thread
Points on page 16 to learn more.
3 Choose Toolpaths, Contour.
4 Because the lead in should be perpendicular to the wirepath

and because Mastercam starts a wirepath only at an entity
endpoint, select Break closest entity to thread point in the
Chaining Options dialog box. When you chain the contours,
Mastercam automatically breaks the entity that is closest to
the thread point and creates a break that is perpendicular to
the thread point. This provides an entity endpoint for the
start of the contour that is perpendicular to the lead in.
5 Using the window chaining method, select the contours and

thread points in a single window.
6 Make parameter selections in each of the appropriate dialog
box pages. The parameter selections are applied to all of the
4
contours in the operation.
7 To have the point entity serve as both a cut and thread point,
use one of the following methods: 42
 Select the Auto position cut point check box in the Leads
page.
 Leave the Lead distance (overrides thread/cut point)
check box deselected in the Lead Distance page.
43
Mastercam will use the point entity as the thread position.
8 Choose OK.
9 If necessary, press [Esc] to exit Change at point and generate

the wirepath.
4
Notes:
• When Mastercam generates a multiple-contour wirepath, it
gives you the option to make point-based changes on the first
45
contour of the wirepath. To make these changes to other
contours, choose the Geometry icon for the operation in the
Toolpath Manager, and then select the contour from the Chain
Manager. Right-click and choose Change at point.
46
• To change the order in which the contours are sorted in the
operation, choose the Geometry icon for the operation in the
Toolpath Manager. When the Chain Manager opens, right-
click and choose Sort options. 47
Separating Passes from Multiple Contours into
Single Operations 48
Operations consisting of multiple contours can also be expanded.
When creating an operation that consists of multiple contours,
chaining is simplified by using window chaining to select all of the
chains in a single action. However, when using window chaining, all
49
the contours have the same wirepath parameters. By using Expand
operation on the Cut Parameters page when you first create the wire-
path, you can edit parameters such as tab width for each of the
resulting operations. 410
For example, when you have three contours with two rough cuts, two
tab cuts, and two cuts after tab, and you choose Expand operation,
Mastercam creates three operations for each contour, for a total of
nine operations: three operations contain the rough cuts for each
contour, the next three operations contain the tab cuts for each
contour, and the last three operations contain the skim cuts for each
contour.
Note: Expand operation is available only when you first create

the wirepath.
Sorting Thread Points in a Multi-Contour Operation

Mastercam allows sorting of multiple contours when using the
window chaining method. Sorting acts on the thread points rather
than the actual contours.
 To edit the sort order of the contours

1 In the Toolpath Manager, click the geometry icon for the
multi-contour operation to open the Chain Manager.
2 Right-click in the Chain Manager and choose Sort options
from the menu.
3 Choose a sorting method from the Sorting dialog box and
choose OK.
4 Choose OK to close the Chain Manager.
5 Choose Regenerate all selected operations to regenerate

the operation.
Selecting and Editing Multiple Operations

Use this procedure to work with multiple wire operations. Note that
this procedure can be used only on multiples of the same type of
wirepath, such as multiple contour wirepaths.
 To select and edit multiple operations

1 In the Toolpath Manager, right-click and choose Select to
open the Selection Options dialog box.
2 Select the Geometry option and click the arrow to return to
the graphics window.
3 In the graphics window, select the geometry for which you
want to change parameters.
4 Press [Enter] and then OK to exit the Selection Options dialog

box. The Toolpath Manager returns with the operations
selected that belong to the geometry you selected in the
graphics window.
4
5 Right-click in Toolpath Manager and choose Edit selected
operations, Edit common parameters. This command
allows you to change parameters that are common to all of
the selected operations, such as the tab width or the wire
42
library.
Canned Wirepaths 43
Mastercam Wire provides many parameters for creating a wirepath.
However, some specialized industries must set unique parameters to
get certain results. Because of this, Mastercam provides customizable
canned parameters that you can make exclusive to your particular 4
work.
A canned cycle is an area in your post processor where you can assign
special commands, cycles, or parameters to points or entities. For
example, you can use canned parameters to support custom features 45
on the wire EDM machine, such as a positioning routine that centers
the wire in a drill hole.
Defining Canned Cycles 46

The post processor customization (*.PST) file configures the format of
all canned cycles. Each post processor (PST) file may contain a
different set of canned cycle definitions. The following occurs if you
assign a canned cycle to a wirepath. 47
 The canned cycle parameter text is read from the Text page of
the control definition.
 The selected point positions are written to the NCI file along
with the values entered in the Canned Cycle and Cycle
48
Custom Parameters pages of the canned wirepath dialog
box.
 The post processor reads the NCI file and assigns the values
to variables.
49
 The variables are formatted by the post processor.
 The procedures defined within the post processor format the
NC output.
410
Custom canned cycles are defined in the post processor to control

functions specific to the control and wire EDM machine. You can set
up the custom canned cycles in the Canned Cycle page in the canned
The following appear on that page:
Cycle —Selects a cycle ranging from Cycle 1 to Cycle 20 to indicate to
the post processor which type of option to run as defined in the
Canned 1 - Canned 7 cycle text boxes.
Canned 1 - Canned 7— Determines the information that the post
processor needs to perform the canned cycle.
Z depth —Sets the depth (Z coordinate) assigned to the selected
points.
Custom canned parameters provide additional parameters for use by
the post processor to control functions specific to the wire EDM
control and machine. You can set the parameters for the custom
canned cycles in the Cycle Custom Parameters page in the canned
The following selections appear on that page:
Apply Custom parameters— Enables custom canned parameters. The
post processor determines the custom canned parameters that are
applied.
Cycle parameter #1 - #10 — Customizes canned parameters. Custom
canned parameters are values unique to your job that are not specifi-
cally provided for in Mastercam.
TIP: You can make changes to points in a canned wirepath,

such as adding, deleting, or changing the selection order of the
points. Click the Geometry icon for a canned wirepath in the
Toolpath Manager to open the Drill Point Manager.
No Core Wirepaths
The no core wirepath pockets out areas of material without producing
a slug. The wirepath typically starts at a pre-drilled hole in the mate-
4
rial, and zigzags or spirals outward until all material within the
chained geometry is removed.
42
43
4
Mastercam requires closed chains for no core wirepaths. The no core

45
wirepath can act on more than one chain at a time, and the chains
can be nested within an outer chain. In the instance of nested chains,
the inner chains represent areas on the part where material has
already been removed in a previous machining operation. Mastercam
46
looks at the inner chains (or boundaries) as areas that are already
machined.
47
Outer chain
48
Inner chain (island)
49
410
Use the NoCore page to establish the no core wirepath settings such
as the Z depth of a rapid move, the positions of the upper and lower
wire guides, the UV and XY heights, and the arc moves around
corners. You can also enable/disable wire threading, voltage, wirepath
start position, and wirepath end position options.
Use the Rough and Finish pages to establish the no core wirepath
roughing and finishing settings. The roughing pass is the portion of
the no core wirepath that removes almost all of the material. The
finish pass(es) smooth edges left by the roughing pass and also
remove additional material.
In the Rough page, you define the wire cutting method, the stepover
percentage and distance, the angle of the zigzag pattern, the direction
for spiral cutting methods. You can also set Mastercam to apply an
additional check on the wirepath when the shape of the part results in
a wirepath that contains slivers.
In the Finish page, you define the number of finish passes, finish pass
cut amounts, and wire compensation. Additionally, you can set the
start point of the finish pass, set the roughing and finishing order in
which multiple wirepaths are cut, eliminate arcs in the wirepath, and
access the Wire Contour dialog box to establish finish passes as sepa-
rate operations.
No Core Roughing and Finishing

The roughing pass is the portion of the no core wirepath that removes
most of the material. The finish pass(es) smooth edges left by the
roughing pass and also remove additional material.
No Core Roughing
The cutting method options are patterns Mastercam uses to clean out
the no core part. The Zigzag cutting method requires a roughing
angle. The spiral methods require a direction (clockwise or counter-
clockwise).
No Core Finishing
A finish pass can be used to smooth out rough edges left by the no
core roughing pass. The finish pass can also take off additional mate-
rial as specified by the finish pass spacing. Mastercam offsets the
roughing pass by the amount of material to be removed by the finish
pass. The finish pass can be combined with the no core roughing
passes in the same operation, and can also be separated into its own
operation.
Adding a Finish Contour Operation

Instead of, or in addition to, finish passes, Mastercam provides the
option of adding a separate contour operation after the no core oper- 4
ation. When you choose this option, Mastercam opens the contour
wirepath dialog box where you can specify all the parameters of a
regular contour operation, including tabs, lead ins, and lead outs.
Mastercam generates the contour operation on the same geometry
that you selected for the no core operation.
42
Note: Adding a contour operation is only available when you first
generate a no core wirepath, not on subsequent edits. 43
Guidelines for No Core Wirepaths
Use these guidelines to set up a no core wirepath (NoCore page): 4
 The part geometry and typically the bottom of the part reside
in the XY height plane.
 Enter the part height (UV height) and trim planes (used to
locate the wire guides, if required by the control). 45
 General machine settings control the initial state of Power,
Wire, Flush, and whether the tank is full.
 Select Auto entry to ensure that the no core wirepath starts at
the thread position. When Auto entry is deselected, the wire
46
starts cutting at a position calculated by Mastercam.
 Auto exit causes the wire to exit the no core wirepath at the
cut position. When cleared, the wire exits the part at a posi-
tion calculated by Mastercam. 47
Rough Parameters Guidelines (Rough Page)
 Choose a Cutting method that follows the shape of the part. 48
 Enter either a Stepover percentage or a Stepover distance
to set the distance the wire shifts over between XY moves.
 Enter a Roughing angle to change the direction of the zigzag
cutting method. 49
 Choose Clockwise or Counter clockwise to set the direction
when using a spiral cutting method.
410
Finish Parameters Guidelines (Finish Page)

 Select the Enable Finish check box to activate the finish pass
and its parameters.
 Specify the number of finish passes in the Passes field.
 Pass spacing specifies the amount of material to be removed
in a single finish pass. Mastercam offsets the roughing pass
by the amount of material to be removed by the finish pass.
 Set Compensation type to computer for the finish pass to
offset the wire as part of the wirepath. Set compensation to
control to have the control offset the wire. The both option
applies the offset to the wirepath (computer) but also allows
for additional compensation to be set in the control.
 Use the Roll around corners field to insert arc moves around
corners in the wirepath. The radius of the arc moves equals
the radius of the wire. Select None to guarantee all sharp
corners, Sharp to only roll the wire around sharp corners
(135 degrees or less), or All to roll the wire around all corners.
 Check Optimize if the cutting method and shape of the part
together create slivers in the resulting wirepath. Optimize
will eliminate the slivers but may take longer to process.
 Select the Output finish passes after all roughing all check
box when multiple no core wirepaths exist in a single opera-
tion, so that Mastercam cuts the roughing pass on each no
core first. After completing all the roughing passes,
Mastercam Wire then cuts the finish passes on each no core
wirepath.
 Check Start pass at closest entity to begin the finish pass at
the closest endpoint of the closest entity at the end of the
roughing wirepath. When cleared, the finish pass begins with
the first entity in the chain as it was originally selected.
 When you choose OK in the no core dialog box, the Add
finish contour operation option launches the contour dialog
box so that additional finish passes can be created with the
full functionality of the contour wirepath. The contour oper-
ation is generated as a separate operation in the Toolpath
Manager. The option to add a finish contour is only available
when first generating a no core wirepath and becomes
disabled for any subsequent editing.
4-axis Wirepaths
4-axis wirepaths have geometry in both the XY plane (the lower
contour) and UV plane (the upper contour). Where a contour wire-
4
path derives a second contour from geometry in a single plane, a 4-
axis wirepath can have completely different geometry in the two
planes, resulting in different wire movement in the XY and UV planes.
The picture below shows a 4-axis wirepath with different geometry in 42
the XY and UV planes.
43
4
45
46
Use the 4 Axis page to establish the 4-axis wirepath settings such as
the Z depth of a rapid move, the positions of the upper and lower wire
guides, and wire offset parameters.
47
You can also establish the synchronization of the lower (XY) and
upper (UV) contours, trimming options, and linear arc move format
(direct or taper) 4-axis tracking. 48
The 4-axis tracking option, when supported by the wire EDM
machine and the control, outputs variable Z depths for the upper wire
guide to closely track a wirepath where the upper geometry is not
49
410
parallel to the XY plane. Mastercam requires the XY plane (bottom of

the part) to be flat.
UV plane
XY plane
Isometric view Side view
UV geometry is not parallel to the XY plane.

3D tracking keeps the upper guide close to the
non-parallel geometry.
4-axis Trimming
Trimming in a 4-axis wirepath is the method that Mastercam uses to
reference Z values in the wirepath. The trimming method is set in the
Trimming section of the 4 Axis page (Wirepath 4 Axis dialog box). The
following are choices in the Trimming section:
In computer—Uses the XY and UV trim planes to reference the Z
values for the wirepath.
In control —Uses the XY and UV height planes (by default, the loca-
tions of the XY and UV geometry) to reference the Z values for the
wirepath.
3D tracking— Includes variable Z depths with UV plane. When
supported by the wire EDM machine and control, 3D tracking allows
machining of geometry that does not lie completely in a single
construction plane. With 3D tracking, the wire guides on the machine
follow the nonplanar geometry. When 3D tracking is selected,
Mastercam enables two additional planes: the XY and UV extensions.
Setting XY/UV Extensions

The XY and UV extension parameters become enabled when you
select the 3D tracking option for Trimming. 3D tracking allows the
wire guides to follow geometry that does not lie in a plane that is
parallel to the Cplane. The UV extension requires a positive incre-
mental value to lift the extension above the UV height and trim
planes. The XY extension requires a negative incremental value to
place the extension plane below the XY height and trim plane.
4-axis Wirepath Chain Synchronization

When generating a 4-axis wirepath, Mastercam uses chain synchroni-
zation to align the upper and lower contours. When synchronizing
4
the contours, Mastercam breaks each chain into a number of separate
subchains, and then matches up the chains using the Sync mode
selection in the Chaining Options dialog box, the Wirepath 4 Axis
dialog box, or the Sync Mode dialog box. 42
The Sync mode option provides several methods that Mastercam can
use to align the top contour with the bottom contour: by entity, point,
branch, node (if both contours are made up of splines), or where you
tell it (manual, manual/density). 43
Sync point created by
adding branch lines to
the geometry
4
45
46
Sync points created by
adding branch lines to
47
the geometry
48
Note: If you create a 4-axis wirepath but only the lead in/out
motion appears in the graphics window, return to the Toolpath
Manager, click the Parameters icon, and check the Sync mode
option. If sync mode is set to by Branch and there are no branch
points in the 4-axis geometry, Mastercam will not create the 4-
49
axis wirepath.
410
Guidelines for 4-axis Parameters

Use these guidelines when setting up a 4-axis wirepath:
 The Z depth of the geometry for the lower contour appears in
the XY height field. If incremental, the XY height, trim
plane, and extension are relative to the Z depth of the XY
geometry.
 The Z depth of the geometry for the upper contour appears
in the UV height field. If incremental, the UV height, trim
plane, and extension are relative to the Z depth of the UV
geometry.
 You can use the XY and UV trim plane values as the Z depth
of the wire guides.
 Enter a positive UV extension to locate the extension plane
above the UV trim plane. Enter a negative XY extension to
locate the plane below the XY trim plane.
 Set the Compensation direction to offset the wire to the right
or left of the wirepath. Auto sets the compensation direction
depending on the location of the thread point inside or
outside of a closed contour, or to the right or left of an open
contour.
 Choose a Sync option for aligning the lower and upper
contours.
 For Trimming, choose In computer to reference Z values for
the wirepath from the XY and UV trim planes. In control
references Z values from the XY and UV height planes.
 Select 3D tracking in the Trimming section to output Z
depths for the upper wire guide to track along geometry that
is in a plane that is not parallel to the XY plane. 3D tracking
enables two additional planes, the XY and UV extensions.
 For Format, choose 4 Axis taper to output wire moves as
linear moves, or Direct 4 axis (if supported by the control) to
output wire moves as both linear and arc moves.
Guidelines for creating multiple 4-axis wirepaths in

the same operation 4
 The default Chain selection method (button shown below) is
recommended for chaining multiple 4-axis wirepaths. This
provides the control you need to select each entity in the
order you require. When using this selection method, make
sure to choose the thread point before each XY/UV pair of
42
chains and the cut point after each pair of chains.
 When setting thread and cut points for multiple wirepaths,

43
you must be consistent. You can locate the thread point in
the upper contour and the cut point in the lower contour, or
you can locate the thread point in the lower contour and the
cut point in the upper contour. Either way is fine, but you
must locate all the thread points on one contour (such as the
4
upper) and all the cut points on the opposite contour (in this
case, lower) for all chains in the wirepath.
 When chaining, make sure you choose the upper and lower
contours in the order you want them placed within the oper-
45
ation. For example, choose the first entity of the upper
contour, then the corresponding first entity of the lower
contour, then the upper contour of the next pair of chains,
then the lower contour of that pair of chains (as shown in the 46
example below).
47
48
You can also select them in reverse order (as shown below).
49
410
Note: You cannot choose two upper contours, two lower contours,
or an upper and lower contour that are not intended to be the
upper and lower rails of the same cut.
 Make sure the direction of upper and lower contour chains

for each entity in the wirepath are set to chain in the same
direction. Use the Reverse button (shown below) on the
Chaining dialog box if necessary.
 Although easy to use, Window, Area, and Polygon selection

methods can sometimes result in undesired start points,
chaining directions, and upper and lower chain alignments.
If you need to edit your chaining results, click the Geometry
icon for the operation in the Toolpath Manager to open the
Chain Manager, where you can re-order and otherwise edit
the chains.
 When window chaining multiple 4-axis wirepaths, make sure
that the Lock the UV height above the XY height option in
the Cuts page of the Control Definition is selected (as shown
below) so that the lower contour (XY) is located first.
This is the desired setting because when you create multiple

4-axis wirepaths using the window selection chaining
method, Mastercam looks for pairs of chains that have the
closest endpoint to each thread point in the window. If you
chain multiple 4-axis parts that do not have corresponding
thread points, the start points may be random.
 After window chaining multiple 4-axis wirepaths, if you did
not get your desired results, re-chain the wirepaths using a
different chaining method.
 Window selection during chaining of multiple 4-axis wire-
paths is not recommended if you have chosen to synchronize
your wirepaths by branch (as shown below).
4
42
Mastercam recognizes branch lines as entities. When you
window chain, the branch lines are picked up, which usually
results in an unwanted chaining pattern. If you are synchro-
nizing by branch, use the default chain selection method and
manually select each of the XY and UV chains.
43
 Use the Partial selection method to effectively chain open
contours. When using this selection method, make sure to
choose the thread point before each XY/UV pair of chains
and the cut point after each pair of chains.
4
 Single, Point, and Vector selection methods are not recom-
mended for chaining multiple 4-axis wirepaths. These types
of entity selection either do not apply to multiple 4-axis wire-
path chaining, or do not provide sufficient control during
45
entity selection, resulting in faulty wirepaths.
46
47
48
49
410
Creating a 4-axis wirepath from a solid using

Autosync Rails
Note: By default, Autosync Rails selects all lines in your part as

sync lines. Before you begin to create rails using this function, it is
recommended that you move any existing lines in your part to
another level and don't display that level while using the Auto-
sync Rails function.
 Follow these steps to use Autosync Rails to create upper and

lower rails as contours for a 4-axis wirepath.
1 Open the solid part in Mastercam.
2 If there are any visible entities other than the solid, use the
Level Manager to make sure they are located on another level
and make that level invisible. This will ensure that Autosync
Rails does not pick up any lines or arcs when chaining the
upper and lower rails during the creation of the 4-axis wire-
path.
3 Choose Create, Autosync Rails.
4 Click the Activate solid selection button on the General

Selection ribbon bar.
4
5 Click the Select body button on the General Selection ribbon
bar. 42
Note: If necessary, deselect the Select face button to make it easier 43
to select only the whole solid.
4
6 Move your mouse over the solid until your cursor displays the
3D Solids visual cue.
45
7 Click the solid.
8 Click the End Selection button on the General Selection

ribbon bar. 46
9 Click Done on the Drive srfs Selection dialog box. 47
10 Enter the Z height value to establish the slicing plane Z
height, which Mastercam uses to create the initial sync lines.
Note: This value defaults to the midpoint of the height of the

48
solid. Type over the default value if you want to enter a different Z
height value.
11 Press [Enter]. 49
12 In the Slicing params dialog box, enter the following values:
 Tolerance – Controls the accuracy of the slice you are

creating. This will affect how accurately the slice is
matched to the surface data. A large tolerance will
410
“chamfer” sharp corners and facet smooth corners,
directly affecting your wirepath.
 Step increment – Establishes the spacing between the

sync lines created along the slicing plane Z height. A
smaller value creates a more accurate wirepath, but may
take longer to generate the wirepath and create a longer
NC program.
 Fanning distance – Determines the minimum distance
that the wire travels between a corner position and a posi-
tion where the wire is perpendicular to the cut direction.
A larger fan distance creates a wider fan. Enter the
minimum distance that the wire travels between the first
endpoint of an arc and the last endpoint of the same arc (a
position where the wire runs perpendicular).
13 Click OK. Mastercam calculates and creates the slice at the Z
slicing height. This slice is used to create a series of synchro-
nized vector lines. This series of vector lines remains
selected.
14 Press [Enter] to accept the selected vector lines, or manually
choose the vector lines that you want to use to create the
synchronization and then press [Enter].
15 In the AutoSync dialog box, enter the following values:
 Fit tolerance – Tolerance value that applies to how closely

the AutoSync vector lines fit along the upper and lower
rails (the curve fitting tolerance to fit curves, line or arcs to
the surfaces)
 Trim max z - Z height value for the upper (UV) contour
(rail)
 Trim min z - Z height value for the lower (XY) contour
(rail)
 Max Arc Radius - Maximum allowed radius size
 Min Arc Radius - Minimum allowed radius size
 Fit type - Choose the G-code movements that apply to
your specific machine
16 Click OK. Mastercam calculates the Autosync Rails settings
and creates the upper and lower rails, which are projected as
wireframe contours with branch lines to create sync points
(nodes) where the upper and lower rail vectors are not
perpendicular. This may take a few minutes. Please note the
percent of progress displayed in the yellow prompt.
Note: The graphic below shows an example of how the upper and
lower rails created by Autosync Rails appear. In this example, we
have set the maximum Z height at a height above the top of the
4
solid, and a minimum Z height at a height below the bottom of
the solid.
42
43
4
45
 Follow these steps to use the upper and lower rails created by
Autosync Rails to create the 4-axis wirepath.
1 Choose Machine Type, Wire, and choose the wire machine
definition that fits your needs.
46
2 Choose Toolpaths, 4 Axis, and create your NC file name.
3 In the Chaining dialog box, select the C-plane radio button.

4 Click the Options button to open the Chaining Options
47
dialog box.
5 In the Sync mode drop-down field, select by Branch or by
Entity. 48
6 Set other chaining options as necessary and click OK.
7 Chain both the top and bottom contours (rails) you created
with Autosync Rails. Make sure that the chaining direction is
the same on both chains.
49
8 Click OK.
9 Set your 4-axis wirepath parameters on each of the Wirepath

– 4 Axis dialog box property pages and click OK. 410
Point Wirepaths
Point wirepaths create non-cutting moves made at the machine’s feed
or rapid speed at a specified height so that the wire guides clear a
clamp or fixture.
You can enter positions for the point-to-point moves when creating
the point toolpath if you do not already have point entities in the
graphics window.
Use the Point page to establish the point wirepath settings such as the
Z depth of a rapid move, the positions of the upper and lower wire
guides, and the UV and XY heights.
Guidelines for Point Wirepaths

Follow these guidelines when setting up point wirepaths. Choose
Point from the Toolpaths menu. The Point Toolpath ribbon bar
appears for you to select positions in the graphics window and assign
either the rapid (G0) rate or feed rate to the selected points.
After selecting the point positions, click OK. The ribbon bar closes
and the wirepath dialog box appears. Choose the Point page and
follow these guidelines for the point wirepath.
 For Rapid height, enter the height for the rapid moves that
make up the point wirepath.
 For UV height, enter the part or material height. For UV trim
plane, enter the location of the upper wire guide.
 For XY height, enter the Z depth of the XY plane where the
points are located. For XY trim plane, enter the location of
the lower wire guide.
 Machine and control definition settings, along with the
settings on the Wire/Power page, control the initial state of
power, wire, flush, and tank fill.
Transform Wirepaths
Transform wirepaths create copies of operations in different orienta-
tions. Use this function to translate operations into multiple copies
arranged in a matrix, or a vertical, horizontal, or diagonal row. The
arrangement of the copies is determined by the method you use to
translate the operations.
Transform also supports a Rotate option, which allows you to select a

point of rotation, the angle, and the number of copies (steps) to create
for the operation.
Transform operations are associative. If Transform is used on an oper-
4
ation and the operation’s information changes, the transformed oper-
ation that is linked to that wirepath is also updated.
The Translate tab of the Transform Operation Parameters dialog box
provides options for arranging operation copies.
42
 To set up transform wirepaths
Transform requires at least one previously created operation. 43
1 From the Toolpaths menu, choose Transform.
2 Choose the transform type.
 Translate creates operation copies arranged in a matrix,

or a vertical, horizontal or diagonal row.
4
 Rotate creates operation copies arranged around a rota-
tion point at a specified angle.
3 If you selected the Translate type, choose the method for
Mastercam to handle the work origin. This origin selection
45
does not apply to the Rotate method.
 Select Tool plane origin only to have Mastercam shift the
work origin in the 1013 line of the NCI file instead of
shifting the coordinates for each repetition of the opera-
46
tion. Clear this option to have Mastercam shift the coordi-
nates for each repetition of the operation.
4 Select the operations to transform. Use the [Shift] or [Ctrl]
key while clicking on the operations to select more than one.
47
5 Choose the method for creating the transform operation:
 Choose Create new operations and geometry to create a

separate operation for each copy. Each copy has the same 48
parameters as the source operation. A Transform opera-
tion (which contains the parameters from the Transform
Operation Parameters dialog box) will not be created
unless you check the Keep this transform operation box.
 Choose Copy source operations to create a Transform
49
operation that contains the transform copies and copies
of the source operations. To prevent the source operations
from being posted twice, choose the Disable posting in
selected source operations box.
410
6 If you chose Translate in step 2, choose the Translate dialog
box tab to set the arrangement and spacing of the copies.
7 If you selected Rotate in step 2, choose the Rotate tab to set

the rotation point and arrangement of the copies.
8 Choose OK to generate the Transform operations. Mastercam
draws the copies in the graphics window and creates entries
for the transformed operations in the Toolpath Manager.
WIREPATHS / Setting Wirepath Parameters • 89
Setting Wirepath Parameters

4
Power Settings Libraries
A wire power settings library contains wire EDM machine-specific
settings documented by the manufacturer for the material you are
42
cutting. A power settings library is stored in a file with a .power exten-
sion. A wire power settings library is organized into 24 passes. Each
pass can have unique settings. For example, Pass 1 in the library may
contain the settings for a rough cut, Pass 2 a tab cut, and Passes 3 – 5 43
finish cuts (also known as skim cuts).
Note: In Mastercam, a “pass” refers to a single path made by the

wire around a contour. The term “pass” is synonymous with “cut”
and is often used interchangeably within Mastercam.
4
Each pass in the library has the following settings:
Offset —A wire diameter offset register number used when wire
45
compensation is generated by the control. You may need to reference
your wire machine documentation for this information.
Condition code —A wire machine-specific value that corresponds to a
register number in the control. Refer to your wire machine documen-
46
tation for condition codes for material and wire type and thickness.
Feed rate —Most EDMs do not use a feed rate. However, this value is
available if needed by the control.
Wire diameter — Works with the radius parameter and is automati-
47
cally entered when a radius is entered.
Wire radius —Works with the diameter parameter and is automati-
cally entered when a diameter is entered. 48
Wire overburn —The amount of material beyond the wire diameter
that can be removed.
Stock to leave —The amount of stock to leave for finish passes. Stock
to leave offsets the wire in the direction specified by the compensa-
49
tion direction.
Total offset—Sum of the wire radius, overburn, and stock to leave; for
display only.
Registers 1 - 10 —Open values that correspond to registers in the
410
machine control and can be used for post processor customization.
Pass Comment —Information about the power settings for the

current pass number. For example, the Pass 1 settings could be
commented as Rough Cut for a certain material type and thickness.
TIP: You can create unique power library settings that are
saved only with the wirepath operation in the Mastercam part
file by deselecting Associate to library.
Default Power Settings Library

Mastercam reads the default power settings library into the Wire/
Power page of the wirepath dialog box when you initiate a wirepath.
The default power settings library is selected in the Files page of the
control definition. When you create a machine group by selecting a
machine definition, Mastercam reads the name and location of the
default power settings library into the Files tab of the Machine Group
Properties dialog box.
The chosen power library and its path display in the Power library
field in the Wire/Power page as shown below. To use a different power
settings library, choose the Edit Library button.
The Edit Library button opens the Edit Library dialog box where you
can either edit the current power library or choose the Select Library
button and navigate to a different .power file to use. 4
42
43
4
Associating a Power Settings Library with an 45
Operation
Wire libraries can be associated to the operation by checking the
Associate to library check box on the Wire/Power page of any wire- 46
path dialog box.
47
When this option is checked, any changes to the library since an oper-
ation was created require the operation to be regenerated.
48
When Associate to library is deselected, the power settings library is
not associated to the wirepath. When you first create a wirepath,
Mastercam reads the power settings from the library but allows them
to be changed for the operation. Mastercam retains the power
49
settings that you make if you change the toolpath or the power
settings library that the settings were based on.
410
Creating or Editing Power Settings Library

When you first create an operation, Mastercam uses the wire power
settings library set in the Files tab of the Machine Group Properties
dialog box. You can change the power settings library in the Wire/
Power page for an operation, and save these changes to a new library.
 To create a power settings library

1 With a wire machine definition selected in the Toolpath
Manager, initiate a wire operation by choosing an operation
from the Toolpaths menu, and then selecting geometry.
2 In the Wire/Power page, deselect the Associate to library
check box. The power settings become enabled so that you
can enter new settings.
3 Use the Starting pass # to select each pass that you want to
include in the library.
4 Enter the new power settings for each pass.
5 Choose the Save Library button and assign the new library a
name.
 To change a power settings library

1 With a wire machine definition selected in the Toolpath
Manager, initiate a wire operation by choosing a toolpath
from the Toolpaths menu, and then selecting geometry.
4
2 Choose the Edit Library button to open the Edit Library
dialog box:
42
43
4
45
46
3 Choose the Pass number, and make changes to the power
settings. 47
4 Choose OK when finished.
How Stock to Leave is applied in Wire

The Stock to Leave values, established on the Wire/Power page in
48
the wirepaths dialog boxes, set the amount of stock to leave for all
passes.
49
410
All Stock to Leave options are only available for Contour and 4-Axis
wirepaths. The Apply additional offset to section is not available for
No Core wirepaths, and none of the Stock to Leave options are avail-
able for Canned or Point wirepaths.
Stock to Leave offsets the wire in the direction specified by the
Compensation direction on the Compensation page.
The Program coordinates and Machine offset register options

determine how the Stock to Leave value is applied to a wirepath. The
defaults for these options are set in the Stock to leave application
section of the Cutter compensation page in the Control Definition.
When Program coordinates is selected and:

 Compensation type is set to Control, all the wirepath coordi-
nates in the NCI are offset by the Stock to Leave value.
 Compensation type is set to Computer, Both, or Reverse
Both, all the wirepath coordinates in the NCI are offset by the
Total Offset value (Wire Radius + Overburn + Stock to
Leave).
 Compensation type is set to Off, all the wirepath coordinates
in the NCI are offset by the Stock to Leave value. When
Compensation direction is set to Auto, Mastercam knows to
which side of the wirepath to apply the offset, or you can
choose Left or Right to manually set the compensation direc-
tion.
Note: When Compensation type is set to Computer or Off,

Mastercam does not create an offset command line (G41/G42)
output to your machine control. In this case, Mastercam Wire
4
defaults the Stock to leave application to Program Coordi-
nates, and the Machine offset register option is disabled.
When Machine offset register is selected and: 42

 Compensation type is set to Control, Mastercam does not
offset the wirepath coordinates in the NCI. The post
processor takes the combined offsets (Wire Radius + Over-
burn + Stock to Leave) and applies that value to the offset 43
register in your machine control.
 Compensation type is set to Both or Reverse Both,
Mastercam offsets the wirepath coordinates in the NCI
according to the total value of Wire Radius + Overburn. The
post processor takes the additional offset (Stock to Leave)
4
and applies it to the offset register in your machine control.
In any case where Stock to Leave values are applied, if the Compen-
sation direction is set to Auto, Mastercam recognizes either a defined
or implied start point, allowing it to determine to which side to apply
45
the Stock to Leave.
46
47
48
49
410
Notes:
• The Stock to Leave values are not associated with the active
POWER library. Therefore, the Stock to Leave field and
related Apply additional offset to choices on the Wire/Power
page remain active, regardless of whether or not the wirepath
is associated with a POWER library.
• When you load an MCX file that was created in any Mastercam
Wire version prior to X2 MR2, Mastercam Wire checks the
Stock to Leave values programmed in the active POWER
library. If the Stock to Leave values in the assigned POWER
library contain a constant value for all the operation's passes,
Mastercam loads this value into the Stock to Leave field.
• If varying Stock to Leave values have been set for different
passes in the active POWER Library (allowed in Mastercam
versions prior to X2 MR2), a dialog appears stating that these
varying Stock to Leave values will be added to the Wire Over-
burn values for each pass. In this case, Stock to Leave is set to
0.0, reproducing the previously established wirepath values.
• All Contour, No Core, and 4-Axis wirepaths operations created
in any Mastercam Wire version prior to X2 MR2 are marked
dirty, and have the Associate to library option unchecked.
• When you apply a Stock to Leave value and Compensation is
set to Off (on the Compensation page), the Stock to Leave
amount will be reduced by the wire radius plus the Overburn
value.
• On 4-axis wirepaths, the Stock to Leave value is applied
perpendicular to the wire, not in the XY and UV planes. There-
fore, the actual offset of the XY and UV planes will vary,
depending on the angle of the taper. Examples:
Stock to Leave (no 4-axis angle)
4
42
43
4
45
Stock to Leave (4-axis angle)
46
47
48
49
410
• The Machine offset register parameters do not apply to No Core

wirepaths. Therefore, the Apply additional offset to options
will not appear in the Wire/Power page for No Core wirepaths,
and the Stock to Leave value is calculated as if the Machine
offset register choice was selected.
• Stock to Leave settings are not available for Canned and
Point wirepaths. Therefore, the Stock to Leave area (as shown
below), including the Apply additional offset to choices, will
not appear in the Wire/Power page for those types of wirepaths.
• Applying Stock to Leave settings may require post customiza-

tion.
Wire Compensation
Wire compensation offsets the wire from the geometry to the right or
left of the geometry, relative to the chaining direction. This offset may
4
be generated by Mastercam (compensation in computer), by the
control (compensation in control), or a combination of both (“both”
and “reverse both” compensation). Most wire EDM machines use
compensation in control. 42
Wire compensation for contour and 4-axis wirepaths is set in the
Compensation page of the wirepath dialog box as shown below.
43
4
45
46
47
Compensation for no core finish wirepaths is set in the Compensation
type field of the Finish page of the Wirepath No core dialog box. 48
Notes:
• Canned and point wirepaths do not use wire compensation
offsets.
• Be sure to enable compensation in control in the Cutter
49
Compensation page of the control definition. See Control Defi-
nition Manager on page 34.
410
Compensation Types
Mastercam supports these types of wire compensation:
Computer —Mastercam computes the compensated wirepath and
does not output control codes for compensation.
Control —Mastercam outputs control codes for compensation and
does not compute the compensated wirepath.
Notes:
• When Compensation type is set to Control, Mastercam gener-
ates a simulated wirepath because the actual wirepath is
dependent upon the machine control.
• When viewing larger parts with a relatively small wire offset, it
can be difficult to see to which side the compensation is
applied. When the cutter compensation is set to Control, you
can display arrows in the backplot display that indicate direc-
tion. See Backplotting Wirepaths on page 165 to learn more.
Both—Mastercam both computes the compensated wirepath and

outputs control codes for compensation. Compensation direction in
the computer and control are the same.
Reverse both— Mastercam both computes the compensated wirepath
and outputs control codes for compensation. Compensation direc-
tion in the computer and control are opposite each other.
Off —No wire offset. Mastercam computes the wirepath with the wire
cutting the centerline of geometry.
Compensation Direction
For contour and 4-axis wirepaths, where the Compensation type
field is accompanied by the Compensation direction, you can set the
4
wire to offset to the right or left of the wirepath. The Auto setting
offsets the wire to either the right or left depending on the location of
the thread point inside or outside of the contour. When selecting
multiple contours to be cut in a single operation, using the Auto 42
compensation setting ensures that the wire is offset on the correct
side of each contour.
Left
43
Right
Chaining direction Off

4
45
46
47
48
49
410
Lead ins and outs

Use the lead in and lead out parameters to control the entry and exit
motion for wirepaths. The default lead in/out parameters are set in
the wire control definition (see Start/Leads on page 38). Mastercam
supports three types of leads for certain types of wirepaths.
Contour Leads — Sets the entry and exit motion for the rough cut and
any skim cuts before a tab cut. These settings are located on the Leads
page of contour, no core, and 4-axis wirepath dialog boxes.
Tab Cut Leads — Sets the entry and exit motion for the tab cuts.
These settings are located on the Tab/Finish Leads page of contour
and 4-axis wirepath dialog boxes.
Finish Leads — Sets the entry and exit motion for any skim cut. These
settings are located on the Tab/Finish Leads page of contour and 4-
axis wirepath dialog boxes.
The Tab/Finish page will be unavailable unless you:
 Deselect the Tab cuts (no dropout method) check box (as
shown below) on the Leads page.
 Select the Tab check box (as shown below) on the Cut Param-
eters page.
If either of these conditions is not met, the disabled icon is displayed

next to Tab/Finish Leads in the Tree View list of pages, and the
options in the page will not be available.
You can also use the Lead Distance page to override the thread point
and establish a lead in distance and position. The options on this
page are unavailable unless the Lead Distance (overrides thread/cut
point) check box is selected.
Use these guidelines when setting up lead in/out moves for a wire-
path.
 For all lead types, choose the shape of the wire motion as a 4
line, an arc, or a combination of both. Whether or not these
options are enabled depends on the Start/Leads settings in
the control definition. See Start/Leads on page 38 to learn
more. 42
Lead in
arc
43
Lead in line
Start of
Start and
thread point
Contour
4
Cut point at Overlap
maximum distance
lead out length
Lead out
45
arc
Lead out line
 When an arc makes up part of the lead in or lead out, enter

the Arc radius. For compensation in control, the arc radius
46
must be slightly larger than the wire diameter plus twice the
overburn. This radius may allow dropout but could prevent a
machine fault if the arc sweep is too small.
 Enter the Arc sweep in degrees.
47
 Enter an Overlap amount. This parameter is optional. An
overlap eliminates potential overburn, which can occur from
the wire dwelling on the same point twice. Mastercam over-
laps the start and end of the contour by the amount entered. 48
 To limit the lead out length, select the Max lead out check
box and enter an amount for the lead out length.
 To have Mastercam move the cut point to a position closer to
the contour after the final lead out, select the Trim final lead
49
out check box.
 The Tab cuts (no dropout method) option provides a
method for eliminating slugs or slivers that sometimes result
from a tab cut. Selecting this option disables the tab cut and 410
finish cut leads. Mastercam calculates the tab cut lead in/out
to eliminate material dropout.
 To allow Mastercam to control the position of the cut point

(recommended), select the Auto position cut point check
box (available when Tab cuts, no dropout method is dese-
lected).
 To allow Mastercam to set the job start point to the thread
point, choose Set start position to thread point.
 Check Rapid from Thread point to start the lead in move at
the thread point and move toward the contour chain at a
rapid move. Uncheck to start the lead in move at the thread
point and move toward the contour chain at a normal feed
rate. The point at which the feed rate is transformed to a
rapid move is established in the Lead in section on the Leads
page.
 Check the Rapid to Cut point check box to set the lead out
move as a rapid move. Uncheck to set the lead out move at a
normal feed rate. The point at which the feed rate is trans-
formed to a rapid move is established in the Lead out section
on the Leads page.
 Check the Rapid to start position at end of program check
box to establish a rapid move from the end of the wirepath to
the initial start position. Uncheck to continue with the
normal feed rate from the end of the wirepath to the start
position.
Cuts
Mastercam provides three different types of cuts for wirepaths. You
select the number of rough, skim, and tab cuts, and select general
options for them in the Cuts Parameters page of the wirepath dialog
box. More specific cuts options are located on the Compensation,
Stops, Subprograms, and Filter pages.
Here are some brief descriptions of the types of wirepath cuts:
Rough cuts —A rough cut always uses the power settings from the
Starting Pass # in the power library (Wire/Power page).
Tab cuts —A tab cut removes the last tab holding the part in the mate-
rial.
Skim cuts —A skim cut acts as a finish pass that removes a smaller
amount of material than the rough cut. Mastercam can make skim
cuts both before and after the tab cut.
Mastercam displays the cuts for each chain in the cuts list (shown
below) located in the lower right corner of the Cuts Parameters page
of the contour and 4-axis dialog boxes. 4
42
Mastercam outputs the tab cut; after the rough cut, and any skim cuts
before the tab cut, and before the finish cuts (skim cuts after the tab
cut).
43
You can choose whether the tab is cut with a skim cut or with its own
cut, and set the number of each type of cut.
Use these guidelines when setting the cut parameters to set up tabs,
and cuts before and after tab cuts.
4
 Select Perform rough cut to create a rough cut for the
contour. Clear this check box in operations where you want
only a tab or skim cut. The rough cut uses the Starting Pass
# settings from the wire power settings library.
45
 To place tabs in the wirepath, select Tab, enter a Tab Width,
and enter the number of tab cuts.
TIP: To create an operation consisting of only a skim cut, dese-

46
lect Perform rough cut, and enter 0 for Number of tab cuts.
 Select Make tab cutoff move with skim cut to append the
tab cut to a skim cut instead of making the tab cut a separate
47
cut.
 You can assign when the tab cut occurs in relation to the
rough and skim cuts. Make this selection from the drop-
down menu in the Tabs area. The drop-down menu is only
48
enabled when you have chained multiple contours for the
operation.
All passes for each contour in the operation are shown in the
list in the lower right corner of the dialog box tab. 49
 The Skim cuts after tab option sets up the finish passes for
the wirepath. Mastercam uses the finish lead in/out settings
for the skim cuts made after the tab cut. Choose the Together
option to have Mastercam make all the skim cuts on a single 410
contour before moving to the next contour in the operation.
To make one skim cut at a time per contour, enter a number
in the Separate field. The separate option is available only

when you’ve selected multiple contours in a single operation
and when the Rough, tab, and finish separately is also
selected.
 Choose the Cutting method. Reverse causes the wire

machine to swap the cutting direction for each pass. One
way cuts in a single direction and, when cutting open
contours, causes the wire machine to cut the wire at the end
of each pass, rapid to the thread point, and re-thread for the
next pass.
 Place the tabs on the part using one of the following
methods:
 Select Automatic and enter the number of tabs to
place on each contour in the operation. Mastercam
spaces the tabs equally over the contour.
 Select Manual, and then choose the Position button. In
the graphics window, select an entity. Two yellow lines
appear that represent the tab. Position the tab on the
entity and click to set it in place. Select another entity
and repeat. Press [Enter] when you have placed all the
tabs needed in the operation.
 Select Manual, and then select Use square points.
Mastercam places tabs on the locations where you
have placed square point entities on the geometry.
Make a selection to position the tab at the Start,
Midpoint, or End position at the square point.
 Select Reset pass number on tab cuts to have the tab cut
use the starting pass number settings (set on the Wire Param-
eters tab for the operation).
 To suppress the writing of thread and/or cut flags to the NCI,

check Suppress all wire threads and/or Suppress all wire
cuts.
 To separate all rough, tab, and skim cuts after tabs into indi-
4
vidual operations, select Expand operation. This option is
only available when first creating the wirepath.
 On the Stops page, make a choice to determine how
Mastercam outputs stop codes in tab cuts, then choose the
42
type of stop code in the Output stop code group box. The
stop code appears before the tab cut. The code that is output
for the stop is post-dependent, but usually:
 M01 = Glue stop
43
 M00 = Program stop
Thread Positions 4
Mastercam provides options for setting the thread positions in four
pages in the wirepath dialog box. These pages are the Leads, the Lead
Distance, the Start Position, and the Tapered Thread pages.
 To change the thread point position, check the Lead distance
45
check box (Lead Distance page) and enter a value in the
corresponding field. When Lead distance is 0, Mastercam
uses the thread point that you have created with a point
entity and chained with the part geometry.
46
 When using the Lead distance to set the thread point and
chaining a Closed contour, choose whether the lead in and
lead out will be located on the inside or outside of the
contour. For an Open contour, choose whether the lead in
47
and lead out will be located on the right or left of the contour.
48
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Wirepath Dialog Boxes

Wirepath parameters are set in the Wirepath dialog boxes. Each type
of wirepath has a wirepath-specific dialog box with pages and settings
unique to that wirepath type.
Wirepath Dialog Box Layout

Wirepath dialog boxes have three distinct areas: Tree View, Page, and
Quick View Settings.
WIREPATHS / Wirepath Dialog Boxes • 109
Tree View Area

This area displays all of the available dialog box property pages. The
list of pages depends on the wirepath type selected in the Toolpath
4
menu. Some pages may have a plus or minus symbol, designating
that the page has subpages and can expand and contract to either
display or hide the subpages.
42
43
4
Titles of pages where data has changed in the current session will
have an edited symbol in front of them.
45
Titles of disabled pages will have a disabled symbol in front of them.
46
47
Pages can be disabled in two ways. Sometimes when you select or
deselect an option on one page, a dependent page is either enabled or
48
disabled. For contour wirepaths, deselecting the Tab check box on the
Cut Parameters page disables the Stops page.
Other times, a check box or radio button at the top of a page enables
and disables the page. For instance, the Lead Distance (overrides
49
thread/cut point) check box at the top of the Lead Distance page
enables and disables that page.
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Page Area
The contents of the Page area change with each choice you make in
the Tree View area. Wirepath dialog boxes will have many similar, if
not exactly the same, pages. For instance, all wirepaths offer a
Flushing page, and the content of that page is not wirepath-specific.
The same holds true for the Planes (WCS) and Canned Text pages.
Quick View Settings Area

This window summarizes key toolpath/wirepath information from
parameters you set on the different pages. It updates automatically as
you make changes in the pages, and is always visible.
Below is an example of information displayed in the Quick View
Settings area for a contour wirepath with a five-degree taper angle
applied to the right of the wirepath.
Wirepath Dialog Box Descriptions

Here is a brief description of each of the wirepath dialog boxes:
Contour - Establishes the contour wirepath settings such as the wire
power settings, taper of the wirepath, the height of the part and axes
moves, the wire offsets, and the type of cornering. Also sets the lead in
and out, cuts, and some general settings such as cutting method,
thread distance, and flushing.
Canned Cycle - Establishes the canned cycle wirepath settings such
as wire power settings, custom canned cycles, custom canned param-
eters, and additional parameters used by the post processor to control
functions specific to the wire EDM control and machine.
No Core - Establishes the no core wirepath settings such as wire

power settings, Z depth of a rapid move, positions of the upper and
lower wire guides, the lead in and out settings, and roughing and
finishing parameters. You can also enable/disable wire threading,
4
voltage, wirepath start position, and wirepath end position options.
4-Axis - Establishes the 4-axis wirepath settings such as the Z depth
of a rapid move, the positions of the upper and lower wire guides, wire
offset parameters, synchronization of the lower (XY) and upper (UV)
42
contours, trimming options, and linear arc move format (direct or
taper). Also sets the lead in and out, cuts, and some general settings
such as cutting method, thread distance, and flushing.
Point - Establishes the point wirepath settings such as the Z depth of
43
a rapid move, the positions of the upper and lower wire guides, the
UV and XY heights, and the arc moves around corners.
4
45
46
47
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Wirepath Dialog Box Pages

As discussed, there are property pages in wirepath dialog boxes that
contain options to set parameters for each wirepath.
These pages are:
Table 1:
Page Applies to these wirepaths
Wirepath Type All
Wire/Power All
Misc. Values Contour, no core, and 4-axis
Aux. Registers Contour, no core, 4-axis, and point
Cut Parameters Contour and 4-axis
Compensation Contour and 4-axis
Stops Contour and 4-axis
Subprograms Contour and 4-axis
Filter Contour, no core, and 4-axis
Leads Contour, no core, and 4-axis
Tab/Finish Leads Contour and 4-axis
Lead Distance Contour and 4-axis
Start Position Contour, canned, no core, and 4-axis
Taper Contour
Corners Contour
Tapered Thread Contour and 4-axis
Planes (WCS) All
Canned Text All
Flushing All
Canned Cycle Canned
Cycle Custom Parameters Canned
No Core No core
Rough No core
Finish No core
4 Axis 4-axis
Point Point
Note: Agievision-specific wirepaths are covered beginning on page

146.
Wirepath Type Page

This dialog box property page applies to all wirepath types (contour,
canned, no core, 4-axis, and point).
4
The following graphic shows the Wirepath Type page for a contour
wirepath.
42
43
4
45
46
Use this page to view the type of wirepath you are creating or editing.
You can also add/edit/delete comments for the wirepath. Comments
help identify the operation in the Toolpath Manager as shown below.
47
48
Comments can be output in the NC file when you post if you select
the proper option in the Files tab of the Machine Group Properties
dialog box.
49
410
Click the arrow in the Chain Geometry section (shown below) to

open the Chain Manager dialog box, where you can modify the chain
while creating the wirepath or after it has been generated.
After completing this page, work on other pages by selecting them in

the window on the left. Do not click OK until you have finished with
all pages. When you click OK, Mastercam generates the wirepath and
closes the dialog box.
Wire/Power Page
Use this page to choose a wire power settings library file and use its
values for the wirepath operation. By default, the power settings
library file is associated (dynamically linked) with the operation as an
external file. The settings that display in this page reflect the most
recent version of the associated power library file in its saved location.
You can also set the pass number for the first pass of the wirepath,
and specify the settings for a single pass. Each pass can have unique
settings. Up to 24 passes can be stored in a single wire library file.
By default, the power settings library file, including each of the pass
4
settings, is associated (dynamically linked) with the operation as an
external file. Therefore, the fields you use to edit the power settings for
each pass are unavailable unless you have disassociated the wirepath
from the power settings library by deselecting the Associate to
42
library check box. Using this method allows you to create unique
power library settings that are saved only with the wirepath operation
in the Mastercam part file.
43
4
Misc. Values Page
This dialog box property page applies to contour, no core, and 4-axis
45
wirepaths.
46
47
48
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Use this page to enter values for custom parameters that have been
defined for the current post processor. You can set values for up to 20
miscellaneous values: 10 reals (mr1-mr10) and 10 integers (mi1-
mi10). The default values, the text labels, and how the post processor
formats and uses these values is unique to each post processor. The
default values and text are set in the control definition.
You can set the values for them in one of four ways:
 Enter values directly in each field. The values are stored with
the operation.
 Choose Set to post values to read the default values stored
in the post processor file. You can edit or override the default
values by entering new values here. The values are stored
with the operation.
 Choose Set to Op Defaults to read the default values stored
in the .DEFAULTS file. You can edit or override the default
values by entering new values here. The values are stored
with the operation.
 Choose Automatically set to post values when posting to
disable all the other fields and controls on this dialog box.
Mastercam will disregard all the information from this dialog
and will read the values from the post processor when you
post. This lets you use updated values whenever your post
processor changes without needing to edit each operation.
No values are stored with the operation.
Replacing Misc. Values with a C-Hook

You can also set up this page to replace the Misc. Values function with
easy access to a C-Hook such as an AgieVision C-Hook. This is a
machine-specific setting that is set up in the Files page of the Control
Definition Manager. This allows you to customize the Misc. Values
function for a particular machine.
Note: Setting up the Misc. Values page to access a C-Hook needs to

be performed on the master copy of the machine and control defi-
nition. This means that you need to enter the Machine Definition
Manager from the Settings menu, not from the Toolpath
Manager.
When you change Misc. Values to access a C-Hook, the following two
things change in the wirepath dialog box:
 The Misc. Values page title in the Tree View area changes 4
according to the C-Hook you have chosen.
 A button with a link to the C-Hook appears in the dialog box
Page area.
For example, when you set up the Misc. Values in the Control Defini- 42
tion Manager to access the AgieVision C-Hook, the Misc. Values title
in the Tree View area of the wirepath dialog box changes to AgieVi-
sion as shown below.
43
4
45
46
Also, in the Page area, you will see an explanation of the Control Defi-
nition settings, and a button that you can click to initiate the C-Hook:
47
48
For detailed information on this function and step-by-step proce-
dures, please see the Replacing Misc Values with a C-Hook topic in
the Mastercam Help. 49
410
Notes:
• Mastercam Wire writes the miscellaneous values to the NCI file
at the beginning of each operation and links each value to the
appropriate variable when you run the post processor.
• Use [Page Up] and [Page Down] to change the pass number
(from 1 to 24) so that you can enter a value in the same field for
multiple passes.
• Use the Misc Int/Real page in the Control Definition Manager
to manage the default values and behavior. The exact appear-
ance of this dialog and the fields that it displays vary
depending on the selected machine.
• Use the Active field button to apply the selected (highlighted)
miscellaneous real or integer value to all passes in the library.
• Use the All fields button to apply the current miscellaneous
reals and integers values to all passes in the library.
Aux. Registers Page

Use this page to set values that correspond to registers in the machine
control. A register holds a variable used to give special instructions to
the post processor. Certain CNC controls require registers to be set on
entry and at various points in the wirepath. Each Wire library lets you
4
enter up to ten real values that set registers on the control. Registers
can be set per pass or per point.
By default, the power settings library file, including the register
settings, is associated (dynamically linked) with the operation as an
42
external file. Therefore, you cannot edit the options on this page
unless you have disassociated the wirepath from the power settings
library by deselecting the Associate to library check box (shown
below) on the Wire/Power page. 43
4
When you deselect the Associate to library check box, the register
settings you change on the Aux. Registers page will be applied only to
45
the current wirepath, not saved back to your power library. To edit the
register settings in a library, click the Edit Power Library button
(shown below) on the Wire/Power page to work in the Edit Library
dialog box.
46
47
48
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Cut Parameters Page

This dialog box property page applies to contour and 4-axis wire-
paths. The following graphic shows the Cut Parameters page for a
contour wirepath.
Use this page to:

 Define the type and number of cuts you will make in the
wirepath.
 Optionally divide the cuts into separate operations.
 Suppress thread or cut flags.
 Control stop codes.
The Cut Parameters page options for contour wirepaths differ from
those for 4-axis wirepaths. Contour wirepaths have additional options
and fields (example shown below).
Contour wirepath options 4-axis wirepath options
4
42
43
4
45
Note: Mastercam Wire supports three main categories of cuts:
rough and skim cuts before the tab, tab cuts, and skim cuts after
the tab. The Cut Parameters page lists the programmed cuts and
46
indicates their grouping as operations.
47
48
49
410
Compensation Page
paths.
Use this page to:

 Set the compensation method by which Mastercam Wire
offsets the wire from the wirepath.
 Choose to offset the wire to the right or left of the wirepath.
 Eliminate arcs in the wirepath that are less than or equal to
the radius of the wire.
 Insert arc moves around corners in the wirepath.
 Set Mastercam to check for and eliminate unwanted inter-
sections in the wirepath.
Stops Page
paths.
4
42
43
4
45
Use this page to create optional stops (M01) or program stops (M00)
46
in a wirepath. For contour wirepaths, you have the options to apply
the stops before and/or after tabs.
This page is disabled unless you select the Tab check box on the Cut
Parameters page (as shown below).
47
48
49
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Subprograms Page
paths.
Use this page to use subprograms to repeat XY moves in wirepaths.

You can disable and enable this page with the Create Subprograms
check box (as shown below).
Filter Page
wirepaths. The following graphic shows the Filter page for contour
4
wirepaths.
42
43
4
45
46
Use this page to optimize toolpaths by replacing many small moves
(within a specified tolerance value) with single moves. You can
control the following variables:
 The tolerance for replacing multiple linear moves with a
47
single move.
 The number of points Mastercam will look ahead when
filtering the wirepath. 48
 An option for one-way filtering. This filters a wirepath in one
direction, usually for a finish wirepath, to avoid small polyg-
onal patterns on the finish that can happen with zigzag
filtering.
 Replacement of linear moves with arcs. The active control
49
definition specifies the planes in which arcs can be created.
410
Note: You can filter contour, no core, and 4-axis wirepaths as they
are being created. You can also filter these wirepaths after genera-
tion through the Toolpath Manager, or filter any NCI file using
your preferred editor. To maintain associativity, we recommend
that you filter wirepaths while they are being created.
Leads Page
wirepaths. The following graphic shows the Leads page for a contour
wirepath.
Use this page to set the wire motion when entering or exiting a part.
Leads Page for Contour and 4-axis Wirepaths

Use this page to set the wire motion when entering or exiting a part
when making:
 a rough or skim cut before a tab cut
 a tab cut
 a skim cut after a tab cut
You can also enable/disable tab and finish cut lead settings, allow
Mastercam to determine the cut points, and automatically move the
start point to the thread point of the first contour. 4
Leads Page for No Core Wirepaths
Use this page to set the wire motion when entering or exiting a part,
allow Mastercam to determine the cut points, and automatically
move the start point to the thread point of the first contour.
42
Tab/Finish Leads Page
This dialog box property page applies to contour and 4-axis wire- 43
paths.
4
45
46
47
48
Use this page to set the wire motion when entering or exiting a part
when making tab cuts (Tab Cut Leads section) and skim cuts after a
tab cut (Finish Leads section).
49
410
 This page is disabled unless you do the following:

1 Deselect the Tab cuts (no dropout method) check box (as
shown below) on the Leads page.
2 Select the Tab check box (as shown below) on the Cut Param-
eters page.
If either of these conditions is not met, the disabled icon is displayed

next to Tab/Finish Leads in the Tree View list of pages, and the
options in the page will not be available.
Lead Distance Page

paths. The following graphic shows the Lead Distance page for a
4
contour wirepath.
42
43
4
45
46
Use this page to override the thread point and establish a lead in
distance and position.
The options on this page are unavailable unless the Lead Distance
(overrides thread/cut point) check box is selected.
47
48
49
410
Start Position Page

This dialog box property page applies to contour, canned, no core,
and 4-axis wirepaths. The following graphic shows the Start Position
page for contour wirepaths.
Use this page to override a wirepath's default start position. The start
position is Mastercam's default start point for wire operations.
To override the start position using this page, specify the new start
position in one of three ways:
 Enter coordinate positions directly in the X, Y, and Z fields.
Enter coordinate values relative to the current Tplane and
Tplane origin.
 Choose From Machine to read the start position established
in the Start Position section of the Machine axis combina-
tions dialog box (Wire).
 Choose Select to return to the graphics window and select a
point. Mastercam will automatically enter the point's coordi-
nates in this dialog box.
For contour, no core, and 4-axis wirepaths, this page will be disabled if
the Set start position to thread point check box in the Leads page is
selected. For canned cycles, this check box is located on the Canned
Cycle page.
4
If the Set start position to thread point check box is selected, the
42
disabled icon is displayed next to Start Position in the Tree View list of
pages, and the options in the page will not be available.
The source of the default start position is specified in the Start/Leads,
Wire page of the control definition. It can also come from the
43
machine definition or the wirepath defaults file. Regardless of where
the default value comes from, you can use this page to override it for
any operation.
4
Taper Page
This dialog box property page applies to contour wirepaths.
45
46
47
48
49
Use this page to taper the contour wirepath inward or outward and
specify the location of the land (the point at which the taper begins).
You can also select how to apply the taper to passes and specify the tilt
410
direction of the taper (left or right of the wirepath).
Notice that you must check the Taper check box (highlighted below)
to activate the wirepath taper options.
You can also use this page to set the following taper heights:
 Z height of the upper wire guide for rapid moves
 Location of the upper wire guide (UV Trim Plane) and the
lower wire guide (XY Trim Plane)
 Height of the part (the upper contour of the wirepath)
 Plane at which the wire pivots to the taper angle (available
only for land up or land down taper styles)
 Location of the XY plane (the lower contour of the wirepath)
Corners Page
This dialog box property page applies to contour wirepaths. 4
42
43
4
45
Use this page to control the shape of the clockwise and counterclock-
wise sharp and smooth (arc) corners. The settings in the Wire Corner
46
page of the Control Definition Manager establishes the types of
corners available in the drop-down fields of this page.
Note: When you choose Other as an arc or corner type, Mastercam

47
allows you to specify a radius for a custom arc/corner defined in
the post processor. However, because Mastercam Wire cannot
anticipate what type of arc/corner the post processor will specify,
the wirepath will always be displayed with sharp corners in the
48
Mastercam graphics window, regardless of how the actual wire-
path arcs and corners will be cut.
49
410
Tapered Thread Page

paths. The following graphic shows the Tapered Thread page for a
contour wirepath.
Use this page to specify an XY location in the UV plane for the thread
or cut position and to create a tapered thread (non-vertical thread
cut).
You can specify one tapered thread/cut position for the thread posi-
tion, the cut position, or both. In an operation of multiple contours,
Mastercam Wire uses the thread/cut position of the first contour to
set up a tapered thread/cut. It then uses the same relative tapered
thread/cut for the remaining contours.
Planes (WCS) Page

This dialog box property page applies to all wirepath types. The
following graphic shows the Planes (WCS) page for a contour wire-
4
path.
42
43
4
45
46
Use this page to set the planes in which your wirepath will be created.
You can set the Working Coordinate System (WCS) and the work
plane origin.
Set the X, Y, and Z offsets for the WCS origin in the Working coordi-
47
nate system section of this dialog box. These coordinates are relative
to the view you have set as the WCS. You can also select a named view
as the new WCS and have Mastercam set the Tplane relative to it. In
this case, Mastercam will use the work offset that is stored with the
48
work coordinate system.
In the Work plane section, set the X, Y, and Z offsets for the work
origin in this section. These offsets are relative to the WCS. 49
410
Notes:
• Use the Work offset field to enter a work offset code to be
output with the operation when you post it. You can display
the work offset number with the operation in the Toolpath
Manager.
• Click the View Selection button to select a new view in the
View Selection dialog box.
• As an alternative to typing the coordinates of the new origin

directly in the dialog box, click the Select button, and click on
the desired location in the graphics window to select a new
origin.
Canned Text Page

following graphic shows the Canned Text page for a contour wirepath.
Use this page to insert canned text commands in your NC program.

Canned text commands selected here will be inserted at the begin-
ning of each operation.
The canned text commands that are available to you depend on the
4
current control definition. They are listed in the left window. To insert
commands in your program, follow these steps:
1. Click on a canned text command in the left window to highlight
it.
42
2. Choose Add before, Add with, or Add after to tell Mastercam
where you want the command inserted relative to the active point
or tool change block.
Mastercam copies the selected command to the proper window.
43
Repeat steps 1 and 2 to build lists of commands at the desired loca-
tions in your program.
You can add as many commands as you wish to the list, as well as
multiple instances of the same command.
4
Notes:
• Depending on how the coolant/flushing settings for your 45
control and post are defined, you might also see coolant/
flushing options included in the list of available canned text
options. If this is the case, selecting a canned text coolant/
flushing option here has the same effect as choosing it in the
Flushing page of the Control Definition.
46
• Use the Change at point dialog box to insert canned text at
specific points in the wirepath.
47
48
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Flushing Page
following graphic shows the Flushing page for a contour wirepath.
Use this page to turn flushing on or off. The flushing options are
defined in the Flushing commands tab of the General Machine
Parameters dialog box.
For each type of coolant, you can set a maximum of two states:
 Whether to turn the coolant on, off, or maintain the current
state (as set by a previous operation or point).
 Whether to apply the change at the current location/block,
before it, or after it.
Your machine definition might not allow all possible states. For
example, you might be limited to a simple On/Off toggle. You can also
turn on several different flushing options at the same time, if your
machine definition allows it.
Generally, you will be able to turn different flushing options off indi-
vidually. However, for some machines, the first flushing off code will
turn off all flushing. The flushing section of the machine definition
contains this setting.
Canned Cycle Page

This dialog box property page applies only to canned wirepaths. 4
42
43
4
45
Use this page to: 46
 Establish a cycle ranging from Cycle 1 to Cycle 20 to indicate
to the post processor which type of option to run as defined
in the Canned 1 - Canned 7 text boxes.
 Provide information that the post processor needs to
47
perform the canned cycle.
 Assign a Z coordinate depth to the selected points.
 Set the start position to be automatically set to the thread
position.
48
functions specific to the control and wire EDM machine.
49
410
Cycle Custom Parameters Page

This dialog box property page applies only to canned wirepaths.
Use this page to set up the custom canned cycles, which determine
the information that the post processor needs to perform the canned
cycle.
functions specific to the control and wire EDM machine.
No Core Page
This dialog box property page applies only to no core wirepaths. 4
42
43
4
45
Use this page to establish the no core wirepath settings such as the Z
depth of a rapid move, the positions of the upper and lower wire
46
guides, and the UV and XY plane heights (usually the upper and lower
contour of the geometry).
You can also set the linearization tolerance and enable/disable the
wirepath start and end positions to automatically start and end at the
47
thread and cut points.
48
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Rough Page
This dialog box property page applies only to no core wirepaths.
Use this page to create and set up rough passes on no core wirepaths.
You can:
 Define the type of no core cutting method (Zigzag, Constant
Overlap Spiral, Parallel Spiral, Parallel Spiral with Clean
Corners, Morph Spiral, or True Spiral).
 Set the stepover percentage and distance.

 Set the roughing angle for Zigzag cutting methods.
 Set the clockwise/counterclockwise direction for all cutting
methods other than Zigzag.
Note: The roughing pass is the portion of the no core wirepath

that removes most of the material. Finish passes, that are set up
on the Finish page, smooth edges left by the roughing pass and
4
also remove additional material.
Finish Page 42
This dialog box property page applies only to no core wirepaths.
43
4
45
46
47
Use this page to create and set up finish passes on no core wirepaths.
You can:
 Define the number of finish passes, finish pass cut amounts,
48
and wire compensation.
 Set the start point of the finish pass.
 Set the roughing and finishing order in which multiple wire-
paths are cut.
49
 Eliminate arcs in the wirepath.
 Add a finish contour operation.
410
Note: Finish passes smooth edges left by the roughing pass and
also remove additional material. The roughing pass, created on
the Rough page, is the portion of the no core wirepath that
removes almost all of the material.
4 Axis Page
This dialog box property page applies only to 4-axis wirepaths.
Use this page to establish 4-axis wirepath settings such as the linear
arc move format (direct or taper), trimming options, and synchroni-
zation of the lower (XY) and upper (UV) contours.
If you have chosen to synchronize the contours, you can also set the
linearization tolerance (when converting 3D arcs and 2D or 3D
splines in the chained geometry from curves to lines). If you have
chosen not to synchronize the upper and lower contours, Mastercam
Wire places points on the wirepath so the wire can follow the chain.
Use the Step size field to specify how far apart the points are placed.
You can also use this page to set the Z depth for rapid moves, loca-
tions of upper and lower wire guides, and the XY and UV planes
(heights).
Point Page
This dialog box property page applies only to point wirepaths. 4
42
43
4
45
Use this page to establish the point wirepath settings such as the Z
depth of a rapid move, the positions of the upper and lower wire
46
guides, and the UV and XY heights.
47
48
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Agievision Wirepaths
Mastercam provides an Agievision interface for those using Agievi-
sion controllers. The wirepath options are intentionally designed as
close to the Agievision interface for a familiar look and ease of use.
The following are Agievision-specific dialog box pages:
 Machining page (page 148)
 Group page (page 150)
 Cut Parameters page (page 151)
 Collar page (page 152)
 Rough page (page 153)
 Finish page (page 154)
 Start Point page (page 156)
 Entry page (page 157)
 Exit page (page 158)
 Threading page (page 159)
 Taper page (page 160)
 Corners page (page 161)
 Attributes page (page 162)
Notes:
• The Misc. Values and Aux. Registers property pages are not
specific to Agievision wirepaths and are covered on pages 115
and 118, respectively.
• For brief descriptions on each of the dialog box property page
fields, please refer to the Mastercam Help. For detailed,
machine control-specific information, please refer to your
Agievision manufacturer's documentation.
WIREPATHS / Agievision Wirepaths • 147
The Agievision interface includes a complete set of machine defini-

tion/control definition/post processor files:
 AGIE GENERIC AGIEVISION_AWF 4X WIRE.WMD 4
 AGIE GENERIC AGIEVISION_AWF 4X WIRE MM.WMD
 AGIE GENERIC AGIEVISION_AWF 4X WIRE.control
 Agie Generic Agievision_AWF 4X Wire.pst 42
43
To use the Agievision interface, you must use these specific files.
Select the AGIE GENERIC AGIEVISION_AWF 4X WIRE (or MM)
machine definition from the Files tab of the Machine Group Proper-
4
ties dialog box to automatically enable the Agievision interface.
The Mastercam Agievision interface is not compatible with existing
parts that have been created with the Agie C-Hook.
The Agievision interface includes a specific control definition page
45
that supplies key information to the post processor. This means that
any current Agie posts—in other words, posts that have been devel-
oped to work with the Agie C-Hook (Agie Generic Agievision 4X
Wire.pst)—are incompatible. If you try to use the Agie C-Hook post
46
with the new interface, you will receive an error message and will not
be able to post.
New Agievision posts do not read the .ADT files generated by the C-
Hook; instead, in connection with the new interface, new blocks of
47
NCI data have been defined for Agie data.
Also, parts and toolpaths created by the Agie C-Hook cannot be
migrated to the new interface. The part geometry can be used, but all
the wirepaths must be recreated using the new interface.
48
Notes:
• Mastercam is still installed with the Agie C-Hook, allowing you
to run and maintain your current Agie C-Hook parts, using
49
your current Agie machine definition and post.
• The Agie C-Hook included two DLLs, AGIE.DLL and
AGIEREG.DLL. AGIEREG.DLL is still used by other Mastercam
functions, so do not remove it. It is called automatically by the
410
new interface.
To summarize:
 Posts written for the Agie C-Hook cannot be used with the
new Agievision interface.
 Wire machine and control definitions created for the Agie C-
Hook cannot be used with the new interface.
 Wirepaths created with the Agie C-Hook cannot be ported or
migrated to use the new interface.
 The new Agievision post cannot be used with parts created
with the Agie C-Hook.
 The name of the new post that supports the Agievision inter-
face is Agie Generic Agievision_AWF 4X Wire.pst.
Machining page
Use the Machining page (Agie Contour and 4-Axis wirepaths) to set/
edit the following:
 The machining name (optional, but recommended).
 The quality of the cut.
 The wire type (material and diameter).
 The machining strategy (user technology) to be used.
You can also use this page to set the technological height, priority, and
distance between the piece and the machine reference point.
Note: The wire type, quality, and strategy defaults are established
4
in the Details tab of the Machine Group Properties dialog box.
 To access the Machining page: 42

1 Make sure you have an Agie machine definition selected.
2 Select Contour or 4 axis from the Toolpaths menu. The
dialog box appears after you have chained the entities for the
wirepath.
43
3 Select Machining from the Tree View list of pages in the Wire-
path dialog box.
Note: You can also Click the Parameters icon in the Toolpath
4
Manager for an Agie contour or 4 axis wirepath to open the dialog
box.
45
46
47
48
49
410
Group page
Use the Group page (Agie Collar and No Core wirepaths) to set/edit
the following settings:
 The group name (optional, but recommended).
 The priority assigned to the group.
 The origin for this operation in relation to the part origin.
You can also use this page to set the priority and the distance between
the piece and the machine reference point.
 To access the Group page:

2 Select Collar or No Core from the Toolpaths menu. The

wirepath.
3 Select Group from the Tree View list of pages in the Wirepath
dialog box.
Note: You can also click Parameters in the Toolpath Manager for
an Agie Collar or No Core wirepath to open the dialog box.
Cut Parameters page

Use the Cut Parameters page to establish the punch or die cut param-
eters, including the cut separation and clearance, the minimum
4
radius for the last cut, and the option for a reverse cut.
42
43
4
45
46
For 4-axis wirepaths, you can also set the wirepath 4-axis output
format, sync option, linearization tolerance, and the step size.
 To access the Cut Parameters page:

47
2 Select any Agie wirepath type from the Toolpaths menu. The
wirepath.
48
3 Expand either the Machining selection (for Contour or 4 axis
wirepaths) or Group selection (for Collar wirepaths) in the
Tree View list. 49
4 Select Cut Parameters from the Tree View list of pages in the
Wirepath dialog box.
any Agie wirepath to open the dialog box.
410
Collar page
Use the Collar page (Agie Collar wirepaths to choose the type of collar
wirepath you want to use, and to establish the quality for each of the
collar levels in the chosen wirepath.
Click one of the three buttons (shown below) to set the location of the
conical sections of the part:
- Conical section of wirepath at top.
- Conical section of wirepath at bottom.
- Conical sections of wirepath at top and bottom.
When choosing the quality settings, you can click the User Tech
buttons to access the Technology Database dialog box (164), where
you can create/edit Agievision technologies used in Agievision
controllers.
 To access the Collar page:

2 Select Collar from the Toolpaths menu. The dialog box

4
appears after you have chained the entities for the wirepath.
3 Expand either the Group selection in the Tree View list.
4 Select Collar from the Tree View list of pages in the Wirepath
dialog box.
42
an Agie Collar wirepath to open the dialog box. 43
Rough page
Use the Rough page (Agie No Core wirepaths) to set/edit the
4
following:
 The quality of the cut. 45
 The machining strategy (user technology) to be used.
46
47
48
49
410
You can also use this page to set the technological height, priority, and
distance between the piece and the machine reference point.
When choosing the quality settings, you can click the User Tech
controllers.
in the Details tab of the Machine Group Properties dialog box.
 To access the Rough page:

2 Select No Core from the Toolpaths menu. The dialog box

3 Select Rough from the Tree View list of pages in the Wirepath
dialog box.
an Agie no core wirepath to open the dialog box.
Finish page
Use the Finish page to enable the finish cut of an Agie No Core wire-
path. Just as in the No Core rough wirepaths, you can set:
 The quality of the cut.
 The machining priority.
4
42
43
4
45
When choosing the quality setting, you can click the User Tech
controllers.
46
in the Details tab of the Machine Group Properties dialog box. 47
 To access the Finish page:
2 Select No Core from the Toolpaths menu. The dialog box
48
3 Select Finish from the Tree View list of pages in the Wirepath
dialog box. 49
an Agie no core wirepath to open the dialog box.
410
Start Point page

Use the Start Point page to set the start point parameters, including
the name, XYZ coordinates, and the diameter of the start point.
 To access the Start Point page:

wirepath.
3 Select Start Point from the Tree View list of pages in the Wire-
path dialog box. (For No Core wirepaths, access the Start
Point page by expanding either the Rough or Finish options
in the tree view.)
Entry page
Use the Entry page to set the following: 4
 Location of entry for start point (beginning, middle, or end).
 Angle of entry (free, perpendicular, or tangential).
 Distances between entry points and other wirepath cut
points on entities.
42
 Deviation distances between the start point and the contour
in both the X and Y directions.
43
4
45
46
47
 To access the Entry page:
1 Make sure you have an Agie machine definition selected. 48
wirepath.
3 Expand the Start Point selection in the Tree View list.
49
4 Select Entry from the Tree View list of pages in the Wirepath
dialog box.
410
Exit page
Use the Exit page to set the following:
 Angle of exit (free, perpendicular, or tangential).
 Distance of the exit commutation point from the exit.
 Deviation distances from the contour exit points (open
contour only).
 To access the Exit page:

wirepath.
3 Expand the Start Point selection in the Tree View list.
4 Select Exit from the Tree View list of pages in the Wirepath
dialog box.
Threading page
Use the Threading page to set the threading location and start hole
diameter for the wirepath start point.
4
42
43
4
45
46
 To access the Threading page:
47
wirepath.
3 Select Threading from the Tree View list of pages in the Wire-
path dialog box.
48
49
410
Taper page
Use the Taper page to control the type, direction, and angle of tapered
Agie contour wirepath cuts.
Click one of the three buttons (shown below) to control both the taper
definition type and direction. :
- Select the left button to apply a left taper (upper wire

guide moves left), with the taper angle defined by the Alfa field.
- Select the middle button to apply a right taper (upper wire

guide moves right), with the taper angle defined by the Alfa field.
- Select the right button to apply a fixed taper defined by

the X and Y component fields. Options other than the X Component
and Y Component fields are disabled.
 To access the Taper page:

2 Select a Contour wirepath type from the Toolpaths menu.

4
The dialog box appears after you have chained the entities for
the wirepath.
3 Select Threading from the Tree View list of pages in the Wire-
path dialog box.
42
an Agie contour wirepath to open the dialog box.
43
Corners page
Use the Corners page to set the type of radius on corners for any Agie
wirepath. You can set values for both the internal and external corners
4
of the wirepath.
45
46
47
48
49
410
 To access the Corners page:

wirepath.
3 Select Corners from the Tree View list of pages in the Wire-
path dialog box.
Note: You can also Click the Parameters icon in the Toolpath
Manager for any Agie wirepath to open the dialog box.
Attributes page
Use the Attributes page to set the cutting method for any Agie wire-
path according to the level of complexity and difficulty of the wire-
path. Use the buttons on the property page to select the cutting
method you want to use.
You can also set the trim cut security level (clearance for the wire
overburn) on this page.
Select one of the following buttons to set the working conditions for
VARIOCUT. The levels of difficulty range from 1 (left button default =
normal) to 4 (right button = highest difficulty). 4
- Most simple (normal). 42
- More complex, but still not very detailed or difficult.

43
4
- Complex, with some difficult details.
45
- Most complex, with the highest level of details/difficulty.
 To access the Attributes page:

46
wirepath.
3 Select Attributes from the Tree View list of pages in the Wire-
47
path dialog box.
48
49
410
Technology Database dialog box

Use the Technology Database dialog box to create/edit Agievision
technologies used in creating wirepaths.
 To access the Technology Database dialog box:

Select the User Tech button in any Agie wirepath. This button can be
found in several locations:
 Machining page in a contour or 4 axis wirepath
 Collar page in a collar wirepath
 Group, Rough, or Finish page in a no core wirepath
WIREPATHS / Backplotting Wirepaths • 165
Backplotting Wirepaths
4
Backplotting a wirepath lets you look at a graphical, animated display
of wire motion. You can check for programming errors in a backplot
before sending the wirepath to the machine.
Backplot is located within the Toolpath Manager. To run a backplot,
42
you will need to select operations, and then choose the Backplot
selected operations button.
The following sections describe options in Backplot that apply only to
Wire. See “Backplotting Operations” in the Mastercam X4 Getting
43
Started Guide and the online Mastercam X4 Reference Guide to learn
more about backplot.
4
Backplot Display Options
Use the Options button to change backplot settings that control the
colors the wirepath is displayed in, how backplot steps through the
toolpaths, and to display pointers to show the wire compensation
45
direction.
46
47
 Setting the colors for XY and UV motion affects how the back-
plot displays, and also sets the colors for the wirepath display
in the graphics window when not running backplot.
Note: Make certain to click the Display with color codes button
48
on the Backplot dialog box to display the wirepaths in the colors
that you selected in the Backplot Options dialog box.
 The Show wire comp vectors option displays arrows at

49
entity endpoints that show the compensation direction. Use
the compensation vectors when you need to see to which
side of the geometry the wire is offset. In the following
picture, the compensation vectors point to the inside of the
410
geometry. You can also select the color for the compensation
vectors.
Backplot Symbols
Backplot can insert symbols along the displayed wirepath that mark
where information such as control flags, control settings, or register
settings have been changed. You can turn off the display of backplot
symbols by choosing Settings, Configuration, Screen:
Backplot symbols are shown below:
Wire thread position
Wire cut position
Stop symbol
chapter 5
Editing Wirepaths
This chapter covers the following topics:
 Editing Wirepath Methods . . . . . . . . . . . . . . . . . . . . page 168
 Wirepath Editing Dialog Boxes . . . . . . . . . . . . . . . . page 169
 Editing Wirepaths Guidelines . . . . . . . . . . . . . . . . . . page 175
 Edit Wirepath Dialog Box Procedures . . . . . . . . . . . page 178
 Change At Point Dialog Box Procedures . . . . . . . . page 184
Editing Wirepath Methods

Mastercam Wire provides two methods for changing wirepaths:
Parameter editing and point-based editing.
Parameter editing—To change wirepath parameters, lead ins, lead
outs, and tabs, click the Parameters icon for the operation in the Tool-
path Manager to open the wirepath dialog box.
Point-based editing—Mastercam Wire provides two methods for
point-based editing of wirepaths: using the Change At Point dialog
box or the Edit Wirepath dialog box.
For contour wirepaths only, use the Change At Point dialog box to
change a parameter, control setting, control flag, or canned text at a
point.
Note: Change at Point changes are made to the geometry and

prompt wirepath regeneration if the geometry or parameters
change in the future.
For 4-axis, no core, or contour wirepaths, use the Edit Wirepath dialog
box. You can use this dialog box and associated dialog boxes to make
changes to the wire motion.
Note: Unlike the Change at Point changes, these edits are written
directly to the NCI file, not to the geometry. To preserve these NCI
changes, Mastercam locks the NCI file and prevents further regen-
eration of the wirepath. If you manually unlock the NCI file, the
previous parameter settings will prevail.
EDITING WIREPATHS / Wirepath Editing Dialog Boxes • 169
Wirepath Editing Dialog Boxes
Edit Wirepath Dialog Box

For 4-axis, no core, or contour wirepaths, use the Edit Wirepath dialog
box. You can use this dialog box and associated dialog boxes to make
changes to the wire motion.
Figure 5-1: Edit Wirepath dialog box
To access the Edit Wirepath dialog box, select a single wirepath opera-
tion in the Toolpath Manager, right-click on the operation title, and
choose Wirepath Editor from the Toolpath Manager right-click
menu.
Use the Edit Wirepath dialog box to modify an existing wirepath. You
can:
 Edit wire motion at specific point positions in the toolpath.
 Add points to increase wire motion.
 Move points to adjust wire motion.
 Delete selected points, passes, and sections of a wirepath.
TIP: Unlike the changes you make using the Change at Point
dialog box, these edits are written directly to the NCI file, not to
the geometry. To preserve these NCI changes, Mastercam
locks the NCI file and prevents further regeneration of the wire-
path. If you manually unlock the NCI file, the previous param-
eter settings will prevail.
You can also use the Edit Wirepath dialog box to view information
associated with the selected wirepath point position, including the G-
code, canned text settings, feed rate, and endpoint coordinates.
For additional wirepath editing functionality, you can access the Edit
Point, Control Settings, and Control Flags dialog boxes through the
Edit Wirepath dialog box.
Edit Point Dialog Box

Use this dialog box to change the point parameters of a wirepath.
Figure 5-2: Edit Point dialog box.
To access the Edit Point dialog box from the Edit Wirepath dialog box,
click the Edit Point button.
This dialog box gives you control over the motion in a wirepath on a
point-by-point basis. For example, you can use this dialog box to
perform such functions as:
 Add taper to a single point or a series of points
 Access other dialog boxes to assign control flags for machine
events such as flush or power
 Add flag settings to trigger machine events such as stops, glue
stops, threading the wire
 Change corner type
Note: In the Edit Point dialog box, Rapid Move is unavailable for
arcs and Feedrate is disabled for rapid moves.
Control Settings Dialog Box

Use this dialog box to change the wirepath control settings on a point-
by-point basis.
5
Figure 5-3: Control Settings dialog box
To access the Control Settings dialog box from the Edit Point dialog
box, select the Control Settings check box, and then click the Control
Settings button.
A control setting initiates a mode or state in the control for a partic-
ular pass (selected in the Pass field in the Edit Wirepath dialog box) by
generating a G1010 code (wire condition change).
To change a control setting, check the box next to the setting and
enter a value.
Notes:
• After changing any control settings, the Wirepath will be locked
and you will need to manually unlock it to make any future
changes.
• In a multi-contour operation, the endpoints defining the chain
being changed must be on the same contour.
• New register values override values entered in the Aux. Regis-
ters page.
• The register values stay in effect until new values are entered.
Control Flags Dialog Box

Use this dialog box to assign control flags to a point in a wirepath.
Figure 5-4: Control Flags dialog box
To access this dialog box from the Edit Point dialog box, select the
Control Flags check box, and then click the Control Flags button.
A control flag triggers machine events such as stops, glue stops,

threading the wire, cutting the wire, or setting the water flush. These
events are applied to a single pass (selected in the Pass field in the
Edit Wirepath dialog box).
To change a control flag, check the box next to the setting and edit the
settings.
Notes:
• You can assign multiple flags to a single point.
• After changing any control flags, the wirepath will be locked
and you will need to manually unlock it to make any future
changes.
Change At Point Dialog Box

Use this dialog box to make associative changes to a contour wire-
path. You can assign taper, corner types, and wire parameters to
entity endpoints on the geometry. Change At Point is available only
on contour wirepaths.
5
Figure 5-5: Change At Point dialog box
To access this dialog box, click the geometry icon for a contour wire-
path, select a chain in the Chain Manager, and then right-click and
choose Change at point from the menu.
Note: Changes made with Change at point remain in effect if you

change the geometry. However, Mastercam Wire erases the point
changes if you rechain the geometry.
EDITING WIREPATHS / Editing Wirepaths Guidelines • 175
Editing Wirepaths Guidelines
Edit Wirepath Dialog Box Guidelines

The following are guidelines to keep in mind when editing wirepaths
using the Edit Wirepath and related dialogs described herein:
 The Edit Wirepath dialog box is not available for manual
entry wirepaths.
 Be sure to make all other changes to the wirepath (such as
wire or parameter changes) before using the Edit Wirepath
dialog box and related dialog boxes. Because these edits are
written directly to the NCI file, not to the geometry,
Mastercam locks the wirepath and prevents regeneration.
Locked wirepaths, identified in the Toolpath Manager by the
Locked icon (shown below),
are not updated by Mastercam. To further modify a locked 5

wirepath, you must manually unlock it by clicking the Toggle
locking on selected operations button in the Toolpath
Manager. If the wirepath is regenerated after editing, any
previous modifications to the NCI file will be overwritten.
 Because changes made through the Edit Wirepath dialog box
are made to the machine motion, not the geometry, they are
not associative.
 Use the fields in the Position section of the Edit Wirepath
dialog box to select the wirepath point position to edit.
 If the wirepath includes multiple passes, you can also choose

to delete a pass in that point position.
 Use one of the following selection methods:
 Click the up and down scroll arrows, or click in the field
and use the mouse wheel or arrow keys to scroll.
 Enter a number directly in the field.
 Click a position in the graphics window.
 The selected position appears highlighted in the graphics

window wirepath display. The display changes as you use
other options to move, edit, or delete the selected wirepath
point or pass.
 Pass is available only if multiple passes are used in the wire-
path.
 When adding a new point, select the Before check box to
insert the new point before the point position in the wire-
path. Deselect it to add the new point after this point posi-
tion.
 Use the options in the Show section of the Edit Wirepath

dialog box to set wirepath display options in the graphics
window. You can view only the pass you choose in the corre-
sponding Position field.
 The Delete Section option lets you remove a defined section

of the wirepath, based on the starting and ending point posi-
tions you choose.
 Click Cancel in the Edit Wirepath dialog box to cancel all
changes you made to the wirepath during a single session in
the Edit Wirepath dialog box, including those made in the
Edit Point, Control Settings, and Control Flags dialog boxes.
Change At Point Dialog Box Guidelines

The following are guidelines to keep in mind when editing wirepaths
using the Change At Point dialog box:
 Select the point by clicking on the line next to it, not on the
point itself.
 Where lines converge, more than one endpoint can exist at
the same location.
 If you have selected the Wire check box in the Toolpaths
property page of the System Configuration dialog box, the
Chain Manager dialog box automatically opens when you
create a contour wirepath and click OK.
EDITING WIREPATHS / Editing Wirepaths Guidelines • 177
 If you have selected Multi-Select in the Chain Manager right-

click menu, you can choose as many points on the active
chain as you want. When you are done, press the [Esq.] key to
open the Change At Point dialog box. If you deselected Multi-
Select, as soon as you click the wirepath, the Change At Point
dialog box opens.
 When selecting entity endpoints, the endpoints of two adja-
cent entities may lie at the same location and appear to be
the same point in the graphics window. However, when using
wire compensation to the outside of the geometry, these two
endpoints actually correspond to different locations on the
contour because the wirepath has corner arc.
For additional guidelines on using the Change At Point dialog box, see
the Guidelines for Change At Point section in Chapter 4, Wirepaths.
5
Edit Wirepath Dialog Box Procedures
Adding a Point to a Wirepath

 To add a point to a wirepath using the Edit Wirepath dialog
box:
1 In the Toolpath Manager, select the wirepath operation you
want to edit.
2 Right-click the operation to bring up the Toolpath Manager
right-click menu and choose Wirepath Editor. The Edit Wire-
path dialog box opens.
3 Using the Point field, select a point in the wirepath close to
the position where you want to add a point. The selected
point is highlighted in red.
4 Check or uncheck the Before check box to place the new
point before or after the position you designated.
Note: The before/after setting is relative to the direction of the

chain.
5 Click the Add Point button. The Edit Wirepath dialog box
minimizes.
6 Click in the graphics window or use the AutoCursor to posi-
tion the new point. The wirepath redraws showing the new
point, and the Edit Wirepath dialog box reappears.
7 Choose OK to return to the Toolpath Manager.
Deleting a Point from a Wirepath

 To delete a point from a wirepath using the Edit Wirepath
dialog box:
want to edit.
EDITING WIREPATHS / Edit Wirepath Dialog Box Procedures • 179
3 Using the Point field, select the point that you want to delete.
The selected point is highlighted in red.
4 Click the Delete Point button.
Moving a Point in a Wirepath

 To move a point in a wirepath using the Edit Wirepath dialog
box:
want to edit.
3 Using the Point field, select a point in the wirepath close to
the position where you want to add a point. The selected
point is highlighted in red.
4 Click the Move Point button. The Edit Wirepath dialog box
5
minimizes.
5 Click in the graphics window or use the AutoCursor to reposi-
tion the point. The wirepath redraws showing the reposi-
tioned point, and the Edit Wirepath dialog box reappears.
Deleting a Pass from a Wirepath

 To delete a pass from a wirepath using the Edit Wirepath dialog
box:
want to edit.
3 Using the Pass field, select the pass that you want to delete.
The selected pass is highlighted in the graphics window.
4 Click the Delete Pass button.

Deleting a Section from a Wirepath

 To delete a section from a wirepath using the Edit Wirepath
dialog:
want to edit.
3 Use the Point field to select the start point of the section you
want to delete.
4 Click the Delete Section button. The Section dialog box
opens.
5 Scroll through the endpoints to select the section that you
want to delete. The selected section is highlighted in the
graphics window.
Note: The section begins with the point position value you defined
in the Edit Wirepath dialog box, and ends with the point position
you enter here.
6 Click the OK button. The Section dialog box closes, the Edit
Wirepath dialog box opens, and the section you chose is
deleted.
7 Choose OK to close the Edit Wirepath dialog box and return
to the Toolpath Manager.
Changing Control Flags with Edit Point

Dialog Box
 To change the control flags for an existing point in a wirepath:
TIP: A control flag triggers a machine event such a stop, glue

stop, threading the wire, cutting the wire, or flush.
1 In the Toolpath Manager, select the wirepath you want to

edit.
2 Right-click on the operation and choose Wirepath Editor
from the right-click menu. The Edit Wirepath dialog box
opens.
3 Select a point in the wirepath that you want to change using

the Pass and Point fields. The selected point is highlighted in
red.
4 Choose Edit Point. The Edit Point dialog box opens and the
wire move prior to the selected point is highlighted in red.
5 Click the Control Flags check box and then the Control
Flags button.
6 In the Control Flags dialog box, check the box next to the
setting and set the related values:
 Contour assigns a contour start or end flag to the
currently selected point.
 Lead inserts a lead in/out start or end flag.
 Stop/Glue assigns a stop or optional (glue) stop flag to the
selected point.
 Thread/Cut determines where to thread or cut the wire.
Be sure that there is a cut position for each thread posi-
tion.
 Power inserts a power on/off flag.
 Tank level sets the state for the fluid tank.
5
 Choose the Flushing button to open the Flushing dialog
box (Coolant dialog box). In this dialog box, you can set
the water On or Off.
7 Click OK to accept changes and return to the Edit Point
dialog box.
8 Choose OK to return to the Edit Wirepath dialog box.
Changing Control Settings with Edit Point

Dialog Box
 To change the control settings for an existing point in a
wirepath:
edit.
opens.

the Pass and Point fields. The selected point is highlighted in
red.
5 Click the Control Settings check box and then the Control
Settings button.
6 In the Control Settings dialog box, check the box next to the
setting and enter a value. The following default settings are
available:
 Condition Code inserts a wire condition code register
value at the selected point.
 Wire Offset requires a wire offset register number. You
may need to reference your wire machine documentation
for this information.
 Wire Diameter changes the wire width.
 Wire Overburn sets the width of the spark gap between
the wire and the part.
 Registers 1 – 10 correspond to registers in the machine
control. The new value overrides a value entered in the
Aux. Registers page of the wirepath dialog box. The
register values stay in effect until new values are entered.
7 Click OK to accept changes and return to the Edit Point
dialog box.
Editing Points Using the Edit Point Dialog

Box (Wire)
 To change any point parameter in an existing wirepath:
edit.
opens.
the Point field. The selected point is highlighted in red.
Note: In the Edit Point dialog box, Rapid Move is unavailable for
arcs and Feedrate is disabled for rapid moves.
5 Make changes to the selected point in the dialog box.

5
Change At Point Dialog Box Procedures
Assigning Canned Text with Change At

Point
 Follow these steps to assign canned text to a point in a
wirepath:
1 In the Toolpath Manager, click the Geometry icon for the
contour wirepath.
2 In the Chain Manager, highlight the chain to edit, right-click,
and choose Change at point.
3 When prompted, click the point to change on the contour
wirepath.
Notes:
• Select the point by clicking on the line next to it, not on the
point itself.
• Where lines converge, more than one endpoint can exist at the
same location.
• If you have selected Multi-Select in the Chain Manager right-
click menu, you can choose as many points on the active chain
as you want. When you are done, press the [Esc] key to open the
Change At Point dialog box. If you deselected Multi-Select, as
soon as you click the wirepath, the Change At Point dialog box
opens.
4 In the Change At Point dialog box, select the Canned Text

check box, and then choose the Canned Text button. The
current canned text settings display in the Canned text dialog
box.
5 To assign canned text to a point, select a canned text variable
from the list, choose to add it before, with, or after the
selected point, and then choose Add.
Note: Choose the Remove button to eliminate the canned text

variable from the selected point.
6 Choose OK to close the Canned text dialog box.

EDITING WIREPATHS / Change At Point Dialog Box Procedures • 185
7 Make additional changes to the selected point, as necessary,

and then choose OK to close the Change At Point dialog box.
8 To change other points, return to step 3. Otherwise Press
[Esc], and then click OK to close the Chain Manager.
9 Choose Regenerate all selected operations in the Toolpath
Manager to regenerate the contour operation and apply
point changes.
Changing Control Flags with Change At

Point
 Follow these steps to use the Change At Point dialog box to
assign control flags to a point in a wirepath:
1 In the Toolpath Manager, click on the Geometry icon for the
contour wirepath.
5
Notes:
• You can assign multiple flags to a single point.
• When prompted, click the point to change on the contour wire-
path.
point itself.
same location.
opens.
3 In the Change At Point dialog box, check the Control Flags

box, and then choose the Control Flags button. The current
control flags are shown in the Control Flags dialog box.
4 To change a control flag, check the box next to the setting and
set the related values:
 Contour assigns a contour start or end flag to the

currently selected point.
 Lead inserts a lead in/out start or end flag.
 Stop/Glue assigns a stop or optional (glue) stop flag to the
selected point.
 Thread/Cut determines where to thread or cut the wire.
Be sure that there is a cut position for each thread posi-
tion.
 Power inserts a power on/off flag.
 Tank level sets the state for the fluid tank.
 Flush sets the water flushing on or off for all passes. If you
select this option, you can choose the Flushing button to
open the Flushing dialog box (Coolant dialog box). In this
dialog box, you can set the water On or Off.
5 Choose OK to close the Control Flags dialog box.
6 Choose OK to close the Change At Point dialog box.
Note: If necessary, press [Esc] and OK to exit the Chain Manager.

point changes.
Changing Control Settings with Change

At Point
change control settings on a point-by-point basis:
1 In the Toolpath Manager, click on the Geometry icon for the
contour wirepath.
wirepath.
EDITING WIREPATHS / Change At Point Dialog Box Procedures • 187
Notes:
point itself.
same location.
opens.
4 In the Change At Point dialog box, check the Control

Settings check box, and then choose the Control Settings
button. The current control settings are shown in the Control
Settings dialog box.
5 To change a control setting, check the box next to the setting
and enter a value.
 All passes applies the control setting to the selected point
5
for the entire wirepath.
 Condition Code inserts a wire condition code register
value at the selected point.
 Wire Offset requires a wire offset register number. You
may need to reference your wire machine documentation
for this information.
 Wire Diameter changes the wire width.
 Wire Overburn sets the width of the spark gap between
the wire and the part.
 Registers 1 – 10 correspond to registers in the machine
control. The new value overrides a value entered in the
Aux. Registers page of the wirepath dialog box. The
register values stay in effect until new values are entered.
6 Choose OK to close the Control Settings dialog box.
7 Choose OK to close the Change At Point dialog box.
Note: If necessary, press Esc and OK to exit the Chain Manager.

point changes.
Making Associative Changes with

Change At Point
make associative parameter changes to a wirepath point:
1 In the Toolpath Manager, click the Geometry icon for the
contour wirepath.
2 In the Chain Manager dialog box, highlight the chain you
want to edit and right-click.
3 Choose Change at point from the right-click menu.

wirepath.
Notes:
point itself.
same location.
opens.
5 Make parameter changes as needed and click OK. The

Change At Point dialog box minimizes and you are prompted
to select another point.
6 Press [Esc] when done, and choose OK to close the Change At
Point dialog box.
7 Choose OK to close the Chain Manager.

point changes.
• 189
Index
Numerics component groups ................................. 30

4-axis wirepaths ................... 14, 71, 75, 82 components
chain synchronization ........................ 77 linear axis ............................................ 31
guidelines............................................ 78 wire guides .......................................... 32
setting XY/UV extensions ................... 76 conical corners........................................ 60
trimming ............................................. 76 constant corners ..................................... 59
contour wirepaths
corner types .................................. 40, 58
A multiple contours ......................... 66, 67
Agievision .............................................. 146 overview .............................................. 56
associative parameters taper .................................................... 58
editing ............................................... 188 tapers .................................................. 56
Autosync Rails function .......................... 82 contours
chaining .............................................. 25
B geometry ............................................. 12
backplot................................................. 165 open and closed.................................. 13
breaking geometry .................................. 21 Control Definition Manager ................... 34
C
control definitions
4-axis paths ......................................... 43 66
corner.................................................. 40
canned text cuts...................................................... 39
editing ............................................... 184 feed...................................................... 38
canned wirepaths.................................... 69 files ...................................................... 35
defining canned cycles ....................... 69 linear ................................................... 37
chaining no core ................................................ 44
contours and points............................ 25 reverse cuts auxiliary .......................... 42
synchronization .................................. 14 reverse cuts contour ........................... 41
window................................................ 24 selecting .............................................. 33
change at point start/leads ........................................... 38
assigning canned text ....................... 184 subprograms ....................................... 44
associative changes.....................64, 188 text ...................................................... 45
control flags....................................... 185 wire ..................................................... 34
control settings ................................. 186 control flags
dialog box.......................................... 173 Control Flags dialog .......................... 172
guidelines............................................ 65 editing ....................................... 180, 185
C-Hooks control settings
Agie...................................................... 35 Control Settings dialog ..................... 171
compensation offsets.............................. 99 editing ....................................... 181, 186
direction............................................ 101 corner types ............................................ 58
types .................................................. 100 creating ................................................... 87
cut points................................................. 18 descriptions ...................................... 110

cuts layout ................................................ 108
rough, tab, skim ................................ 104 list of pages........................................ 112
cutting direction...................................... 58 list of pages (Agie) ............................. 146
Page area ........................................... 110
D Quick View Settings area................... 110
Tree View area................................... 109
dialog box pages
documentation
4 Axis ................................................. 144
resources ............................................... 6
Attributes (Agie) ................................ 162
Aux. Registers .................................... 118
Canned Cycle .................................... 139 E
Canned Text ...................................... 136 Edit Point dialog............................170, 182
Collar (Agie)....................................... 152 Edit Wirepath dialog ............................. 175
Compensation................................... 122 editing wirepaths
Corners.............................................. 133 associative parameters ..................... 188
Corners (Agie) ................................... 161 Change At Point dialog ..................... 173
Cut Parameters.................................. 120 Control Flags dialog .......................... 172
Cut Parameters (Agie) ....................... 151 Control Settings dialog ..................... 171
Cycle Custom Parameters................. 140 dialogs ............................................... 169
Entry (Agie)........................................ 157 Edit Point dialog................................ 170
Exit (Agie) .......................................... 158 Edit Wirepath dialog ......................... 175
Filter .................................................. 125 guidelines.......................................... 175
Finish................................................. 143 methods ............................................ 168
Finish (Agie) ...................................... 154 procedures ........................................ 178
Flushing............................................. 138 editors
Group (Agie) ...................................... 150 Change At Point dialog ..................... 176
Lead Distance.................................... 129 Edit Wirepath dialog ......................... 175
Leads ................................................. 126 wirepath ........... 169, 170, 171, 172, 173
list of .................................................. 112 expand operation ............................67, 107
Machining (Agie)............................... 148
Misc.Values ....................................... 115 F
No Core ............................................. 141
feed rates
Planes (WCS) ..................................... 135
operation............................................. 32
Point .................................................. 145
fishtail corners ........................................ 61
Rough ................................................ 142
fixed corners............................................ 62
Rough (Agie)...................................... 153
Start Point (Agie) ............................... 156
Start Position..................................... 130 G
Stops.................................................. 123 geometry
Subprograms..................................... 124 4-axis wirepath.................................... 14
Tab/Finish Leads .............................. 127 breaking .............................................. 21
Taper ................................................. 131 overview .............................................. 12
Taper (Agie)....................................... 160 guidelines ................................................ 86
Tapered Thread................................. 134
Threading (Agie)................................ 159 H
Wire/Power ....................................... 114 Help
Wirepath Type................................... 113 using...................................................... 4
dialog boxes
• 191
L start point................................................ 26
lead ins and lead outs............................ 102 start-up ..................................................... 2
stock to leave........................................... 93
stops
M program, glue.................................... 107
Machine Definition Manager ................. 28 subprograms ........................................... 44
machine definitions switch between products.......................... 3
default ................................................. 33
overview .............................................. 28
machine groups T
files ...................................................... 47 taper ........................................................ 58
overview .............................................. 46 thread points
program settings ................................. 49 break geometry perpendicular to ....... 21
stock setup .......................................... 49 creating ............................................... 16
positions ........................................... 107
sorting ................................................. 68
N using a thread distance..................... 107
no core wirepaths.................................... 71 transform wirepaths ......................... 86, 87
control settings ................................... 44
finishing .............................................. 72
guidelines............................................ 73 U
overview .............................................. 71 using Mastercam Help.............................. 4
roughing.............................................. 72 UV plane.................................................. 13
P W
wire compensation
PDF
viewing .................................................. 7
point wirepaths ....................................... 86
direction............................................ 101
offsets .................................................. 99
66
points types.................................................. 100
chaining .............................................. 25 wirepath dialog boxes
cut ....................................................... 18 4 Axis page......................................... 144
thread .................................................. 16 Attributes page (Agie) ....................... 162
thread and cut overview ..................... 14 Aux. Registers page ........................... 118
post processor Canned Cycle page ........................... 139
selecting .............................................. 33 Canned Text page ............................. 136
UpdatePost ......................................... 34 Collar page (Agie).............................. 152
power settings libraries Compensation page.......................... 122
associating to operation ..................... 91 Corners page ..................................... 133
associating with an operation............. 91 Corners page (Agie) .......................... 161
creating or editing............................... 92 Cut Parameters page......................... 120
default ................................................. 90 Cut Parameters page (Agie) .............. 151
overview .............................................. 89 Cycle Custom Parameters page........ 140
descriptions ...................................... 110
Entry page (Agie)............................... 157
R Exit page (Agie) ................................. 158
running Mastercam .................................. 2 Filter page ......................................... 125
Finish page........................................ 143
S Finish page (Agie) ............................. 154
sharp corners .......................................... 60 Flushing page.................................... 138
Group page (Agie) ............................. 150 point .................................................... 86

layout................................................. 108 taper and direct................................... 43
Lead Distance page ........................... 129 transform ............................................ 86
Leads page......................................... 126
list of pages........................................ 112 X
Machining page (Agie) ...................... 148
XY plane .................................................. 13
Misc. Values page.............................. 115
No Core page..................................... 141
Page area ........................................... 110
Planes (WCS) page ............................ 135
Point page ......................................... 145
Quick View Settings area................... 110
Rough page........................................ 142
Rough page (Agie) ............................. 153
Start Point page (Agie) ...................... 156
Start Position page ............................ 130
Stops page ......................................... 123
Subprograms page ............................ 124
Tab/Finish Leads page...................... 127
Taper page......................................... 131
Taper page (Agie) .............................. 160
Tapered Thread page ........................ 134
Technology Database (Agie) ............. 164
Threading page (Agie) ....................... 159
Tree View area ................................... 109
Wire/Power page............................... 114
Wirepath Type page .......................... 113
wirepath editing
Change At Point dialog...................... 173
Control Flags dialog .......................... 172
Control Settings dialog...................... 171
Edit Point dialog........................170, 182
Edit Wirepath dialog ......................... 169
methods ............................................ 168
passes ................................................ 179
points ............................... 178, 179, 188
sections ............................................. 180
wirepaths
4-axis .............................................71, 75
backplotting ...................................... 165
canned................................................. 69
contour................................................ 56
defining canned cycles........................ 69
editing ...................... 169–173, 175, 178
editing multiple operations ................ 68
no core................................................. 71
no core finishing ................................. 72
no core roughing................................. 72

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Mastercam® X4 Wire Getting Started Guide

1. Introduction to Mastercam X4 Wire ...........................1

2. Wire Part Geometry ...........................................................11

3. Wire Machine and Control Definitions .....................27

 Wire Machine Group Properties ........................................46

5. Editing Wirepaths .............................................................167

 Edit Wirepath Dialog Box Procedures .............................178

Starting Mastercam Wire

 To start Mastercam Wire

Or select Mastercam X4 from the Windows Program menu.

Once you have selected a wire machine definition,

 To switch between Mastercam products

Using Online Help

 To view a PDF document:

TIP: For quick access to the Mastercam X4 Reference Guide,

Note: For more information on working with PDFs, refer to the

Mastercam Support and Services

CNC Software, Inc. Educational Divi-

For assistance with installing Mastercam, its SIM HASP or NetHASP,

TIP: Use Mastercam’s Zip2Go utility to gather Mastercam part

Important Contact Information

Address CNC Software, Inc.

Phone (860) 875-5006

Fax (860) 872-1565

FTP Address ftp://ftp.mastercam.com

Internet Address http://www.mastercam.com

Basic Requirements for Wire Geometry

4-axis Wirepath Geometry

Creating Thread Points

TIP: You can let Mastercam create thread positions by using

4 Click the position for the thread point in the graphics

Creating Cut Points

 To create a cut point

2 Select the cut point style.

3 Choose Create, Point, Position.

Creating Thread and Cut Points with

 To add the thread and cut point toolbar buttons to the

2 Under Category, select Geometry.

 To automatically create thread or cut points

1 Click the Create Thread Point or Create Cut Point button.

Breaking Geometry Perpendicular

 To automatically break an entity perpendicular to the thread

3 Select the Break closest entity to thread point check box,

5 Click to enter a search point.

6 Choose OK to exit the Chaining dialog box and open the

Note: If Mastercam Wire displays the message “cannot break line

 To break an entity and create a perpendicular thread point

TIP: Right-click in the graphics window and choose Auto-

1 In the Status Bar, Attributes section, set the point style to

3 On the Trim/Extend/Break ribbon bar, select these two

4 Select the entity to break.

5 Select the midpoint of the entity to break it in half.

8 Select one of the segments of the entity that was broken in

10 Using the dynamic arrow, position the cursor on the side of

Chaining Wire Geometry

 To window chain thread points and geometry

3 In the graphics window, click and drag a rectangle around all

Click and drag a rectangle around the part...