2023 Multiaxis

Multiaxis
Professional Courseware
Mastercam 2023 Multiaxis Professional Courseware
Copyright: 1998 - 2023 In-House Solutions Inc. All rights reserved
Software: Mastercam 2023
Date: July 4, 2022

Author: Mariana Lendel
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Table Of Contents
Multiaxis Professional Courseware 1
4 Axis Introduction 30
Introduction To 4 - Axis Programing 31
Mastercam® User Interface: 35
Setting The Grid 36
Home Tab And The Mini Toolbar 37
Data Entry Shortcuts 39
The Right Mouse Click Menu 40
AutoCursor 41
About Rotary Axis Control 42
Mastercam® 4 - Axis Work Flow: 43
Conventions Used In This Book 47
Axis Substitution Roll 48
Introduction: 49
Instructor Demonstration Preview: 51
Exercise 1: Axis Substitution - Roll The Geometry 52
Step 1: Locate Part Geometry 52
Step 2: Open File 52
Step 3: Set The Stock As Cylinder In The Stock Setup 52
Step 4: Roll The Geometry 56
Step 5: Drill The 0.25" Diameter Holes 58
Step 6: Substitute X-axis 59
Step 8: Slot Mill The Inside Obround Shape 62
Step 9: Contour The Outside Obround 64
Axis Substitution Unroll 68
Introduction: 69
Exercise 2: Axis Substitution - Unroll The Geometry 71
3
Locate Part Geometry 71
Step 2: UnRoll The Geometry 71
Step 3: Create Extra Geometry To Be Able To Machine The Open Areas 72
Step 4: Use Pocket Toolpath To Machine The Part 73
Step 5: Change The Tool And The Stepover 78
Step 6: Rolldie C-Hook 79
Using Rolldie C-hook To Machine With The Side Of The Tool 79
Axis Substitution Helix 82
Introduction: 83
Exercise 3: Axis Substitution - Creating A Cylindrical Helix 85
Step 1: Create The Geometry For The Helix 85
Step 2: Select The Default Mill Machine 87
Step 3: Machine The Helix Using Contour With Axis Substitution 89
Exercise 4: Axis Substitution - Creating A Conical Helix 92
Create The Geometry For The Conical Helix 92
Step 4: Use Analyze Entity Properties Command To Modify The Geometry 92
Step 5: Machine The Conical Helix 93
Axis Substitution Dynamic Mill 95
Introduction: 96
Exercise 5: Axis Substitution Pocket 98
Locate Part Geometry 98
Step 2: Create The Wireframe Using Curve All Edges 98
Step 3: Unroll The Geometry 99
Step 4: Fix The Geometry 101
Step 5: Create A Rectangle Using Bounding Box 102
Step 6: Select The Machine And Set The Properties 103
4
Step 7: Dynamic Toolpath To Machine The Triangles 104
Axis Substitution & Rolldie 108
Introduction: 109
Exercise 6: Axis Substitution & Rolldie - Barrel Cam 111
Step 1: Select A Machine And Set The Properties 111
Step 2: Create The Contour Toolpath Using Axis Substitution 112
Step 3: Rolldie C-Hook To Machine The Barrel Cam 116
Step 4: Using Rolldie C-hook To Machine The Right Side 116
Step 5: Using Rolldie C-hook To Machine The Left Side 118
Axis Positioning & Transform 120
Introduction 121
Exercise 7: Axis Substitution, Positioning & Transform 123
Step 2: Drill The Four 3/8" Holes Y-Axis Substitution 124
Step 3: Drill The Eight Holes Using Rotary Axis Positioning 126
Step 4: Engrave The Numbers Using Axis Substitution 127
Step 5: Machine One Slot Using 2D Contour 129
Step 6: Transform - Rotate Toolpath 130
Planes - Indexing A-Axis 132
Introduction: 133
Exercise 8: Tool Planes - Indexing About A-Axis 135
Step 1: Machine The Cutouts Using Contour - Axis Substitution. 135
Step 2: Setup The Tool Plane Using Dynamic 138
Step 3: Drill The 25/64" Diameter Hole 139
Step 4: Transform - Rotate To Machine The Other Two Holes 141
Step 5: Machine The Top Cutout Using Contour Toolpath 143
Step 6: Machine The Bigger Slot At 120 Degrees 144
5
Step 7: Verify The Toolpaths 146
Step 8: Remove The Chips 147
Planes - Horizontal Machining 148
Introduction 149
Instructor Demonstration 150
Exercise 9: Tool Planes - For Horizontal Machining Centers 151
Step 2: Setup The Plane At An Angle 152
Step 3: Machine The Face 153
Step 4: Drill The 3/8" Hole 154
Step 5: Circle Mill The 0.75" Hole 155
Step 6: Setup The Right Side Plane 157
Step 7: Machine The Right Side Slot 158
Step 8: Setup The Left Side Plane 159
Step 9: Machine The Left Side Slot 160
Step 10: Setup The Front Plane 161
Step 11: Machine The Front Boss 162
Step 12: Machine The Front Pocket 165
Step 13: Drill The 1/4" Holes To 0.625" Depth 166
Step 14: Machine The Back Face. 166
Legacy Multiaxis Introduction 167
Introduction: 168
Legacy 5-Axis Toolpaths 176
Curve - 5 Axis 176
Drill & Circle Mill - 5 Axis 176
Swarf 5 Axis Toolpath 176
Flow - 5 Axis Toolpath 176
Multisurface 176
Rotary Toolpath 177
Introduction 178
6
Exercise 1: Rotary Toolpaths 182
Step 1: 4 Axis Rotary Toolpath With Rotary Cut 182
Step 2: 4 Axis Rotary Toolpath WITH Axial Cut 185
Exercise 2: Axis Rotary Toolpath - Axial Dampening 187
Step 3: Axis Dampening Length = 0.002. 188
Step 4: Change Axis Dampening Length To 0.2 189
Step 5: Change The Axis Dampening Length To 2.0 189
Curve 5-Axis 190
Introduction: 191
Exercise 1: Curve Type - 3D Curves 193
Step 2: Create A Curve Toolpath Selecting A 3D Curve 193
Exercise 2: Curve Type - Surface Edge Single 199
Step 3: Create A Curve Toolpath Selecting An Edge 199
Step 4: Select The Toolpath 199
Exercise 3: Curve Type - Surface Edge All 203
Step 5: Create A Curve Toolpath At All Edges Of A Surface 203
Exercise 4: Tool Axis Control - Lines 206
Step 8: Machine The Opposite Wall 209
Exercise 5: Tool Axis Control - Plane 210
Step 9: Curve Toolpath Tool Axis Control Towards A Plane 210
Exercise 6: Tool Axis Control - From Point 213
Step 10: Curve Toolpath With Tool Axis Control From A Point 213
Exercise 7: Tool Axis Control - To Point 215
Step 12: Curve Toolpath With Tool Axis Control Set To A Point 215
7
Step 13: Select The Toolpaths 215
Step 14: Machine Simulation 219
Step 15: Change The Tool Axis Control To Chain 220
Exercise 8: Tool Axis Control - Chain 224
Step 16: Curve Toolpath With Tool Axis Control Set From A Chain 224
Step 18: Create A Chain 227
Step 19: Change The Tool Axis Control 228
Exercise 9: Curve 5 Axis - Output Format 229
Step 20: Output Format Set To 3 Axis 229
Exercise 10: Curve - Tip Control 233
Step 24: Tip Control On Selected Curve 233
Step 26: Tip Control Set To Comp To Surface 234
Exercise 11: Curve 5 Axis - Projection Type 235
Step 27: Projection Set To Normal To Plane 235
Step 29: Projection Set To Normal To Surface 237
Exercise 12: Curve 5 Axis - Review 238
Step 30: Create A Stock Model 238
Step 31: Set The Toolpaths 238
Step 32: Curve And Tool Axis Control Lines 238
Step 33: Curve Tool Axis Control Surface & 4 Axis Output 240
Step 34: Curve Tool Axis Control Plane 240
Step 35: Curve Tool Axis Control From Point 241
Step 36: Curve Surface Edge Using Tool Axis Control To Point 242
Drill 5-Axis 244
8
Introduction 245
Instructor Demonstration: 246
Exercise 1: Drill - Entity Type Points 247
Step 1: Drill 5 Axis By Selecting The Geometry As Points 247
Excercise 2: Drill 5 Axis - Entity Type Lines & Holes 249
Step 2: Create The Lines For Drilling From Surfaces 249
Step 3: Make Sure That Level 10 Is The Active Level 249
Step 4: Create Line Normal To Point 250
Step 5: Drill The Through Holes Using The Lines As Geometry 251
Step 6: Circle Mill 5 Axis - Geometry Type Hole 253
Exercise 3: Drill 5 Axis - Geometry 256
Step 7: Drill The Holes 256
Exercise 4: Drill 5 Axis - Tool Axis Control - Plane 260
Step 9: Drill The 1.5" Diameter Hole Tool Axis Control Plane 262
Exercise 5: Circle Mill 5 Axis - Tool Axis Control To Plane 264
Step 10: Circle Mill With The Tool Axis Control Plane 264
Swarf 5-Axis 268
Introduction 269
Exercise 1: Swarf 5 Axis - Walls As Surfaces; Output Format 4 Axis 271
Step 1: Swarf 5 Axis With The Output Format Set To 4 Axis 271
Exercise 2: Swarf 5 Axis - Walls Defined By Chains 276
Step 2: Swarf 5 Axis With The Output Format Set To 5 Axis 276
Step 4: Add Fanning To The Toolpath 280
Exercise 3: Swarf - Surface Walls; Output Format 5 Axis 281
Step 5: Swarf 5 Axis With Output Format Set To 5 Axis 281
9
Step 7: Using Multi Passes To Machine The Walls 283
Exercise 4: Swarf 5 Axis - Walls Defined By Chains 284
Step 8: Create The Chains 284
Step 9: Option 1: Create The Chains Using Project 284
Step 10: Swarf Toolpath With Walls Defined By Two Chains 287
Exercise 5: Swarf - Tip Control To The Lower Rail 290
Step 11: Swarf 5 Axis With Tip Control Set To Lower Rail 290
Flow 5-Axis 293
Introduction 294
Exercise: Flow 5 Axis - Tool Axis Control Limits 296
Step 1: Without Axis Limits 296
Step 2: USE Axis Limits And Delete Motion That Exceeds Limits 300
Step 3: USE Axis Limits And Modify Motion That Exceeds Limits 301
Step 4: Flow 5 Axis - Tool Axis Control Boundary 303
Multisurface Toolpath 304
Introduction 305
Exercise: Multisurface - Cut Pattern 308
Step 1: Finish The Part Using MultiSurface 308
Step 2: Rough Out The Part Using Multisurface 312
Step 3: Define The Stock 313
Deburr Toolpath 315
Introduction 316
Exercise: Deburr 318
Step 1: Select The Machine And Set Up The Stock 318
Step 2: 3 Axis Deburr 319
Step 3: 5-Axis Deburr Toolpath 326
10
Step 4: Deburr With A Flat Endmill 329
Advanced Multiaxis Intro 331
Advanced 5-Axis Toolpaths 332
1. Parallel 332
2. Morph 333
3. Along Curve 333
4. Project Curves 333
New Concepts Covered: 334
Exercise 1: Unified Cut Patterns 335
Step 1: Parallel To Angle (Custom Angles) Pattern 336
Step 2: Parallel To Surfaces Pattern 339
Step 3: Parallel To Curves Pattern 340
Step 4: Morph Between 2 Surfaces Pattern 341
Step 5: Morph Between 2 Curves Toolpath 345
Step 6: Along Curve Pattern 347
Step 7: Project Pattern 352
Exercise 2: Area Settings 357
Step 8: Unified - Parallel Angle Toolpath 358
Step 9: Round Corners 361
Step 10: Extend / Trim 362
Step 11: Containment 363
Step 12: Angle Range 363
Exercise 3: Sorting 365
Step 13: Machine By Region 366
Step 15: Flip Step Over 369
Step 16: Machine By Lanes 370
Step 17: Cut Order - From Center Away 371
Step 18: Cut Order - From Outside To Center 372
Exercise 4: Tool Axis Control - Side Tilt Definition 373
11
Step 19: Follow Surface Iso 374
Step 21: Ortho To Lower Edge Curves 377
Step 22: Ortho To Cut Direction At Each Position 378
Step 23: Ortho To Cut Direction At Each Contour 379
Step 24: Use Spindle Main Direction 380
Step 25: Use User Defined Direction 381
Step 26: Rotate The Red Line In The Front Plane -30 Degrees 382
Step 27: Use Tilt Line Definition 382
Exercise 5: Collision Control 383
Step 28: No Collision Control 384
Step 29: Retracting Tool Along Tool Axis 387
Step 30: Retract Tool Along Surface Normal 388
Step 31: Tilt Tool Using Side Tilt Angle 389
Step 32: Trim And Relink Toolpath 390
Unified Multiaxis Toolpath 391
Introduction 392
Exercise 1: Unified Multiaxis Toolpath 395
Step 1: Machine The Top Face Using Unified 395
Step 2: Rough The Groove Using Unified 404
Step 3: Unified Toolpath For Engraving - Project Style 410
Step 4: Verify The Toolpaths 415
Step 5: Unified Toolpath For Port Machining 416
Exercise 2: Unified Multiaxis Toolpath 435
Step 6: Unified Toolpath From Curve - Guide Style 435
Step 7: Unified Toolpath From Curve - Guide Style 443
Unified - Projection Toolpath 451
Introduction 452
12
Exercise 1: Projection Toolpath 453
Step 2: Engrave The Letters Using Project Curve 453
Parallel To Angle 458
Introduction 459
Exercise 2: Unified Custom Angles Toolpath 460
Step 1: Finish The Camshaft Unified Custom Angles 461
Step 2: Machine The Left Side 461
Step 3: Machine The Right Side 467
Swarf Milling Toolpath 468
Introduction 469
Exercise 1: Swarf Milling 471
Step 1: Setup The Stock 471
Step 2: Use Pocket Toolpath To Machine The Inside Cutout 472
Step 3: Use Pocket Toolpath To Machine The Open Cutout 475
Step 4: Machine The Walls Using Swarf Milling 479
Exercise 2: Swarf Milling 485
Step 5: Create A Stock Model Toolpath 486
Step 7: Machine The Walls Using Swarf Milling 487
Step 8: Change The Tool Cutting And Shoulder Lengths 491
Step 9: Add The Overlap & The Lead In/out 491
Step 10: Unified Parallel To Guide 493
Create An Stl File In Verify 499
Step 11: Machine Simulation 500
Step 12: Simulate The Toolpath In The Material Mode (verify) 503
Unified Parallel & Morph 505
Introduction 506
13
Exercise 5: Parallel Custom Angles Toolpath 507
Step 1: Finish The Blade - Unified Parallel To Custom Angles 507
Unified Morph Between 2 Curves Guides Style 512
Step 2: Unified Morph Between 2 Curves - Guide Style 512
Morph Between 2 Curves Toolpath 514
Step 3: Morph Between 2 Curves - Morph Style 514
Step 4: Spiral Cutting Method And Set The Margins 516
Step 5: Output Format To 5 Axis & Gradual Side Tilt Angle 517
Unified Parallel To Curves Review 519
Step 6: Finish The Left Side - Parallel To Curves 519
Step 7: Finish The Right Side End Of The Blade 524
Propeller & Unified Guides 526
Introduction 527
Exercise 6: Machine The Propeller -Swarf Milling & Morph 528
Step 1: Setup Stock 528
Step 2: Rough Out The Part Using 2D HS Dynamic 529
Step 3: Machine The Walls Using Swarf 533
Unified Guide Between 2 Curves Toolpath 537
Step 4: Finish The Blade - Unified Guide Between 2 Curves 537
Advanced Rough Toolpath 544
Introduction 545
Exercise: Advanced Rough 546
Step 1: Rough Out The Part Using Rotary Advanced Toolpath 546
Finish The Floor - Unified Morph (2 Curves) 551
Step 2: Finish The Floor - Unified Morph (2 Curves) 551
Machine The Fillet Surfaces - Unified Guide To Curves 556
Step 3: Unified Guide To Machine The Left Fillet Surface 556
14
Step 4: Unified Guide To Machine The Right Fillet 561
Step 5: Simulator Settings 562
Surface High Speed Scallop 563
Step 6: Cleaning The Helical Ridge End 563
Gouge Check 566
Introduction 567
Exercise: Gouge Check Exercise 569
Step 1: Unified Guide Toolpath Without Collision Control 569
Step 2: Tilt Tool Away With Max Angle 573
Step 3: Smooth The Transition At The Sharp Edge 576
Step 4: Linking Parameters To Keep The Tool Down 578
Step 5: Collision Control - Retract Tool Along Tool Axis 579
Step 6: Retract Tool Along +Z 580
Step 7: Machine The Entire Surface 581
Worm Gear- Review 582
Introduction 583
Exercise: Worm Gear 583
Unified Morph To Curves With No Tilt Axis 584
Step 1: Rough The Area Between Two Blades 584
Step 2: Finish The Area Between The Two Blades 590
Unified Parallel To Curve With Tilt Set To Lines 591
Step 3: Semifinish The Blade Using Unified Parallel 591
Unified Morph To Curves With Tilt Angle 599
Step 4: Finish The Blade Using Unified Morph Curves 599
Unified Parallel To Surface Toolpath 605
Step 5: Finish The Fillet Using Parallel To Surface 605
3D High Speed Scallop 610
Step 6: Scallop - Clean The Back Of The Blade 610
15
Step 7: Equal Scallop Clean The Front 613
Machine The Entire Part 616
Step 8: Use Transform - Rotate To Complete The Entire Part 616
Port Expert Toolpath 620
Introduction 621
Exercise 10: Port Expert Toolpath 623
Step 1: Instructions On How To Create A Spine Curve 623
Step 2: Rough Out The Port Using A Port Expert Toolpath 626
Step 3: Finish The Port Using A Port Expert Toolpath 631
3 Axis To 5 Axis Toolpath 632
Introduction 633
Exercise 11: 3 Axis To 5 Axis Toolpath 634
Step 1: 3D HS Waterline Toolpath With Trim To Avoid Gouge 634
Step 2: 3D HS Waterline Toolpath With Tilt To Avoid Gouge 638
Multiaxis Pocketing Toolpath 639
Introduction 640
Multiaxis PocketingToolpath 642
Step 1: Setup The Stock Using The Solid On Level 55 642
Step 2: Rough Out The Part Using Pocketing Toolpath 643
Step 3: Rest Roughing The Part Using Multiaxis Pocketing 647
Step 4: Finish The Part Floor Using Multiaxis Pocketing 650
Step 5: Finish The Part Walls Using Swarf Milling 651
Step 6: Clean The Island Top With 3D Scallop Toolpath 655
Multiaxis Review 659
Introduction 660
Exercise: Multiaxis - Review 662
16
Step 2: Use Transform Dynamic To Orient The Part 663
Step 3: Create A Stock Using Model Prep Options 664
Step 4: Use Modify Feature - Remove All Pockets And Holes 665
Step 5: Remove All The Fillets Inside The Channel 666
Step 6: Use Modify Feature To Remove The Channel 666
Step 7: Setup The Tool Settings And The Stock Setup 667
Step 8: Create Pocket Surfaces Using From Solid Command 668
Step 9: Create Curves At The Top Edges Of The Pocket 669
Step 10: Rough The Pocket Using Multiaxis Pocketing 670
Step 11: Finish The Pocket Floor Using 2D HS Area Mill 673
Step 12: Machine The Pocket Walls Using Swarf 5 Axis 676
Step 13: Create Curves At The Top Of The Fillet Surfaces 679
Step 14: Create A Point With The Coordinate Values Of X1.5, Y-1.5, Z6.0 679
Step 15: Machine The Fillets - Unified Parallel To Curve 679
Step 16: Machine The Rest Of The Pockets 682
Step 17: Drill The 0.3975 Diameter Holes 686
Step 18: Circle Mill The 0.8125 Diameter Holes 689
Step 19: Rough The Channel - Unified Morph Curves 694
Step 20: Finish The Channel Floor - Unified Morph (2 Curves) 699
Step 21: Machine The Upper Channel Wall - Swarf Milling 699
Step 22: Machine The Lower Channel Wall Using Swarf Milling 703
Step 23: Machine The Lower Fillet Unified Parallel To Curve 704
Step 24: Machine The Upper Fillet Unified Parallel To Curve 706
Step 25: Create A Stock Model 708
Accelerated Finish Tools 711
Introduction 712
Exercise: Accelerated Finish Using Barrel Tools 715
Step 1: Create A Stock Model For A Casting Part 715
17
Step 2: 3D High Speed Horizontal 717
Step 3: Unified Parallel To Curve 720
Step 4: Unified Parallel To Surface 726
Unified Morph Between Two Curves 728
Step 5: Finish The Walls Using Morph Between 2 Curves 728
Step 6: Unified Morph Between Two Surface 733
Impeller 736
Introduction 737
Exercise: Machine The Impeller Floor - Unified Morph 738
Step 1: Rough Out The Area Between Two Blades 738
Step 2: Finish The Impeller Floor 747
Machine The Impeller Blade - Unified Parallel To Curves 748
Step 3: Unified Parallel To Curves 748
Step 4: Set Tool Axis Control 751
Unified Parallel To SurfaceS Toolpath 753
Step 5: Finish The Area Between The Floor And The Fillet 753
Step 6: Transform - Rotate 757
Step 7: Transform Rotate The Second & Third Toolpaths 760
Step 8: Transform Rotate Last Toolpath 761
18
Multiaxis Projects
4 Axis Introduction Topics Covered
n Introduction to 4-Axis Programing.
n Graphical User Interface (GUI).
n Navigate through Mastercam.
n Setting the Grid.
n Home Tab and Minitoolbar.
n Data Entry Shortcuts
n Right Mouse Click dialog box.
n About Rotary Axis Control.
n 4-Axis Workflow.
Exercise 1: Axis Substitution & Roll Topics Covered
n Transform Roll.
n Drill Toolpaths with Axis Substitution
(Y axis).
n Slot mill Toolpath with Axis
Substitution (Y axis).
n Contour Toolpath with Axis
Substitution (Y axis).
Exercise 2: Axis Substitution Unroll Topics Covered
n Transform Roll - Unroll.

n Pocket Toolpath with Axis Substitution
(Y-axis).
n Rolldie.
19
Exercise 3: Axis Substitution Helix Topics Covered
n Geometry required for a cylindrical and a

conical shape.
n Contour Toolpath with Axis Substitution (Y-
axis).
Exercise 4: Axis Substitution Dynamic Mill Topics Covered
n Create curves at the edges of the solid

n Unroll geometry.
n Levels.
n 2D HS Dynamic Toolpath with Axis
Substitution (Y-axis).
Exercise 5: Axis Substitution Rolldie Topics Covered

axis).
n Rolldie Chook.
20
Exercise 6: Axis Position & Transform Topics Covered
n Drill Toolpath with Axis Substitution (Y-axis).

n Drill Toolpath with Rotary Axis Positioning.
n Contour Toolpath with Axis Substitution.
n Contour Toolpath in the Top plane.
n Transform - Rotate.
Exercise 7: Planes - Indexing A-Axis Topics Covered
n Contour Toolpath - Axis Substitution.

n Create a new plane using Dynamic.
n Drill Toolpath.
n Transform - Rotate by Tool Plane.
n Contour Toolpaths using Tool Planes.
Exercise 8: Planes - Horizontal Machining Topics Covered
The following Create New Planes options are

used:
n From Geometry.
n Right Side Plane Duplicate.
n Left Side Plane Duplicate.
n Front Plane Duplicate.
n Back Plane Duplicate.
21
Legacy Multiaxis Introduction Topics Covered
n Multiaxis Basic.
n Machine Limits.
n The Effect Of Changing Tool Length.
n Multiaxis Machine Types.
n Multiaxis Toolpaths.
n Legacy 5-Axis toolpaths.
Exercise 9: Rotary Toolpath Topics Covered
n Rotary 4 axis - Rotary Cut.

n Rotary 4 axis - Axial Cut.
n Axial dampening.
Exercise 10: Curve 5-Axis Topics Covered

n Curve - Curve type 3D.
n Curve - Curve type Surface edge - single.
n Curve - Curve type Surface edge - all.
n Curve - Tool Axis Control - Lines.
n Curve - Tool Axis Control - Plane.
n Curve - Tool Axis Control - From point.
n Curve - Tool Axis Control - To point.
n Curve - Tool Axis Control - Chain.
n Curve - Output 3 axis.
n Curve - Tip control On selected curve.
n Curve - Tip control On projected curve.
n Curve - Tip control Comp to surfaces.
n Curve - Projection Normal to plane.
n Curve - Projection Normal to surface
22
Exercise 11: Drill 5-Axis Topics Covered
n Drill - 5 Axis geometry type Points.

n Drill - Geometry type Lines.
n Circle Mill - Geometry type Holes.
n Drill - Tool Axis Control to Plane.
n Circle Mill -Tool Axis Control to Plane.
Exercise 12: Swarf 5-Axis Topics Covered
n Swarf - Walls set to surfaces; floor defined by

surfaces; output format 4 axis.
n Swarf - Walls set to surfaces; floor defined by
n Swarf - Walls set to chains; floor defined by
lower rail; output format 4 axis.
Exercise 13: Flow 5-Axis Topics Covered
n Flow - Tool axis control - Pattern surface.

n Flow - Tool axis control - Pattern surface
limits.
n Flow - Tool axis control - Boundary.
Exercise 14: Deburr Toolpath Topics Covered
n Create a 3 Axis Deburr toolpath.

n Create a 5 Axis Deburr toolpath.
n Create a 5 Axis Deburr with a Flat Endmill
23
Exercise 15: Multisurface Toolpath Topics Covered
n Multisurface - Pattern surface rough toolpath.

n Multisurface - Pattern surface finish toolpath.
Advanced Multiaxis Intro Topics Covered

n Advanced 5-Axis toolpaths.
n Cut Patterns in Unified Toolpath

n Parallel to Angle.
n Parallel to Surfaces.
n Parallel to Curves/Guides.
n Morph between two surfaces.
n Morph between two Curves/Guides.
n Along Curve.
n Project.
n Area
n Area Type.
n Round corners.
n Extend / Trim.
n Angle range.
n Containment.
n Sorting
n Flip step over.
n Start point.
n Cutting method.
n Cut order.
n Machine by.
n Tool Axis control -Side Tilt Definition
n Follow surface iso direction.
n Ortho to lower edge curve.
n Ortho to cut direction at each position.
n Ortho to cut direction at each contour.
n Use spindle main direction.
n Use user defined direction.
n Use tilt line definition.
n Colission Control
n Retract tool along tool axis.
n Retract tool along surface normal.
n Tilt tool with Use side tilt angle.
n Leaving out gouging points with Trim toolpath
between first and last collision.
24
Exercise 16: Unified Multiaxis Toolpaths Topics Covered
n Unified Multiaxis toolpath to finish the top
using Automatic.
n Change Unified Multiaxis toolpath to finish the
top using Curve and setting the Style to Guide.
n Check the different Styles available with one
Curve.
n Add another curve and change the Style to
Morph.
n Unified Multiaxis toolpath to machine the
groove using Curve with Morph Style.
n Unified Multiaxis toolpath to engrave the
letters using Curve with Project Style.
n Unified Multiaxis toolpath to finish the port
shape from the top using Curve and
Perpendicular Style.
n Add another Curve and change the style to
Morph.
n Unified Multiaxis toolpath to finish the port
shape from the bottom using the same
settings.
n Demonstrate Fill hole option.
n Unified Multiaxis toolpath to finish the wall
using Curve with Guide Style.
n Set the Tool Axis Control to From Chain.
n Set the Tool Axis Control to Tilt relative to
refrerence surface.
n Unified Multiaxis toolpath to finish the floor
using Curve with Parallel Style and a
Tapered Form Tool.
Exercise 17: Projection Toolpath Topics Covered
n Unified Project Curve toolpath.
25
Exercise 18: Parallel to Angle Topics Covered
n Unified Parallel Custom Angles toolpath.
Exercise 19: Swarf Milling Toolpath Topics Covered
n Swarf Milling toolpath.

n Unified Parallel to Curve toolpath.
n Create an STL file in Verify.
n Machine Simulation.
Exercise 20: Parallel & Morph to Curves Topics Covered
n Unified Parallel (Custom Angles) toolpath to

finish the blade.
n Unified Guide (between 2 curves) toolpath to
finish the blade.
n Unified Morph (between 2 curves) toolpath to
finish the blade.
n Unified Parallel (Curves) toolpath to machine
the two fillets surfaces at the end of the blade.
Exercise 21: Propeller & Morph To Curves Topics Covered
n 2D HS Dynamic Mill to rough out the part.

n Swarf toolpath to semifinish the blades.
n Unified Guide (between 2 curves) toolpath to
finish the blades.
26
Exercise 22: Advanced Rough Toolpath Topics Covered
n Rotary Advanced to rough out the part.

n Unified Morph to Curves to finish the floor.
n Unified Guide to Curve to finish the walls.
n High Speed Scallop to a plane to clean up
some areas.
Exercise 23: Gouge Check Topics Covered
n Tilting tool; Use side tilt angle.

n Retracting tool; Along tool axis.
n Moving tool away; Retract on +Z.
Exercise 24: Worm Gear -Review Toolpaths Topics Covered

n Unified Morph between 2 Curves to rough
the area between to consecutive blades.
n Unified Morph between 2 Curves to finish the
floor between to consecutive blades.
n Unified Parallel to Curves to semifinish the
blade in a swarf manner.
n Unified Morph between 2 Curves to finish the
blade walls.
n Unified Parallel to Surface to finish the blade
fillet.
n 3D High Speed Scallop to clean the back and
front of the blade.
n Transform - Rotate to machine the entire
part.
27
Exercise 25: Port Expert Toolpath Topics Covered
n Create the spine curve for a Port Expert

toolpath.
n Create the Port Expert toolpath.
Exercise 26: 3 Axis to 5 axis toolpath Topics Covered
n Create the 3D High Speed Waterline finish

toolpath.
n Collision checking using Trim to avoid gouge.
n Collision checking using Tilt to avoid gouge.
Exercise 27: Multiaxis Pocketing Toolpath Topics Covered
n Multiaxis Pocketing toolpath to rough out the

part.
n Multiaxis Pocketing toolpath to semifinish the
walls.
n Multiaxis Pocketing toolpath to finish the
floors.
n Swarf milling toolpath to finish the walls.
28
Exercise 28: Multiaxis Review Topics Covered
n Solid Model Prep commands.
n Multiaxis Pocketing.
n 2D Area Mill.
n Swarf 5 Axis.
n Unified Parallel to Curves.
n 5 Axis Drill.
n Circle Mill 5 Axis.
n Unified Morph between 2 curves.
n Swarf Milling.
n Stock Model.
Exercise 29: Accelerated Finish Tools Topics Covered
n Stock model to create a casting part.

n 3D High Speed Horizontal to finish the
bottom floors.
n Using Circle Segment tools to finish the walls.
n Unified Parallel to Curve with Tilt side angle.
n Unified Parallel to Surface with Tilt side
angle.
n Unified Morph between 2 curves with From
point axis control.
n Unified Morph between 2 surfaces with From
point axis control.
Exercise 30: Impeller Topics Covered

n Unified Morph (between 2 surfaces) toolpath
to rough the area between two blades.
to finish the floor.
n Unified Parallel (to curves) toolpath to finish
the blade.
n Unified Parallel (to surface) toolpath to finish
the fillet.
n Transform rotate toolpath to machine the
entire impeller.
29
4 Axis Introduction
30
4 Axis Introduction Introduction To 4 - Axis Programing
WHO THIS BOOK IS FOR:

This book is for the machine tool programming student who wants to learn how to program 4 Axis to Multiaxis
parts using Mastercam. This book is intended to be used as reinforcement exercises as part of classroom
training. While a student can learn from books or videos if they are highly motivated, there is no substitution
for the interaction with a “live” instructor.
This book covers Mastercam Multiaxis toolpaths and assumes you are an experience Mastercam user. This
book also assumes that the student using this book is familiar with machining processes, tools and how
Numerical Control (NC) machines operate. This book is intended to teach you how to get your job done
using Mastercam.
INTRODUCTION TO 4 - AXIS PROGRAMING

The first exercises of this book deals only with simultaneous toolpaths where the center of the tool mostly
points to the center of axis rotation. Shapes that require simultaneous rotary motion where the tool moves
off-center require Mastercam Multiaxis.
Adding a rotary axis to a CNC machine can greatly increase machining capability and efficiency. Some parts,
such as cam slots, require a 4th axis. Other parts benefit from using a 4th axis to position the part, reducing
the number of setups required.
Rotary devices are mounted parallel to one of the machine linear XYZ axis. They require a controller card
and wiring. If your machine does not have these, they must be added to control the rotary axis.
There are two types of rotary tables: indexers and servo rotary tables.
Indexers are used to position the part, allowing different sides to be machined with a single setup. Not only
does this save setups and time, in some cases it can improve dimensional accuracy compared with moving
and flipping the part using vise setups. Indexers have an internal brake that releases during rotary motion
and locks when the programmed angle is reached. Some indexers require unlock codes before the indexing
move, and a lock code after the move.
Indexing rotary heads are not capable of continuous rotary motion. Using an indexing-only head for sim-
ultaneous machining can damage the internal mechanism. Be sure to check the manufacturer's doc-
umentation included with the rotary axis to determine whether it is capable of simultaneous rotary motion
before using it in this mode.
Servo rotary heads are capable of continuous rotary motion while machining as shown. These are used to
machine shapes that cannot be machined without rotary motion.
31
VMC Setups
Most VMC's mount the rotary table parallel

to the X-axis. The table is usually mounted
on the right side of the table to provide
clearance for the tool changer as shown.
HMC Setups
Some Horizontal Machining Centers

(HMC's) have a rotary table mounted
parallel to the Y-axis.
32
Axes Designation
Axes are designated based on how the rotary axis is mounted on the
machine. The Figure shows the axis designation for a typical rotary table
mounted parallel to the X-axis on a Vertical Machining Center (VMC).
Axis Label Definition

A Rotary axis mounted parallel to X-axis.
B Rotary axis mounted parallel to Y-axis.
C Rotary axis mounted parallel to Z-axis.
Centerline Vs Off-center Machining
Axis substitution toolpaths always locate the centerline of the

tool so that it passes through the centerline of the rotational axis
as shown.
Shapes that require the tool to move off center during rotary motion cannot
be machined using axis substitution toolpaths as shown. Off-center
rotary machining is a more complex motion that requires multiaxis
toolpaths such as Swarf and 5-axis curve machining.
33
PROGRAMMING TECHNIQUES USED IN EXAMPLES:

The example exercises in this book can be programmed an infinite number of ways. In fact, any two pro-
grammers would likely approach each part a different way and probably use different tools or toolpaths. For
the exercises in this book, we used settings that were the personal preference or that came from the exper-
ience of multiple Mastercam authorized instructors. All of the examples and exercises have options that can
be set or changed to suit your experiences or company standards.
We chose one method rather than clutter the book with all of the possible options and disrupting the workflow
of the exercises. Utilize the Mastercam Help that is accessible from most dialog boxes whenever you need
more information about options.
34
4 Axis Introduction Mastercam® User Interface:
MASTERCAM® USER INTERFACE:

Mastercam is a completely graphic programming interface that includes built in CAD tools. You will find the
interface to be very streamlined and easy to access all of the toolpath generating commands. There are sev-
eral places you need to know to access all of the Mastercam commands. The locations for the Mastercam
commands and tools are shown in the screen display below.
Quick Access Toolbar (QAT) allows you to quick access the most
Quick Access Toolbar
common used functions.
Ribbon Tabs Access to all Mastercam commands, features and functions.
Expanded Gallery and Tooltips Additional icons to start toolpaths and hints on the toolpath.
General Selection Bar Used to access AutoCursor settings and selection options.
Mini Toolbar Quick access to attributes.
Quick access to commands relevant to the graphics view and analyze
Right Mouse Click Menu
commands.
Quick Mask Toolbar Used to control entity masking for easier selection.
This is where all toolpath operations you create are stored. They can
Mastercam Toolpath Manager be accessed here for editing the Parameters, Tools, and the
Geometry of the toolpaths.
Toolpath Manager Right
Special commands for working with the operations you have created.
Mouse Click Menu
Managers Tabs Tabs to control which panel is displayed in the Manager panel.
Displays the current WCS, Tool and Construction plane info and
Status bar
current cursor location and also displays the Section View.
35
4 Axis Introduction Setting The Grid
SETTING THE GRID

Before starting the geometry enable the Grid. It will show you where the origin of the part is.
File
n Configuration.
n Select Screen from the
configuration Topics.
n Select the plus sign (+)
beside screen as shown.
n Spacing
n X = 0.25.
n Y = 0.25.
n Origin
n X = 0.0.
n Y = 0.0.
n Size = 1.0.
n Select the OK button to exit.
n Select the Yes button to

save the settings in the
System Configuration.
n To see the Grid in the

graphics window, from the
View ribbon enable Show
Grid as shown.
n The Grid
should look as
shown.
36
4 Axis Introduction Home Tab And The Mini Toolbar
HOME TAB AND THE MINI TOOLBAR

The Home tab Attributes and Organize groups or the Mini Toolbar allows you to set the attributes (color, level,
style and width) and Z depth currently used.
The Home tab with the

Attributes and Organize
groups should look as shown.
Example of the default Mini Toolbar.
Sets the display of points. The box or circle point styles are especially
Point Style
useful when working with 3D Drawings.
Line Style Line style, such as solid, hidden, or phantom.
Line Width Line width and surface UV line width.
You can choose to set or change the Wireframe color, the Solids color
and the Surface color. Colors help organize and simplify the drawing.
Wireframe, Solids & Surface
Up to 256 colors are available. Select from the color dialog box by
Color
clicking on the colored area. The number inside the box represents the
color palette number.
Removes the group and result colors from affected entities and from
the database. When performing a transform function, Mastercam
creates a temporary group from the originals (red) and a result
Clear Colors
(purple) group from the transformed entities. However, the groups
stay in effect only until you use the Screen, Clear Colors function or
perform another transform function.
Select All Changes multiple attributes.
Allows you to select an existing entity and sets the current attributes
Set from entity
based on the entity attributes.
2D or 3D drawing mode. Determines whether Z-inputs are from the
2D/3D Mode
Working Depth field or from mouse.
Z Sets the Z depth of the Construction plane.
Change Level Change the level of the selected entities.
Set Material Displays and sets the material for selected objects.
37
4 Axis Introduction Home Tab And The Mini Toolbar
Example Of Setting The Current Wireframe Color
n First, make sure that no entities are selected in the

graphics window.
n Right mouse click to open the Mini Toolbar and click
on the drop down arrow next to the Wireframe color
as shown.
n Select the desired color from the dialog box as shown.
Note: Any geometry on your screen will remain in the

previous system color. This change will only affect the
geometry you create going forward.
Example Of Changing The Current Wireframe Color
n To change the color or any other attribute of a pre-existing

entity you first need to select the entities that have to be
changed.
n Right mouse click to open the Mini Toolbar and click on
the drop down arrow next to the Wireframe color as
shown.
n Select the desired color from the dialog box as shown.
38
4 Axis Introduction Data Entry Shortcuts
DATA ENTRY SHORTCUTS

Mastercam lets you use several shortcuts to enter information into text boxes when creating geometry.
These shortcuts let you get data from an existing entity and use it when creating new geometry.
The shortcuts are as follows:
A Use "A" to input an existing angle.

D Use "D" to input an existing diameter.
L Use "L" to input an existing line length.
R Use "R" to input an existing radius.
S Use "S" to input the distance between two existing points.
X Use "X" to input an existing X coordinate.
Y Use "Y" to input an existing Y coordinate.
Z Use "Z" to input an existing Z coordinate.
To Use A Shortcut
n Type a letter (from the list above) instead of a value into the text box.
n Press Enter. Mastercam prompts you to select the existing entity from which you want to get the data.
n Select the entity you want to use.
n Mastercam displays the data it gets from the existing entity.
n Press Enter to accept the data. Type a different value and press Enter.
n Mastercam uses the data from the existing entity in creating the new entity.
Data Entry Shortcut Example
This example uses the "L" data entry shortcut to create a line.
Create a line with Endpoints of 0,0,0 and 3,0,0.
This will be the existing line from which you get data by using "L".
n Select the Wireframe tab and click on the Line Endpoints icon.
n Select the Origin as the first line Endpoint.
n Set 45 as the angle of the line and press Enter.
n Type "L" to activate the Length field and then highlight the existing value and type "L" in the field and
press Enter again.
n Mastercam prompts you to select an existing line.
n Select the existing line.
n Mastercam displays the data it gets from the existing line.
n Press Enter to accept this data.
n Select the OK button to exit.
n Mastercam creates the new line.
39
4 Axis Introduction The Right Mouse Click Menu
THE RIGHT MOUSE CLICK MENU
Magnifies a portion of the graphics window. When you use this function,
Zoom Window Mastercam prompts you to draw a rectangular window around the portion of the
graphics area that you want to magnify.
Unzoom 80% Reduces the size of the displayed geometry to 80% of its current size.
Lets you dynamically rotate entities in the graphics window around a selected point
or position. When you choose this function from the menu or toolbar, you first
Dynamic Rotation select an Endpoint, Point, or a position in space, and then move the mouse to
rotate entities around the selected point. Mouse click when the drawing is in the
desired position.
Fit Fit screen maximizes your view of visible geometry in the graphics window.
Top Sets the graphics view to the top view.
Front Sets the graphics view to the front view.
Right Sets the graphics view to the right view.
Isometric Sets the graphics view to an isometric view.
Allows you to set the graphics view from Back, Left, Bottom, Isometric Reverse or
Gview
Trimetric.
Delete Entities Erases the selected entities.
Analyze Distances Analyzes the distance between two points.
Analyzes and allows you to edit selected entity lengths, angles, positions and
Analyze Entity
attributes.
40
4 Axis Introduction AutoCursor
AUTOCURSOR
Allows the user to select Endpoints, Midpoints, Arc Center Points or various other entity points.
Mastercam prompts you to enter a point. To select a point move the cursor over the geometry on the
screen. A little square will appear on the screen and a corresponding cursor icon will be displayed.
AutoCursor options are available each time Mastercam prompts you to enter a point. You can select to over-
ride the AutoCursor or to set the defaults from the General Selection Bar.
Note: You can set the AutoCursor defaults. This will determine which entities are shown when your
cursor hovers near by.
Cursor Icons
n Origin.
n Arc Center.
n Face Center.
n Endpoint.
n Intersection.
n Midpoint.
n Midpoint 2
Points.
n Point.
n Quadrant.
n Along.
n Nearest.
n Relative.
n Tangent.
n
Perpendicular.
41
4 Axis Introduction About Rotary Axis Control
ABOUT ROTARY AXIS CONTROL

Mastercam allows you to configure rotary axis motion for 2D or 3D toolpaths.
You can select one of three types of rotary motion:
Rotary Axis Positioning is used to index the part to a specified tool plane. The tool can then move in
three axes.
3-axis is used to rotate the part while the tool axis stays parallel to the axis of rotation. Also called polar
conversion, this replaces linear motion in X, Y, or Z with rotary motion. This is typically used to machine a
toolpath on a face of a part.
Axis Substitution is used on machines that allow simultaneous four-axis movements. The toolpath
replaces X or Y-axis with a rotary axis, known as A-axis or B-axis. Using this option, the part will be rotated
about the rotating axis while the tool moves perpendicular to the axis of rotation.
Rotary Diameter sets the size of the cylinder that the toolpath is rotating about. It is used mainly for
toolpaths on cylinders.
Note: Before you can create rotary axis motion, you need to properly configure the rotary axis
components in your machine definition. You will only be able to select rotary axis options which are
supported by your machine definition.
Mastercam can simulate the rotary axis performance while backplotting the toolpath. To enable this
feature, go to the Backplot Options dialog box and select Simulate Axis Substitution or Simulate Rotary
Axis.
n The Rotary Axis

Control page
should look as
shown.
42
4 Axis Introduction Mastercam® 4 - Axis Work Flow:
MASTERCAM® 4 - AXIS WORK FLOW:

The process to generate a 4 -Axis toolpath will be repeated over and over through the tutorials in this book.
You will find the process simple and straightforward once you have programmed a few parts. Following is an
outline of the process we will follow to create programs:
1. Create the Geometry or Open the Mastercam file

and select the Machine.
2. Define the stock size

that your part will be cut
from and set tool
information.
3. Select a
toolpath
operation type
such as
Contour.
43
4. Select the wireframe, the surfaces or

the solid faces of the part you will
machine with the selected operation
using geometry selection tools.
5. Select the tool and set the toolpath

parameters.
6. Select the Axis Control

and set the Rotary Axis
Control parameters.
44
7. Verify the toolpath on your computer

screen to confirm the results are as you
expected, using Backplot and/or Solid
Verify.
8. Make any changes as required

by changing parameters.
9. Enable Generate toolpath in the parameters or click on

the Regenerate the “Dirty” operation to update the
parameter changes.
10. Verify again to make sure the toolpath

is correct.
45
11. Post selected operation.
12. The Code Expert will

appear with the G-code.
You can transfer the G-
code file to the machine.
46
4 Axis Introduction Conventions Used In This Book
CONVENTIONS USED IN THIS BOOK

We have attempted to make this manual as uncluttered as possible and provide you with reference inform-
ation when it is appropriate. It is not intended to be a Reference Guide or all-encompassing user manual.
The text styles used are the followings:
Bold Text - Represents menu commands, dialog box settings or other similar items from the screen
Standard Text - Represents normal wording needed to provide you the instruction.
STEP 1: STEP TITLES

1.1 Sub step titles
Information about the current step or terms or parameter definitions describing the parameters and
description.
Note: Represents information about the process/step that is important or may require an explanation.
n Bulleted text are step by step instructions that have to be followed.
TUTORIALS FILES:
The training files are mostly Mastercam files. These files are available for download at http://www.e-
mastercam.com/files/.
47
Axis Substitution Roll
48
Axis Substitution Roll Introduction:
INTRODUCTION:
AXIS SUBSTITUTION
Axis substitution toolpaths start with a flat XY contour. This contour is wrapped around a constant dia-
meter cylinder by converting, or substituting, one of the linear axes to a rotary motion.
This Figure below shows a flat contour wrapped around the X-axis. Y-coordinates are converted to A-axis
rotary motion.
49
Axis Substitution Roll Introduction:
OVERVIEW OF EXERCISE:
In this lesson you will become familiar with the Mastercam Axis Substitution. You will learn how to roll the flat
geometry and save it on a different level. You will be using the rolled geometry to backplot the toolpaths.
You will create the 2D toolpaths such as Contour, Slot Mill and Drill from the flat geometry. You will set the
Rotary Axis parameters with the Rotary diameter. Check the toolpath in both Backplot and Verify.
CONCEPTS COVERED IN THIS LESSON:

n Select a machine and set the stock.
n Set a new active level and name it.
n Transform - Roll command used to wrap the chained curves about an axis as though around a cylinder.
n Make only the level with the flat geometry visible.
n Create Drill toolpaths to machine the holes.
n Backplot the toolpath.
n Modify the toolpath parameters by setting the Axis Substitution in the Rotary Axis dialog box.
n Machine the cut through using Slot Mill toolpath with Axis Substitution.
n Machine the step using Contour toolpath with Axis Substitution.
n Verify all toolpaths.
50
Axis Substitution Roll Instructor Demonstration Preview:
INSTRUCTOR DEMONSTRATION PREVIEW:
Note: This entire lesson is a joint Instructor / Student exercise.
Topics
n Transform Roll.
n Drill Toolpaths with Axis Substitution (Y axis).
n Slot mill Toolpath with Axis Substitution (Y axis).
n Contour Toolpath with Axis Substitution (Y axis).
NOTES:
51
Axis Substitution Roll Exercise 1: Axis Substitution - Roll The Geometry
EXERCISE 1: AXIS SUBSTITUTION - ROLL THE GEOMETRY

Axis Substitution is used on machines that allow simultaneous four-axis movements. The toolpath replaces X or
Y-axis with a rotary axis, known as A-axis or B-axis. Using this option, the part will be rotated about the rotating axis
while the tool moves perpendicular to the axis of rotation.
STEP 1: LOCATE PART GEOMETRY

Step Preview:
STEP 2: OPEN FILE

n From the QAT, select the Open icon.
n Select AXIS SUBSTITUTION - ROLL THE

GEOMETRY.MCAM.
STEP 3: SET THE STOCK AS CYLINDER IN THE STOCK SETUP

3.1 Load the Mill Default if needed
n From the Machine tab, select Mill and

Default.
n Expend the Machine Group Setup.

n Select the Stock setup as shown.
52
Axis Substitution Roll Step 3: Set The Stock As Cylinder In The Stock Setup
3.2 Set the Stock
n Enable Show wireframe entities.

n Select the Add from a bounding boxbutton.
n Enable All shown.

n Enable Cylindrical.
n Set the Axis to X.
n Set the Origin as shown.
n Enter Radius = 3.0.
n Height = 3.
53
n Right mouse click in the graphics window and select the Isometric
view.
n The stock should look as shown.
n Select the OK to accept and close Bounding Box.
3.3 Set the Tools
n Select the Tools and change the parameters as shown.

n Feed Calculation set to From Tool.
n Enable Assign tool numbers sequentially.
n Expand the panel, and enable Override defaults with
modal value and check all options.
n Select theOK to accept and close theMachine Group
Setup.
54
n To check the stock, in the Toolpaths ribbon you can

enable Stock display.
n Disable the Stock Display.
55
Axis Substitution Roll Step 4: Roll The Geometry
STEP 4: ROLL THE GEOMETRY
4.1 Change the Active Level to 2 and name it "Rolled

Geometry"
n In the Levels Manager set the Active Level to 2.
4.2 Roll the Geometry

Transform
n From the Position group,

select the Roll icon.
n Select the geometry using
Window selection.
n Make a Window around the
geometry and Sketch the
approximate start point at the
lower left corner of the
rectangle.
56
Axis Substitution Roll Step 4: Roll The Geometry
n Method set to Copy.

n Type set to Roll.
n Rotate about X axis.
n Diameter = 6.0 (Press Enter).
n Angle Tolerance = 0.5.
n Positioning Angle = 0.0.
n Style set to Lines and arcs.
n In the Advanced tab, enable New Attributes to ensure the

geometry is created on Level 2 with dark blue color.
57
Axis Substitution Roll Step 5: Drill The 0.25" Diameter Holes
Note: In the Isometric view you should see

the rolled geometry as shown to the right.
4.3 Make Visible Only Level 1, the flat geometry

n In the Levels Manager, make Level 1 the Active level and
remove the X in the Visible column to make Level 2 invisible.
STEP 5: DRILL THE 0.25" DIAMETER HOLES

5.1 Select The Toolpath
Toolpaths
n From the 2D group, select the Drill icon.

n Select the 0.25" diameter holes.
5.2 Set Tool
n Select the 0.25" Drill.
5.3 Set Cut Parameters
n Enable the Cycle Drill/Counterbore.
5.4 Set Linking Parameters
n Clearance = 2.0 (Absolute) and enable Use clearance only at the start and end of
operation.
n Retract = 0.1 (Absolute).
n Top of stock = 0.0 (Absolute).
n Depth = -0.25 (Absolute).
58
Axis Substitution Roll Step 6: Substitute X-axis
5.5 Set Tip Comp
n Enable Tip comp.

n Breakthrough amount set to 0.0.
5.6 Backplot the toolpath
Note: The toolpath motions

are only 3-axis.
STEP 6: SUBSTITUTE X-AXIS
n From the Toolpaths Manager, select Parameters

and choose the Rotary Axis Control page.
n Enable Axis substitution and Substitute Y axis.
n Enable CCW.
n Enter a Rotary diameter of 6.0.
n Make sure Unroll is disabled.
n Enable Generate toolpath.
Note: For this toolpath we selected the flat geometry which makes the Unroll function not necessary.
59
Axis Substitution Roll Step 6: Substitute X-axis
6.1 Make only Level 2 visible

n From the Toolpath Manager, select the Backplot selected

operation icon.
n In the Backplot dialog box, ensure that Display with color codes, Display
tool, Display holder and Display rapid motion are enabled as shown.
n Select the Backplot options icon.
n Make sure that Simulate Axis

Substitution is enabled in the Backplot
Options.
Note: With Simulate Axis Substitution

enabled the part is maintained in the same
position, while the tool moves around. You
can also enable Simulate Rotary Axis to
see the part rotated as well.
n Click on the Play button to run Backplot.
60
Axis Substitution Roll Step 7: Drill The 0.5" Diameter Holes

7.1 Make only Level 1 visible to see the flat geometry
Toolpaths

n Select the 0.5" diameter holes.
7.3 Set Tool
n Select a 1/2" Drill.
operation.
7.6 Set Tip Comp
n Enable Tip comp.

n Breakthrough amount set to 0.0.
7.7 Set Rotary Axis Control
n Enable Axis Substitution and Substitute X axis.

n Enable CCW.
61
Axis Substitution Roll Step 8: Slot Mill The Inside Obround Shape

STEP 8: SLOT MILL THE INSIDE OBROUND SHAPE
Toolpaths
n From the 2D group, click on the Expand gallery arrow and select Slot
Mill.
n Chain the inside obround shape.
62
Axis Substitution Roll Step 8: Slot Mill The Inside Obround Shape
8.2 Set Tool
n Select a 3/8" Flat Endmill.
n Stock to leave on walls/floors

= 0.0.
8.4 Set Rough/Finish
n Leave the defaults for

Rough/Finish parameters.
n Enable Keep tool down.
n Clearance = 2.0 (Absolute).

n Feed plane = 0.1 (Absolute).
63
Axis Substitution Roll Step 9: Contour The Outside Obround
n Enable Axis Substitution and Substitute Y axis.

n Enable CCW.
STEP 9: CONTOUR THE OUTSIDE OBROUND

n From the 2D group, click on the Expand gallery

arrow and select the Contour icon.
n Chain the outside obround shape CCW.
64
9.3 Set Tool
n Select the 3/8"

Flat Endmill.
n Enable Force tool
change to retract
the tool to avoid
possible collision.
n Compensation type set to

Computer and
Compensation direction set
to Left.
n Leave the rest of the
parameters to the defaults.
65
9.5 Set Lead In/Out
n Enable Lead In/Out.

n Enable Gouge check if needed.
n Make all Length and Radius
values equal to 60% of the tool
diameter.

Note: The absolute values are measured from the 6.0" diameter cylinder, setup in the Rotary axis
control page.

n Enable CCW.
66
9.10 Verify all the toolpath
n From the Toolpaths Manager, click on the Select

all operation icon. These will select all the toolpaths.
n Click on the Verify selected operations icon.
n Mastercam
Simulator
window is
launched.
n Make sure that in
the visibility group
you have the
Tool and the
Stock enabled
as shown.
67
Axis Substitution Unroll
68
Axis Substitution Unroll Introduction:
INTRODUCTION:
This lesson will reinforce how to use Axis Substitution in Mastercam. The original geometry is already a 3D
shape. Mastercam can only machine a flat geometry using the Pocket toolpath. You will learn how to use the
Roll command to flatten the geometry. You will also learn how to use Rolldie to properly machine the walls.
Rolldie is an Add-in formerly known as a C-hook. These are applications or utilities that customize, enhance,
or extend Mastercam's functionality. They can be created by individual users, Mastercam Resellers, third-
party application developers, or by CNC Software.
Note: The Rolldie is not available with the Home Learning Edition known as HLE.
In this exercise you will use the Roll command and unroll pocket geometry. You will adjust the size of the
pocket geometry to allow the tool to overlap the open areas. The pocket toolpath you are creating will use
Rotary axis options with Axis Substitution set to Y - Axis.
As you learned in the Introduction lesson, Axis substitution toolpaths always locate the centerline of the
tool so that it passes through the centerline of the rotational axis. To machine the sides of the pocket with the
tool aligned parallel to the walls and of the center, you will learn how to use Rolldie toolpath.
NEW CONCEPTS COVERED IN THIS LESSON:

n Pocket Toolpath with Axis Substitution (Y-axis).
n Rolldie Add-In.
69
Axis Substitution Unroll Instructor Demonstration Preview:
Topics

n Pocket Toolpath with Axis Substitution (Y-axis).
n Rolldie.
NOTES:
70
Axis Substitution Unroll Exercise 2: Axis Substitution - Unroll The Geometry
EXERCISE 2: AXIS SUBSTITUTION - UNROLL THE GEOMETRY

LOCATE PART GEOMETRY
STEP 1: OPEN FILE

n Select AXIS SUBSTITUTION - UNROLL THE
GEOMETRY.MCAM.
STEP 2: UNROLL THE GEOMETRY

2.1 Change the Active Level to 2
n In the Levels Manager, make Level 2 the Active

Level.
n Name Level 2 : "Unrolled Geometry".
2.2 Transform
Transform
n From the Position group, select

the Roll icon.
n Using Single chaining selection,
select the two highlighted arcs in
the same direction as shown.
71
Step 3: Create Extra Geometry To Be Able To Machine The
Axis Substitution Unroll
Open Areas
n Enable Copy.
n Enable Unroll.
n Rotate about X axis.
n Diameter 2.5 (Press Enter).
n Angle tolerance 0.5.
n Positioning = 0 degrees.
n Style set to Line/Arcs.
n Enable CounterClockwise.
n In the Advanced, enable Color
and Level 2.
n Fit the geometry to the screen and
you should see the two lines
generated in the result color
(magenta), as shown.
STEP 3: CREATE EXTRA GEOMETRY TO BE ABLE TO MACHINE THE OPEN AREAS

3.1 Create parallel lines
n Use the Line Parallel command in Wireframe ribbon
to offset the lines outside by 0.25" (the radius of the
tool).
3.2 Create two lines to close the rectangle

n Create two lines using the Line Endpoints command
to close the rectangle as shown.
n Delete the original lines.
3.3 Make visible only Level 2 to see only the

flat geometry
72
Axis Substitution Unroll Step 4: Use Pocket Toolpath To Machine The Part
STEP 4: USE POCKET TOOLPATH TO MACHINE THE PART

n From the 2D group, click on the Expand gallery arrow and

select the Pocket icon.
n Enable Chain.
n Select the flat rectangle.
4.2 Set Tool
n Select the 1/2" Flat Endmill.
n Enable as Pocket Type,

Standard.
n Stock to leave on
walls/floors = 0.0.
73
4.4 Set Roughing
n Cutting Method set to

Zigzag.
n Stepover percentage set to
50%.
4.5 Set Entry Motion
n Enable Helix.
n Set Minimum and Maximum radius to 50%.
4.6 Set Finishing
n Enable
Finishing.
4.7 Lead In/Out
n Set the Entry Line

to Tangent.
n Length =100%.
n Radius = 30%.
n Same settings for
the Exit.
74
operation.
n Feed Plane = 0.3 (Absolute).
n Depth = 0.0 (Absolute).
control page.

n Enable CCW.
n Make sure that Unroll is disabled.

n Make sure that Simulate Axis Substitution is enabled in

Backplot Options.
4.12 Set the stock as cylinder in the Stock Setup
Machine
n In the Machine Type, click on the Mill arrow and select the Default.

75
n In the Stock Setup, enable Show wireframe

entities.
n Select the Add from a bounding box icon.
76
n Enable 3D construction
mode.
n Enable All shown.
n Shape set to Cylindrical.
n Diameter 3.0.
n Length 2.0.
n Axis set to X.
4.13 Verify the toolpath
77
Axis Substitution Unroll Step 5: Change The Tool And The Stepover
4.14 Change the graphic view to Right Side and backplot the toolpath again
Note: The side of the tool does not machine the

pocket walls. Rolldie C-hook toolpath is designed to
compensate to the side of the tool and not to the
center of the tool as the pocket or the contour
toolpaths are designed.
STEP 5: CHANGE THE TOOL AND THE STEPOVER
To have a better finish, change the tool to a Ball Endmill and change the stepover.
n Select the Parameters in the

Toolpaths Manager.
n Select the 1/4 Ball Endmill
n In the Roughing dialog box, change
the Stepover percentage to 20%
as shown.
5.1 Regenerate and Verify the toolpath
78
Axis Substitution Unroll Step 6: Rolldie C-Hook
STEP 6: ROLLDIE C-HOOK
The Rolldie C-Hook creates toolpaths around a rotary axis. The toolpath can be rounded or squared on outside
sharp corners. When a tapered tool is used, the tool can run up and down the crease formed at the intersection of two
walls at a sharp corner. The tool is not perpendicular to the tool axis and it is compensated to the tool edge.
USING ROLLDIE C-HOOK TO MACHINE WITH THE SIDE OF THE TOOL

n Change the Graphic View to Isometric.
Home
n From the Add-Ins select Run Add-In icon.

n Select Rolldie from the Chooks directory.
Or,
n Hold-down Alt key and enter C.
n Select Rolldie from the Chooks directory.
n From the Chaining dialog box,

enable Single button and select the
two highlighted lines in the same
directions as shown.
6.1 Set Toolpath Type
n Contour should be enabled.
6.2 Set Tool
n Compensation direction set to Right.
79
Axis Substitution Unroll Using Rolldie C-hook To Machine With The Side Of The Tool

n Feed plane= 0.5 (Absolute).
n Enable Axis Substitution and Substitute Y

axis.
n Enable CW.
n Enable Unroll.
n Select the OK button to continue.
80
Axis Substitution Unroll Using Rolldie C-hook To Machine With The Side Of The Tool
6.6 Rolldie Parameters
n Chordal deviation = 0.001.

n Corners set to square.
n Enable Z = Radius.
n Prerolled about X.
Note: The system might change

the tool type and size and you
might need to reselect the 1/2"
Flat Endmill.
Note: Rolldie does not support Lead In/Out. The geometry has to be extended.
6.7 Backplot the toolpath from Right Side view
n Make sure that Simulate Axis Substitution is

enabled in Backplot Options.
6.8 Verify all the toolpaths
81
Axis Substitution Helix
82
Axis Substitution Helix Introduction:
INTRODUCTION:
This lesson will explain how to create the geometry required to machine a basic helix around a cylinder or a
cone.
First you will learn the math that allows you to create a straight line that could be then roll around a cylinder to
become a helix. You will machine the geometry using the Contour toolpath with Axis Substitution.
You will also learn how to modify the geometry to roll it around a cone and then machine it.

n Create the geometry required to machine a helix with Axis Substitution.
n Machine the cylindrical and conical helix using Contour with Axis Substitution.
83
Axis Substitution Helix Instructor Demonstration Preview:
Topics
n Geometry required for a cylindrical and a conical

shape.
axis).
NOTES:
84
Axis Substitution Helix Exercise 3: Axis Substitution - Creating A Cylindrical Helix
EXERCISE 3: AXIS SUBSTITUTION - CREATING A CYLINDRICAL HELIX

Drawing:
STEP 1: CREATE THE GEOMETRY FOR THE HELIX
Note: The part geometry can be downloaded from www.emastercam.com.
1.1 Create the horizontal line

Wireframe
n From the Lines group, select the Line Endpoints.

n Sketch the line starting in the Origin and ending to the right of it.
n Enable Horizontal radio button and enter the Length = 8.0.
n Select the OK and Create New Operation icon to continue in the same command.
85
Axis Substitution Helix Step 1: Create The Geometry For The Helix
1.2 Create the Vertical line
Note: To calculate the length of the line in Mastercam enter #pi*2*4.
n Enable the Vertical radio button.

n Sketch the line starting in the Origin.
n Enter the Length = #pi*2*4.
n Select the OK button to exit the command.
1.3 Create Line Parallel
n Create a parallel line with the horizontal line, through the upper endpoint of the vertical line.
1.4 Create the hypotenuse of the right angle triangle as shown in the drawing
n Enable Freeform radio button and select the Origin and the open endpoint of the
parallel line.
n Select the OK button to exit the command .
1.5 Delete the two horizontal lines and the vertical line
n The geometry should look as shown.
86
Axis Substitution Helix Step 2: Select The Default Mill Machine
STEP 2: SELECT THE DEFAULT MILL MACHINE
Machine
n In the Machine Type, click on the Mill arrow and select the Default.

2.1 Set the Stock

n Select the Add from a bounding box
button.
87
Axis Substitution Helix Step 2: Select The Default Mill Machine
n Enable All shown.

n Set the Origin as
shown.
n Height = 8.0.
n The stock should look
as shown.
n Select the OK to
accept and close
Bounding Box.
2.2 Set the Tools

Properties.
88
Axis Substitution Helix Step 3: Machine The Helix Using Contour With Axis Substitution
n To check the stock, in the Toolpaths ribbon you can

enable Stock display.
n Save the file as "Cylindrical Helix".
STEP 3: MACHINE THE HELIX USING CONTOUR WITH AXIS SUBSTITUTION

Toolpaths
n From the 2D group, select the Contour icon.

n Select the line.
3.2 Set Tool
n Select the 1/2" Ball Endmill.
n Enable the Compensation type to Off.
89
Step 3: Machine The Helix Using Contour With Axis
Axis Substitution Helix
Substitution
3.4 Set Depth Cuts
n Enable Depth cuts.

n Max rough step = 0.25.
3.5 Set Lead In/Out

n Disable Entry and Exit.
n Extend the Start and the End
of the contour with 0.6.

n Feed plane = 0.1 (Incremental).
control page.
90
Axis Substitution Helix Step 3: Machine The Helix Using Contour With Axis Substitution
n Enable Axis Substitution.

n Substitute Y axis.
n Enable CCW.
n Rotary diameter = 4.0.
n The Unroll option should be disabled.
3.10 Save the file as "Cylindrical Helix"
91
Axis Substitution Helix Exercise 4: Axis Substitution - Creating A Conical Helix
EXERCISE 4: AXIS SUBSTITUTION - CREATING A CONICAL HELIX

Drawing:
CREATE THE GEOMETRY FOR THE CONICAL HELIX

n Open "CYLINDRICAL HELIX.MCAM".
n Save it as "CONICAL HELIX.MCAM".
n Delete the toolpath.
STEP 4: USE ANALYZE ENTITY PROPERTIES COMMAND TO MODIFY THE GEOMETRY

Home
n From the Analyze group, select Analyze Entity.

n Select the line.
n Change only the Z value of the endpoint with the coordinate
values X8.0, Y25.1327, to -0.5.
Note: The -0.5" value represents half of the difference between

the two diameters.
92
Axis Substitution Helix Step 5: Machine The Conical Helix
STEP 5: MACHINE THE CONICAL HELIX


n Select the line.
5.2 Set Tool
n Enable the Compensation type to Off.
5.4 Set Depth Cuts

5.5 Set Lead In/Out
n Enable Lead in/out.

n Enter 0.0 for the Line Length and Arc Radius entry and exit.
n Extend the Start and the End of the contour with 0.6 or 120%.

n Depth = 0.0 .
control page. The depth is based on the geometry as the contour is now a 3D contour.
n Enable Axis Substitution.

n Substitute Y axis.
n Rotary diameter = 4.0.
93
Axis Substitution Helix Step 5: Machine The Conical Helix
5.9 Change the graphics view to Right side view.
5.11 Save the file as "Conical Helix"
94
Axis Substitution Dynamic Mill
95
Axis Substitution Dynamic Mill Introduction:
INTRODUCTION:
This lesson will review how to unroll geometry from a cylindrical shape. The geometry required to machine a
pocket using Axis Substitution. You will use 2D Dynamic Mill to machine the pocket
In this lesson we will become familiar with the Mastercam screen components and learn tools and shortcuts
to begin creating basic line geometry shapes.

n Create curves using Curve all edges command.
n Unroll and prepare the geometry for toolpath.
n 2D Dynamic Mill with Axis Substitution.
96
Axis Substitution Dynamic Mill Instructor Demonstration Preview:
Topics
n Create curves at the edges of the solid

n Unroll geometry.
n Levels.
n 2D HS Dynamic Toolpath with Axis Substitution
(Y-axis).
NOTES:
97
Axis Substitution Dynamic Mill Exercise 5: Axis Substitution Pocket
EXERCISE 5: AXIS SUBSTITUTION POCKET

LOCATE PART GEOMETRY
STEP 1: OPEN FILE

n Select 4-Axis Pocket.MCAM.
STEP 2: CREATE THE WIREFRAME USING CURVE ALL EDGES

2.1 Make only Level 100 active
n Name Level 100: Rolled Geometry.

n Make Level 100 the Active Level.
Wireframe
n From the Curves group, select Curve All

Edges.
n Activate the solid selection and enable only
the Face Selection.
n Select the cylinder face.
n Press Enter to end the selection
98
Axis Substitution Dynamic Mill Step 3: Unroll The Geometry
n In the Curve On All Edges panel, enable Fit arcs and

lines.
n Press Alt + S to unshade the solid.

n The curves should look as shown.
STEP 3: UNROLL THE GEOMETRY

3.1 Make Level 200 the Active Level
Note: To machine a pocket with islands on a rotary axis you have to select flat geometry. In
our case, we will need to use the Roll command to unroll the geometry.
n Name Level 200: Flat Geometry.
99
Axis Substitution Dynamic Mill Step 3: Unroll The Geometry
Transform
n From the Position tab, select Roll icon.

n Select the entire part using Window selection.
n Select the Origin as approximate starting point.
n In the Roll panel parameters should be set as shown.

n Enable Copy.
n Enable Unroll.
n Rotation Axis set to X.
n Diameter = 3.0.
n Angle Tolerance = 0.5
n Positioning Angle = -90.0 (To match the machine
orientation).
n Enable Lines and arcs.
n Counterclockwise enabled.
100
Axis Substitution Dynamic Mill Step 4: Fix The Geometry
n Select the Advanced tab and enable New Attributes and change
the color to red.
The geometry might look as shown.
Note: Depending on where you selected the start position, the

geometry may look different from the geometry shown. If this is the
case, you will need to translate some entities.
STEP 4: FIX THE GEOMETRY

4.1 Make only Level 200 visible.
4.2 Delete the vertical lines
4.3 Translate move the triangle
n Use Translate command.

n Select the triangle.
n Click on the Y axis and drag the triangle up to the midpoint of the existing
triangle.
n Enable Move.
101
Axis Substitution Dynamic Mill Step 5: Create A Rectangle Using Bounding Box
STEP 5: CREATE A RECTANGLE USING BOUNDING BOX
n From the Wireframe ribbon, select Bounding Box.

n Press Ctrl + A to select all entities.
n In the Bounding Box panel set the X to 4.0 and Y to 10.
Note: The rectangle needs to be bigger to ensure the geometry will

be fully machined.
5.1 Use Analyze Chain to check all chains
n Use the Analyze Chain command and select each triangle
102
Axis Substitution Dynamic Mill Step 6: Select The Machine And Set The Properties
STEP 6: SELECT THE MACHINE AND SET THE PROPERTIES

6.1 Set the Stock

n Select the Add from a bounding box button.
n Enable All shown.

n Height = 4.
n Enable Center on axis.
n Select the OK to accept and
close Bounding Box.
103
Axis Substitution Dynamic Mill Step 7: Dynamic Toolpath To Machine The Triangles
n Expand Stock Plane

Transformation.
n In the Origin set the X to 0.25.
6.2 Set the Tools

Properties.
STEP 7: DYNAMIC TOOLPATH TO MACHINE THE TRIANGLES

Toolpaths
n From the 2D group, select the Dynamic

Mill icon.
n Enable From outside.
n In Machining regions, click on the Select
button and select the outside rectangle.
104
n In the Avoidance regions, click on the

Select button and select all 18 triangles.
7.2 Preview chains
n Select Preview chains button to verify

the chaining.
7.3 Set Tool
n Select the 0.125" Flat Endmill.
105
n Set the Stepover percentage to

25%.
n No Stock to leave on walls or
floors.
7.5 Corner Pretreatment disabled

7.6 Depth Cuts disabled

n Feed Plane = 0.2 (Incremental).
control page.
n Set the Entry method to Plunge only.
106

n Set the Rotation direction to CCW.
107
Axis Substitution & Rolldie
108
Axis Substitution & Rolldie Introduction:
INTRODUCTION:
This exercise reviews Contour with Axis Substitution and Rolldie toolpaths.
The Rolldie add-in creates toolpaths around a rotary axis. The toolpath can be rounded or squared on out-
side sharp corners. When a tapered tool is used, the tool can run up and down the crease formed at the inter-
section of two walls at an inside sharp corner.
The chained entities selected to create the toolpath can be in the flat or already rolled. Typically this toolpath
is used to generate 5-axis tool vectors around a rotary axis, but there is an option to produce a 3-axis toolpath
from flat input. This is typically selected for tapered tools.
A contour operation with the axis substitution always cuts on Y0 and not tangent to the profile. To better con-
trol the resulted shape you can use Rolldie C-Hook.
In this exercise you will create a Contour toolpath with Multipasses and Axis Substitution about Y-axis. You
will finish the walls of the barrel using Roldie chook.
CONCEPTS REVIEWED IN THIS LESSON:

n Contour with Axis Substitution.
n Roldie to machine the two walls.
109
Axis Substitution & Rolldie Instructor Demonstration Preview:
Topics
n Contour Toolpath with Axis Substitution (Y-axis).

n Rolldie Chook.
NOTES:
110
Axis Substitution & Rolldie Exercise 6: Axis Substitution & Rolldie - Barrel Cam
EXERCISE 6: AXIS SUBSTITUTION & ROLLDIE - BARREL CAM
Open File

n Select BARRELCAM.MCAM.
Make All Levels Visible Except Level 3 And Level 1
STEP 1: SELECT A MACHINE AND SET THE PROPERTIES

1.1 Set the Stock
n Enable All shown.

n Select the OK to accept and close Bounding
Box.
1.2 Set the Tools settings

Properties.
111
Axis Substitution & Rolldie Step 2: Create The Contour Toolpath Using Axis Substitution
STEP 2: CREATE THE CONTOUR TOOLPATH USING AXIS SUBSTITUTION


n Enable Point button in the Chaining dialog box
and select the center of the start hole.
n Enable Chain button in the Chaining dialog box

and select the contour in the CCW direction.
2.2 Set Tool
112
n Set the Compensation type to

Computer and to Left.
n Stock to leave on walls set to -
0.001 to be able to see the
material removed.
2.4 Set Depth Cuts

2.5 Set Lead In/Out

n Enter 0.0 for both the
Length and the Arc
Radius entry and
exit.
n Enable Use entry
point and Use exit
point.
113
2.6 Set Multi Passes
n Set the Rough parameters to Number 3 and Spacing to 0.3.


n Feed Plane = 0.5 (Incremental).
control page.

n Enable CW.
n Enter a Rotary diameter to 4.218.
114

n Disable Simulate Rotary Axis.

n Set up the stock in Properties; Stock Setup to Solid.
n Select the solid from the graphics window.
Note: The contour operation with the axis substitution

always cuts on Y0 and not tangent to the profile. To better
control the resulted shape we will use the Rolldie C-Hook.
115
Axis Substitution & Rolldie Step 3: Rolldie C-Hook To Machine The Barrel Cam
STEP 3: ROLLDIE C-HOOK TO MACHINE THE BARREL CAM
Note: For the Rolldie toolpath we will chain the center contour. Rolldie does not currently support lead in/
out. We have to create them as geometry and select them as part of the chain.
3.1 Make Level 1 and Level 55 visible

3.2 Create the arcs for the Lead in/out
n Create the arc using Arc Polar Endpoint located in the Wireframe ribbon.
n Make sure Start point is enable and select the Origin.
n Radius = 3.0.
n Start angle = 180.
n End angle = 200.
n Use Transform/Mirror, Copy about Y axis to create the other arc.
n Use Transform/Translate, Copy and translate both entry arcs at the other
end of the chain.
n Use Transform/Mirror, Move about X axis and select the Y value from the
graphics view to create the other two arcs.
STEP 4: USING ROLLDIE C-HOOK TO MACHINE THE RIGHT SIDE
Note: We will create two Rolldie toolpaths to machine each side of the slot.

n Select Rolldie from the C-Hook directory.
n Select the first chain starting from the bottom.
116
Axis Substitution & Rolldie Step 4: Using Rolldie C-hook To Machine The Right Side
4.2 Set Tool
4.4 Depth Cuts Disabled

4.5 Set Lead In/Out Disabled
4.6 Set Multi Passes Disabled


n Enable CW.
n Disable Unroll.

n Disable Z = Radius.
n Prerolled set to NO.
n Enable Slot and enter the Slot width =
2.26.
117
Axis Substitution & Rolldie Step 5: Using Rolldie C-hook To Machine The Left Side

n In the Backplot Options page, click on the Enable
Vectors to display the tool vectors for 4-5 Axis and
then select Play to run the simulation.
STEP 5: USING ROLLDIE C-HOOK TO MACHINE THE LEFT SIDE

n Select Rolldie from the C-Hook directory.
n Select the chain starting from the top.
5.2 Set Tool
n Set the Compensation type to Computer and to Left.
118
Axis Substitution & Rolldie Step 5: Using Rolldie C-hook To Machine The Left Side
5.4 Depth Cuts Disabled

5.5 Set Lead In/Out Disabled
5.6 Set Multi Passes Disabled


n Enable CW.
n Unroll disabled.

n Disable Z = Radius.
n Prerolled set to NO.
n Enable Slot and enter the Slot width = 2.26.

n Make sure that Simulate Axis Substitution is enabled in
Backplot Options.
5.11 Verify the toolpaths

n Set the stock using the existing solid.
n Select all three operations.
119
Axis Positioning & Transform
120
Axis Positioning & Transform Introduction
INTRODUCTION
Axis Positioning Or Indexing.
The Axis Positioning (Indexing) toolpaths, command the rotary table to position itself to a specified angle.
Once the rotation is complete, machining operations are generated as if working in the Top WCS. In the fol-
lowing figure, the shaded face is rotated until it is normal to the machine spindle.
Notice the part datum is located at the finished face of the part and at the center of rotation of the rotary axis.
This is typical for rotary work. Other options include setting the datum on the jaws or from a part stop located
in the bore of the rotary table.
Transform Toolpath
Transform toolpaths allow you to rotate an existing toolpath, to move or copy these operations onto one or
more sides of the part. In cases where machining operations are repeated around an axis, use this method to
move or copy operations from one tool plane to another.
As a rule of thumb have the part WCS set to Top. If a WCS other than Top is used to set up the part, make
the WCS active using the Plane Manager instead of selecting Top WCS.
In this exercise you will drill the first set of holes using Axis Substitution and the second set of holes using Axis
Positioning. You will engrave the figures using a Contour toolpath with Axis Substitution. Next, you will
machine the top slot using Contour toolpath. To machine the rest of the slots you will use Transform - Rotate
toolpath.

121
Axis Positioning & Transform Instructor Demonstration Preview:
Topics
The following toolpaths are covered in this exercise:
n Drill Toolpath with Axis Substitution (Y-axis).

n Contour Toolpath with Axis Substitution.
n Contour Toolpath in the Top plane.
NOTES:
122
Axis Positioning & Transform Exercise 7: Axis Substitution, Positioning & Transform
EXERCISE 7: AXIS SUBSTITUTION, POSITIONING & TRANSFORM

Open file
n Select AXIS SUBSTITUTION -

ROTARY AXIS POSITIONING &
TRANSFORM.MCAM.
1.1 Set the Stock

123
Axis Positioning & Transform Step 2: Drill The Four 3/8" Holes Y-Axis Substitution
n Enable Manual and

select the 2 circles.
n The stock should look
as shown.
n Select the OK to
accept and close
Bounding Box.
1.2 Set the Tools

n Select the OK to accept and close the Machine Group
Setup.
n In the Properties, select Tool settings and enable Assign tool numbers sequentially.
STEP 2: DRILL THE FOUR 3/8" HOLES Y-AXIS SUBSTITUTION


n Make sure that the construction mode is set to 3D.
n Select the four points that are on the line.
124
Axis Positioning & Transform Step 2: Drill The Four 3/8" Holes Y-Axis Substitution
2.2 Set Tool
n Select the 3/8" Drill.
n Set the Cycle to Drill/Counterbore.
n Clearance = 2.0 (Absolute)

n Make sure that Use clearance only at the start and end of operation disabled.

axis.
n Enable CCW.
n Make sure the Unroll feature is not activated.
n Backplot the toolpath from the Front view.
125
Axis Positioning & Transform Step 3: Drill The Eight Holes Using Rotary Axis Positioning
STEP 3: DRILL THE EIGHT HOLES USING ROTARY AXIS POSITIONING
Use Rotary axis positioning to index the part to a specified tool plane. The tool can then move in three axes.
n From the Toolpaths ribbon, select the Drill icon.

n Set the Depth filters to Off.
Note: This allows you to pick the points that are

directly on top of each other when you look from
the Top view. With the Depth filter on the points
will be removed.
n Select the eight points rolled around the part.
3.2 Set Tool
n Select a 3/8" Drill.
n Clearance = 2.0 (Incremental).

n Retract = 0.1 (Incremental).
n Top of stock = 0.5 (Incremental).
n Depth = 0.0 (Incremental).
n Enable Rotary axis positioning.

n Enable Rotate about X axis.
126
Axis Positioning & Transform Step 4: Engrave The Numbers Using Axis Substitution
n Make sure that Simulate Axis Substitution is enabled in the

Backplot Options.
STEP 4: ENGRAVE THE NUMBERS USING AXIS SUBSTITUTION

Toolpaths
n From the 2D group, click on the

Expand gallery arrow and select
the Contour icon.
n In the Wireframe Chaining dialog,
enable Window and select the
Options icon.
n Enable mask on color and select
the color #13 (magenta).
n Select the OK button twice to exit
Color Mask and Chaining
Options.
n Make a window around the figures and click on the point in

front of the 0 figure to select the approximate sketch point.
127
Axis Positioning & Transform Step 4: Engrave The Numbers Using Axis Substitution
4.2 Set Tool
n Compensation Type set to Off.
4.4 Set Lead In/Out
n Disable Lead in/out.


n Enable CW.
n Make sure that Simulate Axis Substitution is enabled in Backplot

Options.
128
Axis Positioning & Transform Step 5: Machine One Slot Using 2D Contour
STEP 5: MACHINE ONE SLOT USING 2D CONTOUR

Toolpaths

n Disable mask on Color.
n Enable Single button.
n Select the line at the top.
5.2 Set Tool
n Compensation Type set to Off.
5.4 Set Depth Cuts

n Set the Max rough step to 0.2.
5.5 Set Lead In/Out
n Disable Lead in/out.

n Rotation type set to No Rotation.
129
Axis Positioning & Transform Step 6: Transform - Rotate Toolpath
STEP 6: TRANSFORM - ROTATE TOOLPATH
Transform-Rotate toolpath allows you to machine the remaining slots.
Toolpaths
n From the Utilities

group, select the
Toolpath
Transform icon.
n From Type, enable
Rotate.
n As Method, enable
Tool plane which
creates a new tool
plane for the
transformed
toolpath.
n Disable Include
origin to maintain
the same origin.
n In the Source
enable NCI if
needed.
n Make sure that
operation 4 is
selected in the list.
n Enable Maintain
source
operation's.
130
Axis Positioning & Transform Step 6: Transform - Rotate Toolpath
6.2 Rotate
n Enable Origin as the Rotate

point.
n # set to 7.
n Enable Angle between.
n Start angle = 45.
n Rotation angle = 45.
n Rotate plane set to Right Side.
6.3 Backplot the last toolpath

n Set up the stock in Properties.
n Set the Stock Shape to Cylindrical.
n Axis set to X.
n Diameter = 4.0 Length = 8.0.
n Select all operations and Verify.
131
Planes - Indexing A-Axis
132
Planes - Indexing A-Axis Introduction:
INTRODUCTION:
This lesson will further your knowledge of machining parts using Tool planes when indexing a part on a 4-
Axis Vertical CNC machine.
Changing Tplanes produces a rotary motion code when you post the toolpath so that the tool axis or fixture
will move to properly position the part. You should use Tplanes when you are indexing the part on a 4-Axis or
on Horizontal CNC machine. In contrast, changing the WCS typically does not produce any rotary code; its
effect is apparent inside Mastercam, before you post the part. In this lesson you will maintain the same WCS
and Origin allowing the part to rotate around the X-axis.
In this lesson you will machine the cutouts using Contour toolpath with Axis Substitution. You will use
Plane Manager to create a new plane at -70 Degrees from the top plane using Dynamic option. Next you
will set the new plane as Construction plane (Cplane) and Tool plane (Tplane) and leave the WCS set to
Top. This ensures that a rotation movement will appear in the code. You will then drill the hole. Using Trans-
form - Rotate toolpath you will drill the other two holes that are equally spaced at 120 degrees angle.
You will reset the Tplane and Cplane back to the Top plane and machine the top slot using Contour
toolpath.
To machine the larger slot, you will create another plane in the Plane Manager using the Dynamic option.
To machine the slot you will use Contour toolpath.

n Using Tplane to index the part on a 4-Axis Rotary mounted on a vertical Machining center.
n Using Plane Manager to define a new Cplane and Tplane using Dynamic option.
n Set the Cplane and Tplane to the new plane and leave the WCS set to top and the Origin to the center
of the cylinder.
133
Planes - Indexing A-Axis Instructor Demonstration Preview:
Topics:
n Contour Toolpath - Axis Substitution.

n Create a new plane using Dynamic.
n Drill Toolpath.
n Transform - Rotate by Tool Plane.
n Contour Toolpaths using Tool Planes.
NOTES:
134
Planes - Indexing A-Axis Exercise 8: Tool Planes - Indexing About A-Axis
EXERCISE 8: TOOL PLANES - INDEXING ABOUT A-AXIS

When indexing a part about an axis, the main plane about which the part is rotated is the Top plane. All the other
planes can be defined by rotating the Top plane at the suitable angle.
Open file
n Select 4AXIS INDEX_A AXIS.MCAM.
STEP 1: MACHINE THE CUTOUTS USING CONTOUR - AXIS SUBSTITUTION.

Toolpaths
n From the 2D group, select the

Contour icon.
n Chain all three cutouts pocket
shapes in the CCW.
1.2 Set Tool
n Enable Compensation type set to Computer and Compensation direction set to Left.
135
Planes - Indexing A-Axis Step 1: Machine The Cutouts Using Contour - Axis Substitution.
1.4 Set Lead In/Out

n Make all Length and
Radius values equal to 60%
of the tool diameter.
n Clearance = 2.0 (Absolute) .

n Depth = -0.15.
Note: The absolute values are measured from the 2.7165" diameter cylinder, set in the Rotary Axis
Control page.
136
Planes - Indexing A-Axis Step 1: Machine The Cutouts Using Contour - Axis Substitution.

axis.
n Enable CCW.
n Enable Unroll.
n Leave the Unroll tolerance = 0.01.

n Make sure the tool cuts inside the cutouts.
137
Planes - Indexing A-Axis Step 2: Setup The Tool Plane Using Dynamic
n If the contours are not cut on the proper side, from the
Toolpaths Manager, select Geometry.
n In the Chain Manager, select the chain that needs to be
modify.
n Right mouse click on the chain and select Reverse
chain.
STEP 2: SETUP THE TOOL PLANE USING DYNAMIC
n Open Plane Manager.

n Make sure the current Tplane and Cplane are set to Top.
n Select Create a new plane.
n Select Dynamic.
n Place the gnomon into the Origin.

n Rotate the Z axis 70 degrees.
138
Planes - Indexing A-Axis Step 3: Drill The 25/64" Diameter Hole
n Name the view "Rotate 70".

n Make sure WCS is disabled.
n Make sure that the Construction plane (C) and the Tool plane
(T) are set to this plane.
Note: The Origin is set at the center of the cylinder and it will be the same in all the new views. We
should only have one work offset for all the operations.
STEP 3: DRILL THE 25/64" DIAMETER HOLE

Toolpaths

n Select the center point of the 25/64" diameter hole.
3.2 Set Tool

n Depth = -0.25 (Incremental).
139
Planes - Indexing A-Axis Step 3: Drill The 25/64" Diameter Hole
Note: As there is no axis substitution for this toolpath, all the linking parameters should be set to
Incremental. The values will be measured from the selected center point.
3.5 Set Tip Comp
n Enable Tip comp.

n Set the Breakthrough amount to 0.05.
140
Planes - Indexing A-Axis Step 4: Transform - Rotate To Machine The Other Two Holes
STEP 4: TRANSFORM - ROTATE TO MACHINE THE OTHER TWO HOLES

Toolpaths

group, select the
Toolpath Transform
icon.
n From Types, enable
Rotate.
n As Method, enable
Tool plane which
creates a new tool plane
for the transformed
toolpath.
n Disable Include origin.
n Make sure that
operation #2 is selected
in the list.
n The Source is set to
NCI.
n Group NCI output by
Operation type.
4.2 Set Rotate
n Enable Origin as the Rotate point.

n Instances.
n # set to 2.
n Start angle = 120.
n Rotate plane set to Right side.
141
Planes - Indexing A-Axis Step 4: Transform - Rotate To Machine The Other Two Holes
4.3 Backplot only the last toolpath
n Select the Plane tab and set the C and T

plane to Top.
n Select the Toolpaths tab.
142
Planes - Indexing A-Axis Step 5: Machine The Top Cutout Using Contour Toolpath
STEP 5: MACHINE THE TOP CUTOUT USING CONTOUR TOOLPATH

Toolpaths

n Enable Partial button and select the top contour in the CCW direction.
5.2 Set Tool
n Enable Cutter compensation in Computer to the Left.
5.4 Set Lead In/Out

n Make all Length and Radius values equal to 60% of the tool diameter.
1. Set Linking Parameters

n Depth = -0.10.
2. Set Rotary Axis Control
n Rotation type set to No rotation.
3. Backplot the toolpath
143
Planes - Indexing A-Axis Step 6: Machine The Bigger Slot At 120 Degrees
STEP 6: MACHINE THE BIGGER SLOT AT 120 DEGREES
n Make sure the current Tplane and Cplane are set to

Top.
n Select Planes tab, and select the Dynamic.
n Place the gnomon into the Origin.
n Rotate the Z axis -120 degrees.
n Name the plane "Rotate -120".

n Set the Cplane and the Tplane to this plane.

n Select the contour in the CCW direction.
6.2 Set Tool
n Enable Compensation type set to Computer and Compensation direction set to Left.
6.4 Set Lead In/Out

n Make all Length and Radius values equal to 60% of the tool diameter.
144
Planes - Indexing A-Axis Step 6: Machine The Bigger Slot At 120 Degrees

n Rotation type set to No rotation.
6.8 Make Level 3 visible
145
Planes - Indexing A-Axis Step 7: Verify The Toolpaths
6.9 Set the Stock
n Enable Manual and select

the solid.
n The stock should look as
shown.
n Select the OK to accept and
close Bounding Box.
6.10 Set the Tools

n Expand the panel, and enable Override defaults with modal value and check all options.
n Select theOK to accept and close theMachine Group Setup.
STEP 7: VERIFY THE TOOLPATHS
n In the Simulator Options, enable Solid/Mesh and

select the solid.
n Select all operations and verify them.
146
Planes - Indexing A-Axis Step 8: Remove The Chips
STEP 8: REMOVE THE CHIPS
n Select the Verify tab.

n Enable Keep Chips.
n Click on the part that you want to keep.
147
Planes - Horizontal Machining
148
Planes - Horizontal Machining Introduction
INTRODUCTION
A Horizontal Machining Center (HMC) operates with its spindle in a horizontal position instead of a Vertical
position like a VMC. The CNC horizontal milling machine model allows constant load and unloading of pro-
duction work with 2 or more pallets.
Horizontal centers with their horizontal spindles are better suited to larger, boxy workpieces. With a hori-
zontal spindle, a wider variety of workpiece shapes are easier to mount and chips fall out of the way better.
Like vertical machining centers, horizontal centers have multiple-axis table movements.
Typically, the horizontal center’s table rotates to present all four sides of a workpiece to the tooling.
This tutorial explains how Mastercam uses the planes to machine a part on a Horizontal Machining Center
and determine the table indexing angles.
Horizontal machining center (tombstone)

and axis orientation. Sample G-Code and the B angles for the Right Side and
Back planes.
149
Planes - Horizontal Machining Instructor Demonstration
INSTRUCTOR DEMONSTRATION
Topics:
n Facing Toolpath.
n Drill Toolpath.
n Slot mill Toolpath.
n Pocket Toolpaths.
The following Create New Planes options are used:
n From Geometry.
n Right Side Duplicate.
n Left Side Plane Duplicate.
n Front Plane Duplicate.
n Back Plane Duplicate.
NOTES:
150
Planes - Horizontal Machining Exercise 9: Tool Planes - For Horizontal Machining Centers
EXERCISE 9: TOOL PLANES - FOR HORIZONTAL MACHINING CENTERS

The main plane in a 4-axis Horizontal Machining Center is the Front plane. The Front plane axis orientation is the
plane that matches the axis orientation on a Horizontal Machining Center. The other planes, when the part is rotated
about the B axis, have to match the front plane axis orientation.
Open file

n Select TOMBSTONE.MCAM.
1.1 Set the Stock
n Enable All shown.

n The stock should
look as shown.
n Select the OK to
accept and close
Bounding Box.
1.2 Set the Tools

n Expand the panel, and enable Override defaults with modal value and check all options.
n Select the OK to accept and close theMachine Group Setup.
151
Planes - Horizontal Machining Step 2: Setup The Plane At An Angle
STEP 2: SETUP THE PLANE AT AN ANGLE
Note: The Origin is set at the middle of the part and at the bottom. To be able to program the part with
different work offsets on each view, we will use the Planes Manager.
n Make sure the Construction mode is set to 3D.

n Select Planes tab.
n Select Create a new plane and select the From geometry
from the list.
n Select the circle as shown and select the next view button
until the axis orientations are matching the screenshot.
n Name the new view "Angle plane".
n Make sure the WCS is unselected.

n Enable Cplane.
152
Planes - Horizontal Machining Step 3: Machine The Face
STEP 3: MACHINE THE FACE

3.1 Select The Face Toolpath
n From the 2D group, select the Face icon.

n Enable C-plane and Chain.
n Select the rectangle.
3.2 Set Tool
n Select the 2.0" Face mill.
n Set Style to One Pass.

n Enable Auto Angle.
n Stock to leave on floors = 0.0.
3.4 Set Depth Cuts
n Enable Depth Cuts.

153
Planes - Horizontal Machining Step 4: Drill The 3/8" Hole

STEP 4: DRILL THE 3/8" HOLE


n Select the center point of the circle.
4.2 Set Tool
154
Planes - Horizontal Machining Step 5: Circle Mill The 0.75" Hole
n Set Cycle to Chip Break.

n Peck = 0.1.

4.5 Set Tip Comp
n Enable Tip comp.
STEP 5: CIRCLE MILL THE 0.75" HOLE
n Select Planes tab and make sure that the Cplane and Tplane are set to Angle plane.
n From the 2D group, select the Expand gallery arrow

and click on the Circle Mill icon.
n Click on Entities and select the circle.
155
Planes - Horizontal Machining Step 5: Circle Mill The 0.75" Hole
5.2 Set Tool
n Compensation type set to Computer.

n Compensation direction set to Left.
n Stock to leave on walls/floors = 0.0.
5.4 Set Transitions
n Enable Lead In/Out and Start/ End at center.
5.5 Set Depth Cuts

n Set Max rough step to 0.2.

156
Planes - Horizontal Machining Step 6: Setup The Right Side Plane
STEP 6: SETUP THE RIGHT SIDE PLANE
n Select the Planes tab.

n In the Planes Manager, click on the Right side plane, right
mouse click and select the Duplicate.
n Right click on the copy and rename it Right Slot.

n Set the Cplane and the Tplane to the Right Slot plane.
n Click on Set your current tool plane and Set your current
construction plane buttons.
n Click on Select a new origin for the selected plane button.
n Select the new origin at the left side bottom of the view,
as shown.
n Associate plane origin to new geometry.
157
Planes - Horizontal Machining Step 7: Machine The Right Side Slot
STEP 7: MACHINE THE RIGHT SIDE SLOT

n From the 2D group, select the Expand gallery

arrow and click on the Slot Mill icon.
n Enable C-plane and chain the slot CW.
7.2 Set Tool

n Stock to leave on walls/floors = 0.0.
7.4 Set Rough/Finish
n Leave the defaults.
7.5 Set Depth Cuts


158
Planes - Horizontal Machining Step 8: Setup The Left Side Plane
STEP 8: SETUP THE LEFT SIDE PLANE
n Select Planes tab.

n In the Plane Manager, right mouse click on the Left side and
select Duplicate.
n Right mouse click on the Left side-1 and select Rename.

n Rename it Left Slot.
n In the Left Slot plane row, click in the C column to set both
Cplane and Tplane to this plane.
159
Planes - Horizontal Machining Step 9: Machine The Left Side Slot
n Click on Select a new origin for selected

plane to select the new origin at the left side
bottom of the view as shown.
n Select the Toolpaths tab.
STEP 9: MACHINE THE LEFT SIDE SLOT

n From the 2D group, select the Expand gallery arrow and click on the Slot Mill icon.
n Enable C-plane and chain the slot CW.
9.2 Set Tool

9.4 Set Depth Cuts


160
Planes - Horizontal Machining Step 10: Setup The Front Plane
n To see the translucent part, in the Visibility

group click on the Stock until the check box
has a shaded rectangle inside as shown.
STEP 10: SETUP THE FRONT PLANE
n Select the Planes tab.

n Right mouse click on the Front plane.
n Select the Duplicate button.
n Right mouse click on the copy and select Rename.

n Rename it Front Boss.
n In the Front Boss plane row, click in the C column to set both
Cplane and Tplane to this plane.
161
Planes - Horizontal Machining Step 11: Machine The Front Boss
n Click on Select a new origin for selected plane.

n Select the new origin at the lower left corner as shown.
STEP 11: MACHINE THE FRONT BOSS

Toolpaths
n From the 2D group, select the Expand

gallery arrow and click on the Dynamic
Mill icon.
n In the Machining regions, click on the
Select button.
n Enable C-plane and select the outside
rectangle.
n In the Avoidance regions, click on the Select

button.
n Enable C-plane and select the inside boss (at the
bottom as shown).
162
n Enable From outside.

n Click on the Preview chains button.
n The preview should look as shown.
11.2 Set Tool
163
n Approach
distance = 0.0
and enable
Bottom left.
n Set the Stepover
to 15%.
n Gap size set to
100.0% of tool
diameter.
n Set Stock to
leave on
walls/floors to
0.0.

n Set the Entry method to Helix only.
164
Planes - Horizontal Machining Step 12: Machine The Front Pocket
STEP 12: MACHINE THE FRONT POCKET

n From the 2D group, select the Expand gallery

arrow and click on the Dynamic Mill icon.
n In the Machining regions, click on the Select
button.
n Enable C-plane and select the inside pocket (at
the top as shown).
n Enable Stay inside.
12.3 Set Tool
n Approach distance = 0.0 and enable Bottom left.

n Set the Stepover to 15%.
n Gap size set to 100.0% of tool diameter.
n Set Stock to leave on walls/floors to 0.0.
165
Planes - Horizontal Machining Step 13: Drill The 1/4" Holes To 0.625" Depth

STEP 13: DRILL THE 1/4" HOLES TO

0.625" DEPTH
n The part should look as shown.
STEP 14: MACHINE THE BACK FACE.
n Follow the same steps.

n The final part should look as shown.
166
Legacy Multiaxis Introduction
167
Legacy Multiaxis Introduction Introduction:
INTRODUCTION:
There are many different Multiaxis machine tool configurations. Most control three linear axes (XYZ) plus
two rotational axes. The rotational axes are some combination of the ABC axes, depending on the machine
design. Multiaxis machines are indispensable for manufacturing parts common in the aerospace, mold, and
die industries. This section presents the basic concepts and knowledge you need to understand Multiaxis
machines and toolpaths.
MULTIAXIS BASIC
Setting up, programming, and operating a Multiaxis machine presents some unique challenges. The first
hurdle is to fully appreciate the machine limits and collision problems associated with Multiaxis machines. A
Multiaxis machine is much easier to over-travel or crash than a three axes machine. To illustrate why, con-
sider the motion of a gantry type 5-axis router, like the one shown.
n The head is attached to a cross beam which is supported

by two vertical columns.
n X-motion is accomplished by moving the head along the
beam.
n Y-motion is accomplished by moving the table.
n Z-motion is accomplished by the head moving up and
down on the beam.
n C-axis rotation is accomplished by rotating the head about
the Z-axis.
n A-axis rotation is accomplished by rotating the head about
the X-axis (machine at C0).
n The linear (XY) axes limits extend to the edges of the
table.
MACHINE LIMITS
Notice that since the center line of the machine

column cannot travel past the table edge, when the
machine head is tilted, the effective envelope of the
machine gets smaller as shown.
When the head is tilted until it is parallel to the table,
the machine envelope is reduced by length of the
head, tool, and holder.
168
WIND/UNWIND
There are usually some limits on how far an axis can rotate. For example, the physical construction of the
gantry machine on the previous page limits the A-axis travel to just beyond 90 degrees from vertical.
The C-axis rotation of this machine may also be limited. The internal wiring for this axis can only be extended
so far until it is pulled from its plug. Thus, the manufacturer restricts the C-axis motion to prevent damaging
the machine. An "unwind" move to re-slack the wire is required when rotation approaches this limit.
An unwind move involves retracting the tool away from the cut, spinning the axis in the opposite direction
away from the rotational limit, then moving back to the cut to proceed.
Since unwind commands take time, the programmer plans operations to minimize or eliminate unwind
moves when possible.
THE EFFECT OF CHANGING TOOL LENGTH
The figure illustrates how a change in tool

length affects the control points for a gantry-
type CNC machine.
Notice that as the tool length changes, the YZ
coordinates in the NC program change to
place the tip of the tool at the same point on the
part as shown.
169
MULTIAXIS MACHINE TYPES

The Multiaxis machine configuration affects the following:
n Where the part is positioned in Mastercam.

n Where the program datum is set on the machine.
n Whether a change in tool gage length requires the program to be re-posted in Mastercam.
The most common machine configurations are described on the following pages. Each example includes tips
on how to set up the part on the machine, set tool length, and locate the part in Mastercam.
Most 5-axis machine tools can be classified into three major configurations:
n Rotary motion in the head only (Head-Head).

n Rotary motion in the table only (Table-Table or Nutating).
n Rotary motion in both the table and head (Table-Head).
Note: Even if your machine appears to look exactly like one of these examples, never assume it is
configured in a standard or predictable way. To do so would be to risk serious bodily injury or damage to
equipment.
Always refer to your machine operation and programming manuals and technical support from the
machine tool manufacturer. The manufacturer of your specific machine tool should always have the final
word.
In any case where the information in this book conflicts with these resources, you should rely on them, not
this book.
ROTATION IN HEAD ONLY

Machines with rotary motion in the head only are referred to as Head-Head configurations. These fall into
two main categories:
n A-C Rotation (Tilt-Rotary Head).

n A-B Rotation (Tilt-Tilt Head).
Tilt-Rotary Head (TRH) configurations rotate about the A and C

axes as shown.
170
Tilt-Tilt Head (TTH) configurations rotate about the

A and B axes as shown.
Note: TRH and TTH machine configurations locate the XYZ datum at some known point on the part or
fixture.
Tool length offsets can be set anywhere, like any conventional 3-axis machine, but the program controls
the pivot point, not the tool tip. Mastercam needs the gage length to post the program, and if the tool
length changes, the program must be re-posted with the new value.
ROTATION IN TABLE ONLY

Machines with rotary motion in the table only are referred to as Table-Table configurations. These machines
fall into two categories:
n A-C Rotation (Tilt-Rotary Table).

n A-B Rotation (Tilt-Rotary Table, Fadal Style).
The Tilt-Rotary Table (TRT) A-C configuration tilts

about the X and Z axes as shown.
171
The Tilt-Rotary Table (TRT) A-B configuration tilts

about the X and Y axes (Fadal Style) as shown.
Note: Tilt-Rotary Table configurations require the part to be located in Mastercam as it sits on the
machine. The part and program datum is at the center of the axis of rotation, not necessarily on the part
itself.
NUTATING HEAD
The Table-Table (Nutating) configuration has a rotary

table mounted on another rotary table. The base table is
set at an angle, up to 45 degrees, to the machine Z axis
as shown.
Note: The part is located in Mastercam as it sits on the machine. The part and program datum is at the
center of the axis of rotation, not necessarily on the part itself.
172
ROTATION IN TABLE AND HEAD

Machines with rotary motion in both the table and head are sometimes referred to as Table-Head con-
figurations. These hybrid configurations are less common than other types and are usually of the following
types:
n A-B Rotation (Tilt Head-Rotary Table).

n A-B Rotation (Tilt Head-Rotary Table, Bostomatic Style).
The Tilt-Head Rotary Table (TH-RT)

Horizontal Mill configuration tilts about the X and
Y axes as shown.
The Tilt-Head Rotary Table (TH-RT)

Bostomatic Style configuration tilts about the X
and Y axes as shown.
Note: These configurations require the part to be located in Mastercam where it sits on the machine with
the coordinate system origin at the center of the axis of rotation.
173
PIVOT LENGTH
If the machine has rotation in the head, the post processor has to know the distance from the head pivot point
to the tip of the tool. The first step in getting this number is to find the exact distance from the pivot point of the
head to the face of the spindle, called the pivot length.
The pivot length for the machine is often given in the user manual, but don't trust this number as it may not be
precise. The exact pivot length for your machine must be known since even a small error in this value results
in large tool position errors.
MULTIAXIS TOOLPATHS
Multiaxis toolpaths can be classified into two broad categories:
n Axis Positioning
n Simultaneous Multiaxis
AXIS POSITIONING
Axis Positioning involves moving one or more rotary axes to orient a feature towards the spindle. The
rotary axes are then locked in position and only the linear axes are moved simultaneously to machine the fea-
ture.
Since three axes move and two are fixed, this type of motion is referred to as "3 plus 2" machining. With the
right post processor, any Mastercam mill toolpath will output 3+2 code. Just set the WCS tool plane to any
plane other than Top.
Mastercam Axis Positioning Multiaxis toolpaths include:
n Axis Positioning.
n Simultaneous Multiaxis.
174
SIMULTANEOUS MULTIAXIS MACHINING

Simultaneous Multiaxis Machining controls up to five axes at once: three linear and one or two rotary.
Multiaxis toolpaths can be split between two types: Pattern and Application.
Pattern toolpaths are general toolpaths that can be used in a variety of ways to manufacture your part. The
toolpaths are very flexible and provide a wide range of machining options.
Application toolpaths are designed to solve particular machining problems while automating some of the
processes. These toolpaths include machining options and strategies specific to the application. Mastercam
Simultaneous Multiaxis toolpaths include:
Pattern Toolpaths Description

Curve Machines 3D chains or edges.
Keeps the side of the tool in contact with the selected surfaces or
Swarf Milling
solids, to create a better surface finish quality.
Allows you to select multiple pieces of input geometry to generate the
toolpath pattern. Then, using those geometry choices, the toolpath
Unified Multiaxis picks the best algorithm to calculate the path. Besides its other uses,
Unified can be used to create morph, parallel, along curve, and project
curve motion.
Flow Generates motion along the UV lines of the selected geometry.
Machines based on the selected pattern options, cylinder, sphere, or
Multisurface
box.
Machines where the tool is always in contact with the machining
Triangular Mesh
surfaces.
Application Toolpaths Description

Deburr Breaks edges and removes burrs.
Pocketing Machines with roughing passes for undercuts, wall, and floor finishing.
Creates a 4-axis rotary toolpath that allows for more control over tool
Rotary Advanced
motion through the selection of walls, hubs, and shroud surfaces.
Analyzes the part and creates multi-plane roughing operations to
3+2 Automatic Roughing
efficiently remove material.
Rotary Creates a toolpath along or around the selected rotary axis.
Creates multiaxis motion that keeps the side of the tool in contact with
Swarf
the selected wall geometry.
Blade Expert Cuts simple, split, or multi-bladed impellers.
Port Expert Cuts a port or internal chamber of a part.
175
Legacy Multiaxis Introduction Legacy 5-Axis Toolpaths
The toolpaths are grouped in this book in two families: Legacy and Advanced toolpaths.
In this section you will learn how to machine the parts using the Legacy Multiaxis toolpaths.
The following toolpaths are part of the Legacy Multiaxis toolpaths and will be covered in this order:
n Rotary
n Curve
n Drill & Circle Mill
n Swarf
n Flow
n Multisurface
LEGACY 5-AXIS TOOLPATHS

Multiaxis toolpaths are grouped into different toolpath families based on their calculation type.
The Classic toolpaths contain the following toolpaths: Curve, Swarf, Flow, MultiSurface, Port, and
Rotary.
CURVE - 5 AXIS
Curve toolpaths create a 3-axis, 4-axis or 5-axis toolpath along a 3-D curve or along one or all edges of a sur-
face. The tool axis can be oriented parallel to existing lines, normal to a surface, normal to a plane, or ori-
ented from a point or to a point.
DRILL & CIRCLE MILL - 5 AXIS

Drill 5-Axis can create 3-axis, 4-axis or 5-axis toolpaths allowing individual tool axis control for each drill pos-
ition in the operation. The tool axis can be oriented parallel to existing lines, normal to a surface, and normal
to a plane.
Use Circle Mill to generate 5-axis motion to orient the selected geometry and then cut the geometry using
3-axis motion.
SWARF 5 AXIS TOOLPATH

Swarf 5-axis can create a 4-axis or 5-axis toolpaths along a wall defined by surfaces or two chains.
FLOW - 5 AXIS TOOLPATH

Flow 5-Axis Toolpath can create a 4-axis or a 5-axis toolpath along a surface or a row of adjacent drive sur-
faces. The Flowline 5-axis toolpaths allow either precise control of the scallops left on the part or constant dis-
tance stepovers, creating an exact, smooth finish.
MULTISURFACE
Multisurface toolpaths can create 4-axis or 5-axis toolpaths along multiple surfaces. The Multisurface
toolpaths allow either precise control of the scallops left on the part or constant distance stepovers, creating
an exact, smooth finish.
176
Rotary Toolpath
177
Rotary Toolpath Introduction
INTRODUCTION
The purpose of this chapter is to introduce machining that uses a single simultaneous rotary axis and the Mul-
tiaxis Rotary toolpath.
Multiaxis Rotary toolpaths are optimized to support machines with a single rotary axis. The most common
configuration is a vertical machining center with a rotary table mounted parallel to the X-axis as shown.
There are two types of rotary tables:
n Servo rotary tables.

n Indexing tables.
Servo rotary tables are capable of simultaneous rotary cutting motion.
Indexing tables are used to only orient the part towards the spindle. The rotary mechanism is then locked in
position. Indexers are not designed for simultaneous rotary machining and using them for this purpose can
damage their mechanisms.
Check the manufacturer's specifications to ensure your rotary table is capable of simultaneous machining
before using it for rotary 4-axis machining.
Rotary axis toolpath allows you to choose between two methods on how the tool is oriented in relation to the
geometry being cut:
n Rotary cut
n Axial cut
178
TOOL AXIS CONTROL - ROTARY CUT
Rotary cut means the tool rotates about the

rotary axis as shown.
Use Center Point
Use center point allows placement of a center point on the part

to fix the tool axis for a 4-axis toolpath. With this option selected,
Mastercam outputs the tool axis orientation relative to the
selected point as shown.
If not selected, the tool axis orientation is output relative to the
surface.
Axis Dampening Length
The Axis dampening length determines the

position of the tool axis based on a specific length
along the surface of the part. Use this option to
reduce abrupt changes in the toolpath, especially at
inflection points as shown.
A shorter length provides more tool movement and a
toolpath that adheres closely to the surface.
A longer length produces less tool movement.
179
Lead/Lag Angle
Lead/Lag angle controls how far the tool shank tilts

forward (lead, positive value) or behind (lag, negative
value) in relation to the direction of the toolpath as shown.
TOOL AXIS CONTROL - AXIAL CUT
Axial cut means the tool travels along the rotary axis as
shown.
OVERVIEW OF LESSON:
In this lesson you will rough out the cam using Rotary 4 Axis with the Rotary Cut option which cuts around
the diameter of a part. Then, you will finish the cam using Rotary 4 Axis with the Axial Cut which cuts parallel
to the axis of rotation.
You will also use Axis dampening length to see how you can control the tool axis abrupt change.

n Axis dampening.
180
Rotary Toolpath Instructor Demonstration
Topics:

n Axial Dampening
NOTES:
181
Rotary Toolpath Exercise 1: Rotary Toolpaths
EXERCISE 1: ROTARY TOOLPATHS

Rotary toolpaths are designed to cut around the diameter of a part or parallel to the axis of rotation using 4-axis
output.
Resources -Download the file from http://www.emastercam.com/trainingfiles
Open File
n Select 4 - AXIS ROTARY TOOLPATH.MCAM.
STEP 1: 4 AXIS ROTARY TOOLPATH WITH ROTARY CUT

n From the Multiaxis group, select the Expand gallery arrow

and click on the Rotary icon.
1.2 Set Tool

n Change the Tool # to 1.
182
Rotary Toolpath Step 1: 4 Axis Rotary Toolpath With Rotary Cut
1.3 Set Cut Pattern
n In the Surface area, click on the Select

button to return to the graphics window and
select the surfaces.
n Using the Quick Mask buttons, click on the
left half of the Select all surface entities
button and click on the front and the back
flat surfaces to unselect them.
n Press Enter to finish the selection.
n Enable Rotary cut.
n Stock to leave on drive surfaces = 0.03.
n Cut tolerance = 0.001.
n Enable Climb and One way.
1.4 Set Tool Axis Control
n Leave the Output format set to 4 axis.

n Set Rotary axis to X axis.
n Make sure that Use center point is
disabled.
n Lead/Lag angle = 15.
n Maximum step = 0.1.
n Leave the Tool vector length set to 1.0.

n Keep tool down within = 1000.0%.
183
Rotary Toolpath Step 1: 4 Axis Rotary Toolpath With Rotary Cut
Note: The 15-degree lead angle.
n Make sure that Display vectors is enabled in the

Backplot Options.
n For a better display, change the vector

size to 0.05 when checking the toolpath
in the isometric view. This will help you
visualize the toolpath.
184
Rotary Toolpath Step 2: 4 Axis Rotary Toolpath WITH Axial Cut
STEP 2: 4 AXIS ROTARY TOOLPATH WITH AXIAL CUT

2.1 Copy the last operation.
2.2 Set Cut Pattern
n Enable Axial cut.

n Stock to leave on drive surfaces =
0.0.
n Enable Climb and Zigzag.

n Maximum angle increment = 1.0.
n Start angle = 0.0.
n Sweep angle = 360.
n Leave the Tool vector length set to
1.0.
2.4 Regenerate the toolpath if needed.
185
Rotary Toolpath Step 2: 4 Axis Rotary Toolpath WITH Axial Cut
Note: The tool is rolling at the edges of the drive surfaces.

To remove the roll we will add the flat surfaces as check
surfaces in the toolpath.
n Select Parameters of the last operation.

n Select the Collision Control page and click on the Select button next to Check surface(s) to
return to the graphics window.
n Select the two flat surfaces.
n Set the Stock to leave as 0.002.
186
Rotary Toolpath Exercise 2: Axis Rotary Toolpath - Axial Dampening
2.6 Regenerate the toolpath

2.7 Backplot the toolpath again
EXERCISE 2: AXIS ROTARY TOOLPATH - AXIAL DAMPENING

Axial Dampening allows you to enter a value that determines the position of the tool axis based on the specified
length away from the surface of the part. A longer axis dampening length creates less angular change between the
vectors. A shorter length provides more tool positions and a toolpath that adheres closer to the surface.
Step Preview:
Open File

n Select 4 - AXIS ROTARY TOOLPATH - AXIAL
DAMPENING.MCAM.
187
Rotary Toolpath Step 3: Axis Dampening Length = 0.002.
STEP 3: AXIS DAMPENING LENGTH = 0.002.

n From the Multiaxis group, select the Expand gallery arrow and
click on the Rotary icon.
3.2 Set Tool

3.3 Set Cut Pattern
n Click on the Select button to return to the graphics window.

n Select the surface.
n Enable Rotary cut.
n Enable Climb and One way.

n Make sure that Use center point is disabled.
n Axis dampening length = 0.002.
n Lead/Lag angle = 0.0.
n Leave the Tool vector length set to 1.0.

n Keep tool down within = 300.0%.
188
Rotary Toolpath Step 4: Change Axis Dampening Length To 0.2
3.6 Backplot the toolpath in the Right Side view and

zoom in on the sharp corner
Note: When the tool axis dampening length is set to a

small amount, the tool axis pivots around the sharp
corner and generates more tool movement.
STEP 4: CHANGE AXIS DAMPENING LENGTH TO 0.2
n Copy the last operation and select the Parameters.

n In the Tool Axis Control, change the Axis
dampening length to 0.2.
n Regenerate the toolpath
4.1 Backplot the toolpath from the Right Side view

and zoom in on the sharp corner
Note: When the tool axis dampening length is set to a

larger amount, the tool axis pivots around the sharp
corner and generates less tool movement. The tool
might gouge the part.
STEP 5: CHANGE THE AXIS DAMPENING LENGTH TO 2.0
n Copy the last operation and select the Parameters.

n In the Tool Axis Control, change the Axis dampening
length to 2.0.
n Regenerate the toolpath
5.1 Backplot the toolpath from the Right Side view and
zoom in on the sharp corner
Note: When the tool axis dampening length is set to a large

amount, the tool vectors remain relatively constant and roll
the tool over the sharp corner instead of pivoting around it.
189
Curve 5-Axis
190
Curve 5-Axis Introduction:
INTRODUCTION:
The purpose of this chapter is to introduce Multiaxis Curve toolpaths.
Curve toolpaths are used to move the tip of the tool along a
3D curve while controlling the tool axis. This toolpath has
many applications. The screenshot shows a Curve toolpath
being used to control a laser to trim cut a molded manifold.
In this section you will become familiar with how to create a Multiaxis Curve toolpaths. You will learn how to
define the path of the tool using 3D curves or surface edges. You will understand the difference between 3, 4
and 5-axis output. This section will also explain how to control the tool axis using all available methods. You
will also learn how to use the tool tip compensation as it relates to multiaxis curve machining. You will also
complete an exercise that shows you the difference between Surface and Plane projections.

n Curve Type
n Curve 3D.
n Surface edge - single.
n Surface edge - all.
n Curve - Tool Axis Control
n Lines.
n Plane.
n From point.
n To point.
n Chain.
n Curve Output
n 3 axis.
n 4 axis.
n 5 axis.
n Curve Tip control
n On selected curve.
n On projected curve.
n Comp to surfaces.
n Curve - Projection
n Normal to plane.
n Normal to surface
191
Curve 5-Axis Instructor Demonstration Preview:
Topics:
n Curve - Curve type 3D.

n Curve - Curve type Surface edge -
single.
n Curve - Curve type Surface edge - all.
n Curve - Tool Axis Control - Lines.
n Curve - Tool Axis Control - Plane.
n Curve - Tool Axis Control - From
point.
n Curve - Tool Axis Control - To point.
n Curve - Tool Axis Control - Chain.
n Curve - Tip control On selected
curve.
n Curve - Tip control On projected
curve.
n Curve - Tip control Comp to
surfaces.
n Curve - Projection Normal to plane.
n Curve - Projection Normal to surface
NOTES:
192
Curve 5-Axis Exercise 1: Curve Type - 3D Curves
EXERCISE 1: CURVE TYPE - 3D CURVES

Curve Type set to 3D Curves uses a chain of curves as the drive curves.
STEP 1: OPEN FILE

n Select CURVE 5 AXIS CURVE TYPE 3D

CURVES.MCAM.
STEP 2: CREATE A CURVE TOOLPATH SELECTING A 3D CURVE

2.1 Check the Surface Normals
A Surface normal is a vector (direction) that is perpendicular to the surface at the point of tangency. If the Tool
Axis Control is set to Surface in a Multiaxis toolpath, the normal direction determines how the tool approaches the
surface. The tool always approaches in the direction opposite to the normal as shown.
n Before starting the toolpath, check the surface normal.
Surfaces
n From the Normals group, select Change command.

n Hover the cursor above the surface to see the normal
orientation. The normal should point upwards as shown.
n Click on the surface if you need to change the normal.
n Press Esc to exit.
Note: To check the surface normal, you can also select Backside from the View tab. The back of the
surface is displayed in green color. If you see the real color of the surface, the surface normals point away
from the center of the geometry as it should. If the surface normal needs to be changed, from the
Surfaces tab, click on the Change icon and select the surface whose normal needs to be changed.
193
Curve 5-Axis Step 2: Create A Curve Toolpath Selecting A 3D Curve
Toolpaths
n From the Multiaxis group, select the Curve

icon.
2.3 Set Tool

The Tool page allows you to select a tool, edit its properties, and enter feeds and speeds. You can insert a comment
that will be output in the NC file after running the post processor.

2.4 Set Cut Pattern

The Cut Pattern page allows you to select the curve type, compensation type, direction, maximum step, cut
tolerance and projection type.
n Set Curve type to 3D Curves.

n Click on the Select button.
n Make sure 3D and Chain

button are enabled.
n Select the curve.
194
n Set Compensation type to Off.

n Set Tip compensation to Tip.
n Radial offset = 0.0.
Tool Axis Control settings determine the tool's orientation in relation to the geometry being cut.
The tool axis can be oriented parallel to existing lines, normal to a surface, normal to a plane, oriented from a point or
to a point or towards an open chain.
You can further control the tool axis forward/backward tilt in the direction of cutting by using lead/lag angles. You can
also apply a side tilt angle to tilt the tool to the right or left side in the direction of cutting.
n Set Tool axis control to Surface.

n From the Quick Mask Toolbar, click on the Select
all surfaces.
n Press Enter to exit the selection.
n Set Output format to 5 axis.

n Set Backplot rotary axis to Z axis.
n Lead/lag angle = 0.0.
n Side tilt angle = 0.0.
n Angle increment = 3.0.
n Tool vector length = 1.0.
n Projection set to Normal to surface.

n Maximum distance = 0.0001.
195
2.6 Set Collision Control
The Collision Control page allows you to set the collision control parameters for the multiaxis Curve toolpath.
Collision control settings determine tip compensation, establish check and compensation surface behavior, and set
gouge process settings.
n Set Tip control to On projected curve.

n Vector depth = -0.125.
Linking parameters set the links between the cutting passes. In general, you can think of linking moves as air
moves when the tool is not in contact with the part.
Clearance sets the height at which the tool moves to and from the part.
Retract sets the height that the tool moves up to before the next tool pass.
Feed plane sets the height that the tool rapids to before changing to the plunge rate to enter the part. The tool also
moves to this height between operations if you do not enter both the clearance height and the retract height.
Keep tool down within instructs Mastercam not to create a retract move if the distance from the end of one pass to
the start of the next pass is less than this value. The tool will move directly between the passes at the feed rate.
n Clearance = 6.0.
n Retract = 5.0.
n Feed plane = 0.1.
n Keep tool down within = 300.
196
2.8 Set Roughing

Roughing provides settings for depth cuts and multi passes within an operation.
n Leave Roughing disabled for this toolpath.
Note: A warning that "Rapid move hits operation surface" might appear. To fix the problem we
will need to apply entry/exit curves to the beginning/end of the toolpath.

n From the Backplot dialog box, select the Options icon.
n In Backplot Options enable Display

vectors.
n Leave the Length set to 1.0.
n Run Backplot.
197
n From the Toolpaths Manager, select

the Parameters of the operation.
n Expand Linking and select the
Entry/Exit page.
n Enable Entry curve and set the
Length to 0.25, Thickness to 0.25, and
Height to 0.25.
n The parameters are as shown.
n Select the double down arrow button to copy the settings to the
Exit curve area.
n Make sure Generate toolpath is enabled.
198
Curve 5-Axis Exercise 2: Curve Type - Surface Edge Single
EXERCISE 2: CURVE TYPE - SURFACE EDGE SINGLE

Curve type in the Curve 5 axis toolpath set to Surface edge - single allows you to click on the select button to
return to the graphics window and select surfaces and a single edge.
Open File
n Select CURVE TYPE SURFACE EDGE ONE.MCAM.
STEP 3: CREATE A CURVE TOOLPATH SELECTING AN EDGE

STEP 4: SELECT THE TOOLPATH
Toolpaths
n From the Multiaxis group, select the Curve icon.
4.1 Set Tool

4.2 Set Cut Pattern
n Set Curve type to Surface edge -

single.
n Click on the Select button and select
the orange color surface.
n Move the cursor close to the open edge.
199
Curve 5-Axis Step 4: Select The Toolpath
n Chain from top to bottom

(Reverse the direction if needed).
n Set Compensation type to
Computer.
n Set Compensation direction to
Right.
Note: The radial offset value will be

automatically added.


200

n Clearance = 4.0.
n Retract = 0.5.
n Feed plane = 0.1.
4.6 Set Roughing
n Leave all of the Roughing settings disabled for this toolpath.
Note: The tool orientation is

perpendicular (normal to the surface)
and it might gouge into the fixtures. To
change the tool orientation, we will use
the side tilt angle.
201
n From the Toolpaths Manager, select the

Parameters of the operation.
n Select the Tool Axis Control page and
change the Side tilt angle to 75 degrees.
4.8 Entry /Exit
n Make sure that both Entry

curve and Exit curve are
enabled.
n Length = 0.25".
n Thickness = 0.25".
n Height = 0.25."
4.9 Backplot the toolpath again
202
Curve 5-Axis Exercise 3: Curve Type - Surface Edge All
EXERCISE 3: CURVE TYPE - SURFACE EDGE ALL

Open File
n Select CURVE TYPE SURFACE EDGE

ALL.MCAM.
STEP 5: CREATE A CURVE TOOLPATH AT ALL EDGES OF A SURFACE

Toolpaths
6.1 Set Tool
6.2 Set Cut Pattern
n Set Curve type to Surface edge -

all.
n Select the surface. Press Enter.

n Chain direction should be CW as shown.
Otherwise, click on the Reverse direction
button.
n Set Compensation type to Computer.

n Set Compensation direction to Left.
203
Note: The radial offset value will be

automatically added.


204

n Clearance = 4.0.
n Retract = 0.25.
n Feed plane = 0.1.
6.6 Entry /Exit
n Make sure that both Entry curve and

Exit curve are enabled.
n Length = 0.25".
n Thickness = 0.25".
n Height = 0.25."
6.7 Set Roughing
n Leave Roughing settings disabled for this toolpath.
205
Curve 5-Axis Exercise 4: Tool Axis Control - Lines
EXERCISE 4: TOOL AXIS CONTROL - LINES

Tool Axis Control set to Lines keeps the tool axis parallel to the selected line entities.
Open File
n Select CURVE 5 AXIS TOOL AXIS CONTROL

LINES.MCAM.
Toolpaths
7.1 Set Tool
7.2 Set Cut Pattern
n Curve type set to 3D Curves.

n In the Wireframe Chaining dialog box, click on the Options button.
206
n Enable Color, click on the Color button and select only red.
n Select the red color curve start

at the upper left corner.

n Tip compensation set to Tip.
n Set Tool axis control to Lines.

207
n Select the lines close to the chain. The arrows

should point upwards.
Note: Make sure that the arrows point upwards.

n Set Tip control to Comp to surfaces.

n Click on the Select button and select the solid face.
n Vector depth = 0.0.
n Stock to leave = 0.0.
7.5 Set Linking
n Clearance = 4.0.
n Retract = 0.5.
n Feed plane = 0.1.
208
Curve 5-Axis Step 8: Machine The Opposite Wall
7.6 Entry / Exit
n Enable Entry curve.

n Length = 0.3.
n Set the Exit curve the
same.
7.7 Set Roughing
n Leave the Roughing settings disabled for this toolpath.
STEP 8: MACHINE THE OPPOSITE WALL
n Create the Curve toolpath.

n Select the edge.
n In the Tool Axis Control, select the vertical open edges as the lines.
n In the Collision Control, set the Tip control to Comp to surfaces and select the face.
n In the Roughing section, enable Depth cuts.
n Set the # Rough cuts to 6.
n Rough step = 0.25.
209
Curve 5-Axis Exercise 5: Tool Axis Control - Plane
EXERCISE 5: TOOL AXIS CONTROL - PLANE

Tool Axis Control set to Plane sets the tool axis normal to a selected plane.
Open File
n From the QAT, select the Open
icon.
n Select CURVE 5 AXIS TOOL
AXIS CONTROL PLANE.MCAM.
STEP 9: CURVE TOOLPATH TOOL AXIS CONTROL TOWARDS A PLANE

9.1 Select the Toolpaths
Toolpaths
9.2 Set Tool
210
Curve 5-Axis Step 9: Curve Toolpath Tool Axis Control Towards A Plane
9.3 Set Cut Pattern

n Click on the Select button and select the
blue color curve in CW direction.
n Compensation type set to Off.
n In the Tool axis control enable Plane

and click on the Select button.
n From the Plane Selection click on the

Entities button.
n Select two of the intersecting lines from
the red colored rectangle.
Note: The arrow has to point upwards as

shown otherwise click on the Reverse
button.

n Click on the Select button and select all surface entities, from the QM buttons, click on the Select
all surface entities left half button. Press Enter to finish the selection.
n Clearance = 4.0.
n Retract = 0.25.
n Feed plane = 0.1.
211
Curve 5-Axis Step 9: Curve Toolpath Tool Axis Control Towards A Plane
9.7 Set Entry/Exit

Length to 0.2, Thickness to 0.2, and
Height to 1.0.
n Direction set to Left.
n Select the double down arrow button to
copy the settings to the Exit curve
area.
9.8 Set Roughing
212
Curve 5-Axis Exercise 6: Tool Axis Control - From Point
EXERCISE 6: TOOL AXIS CONTROL - FROM POINT

Tool Axis Control set to From point limits the tool axis to originate from a selected point.
Open File

FROM POINT.MCAM.
STEP 10: CURVE TOOLPATH WITH TOOL AXIS CONTROL FROM A POINT
11.1 Set Tool
11.2 Set Cut Pattern
n Curve type set to 3D

Curves.
n Select the blue color curve in CW

direction.
213

n Set Tool axis control to From point.

point.


n Click on the Select button and from the QM buttons, click
on the Select all surface entities button to select all
surfaces.
n Clearance = 4.0.
n Retract = 0.5.
n Feed plane = 0.1.
214
Curve 5-Axis Exercise 7: Tool Axis Control - To Point
11.6 Set Entry/Exit
n Enable Entry curve and set the Length to 0.2, Thickness to 0.2, and Height to 1.0.
n Direction set to Right.
n Select the double down arrow button to copy the settings to the Exit curve area.

n In the Backplot Options page, enable
Display vectors and change the Length to
3.0.
EXERCISE 7: TOOL AXIS CONTROL - TO POINT

Tool Axis Control set to To point limits the tool axis to terminate at a selected point.
Open File
n Select CURVE 5 AXIS TOOL AXIS CONTROL TO

POINT.MCAM.
STEP 12: CURVE TOOLPATH WITH TOOL AXIS CONTROL SET TO A POINT
STEP 13: SELECT THE TOOLPATHS
Toolpaths
215
Curve 5-Axis Step 13: Select The Toolpaths
13.1 Tool
13.2 Cut Pattern

n Click on the Select button and select the blue
color curve in CW direction.
n Disable Color mask if needed.

Computer.
n Compensation direction set to
Left.
13.3 Tool Axis Control
n Set Tool axis control to To point.

point.
216
13.4 Collision Control

n Click on the Select button and from the QM
buttons, click on the Select all surface entities
button to select all surfaces.
Note: The vector depth is set to such a big value to

be able to better visualize the tool axis orientation
in backplot.
13.5 Linking Parameters
n Clearance = 4.0.
n Retract = 0.5.
n Feed plane = 0.1.
13.6 Entry/Exit

Length to 0.2, Thickness to 0.2,
and Height to 1.0.
n Select the double down arrow
button to copy the settings to the
Exit curve area.
217

n In the Backplot Options
page, enable Display vectors
and change the Length to 3.0.
Note: The depth is too big. We

use this setting to see in
backplot what tool axis control
set to point will look like.
13.8 Change the depth
n In the Toolpaths Manager, select Parameters.

n In Collision Control, change the Vector depth
to -0.1.
218
Curve 5-Axis Step 14: Machine Simulation
STEP 14: MACHINE SIMULATION
n From the Machine tab, select Machine

Simulation Options button.
n Select the A8
HERMLE_VMCTTAC.
n Geometry set to All
elements.
n Position set to
Translation in XYZ; X
0; Y0; Z 1.0.
n Click on the Simulate
button.
n Close Measure, CutSim and Analysis panels if needed.

n Click on the title bar on the Move List and move it below the Report panel.
n In the Visibility group from Machine Simulation, enable Toolpath, Tool, Workpiece and Machine
Housing.
219
Curve 5-Axis Step 15: Change The Tool Axis Control To Chain
n The toolpath should

look as shown.
Note: The tool axis tilt is

to big. To better control
the tool axis tilt, we will
change the tool axis
control method.
STEP 15: CHANGE THE TOOL AXIS CONTROL TO CHAIN
Transform
n From the Offset

group, select
Chains.
n Select the chain.
220
n To indicate the offset direction, click somewhere outside

the chain.
n Make sure that the offset chain is created outside the
original chain.
n In the Method make sure that Copy is enabled.
n Distance = 0.5.
n Depth = 1.0.
Note: The Angle is automatically calculated to 26.5651

degrees. This option allows you to set the tilt angle based
on the multiaxis machine capability.
n Change the Angle to 25. This will change the

distance automatically.
n Enable Modify Fillet Corners and Sharp.
221
15.1 Change the Tool Axis Control
n In the Toolpaths Manager, select

Parameters.
n In the Tool Axis Control page set the Tool
axis control to Chain.
n Select the chain as shown.
n In the Chain Options dialog box, enable Closest point on

chain.
222

n Change the vector length to 1.0
15.4 Machine Simulation
223
Curve 5-Axis Exercise 8: Tool Axis Control - Chain
EXERCISE 8: TOOL AXIS CONTROL - CHAIN

Tool Axis Control set to Chain limits the tool axis to terminate at a selected point.
Open File

CHAIN.MCAM.
STEP 16: CURVE TOOLPATH WITH TOOL AXIS CONTROL SET FROM A CHAIN
17.1 Create a 1/4" taper Tool
n Right mouse click in the tool window and select

Create tool.
n Select the Taper mill

icon.
224
n Tip diameter = 0.05.

n Angle = 5.
n Cutting length =
0.25.
n Shoulder length =
1.125
n Overall length = 2.
n Shank diameter =
0.25.

blue color curve in CW direction.
n Set Tool axis control to

Chain.
n Select the line from the endpoint closer to the chain starting
location.
225
n Enable Step along whole chain.

n Set Tip control to On selected curve.

17.5 Linking
17.6 Entry/Exit
n Disabled.
17.7 Roughing
Note: The step along the whole chain option has the tool axis
vector transition along the selected chain. Every tool axis position
corresponds to a different point along the chain. In our case at the
end of the toolpath the tool is orientated towards the farthest
endpoint of the line as shown.
226
Curve 5-Axis Step 18: Create A Chain
n From the Toolpaths Manager, select the Parameters of the operation.

n Select the Tool Axis Control page and click on the Select button.
n Enable Closest point on chain.
Note: For a better tool axis control, the chain has to be flat.
You will create a new chain in the next steps.

STEP 18: CREATE A CHAIN
Transform
n From the Position group,

select the Project icon.
n Holding down the Shift key and
select the magenta chain. Press
Enter.
n Make sure the Method is set to
Copy.
n Project the chain to a Distance
of 2.6.
Transform
n From the Offset group, select Chains icon.

n Select the magenta chain.
n Click inside of the chain to indicate the offset direction.
n Enable Move.
n Set the Distance to 0.25 and the Depth to 0.0.
n Make sure that the offset is inside the original chain,
otherwise select Opposite side.
n The chain should look as shown.
227
Curve 5-Axis Step 19: Change The Tool Axis Control
STEP 19: CHANGE THE TOOL AXIS CONTROL

Parameters.
n In the Tool Axis Control page set
the Tool axis control to Chain.
n Unselect the existing chain.
n Select the chain.
n Enable Step along whole chain.

19.3 Change the Chain Options to Closest

point on chain.
228
Curve 5-Axis Exercise 9: Curve 5 Axis - Output Format
EXERCISE 9: CURVE 5 AXIS - OUTPUT FORMAT

Output format - 5-Axis Curve toolpaths can output 3-axis, 4-axis, or 5-axis tool moves for the selected curves.
Open File
n Select CURVE 5 AXIS OUTPUT

FORMAT.MCAM.
STEP 20: OUTPUT FORMAT SET TO 3 AXIS
n In the Toolpaths Manager, move the insert arrow below the Output format 3 axis group.
21.1 Set Tool

n Click on the Select button and select the curve.
229

the surface.
n Output format set to 3 axis.
Note: The output format set to 3 axis

limits the output to a single plane and
the tool axis control is limited to the
surface. No lead/lag or side tilt angles
will be taken into consideration while
Mastercam generates the toolpath.

n Normal to surface enabled.

n Clearance = 4.0.
n Retract = 0.25.
n Feed plane = 0.1.
Note: The tool axis is limited along one direction and no

rotation is available.
230
Curve 5-Axis Step 22: Output Format Set To 4 Axis
n Front View n Right View
n Move the insert arrow below the Output

format 4 axis and copy the toolpath.
n From the Toolpaths Manager, select the
Parameters of the second operation.
n Select the Tool Axis Control page, change
the Output format to 4 axis and set the
Rotary axis to X axis.
n Set the Backplot rotary axis to X axis.
Note: A warning that "Rapid move hits operation surface " might appear. To fix the problem we will
need to apply entry/exit curves to the beginning/end of the toolpath.
Note: The tool axis rotates around the X axis.

The 4-axis output creates tool vectors parallel to a
plane that is perpendicular to the 4th axis.
231
Curve 5-Axis Step 23: Output Format Set To 5 Axis
n Front View n Right View
n Move the insert arrow below the

Output format 5 axis and copy the
toolpath.
n From the Toolpaths Manager, select
the Parameters of the third
operation.
n Select the Tool Axis Control page,
change the Output format to 5 axis.

Note: The tool axis rotates around both the X axis and the Y axis.
n Right View
n Front View
232
Curve 5-Axis Exercise 10: Curve - Tip Control
EXERCISE 10: CURVE - TIP CONTROL

Mastercam uses the drive geometry such as curves projected onto a surface or multiple surfaces to calculate points
where each tool axis vector is positioned. From these points you can set the tool depth at which the tool needs to
cut.
Open File
n Select CURVE 5 AXIS TIP CONTROL.MCAM.
STEP 24: TIP CONTROL ON SELECTED CURVE

Toolpaths
25.1 Set Tool

n Select the projected curve.

n Click on the Select button and select the point from the graphics window.
233
Curve 5-Axis Step 26: Tip Control Set To Comp To Surface
n Set Tip control to On selected curve.

n Leave the default settings.
Note: The On projected curve option sets the tool tip

on the curve that is projected onto a surface. Use this
when the projection of the curves is to be cut instead of
the curves that were selected. The center of the tool
follows the curve and the tool gouges into the surface.
STEP 26: TIP CONTROL SET TO COMP TO SURFACE
n In the Toolpaths Manager, copy the toolpath and

select the Parameters of the second operation.
n Select the Collision Control page and change the Tip
Control to Comp to surfaces.
n Select all surfaces.
234
Curve 5-Axis Exercise 11: Curve 5 Axis - Projection Type
Note: With the Tip Control set to Comp to surfaces, the

tool is retracted and does not gouge into the surface.
EXERCISE 11: CURVE 5 AXIS - PROJECTION TYPE

Mastercam projects curves onto surfaces using the current construction plane direction or normal to the tool axis
control surfaces.
Open File

n Select CURVE 5 AXIS PROJECTION NORMAL TO
SURFACE.MCAM.
STEP 27: PROJECTION SET TO NORMAL TO PLANE

28.1 Set Tool

n Select the curve.
235

n Click on the Select button and select the surfaces.
n Projection set to Normal to plane.
n Tip control = On projected curve.

n Clearance = 4.0.
n Retract = 0.5.
n Feed plane = 0.1.
28.6 Set Entry/Exit
n Enable Entry curve and set the Length to 0.2, Thickness to 0.2, Height to 1.0.
Note: With the projection set to normal to the plane,

Mastercam projects the curve in the current
construction plane, the Top Plane. The projection
normal to the plane generates a bad toolpath in the
areas where the surface has vertical walls (90
degrees).
236
Curve 5-Axis Step 29: Projection Set To Normal To Surface
STEP 29: PROJECTION SET TO NORMAL TO SURFACE
n In the Toolpaths Manager, copy the toolpath and select the Parameters of the second
operation.
n Select the Tool Axis Control page and change the Projection to Normal to surfaces.
Note: Maximum distance is only available with the Normal to surface projection and allows you to
set the maximum distance from the 3D curves to the surfaces onto which they will be projected.
This is useful in situations where you have multiple surfaces available for curves to be projected
onto, such as the inner and outer surfaces of a mold.

237
Curve 5-Axis Exercise 12: Curve 5 Axis - Review
EXERCISE 12: CURVE 5 AXIS - REVIEW

Open File
n Select CURVE 5 AXIS REVIEW

FILE.MCAM.
The following functions/toolpaths are covered in this

exercise:
n Curve Tool axis control - Lines.

n Curve 4 axis output Tool axis control - Surfaces.
n Curve Tool axis control - Plane.
n Curve Tool axis control - From point.
n Curve Tool axis control - To point.
STEP 30: CREATE A STOCK MODEL

STEP 31: SET THE TOOLPATHS
n From the Stock group, select the Stock Model icon.

n In the Stock Definition page, click on the Stock Setup button and enter the Name "Stock1".
n Select the Source Operations page.
n Select the Surface Rough Pocket and the Surface Finish Constant Scallop toolpaths.
STEP 32: CURVE AND TOOL AXIS CONTROL LINES
n Geometry to be used: the yellow curve and the yellow lines.
32.1 Tool
n Select the 3/4" Bull Endmill.
238
Curve 5-Axis Step 32: Curve And Tool Axis Control Lines
32.2 Cut Pattern

n Select the yellow color curve in CW direction.
n Set Tool axis control to Line.

n Select the orange lines in the upward direction.
n Tip control set to On selected curve.

n Clearance = 4.0.
n Retract = 0.25.
n Feed plane = 0.1.
32.6 Entry/Exit
n Enable Entry curve and set the Length to 0.2, Thickness to 0.2, Height to 1.0.
239
Curve 5-Axis Step 33: Curve Tool Axis Control Surface & 4 Axis Output
STEP 33: CURVE TOOL AXIS CONTROL SURFACE & 4 AXIS OUTPUT
n Geometry to be used: the dark green curve.
33.1 Tool
33.2 Cut Pattern

n Select the dark green color curve in CW direction.

n Output format set to 4 axis (Y axis).
n Normal to surface enabled.
n Tip control set to On projected curve.

STEP 34: CURVE TOOL AXIS CONTROL PLANE
n Geometry to be used: the blue curve. To define the plane use the blue rectangle.
34.1 Tool
240
Curve 5-Axis Step 35: Curve Tool Axis Control From Point
34.2 Cut Pattern

n Select the blue color curve in CW direction.
n Set Tool axis control to Plane.

n Select two intersecting lines to define the plane. The arrow should point outwards.
n Tip control set to Comp to surfaces. Select the surface.

STEP 35: CURVE TOOL AXIS CONTROL FROM POINT
n Geometry to be used: the magenta curve and the magenta point.
35.1 Tool
35.2 Cut Pattern

n Select the magenta color curve.

n Select the point.
241
Curve 5-Axis Step 36: Curve Surface Edge Using Tool Axis Control To Point

STEP 36: CURVE SURFACE EDGE USING TOOL AXIS CONTROL TO POINT
n Geometry to be used: dome surface open edge and the blue point.
36.1 Set Tool
n Curve type set to Surface edge - single.

n Select the edge of the semi sphere surface in the CW direction.
n Set Tool axis control to To point.

n Select the point.
242
Curve 5-Axis Step 36: Curve Surface Edge Using Tool Axis Control To Point

36.5 Set Entry/Exit
n Enable Entry curve and set the Length to 2.0, Thickness to 1.2, and Height to 3.0.
n Set the Direction to Right.
n Copy the settings to the Exit curve area.

n In the Backplot/Verify Options, enable Stock
model and select Stock1.
n Select all the Curve 5 Axis toolpaths.
Note: To simulate 5 axis toolpaths in the

Mastercam Simulator, under
File/Options/General, make sure you have the
Simulation engine set to 5-axis.
243
Drill 5-Axis
244
Drill 5-Axis Introduction
INTRODUCTION
This lesson covers the Multiaxis Drilling toolpaths. Hole making is likely the most fundamental and widely
used machining operation.
Multiaxis Drilling operations involve moving the tool linearly once the tool is positioned over the hole with the
desired tool axis orientation as shown.
Once positioned and oriented, drill motion looks and acts similar to three axes drilling, but there are dif-
ferences. Most multiaxis machines with rotation in the head usually do not support drill cycles such as G81 or
G83. All drilling motion is output as G0/G1 moves. Therefore, the code can be much longer for multiaxis
drilling.
Multiaxis machines are often less rigid than three axis machines, so be prepared to slow cutting speeds and
feeds accordingly.
In this lesson you will learn how to create a Drill 5-axis toolpath to machine holes that are defined by their cen-
ter points and have the tool axis normal to surfaces. You will learn how to create lines normal to surfaces that
will be used as geometry in the drill toolpath. Next, you will use a solid as a geometry and you will circle mill
the holes defined by selecting their faces. You will also have an exercise that will show you how to create the
axis of holes using Hole Axis. You will also create a Drill toolpath and a Circle Mill toolpath with axes oriented
towards a plane.
NEW CONCEPTS COVERED IN THIS TUTORIAL:

n Drill - Geometry type Points and Tool axis control set to Surface.
n Circle Mill - Geometry type Solid faces.
n Create Hole Axis for Tool Axis Control.
245
Drill 5-Axis Instructor Demonstration:
INSTRUCTOR DEMONSTRATION:
Topics:
n Drill - 5 Axis geometry type Points.

n Circle Mill - Geometry type Holes.
NOTES:
246
Drill 5-Axis Exercise 1: Drill - Entity Type Points
EXERCISE 1: DRILL - ENTITY TYPE POINTS

Open File

n Select DRILL ENTITY POINTS.MCAM.
STEP 1: DRILL 5 AXIS BY SELECTING THE GEOMETRY AS POINTS

Toolpaths
1.2 Toolpath Hole Definition
The Toolpath Hole Definition panel to select holes for a hole-making toolpath. Mastercam provides
many techniques for selecting entities; use any that are appropriate for your application. Entity types that
can be selected include the following: Points, Arcs, Lines, Solid features & Solid arcs.
n Make a window around the points as shown.

n The points will be automatically highlighted and in the Toolpath Hole
Definition Panel you will see all the points listed.
247
Drill 5-Axis Step 1: Drill 5 Axis By Selecting The Geometry As Points
1.3 Tool
The Tool page allows you to select a tool, edit its properties, and enter feeds and speeds. You can insert a comment
that will be output in the NC file after running the post processor.
n Select the 0.025"(No 72) Drill.
1.4 Cut Parameters

The Cut Parameters page allows you to select the drilling Cycle.
The tool axis can be oriented parallel to a line, normal to a surface or normal to a plane.
You can also decide what output format you want to generate: 5 axis, 4 axis or 3 axis.

n Click on the Select button and select the surface.
n Clearance = 6.0.
n Retract = 5.0.
n Top of stock = 0.0.
n Depth = -0.25.
248
Drill 5-Axis Excercise 2: Drill 5 Axis - Entity Type Lines & Holes
EXCERCISE 2: DRILL 5 AXIS - ENTITY TYPE LINES & HOLES

Open File
n Select DRILL LINES_HOLES.MCAM.
STEP 2: CREATE THE LINES FOR DRILLING FROM SURFACES
Note: These steps are used when the part model has surfaces only. For solid parts, other options are
available.
STEP 3: MAKE SURE THAT LEVEL 10 IS THE ACTIVE LEVEL

3.1 Make sure that Level 20 Is invisible
3.2 Create the circles
Note: This step is not necessary with a solid model as you can also select the solid hole edges to create a
normal line to a point. On Level 20 you have the solid model.
Wireframe
n From the Curves group, select Curve One Edge

command.
n Enable Fit arcs and lines, and select the respective
surfaces and drag the arrows to the edges of the
smaller size holes.
249
Drill 5-Axis Step 4: Create Line Normal To Point
STEP 4: CREATE LINE NORMAL TO POINT

Wireframe
n From the Lines group, select the drop down arrow and click on
the Line Normal to Point icon.
n In the Line Normal change the Length to 0.25.
n Select one of the arcs.
n The line should look as shown.

n Enable Reverse normal is needed.
n Repeat the steps for the other three holes.

250
Drill 5-Axis Step 5: Drill The Through Holes Using The Lines As Geometry
STEP 5: DRILL THE THROUGH HOLES USING THE LINES AS GEOMETRY

Toolpaths
n Select the lines created using Quick Mask.

n Make sure that the arrows are pointing in the upper
direction as shown.
Note: To change the direction you can right mouse click on the
line and select Reverse direction.
n In the Toolpath Hole Definition pane, you will see all four lines
listed.
251
Drill 5-Axis Step 5: Drill The Through Holes Using The Lines As Geometry
5.3 Set Tool
5.4 Cut Parameters
Note: Because we selected Lines as the Entity type, the Tool axis control is grayed out and cannot be
changed.

n Backplot rotary axis set to Z axis.
n Enable Calculate incremental values

from holes/lines for Mastercam to set the
depth automatically.
n Clearance = 3.0.
n Retract = 2.0.
n Top of stock =0.1.
n Depth = 0.0.
5.7 Tip Comp
n Enable Tip Comp and add a Breakthrough amount

of 0.1.
252
Drill 5-Axis Step 6: Circle Mill 5 Axis - Geometry Type Hole
STEP 6: CIRCLE MILL 5 AXIS - GEOMETRY TYPE HOLE
In this step you will use only solid geometry to define the holes geometry.
6.1 Make Level 20 the Active Level

6.2 Make Level 1 invisible
Note: With Level 20 the only level visible you can only see a solid.
Toolpaths
n From the 2D group, select the Expand gallery arrow and click on the Circle Mill icon.
6.4 Select the geometry - hole faces
n Zoom in and hold down Ctrl key and select the face of
the hole as shown.
253
n The arrow pointing upwards should appear on the

screen.
n All the other holes with the same

diameter will be automatically
selected.
6.5 Tool
6.6 Cut Parameters

Computer.
Left.
n Make sure Override geometry
diameter is disabled. Mastercam
determines the holes diameter
based on the selected geometry.
n Stock to leave on walls/ floors =
0.0.
254
6.7 Transitions

n Entry/exit arc sweep = 25.0.
n Enable Start/End at center.
n Change the Output format to 5 axis.

Note: Because we selected the holes as

the geometry type, the Tool axis control
is grayed out and cannot be changed.

from holes/lines.
n Clearance = 5.0.
n Retract = 0.5.
n Feed plane = 0.1.
n Depth = 0.0
255
Drill 5-Axis Exercise 3: Drill 5 Axis - Geometry
n Change the Vector length in the Backplot

Options to a smaller value.
EXERCISE 3: DRILL 5 AXIS - GEOMETRY

Open File
n Select DRILL 5 AXIS HOLE AXIS.MCAM.
STEP 7: DRILL THE HOLES

Toolpaths
256
Drill 5-Axis Step 7: Drill The Holes
7.2 Toolpath Hole definition
n Hold Down the Ctrl key and select the inside face of one hole.
The rest of the holes with the same diameter will be automatically
selected.
n Make sure that the arrows are pointing upwards.

n Click on the arrows which direction you need to
change.
Note: The order in which the holes are machining

has to be improved.
7.3 Reorder the hole selection
n In the Toolpath Hole Definition panel, click on the Sort button

and select Point to point.
257
n Select the start hole as shown.
n The drilling path should look as shown after sorting.
7.4 Tool
7.5 Cut Parameters
n Set the Output format to 5 axis.

258
7.7 Linking parameters

from holes/lines.
n Clearance = 4.0.
n Retract = 1.0.
n Depth = 0.0.
7.8 Tip Compensation
n Enable Tip Comp and set the Breakthrough amount to 0.05.
259
Drill 5-Axis Exercise 4: Drill 5 Axis - Tool Axis Control - Plane
EXERCISE 4: DRILL 5 AXIS - TOOL AXIS CONTROL - PLANE

Open File
n Select DRILL TOOL AXIS CONTROL PLANE.MCAM.

Toolpaths
n Select the center point at the bottom of the holes as

shown.
n Select the rest of the center points.
260
Drill 5-Axis Step 8: Drill The 0.25" Diameter Holes
8.3 Tool
8.4 Cut Parameters

n Tool axis control set to Plane.
n In the Plane Selection dialog

box, enable Entities.
n The arrow should point as shown.
n Clearance = 3.0.
n Retract = 1.0.
n Top of stock= 0.5.
n Depth = 0.0.
261
Drill 5-Axis Step 9: Drill The 1.5" Diameter Hole Tool Axis Control Plane
STEP 9: DRILL THE 1.5" DIAMETER HOLE TOOL AXIS CONTROL PLANE
Toolpaths
n Select the bottom of the hole center.
262
Drill 5-Axis Step 9: Drill The 1.5" Diameter Hole Tool Axis Control Plane
9.3 Tool
9.4 Cut Parameters

n Set Tool axis control to Plane.
n Click on the Select button and, from the Plane Selection
dialog box, select the Entities button.
n Select the edge as shown.
n Make sure the arrow points away from the part. Otherwise,
click on the Reverse button.
n Retract = 5.0.
n Feed plane = 0.6.
n Depth = 0.0.
263
Drill 5-Axis Exercise 5: Circle Mill 5 Axis - Tool Axis Control To Plane
EXERCISE 5: CIRCLE MILL 5 AXIS - TOOL AXIS CONTROL TO PLANE

STEP 10: CIRCLE MILL WITH THE TOOL AXIS CONTROL PLANE
n From the 2D group, select the Circle Mill icon.
n Select the bottom of the hole center.
11.2 Tool
n Select a 1.0" Flat Endmill.
11.3 Cut Parameters
n Set Compensation type to

Computer.
n Set Compensation
direction to Left.
n Make sure that Circle
diameter is 1.5, otherwise
enable Override geometry
diameter and enter the
value.
n Stock to leave on
walls/floors = 0.0.
264
Drill 5-Axis Step 11: Select The Toolpaths
11.4 Roughing Disabled

11.5 Finishing
n Enable Finishing.
n In the Finish area, set the Number to 1 and
the Spacing to 0.02.
n Enable Keep tool down at the Final depth.
11.6 Transitions

n Entry/exit arc sweep = 25.
n Enable Start/End at center.
n Overlap = 0.02.
11.7 Depth Cuts

n Maximum rough step = 0.25.
n # Finish cuts = 0.
n Depth cut direction set to Step down.
265

n Set the Tool axis control to Plane.
n Click on the Select button and, from the Plane Selection
dialog box, select the Entities button.
n Clearance = 2.0.
n Retract = 0.5.
n Feed plane = 0.1.
n Depth = 0.0.
266
11.11 Make only Level 10 "Stock" visible

n From the Toolpaths Manager, select Simulator

Options.
n Enable Solid in the

Simulator Options
and select the solid from
Level 10.
n Run the simulation.
n In the Verify Visibility area

click on the Stock once to
make it translucent as
shown.
267
Swarf 5-Axis
268
Swarf 5-Axis Introduction
INTRODUCTION
The purpose of this section is to introduce you to Swarf Milling machining; machining walls along curves with
the side of the cutter.
Swarf (Side Wall Axial Relief Feed) toolpaths allows you to machine the wall surfaces with the side of the
tool. This type of milling is common in the aerospace industry where part walls are tapered for increased
strength and low weight as shown.
Some parts that can be machined using three axes mill and surface toolpaths can be machined much more
efficiently using Swarf toolpaths since the Swarf toolpath can reduce the number of machining setups and
cut passes.
In this lesson you will machine the part shown by first using the Contour Toolpath with multiple passes to
machine the two steps. You will compare this toolpath with the Peel Mill Toolpath.
You will machine the slots using Contour - Ramp Toolpath.

n Swarf - Walls defined by surfaces; floor defined by surfaces; output format 4 axis.
n Swarf - Walls defined by surfaces; floor defined by surfaces; output format 5 axis.
n Swarf - Walls set to chains; floor defined by surfaces; output format 5 axis.
n Swarf - Walls defined by chains; Tip control to lower rail; output format 4 axis.
269
Swarf 5-Axis Instructor Demonstration
Topics:
n Swarf - Walls set to surfaces; floor defined

by surfaces; output format 4 axis.
n Swarf - Walls set to surfaces; floor defined
by surfaces; output format 5 axis.
lower rail; output format 4 axis.
NOTES:
270
Swarf 5-Axis Exercise 1: Swarf 5 Axis - Walls As Surfaces; Output Format 4 Axis
EXERCISE 1: SWARF 5 AXIS - WALLS AS SURFACES; OUTPUT FORMAT 4

AXIS
Swarf 5-axis can create a 4-axis or 5-axis toolpaths along a wall defined by surfaces or two chains.
Open File
n Select SWARF OUTPUT FORMAT 4 AXIS.MCAM.
STEP 1: SWARF 5 AXIS WITH THE OUTPUT FORMAT SET TO 4 AXIS
Toolpaths
n From the Multiaxis group, select the Expand gallery arrow

and from the Application family select Swarf.
1.1 Tool
n Select the 1.0" Bull Endmill with a Corner radius of 0.25".
271
Swarf 5-Axis Step 1: Swarf 5 Axis With The Output Format Set To 4 Axis
1.2 Cut Pattern
The Cut Pattern page allows you to select the wall geometry using Surface or Chains. It also allows you
to set the compensation type and direction, maximum step, cut tolerance and starting location for closed
walls.
n Walls set to Surface.

n From the QM buttons, click on the left half of the Select all entities by color button.
n Select the red color.
n Select the first wall

and move the arrow
to the lower edge of
the wall.
n The chain direction
should be CCW,
otherwise Reverse
Direction.
272
n Cutting method set to One Way.

n Stock to leave on walls = 0.0.
n Distance = 0.1.
n Enable Enter at middle of first wall.

They allow you to set the output format, fanning, angle increment, and minimize the tool movement when cutting
corners.

n Rotary axis set to X axis.
n Enable Minimize corners in toolpath to remove vectors
immediately before and after any corner in the toolpath.
273
The Collision Control page allows you to set the collision control parameters for the Swarf toolpath. Collision
control settings determine the tip compensation, establish the check and compensation surface behavior, and set
the gouge process settings. The tip compensation can be set to a plane, to surfaces or to the lower rail.
n Tip control set to Surface.

n From the Compensation surfaces area, click on the Select
button.
n From the QM buttons click on the Select all entities by color left half button.
n Select all blue colored surfaces.
n No check surfaces are required.

n Enable Look ahead 100 to evaluate ahead of the tool
position.
274
1.5 Linking
n Clearance = 4.0.
n Retract = 0.5.
n Feed plane = 0.1.
1.6 Entry/Exit
n Enable Entry/Exit curve and set the Length to

1.0, Thickness to 0.5, and Height to 2.0.
n Set the Direction to Left.
1.7 Roughing disabled
n Select the OK button to generate the toolpath.
275
Swarf 5-Axis Exercise 2: Swarf 5 Axis - Walls Defined By Chains
EXERCISE 2: SWARF 5 AXIS - WALLS DEFINED BY CHAINS

Open File
n Select SWARF1.MCAM.
STEP 2: SWARF 5 AXIS WITH THE OUTPUT FORMAT SET TO 5 AXIS

Toolpaths
n From the Multiaxis group, select the Expand gallery arrow and select Swarf.
3.1 Tool
n Select the 0.25" Bull Endmill with a Corner radius of 0.03125".
276
Swarf 5-Axis Step 3: Select The Toolpath
3.2 Cut Pattern

The Cut Pattern page allows you to select the wall geometry using Surface or Chains. It also allows you to set the
compensation type and direction, maximum step, cut tolerance and starting location for closed walls.
n Walls set to Chain.

n In the Wireframe Chaining dialog box, click on the Option button.
n Set the Sync mode to by Entity.
n Select the lower contour in the CCW

direction, otherwise Reverse
Direction.
n Select the upper contour in the CCW
direction. Make sure that the start point
is aligned with the lower contour.
277

n Distance = 0.1.

They allow you to set the output format, fanning, angle increment, and minimize the tool movement when cutting
corners.

n Enable Minimize corners in toolpath to remove vectors immediately before and after any
corner in the toolpath.
The Collision Control page allows you to set the collision control parameters for the multiaxis swarf toolpath.
Collision control settings determine the tip compensation, establish the check and compensation surface behavior,
and set the gouge process settings. The tip compensation can be set to a plane, to surfaces or to the lower rail.

n From the Compensation surfaces area, click on the Select button.
n Select the brown color.
n Enable Look ahead 100 to evaluate ahead of the tool position.
278

Linking parameters set the links between the cutting passes. In general, you can think of linking moves as air
Clearance sets the height at which the tool moves to and from the part.
Retract sets the height that the tool moves up to before the next tool pass.
Feed plane sets the height that the tool rapids to before changing to the plunge rate to enter the part. The tool also
moves to this height between operations if you do not enter both the clearance height and the retract height.
Keep tool down instructs Mastercam not to create a retract move if the distance from the end of one pass to the
start of the next pass is less than this value. The tool will move directly between the passes at the feed rate.
n Clearance = 4.0.
n Retract = 0.5.
n Feed plane = 0.1.
3.6 Entry/Exit
n Enable Entry/Exit curve and set the Length to 1.0, Thickness to 0.5, and Height to 2.0.
n Change the graphic view to front

and restart the backplot and
notice the tool axis orientation.
Note: A better finish for the walls

can be achieved when the tool is
vertical as much as possible.
279
Swarf 5-Axis Step 4: Add Fanning To The Toolpath
STEP 4: ADD FANNING TO THE TOOLPATH
Fanning distance sets the distance from a toolpath corner where the tool changes between fanning
motion and a normal orientation, which is perpendicular to the lower rail.
n From the Toolpaths Manager, click on the

Parameters.
n In the Tool Axis Control, enable Fanning and set the
Fan distance to 0.5.

n The toolpath should look as shown.
280
Swarf 5-Axis Exercise 3: Swarf - Surface Walls; Output Format 5 Axis
EXERCISE 3: SWARF - SURFACE WALLS; OUTPUT FORMAT 5 AXIS

Open File
n Select SWARF OUTPUT FORMAT

5AXIS.MCAM.
STEP 5: SWARF 5 AXIS WITH OUTPUT FORMAT SET TO 5 AXIS

Toolpaths
n From the Multiaxis group, select the Swarf icon.
6.1 Tool
6.2 Cut Pattern

n From the QM buttons click on
the Select all entities by
color left half button.
n Select the color blue no. 167.
Press Enter.
n Select as the first wall the
surface displayed with thicker
lines and move the arrow to
the lower edge of the wall.
n The chain direction should be
CCW, otherwise Reverse.
281
Swarf 5-Axis Step 6: Select The Toolpaths

n Distance = 0.05.
n Enable Enter at start of first wall.

n Enable Minimize corners in toolpath.

n Select the color red.
n Enable Look ahead 100.
n Clearance = 4.0.
n Retract = 0.25.
n Feed plane = 0.1.
282
Swarf 5-Axis Step 7: Using Multi Passes To Machine The Walls
6.6 Entry/Exit
n Enable Entry/Exit curve and set the Length to 0.5, Thickness to 0.5, and Height to 1.0.
6.7 Roughing
n Leave the Roughing settings disabled.

n Enable Display vectors and change the
Length to 0.5.
STEP 7: USING MULTI PASSES TO MACHINE THE WALLS
n From the Toolpaths Manager, select the Parameters of the

operation.
n From the Roughing page, enable Multi Passes and set the
Number to 2 and Spacing to 0.1.
n No finish passes.
283
Swarf 5-Axis Exercise 4: Swarf 5 Axis - Walls Defined By Chains

EXERCISE 4: SWARF 5 AXIS - WALLS DEFINED BY CHAINS

Swarf allows you to define the walls using two chains; a lower chain and an upper chain. For the toolpath to be
generated, the two chains have to be synchronized. When synchronizing chains, Mastercam breaks a chain into a
number of separate chains for the purpose of creating the toolpath. You can use different methods to synchronize the
chains such as By Entity, By Branch, By Point or By Node.
In our case, we are using By Entity which matches the chains by the endpoints of each entity. This requires both
chains to have the same number of entities.
Open File
n Select SWARF 5 AXIS WALLS CHAIN.MCAM.
STEP 8: CREATE THE CHAINS

STEP 9: OPTION 1: CREATE THE
CHAINS USING PROJECT
n Change the graphics view to Front.
n Create 2 horizontal lines on the magenta
surfaces and above the floor (blue color).
284
Swarf 5-Axis Step 9: Option 1: Create The Chains Using Project
Transform
n From the Position group select the

Project icon.
n Select the two horizontal lines. Press Enter.

n In the Project panel, enable Move.
n Enable Surface/Solids and select all surfaces.
n Enable View.
n Change the Graphic view to Isometric.

n Right mouse click in the graphic area and
select Clear Colors icon.
285
Swarf 5-Axis Step 9: Option 1: Create The Chains Using Project
9.1 Check the chains for gaps by hiding the surfaces
n Hold down the Shift key and select both chains.

n Use the Hide Entity (press Alt + E) command and select the two projected chains.
n Analyze Chain - Select the two projected chains.
n Press Alt + E to bring the rest of the geometry.
Note: Use the Blended spline command if you need to fix the geometry and the trimming function does
not work.
n Hold down the Shift key and select the two chains.
n Click on the Delete key to remove them.
9.2 Option 2: Create the chains using curve slice command
n Cplane set to Top.

n Use the Z construction plane and select the red
point to find the highest point of the curve.
n Z value should be 0.83192 as shown.
Wireframe
n From the Curves group, select the Curve Slice by Plane icon.
286
Swarf 5-Axis Step 10: Swarf Toolpath With Walls Defined By Two Chains
n Select all surfaces.

n In the Plane click on the Z to set the plane to
Plane from Along Axis.
n Click on the arrow in the graphics window and
set the value to 0.8.
n Press enter to locate the curve.
n Select the OK and Create New Operation
button twice.
n Select all surfaces again.

n In the Plane click on the Z to set the plane to Plane from Along
Axis.
n Click and drag the arrow and change the Z value to 0.7.
n Select the OK button.
n The geometry
should look as
shown.
STEP 10: SWARF TOOLPATH WITH WALLS DEFINED BY TWO CHAINS

Toolpaths
10.2 Tool
n Select the 1/2" Bull Endmill with a Corner radius of 0.125".
287
10.3 Cut Pattern
n Walls set to Chain.

n From the Chaining dialog box, select the
Options button and set the Sync mode to by
Entity.
n Select the lower chain and the upper chain from
the same starting location and in the CCW
direction.
n Cutting Method set to One way.

n Distance = 0.1.


n Select the light blue color no. 117.
288
n Clearance = 4.0.
n Retract = 0.25.
n Feed plane = 0.1.
10.7 Entry/Exit
n Enable Entry/Exit curve and set the Length to 1.0., Thickness to 1.0, and Height to 1.0.
10.8 Roughing
n Leave the Roughing settings disabled.
Note: You need to use the

chains to define the walls
when the surfaces of the walls
are not in a row.
289
Swarf 5-Axis Exercise 5: Swarf - Tip Control To The Lower Rail
EXERCISE 5: SWARF - TIP CONTROL TO THE LOWER RAIL

Swarf allows you to control the tool tip to a plane, to surfaces or to the lower rail.
The lower rail is the chain selected as such, or the lowest surface edge when using wall surfaces.
When using the lower rail to control the tip of the tool, you can also enter a distance for the tool center to move above
or below the lower rail. The distance is measured along the tool axis vector. A negative value moves the tool center
below the lower rail.
Open File
n Select SWARF TIP CONTROL LOWER RAIL.MCAM.
STEP 11: SWARF 5 AXIS WITH TIP CONTROL SET TO LOWER RAIL
Toolpaths
12.1 Tool
12.2 Cut Pattern

n From the QM buttons click on the
Select all entities by color left
half button.
n Select the magenta color. Press
Enter to finish the selection.
n Select as the first wall the front
surface and move the arrow to the
lower edge of the wall.
n The chain direction should be CW,
otherwise Reverse.
290

n Distance = 0.05.
n Enable Enter at start of first wall.

n Rotary axis set to X axis.
291
n Tip control set to Lower Rail.

n Distance above lower = -0.1.
n Clearance = 4.0.
n Retract = 0.5.
n Feed plane = 0.1.
12.6 Entry/Exit
n Enable Entry/Exit curve and set the Length to 0.5.; Thickness to 0.5; and Height to 0.5.
12.7 Roughing
n Roughing settings should be disabled.

n Select the OK button to exit Swarf 4-axis Deviation.
292
Flow 5-Axis
293
Flow 5-Axis Introduction
INTRODUCTION
Flow toolpaths follow the natural contour of a surface, allow scallop height control, and leave an excellent sur-
face finish as shown.
Flow also allows for shorter machining times compared to other toolpaths, and its NC file is generally smaller
than other toolpath types.

n Flow - Tool axis control - Pattern surface limits.
294
Flow 5-Axis Instructor Demonstration:
Topics:

n Flow - Tool axis control - Pattern surface
limits.
NOTES:
295
Flow 5-Axis Exercise: Flow 5 Axis - Tool Axis Control Limits
EXERCISE: FLOW 5 AXIS - TOOL AXIS CONTROL LIMITS

The tool axis in a Flow 5-Axis toolpath can be oriented parallel to existing lines, normal to a surface, normal to a
plane, from a point or to a point, or towards a chain or a closed boundary.
Limits serve to keep the tool axis within specified angles of a selected axis.
Note: We already covered the different types of tool axis orientation in the Curve 5 Axis toolpath. The
only specific tool axis orientation not supported in the Curve 5 Axis toolpath is orientation towards a
boundary.
Open File
n Select FLOW 5X-AXIS LIMITS.MCAM.
STEP 1: WITHOUT AXIS LIMITS

1.1 Select the Toolpath
Toolpaths
n From the Multiaxis group, select the Expand gallery

arrow and click on the Flow icon.
296
Flow 5-Axis Step 1: Without Axis Limits
1.2 Tool
The Tool page allows you to select a tool, edit its properties, and enter feeds and speeds. You can also insert a
comment that will be output in the NC file after running the post processor.
1.3 Cut Pattern
The Cut Pattern page allows you to select the surfaces to be machined, flow parameters, cutting method, cut
tolerance and step across.
n Click on the Select button and select the red color

surface.
n Modify the Flowline data parameters until they look as shown.
n Cutting method set to Zigzag.

n Step across set as a Distance = 0.1.
297
The tool axis can be oriented normal to pattern surface, parallel to existing lines, normal to a plane, oriented from a
point or to a point or towards an open chain or closed boundary.
You can also set the output format to 4 axis or 5 axis.
also apply a side tilt angle to tilt the tool to the right or left in the direction of cutting.
n Tool axis control set to Pattern surface.
Note: You are not allowed to select another surface. Mastercam uses the same surface selected in the
Cut Pattern page as the Pattern surface.

1.5 Limits
n No axis is selected.
The Collision Control page allows you to set the collision control parameters for the multiaxis Flow toolpath.
Collision control settings determine the tip compensation, establish check and compensation surface behavior, and
set gouge process settings.
n Click on the Select button and select the red surface as the
Compensation surface.
n No check surfaces.
298
1.7 Linking
n Clearance = 4.0.
n Retract = 0.5.
n Feed plane = 0.1.
1.8 Set Roughing Disabled

Note: Because the tool axis is normal to the pattern

surface, the tool will gouge into the part. We will use
Limits to avoid the gouge.
Note: Due to the tool being perpendicular to the surface at each point along the toolpath, the part
is always cut with center of the tool. To avoid this for a better finish you can use the Lead/lag
angle. While programming multiaxis toolpaths, you need to avoid Singularities. A Singularity is
achieved when the tool axis is parallel to the rotary axis as shown in . Using a Lead/lag angle or a
Side Tilt angle allows you to avoid singularities.
299
Flow 5-Axis Step 2: USE Axis Limits And Delete Motion That Exceeds Limits
STEP 2: USE AXIS LIMITS AND DELETE MOTION THAT EXCEEDS LIMITS
n From the Toolpaths Manager, copy the toolpath

previously created.
n Click on the Parameters of the second toolpath.
n in the Tool Axis Control page, set the Lead/lag
angle to 5 degrees.
n From the Limits page enable Z axis and set the Minimum =
0.0 and Maximum = 55.0.
n Enable DELETE motion that exceeds limits.
Note: With Delete motion that exceeds limits enabled, the

surface is not entirely machined.
300
Flow 5-Axis Step 3: USE Axis Limits And Modify Motion That Exceeds Limits
STEP 3: USE AXIS LIMITS AND MODIFY MOTION THAT EXCEEDS LIMITS
n From the Toolpaths Manager, copy the last toolpath created.

n Click on the Parameters of the third toolpath.
n In the Limits page enable MODIFY motion that exceeds
limits.
3.2 Machine Simulation
Machine
n From the Machine Simulation group, click on the

Machine Simulation Options icon.
301
Flow 5-Axis Step 3: USE Axis Limits And Modify Motion That Exceeds Limits
n In the Machine
Simulation, make
sure the 5_5AXGEN_
VMCTTAB machine
is selected.
n Set the Geometry to
All elements,
Position to
Automatic and
Fixture From Level
and select Level 18.
n Click on the Simulate
button to continue.
n In the Machine Simulation window,

enable Toolpath, Tool, Fixture,
Workpiece and Stock in the Visibility
group.
n In the Toolpath Rendering group,
enable Current Op, Follow, Tool
Vectors, Lead and Links.
n Run the simulation.

n There are collisions between the tool and
fixture as shown.
n From the Toolpaths Manager, click on the Parameters of the

last toolpath.
n In the Limits, change the Z axis Maximum angle to 20 degrees.
302
Flow 5-Axis Step 4: Flow 5 Axis - Tool Axis Control Boundary
n Regenerate the toolpath.

n Use Machine Simulation to check the toolpath
again.
n No collisions are reported.
STEP 4: FLOW 5 AXIS - TOOL AXIS CONTROL BOUNDARY
n From the Toolpaths Manager, copy the last

toolpath created.
n Click on the Parameters of the fourth toolpath.
n From the Limits page disable Z axis.
n In the Tool Axis Control page, select
Boundary as the Tool axis control.
n Click on the Select button and select the top
rectangle.
Note: The flow 5 axis tool axis is contained inside the rectangle. If you verify the toolpath in the Machine
Simulation, the tool will collide with the part. To avoid this, you will still need to used Limits as shown in
the previous toolpath.
303
Multisurface Toolpath
304
Multisurface Toolpath Introduction
INTRODUCTION
The Multiaxis Multisurface toolpath is similar to the Multiaxis Flow toolpath. Multisurface toolpaths do not fol-
low the UV curves of their drive surfaces. However, the toolpaths do allow the use of a separate cut pattern
surface, cylinder, sphere or box to control the flow of the paths as shown.
PATTERN OPTIONS
Set To Cylinder
A cylindrical pattern causes the tool to move around the part
in a radial fashion. In the example below, notice that the tool
axis follows a cylindrical path while the tool remains
compensated to the pattern surface as shown.
Set To Sphere
A spherical pattern causes the tool to move around the
part in a spherical (ball-shaped) pattern. The following
example shows a human tooth being machined using a
spherical cut pattern as shown.
The tool is compensated to the surfaces on the crown of
the tooth while the sphere controls the shape of the along
path. A control curve is used to control the shank of the
tool, and the tool follows a spiral cut method as shown
305
Multisurface Toolpath Introduction
Set To Box
A box pattern causes the tool to move around the part in a cube-
shaped pattern. In the example below, a zigzag cutting method is
generated using a box cut pattern as shown

Multisurface - Pattern surface finish toolpath.
Multisurface - Pattern surface rough toolpath.
306
Multisurface Toolpath Instructor Demonstration:
Topics:
n Multisurface - Pattern surface finish toolpath.

n Multisurface - Pattern surface rough toolpath.
NOTES:
307
Multisurface Toolpath Exercise: Multisurface - Cut Pattern
EXERCISE: MULTISURFACE - CUT PATTERN

In a Multisurface toolpath you can select the pattern that best defines the general machining area for the operation
and the general flow of tool motion. You can select surfaces from the part geometry, surfaces that you create that
best fit the shape of the part, or define a cylindrical, spherical, or rectangular surface that encompasses the
machining area.
Open File

n Select MSURF CUT PATTERN SURFACE.MCAM.
STEP 1: FINISH THE PART USING MULTISURFACE

n From the Multiaxis group, click on the Multisurface

icon.
1.2 Tool
n Select the 1.0" Ball Endmill.
1.3 Cut Pattern
n Click on the Select button and select the red color surface.
Note: The red surface is the pattern surface, not the surface that will be machined. The blue color
surfaces are the drive surfaces to be machined.
308
Multisurface Toolpath Step 1: Finish The Part Using MultiSurface
n The Flow data should look as

shown.

n Stock to leave on drive surfaces
= 0.0.
n Across Stepover = 0.05.
n Along Stepover = 0.05.
309

The tool axis can be oriented normal to pattern surface, parallel to existing lines, normal to a plane, oriented from a
point or to a point or towards an open chain or closed boundary.
You can also set the output format to 4 axis or 5 axis.
also apply a side tilt angle to tilt the tool on to the right or left side in the direction of cutting.
n Tool axis control set to Boundary.

rectangle.
1.5 Set Limits
n No limits.
The Collision Control page allows you to set the collision control parameters for the multiaxis Multisurface
toolpath. Collision control settings determine the tip compensation, establish the check and compensation surface
behavior, and set the gouge process settings.
Note: The surfaces that are selected as Compensation surfaces are the ones that are machined in this
toolpath.
n From the Tip control area, click on the Select button

and select the blue color surfaces.
n No check surfaces.
310
n Clearance = 2.5.
n Retract = 1.0.
n Feed plane = 0.5.
1.8 Entry/Exit
n Enable Entry/Exit and Entry curve.

n Set the Length to 0.2, Thickness to 0.2, and Height to 1.0.
n Copy the settings to the Exit curve area.
1.9 Roughing
311
Multisurface Toolpath Step 2: Rough Out The Part Using Multisurface
STEP 2: ROUGH OUT THE PART USING MULTISURFACE
n From the Toolpaths Manager, Copy the

toolpath.
n Select the Parameters in the first operation.
n In the Cut Pattern page, enter Stock to leave
on drive surface = 0.05.
n Across stepover = 0.2.
n Along stepover = 0.2.
n Select the Roughing page and set the

# Rough cuts = 4.
n Rough step = 0.6.
n Enable By depth to force the tool to
finish all depth cuts at a single step
before moving to the next.
2.1 Backplot the roughing toolpath
2.2 Change the tool in the second operation to 1/2 " Ball Endmill and Cut tolerance to 0.001
312
Multisurface Toolpath Step 3: Define The Stock
STEP 3: DEFINE THE STOCK

n Make Level 11 visible and set the stock.
3.2 Stock Setup
n In the Stock Setup, select the Add

from selection icon.
n Select the solid.
3.3 Tool Settings
n Enable Assign tool number sequentially.

n Enable Override defaults with modal values.
n Make Level 10 visible and make Level 11 invisible.
313
Multisurface Toolpath Step 3: Define The Stock
n Verify the toolpaths.
314
Deburr Toolpath
315
Deburr Toolpath Introduction
INTRODUCTION
After machining, all parts have straight edges or non tangent outer surface where you will find a burr. It
appears when the tool is chipping the metal off that edge. It is an unwanted situation because it can destroy
the functionality of the part or simply is endangering the worker because it is razor sharp. Most of the times it
is necessary and mandatory to remove it.
Deburr toolpath is used to break the edges for 3 to 5 axis, and to remove burrs. Deburr toolpath support Ball
Endmils and Lollipop Mill for undercut. This toolpath creates a path on the outer edges of a part geometry.
The position of the tool center relative to the edge is always the bi vector between the two surfaces of that
edge. The toolpath is fully automatic, you just need to select the part geometry.
It can also support Flat Endmills and Taper Mills allowing swarf-style motion to deburr an edge. This ability
comes with a new control for flank engagement point on the flutes. Additionally, you can set individual angle
step values for both rapid and feed moves in linking. You have to be in 5 axis (simultaneous) when using a
Flat Endmill or Taper Mill tool.

Create a 3 Axis Deburr toolpath.
Create a 5 Axis Deburr toolpath.
5 Axis Deburr toolpath with a Flat Endmill
316
Deburr Toolpath Instructor Demonstration:
Topics:
n 3 Axis Deburr Toolpath

n 5 Axis Deburr Toolpath
n Create a 1/2" Lollipop tool
n 5 Axis Deburr Toolpath with a
Flat Endmill
NOTES:
317
Deburr Toolpath Exercise: Deburr
EXERCISE: DEBURR
In a Deburr toolpath is used to break the edges for 3 to 5 axis, and to remove burrs.
Open File
n Select Deburr.MCAM.
STEP 1: SELECT THE MACHINE AND SET UP THE STOCK

1.1 Select the Machine
n From Machine tab, select Mill Default.
1.2 Stock Setup
n In the Stock Setup, select

the Add from selection
icon.
n Select the solid.
1.3 Tool Settings
n Enable Assign tool number sequentially.

n Enable Override defaults with modal values.
318
Deburr Toolpath Step 2: 3 Axis Deburr
STEP 2: 3 AXIS DEBURR

Toolpaths

arrow.
n Select the Deburr icon as shown.
2.2 Create a 1/2 Lollipop Mill Tool
n In the Tool page, right

mouse click in the tool
list window and select
Create tool as shown
n Select the Lollipop

mill as the tool type
as shown.
n Select the Next
button.
319
n In the Define
Tool
Geometry
page, set the
parameters as
shown.
n Set the rest of

the
parameters as
shown and
then select the
Finish button.
320
2.3 Set the Tool page parameters
n From the Tree View list, select

the Tool page.
n Add a comment in the
Comment area to identify the
toolpath in the Toolpaths
Manager and also in the NC file.
Note: The feeds and

spindle speed are based
on the tool definition. You
can overwrite them with
the feeds and speed that
you want to use. You can
also let Mastercam
calculate the feeds and
speed using the Feed
speed calculator.
2.4 Cut Pattern
n In the Part surfaces click on the Select button

as shown.
n Select the solid as shown.

n Press Enter button.
n In the Edge definition enable User

defined and click on the Select button as
shown.
321
n In the Solid Chaining dialog box, make sure that Solid

face button is enabled and select the top face as shown.
n The rest of the parameters should remain as shown.
Machining geometries allows you to select the surface.

Edge definition allows you to choose between:
User defined allows you to select the edges manually.
Auto detect extracts all the part surface edges. In case a certain edge should not be machined, the user can
select the edges that should be excluded separately.
Avoidance geometries are additional surfaces that are being considered in the tool path calculation for collision
checking.
Edge shape can be set to Constant width or Constant depth.
Inner corner can be trimmed so that the tool path will have a sharp corner or relief grooves can be added.
Direction allows you to set the direction to Climb or Conventional.
Number of cuts along edges can be set to Flat to machine a chamfer or Round for a fillet. The number
allows you to set multipasses.
Length allows you to extends the start and end of the toolpath.
322

For Deburring you have the following choices:
3 axis
4 + 1 axis (auto tilt)
4 axis (rotary)
5 axis (simultaneous)
3 + 2 axis
The tilting set to 3 axis keeps the tool normal to the current Tool plane. In our case is the Top plane. The toolpath
generated is still formatted as 5 axis moves.
n Machining type
= 3 axis.
n Direction set to
Z axis.
n Clearances:
n Holder = 0.1.
n Shank = 0.025.
n Shoulder
=0.01.
n Tool contact
set to 50%.
323
n In the Linking page, change the

Rapid distance to 2.0 and leave
the rest of the parameters as
shown.
324
2.8 Verify the toolpath.
2.9 Create a 0.05 Chamfer
n To create a chamfer, in the Cut Pattern

change the Constant width to 0.05 and
set the Number of cuts along edges to 3.
2.10 Backplot and Verify
325
Deburr Toolpath Step 3: 5-Axis Deburr Toolpath
STEP 3: 5-AXIS DEBURR TOOLPATH
Toolpaths
n From the Multiaxis group, select the Deburr toolpath.
3.1 Tool Page
n Select the existing

tool and add a
comment in the
Comment area.
3.2 Cut Pattern
n In the Part surfaces click on the Select

button as shown.
n Make a window around the solid as shown.
326
n In the Edge definition enable User

defined and click on the Select button
as shown.
n In the Solid Chaining dialog box,

make sure that Face button is
enabled.
n Press Ctrl + T to make the solid
translucent and select the hole edge
and the face edges as shown.
n The rest of the Cut Pattern
parameters should remain as they
are.
3.3 Tool axis Control
n Change the
Machining type to 5
axis (simultaneous)
and the Strategy to
Normal to contour
as shown.
5 axis allows the tool to tilt side wise as well as lead tilt while machining the hole edges.
327
3.4 Linking
n In the Linking page,

leave the parameters as
shown.
328
Deburr Toolpath Step 4: Deburr With A Flat Endmill
STEP 4: DEBURR WITH A FLAT ENDMILL
In this step, you will change the tool of the last toolpath to a 1/4 Flat Endmill. Once the tool is selected in the
Tool Axis Control you will see the Tool contact parameter enabled.
n Copy the last toolpath.

n Select the Parameters and select the 1/4" Flat Endmill.
4.1 Cut Parameters
n In the Extension/Overlap
set the Length to 0.2 to
extend the start and end of
the toolpath.
329
Deburr Toolpath Step 4: Deburr With A Flat Endmill
n In the Tool Axis

Control make sure the
Tool contact is set to
50.0%. This parameter
controls the flank
engagement point on the
flutes.
330
Advanced Multiaxis Intro
331
Advanced Multiaxis Intro Advanced 5-Axis Toolpaths
This Section takes you a step forward to learn how to machine complex shapes more efficient using the
Advanced 5-Axis toolpaths.
ADVANCED 5-AXIS TOOLPATHS

Multiaxis toolpaths are grouped into different toolpath families based on their calculation type.
The Advanced toolpaths contain the following toolpaths: Swarf Milling, Unified, Triangular Mesh, Pock-
eting, Deburr and Rotary Advanced.
SWARF MILLING
Swarf Milling (Side Wall Axial Relief Feed) toolpaths allow you to machine wall surfaces with the side of
the tool. The advantage of this 5-axis toolpath is that you can machine the surface with a single cut using the
whole flute length of the tool.
The Swarf Milling toolpath will keep the tool axis aligned between 2 points on the upper and lower curve
which means that the surface to be machined has to be straight between the points. The system tries to get
the upper and lower curves from the surfaces. If this does not work then the user has to provide the upper
and lower curve separately.
UNIFIED PATTERNS
The Unified toolpath gives you access to all the surface-based toolpaths (Morph, Parallel, Along Curve, and
Project), as well as the geodesic toolpath options (Automatic, Guide), in a single interface.
1. PARALLEL
The Parallel toolpath pattern can be set parallel to Curves, Surfaces or aligned at an Angle.
Parallel To Curves
The Parallel to Curves pattern will align the cut direction with a leading curve. Adjacent cuts are parallel to
each other. It is important to note that the cuts will not simply be copied next to each other. Every new cut is
created at an offset from the previous cut.
The curve must be located exactly on the surface edge, so the best curve would be the edge itself. This is
very important for toolpath generation. If you don't have a proper curve, an incorrect toolpath can be gen-
erated.
Parallel To Surfaces
The Parallel To Surfaces pattern generates cuts on the machining geometry surface parallel to an avoid-
ance geometry surface. There are special options for the edge between the avoidance geometry surface
and the machining geometry surface. You can define a margin to define the exact position where the tool is
located along the edge, positioned as close as possible to both faces.
Parallel To Angle
The Parallel To Angle pattern lets you create tool motions with cuts that are parallel to each other. The dir-
ection of the cuts is defined by the two angles: the Machining angle in X,Y and the Machining angle in Z.
332
Advanced Multiaxis Intro 2. Morph
2. MORPH
The Morph toolpath allows you to choose between two patterns: From Curves and From Surfaces.
Morph - Pattern From Curves
Morph between 2 curves will create a morphed toolpath between two leading curves. A "morphed"
toolpath is one that is approximated between the tilt curves and evenly spread over the surface. This toolpath
will ensure a better finish with less retraction moves.
Morph - Pattern From Surfaces
Morph between 2 surfaces toolpaths create a morphed toolpath on the machining geometry surfaces. The
machining geometry surface is enclosed by two avoidance surfaces. A "morphed" toolpath is one that is
approximated between the avoidance surfaces and evenly spread over the machining geometry surface.
The main advantage is the possibility to compensate the tool to the machining geometry surface and avoid-
ance surface in the left and right corner of the workpiece. All you need to do is set the margin, or distance
between the tool center and the surfaces, equal to the tool radius.
3. ALONG CURVE
Along Curve generates the toolpaths orthogonal to a leading curve. This means that when your selected
curve is not a straight line, the cuts are not parallel to each other. The distance between two neighboring cuts
(at the intersection of the curve and toolpath) is the maximum stepover.
4. PROJECT CURVES
The Project Curves toolpath pattern generates a single toolpath along a curve or multiple curves.
If the curves lie exactly on the surface, the toolpath has the same shape and position as the curves.
If the curve is located above the surface, the curve has to be within a maximum projection distance above the
surface. This value defines the maximum distance between tilt line end points and the machining contour.
TRIANGULAR MESH
Triangular Mesh toolpaths allow you to generate eleven toolpaths that have strategies similar to Master-
cam’s 3-axis strategies, including Rough, Parallel cuts, Parallel curves, Constant Z (contour), Constant cusp
(scallop), Flatlands, Pencil, Geodesic, Projection, Rotary, and Trochoidal. The benefit of these toolpaths is
that they have Multiaxis options such as tool axis control, collision check and linking. You can also use them
to output 3-axis code while supporting undercut machining with lollipops cutters.
ROTARY ADVANCED
Rotary Advanced toolpaths are designed to rough machine parts on a 4-axis machine. It can be used to
mill cylindrical parts like screws. You have to define the stock first to allow Mastercam to trim the tool motion
to prevent excess air cutting. The toolpath removes the material between the defined stock and the part
using a constant radius pattern to define the depth cuts.
DEBURR
Deburr toolpaths are used to break edges for 3 to 5 axis parts and to remove burrs. The toolpath supports
the following tools : Ball Endmill and Lollipop with undercut.
333
Advanced Multiaxis Intro New Concepts Covered:
NEW CONCEPTS COVERED:

n Cut Patterns in Unified Toolpaths.
n Parallel to Angle
n Parallel to Surfaces
n Parallel to Curves/Guides
n Morph between two surfaces
n Morph between two Curves/Guides
n Along Curve
n Project Curves
n Area
n Area Type
n Round corners
n Extend / Trim
n Angle range
n Containment
n Sorting
n Flip step over
n Start point
n Cutting method
n Cut order
n Machine by
n Tool Axis control -Side Tilt Definition
n Follow surface iso direction
n Ortho to lower edge curve
n Ortho to cut direction at each position
n Ortho to cut direction at each contour
n Use spindle main direction
n Use user defined direction
n Use tilt line definition
n Collision Control
n Retract tool along tool axis
n Retract tool along surface normal
n Tilt tool with Use side tilt angle
n Leaving out gouging points with Trim toolpath between first and last collision
334
Advanced Multiaxis Intro Exercise 1: Unified Cut Patterns
EXERCISE 1: UNIFIED CUT PATTERNS

In this exercise you will compare the patterns resulting from the following Unified toolpaths:
n Parallel to Angle (Custom Angles).

n Parallel to Surfaces.
n Parallel to Curves.
n Morph between two surfaces.
n Morph between 2 curves.
n Along Curve.
n Project Curves.
Resources - Download the file from http://www.emastercam.com/trainingfiles
n Select CUT PATTERN 1.MCAM.
The following patterns and their settings are

covered in this exercise:
Parallel To Angle Pattern.
n Machining Custom Angles XY 0 and Z 0.

n Full, start and end at exact surface edges.
n Maximum stepover = 0.25.
Parallel To Surfaces Pattern.

Parallel To Curves Pattern.
Morph Between 2 Surfaces Pattern.
n Start margins = 0.01.
Morph Between 2 Curves Pattern.
335
Advanced Multiaxis Intro Step 1: Parallel To Angle (Custom Angles) Pattern
STEP 1: PARALLEL TO ANGLE (CUSTOM ANGLES) PATTERN
The Parallel To Angle (Custom Angle) Pattern will create tool motion with cuts that are parallel to each
other. The direction of the cuts is defined by the two angles: the Machining angle in X,Y and the Machining angle
in Z.
1.1 Select Toolpaths
n From the Multiaxis group, select the Unified

icon.
1.2 Tool
The Tool page allows you to select a tool, edit its properties, and enter feeds and speeds. You can also
insert a comment that will be output in the NC file after running the post processor.
1.3 Cut Pattern
Cut Pattern settings determine the geometry the tool follows and how it travels along that geometry.
n Select the Add plane row icon.
n In the Style column, select

Custom angles.
336
n Click on the Select button in the

Machine geometries area and
select the dark green (no. 2)
cylindrical surface.
n Machine geometries offset = 0.
n Area Type set to Full,

start and end at
exact surface
edges.
n Cut tolerance =
0.001.
n Maximum stepover
= 0.25".
n Cutting method set
to Zigzag.
1.4 Machining Angles
n In the Machining Angles, make sure that Machining angle in XY and Z are set to 0.
n Make sure Collision Control, Status 1 is disabled.
337
1.6 Linking
n In the Clearance area,

set the Type to
Automatic.
n Make sure Generate
toolpath is enabled.
Note: With the Parallel

toolpath and the Machining
angle set to Z 0, the
toolpath performs constant
parallel cuts around the Z
axis.
338
Advanced Multiaxis Intro Step 2: Parallel To Surfaces Pattern
STEP 2: PARALLEL TO SURFACES PATTERN
The Parallel To Surface Pattern generates cuts on the machining geometry surface parallel to an avoidance
surface.
There are special options for the edge between the avoidance surface and the machining geometry surface. You can
define a margin to define the exact position where the tool is located on the edge, positioned as close as possible to
both faces.
2.1 Copy the toolpath
n In the Toolpaths Manager, copy the toolpath.

n Select the Parameters of the second toolpath.
2.2 Set Cut Pattern
n Click on the Remove all rows icon to remove the Plane with
Custom angles pattern.
n Click on Add Surface row icon.
n Click on the Select button and

select the burgundy (no. 4)
surface.
Note: With the Parallel To Surfaces

Pattern the tool follows the bottom surface
edge along the whole surface.
339
Advanced Multiaxis Intro Step 3: Parallel To Curves Pattern
STEP 3: PARALLEL TO CURVES PATTERN
The Parallel To Curves Pattern will align the cut direction with a leading curve. Adjacent cuts are parallel to
each other. It is important to note that the cuts will not simply be copied next to each other. Every new cut is created
at an offset from the previous cut.
The curve must be located exactly on the surface edge, so the best curve would be the edge itself. This is very
important for toolpath generation. If you don't have a proper curve, an incorrect toolpath will be generated.
n In the Toolpaths Manager, copy the last toolpath.

n Select the Parameters of the third toolpath.
3.2 Set Cut Pattern
n Click on the Remove all rows icon to remove the Surface with
Parallel pattern.
n Click on Add Curve row icon.
n Click on the Select

button and select the
curve at the bottom.
3.3 Preview the toolpath
n Click on the Apply button.

n Select the Hide dialog button.
n The Preview should look as shown.

n Press Esc to exit the preview.
Note: With the Style set to Guide the Area type

changes to Entire machining area. The rest of
the parameters are the same as for the Parallel
to an angle pattern.
340
Advanced Multiaxis Intro Step 4: Morph Between 2 Surfaces Pattern
n Change the Style

column to Parallel to
have the Area Type
options from the
surface edges.
Note: With the Parallel To Curves Pattern set to

Parallel style the toolpath passes are created parallel to
the chain. With Parallel To Curves Pattern set to Guide
the toolpath has more retract movements.
STEP 4: MORPH BETWEEN 2 SURFACES PATTERN
The Morph between 2 surfaces Pattern creates a morphed toolpath on the machining geometry surfaces.
The machining geometry surface is enclosed by two avoidance surfaces. A "morphed" toolpath is one that is
approximated between the avoidance surfaces and evenly spread over the machining geometry surface. This
toolpath pattern is especially useful during impeller machining with twisted turbine blades.
The main advantage is the possibility to compensate the tool to the machining geometries surface and avoidance
surface in the left and right corner of the workpiece. All you need to do is set the margin, or distance between the tool
center and the surfaces, equal to the tool radius.

4.2 Set Cut Pattern
n Click on the Remove all rows icon to remove it.
341
n Click on the Select button and select the dark

green (no. 2) top surface.
n Click on the Select button and

select the brown (no. 4)
surface.
342
n The
parameters
should look as
shown.

n An error appears on the screen and no preview is available.
4.4 Change the Style to Morph
n Change the Style to

Morph.

Morph between surfaces
considers the top and bottom
surfaces as check surfaces and it
should not gouge in the brown
surface at the bottom. It is broken in
Mastercam 2023.
343
n In the Toolpaths Manager,

select the Parameters of the
last operation.
n Area Type set to Full, start
and end at exact surface
edges.
n Expand Cut Pattern, click on

Margins and set the Start
margins to 0.01.
344
Advanced Multiaxis Intro Step 5: Morph Between 2 Curves Toolpath
STEP 5: MORPH BETWEEN 2 CURVES TOOLPATH
The Morph between 2 curves Pattern will create a morphed toolpath between two leading curves. A
"morphed" toolpath is one that is approximated between the tilt curves and evenly spread over the surface. This
toolpath will ensure a better finish with less retraction moves.


5.3 Set Cut Pattern
n Click on the Select button and select the top curve in

the CW direction.
345
Advanced Multiaxis Intro Step 5: Morph Between 2 Curves Toolpath

the bottom curve in CW direction.
n Change the Style to Morph.
Note: The difference between the Morph between surfaces and Morph between two curves is that
Morph between surfaces considers the top and bottom surfaces as check surfaces and does not
gouge in the brown surface at the bottom.
With Morph between two curves you have to use margins to stay away from the brown surface.
346
Advanced Multiaxis Intro Step 6: Along Curve Pattern
STEP 6: ALONG CURVE PATTERN
Along Curve generates the toolpaths orthogonal to a leading curve. This means that when your selected
curve is not a straight line, the cuts are not parallel to each other. The distance between two neighboring
cuts (at the intersection of the curve and toolpath) is the maximum stepover.
To machine the surfaces you should use a lollipop cutter. Just be sure to define the shank of the lollipop
cutter so that it is long enough to clear all potential interferences.
Download the file from http://www.emastercam.com/trainingfiles
n Select CUT PATTERN 2.MCAM.
The following pattern and the settings are covered in

this exercise:
Along Curve Pattern.
347

icon.
6.2 Tool
n Select the 1/2" Lollipop Mill.
6.3 Cut Pattern
n Select the Add Curve row icon.
n Click on the Select button and in

the Wireframe Chaining dialog
box enable Single.
n Select the blue color spline,
starting at the open edge.
n In the Style
column, select
Perpendicular.
348
n In the Machining area click on the Select machining

geometries button and select the surface.
n Change the Cutting method to One way and leave the rest of the parameters as shown.
Note: No toolpath is generated . This is due to the Collision defaults.
349

Disable the Collision Control.
Note: The toolpath pattern is

generated as expected. You need to
set the Tool Axis Control as well as
the Collision Control parameters.
n In the Collision Control, set the First Status to Check the Shoulder, Shank.
n Set the Strategy to Tilt tool, Automatic.
n Enable Machining geometry in the Geometry as shown.
350
n Tool Axis Control set to

Fixed angle to axis.
n Enable Limits.
n In the Limits enable

Conical limit and set the
W1 to 0.0; W2 to 30.0.
n Cone axis set to Z-axis.
351
Advanced Multiaxis Intro Step 7: Project Pattern
Note: This application will be explain later in detail with both sides being machined. Smoother links to
provide a better finish as well as how to create the spline will be covered in a later exercise.
STEP 7: PROJECT PATTERN
The Project Curves toolpath pattern generates a single toolpath along a curve or multiple curves.
If the curves lie exactly on the surface, the toolpath has the same shape and position as the curves.
If the curve is located above the surface, the curve has to be within a maximum projection distance above
the surface. This value defines the maximum distance between tilt line end points and the machining
contour.
The following pattern and the settings are covered in this

exercise:
Project Pattern.
352
n Open Levels Manager

and make visible Level
20.
n From the Multiaxis group, select the Unified icon.
7.3 Tool
7.4 Cut Pattern
n Click on the Select button and in the Wireframe

Chaining dialog box enable Window.
n In the Chaining Options enable Color and
make sure that only color green is enabled.
353
n Make a window around the

green color letters and select
the approximate starting point
at the bottom end of the letter
C.

Project.
n In the Machining area click on the Select

machining geometries button and select the
surface.
354
Note: The tool axis is still set to Fixed

angle to axis and the collision control
is also set from the previous
toolpath. The engraving depth
needs to be set.
7.6 Reload parameters from the default
n To quick get the default parameters, click on the Reload parameters from
the default button.

Disable the Collision Control.
7.8 Cut Pattern
n In the Machining
area, set the
Machining
geometries offset to
-0.02.
355
Note: Both Project and Along Curve Pattern required the

machining geometry surface to have a proper surface
normal. For the along curve the normal should point inside of
the chamber. The project toolpath normal should point
outside of the surface.
356
Advanced Multiaxis Intro Exercise 2: Area Settings
EXERCISE 2: AREA SETTINGS

The Area settings allow you to:
Set the Area Type which determines where the tool starts, ends, and the area to be cut.
Round corners allows you to add fillets to the operation for internal corners. You can extend or trim the cutting
motion when the tool gets to the end of a surface.
Containment allows you to select a chain to machine only the area inside of it.
Extend / Trim determines how the tool behaves when it comes to the end of a surface. By entering a positive
value as the % of the tool diameter you will extend the toolpath over the surface edge. Entering a negative value as
the % of the tool diameter will trim the toolpath.
Angle range is used to limit the cutting motion by entering two angles.

n Select AREA SETTINGS.MCAM.
The following parameters/toolpaths are covered in this exercise:
Unified toolpath.
n Machining angle in X,Y = 90 degrees.

n Machining angle in Z = 90 degrees.
n Full, avoid cuts at exact edges.
n Parallel toolpath.
n Enable Round corners and set the Additional radius to 1.0.
n Enable Extend / trim and set the Start to 100% of the tool
diameter and End to -100% of the tool diameter.
n Disable Extend / trim and enable 2d Containment and select the
chain.
n Disable 2d Containment and enable Angle range, set the View
direction to Z axis and
n Slope angle start = 0 and Slope angle end = 0.1.
357
Advanced Multiaxis Intro Step 8: Unified - Parallel Angle Toolpath
STEP 8: UNIFIED - PARALLEL ANGLE TOOLPATH
n From the Multiaxis group, click on the Unified icon.
8.1 Tool
8.2 Cut Pattern

Custom angles.
n In the Machining Angles, make sure that

Machining angle in XY and Z are set to 90.
358
n Click on the Select button in the Machine

geometries area and select the surfaces.
n Machine geometries offset = 0.
8.4 Linking
n Machining
geometry offset =
0.
n Area Type set to
Full, avoid cuts at
exact edges.
n Cut tolerance =
0.001.
n Maximum
stepover = 0.5.
n Cutting method
set to Zigzag.
359
8.6 Set Linking parameters
n Set the Small

gaps to Direct.
n Small gap size =
150%.
n Set the
Clearance area
Type set to
Automatic.

n Enable Display vector and set the
Length to 0.25.
360
Advanced Multiaxis Intro Step 9: Round Corners
STEP 9: ROUND CORNERS
The Round corners option allows you to add fillets to the toolpath where sharp corners are found.
n Right mouse click in the Toolpaths Manager and select Copy.

n Right mouse click again in the Toolpaths Manager and select Paste.
9.2 Set Cut Pattern
n Enable Round
corners.
n Select the
Round
Corners page
and set the
Additional
radius to 1.0.
Note: The fillets in the

toolpath.
361
Advanced Multiaxis Intro Step 10: Extend / Trim
STEP 10: EXTEND / TRIM
The Extend / Trim page parameters determine how the tool behaves when it comes to the end of a surface. By
entering a positive value as the % of the tool diameter you will extend the toolpath over the surface edge. Entering a
negative value as the % of the tool diameter will trim the toolpath.
Extend/Trim gaps allows you to apply the same extend/trim values to gaps in the surfaces that are applied to the
ends of the surfaces.
10.1 Copy the last toolpath

n Enable Extend / trim.

n Select the Extend /
trim page and set the
Start to 100 % of the
tool diameter and set
the End to -100 % of
the tool diameter.
n Enable Extend/Trim
gaps.
362
Advanced Multiaxis Intro Step 11: Containment
STEP 11: CONTAINMENT
The 2d Containment page is used to select a chain to control the cutting area of the part.

n Enable Containment and click on the Select button to select the chain from the graphics window.
Note: Make sure that the Color mask is disabled.
STEP 12: ANGLE RANGE
Angle range is used to limit the cutting motion by entering two angles. In our example, you will set the angle range
to avoid the flats. The Z axis slope will be set between 0 and 0.1.

n In the Area, disable Extend /

Trim, Containment and enable
Angle range.
363
Advanced Multiaxis Intro Step 12: Angle Range
n Select the Angle Range page and set

the Slope angle start to 0 and Slope
angle end to 0.1.
n Enable Machine outside slope
angle.
n Select the Parameters of

the last operation and
enable Machine between
slope angles.
Note: An extra movement at the

center. (Mastercam bug).
364
Advanced Multiaxis Intro Exercise 3: Sorting
EXERCISE 3: SORTING
The Sorting allows you to determines where the tool starts, ends, and cutting method and cut order.
n Select SORTING AND LINKING.MCAM.
Unified - Parallel to Angle toolpath.
n Machining angle in X,Y = 0 degrees.

n Machining angle in Z = 90 degrees.
n Start point selected from geometry.
n Tilt angle at side of cutting direction = 30 degrees.
n Gaps along cut; Small gaps set to Direct, Large gaps set to Retract to rapid
distance spline, Small gap size = 100%.
n Machine by Regions.
n Enable Flip step over.
n Enable Machine by Lanes.
n Cut order set to From center away.
n Large gaps set to Blend spline.
n Cut order set to From outside to center.
365
Advanced Multiaxis Intro Step 13: Machine By Region
STEP 13: MACHINE BY REGION
Machine by Region splits the toolpath into regions when the tool encounters a gap. It is recommended when the
part geometry creates excessive air motion around the gaps.
14.1 Set Tool
14.2 Cut Pattern
n In the Style column, select Custom

angles.
n In the Machining Angles, make sure that

Machining angle in XY set to 0 and Z set to
90.
366
Advanced Multiaxis Intro Step 14: Select The Toolpaths
n Click on the Machining geometries Select button and select the surface.
n Machining geometries offset = 0.
n Area Type set to Full, avoid cuts at exact edges.
n Enable Start point.
n Machine by: Regions.
n In the Start Point Parameters page, in the Set

point by area enable Position and click on the
Select button.
367
Advanced Multiaxis Intro Step 14: Select The Toolpaths
n Select the point at the upper right corner.
Tool axis control settings determine the tool's orientation in relation to the geometry being cut. Tilt angle at side
of cutting direction allows you to tilt the tool axis in the direction of the cut, relative to the surface normal. A
positive angle tilts the tool to the left; a negative angle tilts the tool to the right.
n Set the Tilt angle at side of cutting

direction to 30 degrees.
n In the Default links area set

the Small gaps to Direct and
the Large gaps to Retract to
rapid distance.
n Set the Small gap size to
110% of the tool diameter.
368
Advanced Multiaxis Intro Step 15: Flip Step Over
STEP 15: FLIP STEP OVER
Flip step over allows you to reverse the cutting direction for the operation.

n In the Sorting area,

enable Flip step over.
n Make Sure Collision Control, Status 1 is disabled.
Note: The tool cuts from the opposite direction.
369
Advanced Multiaxis Intro Step 16: Machine By Lanes
STEP 16: MACHINE BY LANES
Machine by Lanes cuts the part with the selected pattern.

n Enable Machine by Lanes.
370
Advanced Multiaxis Intro Step 17: Cut Order - From Center Away
STEP 17: CUT ORDER - FROM CENTER AWAY
Cut order allows you to select the cut order from a list:
Standard is the default option which usually cuts from one side of the part to the other.
From center away cuts from the approximate center of the part to the outer edges.
From outside to center cuts from the outer edges of the part to the approximate center.

17.2 Cut Pattern
n Change the
Cut order to
From center
away.
n Set the Large gaps to

Blend spline.
371
Advanced Multiaxis Intro Step 18: Cut Order - From Outside To Center
STEP 18: CUT ORDER - FROM OUTSIDE TO CENTER
Cut order allows you to select the cut order from a list:
Standard is the default option which usually cuts from one side of the part to the other.
From center away cuts from the approximate center of the part to the outer edges.
From outside to center cuts from the outer edges of the part to the approximate center.

18.2 Cut Pattern
n Change the Cut order

to From outside to
center.
372
Advanced Multiaxis Intro Exercise 4: Tool Axis Control - Side Tilt Definition
EXERCISE 4: TOOL AXIS CONTROL - SIDE TILT DEFINITION

The Side tilt definition defines the side tilt direction when the tool axis control is set to Surface with lead/lag.
The side tilting definition is an important setting to define proper side milling with the tool. The goal of side milling is to
get a contact line between the tool and the surface.
n Select TOOL AXIS CONTROL SIDE TILT.MCAM.
Unified Parallel (to curve) toolpath.
n Determined by number of cuts.

n Machine by Lanes.
n Tilt angle at side of cutting direction = 90 degrees.
n Side tilt definition set to Follow surface iso direction.
n Side tilt definition set to Ortho to lower edge curve.
n Side tilt definition set to Ortho to cut direction at each position.
n Side tilt definition set to Ortho to cut direction at each contour.
n Side tilt definition set to Use spindle main direction.
n Side tilt definition set to Use user defined direction.
n Side tilt definition set to Use tilt line definition.
373
Advanced Multiaxis Intro Step 19: Follow Surface Iso
STEP 19: FOLLOW SURFACE ISO
Follow surface iso is a good option if linear surfaces are present. Multiple surfaces can be used here. If any
surface does not have a compatible U and V direction with the neighboring surfaces, then this function attempts to
automatically correct these areas. The tool axis orientation follows the iso directions.
n From the Multiaxis group, click on the Parallel icon.
20.1 Tool
n Click on the Select button and select the front

line (hidden line style)at the bottom.
n Change the Style column

to Parallel to have the
Area Type options from
the surface edges.
n Click on the Machining geometries Select button

and select the green surface.
374
Advanced Multiaxis Intro Step 20: Select The Toolpath
n Machining geometries
offset = 0.
n Area Type set to
Determined by number
of cuts.
n Number of cuts = 1.
n Maximum stepover =
0.1.
n Cutting method set to
Zigzag.
n Machine by Lanes.
Tool axis control settings determine the tool's orientation in relation to the geometry being cut. Tilt angle at side
of cutting direction allows you to tilt the tool axis in the direction of the cut, relative to the surface normal. A
positive angle tilts the tool to the left; a negative angle tilts the tool to the right.
n Output format = 5 Axis.

n Maximum angle step = 3.0.
n Tool axis control = Surface with
tilt.
n Set the Side tilt definition to
Follow surface iso direction.
n Set the Tilt angle at side of cutting
direction to 90 degrees.
n Make Sure Collision Control, Status 1 is disabled.
375
Advanced Multiaxis Intro Step 20: Select The Toolpath
20.5 Linking

enable Type to Plane.
Note: The tool axis is parallel with the iso lines of the
surface.
376
Advanced Multiaxis Intro Step 21: Ortho To Lower Edge Curves
STEP 21: ORTHO TO LOWER EDGE CURVES
The Ortho to lower edge curves side tilt direction is determined by an orthogonal line from the lower edge curve
to the current surface contact point. This means that the tool axis is always orthogonal to the lower edge curve.

n As the Side tilt definition

enable Ortho to lower
edge curve.
Note: The tool axis is orthogonal to the chain.
377
Advanced Multiaxis Intro Step 22: Ortho To Cut Direction At Each Position
STEP 22: ORTHO TO CUT DIRECTION AT EACH POSITION
The Ortho to cut direction at each position side tilt direction is determined at the beginning and end of the pass
by the edges of the machining geometry surface and then fans, orienting the tool axis orthogonal to the lower edge
curve. This means that the tool axis is always orthogonal to the toolpath.

n As the Side tilt definition

enable Ortho to cut
direction at each position.
Note: The tool axis is orthogonal to the

toolpath.
378
Advanced Multiaxis Intro Step 23: Ortho To Cut Direction At Each Contour
STEP 23: ORTHO TO CUT DIRECTION AT EACH CONTOUR
The Ortho to cut direction at each contour side tilt direction is determined by an orthogonal line from a
complete contour segment. Mastercam determines the segment and then approximates an orthogonal direction at
each position on the contour. This keeps the tool axis orthogonal to the cut direction along each pass.

23.2 Cut Pattern
n Set the Area type

to Full, avoid cuts
at exact edges.
n As the Side tilt definition enable

Ortho to cut direction at each
contour.
Note: The tool axis is orthogonal to the

toolpath at each pass.
379
Advanced Multiaxis Intro Step 24: Use Spindle Main Direction
STEP 24: USE SPINDLE MAIN DIRECTION
The Use spindle main direction side tilt direction uses the machine definition's spindle main direction vector as
the reference to find the side tilt direction. The side tilting is always happening from the view defined by the spindle
main direction vector. For example, if the spindle main direction vector is the Z axis and side tilting of 90 degrees
from the surface normal takes place, then the tool axis orientation is the surface normal rotated 90 degrees toward
the spindle main direction.


Use spindle main direction.
Note: The tool axis is defined by the

surface normal rotated 90 degrees
toward the spindle main direction (Z
axis).
380
Advanced Multiaxis Intro Step 25: Use User Defined Direction
STEP 25: USE USER DEFINED DIRECTION
The Use user defined direction side tilt direction uses a user-defined vector definition as the reference for finding
the side tilt direction.


Use user defined direction.
n Click on the Select button and pick
the red line close to the top end.
Note: The tool axis is parallel to the line

selected. If you select the line closer to
the lower edge chain the tool will
machine from the bottom.
381
Advanced Multiaxis Intro Step 26: Rotate The Red Line In The Front Plane -30 Degrees
STEP 26: ROTATE THE RED LINE IN THE FRONT PLANE -30 DEGREES
n Change the Cplane to Front.

n Select the red line.
Transform
n Select the Rotate icon.

n Set the Method to Move.
n In the Rotation Center Point and click
on the Reselect button.
n Select the lower endpoint of the red color
line.
n Angle = -30.0
26.1 Regenerate the

Toolpath
STEP 27: USE TILT LINE DEFINITION
The Use tilt line definition uses user-defined tilt line elements as the side tilt direction. This option gives the user
the freedom to define the side tilt direction manually by selecting lines in the geometry.

n As the Side tilt definition enable Use

tilt line definition.
382
Advanced Multiaxis Intro Exercise 5: Collision Control
n Select the Tilt lines button (above)

and pick the left and the right blue
lines.
Note: The tool axis is parallel to the

lines selected. Make sure that you
select the lines from the bottom.
EXERCISE 5: COLLISION CONTROL

Learn how to use the following strategies in Collision Control to avoid gouging:
Retract tool Along tool axis.
Retract tool Along surface normal.
Tilt tool and Use side tilt angle against the Machining geometries and the Avoidance geometries.
Leaving out gouging points with Trim toolpath between first and last collision against the Avoidance
geometries.
Morph between two surfaces.
Morph between 2 curves.
n Select CUT PATTERN 1- COLLISION

CONTROL.MCAM.
383
Advanced Multiaxis Intro Step 28: No Collision Control
Unified - Guide between 2 surfaces.

n Maximum Stepover = 0.25.
n Collision Control:
n Retract tool Along tool axis.
n Retract tool Along surface normal.
n Tilt tool with Use side tilt angle against the Machining geometries and the Avoidance geometries.
n Leaving out gouging points with Trim toolpath between first and last collision against the Avoidance
geometries.
n Same collision control strategies.
STEP 28: NO COLLISION CONTROL
Toolpaths
28.1 Set Tool
n Click on the Select button and select the highlighted top

surface.
384
n Click on the Select button and select the bottom

surface.
n In the Machining geometry click on the Select

button and select cylindrical surface.
n Change the
Cutting
method to
One way.
n Maximum
step-over =
0.25.
n The
parameters
should look
as shown.
385
28.3 No Collision Control

n An error appears.

Morph.
Note: The first pass in the toolpath gouges into the top orange surface. Also the last pass gouges into the
brown surface.
386
Advanced Multiaxis Intro Step 29: Retracting Tool Along Tool Axis
STEP 29: RETRACTING TOOL ALONG TOOL AXIS
Retracting tool along tool axis avoids gouging by retracting the tool away from the surface while maintaining the
same tool axis orientation.
n In the Morph toolpath Parameters,

click on the Collision Control page
and enable Status 1.
n Enable Flute, Shoulder and Shank
and set the Strategy and
parameters to Retracting tool,
Along tool axes.
n In the Geometry, enable the
Machining geometries and the
Avoidance geometries.
n Click on the select button and select
the top orange (no. 138) surface and
the bottom brown (no. 4) as check
surfaces.
29.1 Backplot the

toolpath
Note: The tool retracts along the first two passes to avoid the top check surface. Similarly, it retracts
while reaching the bottom check surface.

387
Advanced Multiaxis Intro Step 30: Retract Tool Along Surface Normal
STEP 30: RETRACT TOOL ALONG SURFACE NORMAL
Retract tool Along surface normal avoids gouging by retracting the tool away from the surface.
There are several options on how the tool is retracted:
Retract tool in +X, +Y, +Z, -X,-Y,-Z, XY Plane, XZ Plane, YZ Plane, Along surface normal, Away
from origin, etc.
n In the Morph toolpath Parameters, in the Cut Pattern make sure that the morph surfaces are
selected. If not reselect them.
n Click on the Collision Control page and change the Strategy and parameters to Retract tool
with Along surface normal.
30.2 Backplot the

toolpath
Note: The tool retracts in the exact same way as it did with the Retract tool Along tool axis options
selected. This is because in the Tool Axis Control page we had the tool axis set to normal to the
surface.
388
Advanced Multiaxis Intro Step 31: Tilt Tool Using Side Tilt Angle

STEP 31: TILT TOOL USING SIDE TILT ANGLE
Tilt tool Using side tilt angle avoids gouging by tilting the tool away from the surface.
Tilting options are:
Use side tilt angle - the tool tilts to the side relative to the cutting direction. Positive angles tilt the tool to the left,
negative to the right. The limits are min. +/-0.01° and max. +/-180°.
Use lead/lag angle - tilts the tool forward or backward relative to the cutting direction. Positive angles tilt the tool
forward, negative backward. Be careful in cases where the tool is not a ball endmill. Tilting the tool forwards or
backwards in case of a flat endmill moves the contact point. This could cause additional collisions. The limits are
min. +/-0.01° and max. +/-180°.
Automatic - with this option Mastercam decides whether to use the side or lead and lag direction for tilting, or a
combination of both. You can set an angle range in which Mastercam can tilt the axes.
n In the Morph toolpath Parameters, in the Cut Pattern make sure that the morph surfaces are
selected. If not reselect them.
n In the Morph toolpath

Parameters, click on
the Collision Control
page.
n Enable Flute,
Shoulder and Shank
and set the Strategy
and parameters to
Tilt tool and
Automatic.
Note: To avoid the gouges on both check surfaces we should be able to use two angles. Instead, we will
use a second strategy to leave out the gouging points.
389
Advanced Multiaxis Intro Step 32: Trim And Relink Toolpath
n Select Parameters in the third operation.
STEP 32: TRIM AND RELINK TOOLPATH
The Trim and relink toolpath will trim the toolpath when a collision is detected. Machining will continue.
Trimming options are:
Trim tool collision only - when a collision is found, the toolpath will be trimmed so that machining continues
after the collision.
Trim toolpath after first or last collision - when a collision is found, the toolpath will be trimmed so that
machining continues with the next cut instead of continuing after the collision.
Trim toolpath before the first or last collision - when a collision is found, the toolpath will be trimmed so
that machining continues only after the first or last collision.
Trim toolpath between first and last collision - when two or more collisions are found along one cut, the
toolpath segments between the collisions will be trimmed.
n Click on the Collision

Control page and enable
Status 2.
n Enable Flute and
Shoulder and set the
Strategy and
parameters to Trim and
relink toolpath and
Trim toolpath between
first and last collision.
n As Geometry, enable
only the Check surfaces
and reselect the two
check surfaces.
n Set the Tolerance to
0.0005.
32.1 Backplot the

toolpath
Note: The tool

does not retract
as shown due to
a bug.
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Unified Multiaxis Toolpath
391
Unified Multiaxis Toolpath Introduction
INTRODUCTION
The new Unified Multiaxis toolpath consolidates all the surface-based toolpaths Morph, Parallel, Along
Curve, and Project in a single interface. The geodesic toolpath options that influence the cut pattern such
as Guide curves and Automatic are also included in this interface.
You can quick change the patterns from a parallel to a chain pattern or to a morph between two surfaces
without starting the toolpath over.
The toolpath allows you to choose between four drive patterns: automatic, curve, surface, plane. The curve,
surface, and plane patterns are similar to options in Parallel or Morph toolpaths, such as Parallel to curve,
Morph between curves, Parallel to surface, Morph between surface or Parallel to a plane.
Add Automatic row will look at the area selected and decide the toolpath that best machines the
geometry. The Style options determine the pattern that will be automatically generated on the selected
machining geometries. The following Styles are available:
Add Curve row allows you to select the curves to generate a Parallel to a curve, a Morph between
curves or Cuts along curve patterns. The Style options depend on the number of curves selected. With one
curve selected the following styles are available:
Two curves selected allows you to choose between the following styles:
If the Style is set to Guide you can have as many curves as you needed added to the toolpath.
392
Unified Multiaxis Toolpath Introduction
Add Surface row allows you to select surfaces to generate patterns that Morph between two
surfaces, Parallel to a surface or flow over a surface.
The following Styles are available with a row of Surfaces option:
The following styles are available with two rows of Surfaces option:
Add Plane row allows you to set a parallel pattern with a constant z step or align to X, Y or Z axis.
You can also aligned the toolpath to the WCS Z axis or XYplane.
You can choose between the following styles:
Remove all rows allows you to clear all selections.
The Unified Multiaxis toolpath uses the new geodesic algorithm when the pattern is set to Automatic or when
curves and surfaces are set to Guide.
Geodesic is defined as the shortest path between two points on a curved surface. Mastercam's geodesic
algorithm eliminates the distortions you may get when generating a toolpath over such a surface. This
strategy allows machining of 3d complex model with a toolpath that has a constant stepover even in shallow
areas.
The geodesic Automatic pattern takes the extents of the geometry you have selected and tries to find its
boundary. It then creates, based on the Style you choose, a toolpath that is either parallel to the boundary or
morphs between a central shape and the boundary.
Upon completion of the training lessons presented in this workbook, you should know how to:
n Use Unified Multiaxis toolpath to create patterns such as Parallel, Morph, Cut along Curve and Project.
393
Unified Multiaxis Toolpath Instructor Demonstration
Topics:
The following functions/toolpaths are covered in this exercise:
n Unified Multiaxis toolpath to finish the top using

Automatic.
n Change Unified Multiaxis toolpath to finish the top
using Curve and setting the Style to Guide.
n Check the different Styles available with one Curve.
n Add another curve and change the Style to Morph.
n Unified Multiaxis toolpath to machine the groove using
Curve with Morph Style.
n Unified Multiaxis toolpath to engrave the letters using
Curve with Project Style.
n Unified Multiaxis toolpath to finish the port shape from
the top using Curve and Perpendicular Style.
n Add another Curve and change the style to Morph.
n Unified Multiaxis toolpath to finish the port shape from
the bottom using the same settings.
The following functions/toolpaths are covered i n this

exercise:
n Demonstrate Fill hole option.

n Unified Multiaxis toolpath to finish the wall
using Curve with Guide Style.
n Set the Tool Axis Control to From Chain.
n Set the Tool Axis Control to Tilt relative to
refrerence surface.
n Unified Multiaxis toolpath to finish the floor
using Curve with Parallel Style and a Tapered
Form Tool.
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Unified Multiaxis Toolpath Exercise 1: Unified Multiaxis Toolpath
EXERCISE 1: UNIFIED MULTIAXIS TOOLPATH

Open File
n Select Unified.MCAM.
STEP 1: MACHINE THE TOP FACE USING UNIFIED

In this step you will use a Unified Multiaxis toolpath to machine the top shape. Different pattern settings will be
used to demonstrate the styles available. In the end you will use two Curves and set the style to Morph.
Create the Morph pattern between two Curves option using the following parameters:
n 1/4" Ball Endmill with B2E4-0025 Holder; Tool Projection 1.25.

n Machining geometries select the top face.
n Automatic with different style Machining boundaries.
n Remove Automatic and add one curve with Style set to Guide.
n Change the Style to Parallel, Perpendicular and Project and check the toolpath preview for
each of them.
n Change the Style to Guide and add another Curve.
n Type Area set to Entire machining area.
n Cutting method = Zigzag; Standard; Direction one.
n Cut Tolerance = 0.001.
n Machining geometries offset = 0.0.
n Extend the toolpath.
n Keep tool down in Linking by increasing the gap size.
395
Unified Multiaxis Toolpath Step 1: Machine The Top Face Using Unified
n From the Multiaxis group, click on the Unified

icon.
1.2 Select the Tool
1.3 Select the Holder
n Select the B2E4-0250 Holder.

n Change the Tool Projection to
1.25 and press Enter to update the
graphics.
1.4 Set the Cut Pattern
n In the Machining geometries area, click on the Select

button and select the faces shown.
Note: Once you select the machining geometry,

Mastercam automatically creates a toolpath with a pattern
that fits the shape of the geometry. You can preview the
toolpath before you make further selections or changes in
the parameters.
396
n In the parameters, click on the Apply icon.
n Click on the Hide dialog button.

n Press Esc to exit the Preview toolpath.
Note: Mastercam automatically created a good parallel pattern

on the selected face.
1.6 Using Automatic row
Note: Automatic uses a geodesic calculation to determine the pattern.
n Select the Add Automatic row icon.
n Automatically a Machining
boundary - Parallel set as
shown.

Note: Mastercam automatically created a scallop like pattern

on the selected face. This pattern is better suited for a more
curved shape.
397
n Change the Style to Machining boundary -

Morph.

Note: The pattern changes to a smooth transition.
1.9 Delete Automatic and add a Curve (Guide) to change the pattern direction
n Delete the row by clicking on the X in the Action

column.
n In the Solid Chaining dialog box, enable Edges

and hold down the Shift key and click on the top
edge as shown.
398

Note: The path is the same as with the Automatic. Both Automatic
and Guide are based on the geodesic algorithm. The toolpath uses
the selected edge to guide the toolpath.
Note: Only with the Guide style

you have the Machining
Geometries -Advanced Options
which allow you to switch the
Calculation type from Tool -
center mode (used with Ball
Endmills) to Contact mode (used
with Flat Endmills). You also have
the option to Fill holes if needed.
1.11 Changing the Style to Parallel
n Click in the Style column and

select Parallel.
n The resulting pattern looks the same as with Guide Style but the
Machining Geometries -Advanced Options are not available.
399
1.12 Changing the Style to Perpendicular
n Click in the Style column and select Perpendicular

n The toolpath direction is going to be at 90 degrees from the original
as shown.
1.13 Changing the Style to Project
n Click in the Style column and select Project.

n The toolpath will be one pass that is the result of projecting the
selected edge onto the selected face.
1.14 Add another Curve and change the Style to Guide between two curves
Note: If the Style you selected for the Curve is Parallel, you will not be able to add a new curve. The
software changes the options available based on the selections you made in the Pattern section. This
makes it easier to set the parameters.
n Click in the Style column and

select Guide.
400
n The toolpath should transition smoothly between the

two Guide curves as shown.
Note: For this face it makes more sense to use a Flat

Endmill with a bigger stepover.
n Select a 1/4 Flat Endmill with

the same holder and
projection.
n Change the
Max step-
over to 0.1875.
401
n If you select the Apply button to preview

the toolpath an warning appears.
Note: This is due to the geodesic

calculation with the Guide style. You have
to change, in the Machining Geometries
-Advanced Options, the Calculation
type from Tool -center mode (used with
Ball Endmills) to Contact mode (used
with Flat Endmills).
n To avoid changing the Calculation type to Contact mode,

change the curves Style to Morph.
n The preview of the toolpath should look as shown.
Note: The tool plunges in the corner and it has an extra retract
along the edge. To avoid the plunge, the toolpath can be
extended with a value bigger then the tool radius and in the
Inkling we can keep the tool down.
1.16 Modify the toolpath

n In the Cut Pattern enable Extend/Trim as shown.
402
n In the
Extend/Trim, set
the tangential
extensions as
shown.
n The toolpath preview should look as shown.
n In the Linking set the Small

gap size to 300%.

n Make sure that Generate toolpath is enabled and select the OK button
to exit the toolpath.
403
Unified Multiaxis Toolpath Step 2: Rough The Groove Using Unified
Note: The result is a smooth toolpath that morphs

between the two curves selected.
STEP 2: ROUGH THE GROOVE USING UNIFIED

In this step you will use a Unified Multiaxis toolpath to rough out the groove shape. The Pattern to be used is
Curve with Parallel Style.
Create the Parallel pattern with the Curve option using the following parameters:
n 5/16" Flat Endmill with B2E4-0025 Holder; Tool Projection 1.25.

n Machining geometries select the wall face of the groove.
n Add one curve and Style set to Parallel.
n Tool Axis Control set to Surface with tilt; Tilt angle at side of cutting direction set to 90.
n To avoid gouging, Small gap in Linking set to Direct.

icon.
404
2.2 Analyze the groove size
n Move the dialog box

and right mouse click
in the graphics and
select Analyze
Entity.

n The length should be 0.315.
2.3 Select the Tool
n Select the B2E4-0312 Holder.

1.25 and press Enter to update
the graphics.
405
n In the Machining geometries area, click on the

Select button and select the face as shown.

Note: Mastercam automatically created a parallel

toolpath. The toolpath needs to be guided for a better
pattern and the tool axis needs to be controlled to not
gouge through the part. The Maximum step-over is
maintained from the previous toolpath. Once you set a
value for any toolpath, Mastercam will continue to
reuse that value as the default for the next toolpath.
You need to reload the default parameters to start
fresh.
2.7 Reload the Default Parameters
n To set the parameters back to the defaults, click on the Reload

parameters from default files button.
2.8 Add a Guide Curve to change the pattern direction
n Delete the row by clicking on the X in the Action

column.
406
n In the Solid Chaining dialog box, enable

Edges and hold down the Shift key and click on
the top edge as shown.
n The warning will appear because we

need a spherical tool to use the tool-
center mode with the Guide Style.
n Select No in the warning and change the
Style to Parallel.
Note: The tool axis needs to be changed. By default the tool axis control
is set to Surface with tilt which orients the tool normal to the selected
surface or face.
407
n In the Tool Axis Control, set the Tilt angle

at side of cutting direction to 90 degrees.

n Select the OK button to exit the toolpath.
408
Note: The toolpath pattern and the tool

axis orientation are now good. Due to the
Blend spline setting in the Linking page for
the Small gaps, the tool gouges in the part
each time it takes a stepover.
2.13 Set the Linking parameters
n In the Toolpath Manager, select

the Parameters .
n In the Linking page, change the
Small gap to Direct.
Note: The direct link takes care of the gouge.
409
Unified Multiaxis Toolpath Step 3: Unified Toolpath For Engraving - Project Style
STEP 3: UNIFIED TOOLPATH FOR ENGRAVING - PROJECT STYLE

In this step you will use a Unified Multiaxis toolpath to engrave the letters using the Project Style.
Create the Project style using the following parameters:
n 1/16" Ball Endmill with B2C4-0011 Holder; Tool Projection 0.5.

n Machining geometries select the face.
n Add Curves select the letters.
n Machining geometries offset = -0.005.
n In Linking set the Retract to feed distance and Gap size to 10 to retract between letters.
n In the Levels Manager make visible Level

2.

icon.
3.3 Reload the toolpath parameters
n In the parameters click on the Reload parameters from defaults

file button.
3.4 Select the Tool
410
n Select the B2C4-0016 Holder.

0.625*8.

Select button and select the face as shown.
3.7 Select the letters

411
n In the Wireframe Chaining dialog box,

select the Window button.
n Make a window around the letters.
n Select an endpoint as shown.
n Preview the toolpath.
Note: The toolpath is generated by offsetting out from

the selected curves.
3.8 Change the Style to Project
n In the Cut Pattern, Style column

select Project.
412
3.9 Project Curves Options
Note: Check always the

Max. projection distance.
If the curves are far from the
face you will need to increase
the distance accordingly. It is
not our current case.
Note: To machine in the curves, in

the Cut pattern, Machining
geometries offset you have to add
the depth of the engraving.
n In the Cut Pattern, set the

Machining geometries offset
to -0.005.
Note: The retract movement are too big. We control them in

the Linking parameters.
413
n In the Linking set the

Large gaps to Retract
to feed distance.
n Small gap size = 10.0
(To force the tool to
retract between letters).
n Entry feed distance =
0.125
n Exit feed distance =
0.125.
n Air move safety
distance = 0.125.
414
Unified Multiaxis Toolpath Step 4: Verify The Toolpaths
STEP 4: VERIFY THE TOOLPATHS
n From the Toolpaths Manager

select Simulator Options button.
n In the Simulator Options, click on
the Solid/Mesh selection button
and select the solid as a stock.
n Click on the Toolpath Group-

1 to select all the operations.
n Click on Verify selected
operations icon.
n In Verify, enable Simulation
to see the default machine (a
trunnion type CNC machine).
n The part should look as shown after

simulation.
415
Unified Multiaxis Toolpath Step 5: Unified Toolpath For Port Machining
STEP 5: UNIFIED TOOLPATH FOR PORT MACHINING
In this step you are going to cut the hole from both sides using two Unified toolpaths that generate the cuts
for port machining.
Create The Top Port Toolpath With Curve Set To Perpendicular
Create the Port pattern with a Curve and the Style set to Perpendicular using the following parameters:
n Create the curves using Curve Flowline and Curve Center.

n 3/8" Lollipop Mill with B2C4-0016 Holder; Tool Projection 2.0.
n Machining geometries; select the inside face of the port.
n Add the top Curve and set the Style to Perpendicular.
n Type Area set to Full, start and end at exact curve points.
n Cutting method = Zigzag.
n Cut order = Standard.
n Create a line to base the tool axis.
n Use Tool Manager and set the Lollipop tool to be displayed.
n Use Modify Vector to rotate line.
n Tool axis control set to Fixed angle to axis; Tilt angle = 0; To = 20; line.
n Extend the outer end of the spline to machine better the top of the part.
5.1 Make visible only Level 300
n In the Levels Manager, make visible only Level

300.
Create The Wireframe To Drive The Toolpath
5.2 Create the Flowline curves
n From the Wireframe tab, Curves group select Curve Flowline.
416
n Select the face as shown.
n Change the Number to 3.

n The curves will look as shown.
Note: Three curves are

automatically generated at the
top, bottom and middle of the
surface. This will allow to
machine the port from both
sides.
n Select the OK and Create New
Operation.
n Select the surface again.

n Change the Direction to V to create the two
rail curves as shown. This will allow us to create
the spine as the center line be twee these
curves.
417
5.3 Create the Center Curve (Driving Curve for the toolpath)
n From the Wireframe tab, Curves group select Curve

Center.
n Enable the Single button and select the two

curves in the same direction as shown.
n Select the OK button to exit Chaining dialog
box and Curve Center panel.
n The wireframe should look as shown.
418
5.4 Break the driving curve in the middle
n From the Wireframe tab, Modify group, click

on the Break Two Pieces icon.
n Select as the entity to break, the driving curve as

shown.
n Select the midpoint of the curve.
Note: Breaking the curve at midpoint will

allow us to machine the port from both
sides.

icon.
419
5.6 Select the Tool
n Create a 3/8"
Lollipop Mill.
n Select the B2E4-0250

Holder.
n Change the Tool Projection
to 2.0.
420
n In the parameters click on the Reload parameters from defaults file

button.
Note: The result is not good as the system tries to machine both sides in
one toolpath. Also because the Unified toolpath parameters are modal
the limits are still on. It is better to Reload the Unified toolpath
parameters.

button and select the inside face of the hole as shown.
5.11 Adding a Curve

421
n In the Wireframe Chaining mode

enable Single button and select the top
spline as shown.
5.12 Set the Style to Perpendicular
n In the Cut Pattern, in the Style

column select Perpendicular.
Note: There are only two passes generated

due to the Collision control defaults and to the
Tool Axis Control set to Surface with tilt which
keeps the tool perpendicular to the selected
face.
422
5.14 Set the Collision Control off

Note: The passes are generated as expected.
Note: Due to the tool axis control set normal to the surface, the
tool gouges through the part. To determine the tool axis you
need to create a line from which the tool can tilt.
5.17 Create the line to base the tool axis
n Change the Graphic View to Top.

n In the Wireframe tab, select Line Endpoints and
create a line from the center of the port straight
down as shown.
423
5.18 Set the Lollipop cutter as the Display Tool
n From Toolpaths
select the Tool
Manager.
n In the Tool Manager, right mouse click

on the 3/8 Lollipop tool and select Set
display tool.
n In the View tab,

enable Show Tool as
shown.
n The tool will be displayed as shown.
424
5.19 Modify the line using Modify Vector command
n Rotate the part as shown.
n From Wireframe, modify group

select Modify Vector icon as
shown.
n Select the line.
425
n The gnomon appears.

n You can rotate the Y axis 20 degrees which looks good .
n Enter the value if needed and select the OK button to
accept the line rotation.
n In the View tab, disable Show Tool.
n The line should look as shown.
5.20 Set the Tool Axis Control
n In the Toolpaths Manager, click on

the Parameters.
n In the Tool Axis Control set the Tool
axis control to Fixed angle to axis.
n Tilt angle set to Line.
426
n Click on the select button.

n Select the line as shown.
Note: This line is basically the new

0 degree.
n Enable To and set it to 20 degrees as shown.
Note: Most trunnion machines can rotate up to +110 -110 degrees. We are already at 90
degrees that is why 20 degrees was set as the limit (110 - 90).
Note: The tool enters the part along the line

and tilts no more than 20 degrees only when
is needed to finish half of the port.
There is an area at the top that is not
finished properly. By extending the curve
the toolpath will be extended too.
427
5.23 Modify the length
n In the Wireframe tab, Modify Length select

the spline at the outer end.
n In the Modify Length panel make sure
Lengthen is enabled and change the
Distance to 0.5.
n Select the OK button and then Regenerate
the toolpath.
5.24 Retract through tube center
n In the Linking parameters,

Exit enable Retr. to
clearance area through
tube center.
Note: This ensures that the

tool retracts towards the
center of the tube before it
rapids to the clearance area.
428
Create The Top Port Toolpath With Two Curves Set To Morph
Create the Port pattern with two Curves and the Style set to Morph using the following parameters:
n Copy last toolpath.

n Delete the existing Curve and set the Style to Perpendicular.
n Cutting method = Zigzag.

5.26 Cut Pattern set to two Morph Curves
n Delete the existing curve.

n Add a curve and select the top curve as
shown.
n Add another curve and select the middle curve

as shown.
429
Note: The toolpath, that uses the more

advanced geodesic algorithm, has a nice smooth
transition between the curves . To improve the
toolpath, change the Cutting method from
zigzag to Spiral for seamless stepovers.

n Click on the Toolpath Group-1
to select all the operations.
n Click on Verify selected
operations icon.
n In Verify, enable Simulation to
see the default machine (a
trunnion type CNC machine).
430
n The part should look as shown after

simulation.
Note: There are collisions with the

machine. A longer tool and a better
fixture will take care of it.
Create The Bottom Port Toolpath
Create the Port pattern with two Curves and the Style set to Guide using the following parameters:
n Create the vertical line.

n Use Tool display and Modify vector to rotate the line -20 degrees.
n 3/8" Lollipop Mill with B2C4-0016 Holder; Tool Projection 1.5.
n Machining geometries select the inside face of the port.
n Add the bottom Curve and middle Curve.
n Cutting method = Spiral.
n Tool axis control set to Fixed angle to axis; Tilt angle = 0; To = 20; line
5.30 Create the line
431
n Set the Lollipop tool in the Tool Manager as the display

tool.
n Enable Show Tool in View tab.
5.31 Use Modify Vector to rotate the line as needed

n Rotate the Z axis -20 degrees.
n In View tab, disable Show Tool.

icon.
5.33 Select the Tool
n Select the 3/8" Lollipop Mill.
432
5.34 The Holder is already selected

n In the Machining geometries area, click on the Select button and select the
inside face of the hole as shown.
5.36 Adding the Curves

n In the Wireframe Chaining mode enable Single

button and select the curve in the same direction as
shown.

n In the Wireframe Chaining mode enable Single button

and select the middle curve in the same direction as
shown.
433
5.37 Set the Tool Axis Control
n In the Toolpaths Manager, click on the

Parameters.
n In the Tool Axis Control set the Tool axis
control to Fixed angle to axis.
n Tilt angle set to Line.
n Select the line.
Note: All the rest of the parameters where set in the previous toolpath
Note: All looks good.
Note: The holder gouges into the part. You need to increase the
Tool projection.
434
Unified Multiaxis Toolpath Exercise 2: Unified Multiaxis Toolpath
EXERCISE 2: UNIFIED MULTIAXIS TOOLPATH

Open File

n Select Unified Toolpath2.MCAM.
STEP 6: UNIFIED TOOLPATH FROM CURVE - GUIDE STYLE

In this step you will use a Unified Multiaxis toolpath to machine the inside walls and the fillets of the part using a
Curve and setting the style to Guide. Tool axis control set to From Chain.
Create the Guide pattern with the Curve option using the following parameters:
n 1/4" Ball Endmill with B2C4-0016 Holder; Tool Projection 1.5.

n Machining geometries select the walls and the fillet faces.
n Add one curve and Style set to Guide.
n Rolling avoidance set to Fill holes.
n Tool axis control set to From Chain.
n Curve tilt type set to From start to end.
435
Unified Multiaxis Toolpath Step 6: Unified Toolpath From Curve - Guide Style

icon.

button.
6.3 Select the Tool
n Select the B2C4-0016 Holder.

n Change the Tool Projection to 1.5.
n In the Machining geometries area, click on

the Select button and select the faces shown.
436

Note: The automatic option did not generate a

good toolpath.
6.7 Adding a Curve to changing the pattern direction

n Hold down the Shift key and click on the top edge as
shown.
n In the parameters, click on the Preview toolpath

icon.
Note: The path direction has been changed. Next, you

are going to fix the pattern in the hole area by
instructing Mastercam to disregard it.
437
6.9 Rolling avoidance - Fill holes
n Expand Cut Pattern in the Tree View list and select

Machining Geometries.
n Enable Fill Holes.
n In the parameters, click on the Apply button.

n Make sure that Generate toolpath is enabled and select the OK button to exit the toolpath.
Note: The tool axis is normal to

the surface and the angle varies
to much along the path. To
control the tool axis you will use a
chain.
438
6.12 Create the Chain Geometry
n From the Wireframe ribbon, select the Curve One Edge

icon.
n Hold down the Shift key to select the entire edge.
6.13 Move the chain using Dynamic
n From the Transform ribbon, select the Dynamic icon.

n Hold down the Shift key to select the entire chain.
n Place the gnomon at the midpoint as shown.
n Select the Z-Axis and drag it upwards 0.5.
439
n Switch the mode to Axes manipulation.
n Rotate the X-Axis -45 degrees as shown.
n Switch the mode to Geometry manipulation.
n Move the X-Axis 2.0.
Note: The chain ends need to be shorten as the tool holder

will follow the start and the end of the chain.
440
n From the Wireframe ribbon,

select Modify Length icon.
n Enable Shorten and set the
Distance to 0.5.
n Click on both ends to shorten
them as shown.
6.14 Set Tool Axis Control From Chain

Parameters.
n Tool Axis Control set to From Chain.
n Change to Wireframe Chaining mode and select the

chain.
6.15 Backplot the

toolpath
441
6.16 Setting the Tool Axis Control from
n In the Solids Manager, right mouse click on the chamfer

and select Suppress to turn it off.
n The solid should look as shown.
n In the Toolpaths Manager, copy

the toolpath.
n Select the Parameters of the
second toolpath.
n In the Tool Axia Control, enable
Tilt relative to reference surface.
n Click on the Reference surface
Select button.
n Select the chamfer as shown.
442
STEP 7: UNIFIED TOOLPATH FROM CURVE - GUIDE STYLE

In this step you will use a Unified Multiaxis toolpath to machine the inside walls and the fillets of the part using a
Curve and setting the style to Guide. Tool axis control set to From Chain.
Create the Guide pattern with the Curve option using the following parameters:
n 3/8"Taper Form with B3J4-0003 Holder; Tool Projection 1.0.

n Machining geometries select the walls and the fillet faces.
n Add one curve and Style set to Parallel.
n Type Area set to Full, start and end at exact surface edges.
n Cutting method = One way; Standard; Climb.
n Tool axis control set to Surface with tilt.
n Curve tilt type set to Ortho to cut direction at each position.
n Set side tilt by Angle.
n Tilt angle at side of cutting direction set to -45.
7.1 Suppress the Chamfer


button.
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7.4 Create a 3/8"Taper Form tool
n Right mouse click in the tool list

window and select Create tool.
n Select the Taper form icon.
n Change the dimensions as
shown.
n Select the B3J4-0003 Holder.

1.0.
n In the Machining geometries area, click on the Select button

and select the bottom face as shown.
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Note: The automatic option did generate a good toolpath but

gouges at the entry and exit. Next you will set the tool to cut
parallel to a curve with the tool axis control set to Tilt angle at
side of cutting direction set to -45 degrees.
7.8 Adding a Curve to changing the pattern direction

n In the Solid Chaining, enable Edges and select the

edge as shown.
n Change the Style to Parallel.
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n Set the Cutting method to One way.

n Cut order set to Standard.
n Direction for one way machining set to Climb.


Parameters.
n Tool Axis Control set to Surface with tilt.
n Tilt angle at side of cutting direction = -45.
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Note: The default Linking parameters need to be

change. The Clearance area set to Automatic
generates the rapid arc moves shown.

Large gaps to
Retract to rapid
distance.
n Rapid distance =
0.5.
n Entry feed distance
= 0.25.
n Exit feed distance =
0.25.
n Air move safety
distance = 0.25.
n Clearance area to
Plane as shown.
n Direction set to Line
and click on the Select
button.
n From the Levels Manager, make visible Level 3 and select

the line. Make sure the arrow points downwards . If not click on
the Reverse button.
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7.12 Make Level 2 Invisible.
Note: The toolpath starts inside and the tool

gouges into the fillets.
7.14 Add the fillet faces into the Avoidance geometry
n To start the toolpath from the outside, in the Cut

Pattern enable Flip step over.
n In the Collision Control, enable Avoidance
geometries and select the fillet faces as shown.
7.15 Create a Stock Model
n From the Toolpaths ribbon, in the Stock

group, select Stock Model icon.
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n In the Name field type Stock.

n In the Initial stock shape enable
Model and click on the Select button.
n Make a window around the part to select it.
n In the Additional offset enter

0.05. This extra stock will be
added all around the part.
n The Stock Model should look as shown.

n Press Alt + T to remove the Stock Model display.
7.16 Set the Simulator Options
n In the Toolpaths Manager, select the Simulator

Options icon.
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n As Stock enable Stock model.

n In the Fixtures enable Levels and enable
Level 2000 to be able to see the fixture in
Verify.
n In the Toolpaths Manger, make sure

the last two toolpaths are selected and
select Verify all operations icon.
n After verifying the part should look as
shown.
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Unified - Projection Toolpath
451
Unified - Projection Toolpath Introduction
INTRODUCTION
The Unified toolpath with Project curve pattern generates a single toolpath along a curve or multiple
curves. If the curves lie exactly on the surface, the toolpath has same shape and position as the curves. If the
curve is located above the face, the curve has to be within a maximum projection distance above the face.
This value defines the maximum distance between tilt line endpoints and the machining contour. This
operation can be used for engraving. The curves should be located exactly on the machining geometry
surface.

n Unified Project toolpath.
Topics:
n Unified Project toolpath.

n Maximum angle step = 3.
n Engraving depth = -0.1.
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Unified - Projection Toolpath Exercise 1: Projection Toolpath
EXERCISE 1: PROJECTION TOOLPATH

Unified Project toolpaths create 5-axis toolpaths that follow curves projected onto surfaces while maintaining the
tool axis normal to the surfaces. This toolpath is mainly used for engraving.
STEP 1: OPEN FILE

n Select 5AX_ENGRAVING.MCAM.
STEP 2: ENGRAVE THE LETTERS USING PROJECT CURVE

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Unified - Projection Toolpath Step 2: Engrave The Letters Using Project Curve
2.2 Create a Taper Mill Tool

The Tool page allows you to select a tool, edit its properties, and enter feeds and speeds. You can also insert a
comment that will be output in the NC file after running the post processor.
n Create a new tool 0.005 Tip

Diameter Taper mill:
n Tip diameter = 0.005.
n Angle = 5.0.
n Cutting length = 0.2055.
n Shoulder length= 1.375.
n Overall length = 2.0
n Shank diameter = 0.25.
2.3 Set Cut Pattern
The Cut Pattern page allows you to select the machining geometries and the projection curves. You can
set the surface quality based on the cut tolerance and the maximum distance.
You can also set the engraving depth with the Machining geometries offset parameter.
2.4 Cut Pattern
n Click on the Select button and in

the Wireframe Chaining dialog
box enable Window.
n In the Chaining Options
enable Color and make sure
that only color red is enabled.
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n Make a window around the letters and select the

approximate starting point at the bottom end of
the letter m.
n In the Style column, select Project.
n In the Machining area click on the Select machining

geometries button and select the gray purple (no. 151) surface.
455
2.5 Reload parameters from the default
n To quick get the default parameters, click on the Reload parameters from
the default button.
Note: The engraving depth needs to be set.
n Disable the Collision Control.
2.8 Cut Pattern
n In the Machining area,

set the Machining
geometries offset to -
0.01.
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2.9 Project Curves Options
n Make sure the Projection dr is set to

Surface normal.
n Max. projection distance = 0.005.
Note: Project requires the machining geometry surface to

have the surface normal pointing outside the part for a proper
machining. Otherwise, the tool will approach and cut from the
inside of the part. The rapid movements are showing that in this
case the surfaces normal are set correct.
n Make Level 2 visible only.

n In the Stock Setup, click on Add from
selection button and select the solid as the
stock.
n Make visible only Level 1.

n Run Verify.
457
Parallel To Angle
458
Parallel to Angle Introduction
INTRODUCTION
This lesson will describe the Unified toolpath with Custom angles pattern. The Unified toolpath with
Custom Angles pattern lets you create tool motion with cuts that are parallel to each other. The direction of
the cuts are defined by the two angles: the Machining angle in X,Y and the Machining angle in Z.
To set the angles you can:
n Enter machining angles in degrees in the fields.

n Set the Machining angle in Z .
n Set the Machining angle in X,Y field.
n The following pictures illustrate how to set the desired cutting direction using the angles in the Cut
Pattern page as shown.

n Unified toolpath with Cut Pattern set to Custom Angles.
459
Parallel to Angle Instructor Demonstration
Topics:
n Create two Unified toolpaths (Custom

Angles pattern) to machine the two cams.
EXERCISE 2: UNIFIED CUSTOM ANGLES TOOLPATH

The Unified Parallel - Custom Angles toolpath will create tool motion with cuts that are parallel to each
other. The direction of the cuts is defined by the two angles: the Machining angle in X,Y and the Machining
angle in Z.
Open File
n Select CAMSHAFT.MCAM.
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Parallel to Angle Step 1: Finish The Camshaft Unified Custom Angles
STEP 1: FINISH THE CAMSHAFT UNIFIED CUSTOM ANGLES
Create the Unified Parallel - Custom Angles toolpath using the following parameters:
n 2-1/2" Face Mill.

n Machining angle in X,Y = 0.0; Machining angle in Z = -90.
n Area type = Full, start and end at exact surface edges.
n Cutting method set to One way; Standard; Clockwise.
n Enable Enforce cutting direction (assume closed contours).
n Output format set to 5 Axis; Maximum angle step = 3 degrees.
n Tool axis control = Fixed angle to axis.
n Fixed tilt angle = 45; X-axis.
STEP 2: MACHINE THE LEFT SIDE

Milling
2.1 Select Tool
n Change the library to mill_inch.tooldb (located: C:\Users\Public\Documents\Shared Mastercam

2023\mill\Tools) to select the 2 1/2" Face Mill.
Note: You can also create a face mill.
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Parallel to Angle Step 2: Machine The Left Side
2.2 Set Cut Pattern

The Cut Pattern Custom Angles settings determine the geometry the tool follows and how it travels along that
geometry. The direction of the cuts is defined by the two angles: the Machining angle in X,Y and the Machining angle
in Z. You can also choose the area type which determines where the tool starts, ends, and the area to be cut. The
Cut Pattern page also allows you to set the Cutting method, the direction for one way machining, the Cut tolerance,
and the Maximum stepover.
n Select the Add plane row

icon.
n In the Style column, select Custom

angles.
462
n Click on the Select button in the Machine

geometries and select the left side orange surface.
n Machining geometry offset = 0.0.

n Area type set to Full, start and end at exact surface edges.
n Cutting method set to One way and Cut order set to Standard.
n Direction for one way machining set to CW for closed cuts.
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n Machining angle in XY = 0.0.

n Machining angle in Z = -90.0.
Tool Axis Control settings determine the tool's orientation in relation to the geometry being cut. You can set the
maximum angle the tool will be allowed to move through between adjacent moves.
You can also apply a lead/lag angle to the tool axis in the direction of the cut, measured relative to the surface
normal.
The side tilt angle is applied to the tool axis in the direction of the cut, relative to the surface normal. A positive angle
tilts the tool to the left; a negative angle tilts the tool to the right.
n Output format set to 5 Axis.

n Maximum angle step = 3 degrees.
n Tool axis control set to Fixed angle to
axis.
n X-axis; Tilt angle = 45.
n Run tool set to Auto to let Mastercam decide
where the tool will touch the surface (at the
radius or tip of the tool).
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n First entry set to Approach from clearance area and to Use Lead-In.
n Last exit set to Retract to clearance area and to Use Lead-Out.
n Small gap size = 20% of tool diameter.
n Clearance area Type set to Cylinder; Direction set to X- axis; Radius = 20.0.
n Rapid distance = 5.0.
n Entry/Exit feed distance = 3.0.
n Air move safety distance = 1.0.
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2.7 Default Lead-in/out
n Type set to Tangential arc

n Arc sweep = 90;
n Arc diameter/tool
diameter % = 10.

n You can click on the Hide dialog icon or drag the dialog box away
to be able to see the preview.

466
Parallel to Angle Step 3: Machine The Right Side
STEP 3: MACHINE THE RIGHT SIDE
n From the Toolpaths Manager, right mouse click on the toolpath and select Copy.
n Select the second operation’s Parameters.
n Click on Cut Pattern.
n Click on the Machining geometries button and remove the existing surface and select the right
side surface.

3.2 Regenerate and Backplot the

toolpath
467
Swarf Milling Toolpath
468
Swarf Milling Toolpath Introduction
INTRODUCTION
Swarf Milling (Side Wall Axial Relief Feed) toolpaths allows you to machine the wall surfaces with the
side of the tool. The advantage of this 5 axis toolpath is that you can machine the surface with a single cut
using the whole flute length of the tool. This provides a better surface finish, shorter machining time and
constant cutting conditions. It should be used mainly on flat surfaces as the tool flank is straight. It cannot
clean free form surfaces that are curved in any directions.
The Swarf machining toolpath will always align the tool between 2 points, one on the upper curve and one on
the lower curve, which means that the surface to be machined has to be straight between the points. The
system tries to get the upper and lower curves from the surfaces. If this does not work then the user has to
provide the upper and lower curve separately. This toolpath is particularly useful for machining fluid parts for
turbo-engines or aeronautical parts like integral elements.
The Unified toolpath with Parallel To Curves pattern will align the cut direction with a leading curve.
Adjacent cuts are parallel to each other. Every new cut is created at an offset distance from the previous cut.
The following graphic shows a Parallel To Curves pattern used to finish turbine blade fillets as shown.

n Swarf Milling toolpath.
n Unified Parallel to Curve toolpath.
n Create an STL file in Verify.
n Machine Simulation.
469
Swarf Milling Toolpath Instructor Demonstration
Topics:
n Machine the pockets using Axis

Substitution.
n Create two Swarf milling toolpaths to
machine the cutouts.
NOTES:
470
Swarf Milling Toolpath Exercise 1: Swarf Milling
EXERCISE 1: SWARF MILLING

Use Swarf milling to machine the wall surfaces with the side of the tool.
Open File
n Select SWARF MILLING.MCAM.
STEP 1: SETUP THE STOCK

n Click in the Number column next to Level 3 to make it the

active level.
n Click in the Visble column for Level 1 and remove the X to
make the level invisible.
1.2 Set the stock
n In the Stock setup click

on Add from selection
and select the solid from
the graphics window.
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Swarf Milling Toolpath Step 2: Use Pocket Toolpath To Machine The Inside Cutout
1.3 Make Level 1 the active level and Level 6 visible
n Click in the Number column next to Level 1 to

make it the active level.
n Make Level 3 invisible and Level 6 visible .
n Press Alt + S to see the geometry unshaded.
STEP 2: USE POCKET TOOLPATH TO MACHINE THE INSIDE CUTOUT

Toolpaths
n From the 2D group, click on the Expand gallery arrow and select
the Pocket icon.
n Select the flat rectangle.
2.2 Select the Tool
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n Pocket Type set to Standard.

n Stock to leave on floors = 0.0
2.4 Set Roughing

Parallel Spiral.
n Stepover percentage
45%.
n Set to Helix.
n Minimum / Maximum radius = 50%.
n Z clearance 0.1.
n XY clearance = 0.1.
n Plunge angle =3.0.
2.6 Set Finishing
n Disable Finishing.
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2.7 Set Depth Cuts
n Enable Depth cuts and set the Max

rough step = 0.15.
n Clearance = 2.0 (Absolute) and enable Use clearance

only at the start and end of operation.
n Retract =1.0 (Absolute).
n Top of stock = 0.0" (Absolute).
n Depth = -0.3" (Absolute).
Note: The absolute values are measured from the 2.0"

diameter cylinder, setup in the Rotary axis control page.

n Enable CW.
n Enter Rotary diameter 2.0.
n Make sure that the Unroll is disabled.
474
Swarf Milling Toolpath Step 3: Use Pocket Toolpath To Machine The Open Cutout

STEP 3: USE POCKET TOOLPATH TO MACHINE THE OPEN CUTOUT

3.1 Make level 6 invisible and Level 7 visible
n Make Level 7 the active level.

n Make Level 6 invisible.
n Press Alt + S to see the geometry
unshaded.
3.2 Change the Cplane and Tplane to Front
n Click on the Cplane in the Status bar and select Front.
475
Toolpaths
n From the 2D group,

click on the Expand
gallery arrow and
select the Pocket icon.
n Select the flat contour.
3.3 Set Tool

n Stock to leave on floors = 0.0
3.5 Set Roughing
n Cutting Method set to Parallel Spiral.

n Stepover percentage 50%.
n Set to Helix.
n Minimum / Maximum radius = 50%.
n Z clearance 0.1.
n XY clearance = 0.1.
n Plunge angle =3.0.
3.7 Set Finishing
n Disable Finishing.
3.8 Set Depth Cuts
n Set the Max rough step = 0.15.
476

n Retract =1.0 (Absolute).
Note: The absolute values are measured from the 2.0"

diameter cylinder, setup in the Rotary axis control page.
n In the Planes make sure the Tool plane and the

Comp / construction plane is set to Front.

n Enable CW.
n Enter Rotary diameter 2.0.
n Make sure that the Unroll is disabled.
477

n Make sure that Simulate Axis Substitution is enabled
in Backplot Options.
n Click in the Number column next to Level 4 to make it the

active level.
n Make Level 1 and Level 7 invisible .
n The geometry should look as shown. Press Alt + S if you need
to see the surfaces in shaded mode.
478
Swarf Milling Toolpath Step 4: Machine The Walls Using Swarf Milling
STEP 4: MACHINE THE WALLS USING SWARF MILLING
Create the Swarf milling toolpath to machine the walls using the following parameters:
n 3/32" Flat Endmill.

n Swarf offset = 0.0.
n Floor clearance = 0.0.
n Tilt lines should be disabled.
n Side set to Autodetect.
n Direction set to Climb.
n Strategy set to Automatic.
4.1 Change the Cplane and Tplane to Front
n Click on the Cplane in the Status bar and select Front.
Toolpaths
n From the Multiaxis

group, select the Swarf
Milling icon.
4.3 Set Tool
n Select the 3/32 Flat Endmill from the library.
479
4.4 Set Cut Pattern
n Click on the Swarf geometries Select button and make a window around all surfaces.
n Swarf clearance = 0.0.
n Floor geometries should be disabled.
n Guide curve should be disabled.
n Orientation = Tool Plane.
n Guide tool at set to Lower curve.
n Start point Type set to Automatic.
n Extensions Type set to Automatic.
n Extension length at start = 0.1.
n Extension length at end = 0.1.
480
n Output format = 5 axis.

n Max. angle step = 3.
n First/Last entry/exit = Don’t

use Lead-In.
n Small gaps set to Blend
spline and Don’t use Lead-
In/Out.
n Large gaps set to Retract to
clearance area and Don’t
use Lead-In/Out.
n Clearance area Type set to
Cylinder and Direction set to
X-axis and Radius set to 5.0.
n Leave the default Distances.

4.8 Backplot the Toolpath

481
Note: If the tool cuts from the opposite site as shown, select
the Parameters in the Toolpaths Manager, and in the Cut
Pattern enable Swap.
4.9 Verify the Toolpaths
Note: To remove the inside material make two passes in the

Swarf milling toolpath.
4.10 Add two passes in the Swarf milling toolpath
n Select the Parameters in the Toolpath

Manager.
n Select Multi Cuts, change the Number of
layers to 3 and the Layer distance to 0.03.
482

n Click in the Visible column next to Level 5
to make it visible.
4.13 Copy the Swarf milling toolpath

n From the Toolpaths Manager, in the second Swarf milling toolpath select the Parameters.
n Clear first the selection and then select the red color surfaces.

483
4.16 Make Level 1 Visible

Note: If the toolpath looks as shown, in the Cut Pattern,

remove or enable Swap.
484
Swarf Milling Toolpath Exercise 2: Swarf Milling
EXERCISE 2: SWARF MILLING

Use Swarf milling to machine the wall surfaces with the side of the tool.
Open File
n Select MOLD BOTTLE.MCAM.
The following functions/toolpaths are covered in this exercise:
n Create a Stock model toolpath.

n Create a Swarf milling toolpath to machine the walls.
n Create a Unified Parallel to Curve toolpath to
machine the fillet surface.
n Verify the part using a Machine Simulation.
485
Swarf Milling Toolpath Step 5: Create A Stock Model Toolpath
STEP 5: CREATE A STOCK MODEL TOOLPATH

Mastercam computes the stock model by processing toolpath operations selected in the Source Operations page
against the stock you define here. The stock used could be set to the job setup stock, an existing CAD file, or a
Model. Once created, you can use stock model operations to verify the toolpath, define the stock for rest milling
toolpaths, visualize the stock or generate stock model compares.
Use the existing Surface toolpaths and generate a Stock model toolpath.
Toolpaths
6.1 Set Stock Definition
n Define the stock from the stock

setup by clicking on the Stock
Setup button.
n Name it "Stock1".
6.2 Set Source Operations
n Click on the Toolpath Group to

select all 4 surface toolpaths.
486
n The stock model should look as shown.

n Pres Ctrl +T to remove the stock model display.
STEP 7: MACHINE THE WALLS USING SWARF MILLING
n 1/8" Taper ball mill with taper angle of 5 degrees.

Toolpaths
n From the Multiaxis group, select the Swarf Milling icon.
487
7.2 Set Tool

n Create a 1/8" Tapered ball nose mill with taper angle 5 degrees.
488
7.3 Set Cut Pattern

n Click on the Swarf geometries Select button and from the Quick Mask buttons, click on the Select all
entities by color button. Select the gray surfaces color no. 56.
n Enable and click on the Floor geometries button and select the green color no. 42 and pink no. 89.
n Guide curve should be disabled.
n Orientation = Tool Plane.
n Guide tool at set to Lower curve.
n Start point Type set to Automatic.
n Extensions Type set to Automatic.
489

n Max. angle step = 3.
7.5 Simulator Options
n Enable Stock model and select the

existing Stock Model.
n In the Verify tab select Enable Vectors.

n In the Home tab, from the Visibility group, enable
Toolpath and click on Stock until it is translucent as
shown.
Note: The tool plunges into the part while entering the
part and retracts at the same entry point. To improve the
toolpath you can add lead in/out movements for a
smooth entry/exit.
You can also overlap the entry by adding a cutting
motion when the tool reaches the end of the edge curve.
Also, the tool cutting length is too short. You will have to
edit the tool length.
490
Swarf Milling Toolpath Step 8: Change The Tool Cutting And Shoulder Lengths
STEP 8: CHANGE THE TOOL CUTTING AND SHOULDER LENGTHS
n From the Toolpaths

Manager, in the Swarf
milling toolpath select the
tool.
n Set the Cutting length to
1.75, the Shoulder length
to 2 and the Overall lenght
to 2.5.
STEP 9: ADD THE OVERLAP & THE LEAD IN/OUT
n From the Toolpaths Manager, in the Swarf milling toolpath select the Parameters.
9.1 Set Cut Pattern
n In the Extension length at start/end set the values to 0.1.
n On the First entry line enable Use

Lead-In.
n On the Last exit line enable Use Lead-
Out.
491
Swarf Milling Toolpath Step 9: Add The Overlap & The Lead In/out
9.3 Default Lead - In/Out

Lead-In determines how the tool feeds into the material as it approaches the part.
Lead-Out determines how the tool retracts from the material at the end of the toolpath.
n From the Tree View list, expand Linking and select the First Entry -
Lead In page. Ensure that the Use default Lead-In is enabled.
n Select the Last Exit -lead Out page and make sure that the Use
default Lead-Out is enabled.
n In the Default Lead-

in/out page set the
Lead-In Type to
Tangential arc with
Tool axis orientation
set to Fixed.
n Width = 0.2; Length =
0.3; Height = 0.2.
n Use the double arrow to
set the Lead-Out
parameters the same.
492
Swarf Milling Toolpath Step 10: Unified Parallel To Guide
STEP 10: UNIFIED PARALLEL TO GUIDE
The Parallel To Guide pattern will align the cuts with a leading curve. The distance between adjacent cuts is
maintained constant along the selected machining geometry. This pattern uses the new geodesic algorithm which is
defined as the shortest line between two points on a curved surface. Mastercam's geodesic algorithm eliminates the
distortions you may get when generating a toolpath over such a surface.
10.1 Finish the fillet surfaces using Unified Parallel to Guide toolpath
Create the Unified Parallel to Guide toolpath using the following parameters:
n Taper ball mill with taper angle of 5 degrees.

n Area type = Determined by number of cuts; Number of cuts = 10.
n Cutting method set to One way; Climb.
n Enable Round corners.
n Start margin = 0.0; Additional margin to overcome surface edge inaccuracies = 0.0018;
Enable Add internal tool radius.
n Tool axis control = From chain.
n Curve tilt type set to Closest point.
n Tilt angle = 0.
n Run tool = At radius.
10.3 Set Tool
n Select the existing Taper mill.
493
The Cut Pattern settings determine the geometry the tool follows and how it travels along that geometry. You can
select an edge curve and the surfaces to be machined. You can also choose the area type which determines where
the tool starts, ends, and the area to be cut. The Cut Pattern page also allows you to set the cutting method, the
direction for one way machining, the cut tolerance and the maximum stepover.

magenta curve at the bottom.
n In the Machining geometry click on the Select button

and, using the QM buttons, click on the Select all
entities by color button and select the pink surfaces
color no. 89 and green color no 42.
494

n Area type set to Determined by number of cuts.
n Cutting method set to One way.
495
Note: Perfect toolpath.
10.6 Change the Style to Parallel and Preview the Toolpath
n Change the Syle to Parallel.
Note: Lots of retract movement and gouges as

the tool center follows the edge of the fillet
surfaces. By adding margins in the toolpath the
tool will be moved from the edge. This is not
needed when you use the Guide style.
n Change the Style of the Pattern back to

Guide.
Note: The first pass starts close to the wall.

Enable Flip step over in the Cut Pattern to
change this.
The Tool cuts into the part. You need to use
Tool Axis Control to tilt the tool towards the red
color chain.
496

the Parameters of the last toolpath.
n Enable Flip step over in the
Sorting area.

normal.

n Tool axis control set to From Chain.
n Select the Chain button and click on the top dark

blue color chain.
n Curve tilt type set to Closest point.

n Tilt angle = 0.
497
Note: The tool plunges into the part.
n First entry set to Approach

from clearance area and to
Use Lead-In.
n Last exit set to Retract to
clearance area and to Use
Lead-Out.
n Small gaps set to Direct
and Don’t use Lead-In/Out.
n Large gaps set to Retract
to clearance area and
Don’t use Lead-In/Out.
n Small gap size = 100% of
tool diameter.
Plane; Direction set to Z-
axis.
n Height = 6.0.
n Incremental height = 6.0.
n Entry/Exit feed distance =
0.4.
n Air move safety distance =
0.4.
498
Swarf Milling Toolpath Create An Stl File In Verify
10.12 Verify both toolpaths
CREATE AN STL FILE IN VERIFY

We are going to use the STL file in the Machine simulation since it does not yet support Stock models.
n In Simulator Option enable Stock Setup to

set the original rectangular shape stock.
499
Swarf Milling Toolpath Step 11: Machine Simulation
n Using Ctrl key select all surface toolpath.

n In Verify, run the surface toolpaths using the End
(Turbo mode) button.
n Select the Verify tab and click on Save Stock as
STL and save the stock as an STL file.
STEP 11: MACHINE SIMULATION

Machine Simulation is an advanced verification module capable of backplotting, verifying stock removal, and full
machine tool simulation with collision checking.
The machining simulation is visualized in two main simulation modes:
Toolpath mode (with collision check).
Material mode (verification with gouge check).
11.1 Simulation startup settings
The Machine Simulation dialog box allows you to select the machine to be simulated, the work piece that will be
shown in the machine simulation, the fixtures, the stock, and the tolerances.
n From the Toolpaths Manager, select only the two 5 Axis toolpaths.
Machine
n From the Machine Simulation group, select the Machine

Simulation Options icon.
500
n Select as the Machine the 5_

5AXGEN_VMCTTAB.
n As Workpiece Geometry select All
elements.
n As Stock enable Load STL file,
and click on the ... button to select it.
n Open the Mold Bottle.stl

file.
settings as they are and
click on the Simulate
button.
11.2 Simulate the toolpath in tool path mode (backplotting)
n In the SIMULATION settings, click on the arrows and make sure that
Backplot, Time Mode and Machine are selected as shown.
501
n To see the entire machine, select the Fit button as shown.
n The machine with the part should

automatically be loaded.
n In the Visibility group of the SIMULATION ribbon,

enable the Toolpath, Tool, Workpiece, and
Machine Housing icons to see them displayed
while running the simulation.
n In the Toolpath Rendering drop down menu

enable Follow and Tool Vectors as shown.
n Click on the View

tab and enable
Move List,
Report and
Progress as
shown.
502
Swarf Milling Toolpath Step 12: Simulate The Toolpath In The Material Mode (verify)
n Move the cursor close to

the part and use the
mouse wheel to zoom in.
n Select the Run button in
the Control group to
simulate the toolpath.
n You can increase

the Simulation
Run Speed using
the Speed Slider
as shown.
n The simulation should

look as shown.
Note: N0 collisions
are reported in the
Report list.
Note: To check the toolpath you can:

Scroll up on the mouse wheel to zoom in.
Hold down the mouse wheel and drag the cursor in the graphics window to rotate the part.
Hold down the Shift key and use the mouse wheel to move the part in the graphics window.
STEP 12: SIMULATE THE TOOLPATH IN THE MATERIAL MODE (VERIFY)
n In the SIMULATION settings, make sure that Material Removal, Time Mode
and Machine are selected as shown.
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Swarf Milling Toolpath Step 12: Simulate The Toolpath In The Material Mode (verify)
n In the Visibility group of the SIMULATION

ribbon, enable the Tool, Stock and Machine
Housing icons to see them displayed while
running the simulation.
n Make sure that the Stock is set to the Opaque.
n Select the Run button

in the Control group to
simulate the toolpath.
n To zoom in scroll up the mouse wheel.

n To rotate the part hold down the mouse
wheel and move the cursor.
n The simulation should look as shown.
n To exit the Machine Simulation select the Exit icon.
504
Unified Parallel & Morph
505
Unified Parallel & Morph Introduction
INTRODUCTION
In this lesson you will review and compare Unified Parallel to Custom Angles pattern and Morph to Curves
pattern. You will use these toolpaths to finish the turbine blade. You will also use Unified Parallel to Curve to
machine the two fillet surfaces at the ends of the blade.
Parallel to Custom Angles pattern creates slices perpendicular to the X axis and parallel to each other.
Unwanted retract movements will be created at the blade ends. This is usually a result of the parallel pattern
and the size of the small moves.
Morph to Curves will create a pattern between two leading curves. A "morphed" pattern is one that is
approximated between the tilt curves and evenly spread over the surface. This toolpath will ensure a better finish with
less retraction moves. You will compare the Pattern Style set to Guide with the Pattern Style set to Morph.
In this lesson you will also learn how the cutting method can influence the surface finish. If the cutting method
is set to One way or Zigzag, the stepover moves are direct. They will leave scallops on the part. Changing the
cutting method from one way to spiral will leave no scallops on the part.
You will also learn the important role of using margins options in the toolpaths to avoid gouges. To be able to
use margins you will have to change the Area Type to Full, start and end at exact surface edges.
You will also learn how to use Tilt angle options and use the Gradually tilt of the tool axis.
This lesson reviews the Parallel to Curve pattern used to machine the fillets at both ends. The Limits options
will be used to restrict the tool axis angles.
Topics:

exercise:
n Create a Unified Parallel (Custom Angles)

toolpath to finish the blade.
n Create a Unified Guide (between 2 curves)
n Create a Unified Morph (between 2 curves)
n Create a Unified Parallel (Curves) toolpath to
machine the two fillets surfaces at the end of
the blade
506
Unified Parallel & Morph Exercise 5: Parallel Custom Angles Toolpath
EXERCISE 5: PARALLEL CUSTOM ANGLES TOOLPATH

Resources - Download the file from http://www.emastercam.com/trainingfiles
Open File
n Select TURBINE BLADE.MCAM.
STEP 1: FINISH THE BLADE - UNIFIED PARALLEL TO CUSTOM ANGLES
The Parallel To Custom Angles pattern will create tool motion with cuts that are parallel to each other. The
direction of the cuts is defined by the two angles: the Machining angle in X,Y and the Machining angle in Z.
Create the Parallel toolpath using the following parameters:
n 1/2" Ball Endmill.

n In Cut Pattern select Custom Angles; Machining angle in X,Y = 0; Machining angle in Z = 90.
n Area type = Full, start cuts at exact edges.
n Lead angle to cutting direction = 0.0.
n Tool axis control = Surface with tilt.
n Tilt angle at side of cutting direction = 0.
Toolpaths
1.2 Set Tool
507
Unified Parallel & Morph Step 1: Finish The Blade - Unified Parallel To Custom Angles
1.3 Set Cut Pattern
The Cut Pattern settings determine the geometry the tool follows and how it travels along that geometry. The
direction of the cuts is defined by the two angles: the Machining angle in X,Y and the Machining angle in Z. You can
also choose the area type which determines where the tool starts, ends, and the area to be cut. The Cut Pattern
page also allows you to set the cutting method, the direction for one way machining, the cut tolerance and the
maximum stepover.

Custom angles.
n Click on the Machining geometries Select

button and using the QM buttons, click on the
Select all entities by color button and select
the green color no. 30.
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offset = 0.
n Area type set to Full, start
cuts at exact edges.
n Cutting method set to One
way.
n Direction for one way
machining set to Climb.
n Enable Enforce cutting
direction (assume closed
contours).
n In the Machining Angles, make sure that Machining angle in XY and Z are set to 90.
1.5 Collision Control disabled
1.6 Preview the Toolpath
n Select the Apply button and then the

Hide dialog button.
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normal.

n Side tilt definition set to Ortho to cut direction
at each position.
n Lead angle to cutting direction = 0.
whether the tool will touch the surface at the radius
or tip of the tool.
1.8 Set The 4th Axis
n Set to X axis.
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from clearance area and to
Don’t use Lead-In.
clearance area and to Don’t
use Lead-Out.
n Small gaps set to Direct and
clearance area and Don’t use
Lead-In/Out.
tool diameter.
Cylinder; Radius = 2.0;
Direction set to X-axis.
n Entry/Exit feed distance =
0.4.
n Air move safety distance =
0.4.
n Change the graphics view to Top.

n From the Backplot Options, change the vector
Length to 0.05.
Note: The slices are perpendicular to the X axis

and parallel to each other. Also note the
unwanted retract movements. This is usually a
result of the parallel pattern and the size of the
small move.
In the next step we will compare this toolpath with
the Morph between 2 curves pattern.
511
Unified Parallel & Morph Unified Morph Between 2 Curves Guides Style
UNIFIED MORPH BETWEEN 2 CURVES GUIDES STYLE

The Morph between 2 curves toolpath will create a morphed toolpath between two leading curves. A "morphed"
toolpath is one that is approximated between the tilt curves and evenly spread over the surface. This toolpath will
ensure a better finish with less retraction moves.
STEP 2: UNIFIED MORPH BETWEEN 2 CURVES - GUIDE STYLE
Create the Morph between 2 curves -Guides Style pattern using the following parameters:
n Copy the toolpath

n Use the 1/2" Ball Endmill.
n Remove all rows.
n Click on the Add Curve row twice and select the green color chains.
n Area type = Entire machining area.
n Cutting method set to One way; Direction one.
2.1 Copy The Toolpath
n In the Toolpaths Manager, copy the Unified toolpath.

n Select the Parameters on the second toolpath.
2.2 Set Cut Pattern
n Click on the Select button and select the green

color curve at the left end of the turbine blade.
512
Unified Parallel & Morph Step 2: Unified Morph Between 2 Curves - Guide Style
n Click on the Select button and select the green color curve at the
right end of the turbine blade.
Note: Select the chains in the same direction and align the
starting locations.
n The rest of the parameters

should look as shown.
n The toolpath should look as

shown.
513
Unified Parallel & Morph Morph Between 2 Curves Toolpath
n Rotate and zoom in into the right side

and you can see fishtail movements.
MORPH BETWEEN 2 CURVES TOOLPATH

STEP 3: MORPH BETWEEN 2 CURVES - MORPH STYLE
Create the Morph between 2 curves Morph Style pattern using the following parameters:
n Change the Guide Style to Morph Style.
n Select the Parameters on the last toolpath.
3.1 Cut Pattern

shown.
Note: The slices are morphing

between the two curves and the
rapid movements are gone.
514
Unified Parallel & Morph Step 3: Morph Between 2 Curves - Morph Style
n Zoom in on the area close to the left fixture and

observe the stepover moves.
Note: The stepover moves are direct. They will

leave scallops on the part. Changing the cutting
method from one way to spiral will leave no
scallops on the part.
Note: The gouge of the tool with the fixture at the

beginning and end of the toolpath. To avoid
gouging the fixture set margins at both ends.
515
Unified Parallel & Morph Step 4: Spiral Cutting Method And Set The Margins
STEP 4: SPIRAL CUTTING METHOD AND SET THE MARGINS
n Select the Parameters of the Unified Morph operation.
4.1 Set Cut Pattern
n Area Type set to Full, start

edges.
Spiral.
4.2 Margins
n Enable Add internal tool radius.

n Set the Additional margin to
overcome surface edge
inaccuracies to 0.00118.

n Select the OK button to generate the
toolpath.
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Unified Parallel & Morph Step 5: Output Format To 5 Axis & Gradual Side Tilt Angle
Note: The tool is moved from the surface edges.
Note: The tool shoulder is too close to the fixture. To avoid

gouging the fixture we will gradually tilt the tool axis.
STEP 5: OUTPUT FORMAT TO 5 AXIS & GRADUAL SIDE TILT ANGLE
n Select the Parameters of the Unified Morph operation.
n Change the Output format to 5 Axis.

517
Unified Parallel & Morph Step 5: Output Format To 5 Axis & Gradual Side Tilt Angle
Note: The fixed tilt angle.
5.3 Advanced Options for Tilting Relative to Cutting Direction
n Gradual Side tilt angle change = 30 degrees.
Note: The tool axis angles at

the start and end of the
toolpath. By adding the
Gradual side tilt angle
change, the last cut will use
the side tilt angle plus the
change value
n Select the OK button to

generate the toolpath.
518
Unified Parallel & Morph Unified Parallel To Curves Review
UNIFIED PARALLEL TO CURVES REVIEW

STEP 6: FINISH THE LEFT SIDE - PARALLEL TO CURVES
Create the Parallel to Curves pattern using the following parameters:

n Enable Curves.
n Area type = Determined by number of cuts; Number of cuts = 10.
n Cutting method = Spiral.
n Cut Tolerance = 0.0005".
n Maximum stepover = 0.0325".
n Limits; Contain tool within conical angles; W1 =80; W2 =80; Cone axis set to X-axis.
6.2 Set Tool
6.3 Reload the defaults
n Click on the Reload parameters from defaults file icon.
519
Unified Parallel & Morph Step 6: Finish The Left Side - Parallel To Curves
6.4 Set Cut Pattern
n Click on the Select button and select the red color contour.
n Click on the Machining geometries

Select button and using the QM buttons,
click on the Select all entities by color
button and select the green color no. 30
and color blue no. 9 surfaces.
n Leave the Style to Guide.

offset = 0.0.
n Area type set to Determined
by number of cuts.

n Cutting method set to Spiral.
machining set to Direction
one.
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n Disable Collision Control.
Note: The tool starts in the fixture. Linking

parameters need to be set. .
To avoid machining with the tip of the Ball Endmill in
the Tool axis control you can add a Lead angle
to cutting direction. You can also restrict the tool
axis movement using Limits.
6.7 Cut Pattern
n To change the start of the

toolpath from the green
surface, enable Flip step
over.
521

n Tool axis control set to Surface with
tilt.
n Side tilt definition set to Ortho to cut
n Lead angle to cutting direction = 10
degrees.
n Tilt angle at side of cutting direction
= 0 degrees.
n Enable Limits.
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6.9 Limits
The tool axis direction limit parameters allow you to limit your tool axis orientation along the toolpath.
Conical limit limits the tool axis to a cone around the Cone axis. The tool is allowed to tilt in all three axis within the
cone.
n Enable Conical limit.

n w1 = 50; w2 = 80.
n Cone axis set to X-axis.
n First entry set to

Approach from
clearance area and to
n Last exit set to Retract
to clearance area and to
n Small gaps set to Direct
and Don’t use Lead-
In/Out.
n Large gaps set to
Retract to clearance
area and Don’t use
Lead-In/Out.
n Small gap size = 100%
of tool diameter.
n Type set to Cylinder;
Radius = 2.0.
n Direction set to X-axis.
n Entry/Exit feed
distance = 0.4.
n Air move safety
distance = 0.4.
523
Unified Parallel & Morph Step 7: Finish The Right Side End Of The Blade
Note: On the last pass the tool gouges into the

surface. We need to provide a margin to the toolpath
to compensate for surface edge accuracy.
6.12 Guide Curve - Advanced Parameters
n Set the Offset from curves to 0.005.
STEP 7: FINISH THE RIGHT SIDE END OF THE BLADE

7.1 Copy the toolpath and change the following:
n As Curve select the red curve at the right side end CCW.
n As Machining geometries select color no. 108 and color no. 30.
n Make sure the Area Type is set to Determine by number of cuts.
n Number of cuts = 10.0.
n Offset from curves = 0.01.
n From Limits change the w1 = 110; w2 =160.
524
Unified Parallel & Morph Step 7: Finish The Right Side End Of The Blade
7.2 Regenerate and Backplot the toolpath
525
Propeller & Unified Guides
526
Propeller & Unified Guides Introduction
INTRODUCTION
In this lesson you will rough out the propeller using 2D HS Dynamic Mill.
You will review the Swarf toolpath using two chains as geometry to semifinish the blades.
The blades are not having straight walls and cannot be finish with a Swarf toolpath. To finish the walls you
will use the Unified Guide between 2 curves toolpath which maintains constant stepovers due to the
geodesic calculation.
Topics:
n 2D HS Dynamic Mill to rough out

the part.
n Swarf toolpath to semifinish the
blades.
n Unified Guide (between 2 curves)
toolpath to finish the blades.
527
Propeller & Unified Guides Exercise 6: Machine The Propeller -Swarf Milling & Morph
EXERCISE 6: MACHINE THE PROPELLER -SWARF MILLING & MORPH

Open File

n Select PROPELLER.MCAM.
STEP 1: SETUP STOCK

n Click in the Number column next to Level 2 to make it the active level.
n Select Turn visible levels off icon the make the rest of the levels invisible.
1.2 Set the stock
n In the Stock setup click on the Add from

selection and select the solid from the graphics
window.
528
Propeller & Unified Guides Step 2: Rough Out The Part Using 2D HS Dynamic
STEP 2: ROUGH OUT THE PART USING 2D HS DYNAMIC

Dynamic Mill toolpath machines pockets, material that other toolpaths left behind, and standing bosses or cores
using the entire flute length. The toolpath supports many powerful entry methods, including a custom entry method.
Entry methods and micro lifts support custom feeds and speeds to optimize and generate safe tool motion.
The toolpath depends on the Machining strategy that you choose in the Chain Options.
If the strategy chosen is From outside, the toolpaths starts at the outmost chain and works its way in taking on the
final shape of the part as it approaches the final pass.
You can also machine pockets in which case the strategy selected is Start inside which keeps the tool inside the
machining regions.
Create the 2D HS Dynamic Mill toolpath using the following parameters:

n Cutting method = Climb.
n Stepover = 15%.
n Min toolpath radius = 10%.
n Micro lift distance = 0.01.
n Stock to leave on floor = 0.0.
n Depth cuts = 0.75.
n Clearance =2.0 Absolute.
n Retract = 0.25 Absolute.
n Feed plane = 0.1 Absolute.
n Top of stock = 1.0 Absolute.
n Depth = -0.1 Absolute.
2.1 Make Level 3 the Active Level and make the rest of the levels invisible
Toolpaths
n From the 2D group, select the Expand gallery arrow and select
the Dynamic Mill.
n From the Chain Options, click on the Select button in the
Machining regions.
529
n Pick the outside circle.

n Enable From Outside to machine the boss.
n In the Avoidance region, click on the Select button and

then the inside shape in the direction shown.
n The Preview toolpath should look as shown.
2.2 Set Tool

n Set the Spindle speed and the Feed rate.
530
2.3 Set Cut parameters
n Set the Cutting method to

Climb.
n Approach distance = 0.0
n First pass offset = 0.0.
n Stepover set as a % of tool dia.
= 15.
n Min toolpath radius = 10%
n Gap size = 500%
n Motion < Gap size, Micro lift set
Micro lift distance = 0.01.
n Motion > Gap size, retract set to
Never.
n Stock to leave on the walls and
floors set to 0.0".
2.4 Set Depth cuts
n Clearance = 2.0" (Incremental).

n Retract = 1.25" (Absolute).
n Feed plane = 0.1" (Incremental).
n Top of stock = 1.0" (Absolute).
n Depth = -0.10" (Absolute).
531
2.6 Entry Motion
n Set to Plunge only.
n Click in the Number column next to Level 1000 to make it the active level.
n Make the rest of the levels invisible.
532
Propeller & Unified Guides Step 3: Machine The Walls Using Swarf
STEP 3: MACHINE THE WALLS USING SWARF

n Walls set to Surfaces.
n Stock to leave on walls= 0.05.
n Distance = 0.05.
n Enter at start if first wall.
n Angle increment set to 3.0.
n Tip Control set to Lower Rail.
n Clearance = 4.0.
n Retract = 1.25.
n Entry/Exit Length = 0.5; Thickness = 0.5; Height = 1.0.
n Multi Passes Number = 3.
n Layer distance = 0.1.
Toolpaths
3.2 Set Tool
n Select the 3/8 Flat Endmill.
3.3 Set Cut Pattern
n Enable Surface and

click on the Select
button.
n Select the wall surfaces.
n Select the first surface
and set the direction to
CW.
533

n Distance = 0.05.
n Enabled Enter at start of first wall.

n Angle increment = 3.
n Tip control set to Lower Rail.

534

n Keep tool down within 300%.
3.7 Entry/Exit
n Enable Entry/Exit.
n Enable Entry curve.
n Length = 0.5.
n Thickness = 0.5.
n Height = 1.0.
3.8 Roughing
n Enable Multi Passes.

n Rough Number set to 3.
n Spacing = 0.1.
535


536
Propeller & Unified Guides Unified Guide Between 2 Curves Toolpath
UNIFIED GUIDE BETWEEN 2 CURVES TOOLPATH

The Unified Guide between 2 curves toolpath will create a morphed toolpath between two leading curves. The
pattern Style set to Guide generates a geodesic toolpath which maintains constant stepovers. This toolpath will
ensure a better finish with less retraction moves.
STEP 4: FINISH THE BLADE - UNIFIED GUIDE BETWEEN 2 CURVES
Create the Unified Guide between 2 curves toolpath using the following parameters:

n Area type = Full, avoid cuts at exact edges.
4.1 Make visible Level 1
n Click in the Visible column of Level 1 to make it visible.
n From the Multiaxis group, select the Morph icon.
4.3 Set Tool
n Select the existing 3/16" Ball Endmill.
537
Propeller & Unified Guides Step 4: Finish The Blade - Unified Guide Between 2 Curves
4.4 Set Cut Pattern
n Click on the Select button and select the top green

color curve.

green color curve starting at the same position and in
the same direction.
Note: Select the chains in the same direction and

align the starting locations.
n In the Machining geometries click on the Select

machining geometries button and select the
walls.
538
n The rest of the parameters


shown.
539
n Click on the Machining

geometries Select button
and select the two wall
surfaces.
offset = 0.0.
n Area Type set to Entire
machining area.
One way.
machining set to
Direction one.
0.02.
4.6 Disable Collision Control

n The Preview toolpath should look

as shown.
Note: The tool axis is normal to the

surface which makes the tool
colliding with the part.
540

n Side tilt definition set to Follow surface iso
direction.
n Run tool set to Auto to let Mastercam to
decide where the tool will touch the surface (at
the radius or tip of the tool).
541
n Enable Strategy 1 and

Check the Flute.
n Set the Strategy to Tilt
tool Automatic and the
Geometry to
Machining
geometries.
n Tolerance = 0.001.
4.10 Set Linking
n First entry set to Approach from

clearance area and to Don’t use
Lead-In.
clearance area and to Don’t use
Lead-Out.
n Small gaps set to Blend spline
and Don’t use Lead-In/Out.
Lead-In/Out.
n Small gap size = 100% of tool
diameter.
n Clearance area Type set to Plane.
n Direction set to Z-axis.
n Height = 6.0.
n Incremental height = 6.0.
542

4.12 Verify the Toolpath

n The propeller should look as shown.
543
Advanced Rough Toolpath
544
Advanced Rough Toolpath Introduction
INTRODUCTION
In this lesson you will learn how to machine a lead screw on a 4-Axis machine. You will rough out the part
using Rotary Advanced toolpath.
To finish the floor you will use Unified Morph to Curves with 4 Axis Output Format. To finish the fillets and the
fillets you will use Unified Guide toolpath with 4 Axis Output Format.
You will rotate the part in position using Tool planes option and clean an area at the back of the helical ridge
using Surface Equal Scallop toolpath.
Topics:
n Rotary Advanced to rough out the part.

n Unified Morph (between two Curves) to
finish the floor.
n Unified Guide to finish the fillets.
n High Speed Scallop to a plane to clean up
some areas.
545
Advanced Rough Toolpath Exercise: Advanced Rough
EXERCISE: ADVANCED ROUGH

Open File
n Select ROTARY ADVANCED.MCAM.
STEP 1: ROUGH OUT THE PART USING ROTARY ADVANCED TOOLPATH
Rotary Advanced toolpaths are designed to rough machine parts on a 4-axis machine. It can be used to mill
cylindrical parts like screws. You have to define the stock first to allow Mastercam to trim the tool motion to prevent
excess air cutting. The toolpath removes the material between the defined stock and the part using a constant radius
pattern to define the depth cuts.
Create the Rotary Advanced using the following parameters:
n Setup the stock.

n 1/4"Ball Endmill.
n Slices pattern = Radius constant.
n Cutting method = One way.
n Engagement = Direction 1.
n Depth steps Distance = 0.02.
n Machining geometries select the solid geometry.
n Max. point distance = 0.02
546
Advanced Rough Toolpath Step 1: Rough Out The Part Using Rotary Advanced Toolpath
1.1 Make Level 20 the Active Level and make the rest of the levels invisible and set the stock
1.2 Stock setup
n In the Stock setup click on the Add

from selection and select the solid
from the graphics window.
1.3 Make Level 1 the Active Level and make the rest of the
levels invisible
Toolpaths
n From the Multiaxis group, click on the Rotary Advanced

icon.
1.5 Set Tool
1.6 Set Stock
n Enable Job Setup.
547
1.7 Set Cut Pattern
n Machining set to Roughing.

n Slices pattern set to Radius
constant.
n Type set to Offset.
n Engagement set to Direction 1.
n Depth steps Distance = 0.02.
Slices pattern set to Radius constant cuts in layers that will always be offset at the X radius regardless of
the shape you are machining.
Type set to Offset defines parallel steps along the rotational axis on the geometry.
Engagement set to Direction 1 follows to U direction of the surface while Direction 2 follows the V direction
of the surface. (Climb or conventional machining).
548
1.8 Set Part Definition
Machining geometries allows you to select the whole part including the floor surfaces.
Max point distance sets the maximum distance between two consecutive points.
Direction allows to select a line or two points to the define the direction.
Base point specifies the point where the rotation axes intersect.
n As Machining geometries,
triple click to select the entire
part.
n Max. point distance = 0.02.
n In the Axis of rotation click
on the Direction button.
n Select the line close to the

origin.
n Click on the Select button to pick a

point.
549
n Select the Endpoint of the line as shown.
n In the Machining area, Area from set to All input geometry.
1.9 Set Linking
550
Advanced Rough Toolpath Finish The Floor - Unified Morph (2 Curves)
FINISH THE FLOOR - UNIFIED MORPH (2 CURVES)

The Morph with pattern from Curves toolpath will create a morphed toolpath between two leading curves. A
"morphed" toolpath is one that is approximated between the tilt curves and evenly spread over the surface. This
toolpath will ensure a better finish with less retraction moves.
STEP 2: FINISH THE FLOOR - UNIFIED MORPH (2 CURVES)
Create the Unified Morph Pattern Between Curves toolpath using the following parameters:

n Area type = Full, start and end at exact edges.
n Cutting method set to Spiral; Climb.
n Margins; Start margins and End margins set to 0.02
n Collision Control; enable Strategy 1 and Check Flute; Retract tool Along tool axis; Geometry
set to Machining geometries;
n Linking; First Entry/Last Entry set to Don’t use Lead-In/Out; Small gaps set to Blend Spline
and Don’t use Lead-In/;
n Large gaps set to Retract to clearance area and Don’t use Lead-In/Out.
n Clearance area Type set to Cylinder; Direction = X-axis; Radius = 5.
2.1 Make Level 100 the Active Level and make the
rest of the levels invisible
551
Advanced Rough Toolpath Step 2: Finish The Floor - Unified Morph (2 Curves)
Toolpaths
2.3 Reload the Defaults

2.4 Set Tool
n Select a 1/8" Ball Endmill.
2.5 Set Cut Pattern
n Click on the Select button and select the right side

blue color curve at the right end of the screw.
n Click on the Select button and select the left side blue
color curve at the right end of the screw.
Note: Select the chains in the same direction and align

the starting locations.
n In the Machining geometries click on the Select machining

geometries button and select all surfaces.
552
Note: The pattern of the toolpath with the Guide Style

has the transition between passes not following the
edges.
2.7 Switch to Morph Style
n Change the
Style to
Morph.
Note: The pattern of the toolpath with the Morph Style has a
better transition between passes but it also has a lot of retract
motions. These retract movements can be controlled with
margins.
553
n Machining
geometries offset =
0.0.
n Area Type set to
Full, start and end
at exact surface
edges.
to Spiral.
n Direction for one
way machining set
to Climb.
n Cut Tolerance =
0.001.
n Maximum stepover
= 0.01.
2.9 Margins
n Start/End margins = 0.02.

n Add internal tool radius disabled.
n Additional margin to overcome surface edge inaccuracies =
0.00118.
n Output Format 4 Axis

n Ensure that the Lead and Tilt angles
are set to 0.
n Side tilt definition to Ortho to cut
n Run tool set to Auto.
554
n Gouge check for the Flute.

n Strategy and
parameters set to
Retract tool and Along
tool axis.
n In the Geometry column,
enable Machining
geometries only.

Lead-In.
Lead-Out.
n Small gaps set to Blend spline;
clearance area; Don’t use Lead-
In/Out.
diameter.
Cylinder.
n Direction = X-axis.
n Radius = 5.
n Leave the default settings for the
Distances.
555
Advanced Rough Toolpath Machine The Fillet Surfaces - Unified Guide To Curves
MACHINE THE FILLET SURFACES - UNIFIED GUIDE TO CURVES

In this step you will create two Unified Guide to Curves toolpaths to finish the fillet surfaces.
STEP 3: UNIFIED GUIDE TO MACHINE THE LEFT FILLET SURFACE
Create the Unified Guide toolpath using the following parameters:

n Curves select the green color curves.
n Machining geometries select the red color fillet surface.
n Type area set to Determine by number of cuts; Number of cuts = 20.
n Cutting method set to Spiral; Climb.
n Margins; Start margins set to 0.
n Side tilt definition set to Follow surface iso direction.
n Enable Limits.
n Enable Conical limit and set w1 = 100 and w2 =120.
n Linking; First Entry/Last Entry set to Don’t use Lead-In/Out; Small gaps set to Blend Spline
and Don’t use Lead-In/;
n Large gaps set to Retract to clearance area and Don’t use Lead-In/Out.
n Clearance area Type set to Cylinder; Direction = X-axis; Radius = 5.
3.1 Make Level 110 the Active Level and

make the rest of the levels invisible
556
Advanced Rough Toolpath Step 3: Unified Guide To Machine The Left Fillet Surface
Toolpaths
3.3 Set Tool
3.4 Set Cut Pattern
n Click on the Select button and select the green color

curve.

Select machining geometries button and using
QM to select entities by color, select the red and
orange color surfaces.
557

n Area Type set to Determine by number of cuts.
n Enable Flip step over.
558
3.6 Guide Curve - Advanced Parameters
n Make sure that Offset from curves is set to 0.0.
n Output Format set to 4 Axis.

tilt.
n Side tilt definition set to Follow
surface iso direction.
n Tilt angle at side of cutting direction
= 0.
n Enable Limits.
3.8 Set Limits
n Enable Conical limit and set w1= 100

and w2 = 120.
n Disable Status 1 and Status 2.
559

Approach from
clearance area and
n Last exit set to
Retract to
clearance area and
Don’t use Lead-
Out.
n Small gaps set to
Blend spline; Don’t
use Lead-In/Out.
n Large gaps set to
Retract to
clearance area;
Don’t use Lead-
In/Out.
n Small gap size =
100% of tool
diameter.
n Clearance area
Type set to
Cylinder.
n Direction = X-axis.
n Radius = 5.
n Leave the default
settings for the
Distances.
560
Advanced Rough Toolpath Step 4: Unified Guide To Machine The Right Fillet
STEP 4: UNIFIED GUIDE TO MACHINE THE RIGHT FILLET

4.1 Copy the Unified Guide toolpath
n Select the Parameters of the second Unified toolpath.
4.2 Set Cut Pattern
n Click on the Unselect button to remove the existing chain.
n Click on the Select button and select the blue color curve.
n In the Machining geometries area, click on the Unselect button to remove the existing surface.
n Click on the Select machining geometries button and select the magenta and orange color
surfaces.
4.3 Set Limits
n Enable Conical limit and set w1= 60 and w2 = 80.

4.4 Regenerate and Backplot

the Toolpath
561
Advanced Rough Toolpath Step 5: Simulator Settings
STEP 5: SIMULATOR SETTINGS
In this step you will learn how to set the Simulator settings to avoid seeing gouges in the part where there
aren't any.
File
n From the Backstage menu, select Configuration.
n Expand Simulation
and in the Simulator
enable Tool starts
from home position
after tool change
and Go to home
position on tool
plane change.
n Save the changes in
the Configuration.
Save
n Save the file and reopen it to make sure the Configuration settings will be updated.
5.1 Verify all the operations.
Note: The extra material at the end of the helical

ridge. You will clean this area using Tool plane
rotation and Surface High Speed Scallop toolpath.
562
Advanced Rough Toolpath Surface High Speed Scallop
SURFACE HIGH SPEED SCALLOP

STEP 6: CLEANING THE HELICAL RIDGE END
Create a Surface High Speed Scallop toolpath to clean up the start and end of the helical ridge, using the following
parameters;
n Use 1/8" Ball Endmill.

n Total tolerance = 0.001".
n Max stepover = 0.02".
n Enable Use approximate start point.
n In the Planes Manager, change the Graphics view and

Cplane/Tplane to Front.
n Leave the WCS set to Top plane as shown.
6.2 Create the Equal Scallop toolpath
Milling
n From the 3D group, select the Equal Scallop icon.
6.3 Model Geometry
n Machining Geometry: Select the floor and the fillet faces.
563
Advanced Rough Toolpath Step 6: Cleaning The Helical Ridge End
n Wall Stock = 0.0.

n Floor Stock = 0.0.
6.4 Set Toolpath Control
n Select the contour as Containment boundary.

n Enable Compensate to Center.
6.5 Set Tool
n Closed/Open contour direction set to One

way.
n Enable Expand inside to out.
n Enable Smoothing.
n Stepover = 0.01.
564
Advanced Rough Toolpath Step 6: Cleaning The Helical Ridge End
n Select Full Vertical

Retract.
n Clearance plane =
5.0 Absolute.
n Linear entry/exit
(incremental) =
0.025.
n Vertical arc
entry/exit = 0.075.
6.8 Backplot the Surface High Speed Scallop

toolpath
6.9 Verify the toolpaths.
565
Gouge Check
566
Gouge Check Introduction
INTRODUCTION
In this lesson you will learn some of the available Collision control options.
Status
There are two independent collision control operation to applied different strategies for the same algorithms.
As an example, you can add a tilt algorithm at the first status and you also can activate the second status to
add a retract for the tool. Those 4 status are applied in order from 1 to 2.
Check
The check option defines the parts of the tool the gouge checking will be done. You can select:
n Flute
n Shaft (between flute length and arbor)
n Arbor (Shank)
n Holder
The dimensions of the tool are set up in the tool parameters. Additional to the tool basis dimensions
clearance distances can be added.
In this lesson you will create a Parallel to Curve toolpath with one pass. Due to some issues in the geometry
you will have to improve the toolpath using Linking parameters and Round corner options. You will make
visible objects that will interfere along the toolpath and learn how to use different strategies to avoid them.
The following strategies will be demonstrated:

567
Gouge Check Instructor Demonstration
Topics:

NOTES:
568
Gouge Check Exercise: Gouge Check Exercise
EXERCISE: GOUGE CHECK EXERCISE
Open File
n Select GOUGE CHECK.MCAM.
Create the Unified Guide toolpath using the following parameters:

n Area type = Entire machining area.
n Cutting method set to Zigzag; Standard.
n Output format set to 5 Axis; Maximum angle step = 3.
STEP 1: UNIFIED GUIDE TOOLPATH WITHOUT COLLISION CONTROL

Toolpaths
1.3 Reload the Parameters

1.4 Set Tool
569
Gouge Check Step 1: Unified Guide Toolpath Without Collision Control
1.5 Set Cut Pattern

curve.

Select machining geometries button and select
the inside surfaces.
n Machining
geometries offset =
0.0.
n Area Type set to
Entire machining
area.
to Zigzag.
n Cut order set to
Standard.
n Cut tolerance =
0.001.
n Maximum step-
over = 0.05.
570

n Side tilt definition set to Ortho to cut direction
at each position.
where the tool will touch the surface (at the radius
or tip of the tool).
n Disable any
Collision Control
settings.
571
1.8 Linking

enable Type to Plane
and Direction set to Z-
axis.
n An error will appear that only tools

with spherical tip are available for
tool-center mode.
n Select No.
1.9 Machining Geometries - Advanced Parameters
n Set the Calculation

type to Contact
mode.
572
Gouge Check Step 2: Tilt Tool Away With Max Angle
Note: With the tool axis

control set normal to the
surfaces and without any
collision control setting the
tool gouges into the
surfaces.
STEP 2: TILT TOOL AWAY WITH MAX ANGLE
Modify the toolpath to create one pass with the tool axis tilted at 90 degrees and gouge checking the entire
tool against the machining geometries
n Area type = Determined by number of cuts.

n Tilt angle = 90.
n Status 1; Check the Flute, Shoulder and Shank; Tilt tool; Use side tilt angle; Geometry set to
Machining geometries.
n From the Toolpaths Manager, select the Parameters of the second operation.
573
2.2 Set Holder
n Select the C4C4-0025 holder from the

list.
2.3 Update the assembly
n Select the OK button to update the assembly and all

operations that use the assembly.
2.4 Set Cut Pattern
n Change the Area Type to

Determined by number of
cuts.
way.
574
n Tilt angle at side of cutting direction =

90.
n Status 1; Check the

Flute, Shoulder and
Shank boxes.
n Set the Strategy and
parameters to Tilt
tool, Use side tilt
angle.
n In the Geometry
column, select
Machining
geometries.
n Holder clearance =
0.1.
n Shank = 0.025.
n Shoulder = 0.01.
575
Gouge Check Step 3: Smooth The Transition At The Sharp Edge
Note: The tool axis changes at the sharp edge in the middle
of the toolpath. Use round corners to make a smooth
transition at the sharp edge.
STEP 3: SMOOTH THE TRANSITION AT THE SHARP EDGE
Modify the toolpath to smooth the transition and enforce the cutting direction:
n Change the Pattern Style to Parallel.

n Cutting method set to One way; Clockwise.
n Set a start point at the left end of the curve.
3.1 Set Cut Pattern

way; Direction for one way
machining set to CW for
closed cuts.
3.2 Start Point Parameters
n Enable Position.
n Click on the Select button and select the point at the left end of the curve.
576
Gouge Check Step 3: Smooth The Transition At The Sharp Edge
n Select the Apply button.

shown.
Note: The round did not work

with the Guide Style.
3.4 Change the Style to Parallel

Parallel as shown.
n Change the Direction
for one way
machining to
Conventional.
Note: The tool retraction along the

toolpath. Zoom in and see that there is a
gap in the surface. Using different
linking methods we can force the tool
down.
577
Gouge Check Step 4: Linking Parameters To Keep The Tool Down
STEP 4: LINKING PARAMETERS TO KEEP THE TOOL DOWN
Modify the linking parameters to keep the tool down:
n Small gaps set to Direct, Large gaps set to Blend Spline.

n Small gap = 300% of the tool diameter.
n Small gaps set to Direct.

n Large gaps set to Blend Spline.
diameter.
578
Gouge Check Step 5: Collision Control - Retract Tool Along Tool Axis
STEP 5: COLLISION CONTROL - RETRACT TOOL ALONG TOOL AXIS
Gouge check the tool to avoid gouging the inside block:
n Status 2; Check the Flute, Shoulder, Shank and Holder; Retracting tool along tool axis;
Geometry set to Check surfaces (red color surfaces) Stock to leave = 0.05.

n From the Toolpaths Manager, select the Parameters of the third operation.
n Status 2; check the Flute,

Shoulder, Shank and
Holder.
n Strategy and parameters
set to Retract tool, Along
tool axis.
n In the Geometry column
disable Machining
geometries , enable
Avoidance geometries,
select color no. 137 as the
check surfaces, and set the
Stock to leave = 0.05.
579
Gouge Check Step 6: Retract Tool Along +Z
STEP 6: RETRACT TOOL ALONG +Z
Show Level 101, add in Status 1 the holder and add as check surfaces the vertical block surfaces:
n Status 1; check Flute, Shoulder, Shank and Holder; Tilt tool, Use side tilt angle; Geometry
set to Machining geometries, enable Avoidance geometries and select the vertical block
surfaces.
n Status 2; Check Flute, Shoulder, Shank and Holder; Retract tool, Along +Z; Geometry set to
Avoidance geometries, leave the existing surfaces.

n From the Toolpaths Manager, select the Parameters of the fourth operation.
n Status 1; check the Flute, Shoulder

Shank and Holder boxes and leave the
existing settings; enable Avoidance
geometries and select color no. 224.
n Status 2; check the Flute, Shoulder,
Shank and Holder boxes. In the Strategy
and parameters column select Retract
tool, Along +Z; leave the Geometry
settings.
6.4 Regenerate and Backplot the last toolpath
580
Gouge Check Step 7: Machine The Entire Surface
STEP 7: MACHINE THE ENTIRE SURFACE
Change the area type to machine the entire surface:

n From the Toolpaths Manager, select the Parameters of the fourth operation.
7.1 Set Cut Pattern
n Set the Area Type to Full, start and end at exact surface edges.
581
Worm Gear- Review
582
Worm Gear- Review Introduction
INTRODUCTION
In this lesson you will review the following toolpaths:
n Unified Morph between 2 Curves to rough the area between to consecutive blades.
n Unified Morph between 2 Curves to finish the floor between to consecutive blades.
n Unified Parallel to Curve to semifinish the blade in a swarf manner.
n Unified Morph between 2 Curves to finish the blade walls.
n Unified Parallel to Surface to finish the blade fillet.
n 3DHigh Speed Scallop to clean the back and front of the blade.
n Transform - Rotate to machine the entire part.
Topics:
n Unified Morph between 2 curves to rough

out the area between blades.
n Unified Morph between 2 curves to finish
the floor area between blades.
n Unified Parallel to curves to semifinish
the blade in a swarf manner.
n Unified Morph between 2 curves to finish
the blade walls.
n Unified Parallel to surface to finish the
blade fillet.
n Surface high speed scallop to clean the
back of the blade.
EXERCISE: WORM GEAR

Open File
n Select WORM GEAR.MCAM.
583
Worm Gear- Review Unified Morph To Curves With No Tilt Axis
UNIFIED MORPH TO CURVES WITH NO TILT AXIS

STEP 1: ROUGH THE AREA BETWEEN TWO BLADES
Create the Unified Morph between 2 curves toolpath using the following parameters:

n Enable Pattern From Curves.
n Margins; Start/End margins = 0.125.
n Extend/Trim; Start/End set as Percentage of tool diameter = -100; Extend/trim gaps.
n Output format set to 5 Axis; Maximum angle step = 0.5.
n Tool axis control = Surface.
n Set the Small gap to 20%.
n Set Clearance area to Cylinder parallel to X with Radius = 2.0.
n Enable Depth cuts; Number = 5 and Spacing 0.125.
584
Worm Gear- Review Step 1: Rough The Area Between Two Blades
1.1 Make Level 110 visible and set the stock in the Stock setup
n Select the Lathe Default.

n In the Stock setup,click on the Properties
button.
n Set the Geometry to Solid entity and click on
the Select Entity button.
n Pick the solid.
1.2 Make Level 101 visible and the rest of the levels invisible
Milling
1.4 Set Tool
1.5 Set Cut Pattern
n Click on the Select button and chain the bottom dark blue
curve from the outside of the part.
585
n Click on the Select button and chain the top dark blue curve
from the outside.
starting locations.

Morph.
n In the Machining geometries click on the Select machining geometries button and select the
color red surface.

n Area Type set to Full, start and end at exact surface edges.
n Enable Flip step over to change the cutting direction.
586
1.6 Set Extend / Trim
n In the Tangential extensions area, Start/End

percentage of tool diameter = -100.
n Leave Extend/trim gaps enabled.
1.7 Set Margins
n Enable Add internal radius.

n Tool axis control set to Surface.
where the tool will touch the surface (at the radius
or tip of the tool).
n No collisions set.
587

Approach from
Don’t use Lead-Out.
n Small gaps set to Retract
n Large gaps set to Retract
tool diameter.
n Clearance area Type set
to Cylinder; Radius = 2.0.
n Set the Direction to X-
axis.
n Rapid distance = 1.
n Entry/Exit feed distance
= 0.4.
n Air move safety distance
= 0.4.
588
1.12 Set Roughing

n Number = 5.
n Spacing = 0.125.
n Sort by set to Passes.
589
Worm Gear- Review Step 2: Finish The Area Between The Two Blades
STEP 2: FINISH THE AREA BETWEEN THE TWO BLADES
Create the Unified Morph between 2 curves toolpath using the following parameters:

n Disable Depth cuts.
n From the Toolpaths Manager, right mouse click and select Copy.
n Right mouse click again and select Paste.
n In the Toolpaths Manager click on the Parameters of the second toolpath.
2.2 Set Tool
2.3 Set Cut Pattern

2.4 Set Roughing
n Disable Depth cuts.
590
Worm Gear- Review Unified Parallel To Curve With Tilt Set To Lines
UNIFIED PARALLEL TO CURVE WITH TILT SET TO LINES

STEP 3: SEMIFINISH THE BLADE USING UNIFIED PARALLEL
Create the Unified Parallel (to Curve) toolpath using the following parameters:

n Set Pattern To Curves.
n Machining Geometries offset = 0.05.
n Area Type set to Determined by number of cuts; 1.
n Enable Extend/trim.
n Cutting method set to One way; Counterclockwise for closed cuts.
n Cut tolerance = 0.001; Maximum stepover = 0.05.
n Extend/trim; Extend the surface 10%.
n Output format 5-axis.
n Tool Axis Control set to Lines.
n Use tilt through Always closest two lines.
n Tilting lines maximum snap = 0.025.
n Collision Control; Enable 2nd Status and Tool flute and Tool shoulder; Retract tool; Along
surface normal against Machining Geometries.
n Default Lead In/Out; Tangential arc; Arc sweep = 90; Arc diameter 100%.
n Links Between Passes; Small and Large moves set to Direct, Don’t use Lead-in/Out; Small
move as value = 110.
n Set Multi passes sort by Passes; 2 Rough passes; Spacing 0.025.
591
Worm Gear- Review Step 3: Semifinish The Blade Using Unified Parallel
3.1 Make the Level 102 the Active Level and make the rest of the levels invisible
Milling
3.3 Reload the Defaults
n Click on the Reload parameters from defaults file icon.
3.4 Set Tool
3.5 Set Cut Pattern
n Click on the Select button and Mask the color green

no. 10; chain the bottom curve CW.

machining geometries button and using QM to select entities
by color, select the red color surfaces.
592

n Area Type set to Determined by number of cuts.
n Number of cuts set to 1.
n Enable Extend / Trim.
n Direction for one way machining set to Follow curve chaining.
n Maximum step-over = 0.05.
3.6 Machining Geometries - Advanced Parameters
n Set the Calculation type to Contact mode.
Note: Because of the tool used is a Flat Endmill that

does not support the Calculation type set to Tool-
center mode.
593
3.7 Collision Control should be disabled

n The toolpath is only generated on one side of the

surfaces.

n The parameters should look as shown.
594
Note: The toolpath follows the curve as expected. There are

still several parameters that need to be set such as Tool axis
control and Linking.
n In the Tangential extensions area, Start/End

percentage of tool diameter = 10.
n Leave Extend/trim gaps enabled.
3.12 Set Margins
3.13 Start Point Parameters
n Click on the select button and pick an endpoint on the front face.

n Tool axis control set to Lines.
n Use tilt through set to Always closest two
lines.
n Select the lines in the upward direction; starting close to the chain starting
point and in the same CW direction
n Tilting lines maximum snap distance = 0.025.
595

n First entry set to Approach from clearance area and use Lead-In.
n Last exit set to Retract to clearance area and use Lead-Out.
n Small gaps set to Direct and Don’t use Lead-In/Out.
n Large gaps set to Direct and Don’t use Lead-In/Out.
n Clearance area Type set to Cylinder; Radius = 2.0.
n Set the Direction to X-axis.
596
n In the Lead-In area,

set the Type to
Tangential arc and
the Tool axis
orientation to
Fixed.
n Arc sweep = 90;
Arc diameter =
250%.
3.17 Set Roughing
n Enable Multi passes.

n Number = 2.
n Spacing = 0.025.
n Sort by set to
Passes.
3.18 Make only Level 3 visible and Backplot the

toolpath
597
n Select the Parameters of the last toolpath.
n Enable 2nd
Status, check the
Flute.
n Use Retract tool;
Along surface
normal against
the Avoidance
geometries.
n Click on the
Select button.
n Select the face as shown.
598
Worm Gear- Review Unified Morph To Curves With Tilt Angle
UNIFIED MORPH TO CURVES WITH TILT ANGLE

STEP 4: FINISH THE BLADE USING UNIFIED MORPH CURVES
Set the following parameters:

n Select the curves and surfaces.
n Margins; Start = 0.2, End = 0.01.
n Lead-In/Out Type set to Vertical Tang. arc.
n Arc sweep 90 degrees and Arc Diameter/tool diameter% = 100.
n No roughing options.

Milling
n Select the Unified icon.
4.2 Tool
n Select the 1/4"Ball Endmill.
599
Worm Gear- Review Step 4: Finish The Blade Using Unified Morph Curves
4.3 Set Cut Pattern
n Click on the Select button and chain the bottom

green color curve in the CW direction.
n Click on the Select button and chain the top green color
curve in the CW direction.
starting locations.

Morph.
n In the Machining geometries click on the Select machining

geometries button and select the color red surface.
600

n Disable Extend/Trim.
n Enable Flip step over to change the cutting direction from the top towards the bottom.
4.4 Set Margins

n End margins = 0.0.
n Make sure Add internal tool radius is disabled.
601

n Tilt angle at side of cutting direction = -
70.
602

n First entry set to Approach from clearance area and use Lead-In.
n Last exit set to Retract to clearance area and use Lead-Out.
n Small gaps set to Direct and use Lead-In/Out.
n Large gaps set to Direct and use Lead-In/Out.
n Clearance area Type set to Cylinder; Radius = 2.0.
n Set the Direction to
X-axis.
603
4.8 Set Default Lead-in/out
n Type set to
Vertical tang.
arc;
n Arc sweep = 90;
n Arc diameter /
tool diameter %
= 100%.

n Disable Multi passes.

604
Worm Gear- Review Unified Parallel To Surface Toolpath
UNIFIED PARALLEL TO SURFACE TOOLPATH

The Unified Parallel to Surface toolpath generates cuts on the machining geometries parallel to an avoidance
geometry.
There are special options for the edge between the avoidance surface and the machining geometry surface. You can
set a margin to define the exact position where the tool is located on the edge, positioned as close as possible to
both faces.
STEP 5: FINISH THE FILLET USING PARALLEL TO SURFACE
Machine the fillet using a Unified Parallel to Surface toolpath using the following parameters:

n Area to be machined set to Determined by number of cuts; 2 cuts.
n Disable start point.
n Cutting method set to One way; Climb and enable Enforce cutting direction.
n Cut tolerance = 0.001; Maximum stepover = 0.02.
n Output format 5-axis.
n Tool axis control set to Surface with lead/lag.
n Side tilt at side of cutting direction = 0.
n Side tilt definition Follow surface iso direction.
n Collision Control; Enable 1st Status and Retract tool Along tool axis.
n Use Lead In/Out on First and Last move.
n Set the Small gap to 20% and Follow surfaces for small and large gaps.
n Lead In/Out Defaults; Vertical tang. arc; Arc sweep = 90; Arc diameter / tool diameter % =
100%.
605
Worm Gear- Review Step 5: Finish The Fillet Using Parallel To Surface
n From the Toolpaths Manager, select the Unified icon.
5.3 Tool
5.4 Cut Pattern
n Click on the Select button and and from the Quick Mask
buttons, click on the Select all entities by color button to
select the burgundy color no. 4.

and from the Quick Mask buttons, click on the Select all
entities by color button to select the green color no. 2 and the
orange color no. 94.
n Set the Pattern Style to

Parallel.
606
offset = 0.0.
n Area type set to
of cuts; Number of cuts
= 2.
n Disable Extend/trim.
One way.
n Cut order set to
Standard.
0.01.
5.6 Set Margins
5.7 Start point Parameters
n Enble Position and click on the Select button.

n Select a point on the lower curve in the front of the
blade.
607

n Tool axis control set to Surface
with tilt.
n Side tilt definition set to Follow
surface iso direction.
n Leave the Lead and Tilt angles to
0.
n Enable 1st Status

and check the tool
Flute.
n Use Retract tool;
Along tool axis and
check the gouge
against the
Machining
geometries.
n Disable Status 2.
608

Approach from
clearance area and
Use Lead-In.
Use Lead-Out.
n Small gaps set to
Follow surfaces.
n Large gaps set to
Follow surfaces.
of tool diameter.
n Clearance area Type
set to Cylinder; Radius
= 2.0.
n Set the Direction to X-
axis.
n Entry/Exit feed
distance = 0.5.
n Air move safety
distance = 0.4.
n Vertical Tang. arc; Arc

sweep = 90; Arc diameter
/ tool diameter % = 100%.
5.12 Set Roughing
n Disable Multi passes.

n Number = 2.0.
n Spacing = 0.05.
609
Worm Gear- Review 3D High Speed Scallop
3D HIGH SPEED SCALLOP

STEP 6: SCALLOP - CLEAN THE BACK OF THE BLADE
Create a 3D High Speed Scallop toolpath to clean up the back of the blade, using the following
parameters;
n Set up a new plane using Plane = Gview.

n Total tolerance = 0.001".
n Max stepover = 0.02".
n Enable Use approximate start point.

6.2 Set up a new plane using Plane = Gview.

n Hold down the Alt key and click on down
arrow (14 times) until the part is rotated as
shown.
610
Worm Gear- Review Step 6: Scallop - Clean The Back Of The Blade
n Click on the Planes Manager tab and click on the Create a new plane
icon and select From Gview.
n Name the plane Scallop Plane.

n Make sure WCS is disabled.
n Set the C and T to the new view.
6.3 Create the Scallop toolpath

Milling
n From the 3D group, select the Scallop icon.

n Machining Geometry: Select the cylindrical surface.
n Set the Wall Stock and the Floor Stock to 0.0.
6.4 Toolpath control
n Select the contour as Boundary chains.

n Enable Compensate to: Inside.
n Set the Offset distance to 0.01.
n Disable Include tool radius.
6.5 Tool
611
Worm Gear- Review Step 6: Scallop - Clean The Back Of The Blade
n Cut method set to One Way.

n Stepover = 0.02.
n Select Full Vertical Retract.

n Clearance plane = 2.0
Incremental.
n Linear entry/exit = 0.025.
n Vertical arc entry/exit = 0.075.

toolpath
612
Worm Gear- Review Step 7: Equal Scallop Clean The Front
STEP 7: EQUAL SCALLOP CLEAN THE FRONT
In this step you will use Equal Scallop as this toolpath allows you to select Avoidance Geometry.
7.1 Set up a new plane using Plane = Gview.

n Hold down the Alt key and click on up arrow (2 times) until
the part is rotated as shown.
n Click on the Planes Manager tab and click on the Create a new plane icon
and select From Gview.
n Name the plane Scallop 2 Plane.

n Set the C and T to the new view.
613
7.2 Create the Equal Scallop toolpath

Milling
n From the 3D group, select the Equal Scallop icon.

n Machining Geometry: Select the cylindrical surface.
n Set the Wall Stock and the Floor Stock to 0.0.
n In the Avoidance Geometry select the fillet surfaces.

n Set the Wall Stock to 0.02 and the Floor Stock to 0.0.
7.3 Toolpath control
n Select the contour as Boundary chains.

n Enable Projected boundary smoothing tolerance =
0.01.
n Strategy set to Closed offsets.
n Enable Compensate to: Inside.
n Set the Offset distance to 0.01.
n Disable Include tool radius.
7.4 Tool
n Cut style set to One Way.

n Enable Optimize cut order.
n Stepover = 0.02.
n Keep tool down within % of tool diameter =
100.
614

Retract.
Incremental.
n Linear entry/exit
(incremental) = 0.025.
n Vertical arc entry/exit =
0.05.
7.7 Backplot the 3DHigh Speed Scallop toolpath
615
Worm Gear- Review Machine The Entire Part
MACHINE THE ENTIRE PART

STEP 8: USE TRANSFORM - ROTATE TO COMPLETE THE ENTIRE PART
8.2 Transform rotate the first three operations
Milling
n From the Utilities group, select the Toolpath Transform icon.
8.3 Set Types and Methods
n Enable Rotate.
n Use Tool plane as the
Method.
n Enable NCI and
Operation type.
n Make sure that just the
first three operations
are selected.
n Enable Copy source
operations and enable
Disable posting in
selected source
operations.
n Work offset
numbering set to
Maintain source
operation’s.
8.4 Rotate
n # set to 7.
n Enable Origin as the Rotate point.
n Start angle = 45.
n Rotation plane set to the Right side
plane.
616
Worm Gear- Review Step 8: Use Transform - Rotate To Complete The Entire Part
8.6 Transform rotate the operation four and fifth

Milling
n From the
Utilities group,
select the
Toolpath
Transform
icon.
n Make sure that
just the fourth
and fifth
operations are
selected.
n Enable
Operation
order.
617
8.7 The rest of the parameters are the same as in the previous transform operation
8.9 Transform rotate the surface high speed scallop operations
Milling
n From the Utilities group, select

the Toolpath Transform icon.
n Set the Method to Tool Plane
and disable Include origin.
n Make sure that just the Surface
High Speed Scallop operations
are selected.
8.10 The rest of the parameters are the same as in the previous transform operation
618
n Select all the transform operations.

n In the Stock setup, Stock Properties, enable Solid entity.
n Select the solid from the graphics window.
8.14 Verify all the

transform
operations
619
Port Expert Toolpath
620
Port Expert Toolpath Introduction
INTRODUCTION
The Port Expert allows you to rough or finish a port or internal chamber by selecting the surfaces and a
central spine. You can machine the port from both ends, the top or the bottom. Mastercam creates as many
movements as it can in a plane, generating 3-axis output, and then tilts the tool to follow the shape of the
internal chamber along the spine. If Both was selected in the Output type, Mastercam automatically
overlaps the toolpaths where they meet.
Note: The Port Expert toolpath is an add-on toolpath in Mastercam. To purchase it please contact your
dealer.
The following graphic shows a Multiaxis Port toolpath used to machine a head port.
Note: A Port toolpath, like a Flow toolpath, is usually limited to single surface machining.
Multisurface Port toolpaths may be possible if the surfaces lie in a well-ordered row. For surfaces
to form a row, adjacent surface edges must be equal in length and tangent. Surfaces usually form
a well ordered row if the shape could be constructed as a single surface
Similar with Flow toolpaths, Port toolpaths require attention to the direction of surface normals. Port uses the
normals to determine which side of the surface to machine.
621
Port Expert Toolpath Instructor Demonstration
Topics:
n Create the spine curve for a Port Expert toolpath.

n Create the Port Expert toolpath.
NOTES:
622
Port Expert Toolpath Exercise 10: Port Expert Toolpath
EXERCISE 10: PORT EXPERT TOOLPATH
Note: The Port Expert toolpath is an add-on toolpath in Mastercam. To purchase it please contact your
dealer.
Use Port Expert to cut a port or internal chamber by selecting surfaces and a central spine.
Open File
n Select PORT 5 AXIS.MCAM.
STEP 1: INSTRUCTIONS ON HOW TO CREATE A SPINE CURVE
Note: The following instructions shows you how to create the spine. The file you opened already
has the spine curve. Delete the spine and follow the instructions to recreate it.
1.1 Create two flat surfaces using Flat Boundary command
Surfaces
n From the Create group, select Flat Boundary surface.

n Select the curves at the ends of the surface.
n The flat surfaces at both ends of the tube shape should look as
shown.
623
Port Expert Toolpath Step 1: Instructions On How To Create A Spine Curve
1.2 Create lines normal to the surfaces
Wireframe
n Click on the drop down arrow and select Line Normal to Point
command.
Note: In the Line Normal to Point panel leave the default Length
1.0 and the Direction set to Normal. If the line is not pointing
upwards, select Reverse Normal. For the opposite surface, in the
Planes Manager, create a new plane using the flat surface and set it
as the Cplane. Repeat the steps to create the other Line Normal to
point.
n Select the top surface and drag the arrow to center point as shown.
n In the Line Normal to Point panel, leave the Length set to 1.0.
n Make sure that the line direction is as shown otherwise select Reverse
normal.
n Repeat the steps on the other surface. Select the point close to
the center.
624
Port Expert Toolpath Step 1: Instructions On How To Create A Spine Curve
1.3 Create a Spline Blended
Wireframe
n From the Spline group, click on the drop down arrow and select
Spline Blended.
Note: Make sure the construction mode is set to 3D in the Status bar.
n Select the top line and move the arrow to the endpoint close to the surface.
n Click to select.
n Select the other line and move the arrow to the endpoints of the
line.
n Click to select.
n The spline should look as shown.
n Delete the flat surfaces and the construction lines.
625
Port Expert Toolpath Step 2: Rough Out The Port Using A Port Expert Toolpath
STEP 2: ROUGH OUT THE PORT USING A PORT EXPERT TOOLPATH

2.1 Set Machine
n From the Machine Type group, select the Mill Default.
Toolpaths

arrow and click on the Port Expert icon.
2.3 Create a Lollipop Tool
n Right mouse click in the Tool list window and select Create
tool.
n Select the Lollipop mill.

n Click on the Next button.
626
n Cutting diameter = 0.5.

n Overall length = 2.0.
n Shoulder length = 1.25.
n Shoulder diameter = 0.25.
n Shank diameter = 0.25.
n Click on the Next button.
n Select the Finish button.
2.4 Set Cut Pattern
Cut Pattern settings determine the geometry the tool follows and how it travels along that geometry. You can select
the surfaces to be machined and the spine that is used as a reference for the tool axis. You can also choose the
cutting method, the direction for one way machining, the cut tolerance and the maximum stepover.
n Pattern set to Roughing.

n In the Machining geometries area,
click on the Select button and select the
surface.
n Offset set to 0.02.

n Disable Automatic spine.
n In the Spine area, click on the Select button and select
the magenta curve.
627
n Output type set to Both.
Note: Mastercam
calculates the entire port
toolpath from both top and
bottom endpoints,
overlapping the toolpaths
in the middle to ensure
that all the stock material is
removed.
n Machine to Midpoint.
n Ramp angle = 5.
0.05.
n Depth step = 0.05.

n Enable Minimize tilting.
628
n Clearance type set to Cylindric.

n Holder = 0.1.
n Shank = 0.02.
n Shoulder = 0.025.
n Enable Check against machining surfaces.
n Radius set to User defined value = 5.0.

n Direction set to X-axis.
n Through set to Auto.
n Feed distance = 2.0.
n Enable Retract to clearance.
629

2.10 Make level 18 visible
n In the Stock Setup select the solid.
630
Port Expert Toolpath Step 3: Finish The Port Using A Port Expert Toolpath
STEP 3: FINISH THE PORT USING A PORT EXPERT TOOLPATH

n In the Toolpaths Manager, right mouse click and select Copy.

n Select the Parameters of the second toolpath.
3.2 Set Cut Pattern
n Set the Pattern to Finishing

around.
n Set the Offset to 0.0.
n Maximum stepover set to 0.02.
631
3 Axis To 5 Axis Toolpath
632
3 Axis to 5 axis toolpath Introduction
INTRODUCTION
This lesson teaches you how to transform a 3 Axis toolpath into a 5 Axis toolpath using the Holder collision
checking options.
You will create two 3 Axis 3D High Speed Waterline toolpaths to finish a deep pocket. The tool is too short
and cannot reach the bottom of the pocket without gouging the part with the holder. You will use the holder
collision checking options to avoid collisions.
The first toolpath will be trimmed to avoid gouges by using the Trim to avoid gouge option.
The second toolpath will be transformed into a 5 axis toolpath by using the Tilt to avoid gouge option. By
tilting the tool you can reach the bottom of the pocket without gouging the part.
This option is especially useful when you need to machine deep pockets or high bosses that otherwise
required a long tool to be machined.
Topics:
n Create the 3D High Speed Waterline

finish toolpath.
n Collision checking using Trim to avoid
gouge.
n Collision checking using Tilt to avoid
gouge.
633
3 Axis to 5 axis toolpath Exercise 11: 3 Axis To 5 Axis Toolpath
EXERCISE 11: 3 AXIS TO 5 AXIS TOOLPATH

In this exercise you will use the holder collision checking options to avoid collisions.
The first toolpath will be trimmed to avoid gouges by using the Trim to avoid gouge option.
The second toolpath will be transformed into a 5 axis toolpath by using the Tilt to avoid gouge option. By tilting the
tool you can reach the bottom of the pocket without gouging the part.
Open File
n Select 3 TO 5 AXIS USING HOLDER OPTION.MCAM.
STEP 1: 3D HS WATERLINE TOOLPATH WITH TRIM TO AVOID GOUGE

Toolpaths
n From the 3D group, select the Expand gallery arrow and click
on the Waterline icon.
1.2 Set Model Geometry

The Model Geometry page allows you to select the surfaces set the Wall Stock and the Floor Stock.
n Machining Geometry: Select all surfaces.

n Wall/Floor Stock = 0.0.
634
3 Axis to 5 axis toolpath Step 1: 3D HS Waterline Toolpath With Trim To Avoid Gouge

The Toolpath Control page allows you to select the Boundary and where the tool is compensated to.
n Click on the Containment Boundaries button and select the

top dark blue color chain.
n Compensate to Center.
1.4 Select Tool
n Select a 1/4 Ball Endmill.
1.5 Set The Holder
n Select the B2E4-0250 holder

from the list.
n Enable Collision checking
and enable Trim to avoid
gouge.
635
The Cut Parameters settings allow you to determine the cut method, the stepdown and the tip compensation.
n Cut method set to

Climb.
n Stepdown = 0.025.
1.7 Set Steep / Shallow
The Steep / Shallow settings allow you to limit how much of your machining geometries will be machined.
n Angle From = 0.0.

n Angle To = 90.
636
The Linking Parameters page allows you to create the links between the cutting passes, which are air

(Incremental).
Retract.
n Leave the default Leads and
Fitting settings.
n Accept the warning that this toolpath has been gouge checked
against the selected Tool Holder.
637
3 Axis to 5 axis toolpath Step 2: 3D HS Waterline Toolpath With Tilt To Avoid Gouge
STEP 2: 3D HS WATERLINE TOOLPATH WITH TILT TO AVOID GOUGE
n Copy the toolpath.

n Click on the second toolpath
Parameters and in the
Holder page enable Tilt to
avoid gouge.
n Max. tilt angle = 10.
n Shank clearance = 0.01.
n Holder clearance = 0.05.
n Enable Clearance on
holder bottom.
2.1 Accept the warning

638
Multiaxis Pocketing Toolpath
639
Multiaxis Pocketing Toolpath Introduction
INTRODUCTION
Multiaxis Pocketing toolpath that can be used to rough out pocket shaped geometries or finish walls and
floors. The user has to specify the floor, wall and ceiling surfaces and the system automatically creates the
roughing toolpath.
Toolpath Geometry
Machining geometries are basically the whole part, including the floor surface.
Floor geometries need to be defined if Morph or Offsets from floor pattern is used. The normal of the
surfaces need to point upwards (out from the part). The surfaces have to cover all the area above that should
be machined. For roughing, the tool axis is always normal to the floor surface when machining.
Stock needs to be defined if Morph or Offsets from ceiling pattern is used. The normal of the surface needs
to point upwards. The surface has to cover all the area underneath that should be machined.
The Strategy can be :
Offset from the floor in which all the cuts generated are all offset cuts from the floor.
Morph between ceiling and floorgradually morphs between the floor surface and the ceiling surface.
Offset from ceiling creates cuts offseted from the selected ceiling surface. Depending on the shape of the
floor this pattern can lea a bid amount of rest material.
640
Multiaxis Pocketing Toolpath Instructor Demonstration
Topics:
n Multiaxis Pocketing toolpath to rough out the part.

n Multiaxis Pocketing toolpath to semifinish the walls.
n Multiaxis Pocketing toolpath to finish the floors.
n Swarf milling toolpath to finish the walls.
NOTES:
641
Multiaxis Pocketing Toolpath Multiaxis PocketingToolpath
MULTIAXIS POCKETINGTOOLPATH
Use a Multiaxis Pocketing toolpath to rough out shapes based on a pattern surface.
Open File

n Select MULTIAXIS POCKETING.MCAM.
STEP 1: SETUP THE STOCK USING THE SOLID ON LEVEL 55
n Make visible Level 55.

n In the Stock Setup, enable Solid/Mesh
and click on the Select button to select
the solid as shown.
n Select the OK button to exit Stock
Setup.
n Make invisible Level 55.
642
Multiaxis Pocketing Toolpath Step 2: Rough Out The Part Using Pocketing Toolpath
STEP 2: ROUGH OUT THE PART USING POCKETING TOOLPATH
Create a Pocketing toolpath to rough out the pocket with an island using the following parameters;
n Use 1/2" Bullnose Endmill with 1/8" corner radius.

n Set the Stock
n Stock to leave on machining geometries = 0.01.
n Stock to leave on floor = 0.05.
n Machining set to Roughing.
n Strategy set to Offset from floor.
n Type set to Dynamic.
n Direction For One Way Machining set to Climb.
n Machine by Levels.
n Constant depth step = 0.2.
n Max stepover = 0.05.
n First depth step = 0.19.
n Links Between Slices set to Ramp.
n Ramp type is set to Automatic with the Ramp angle = 5 and Ramp length (tool diameter %)
set to 80.
Toolpaths
n From the Multiaxis group, select the Pocketing icon.
2.2 Set Tool
n Select the 1/2 Bullnose Endmill with Corner Radius 0.125.
643
2.3 Set Cut Pattern
The Cut Pattern settings determine the geometry the tool follows and how it travels along that geometry. You can
select the surfaces to be machined and the surface pattern (Floor geometries). You can set the strategy, the depth
step, the cut tolerance and the maximum stepover. The cutting method and direction for one way machining are also
set in this page.
n Click on Machining geometries

Select button.
n From the QM buttons, click on the
Select all entities by color button
and enable the green color no. 10, the
red color no. 12, and the orange color
no. 136.
n Click on the Floor geometries Select button and

select the red color surface; Stock to leave =
0.05.
Note: The Floor geometries must be defined,

for the tool axis to be automatically set normal to
these surfaces. It is crucial that the floor surfaces
are below all of the area that should be machined
and that they do not have any gaps.
644
n Strategy set to Offset

from floor.
Note: This strategy

generates the cuts by
offsetting the floor
shape by the depth step
value. The upper cuts
will be trimmed based
on the shape of the part.
n Type set to Dynamic.

Zigzag.
n Direction For One
Way Machining set to
Climb.
n Enable Machine by
Levels to cut the part by
alternating between
pockets for each level.
n Constant depth step
= 0.2.
n Enable Containment and select the top chain as

shown.
645

Within group specifies the connection moves between the offset cuts in a single group.
Between groups specifies the connection moves between the different groups inside a single region on the same
cutting layer.
Links between regions specifies the connection moves between the cutting layers at different heights.

rapid distance; Use ramp.
n Last exit set to Retract to rapid
distance.
n In the Default links area set Between

groups to Retract to Rapid
distance and Don’t use ramp.
n In the Distances area leave the
defaults.
2.5 Set Roughing

The ramp defines the lead-in motion for the rough tool path segments. Ramp type set to Automatic uses the
following sequence; first line ramp is used, and if it fails then helical ramp is tried, and if it fails then zigzag is tried,
and if it fails then profile is used. A particular option may fail if the ramp move gouges.
Stock clearance defines the start point of the ramp with this value as a minimum distance away from the
stock. The value is specified as a percentage of the stepover value.
n Ramp type set to Automatic.

n Ramp angle = 5.
n Max ramp length (tool diameter %) =
80.
n Enable Allow tool outside stock.
2.6 Depth Step
n Expand Cut Pattern in the Tree View list.

n Select Depth Step and enable First depth step and set to 0.19.
646
Multiaxis Pocketing Toolpath Step 3: Rest Roughing The Part Using Multiaxis Pocketing
Note: To change the entry to be

closer to the stock, change the
Entry feed distance to 0.2.
STEP 3: REST ROUGHING THE PART USING MULTIAXIS POCKETING
Use Rest rough to remachine the area that the previous tool could not.
Create a Multiaxis Pocketing toolpath to machine areas that were not machined by the previous tool;
n Use 1/4" Bullnose Endmill.

n Enable Rest rough.
n Constant depth step = 0.1.
n Disable Depth step.
n Rest Roughing: Roughing tool diameter = 0.5;
Roughing corner radius = 0.125; Roughing offset = 0.005.
647
n Right mouse click in the Toolpaths Manager, and select

Copy.
n Click on the Parameters in the second toolpath.
3.2 Tool
n Select the 1/4 Bullnose Endmill with 1/16 corner radius.
3.3 Set Cut Pattern
n Enable Rest
rough.
n Maximum
stepover = 0.02.
3.4 Depth Step
n Disable First depth step in the Depth

Step page.
648
3.5 Rest Roughing
n Expand Cut Pattern.
Note: If the Rest Roughing does not appear in

the Tree View list, click on the Depth Step to
refresh the screen.
n Select the Rest Roughing.

n Roughing tool diameter = 0.5.
n Roughing corner radius = 0.125.
n Offset = 0.005.
3.7 Verify both toolpaths
649
Multiaxis Pocketing Toolpath Step 4: Finish The Part Floor Using Multiaxis Pocketing
STEP 4: FINISH THE PART FLOOR USING MULTIAXIS POCKETING
Create a Multiaxis Pocketing toolpath to finish the pocket with the island floor using the following
parameters;

n Depth step set to Number of slices = 1.
n Disable Rest rough
n Stock to leave on floors surfaces = 0.0.
4.1 Copy the first toolpath
n Make sure that only the first toolpath is selected.

n Right mouse click in the Toolpaths Manager and select Paste.
n Click on the Parameters in the third toolpath.
4.2 Set Tool
n Select the 1/4 Ball Endmill.
4.3 Set Cut Pattern
To finish the floor make sure that the Stock to leave is set to 0 and set the Depth step to Number of slices = 1.
n Set the Floor

surfaces Stock to
leave to 0.0.
n Set the Wall &
Check Surface
Stock to leave to
0.0.
n In the Depth step
area enable Number
of slices = 1.
n Disable Rest rough.
n Cut tolerance =
0.001.
n Maximum stepover
= 0.02.
650
Multiaxis Pocketing Toolpath Step 5: Finish The Part Walls Using Swarf Milling
n Disable First depth step in the Depth

Step page.
4.5 Verify all toolpaths
STEP 5: FINISH THE PART WALLS USING SWARF MILLING
Use Swarf milling to finish the wall surfaces with the side of the tool.
n From the Multiaxis group, select the Expand gallery arrow and click on the Swarf Milling icon.
5.2 Tool
651
5.3 Set Cut Pattern
n In the Swarf geometries area, click on the

Select button and select the green surface
on the inside of the walls.

n Enable and click on the Floor
surfaces Select button and using
the QM buttons, click on the Select
all entities by color button and
enable the orange color no. 136
and the red color no. 12.
652

n Drop tool floor set to
Drop and retract.
n Tilt lines should be
disabled.
n Guide curves should be
disabled.
n Side set to Autodetect
to set the machining side
automatically based on
the selected geometry.
n Guide tool at set to
Lower curve.
n Start point Type set to
Automatic.

n Strategy set to
Automatic.
n Extensions Type set to
Automatic and both
Extension lengths set to
0.0.

n Max. angle step set to 3.
n Enable Minimize rotation axis changes.
n In the First entry enable Use Lead-In and in the Last exit enable Use Lead-Out.

Lead-In determines how the tool feeds into the material as it approaches the part.
Lead-Out determines how the tool retracts from the material at the end of the toolpath.
n From the Tree View list, select the Lead-In page and make sure that Use default Lead-In is
enabled.
n Select the Lead-Out page and make sure that Use default Lead-Out is enabled.
n In the Default page set the Lead-In Type to Tangential arc with the Tool axis orientation set
to Fixed.
n Arc Sweep = 90; Arc diameter/tool diameter % = 200.
n Use the double arrow to set the Lead-Out parameters the same.
653
654
Multiaxis Pocketing Toolpath Step 6: Clean The Island Top With 3D Scallop Toolpath
USE 3D HIGH SPEED SCALLOP TO CLEAN THE ISLAND

STEP 6: CLEAN THE ISLAND TOP WITH 3D SCALLOP TOOLPATH
Create a 3D High Speed Scallop toolpath to clean up the top of the island using the following
parameters;
n Set up a new Plane by geometry.

n Stock to leave on drive walls/floors = 0.0.
n Offset distance = 0.125.
6.1 Set up a new plane using From geometry.
n In the Planes Manager, click on the Create a new plane

arrow and select From geometry.
n Select the flat surface at the top of the island.

n Select the OK button to accept the axis orientation.
655
n Name the plane "Scallop Plane" and enable Set as

Cplane and Tplane if needed.
6.2 Create the Scallop toolpath

Toolpaths
n From the 3D group, select the Expand gallery arrow and click
on the Scallop icon.
6.3 Model Geometry
n Machining Geometry: Select the green surfaces of the island

and the red floor surface.
n Make sure that the Wall

Stock and the Floor Stock
are 0.0.
656
n Select the blue contour as the

Containment boundary.
n Enable Outside and Include tool
radius.
n Offset distance = 0.125.
6.5 Tool

n Disable Expand inside to out.
n Set the Stepover = 0.01.
657
n Select Full Vertical Retract.

Incremental.
n In the Leads area, change the
parameters as shown.

toolpath
658
Multiaxis Review
659
Multiaxis Review Introduction
INTRODUCTION
In this lesson you will start by rotating the part using Transform Dynamic and orient the part for machining.
Next, you will create a copy of the solid model that will be used to define the stock. You will modify this solid
using Model prep functions such as Modify Feature and remove Fillets.
Create surfaces for one pocket using Surface From Solid command.
Create curves at edges of surfaces using Curve One Edge.
Rough out a pocket using Pocketing toolpath and then finish the floor using 2D HS Area Mill.
Semifinish and Finish the walls using Swarf toolpath and finish the fillet surfaces using Parallel to Curve
toolpath.
You will use three Transform - Mirror toolpaths to finish the rest of the pockets.
To drill the 5- Axis holes, you will create the axes of the holes using hole Axis command and then use these
lines to define the tool axis in the Drilling toolpath. You will Circle Mill the larger holes and use the inside hole
faces to define the tool axis.
To rough out the channel, you will use Unified Morph to Curves toolpath. You will copy the Unified Morph
toolpath and modify it to finish the channel floor. To machine the walls you will use two Swarf Milling toolpath.
The channel fillet surfaces you will use the Unified Parallel to Curve toolpath.
To speed the Verify simulation, you will create a Stock Model toolpath after the Circle Mill toolpath. You will
use this stock when verifying the toolpaths used to machine the channel.
660
Multiaxis Review Instructor Demonstration
Topics:
n Solid Model Prep commands.

n 2D Area Mill.
n Swarf 5 Axis.
n 5 Axis Drill.
n Unified Morph between 2
curves.
n Swarf Milling.
n Stock Model.
NOTES:
661
Multiaxis Review Exercise: Multiaxis - Review
EXERCISE: MULTIAXIS - REVIEW

STEP 1: OPEN FILE

n Select 5 AXIS REVIEW.SLDPRT.
The following functions/toolpaths are covered in

this exercise:
n 2D Area Mill.
n Swarf 5 Axis.
n 5 Axis Drill.
n Unified Morph between 2 curves.
n Swarf Milling.
662
Multiaxis Review Step 2: Use Transform Dynamic To Orient The Part
STEP 2: USE TRANSFORM DYNAMIC TO ORIENT THE PART
Note: If a surface is also imported, select it and delete it.
Transform
n From the Position group, select

Dynamic.
n Select the solid.
n Pick the gnomon from the graphic
window.
n Place the gnomon on the origin.
n Pick the arc to rotate the Z axis CCW
and rotate it
n 90 degrees.
n Make sure the Mode is set to Move.
663
Multiaxis Review Step 3: Create A Stock Using Model Prep Options
STEP 3: CREATE A STOCK USING MODEL PREP OPTIONS

3.1 Rename the solid
n In the Solids Manager rename the solid 5 Axis Review.
3.2 Copy the solid and move it onto Level 2
n In the Solids Manager, right mouse click and select

Duplicate Solid.
n Select the solid and then right mouse click in the

graphic window and click on Change level icon.
n In the Change Levels, enable Move.

n Disable Use Active Level and change the Number to 2.
n Name it Stock.
n Open Levels Manager and rename the levels and make

Level 2 the Active Level and hide Level 1.
664
Multiaxis Review Step 4: Use Modify Feature - Remove All Pockets And Holes
STEP 4: USE MODIFY FEATURE - REMOVE ALL POCKETS AND HOLES

Model Prep
n From the Modify group, select the Modify

Feature icon.
n In the Modify Solid Feature, enable Remove.

n To select the entire feature, double click on the pockets and
holes.
n If you missed any faces repeat the command and select

them.
665
Multiaxis Review Step 5: Remove All The Fillets Inside The Channel
STEP 5: REMOVE ALL THE FILLETS INSIDE THE CHANNEL
n From the Modify group, select the

Remove Fillets icon.
n Hold down the Ctrl key and click on

the two fillets with the different radius.
This will select all the fillets around the
channel.
STEP 6: USE MODIFY FEATURE TO REMOVE THE CHANNEL
n In the same Modify Feature command, select all

the channel faces.
n Make sure Remove is enabled.
666
Multiaxis Review Step 7: Setup The Tool Settings And The Stock Setup
STEP 7: SETUP THE TOOL SETTINGS AND THE STOCK SETUP

7.1 Set Machine
n From the Machine Type group, select the Mill Default.
7.2 Tool Settings
n Enable Assign the tool number sequentially.
7.3 Stock Setup
n In the Stock Setup, click

on Add from a
selection icon.
n Select the solid as the
stock.
7.4 Make Level 3 the Active
n Make Level 3 the Active Level and make Level 1

visible and Level 2 invisible.
667
Multiaxis Review Step 8: Create Pocket Surfaces Using From Solid Command
STEP 8: CREATE POCKET SURFACES USING FROM SOLID COMMAND

Surface
n In the Create group, select the From Solid

icon.
n Double click inside of the pocket and select all the faces of the
pocket.
n Press Enter.
n In the Surface From Solids panel, enable Use current and

Keep original solid.
8.1 Make only Level 3 visible.
n In the Levels Manager, disable Level 1.
668
Multiaxis Review Step 9: Create Curves At The Top Edges Of The Pocket
STEP 9: CREATE CURVES AT THE TOP EDGES OF THE POCKET

Wireframe
n In the Curves group,

select the Curve One
Edge icon.
n Select the surfaces one by one and click at the

top edge.
n Repeat the step to complete the geometry as

shown.
669
Multiaxis Review Step 10: Rough The Pocket Using Multiaxis Pocketing
STEP 10: ROUGH THE POCKET USING MULTIAXIS POCKETING

10.1 Model Geometry
Toolpaths
n From the Multiaxis group, select the Pocketing icon.
10.2 Tool
n Select the 3/4" Bull Endmill with a 0.125" corner radius.
10.3 Cut Pattern

button.
n Select all surface as shown.
n Set Stock to leave = 0.03.
n In the Floor surfaces area, click on the Select

button.
n Select the bottom surface as shown.
n Set Stock to leave = 0.03.
670
n Make sure the Machining

is set to Roughing.
n Strategy = Offset from
floor.
n Type = Dynamic.
n Cutting Method = One
way.
n Direction For One Way
Machining = Climb.
n Machine by = Levels
n Constant depth step =
0.2
0.05.
n Desired stepover = 0.04
n Enable Containment.
n Select the top chain.
n In Collision Control, disable Check with in-process

stock.
671
10.4 Linking

rapid distance and Use ramp.
n Last exit set to Retract to rapid
distance.
n Within group set to Direct and Use
ramp.
n Between groups set to Retract to
rapid distance and Don't use
ramp.
10.5 Roughing
672
Multiaxis Review Step 11: Finish The Pocket Floor Using 2D HS Area Mill
STEP 11: FINISH THE POCKET FLOOR USING 2D HS AREA MILL
Toolpaths
n From the 2D group, select the Area Mill.
n For Machining regions, select the curve along the

top of the solid pocket.
n Enable Stay inside.
11.1 Tool
n Select the 3/4" Bull Endmill with a 0.125" corner radius.
673
11.2 Cut Parameters

n Stock to leave on walls =
0.0.
n Stock to leave on floors =
0.0.
11.3 Linking

n In the Top of stock area, select
Associative button.
n From the General Selection bar, select Endpoint.
674
n Select the Endpoint at a surface edge.

n Change the Top of Stock to 0.05.
n Repeat the steps to select the

Depth.
n The Linking parameters
675
Multiaxis Review Step 12: Machine The Pocket Walls Using Swarf 5 Axis
STEP 12: MACHINE THE POCKET WALLS USING SWARF 5 AXIS

Toolpaths
n From the Multiaxis group, Application area, select the Swarf

icon.
12.2 Tool

n Right mouse click on the tool and
select Edit tool.
n Overall length = 4.0.
n Shoulder length = 3.5.
12.3 Cut Pattern
n In the Walls area enable Surface and click on the Select button
to select all the pocket walls (excluding the fillets).
n Select the first wall and ensure the chaining direction is CCW.
676
12.4 Cut Pattern
n Compensation type set to Computer to the

Left.
n Distance set to 0.05.
n Tip control set to Surface and in Compensation surfaces select the

bottom surface and the bottom fillets.
12.6 Linking
n Clearance = 5.0.
n Retract = 4.0.
677
12.7 Entry/Exit
n Enable Entry/Exit and Entry curve.

n Set the Length = 0.2; Thickness = 0.2 and Height
= 1.0.
12.8 Roughing
n Enable Multi Passes.

n Number = 2; Spacing = 0.1.
n Select the OK button to Update assembly and all operations that use the assembly. You might
need to reselect the 3/4 Bull nose for the first two operations.
678
Multiaxis Review Step 13: Create Curves At The Top Of The Fillet Surfaces
STEP 13: CREATE CURVES AT THE TOP OF THE FILLET SURFACES
Wireframe
n Select Curve One Edge and follow the same steps as previously
explained.
n The curves should look as shown.
STEP 14: CREATE A POINT WITH THE COORDINATE VALUES OF X1.5, Y-1.5, Z6.0
Note: Depending on which pocket you selected, you may need to swap the sign on the X and/or Y
coordinates to get the point above your pocket.
Wireframe
n Select Point Position icon.

n Press the Tab key and enter the values in the field 1.5,-
1.5,6.
n Press the Enter key to see the point.
n The point should look as shown.
STEP 15: MACHINE THE FILLETS - UNIFIED PARALLEL TO CURVE

Toolpaths
Tool
679
Multiaxis Review Step 15: Machine The Fillets - Unified Parallel To Curve
Cut Pattern
n Click on the Select button and select the curve at the top of
the fillet.
n Click on the Machining geometries Select button and select the

fillet surfaces and the bottom surface.
15.1 Collision Control turn off

Parallel.
n Area Type set to
of cuts; Number of
cuts set to 1.
n Enable Round corners
and Extend/trim.
0.03.
One way.
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Multiaxis Review Step 15: Machine The Fillets - Unified Parallel To Curve
15.2 Extend / Trim
n In the Tangential extensions, extend

both Start and End by 10 % tool
diameter.
15.3 Margins
n In the Margins page leave the Additional margin to

overcome surface edge inaccuracies.

n Tool axis control set to From point and select
the point.
681
Multiaxis Review Step 16: Machine The Rest Of The Pockets
STEP 16: MACHINE THE REST OF THE POCKETS

16.1 Make visible Only Level 1
n Make Level 1 the Active Level and invisible the rest of the
levels.
16.2 Transform - Mirror the first two operations about the Y Axis
Toolpaths
n From the Utilities group,

select the Toolpath
Transform icon.
n Hold down the Ctrl key and
select the first two
operations.
n Enable Mirror and Tool
plane.
n Disable Include origin.
n Source set to NCI, enable
Operation order.
n Work offset numbering
set to Maintain source
operation’s.
682
n Enable Mirror about X axis.
16.3 Transform - Mirror the first two operations & the Transform about the X axis
Toolpaths
n From the Utilities group, select the

Toolpath Transform icon.
n Hold down the Ctrl key and select the
first two operations and the
Transform/Mirror X Axis toolpath.
n Enable Mirror and Tool plane.
n Source set to NCI, enable Operation
order.
n Work offset numbering set to
Maintain source operation’s.
Note:Operation order enabled allows the tool to machine both operations in one of the pockets and
then the tool moves to the next pocket. This setting is suitable when using the same tool in both
operations.
Operation type enabled instructs the tool to finish the first operation on all three pockets and then starts
the second operation. This setting is suitable when using a different tool for each operation.
n Enable Mirror about Y axis.
683
16.4 Backplot the Transform toolpaths
16.5 Transform - Mirror the last two 5 axis toolpaths about the Y axis
Toolpaths

select the Toolpath
Transform icon.
n Hold down the Ctrl key
and select the last two 5
axis toolpath.
plane.
n Source set to NCI,
enable Operation order.
operation’s.
n Enable Mirror about X axis.
684
16.6 Transform - Mirror the last two 5 axis toolpaths & the Transform about the X axis
Toolpaths

select the Toolpath
Transform icon.
n Hold down the Ctrl key and
select the last two 5 axis
operations and the last
Transform/Mirror Y Axis
toolpath.
plane.
n Source set to NCI, enable
Operation order.
operation’s.
n Enable Mirror about Y axis.
16.7 Backplot all the toolpaths
Note: The cutting direction of the swarf

toolpath is reversed in the mirrored toolpath.
685
Multiaxis Review Step 17: Drill The 0.3975 Diameter Holes
STEP 17: DRILL THE 0.3975 DIAMETER HOLES

Toolpaths
n From the 2D group, select the Drill

icon.
n Hold down the Ctrl key and select the inside

face of one of the holes
n The holes will be all selected as shown.
n For a more efficient toolpath you will need to
sort the holes.
n Click on the arrow in the Sort field and select the Point
to Point as shown.
686
n Select one hole for the start point.
n The order of drilling should look as shown.
17.1 Tool
17.2 Cut Parameters

n Backplot rotary axis set to Z
axis.
687

from holes/lines.
n Clearance = 5.0
n Retract = 2.0.
n Depth = -0.75.
n Disable Calculate depth from top of
line/hole.
17.5 Tip Compensation
n Enable Tip compensation.

n Breakthrough amount = 0.0.
688
Multiaxis Review Step 18: Circle Mill The 0.8125 Diameter Holes
17.6 Backplot the drilling toolpath
STEP 18: CIRCLE MILL THE 0.8125 DIAMETER HOLES
In this step you will Circle mill the larger holes and use the solid faces to select the holes for the toolpath.
Toolpaths
n From the 2D group, select the Circle Mill icon.
n Holding down the Ctrl key to select all the

holes with the same diameter, zoom in and
select the inside face of one of the holes.
689
n The holes will be all selected as shown.
n Click on the arrow in the Sort field and select the Point to Point
as shown.
n Select one hole for the start point.
690
n The order of circle milling should look as

shown.
18.1 Tool
18.2 Cut Parameters
n Compensation type = Computer

Left.
n Make sure the Circle diameter is
0.8125.
n Start angle = 90.
n Stock to leave on walls/floors = 0.0
691
18.4 Finishing
n Enable Finishing and Semi-Finish

and set the Number to 1 and Spacing
to 0.1.
n Enable Finish and set the Number to
1 and Spacing to 0.02.
18.5 Transitions

n Enable Start at the center.
n Enable End at the center.
n Output format = 5axis.

n If a warning message appears: "Rotary
Axis Controls are not supported", click on
the OK button to accept it.
692
n Enable Calculate incremental values from

holes/lines.
n Clearance = 5.0.
n Retract = 2.0.
n Depth = 0.0.
18.8 Backplot the Circle Mill toolpath
n Change the Vector length to 0.2.

693
Multiaxis Review Step 19: Rough The Channel - Unified Morph Curves
STEP 19: ROUGH THE CHANNEL - UNIFIED MORPH CURVES

19.1 Create, on Level 4, the surface of the channel using the Surface from Solid command
n Make Level 4 the Main level.
Surface
n From the Create group, select the From

Solid icon.
n Select all the inside faces of the channel.
n Click on End Selection.
n In the Surface from Solids make sure
Attributes is set to Use current.
19.2 Create the curves on the inside channel edges and at the outer fillet edges
n Make only Level 4 active.
Wireframe
n From the Curves group, select the

Curve One Edge icon.
n Select the surfaces one by one and
click at the appropriate edges.
19.3 Create a 12" diameter circle with the center on the origin at Z 1.525
n In the Status Bar, change the

Z depth to 1.525 and the
construction mode to 2D.
694
Wireframe
n From the Arcs group, select the Circle

Center Point icon.
n Select the origin and create the circle making
sure the diameter is set to 12.0.
Toolpaths
From the Multiaxis group, select the Unified icon.

19.4 Tool
n Select the 3/8" Bull Endmill with a 0.125 corner radius.
19.5 Cut Pattern

the inner surface lower curve (along
the top of the bottom fillet).

the inner surface upper curve (along
the bottom of the top fillet).
695
n As the Machining
geometries select the inner
surface between the fillets.
n Change the curve

Style to Morph.
n Machine
geometries offset
= 0.03.
n Type set to Full,
start and end at
exact surface
edges.
n Cutting method
set to Spiral.
n Cut tolerance =
0.001.
n Maximum
stepover = 0.05.
19.6 Margins
n In the Margins enable Add internal tool radius.
696
19.7 Tool Axis control
n Maximum step angle = 1.

19.8 Linking
n Enable Use
Lead-In and
Use Lead-Out.
n For the First/Last Entry

enable Use Lead-In/Out.
n Set the Default Lead-
in/out to Tangential line;
Length = 0.5 and Height
= 0.5.
697
19.9 Roughing
n Enable Depth Cuts and set the Number to 6

and the Spacing to 0.075.
19.10 Backplot the Unified - Morph Rough toolpath
n Change the Vector length to

0.05.
shown.
698
Multiaxis Review Step 20: Finish The Channel Floor - Unified Morph (2 Curves)
STEP 20: FINISH THE CHANNEL FLOOR - UNIFIED MORPH (2 CURVES)
n Copy the Unified toolpath.

n Select the Parameters of the last operation.
n Select a 3/8" Bull Endmill.

offset = 0.0.
n Disable Roughing.
20.1 Backplot the Unified - Morph Finish toolpath
n Change the Vector length to

0.05.
shown.
STEP 21: MACHINE THE UPPER CHANNEL WALL - SWARF MILLING

Toolpaths
n From the Multiaxis group, select the Swarf

Milling icon.
699
Multiaxis Review Step 21: Machine The Upper Channel Wall - Swarf Milling
21.1 Tool
n Select the 3/8" Bull Endmill.
21.2 Cut Pattern
n As Swarf geometries select the

top channel wall.
n Enable Floor
geometries and select
the upper fillet and the
inner surface of the
channel.

n Guide tool at Lower
curve.
n Cut tolerance set to
0.001.
700
21.3 Linking
n For the First/Last

Entry/Exit enable
Use Lead-In/Out.
n Set the Clearance
area to Plane.
n Set the Default

Lead-in/out to
Vertical tang. arc;
Width = 0.2;
Length = 0.5 and
Height = 0.2.
701
21.5 Multi Cuts
n In the Multi Cuts page set

Depth steps to By number of
slices = 2; Pattern set to
Morph and Direction set to
Along tool axis.
n Tool shift set to Constant for
each slice.
n Number of layers = 1.
n Machine by = Regions
n Method set to One way.
21.6 Backplot the Swarf Mill toolpath
n Change the Vector

length to 0.5.
n The toolpath should
look as shown.
702
Multiaxis Review Step 22: Machine The Lower Channel Wall Using Swarf Milling
STEP 22: MACHINE THE LOWER CHANNEL WALL USING SWARF MILLING
22.1 Copy The Swarf Milling
n Copy the Swarf machining toolpath.

22.2 Cut Pattern
n Unselect the Swarf

geometries, then
select the bottom
channel wall.
n Unselect the Floor surfaces,

then select the lower fillet and the
inner surface of the channel.
22.3 Regenerate & Backplot the toolpath

shown.
703
Multiaxis Review Step 23: Machine The Lower Fillet Unified Parallel To Curve
STEP 23: MACHINE THE LOWER FILLET UNIFIED PARALLEL TO CURVE

Toolpaths
23.1 Tool
n Select a 1/8" Ball Endmill.
23.2 Cut Pattern
n Select the curve at the bottom

edge of the bottom fillet.
n As Machining geometries
select the fillet surface and
the inner channel surface.
704
Multiaxis Review Step 23: Machine The Lower Fillet Unified Parallel To Curve

Parallel.
n Area set to
Determined by
number of cuts;
Number of cuts set to
8.
n Disable Round
corners and
Extend/Trim.
0.03.
n Tool axis control set to From

Chain.
n Curve tilt type set to Closest
point.
n Select the circle.
705
Multiaxis Review Step 24: Machine The Upper Fillet Unified Parallel To Curve

shown.
STEP 24: MACHINE THE UPPER FILLET UNIFIED PARALLEL TO CURVE

24.1 Copy the Unified - Parallel toolpath
n Copy the Unified Parallel toolpath.

24.2 Cut Pattern
n Remove the curve.

n Select the curve at the top edge
of the top fillet.
706
Multiaxis Review Step 24: Machine The Upper Fillet Unified Parallel To Curve
n Unselect the Machining

geometries, then select
the fillet surface and the
inner channel surface.
n Area set to Determined
by number of cuts;
Number of cuts set to 8.
24.3 Regenerate & Backplot the Toolpath
n Backplot the
toolpath.
707
Multiaxis Review Step 25: Create A Stock Model
STEP 25: CREATE A STOCK MODEL
In this step you will create a Stock Model after the Circle Mill toolpath that will be used to verify the
channel toolpaths.
n Move the Insert arrow after the Circle Mill toolpath.
Toolpaths
n From the Stock group, select the Stock Model

icon.
n In the Stock Definition, click

on the Stock Setup button.
n Enter the Name: "Stock for
channel".
708
n In the Source Operations

select all the first 10
Operations.
n The Stock Model should look as shown.
n In the Toolpaths Manager, select the

Simulator Options icon.
n In the Simulator Options enable Stock

model.
709
25.1 Verify the Channel toolpaths
n In the Toolpaths Manager, select all the toolpaths used to

machine the channel.
n Run Verify.
n The part should look as
shown.
710
Accelerated Finish Tools
711
Accelerated Finish Tools Introduction
INTRODUCTION
In this exercise you will learn how to use Circle Segment tools to improve the surface quality of the part and
the machining cycle time. These tools are primarily used in mold-making as well as in the production of tire
molds, turbine blades or impeller blades.
These end mills provide large radii in the cutting area of the respective tool which ensures smaller scallops on
the finish part.
There are four different types of circle segment end mills:
Barrel shape
Oval form
Taper form
Lens shape
712
Accelerated Finish Tools Introduction
The circle segment tools save

cycle time relative to the
ballnose tools. Cycle time has
been reduced due to the
larger stepover while
achieving a better finish.
These tool are ideal for 5-axis machining but they are also supported in 3 + 2 axis machining.
The best toolpath to use these tools are Waterline with an Oval shape tool and Raster toolpath with a lens
shape tool. You need to set the proper Tool Plane for the tools to properly work.
Unified Morph and Unified Parallel are the best toolpaths in a Multiaxis environment. The Tool axis control
will allow us to set the appropriate tangent contact point on the cutting radius of the tool. You will set the tool
axis to Surface with lead/lag and set the Tilt angle at the side of cutting direction.
The Oval form tool is limited to a 15 degree range of motion. The taper form tool angle of engagement cannot
vary by more than 0.1 degree. The ballnose, by contrast, is effectively unlimited in its range of motion. This is
why ballnose tools are routinely used on even basic machining centers, but circle-segment tools are applied
almost entirely on five-axis machines.
In this exercise you will use a Stock model toolpath that allows you to create a casting stock with 0.1" extra
material.
You will finish the bottom of the pockets using 3D High Speed Horizontal toolpath. For the walls you will
review Unified Parallel to Curve with Tilt side angle, Unified Parallel to Surface with Tilt side angle, Unified
Morph between 2 Curves and Unified Morph between 2 Surfaces.
713
Accelerated Finish Tools Instructor Demonstration
Topics:
n Stock model to create a casting part.

n 3D High Speed Horizontal to finish the bottom
floors.
n Using Circle Segment tools to finish the walls
n Unified Parallel to Curve with Tilt side angle.
n Unified Parallel to Surface with Tilt side angle.
n Unified Morph between 2 curves with From point
axis control.
n Unified Morph between 2 surfaces with From
point axis control.
NOTES:
714
Accelerated Finish Tools Exercise: Accelerated Finish Using Barrel Tools
EXERCISE: ACCELERATED FINISH USING BARREL TOOLS

Open File
n Select ACCELERATED FINISH_BARREL MILL.MCAM.
Select The Mill Default
Machine
n In the Machine Type group, select the arrow below the Mill and select the Mill Default.
STEP 1: CREATE A STOCK MODEL FOR A CASTING PART
In this step you will use Stock Model to create a casting part.
1.2 Set Stock Definition
n Name = Casting Sock.

n Enable Model and click on the
Select button.
n Select the solid.
715
Accelerated Finish Tools Step 1: Create A Stock Model For A Casting Part
n Additional offset = 0.1.
n The Stock model should look as shown.

n Press Alt + T to remove the Stock model display.
716
Accelerated Finish Tools Step 2: 3D High Speed Horizontal
STEP 2: 3D HIGH SPEED HORIZONTAL
3D High Speed Horizontal allows you to machine flat surfaces. In our exercise you will machine all the pockets
bottom surfaces.
n From the 3D group, select the Horizontal icon.
2.2 Model Geometry
n In the Machining Geometry select the pocket surfaces.

Double click inside of each pocket.
n Set the Wall Stock to 0.2 and the Floor

Stock to 0.0.
n In the Avoidance Region select the

vertical walls and the fillet surfaces.
Double click inside each pocket and then
unselect the floor face.
n Set the Wall Stock to 0.02.
717
2.3 Set Tool
n Select the 3/8" Bull Nose with 1/16 Corner radius.

n Right mouse click on the tool and select Edit.
n Change the Overall length to 3.0.
2.4 Holder
n Set the Tool Projection to 3.0.
2.5 Cut Parameters
n Number of depth cuts = 1.
2.6 Steep / Shallow
n Enable Minimum depth and

set it to 1.6.
718

Clearance plane to 6.0.
2.8 Entry Motion
n Set the Helix as shown.
719
Accelerated Finish Tools Step 3: Unified Parallel To Curve
STEP 3: UNIFIED PARALLEL TO CURVE
Note: This toolpath requires an Oval form tool. Copy the Emuge-circle - segment_inch.tooldb library in
your C:\Users\Public\Documents\Shared Mastercam 2023\mill\Tools.
Create the Unified Parallel to Curve toolpath using the following parameters:
n Tool from Emuge-circle-segment_inch; 0.4724 (12 mm) Oval Form R2 / R80 Mill.
n Select Add Curve row and select the curve.
n Machining geometries offset = 0.0".
n Area Type set to Full, start and end at exact surface edge.
n Output format set to 5 Axis; Maximum angle step = 3.
n Side tilt definition = Ortho to cut direction at each position.
n Tilt angle = 75.
n Collision Control.
n #1; Flute; Retract tool; Along tool axis against the Machining geometries; Tolerance = 0.001.
n Enable Avoidance geometries and select the bottom flat surface.
n Linking defaults, Clearance set to Plane; Height = 6.0.

icon.
3.2 Tool
n Click on the Select library tool button.
n Click on New
library button.
n Select the Emuge -circle-segment_inch_2023.Tooldb
720
n Disable the Filter.

n Select the 3538L_12080A -12mm-End Mill-Oval Form R2 / R80 Mill 4 Flutes.
n Accept the warnings.
3.3 Holder
n Click on Open library button.
721
n Select the BT30-in.tooldb.
n Select the B2C3-0016.
3.4 Cut Pattern
n Select the rectangular shape pocket

curve.
722
n Machining geometries, click on the Select button

and select the pocket walls.

Parallel.
offset = 0.0.
n Area type set to Full, start
edges.
Spiral.
0.05.
723

n Side tilt definition set to Ortho to cut direction at
each point.
n Lead angle to cutting direction = 0
n Tilt angle = 75.
n Run tool set to Auto to let Mastercam to decide where
the tool will touch the surface (at the radius or tip of the
tool).
n Strategy 1; enable Flute

and.
n Strategy set to Retract
tool; Along tool axis
for the Machining
geometries.
n Enable Avoidance
geometries and click on
the Select button.
n Select the flat face at the bottom of the pocket.
724
3.7 Set Linking

Approach from
to Don’t use Lead-Out.
n Small gaps set to
Blend spline and Don’t
use Lead-In/Out.
n Large gaps set to
area and Don’t use
Lead-In/Out.
of tool diameter.
n Clearance area Type
set to Plane; Height =
6.0.
n Entry/Exit feed
distance = 0.4.
n Air move safety
distance = 0.4.
725
Accelerated Finish Tools Step 4: Unified Parallel To Surface
STEP 4: UNIFIED PARALLEL TO SURFACE
The Unified Parallel to surface toolpath finishes the walls by creating the toolpath passes parallel to a driving
surface. You will use this toolpath to machine the second rectangular shape pocket.
4.1 Copy the Unified Parallel toolpath and change the following parameters
n In the Toolpaths Manager, right mouse click and select

Copy.
n Select the Parameters in the last toolpath.
4.2 Set Cut Pattern
n Delete the existing curve row.
n Click on Add Surface row.
n Click on the Select button and select the bottom flat

surface of the other rectangular shape pocket.
n Change the Pattern Style to Parallel.
726
Accelerated Finish Tools Step 4: Unified Parallel To Surface
n In the Machining geometries area, click

first on the Unselect button to remove the
existing surfaces and then click on the
Select button and select the pocket walls.
n In the Geometry area, as Avoidance

geometries, click on the Select button and
unselect the flat face from the previous pocket
and select the flat face of the current pocket.
4.4 Leave the rest of the parameters as they are and regenerate the toolpath
727
Accelerated Finish Tools Unified Morph Between Two Curves
UNIFIED MORPH BETWEEN TWO CURVES

Unified Morph between two Curves creates a cut pattern that blends from one curve to the other.
STEP 5: FINISH THE WALLS USING MORPH BETWEEN 2 CURVES
Create the Unified Morph between 2 Curves toolpath using the following parameters:
n Tool = 3538_06095A - 6 mm - End Mill - Oval Form A -R1/R95.

n Select Add Curve row twice and select the curves.
n Machining geometries offset = 0.0".
n Output format set to 5 Axis; Maximum angle step = 0.5;
n Tool axis control Surface with tilt; Ortho to cut direction at each position.
n Tilt angle = 75.
n Collision Control: enable Flute; Shoulder, Shank.
n Tilt tool; Use side tilt angle; enable Geometry and Check surfaces;
n Select the bottom fillets and bottom surface as check surfaces.
5.2 Select Tool
n Select the 3538_06095A - 6 mm - End Mill - Oval Form A -R1/R95 4 Flutes

n Edit the Overall Length to 3.0.
n Accept the warning and change the feed rate and spindle speed.
5.3 Select Holder
n Select the B2C3-0016 as shown before.

n Change the Tool Projection to 3.0.
728
Accelerated Finish Tools Step 5: Finish The Walls Using Morph Between 2 Curves
5.4 Set Cut Pattern
n Delete the existing row.

n Select the top curve.
n Select the bottom curve (same direction).

unselect the existing geometries and click
on the Select button and select the pocket
walls.
729
n Change the Pattern

Style to Morph.
n Machining
geometries offset
= 0.0.
n Area type set to
Full, start and end
at exact surface
edges.
n Cutting method
set to Spiral.
n Cut tolerance =
0.001.
n Maximum
stepover = 0.05.


730
n Enable Strategy 1
and Flute.
n Set to Tilt tool;
Automatic.
n Enable Machining
geometries and
enable Avoidance
geometries and click
on the Select button.
n Remove the existing geometries.

n Select the bottom faces.
731
n First entry set to Approach from clearance area and to Don’t use Lead-In.
n Last exit set to Retract to clearance area and to Don’t use Lead-Out.
n Small gaps set to Blend spline and Don’t use Lead-In/Out.
n Large gaps set to Blend spline and Don’t use Lead-Out.
n Clearance area Type set to Plane.
n Direction set to Z-axis.
732
Accelerated Finish Tools Step 6: Unified Morph Between Two Surface
STEP 6: UNIFIED MORPH BETWEEN TWO SURFACE
The Unified Morph between two Surfaces toolpath creates a cut pattern that blends from one surface to the other.
6.1 Copy the Unified Morph toolpath and change the following parameters
6.2 Set Cut Pattern
n Delete the existing Curve rows.

n Click on the Select button. Select the top flat

surface .

bottom of the last pocket.
n Change the Pattern Style to Morph.
733
n In the Machining geometries area, unselect

the existing surfaces and select the pocket walls.
n Unselect the Avoidance geometries and select

the faces at the bottom of the current pocket.
6.4 Leave the rest of the parameters as they are and regenerate the toolpath
734

n In Simulator Options enable Stock model and make sure Casting Stock is selected.
Note: To finish the bottom fillets you can use

Parallel to Curve toolpath with the following
parameters:
Use as geometry the existing curve (create the curve
where needed) and the flat surface and fillets of the
pocket.
Use a 1/8" Ball Endmill.
Area Type set to Determine by number of cuts.
Margins set to only the Additional margin to
overcome surface edge inaccuracies.
Tool axis control set to From point. (Create a
point, where needed, at the center of each pocket at
5.0" Z depth.
735
Impeller
736
Impeller Introduction
INTRODUCTION
Upon completion of the training lessons presented in this workbook, you should know how to:
n Unified Morph (between 2 surfaces) toolpath to rough the area between two blades.
n Unified Morph (between 2 surfaces) toolpath to finish the floor.
n Unified Parallel (to curves) toolpath to finish the blade.
n Unified Parallel (to surface) toolpath to finish the fillet.
n Transform rotate toolpath to machine the entire impeller.
Topics:

exercise:

to rough the area between two blades.
to finish the floor.
n Unified Parallel (to curves) toolpath to finish
the blade.
n Unified Parallel (to surface) toolpath to finish
the fillet.
n Transform rotate toolpath to machine the
entire impeller.
737
Impeller Exercise: Machine The Impeller Floor - Unified Morph
EXERCISE: MACHINE THE IMPELLER FLOOR - UNIFIED MORPH

Open File
n Select IMPELLER WITHOUT TILT CURVE.MCAM.
STEP 1: ROUGH OUT THE AREA BETWEEN TWO BLADES

Unified Morph between 2 Surfaces toolpaths create a morphed toolpath on the machining geometry. The
machining geometry is enclosed by two check surfaces. A "morphed" toolpath is one that is approximated between
the check surfaces and evenly spread over the machining geometries. This toolpath pattern is especially useful
during impeller machining with twisted turbine blades.
The main advantage is the possibility to compensate the tool to the machining geometries and avoidance surface in
the left and right corner of the workpiece. All you need to do is set the margin, or distance between the tool center
and the surfaces, equal to the tool radius.
Note: In this exercise we will create an operation to finish one floor region, then use Mastercam's
Toolpath Transform feature to machine the floors between the other blades.
Create the Unified Morph with the Surface option toolpath using the following parameters:

n Cutting method = Zigzag; Standard.
n Start/End margin = 0.0.
n Additional margin to overcome surface edge inaccuracies = 0.0018.
n Lead angle = 0.
n Tilt angle = 0.
n Clearance area and Distances set to default values.
n Lead in/out set to Tangential arc; Fixed; Width = 0.2; Length = 0.2; Height = 0.3.
738
Impeller Step 1: Rough Out The Area Between Two Blades
1.1 Make Level 25 the Active Level and make the rest of the
levels invisible
1.2 Select Mill Default

1.4 Set Tool
n Click on the Select button and select color no. 152

(violet).
739
n Click on the Select button and select color no. 136

(coral).
n Change the Pattern Style to Morph.

and select color no. 85 (green).
740
n In the Area
Type select
Full, start and
end at exact
surface
edges.
n Cutting
method set to
Zigzag.
n Cut order set
to Standard.
n Machining
geometry
offset = 0.05.


n Press Esc.
Note: Without margins, the tool will cut through the wall surfaces.
741
1.7 Set Margins

n End margins = 0.005.

n Press Esc.
742

n Ensure that the Lead and Tilt angles are
set to 0.
n Side tilt definition to Ortho to cut
n Run tool set to Auto
n Enable Limits.
743
1.10 Set Limits
n Enable Conical limit and set w1 = 0.0

and w2 = 60.0.
n Set the Cone axis to Z-axis.
n Gouge check for the

Flute and Shoulder.
n Strategy and
parameters set to Tilt
tool; Automatic.
n In the Geometry
column, enable only
Avoidance
geometries.
n Stock to leave = 0;
Tolerance = 0.001.
n Click on the Select
button.
n Reselect the wall surfaces.
744

from clearance area and
Use Lead-In.
clearance area and Use
Lead-Out.
n Small gaps set to Follow
surfaces.
clearance area.
tool diameter.
n Lead-In Type set

to Tangential arc.
n Tool axis
orientation set to
Fixed.
n Width = 0.2.
n Length = 0.2.
n Height = 0.3.
n Same settings for
Lead-Out.

n Set the Length of the 4-5 Axis vectors to 0.02.
Note: The toolpath is only a rough operation. We

need to leave stock for the finishing operation and to
add roughing passes.
745
n Select the Parameters in the Unified Morph operation.
offset = 0.05.
1.16 Roughing

n Set the Number of Roughing passes to 5 and the
Spacing to 0.1.
n Apply depth to Whole toolpath.
n Sort by set to Passes.
n Enable Use ramp.
1.17 Regenerate and backplot the toolpath
746
Impeller Step 2: Finish The Impeller Floor
STEP 2: FINISH THE IMPELLER FLOOR
n From the Toolpaths Manager, copy the toolpath.

n Select the Parameters in the second operation and
change only the following parameters.
2.1 Tool
2.2 Set Cut Pattern
n Reselect the surfaces.

n Machining
geometries offset =
0.0.
n Enable Round
corners.
2.3 Margins
n Change Start margins to 0.05.

n Change End margins to 0.05.
747
Impeller Machine The Impeller Blade - Unified Parallel To Curves
2.4 Set Roughing
n Disable Depth Cuts.
2.5 Regenerate and backplot the finish floor toolpath
MACHINE THE IMPELLER BLADE - UNIFIED PARALLEL TO CURVES

In this step you will create a Unified Parallel to Curves toolpath to finish the blades. You should create an
operation to finish one blade, and then use Mastercam's Toolpath Transform feature to machine the floors between
the other blades.
STEP 3: UNIFIED PARALLEL TO CURVES
Create the Unified Parallel to Curves toolpath using the following parameters:

n Type area set to Full, start and end at exact surface edge.
n Extend /trim enabled. Tangential extensions Start/End = 50% of tool diameter. Side
extensions Start/End = 65%
n Margins enable Add internal tool radius.
n Tool axis control set to Surface with tilt; Follow surface iso direction.
n Collision Control; Strategy 1 check the Flute & Shoulder ; Tilt tool set to Automatic; against
Machining geometries.
n Default Lead-In/Out; Tangential line; Fixed; Length 0.5; Height 0.5.
748
Impeller Step 3: Unified Parallel To Curves
n In the Levels Manager, make

Level 10 the Active Level and
the rest of the levels invisible.
n The geometry should look as
shown.
3.3 Tool
n Select the 3/16" Ball Endmill form the library.
3.4 Cut Pattern
n Click on the Select button to select the

blue color curve.

click on the Select button and select the
orange color no. 136 surfaces.
749
Impeller Step 3: Unified Parallel To Curves

Style to Parallel.
offset = 0.0.
n Area Type set to Full,
start and end at exact
surface edges.
n Enable Round corners
and Extend / trim.
One way.
0.03.
n Tangential extensions; Start = 50%,

End = 50%.
n Enable Extend/Trim gaps.
n Side extensions; Start = 65%, End =
65%.
3.6 Margins
n In Margins enable Add internal tool radius.

n No other margins.
750
Impeller Step 4: Set Tool Axis Control
STEP 4: SET TOOL AXIS CONTROL

tilt.
n Side tilt definition set to Follow surface
iso direction.
n Tilt angle at side of cutting direction =
75.
n No Limits

n Enable Status 1 and check the Flute.
n Set the Strategy and parameters to Tilt tool and Automatic and enable Machining geometries.
n Enable Avoidance geometries and select the fillet surface.
751
Impeller Step 4: Set Tool Axis Control
n Set the First entry to

Approach from clearance
area and Use Lead-In.
n Set the Last exit to Retract
to clearance area and Use
Lead-Out.
n Set the Small gaps to
Blend spline and Don’t
use Lead-In/Out.
n Set the Large gaps enable
Retract to clearance area
and Use Lead-In/Out.
n Small gap size = 100%.
n Leave the rest of the settings
as the defaults.
n Lead-In set
to
Tangential
line.
n Tool axis
orientation
set to Fixed.
n Length =
0.5.
n Height =
0.5.
n Same
settings for
Lead-Out.
752
Impeller Unified Parallel To SurfaceS Toolpath
UNIFIED PARALLEL TO SURFACES TOOLPATH

Unified Parallel to Surfaces toolpaths generate cuts on the machining geometries parallel to an avoidance
surface.
There are special options for the edge between the avoidance surface and the machining surface. You can define a
margin to define the exact position where the tool is located on the edge, positioned as close as possible to both
faces.
STEP 5: FINISH THE AREA BETWEEN THE FLOOR AND THE FILLET
Create the Unified Parallel to Surface toolpath using the following parameters:

n Type area set to Determined by number of cuts; Number of cuts = 6.
n Cut method set to One way; Climb.
n Maximum angle step = 1 degree.
n Side tilt definition = Ortho to cut direction at each position.
n Collision control Flute, Shoulder, Shank; Tilt tool Automatic; enable Machining geometries.
n Default Lead-In/Out; Tangential line; Fixed; Length 0.5; Height 0.5.
5.2 Set Tool
5.3 Cut Pattern
n Click on the Select button to select the orange color

surface.
753
Impeller Step 5: Finish The Area Between The Floor And The Fillet
n In the Machining geometries area, click on

the Select button and select the green and
violet color surface.

Style to Parallel.
n In the Area Type,
select Determined
by number of cuts
and set the Number
of cuts to 6.
n Enable Round
corners.
n Enable Extend /trim.
to One way.
n Direction for one
way machining set
to Climb.
n Cut tolerance =
0.001.
n Maximum stepover
= 0.02.
5.4 Set Extend /Trim
n Tangential extensions enabled.

n Start / End = 100%.
754
5.5 Set Margins
n Start Margins = 0.12

n Additional margin to overcome surface edge
inaccuracies = 0.00118.
n Maximum angle step = 1 degree.

n Side tilt definition = Ortho to cut
5.7 No Limits

shown.
755
n Enable Status 1 and

check the Flute and
the Shoulder.
n Set the Strategy and
parameters to Tilt
tool and Automatic
and enable
Machining
geometries.
n Set the First entry to

Approach from
clearance area and
Use Lead-In.
n Set the Last exit to
area and Use Lead-
Out.
n Small gaps set to
Blend spline and
Don’t use Lead-
In/Out.
n Large gaps set to
area and Use Lead-
In/Out.
n Small gap size =
120%.
settings as the
defaults.
756
Impeller Step 6: Transform - Rotate
5.12 Default Lead-in /out
n Lead-In set to
Tangential line.
n Tool axis orientation
set to Fixed.
n Length = 0.5.
n Height = 0.5.
n Same settings for
Lead-Out.
STEP 6: TRANSFORM - ROTATE
Transform toolpaths are used when you want to run the same toolpaths in different locations or at different
orientations in the same part file. You can transform single toolpaths, or several at a time.
757
6.2 Move the Insert arrow below the first operation

group, select the
Toolpath
Transform icon.
n Enable Rotate.
n Use Coordinate as
the Method.
n Enable NCI as
Source.
n Make sure that just
the first operation is
selected.
n Enable Copy
source operations
n Work offset
numbering set to
Maintain source
operation’s.
758
6.5 Rotate
n # set to 11.
n Enable Angle
between.
n Enable the Origin
as the Rotate
point.
n Start angle = 30.
n Rotation angle =
30.
n Enable Rotation
plane and set it to
the Top plane.
6.6 Backplot the Transform/Rotate

toolpath
759
Impeller Step 7: Transform Rotate The Second & Third Toolpaths
STEP 7: TRANSFORM ROTATE THE SECOND & THIRD TOOLPATHS
7.1 Move the insert arrow below the fourth operation

(first Unified Parallel toolpath)
n Enable Rotate.
n Use Coordinate as
the Method.
n Enable Group NCI
output by Operation
type.
n Make sure that just
the second Morph
and the first Parallel
toolpaths are
selected.
n Work offset
numbering set to
Maintain source
operation’s.
760
Impeller Step 8: Transform Rotate Last Toolpath
7.4 Rotate
n # set to 11.
n Enable the Origin as the Rotate point.
n Start angle = 30.
n Enable Rotation plane and set it to the Top plane.
7.5 Backplot the second and fifth operations (both Rotate operations)
STEP 8: TRANSFORM ROTATE LAST TOOLPATH

8.1 Move the insert arrow below all operations
Toolpaths
761
n Enable Rotate.
n Use Tool plane as the
Method.
n Make sure that just the
last Parallel toolpath is
selected.
n Enable Operation
order.
n Enable Copy source
operations.
n Work offset
numbering set to
Maintain source
operation’s.
8.3 Rotate
n # set to 11.
n Enable the Origin as the Rotate point.
n Start angle = 30.
n Enable Rotation plane and set it to the Top plane.
8.4 Backplot the last

operation
762
8.5 Verify the Transform toolpaths
n Make visible only

Level 30 and select
the Stock Setup.
n Click on Add from a
selection the solid
as the stock.

n Verify the part.
763

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Multiaxis

Copyright: 1998 - 2023 In-House Solutions Inc. All rights reserved

Software: Mastercam 2023

Date: July 4, 2022

Multiaxis Professional Courseware 1

Introduction To 4 - Axis Programing 31

Mastercam® User Interface: 35

Setting The Grid 36

Home Tab And The Mini Toolbar 37

Data Entry Shortcuts 39

The Right Mouse Click Menu 40

About Rotary Axis Control 42

Mastercam® 4 - Axis Work Flow: 43

Conventions Used In This Book 47

Axis Substitution Roll 48

Instructor Demonstration Preview: 51

Exercise 1: Axis Substitution - Roll The Geometry 52

Step 1: Locate Part Geometry 52

Step 2: Open File 52

Step 3: Set The Stock As Cylinder In The Stock Setup 52

Step 4: Roll The Geometry 56

Step 5: Drill The 0.25" Diameter Holes 58

Step 6: Substitute X-axis 59

Step 7: Drill The 0.5" Diameter Holes 61

Step 8: Slot Mill The Inside Obround Shape 62

Step 9: Contour The Outside Obround 64

Axis Substitution Unroll 68

Instructor Demonstration Preview: 70

Exercise 2: Axis Substitution - Unroll The Geometry 71

Step 1: Open File 71

Step 2: UnRoll The Geometry 71

Step 3: Create Extra Geometry To Be Able To Machine The Open Areas 72

Step 4: Use Pocket Toolpath To Machine The Part 73

Step 5: Change The Tool And The Stepover 78

Step 6: Rolldie C-Hook 79

Using Rolldie C-hook To Machine With The Side Of The Tool 79

Axis Substitution Helix 82

Instructor Demonstration Preview: 84

Exercise 3: Axis Substitution - Creating A Cylindrical Helix 85

Step 1: Create The Geometry For The Helix 85

Step 2: Select The Default Mill Machine 87

Step 3: Machine The Helix Using Contour With Axis Substitution 89

Exercise 4: Axis Substitution - Creating A Conical Helix 92

Create The Geometry For The Conical Helix 92

Step 4: Use Analyze Entity Properties Command To Modify The Geometry 92

Step 5: Machine The Conical Helix 93

Axis Substitution Dynamic Mill 95

Instructor Demonstration Preview: 97

Exercise 5: Axis Substitution Pocket 98

Locate Part Geometry 98

Step 1: Open File 98

Step 2: Create The Wireframe Using Curve All Edges 98

Step 3: Unroll The Geometry 99

Step 4: Fix The Geometry 101

Step 5: Create A Rectangle Using Bounding Box 102

Step 6: Select The Machine And Set The Properties 103

Axis Substitution & Rolldie 108

Instructor Demonstration Preview: 110

Exercise 6: Axis Substitution & Rolldie - Barrel Cam 111

Step 1: Select A Machine And Set The Properties 111

Step 2: Create The Contour Toolpath Using Axis Substitution 112

Step 3: Rolldie C-Hook To Machine The Barrel Cam 116