MasterCAM ch16

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Chapter 16 Multiaxis Machining Objectives: 1. Know four 5-axis toolpath functions. 2. Know rotary 4-axis toolpath function. 3. Apply multiaxis toolpath functions to cut surface models. Overview Most machining projects can be done with 3-axis machines. However, 3-axis machines may encounter difficulties or be unable to machine some complicated parts which have features such as slope planes, surfaces, undercuts, or multiple faces. In those cases, a 4-axis or 5-axis machine is more suitable to use. The programming for 4-axis and 5-axis machines is more complicated than 3-axis programming. Mastercam is capable of generating toolpaths for 4-axis or 5-axis machining. The 4-axis machining has only one function, Rotary 4-axis. There are four 5-axis machining functions including Curve 5-axis, Drill 5-axis, Swarf 5-axis, and Flowline 5-axis. These multiaxis toolpath functions are used to generate toolpaths for cutting a surface model. This chapter presents these five multiaxis toolpath functions for cutting surfaces. The working principles and defining parameters of each function are covered. These are followed by several projects with step-by-step instructions. 16.1 Rotary Axes and Directions The Electronic Industries Association has established a CNC machine axes identification standard, EIA-267-B. This standard defines 14 different axes, including 9 linear axes and 5 rotary axes, to describe all CNC machines, from simple to complex types. The linear axes on a machine may include 3 primary linear axes, 3 secondary linear axes, and 3 tertiary linear axes. The rotary axes may include 3 primary rotary axes and 2 secondary rotary axes. However, most CNC machines require only 3 linear axes. Some machines have one or two rotary axes in addition to the three linear axes. Three primary rotary axes designated by the characters A, B, and C are used to indicate rotary motions about the X, Y, and Z axes, respectively in Figure 16.1. Rotary motion about the X axis is labeled with an A; rotary motion about the Y axis with B; and rotary motion about the Z axis with C. Figure 16.1 www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete

Transcript of MasterCAM ch16

Page 1: MasterCAM ch16

Chapter 16

Multiaxis MachiningObjectives:

1. Know four 5-axis toolpath functions.2. Know rotary 4-axis toolpath function.3. Apply multiaxis toolpath functions to cut surface models.

Overview

Most machining projects can be done with 3-axis machines. However, 3-axis machines mayencounter difficulties or be unable to machine some complicated parts which have features such as slopeplanes, surfaces, undercuts, or multiple faces. In those cases, a 4-axis or 5-axis machine is more suitableto use. The programming for 4-axis and 5-axis machines is more complicated than 3-axis programming.

Mastercam is capable of generating toolpaths for 4-axis or 5-axis machining. The 4-axismachining has only one function, Rotary 4-axis. There are four 5-axis machining functions includingCurve 5-axis, Drill 5-axis, Swarf 5-axis, and Flowline 5-axis. These multiaxis toolpath functions areused to generate toolpaths for cutting a surface model. This chapter presents these five multiaxis toolpathfunctions for cutting surfaces. The working principles and defining parameters of each function arecovered. These are followed by several projects with step-by-step instructions.

16.1 Rotary Axes and Directions

The Electronic Industries Association has established a CNC machine axes identificationstandard, EIA-267-B. This standard defines 14 different axes, including 9 linear axes and 5 rotary axes,to describe all CNC machines, from simple to complex types. The linear axes on a machine may include3 primary linear axes, 3 secondary linear axes, and 3 tertiary linear axes. The rotary axes may include 3primary rotary axes and 2 secondary rotary axes. However, most CNC machines require only 3 linearaxes. Some machines have one or two rotary axes in addition to the three linear axes.

Three primary rotary axes designated by thecharacters A, B, and C are used to indicate rotarymotions about the X, Y, and Z axes, respectively inFigure 16.1. Rotary motion about the X axis is labeledwith an A; rotary motion about the Y axis with B; androtary motion about the Z axis with C.

Figure 16.1

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The thumb rule is used to determine the direction of the rotation. For example, with the thumbof the right hand pointing in the direction of the positive X axis, the four fingers will curl in the positivedirection of the rotary A axis.

16.2 4-Axis and 5-Axis Machines

4th and 5th axis control can be implemented either on the machine tables or the spindle heads.Rotary indexing tables are common devices used to position the 4th and 5th axis on machine tables. Themachine table is still controlled by three primary linear axes; X, Y, and Z. The indexing table provides4th or 5th -axis positioning control. Figure 16.2 shows two examples using 4-axis positioning on amachine table. Figure 16.3 illustrates 5-axis machining. Rotary axes can be applied to the spindle head ofmachines (Figure 16.4). Profilers are the typical machines of this category.

Figure 16.2a Figure 16.2b

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16.3 Part Features for 4th and 5th Axis Machining

A part feature is the distinctive geometric form or shape being produced from raw material.Typical part features include holes, slots, pockets, shoulders, profiles, angles, threads and surfaces. Thosefeatures that are defined in the XY-plane normally can be machined by 3-axis machines. Those featuresthat are not lying in the XY-plane normally require using a 4- or 5-axis machine depending on theorientation of plane normal. Figure 16.5 shows an example of 4-axis machining and Figure 16.6 is anexample of 5-axis machining.

Figure 16.5 Figure 16.6

16.4 Rotary 4-Axis Function

The rotary 4-axis function generates toolpaths for cutting a surface model in a 4-axis CNCmachine (Figure 16.7). Multiple-surface model can be used in rotary 4-axis function for generatingtoolpaths simultaneously (Figure 16.8). The rotary 4-axis parameter dialog box appears as below.

Figure 16.7 Figure 16.8

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screen � rotary 4-axis

Three parameters that are unique to this toolpath function include: Use center point, Axisdampering length, and Lead/lag angle.

Use center pointThis parameter uses a point at the

center of the part to orient the tool axis(Figure 16.9). Mastercam will output thetool axis relative to the center point. Whenthis parameter is set to Off (no check mark),the system will output the tool axis relativeto the surface.

Figure 16.9

Axis dampering lengthThis parameter decides the position of the tool axis based on the given length along the surface

of the part. This parameter becomes available only when the �Use center point� parameter is set to Off.A shorter dampering length produces more tool movement and a toolpath that adheres closely to thesurface. A longer length provides less tool movement. Figure 16.10 shows the effect of axis damperinglength on the toolpaths.

Figure 16.10a Axis dampering length = 1.0 Figure 16.10b Axis dampering length = 1.0www.cadfamily.com EMail:[email protected] document is for study only,if tort to your rights,please inform us,we will delete

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Figure 16.10c Axis dampering length = 0.1 Figure 16.10d Axis dampering length = 0.1

Lead/lag angleThe �lead/lag angle� parameter specifies the relationship between tool axis and surface by an

angle value. This angle can be the lead angle or lag angle. The lead angle is defined as the angle at whichthe tool passes over the part measured from the surface normal to the shank of the tool (Figure 16.11).

Figure 16.11a Lead angle = 0 Figure 16.b Lead angle = 30O

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: Project 1. Using rotary 4-axis function to cut a single-surface modelThis project shows how to create a set of rotary 4-axis toolpaths to cut a single-surface model.

The loft surface to be used and its 4-axis toolpath are shown in Figure 16.12.

Figure 16.12a Figure 16.12b

6Tips 1. Use the surface model file lofts1.

2. Use the rotary 4-axis function to generate toolpaths.

3. Use a ½� sphere end mill.

Step 1.Open the surface model file lofts1.Select MAIN MENU à File à GetFile name: lofts1The loft surface appears as in Figure 16.13.

Figure 16.13

Step 2.Initiate the rotary 4-axis function.Select MAIN MENU à Toolpaths à Multiaxis à Rotary4axFile name for toolpath: 4ax1Pick the loft surface, then select DoneClick the right mouse button, then select Get tool from librarySelect tool number 256 (1/2 sphere endmill)Select OK

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Chapter 16 Multiaxis MachiningSet the Tool parameters menu as below.

screen � step 2

Step 3.Define the finish parameters.Click the Finish parameters button. Set the finish parameters as below.

screen � step 3

Step 4.Define the rotary 4ax parameters.Click on the Rotary 4ax parameters. Set the rotary 4ax parameters as below.

Screen � step 4

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Step 5. Set gap and edge setting parameters.Click on the Gap settings buttonSet the gap setting parameters as here.

Screen � step 5

Select OK à OK to generate toolpaths

The 4-axis toolpaths are generated as shown in Figure 16.14.

Figure 16.14

Step 6. Save the toolpath file.Select MAIN MENU à NC utils à Edit NCISelect Yes to �Operations have been modified. Created the NCI text file?�Select Quit from the Edit NCI dialog box

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: Project 2. Using rotary 4-axis function for a multiple-surface modelThis project use rotary 4-axis function to generate toolpaths for cutting the dryer surface model.

Figure 16.15 shows both surface model and toolpaths.

Figure 16.15a Figure 16.15b

6Tips 1. Use the surface model file dryers.

2. Use the rotary 4-axis function to generate toolpaths.

3. Use a 3/8� sphere end mill.

Step 1.Open the surface model file dryers.Select MAIN MENU à File à GetFile name: dryersThe surface model appears as Figure 16.16.

Figure 16.16

Step 2.Initiate the rotary 4-axis function.Select MAIN MENU à Toolpaths à Multiaxis à Rotary4axFile name for toolpath: 4ax2Select All à Surfaces à DoneClick the right mouse button, then select Get tool from librarySelect tool number 254 (3/8 sphere endmill)Select OK

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Set the Tool parameters as below.

Screen � step 2

Step 3.Define the finish parameters.Click �Finish parameters� button.Set the finish parameters as below.

Screen � step 3

Step 4.Define the rotary 4-axis parameters.Click �Rotary 4ax parameters� button.

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Set the rotary 4-axis parameters as below.

Screen � step 4

Select OKEnter an approximate starting point: 0,0,0The 4-axis rotary toolpaths are generated as in Figure 16.17.

Figure 16.17

Step 5.Save the toolpath file.Select MAIN MENU à NC utils à Edit NCISelect Yes to �Operations have been modified. Created the NCI text file?�Select Quit from the Edit NCI dialog box

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16.5 5-Axis Toolpath Functions

There are four 5-axis toolpath functions. They are summarized in Table 16.1.

Table 16.1 Four 5-axis toolpath functions

Function Description Illustration

Curve5ax Generate 5-axis toolpathsalong surface edges, chainedcurves, or surface curves.

Drill5ax Generate 5-axis drillingtoolpaths that run in aspecified direction anddepth.

Swarf5ax Generate 5-axis toolpathsfor cutting a surface withthe side of the tool.

Flow5ax Generate 5-axis toolpathsfor cutting over the entiresurface model.

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16.6 Curve 5-Axis Function

The Curve 5-Axis function is used to create a 5-axis toolpath (1) along the edges of a surface,(2) along chained curves, or (3) along projected curves on the surface. Table 16.2 summarizes thefeatures of the three curve 5-axis functions.

Table 16.2 Three curve 5-axis functions

Function Description Illustration

Outer edge Generate 5-axis toolpaths on theedges of the a selected surface.

Chain crvs Generate 5-axis toolpaths alonga set of chained curves that aregeometry entities not on thesurface(s). The system first projectsthese geometry entities onto thesurface(s) to generate a set ofsurface curves, then generates5-axis toolpaths to cut the surfacecurves.

Surf crvs Generate 5-axis toolpaths alongcurves projected onto thesurface(s).

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Curve 5-Axis Common ParametersThose parameters that are commonly used in all three curve 5-axis functions are grouped under

Curve 5-Axis parameter dialog box as shown below.

Screen - curve five axis parameters

Parameter file This parameter specifies the name and directory of the parameter file used forthe current toolpath.

Tool type This parameter is used to select the toolpath as either 3-axis toolpath or 5-axistoolpath. The 3-axis toolpath always has its tool axis perpendicular to the Cplane. The 5-axis toolpathhas the tool axis perpendicular to the surface. Figure 16.18 shows the contrast between a 3-axis and a 5-axis toolpath on a surface.

Figure 16.18a Figure 16.18b

Offset direction There is a group of parameters that are used to define the offset value anddirection of the toolpaths. The Offset Direction parameter is used to set the direction for the toolpathoffset from the surface edges, surface curves, or projected curves. This parameter can be set to one of thefollowing three options (Figure 16.19).

None: The tool lies on the surface edges, surface curves, or projected curves (Figure 16.19a).Left: The tool is offset from the left side by a given distance based on the toolpath direction

(Figure 16.19b).Right: The tool is offset from the right side by a given distance based on the toolpath

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Figure 16.19a Offset direction = None Figure 16.19b Offset direction = LeftFive axis offset = 0.5

Figure 16.19c Offset direction = RightFive axis offset = 0.5

Offset distances

Offset and depth The cutter can be offset in two directions: XY-plane and Z-direction.Mastercam uses the �Five Axis Offset� parameter to specify the offset value in the XY-plane and �FiveAxis Depth� parameter to specify the offset value in the Z-direction.

Side angle and lead angle Two angle parameters also offset the tool axis orientation.The side angle tilts the tool axis to the right or left by a given angle. A positive angle tilts the tool axis tothe left and a negative angle tilts it to the right (Figure 16.20).

Figure 16.20 a. Side angle = 30O

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Figure 16.20b. Side angle = 0O

Figure 16.20c. Side angle = -30O

The lead angle tilts the tool to the front or back. A positive lead angle tilts the top of the toolforward and a negative angle tilts it backward (Figure 16.21).

Figure 16.21a. Lead angle = 30O

Figure 16.21b. Lead angle = 0O

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Gouge checkThe gouge check feature in Curve 5-Axis functions only checks for gouges on the offset

toolpath. It will not check for those non-offset toolpaths. This parameter can be set to one of the follow-ing three options:

Infinite look ahead: evaluates the entire toolpath when looking for gouges.Look ahead: evaluates a given number of toolpath moves ahead while looking for gouges.Off: turns off gouge check.

Show toolpath before gouge checkThis parameter instructs Mastercam to show the toolpath before making any gouge check

changes.

Minimize corners in toolpathSelecting this option to remove the toolpath move immediately before and the toolpath move

immediately after a corner in a toolpath that is offset to the outside.

16.7 Outer Edge Function

The outer edge method generates the 5-axis toolpath on the edges of the selected surface (Figure16.22). This method is only applied to a single surface. There are two sets of surface boundary param-eters dialog box depending on the type of surface you select: trimmed surface boundary and untrimmedsurface boundary. They are shown below.

Figure 16.22

Screen - trimmed surface boundary

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Screen - untrimmed surface boundary

Stepping MethodMastercam uses two methods to determine the stepping distance along the cutting surface

curves: step increment and chord height. With the step increment method, the cutter advances a givendistance for each of the toolpath segments disregarding the tolerance of the toolpath. This method isoften used for surfaces that are relatively flat and simple.

Using the chord height method, a cutter move is determined by the following two parameters:

Chord height: specifies the maximum distance that the toolpath can deviate from the surface.Maximum step: specifies the maximum distance between toolpath segments.

Make Toolpath OnThis parameter uses the following two options to select one surface edge or all surface edges to

generate toolpath (Figure 16.23):

All Edges: generates toolpath along all surface edges.One Edge: generates toolpath along one selected surface edge.

Figure 16.23a All edges Figure 16.23b One edge

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: Project 3. 5-axis outer edge toolpathsThis project generates the toolpaths to machine

the outer edge of a loft surface. Both 5-axis and 3-axistoolpath modes are used, respectively (Figure 16.24).

Figure 16.24a Surface

Figure 16.24b 5-axis toolpath Figure 16.24c 3-axis toolpath

6Tips 1. Use the loft surface file lofts3.

2. Save the 5-axis outer edge toolpath file as 5oe.

3. Save the 3-axis outer edge toolpath file as 3oe.

Step 1.Open the surface model file lofts3.Select MAIN MENU à File à GetFile name: lofts3The drawing of lofts3 will appear as Figure 16.25.

Figure 16.25

Step 2.Initiate the curve 5-axis outer edge function.Select Cplane à TopSelect MAIN MENU à Toolpaths à Multiaxis à Curve5axFile name for toolpath: 5oePick any point on the surface to select itSelect Done à Outer edge

:3

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Pick the surface againSet the Untrimmed surface boundary parameters as below.

Screen � step 2

Step 3.Define curve five axis parameters.Use the pick point in Figure 16.25.Select DoneMove the cursor to the left-front corner and click P1 as shown in Figure 16.25The direction arrow should point toward the +Y direction on the screenSelect OK to accept this default directionSelect Do itSet the Curve five axis parameters as below.

Screen � step 3

Step 4.Define the NC parameters.Click the NC button

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Set the NC parameters as below.

Screen � step 4

Select DonePress <Enter> to continueThe toolpaths are generated as in Figure 16.26.

Figure 16.26

Step 5. Save the toolpath file.Select MAIN MENU à NC utils à Edit NCISelect Yes to �Operations have been modified. Create the NCI text file?�Select Quit from Edit NCI menu

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Step 6. Generate the surface outer edge toolpath for the 3-axis mode.Follow all procedure steps 1-5 except for step 3. This time, in step 3 set the Curve Five Axis

parameters as shown below.

Screen � step 6

The toolpaths in 3-axis mode will appear as Figure 16.27.

Figure 16.27

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16.8 Chain Curves Function

The chain curves method generates 5-axistoolpaths along a set of chained curves that aregeometry entities and not the surface. Mastercamfirst projects these geometry entities onto the surfaceto generate a set of surface curves, then generates5-axis toolpaths to cut the surface curves(Figure 16.28).

This method can applied to both a singlesurface model or a multiple-surface model. Thecurve projection parameters dialog box appearsbelow.

Figure 16.28

Screen - curve projection

Projection MethodThere are two ways to project chained entities onto the surface(s): normal to surface and

normal to plane.

Normal to Surface: the chained entities are projected in the direction perpendicular to the surface.

Normal to Plane: the chained entities are projected in the direction perpendicular to the current construction plane.

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: Project 4. 5-Axis chain curveThis project generates 5-axis toolpaths to machine a curve that is created by projecting a circle

onto a Coons surface. Figure 16.29 shows the surface model and a circle. Figure 16.30 shows thetoolpaths generated from projecting the circle onto the surface using the normal to plane method.

Figure 16.29 Surface and curve Figure 16.30 Toolpaths

6Tips 1. Use the Coons surface file coonss1 as the base surface to be projected onto.

2. Create a circle having its center on (2.5, 3.75) with a diameter of 4� to use as the chain curve.

3. Use the Backplot function to visualize and verify the toolpaths.

Step 1. Open the surface model file coonss1.Select MAIN MENU à File à GetFile name: coonss1The Coons surface appears as Figure 16.31.

Figure 16.31

:4

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Step 2. Create a circle in level 3.Select Cplane à TopSelect Level, then enter 3Select Z, then enter 3.5Select MAIN MENU à Create à Arc à Cir pt+dia à ValueEnter coordinates: 2.5, 3.75Enter the diameter: 4The circle is added as in Figure 16.32.

Figure 16.32

Step 3. Initiate the Curve5ax-Chain cvs function.Select MAIN MENU à Toolpaths à Multiaxis à Curve5axFile name for toolpath: 5ccPick any point on the Coons surfaceSelect Done à Chain cvsPick the circle as the boundarySelect Do itSet the Curve five axis parameters as below.

Screen � step 3

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Step 4.Define the NC parameters.Click the NC buttonSet the NC parameters as below.

Screen � step 4

Select Done to generate the toolpathsPress <Enter> to continueThe toolpaths are shown in Figure 16.33.

Figure 16.33

Step 5.Save the toolpath file.Select MAIN MENU à NC utils à Edit NCISelect Yes to �Operations have been modified. Create the NCI text file?�Select Quit from the Edit NCI menu

Step 6.Backplot the toolpaths.Select MAIN MENU à NC utils à Backplot à Display

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Set the backplot display parameters as below.

Screen � step 6

Select DoneSelect RunThe toolpaths are animated on the screen.

16.9 Surface Curves Function

The surface curves method generates 5-axis toolpaths along curves that were previouslyprojected onto the surface (Figure 16.34). This method is applied only to a single surface. Surfacecurves are 3D curves that lie on a surface and are defined by their location on the surface.

Figure 16.34

Gap ToleranceThis parameter specifies the maximum distance by which adjacent surface curves may be

separated and still be chained. When the distance between two surface curves exceeds this value, thesystem does not chain them.www.cadfamily.com EMail:[email protected]

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: Project 5. Curve 5-axis-surface curveGenerate 5-axis toolpaths to machine a series of surface curves on a surface (Figure 16.35). The

surface curves are created by projecting a rectangle onto a surface. Then use the Curv5ax-surf crvsfunction to generate 5-axis toolpaths.

Figure 16.35a Surface curves Figure 16.35b Toolpaths

6Tips 1. Use the Coons surface coonss1 as the base surface.

2. Create a rectangle.

3. Project the rectangle onto the Coons surface to generate surface curves.

4. Use the Curv5ax-surf crvs function to generate toolpaths to cut surface file coonss1.

Step 1.Open the surface model file coonss1.Select MAIN MENU à File à GetFile name: coonss1The surface model coonss1 will appear as Figure 16.36.

Figure 16.36

:5

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Step 2.Set the drawing environments for creating a rectangle.Select Level, then enter 3Select Z, then enter 3.5Select Gview à TopSelect Cplane à TopThe model shown in the top view will look like Figure 16.37.

Figure 16.37

Step 3.Create a rectangle using the pick points in Figure 16.37.Select MAIN MENU à Create à Rectangle à 2 Points à SketchEnter the lower left corner: pick P1Enter the upper right corner: pick P2Select Gview à IsometricA rectangle is added to the model as in Figure 16.38.

Figure 16.38

Step 4.Project the rectangle onto the surface to create surface curves.Use the pick points in Figure 16.38.Select Level, then enter 4Select MAIN MENU à Create à Curve à ProjectPick P1 to select a surfaceSelect Done

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Select Chain, then pick P2Select Done à OptionsSet projection curve parameters as below.

Screen � step 4

Select DoneSet View/norm to VSelect Do it to generate surface curvesSelect Level à Vis levels, toggle 3 to invisible (dimmed)Select OKThe surface curves are added as in Figure 16.39.

Figure 16.39

Step 5.Generate toolpaths for surface curves.Use the pick point in Figure 16.39.Select MAIN MENU à Toolpaths à Multiaxis à Curve5axFile name: pscPick the surface, then select DoneSelect Surf crvsPick P1Select Do it

Set the curve five axis parameters as shown next.

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Screen � step 5

Step 6.Define the NC parameters.Click the NC button. Set the NC parameters as below.

Screen � step 6

Select DoneThe toolpaths are generated as shown in Figure 16.40.

Figure 16.40

Press <Enter> to continue

Step 7. Save the toolpath file.Select MAIN MENU à NC utils à Edit NCISelect Yes to �Operations have been modified. Create the NCI text file?�Select Quit from Edit NCI menuwww.cadfamily.com EMail:[email protected]

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16.10 Drill 5-Axis Function

The drill 5-axis function is used to drill holes in a specified direction. The location and directionof the drilling can be specified by two methods; points and pts/lines. With the Points method, a referencepoint and a projection surface or plane are used. The system projects the reference point onto the surfaceto obtain the drilling point on the surface, then it uses a normal vector as a reference to set the drillingdirection (Figure 16.41).

Figure 16.41

In Pts/lines method, the endpoint of a line is used as the reference point and the line defines thedrilling direction (Figure 16.42).

Figure 16.42

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Point selection methodsThe following three options are used to select points for drilling:

Manual: manually selects or creates points for generating drilling toolpaths.Automatic: uses three points to automatically select a group of points for generating

drilling toolpaths. The first selected point is used as the first point, thesecond selected point sets the search direction, and the third selected pointis the stop point.

Window: selects a series of points within the window for generating drilling toolpaths.

Project normalThis parameter selects one of the following two methods for the projection of the drill points:

Surface: projects the points normal to the selected surface.Plane: projects the points normal to the current construction plane.

Drill 5-axis parametersDrilling parameters are grouped under drill 5-axis parameters menu as shown below. The drill

parameters are same as in chapter 7 for regular drilling operations. See the Drill section in chapter 7.

Screen � drill 5-axis

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Drill hole locationThis parameter is unique for drill 5-axis function and only applies to the Points method. It

specifies how the selected point Mastercam uses as the reference point for drilling. This parameter hasthe following two options:

On Surface: uses the projected point on the surface as the reference point (Figure 16.43).In other words, the drilling depth is measured from this point and towardthe surface normal direction.

Original Point: uses the original point above the surface as the reference (Figure 16.44).The drilling depth is measured from this point and toward the surfacenormal direction.

Figure 16.43

Figure 16.44

Two projects are presented in this section to demonstrate how to use two functions of the Drill5-axis. The first project uses the points method to generate a drilling toolpath that is normal to a draftsurface, then copy this toolpath to five locations around the Z axis. The second project uses the Point/Line method to generate the toolpaths to drill two holes along the line orientation.

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: Project 6. Drill 5-axis with points optionThis project uses the Drill 5-axis function to generate a toolpath for a point and is perpendicular

to the surface. This drilling toolpath is then copied to 5 locations by using the Edit NCI-Xform-Rotatefunction. Figure 16.45 shows surface model and drilling toolpaths.

Figure 16.45a Surface Figure 16.45b Drilling toolpaths

6Tips 1. Create a cone-shaped draft surface.

2. Use the front view to define a point as the drilling location.

3. Use the Edit NCI à Xform à Rotate function to copy the drilling toolpath to five locations around the cone-shaped surface.4. Use the Backplot function to verify the toolpaths.

Step 1.Create a circle.Select Cplane à TopSelect Gview à IsometricSelect Z, then enter 0Select MAIN MENU à Create à Arc à Cir pt+diaEnter the center point: 0,0Enter radius: 3The circle is created as in Figure 16.46.

Figure 16.46

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Step 2. Create a draft surface.Select MAIN MENU à Create à Surface à DraftPick the circle to select the profile entitySelect DoneAnn arrow pointing upward will appear to indicate the extending direction.Select Length, then enter �4Select Angle, then enter �15Select Do itThe draft surface is created as in Figure 16.47.

Figure 16.47

Select MAIN MENU à File à SaveFile name: 5drl

Step 3. Define the drilling location.Select Cplane à FrontSelect MAIN MENU à Toolpaths à Multiaxis à Drill5axFile name for toolpath: 5drlSelect PointsSet Surface to �Y�Select Manual à ValueEnter coordinates: 0,-1.5,6A point will appear as in Figure 16.48.

Figure 16.48

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Chapter 16 Multiaxis MachiningPress the Esc key to complete point selectionSelect Yes to draw the path between pointsSelect Yes to �Is the path OK?�Pick any point on the surface to select it

Step 4. Define the drilling parameters.Set the five axis drilling parameters as below.

Screen � step 4-1

Select the NC buttonSet the NC parameters as below.

Screen � step 4-2

Select DoneThe drilling path is shown in Figure 16.49.

Figure 16.49

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Step 5. Generate five drilling toolpaths by using Xform-Rotate function.Select Cplane à TopSelect MAIN MENU à NC utils à Edit NCIClick Unknown [T2] under 5DRL.NCISelect Xform à RotateSet the Xform � Rotate menu as below.

Screen � step 5-1

Select DoneThe five drilling toolpaths are added to the file as shown below.

Screen � step 5-2

Step 6. Save the toolpath file.Select File à SaveSelect Yes to overwrite the existing fileSelect Quit to exit the Edit NCI functionThe six drilling toolpaths are shown in the model as in Figure 16.50.

Figure 16.50

Step 7. Backplot the toolpath.Select MAIN MENU à NC utils à Backplot à RunThe toolpaths are backplot on the screen.

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: Project 7. Drill 5-axis using point/line optionGenerate two drilling toolpaths to produce two holes on a cone-shaped surface along two lines

(Figure 16.51). The cone-shaped surface is created in project 6 of this chapter.

Figure 16.51a Surface Figure 16.51b Toolpaths

6Tips 1. Use the cone-shaped draft surface file 5drl.

2. Create two lines to use as the drilling direction for two holes.

3. Use Drill � pts/lines functions to generate toolpaths for two holes.

4. Backplot the toolpaths to verify results.

Step 1.Open the draft surface file 5drl.(or create one by following the instructions in steps 1 and 2 in project 6.)Select MAIN MENU à File à GetFile name: 5drlThe draft surface appears as Figure 16.52.

Figure 16.52

Step 2.Create two lines.Select MAIN MENU à Create à Line à Endpoints à Value

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Enter the following four set of coordinate values:

5, 0, -1 0, 0, -3 for the first line-4, 0, -3.5 0, 0, -3.5 for the second line

The two lines are added as in Figure 16.53.

Figure 16.53

Step 3.Initiate Drill5ax � pts/lines function.Use the pick points in Figure 16.53.Select MAIN MENU à Toolpaths à Multiaxis à Drill5axFile name for toolpaths: 5drllSelect Pts/Lines à Manual à EndpointPick P1 and P2 to select two endpointsPress Esc to complete point selectionSelect Yes to draw path between pointsSelect Yes to �Is the path OK?�

Step 4.Define the drilling parameters.Set the five axis drilling parameters as below.

Screen � step 4-1

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Chapter 16 Multiaxis Machining

Set the NC parameters as below.

Screen � step 4-2

Select Done to generate the drilling toolpaths along two given linesSelect No to �Repeat with same points?�

Step 5.Backplot the toolpaths.Select MAIN MENU à NC utils à BackplotSelect Yes to �Operations have been modified. Create the NCI text file?�Select RunTwo drilling toolpaths will be animated on the screen.

16.11 Swarf 5-Axis Function

The Swarf 5-axis function generates 5-axis toolpaths for cutting a selected surface with the sideof the tool (Figure 16.54). The tool axis (shank) is oriented parallel to the surface.

Figure 16.54

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Swarf 5-axis floorThis parameter specifies the toolpath floor for generating swarf 5-axis toolpaths. The toolpath

floor defines the depth of cut along the selected surface(s). It has the following two options:

Surface: selects a surface for the toolpath floor (Figure 16.55).Plane: defines a plane for the toolpath floor (Figure 16.56).

Figure 16.55

Figure 16.56

There are eight ways to define a plane. They are described in Table 13.2. Refer to page 13-10 inchapter 13 for details.

Chain wireThis parameter allows the wireframe model

to be used as the driving elements for generating swarf5-axis toolpaths (Figure 16.57). Mastercam uses twochained contours to define the wall for cutting; lowercontour and upper contour. The lower chain must bedefined first for the toolpath to generate properly.

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Chapter 16 Multiaxis Machining

Slct wallsThis parameter selects walls as the boundaries

for generating swarf 5-axis toolpaths. This option canselect walls on wireframe contour, surface, or combinationof both. The swarf 5-axis menu appears as below.

Screen � swarf 5-axis: select walls menu

Wire/surf This parameter can be toggled to select a wireframe or a surface for the nextwall of the toolpath. Toggle to �S� for surface mode and �W� for wireframe mode.

Open pock This parameter decides whether an open pocket or a closed pocket is used forgenerating toolpaths. A closed pocket has its starting element and ending element connected (Figure16.58). With an open pocket, the starting element and ending element are not connected (Figure 16.59).

Figure 16.58 Closed pocket Figure 16.59 Open pocket

Step crnr This parameter determines whether the next corner of the toolpaths to movethe tool in an XY direction to a parallel wall. Figure 16.60 shows the effect of this parameter on thetoolpaths.

Figure 16.60

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Fan wall and Fan dist The �Fan wall� parameter decides whether to place fans at the end ofeach wall of the toolpath. The �Fan dist� parameter specifies the fan distance for the current wall of thetoolpaths. The fan distance determines the minimum distance that the tool travels between the cornerposition and a position where the tool is perpendicular to the floor (Figure 16.61).

Figure 16.61

Radius This parameter specifies the radius of the next corner of the toolpath when vieweddown the axis of the tool.

Swarf 5-axis parametersThose parameters related to swarf 5-axis function is grouped under 5-axis Swarf Cutting menu

as shown below.

Screen � 5-axis swarf cutting

Wall passes and floor passesThe total number of toolpaths is the product of number of passes on wall and number of passes

on floor. Mastercam will generate four passes of toolpaths if both numbers of passes are set to 2. Whenthe number of passes becomes greater than one, the stepover parameter becomes active for enteringproper value. Figure 16.62 shows an example of having both numbers of passes equal to 2.

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Figure 16.62

Depth controlThe Depth control parameter specifies how the lowest depth of swarf toolpaths calculate. It has

the following two options:

Floor: places the lowest point of the tool on the selected floor plane.Lower rails: places the center of the tool in line with the lower rails when the tool rests

against the walls.

Stock parametersThe following three stock parameters that allow to specify the amount of material to leave for

further machining:

Stock to leave on walls: specifies the amount of material left on the walls.Stock to leave on floor: specifies the amount of material left on the floor when the floor

option is used.Distance above lower rails: specifies how far the center of the tool descends above or

below the lower boundary.

Retract parametersThe following two parameters control the retraction of the tool:

Retract height: specifies the distance above the floor or lower boundary for the initial and final tool location.

Retract between passes: indicates whether to raise the tool to the retract height at the beginning and end of each pass. This parameter becomes active only when the retract height parameter is ON.

Feedrate parametersThe following two parameters are used to specify the feedrate for cutting fans and corners:

Fan feedrate: specifies the feedrate for machining the fan section of the toolpaths.Corner feedrate: specifies the feedrate for machining the rounding corners of the toolpaths.

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Do fansThis parameter enables or disables the fan capability for the entire toolpaths.

Entry and exit curvesMastercam allows adding an entry curve and exit curve to the toolpaths. Both entry curve and

exit curve have the following three parameters (Figure 16.63):

Length: specifies the span of the entry curve along the wall in the direction the tool travels.

Thickness: specifies the distance of the curve away from the wall.Height: specifies the distance of the curve away from the floor measured along

the tool vector.

Figure 16.63

Entry/exit curve toleranceThis parameter controls the difference between a theoretical curve and its linear approximation.

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Chapter 16 Multiaxis Machining

Along cut distanceThis parameter measures the distance between vectors in the toolpath and at the wide end of

fans in the toolpath (Figure 16.64).

Figure 16.64

Tool vector lengthThis parameter sets all tool vectors in the toolpath to a selected length. Turn this parameter to

Off, the system automatically controls the lengths of the vectors.

Keep generated surfacesThis parameter creates geometry from the ruled surfaces made during the toolpath creation.

Show tool contact line on floorThis parameter generates a line that represents where the tool touches the floor of the toolpath.

Two projects are presented in this section to show how to generate 5-axis swarf toolpaths. Thefirst project uses a wireframe model as the wall for generating swarf toolpaths, and the second projectuses a draft surface as the wall.

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: Project 8. Using 5-axis swarf function with wireframe modelThis project uses 5-axis swarf function to generate toolpaths for cutting a slope surface defined

by using two wireframe contours. Figure 16.65 shows two wireframe contours and its swarf toolpaths.

Figure 16.65a Wireframe Figure 16.65b Toolpaths

6Tips 1. Use the wireframe model 3contour.

2. Delete the bottom circle.

3. Break the right vertical line of the rectangle into two pieces.

4. Use Swarf5ax function to generate swarf toolpaths.

5. Backplot the toolpaths.

Step 1.Open the wireframe model 3contour.Select MAIN MENU à File à GetFile name: 3contourThe wireframe model consisting of three contours appears as in Figure 16.66.

Figure 16.66

Step 2.Delete the bottom circle.Select MAIN MENU à DeletePick the bottom circle to delete it

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Chapter 16 Multiaxis MachiningThe new drawing becomes Figure 16.67.

Figure 16.67

Step 3.Break the right vertical line of rectangle into two entities.Use the pick point in Figure 16.67.Select MAIN MENU à Modify à Break à 2 piecesPick P1 to select the entity to breakSelect Midpoint, then pick P1 to break the line into 2 entitiesThe model is redrawn in Figure 16.68.

Figure 16.68

Step 4.Initiate the Swarf5ax function.Use the pick points in Figure 16.68.Select MAIN MENU à Toolpaths à Multiaxis à Swarf5axFile name for toolpath: swarfSelect Plane à z = constEnter z-coordiante of plane: -1Select Chain wirePick P1 as the lower contourPick P2 as the upper contourSelect Done

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Set the Swarf parameters as below.

Screen � step 4

Step 5. Define the NC parameters.Click the �NC� buttonSet the NC parameters as below.

Screen � step 5

Select Done to generate the toolpaths as Figure 16.69.

Figure 16.69

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Step 6.Backplot the toolpaths.Select MAIN MENU à NC utils à BackplotSelect Yes to �Operations have been modified. Create the NCI text file?�Select Run to backplot the toolpaths on the screen

Note that there are four toolpath passes in this operation.

: Project 9. Using 5-axis swarf function with a surface modelThis project creates swarf toolpaths to cut a draft surface (Figure 16.70). The draft surface is

created in chapter 12 and has a file name drafts2.

Figure 16.70a Surface Figure 16.70b Toolpaths

6Tips 1. Open the draft surface model drafts2.

2. Use the Swarf5ax function to generate toolpaths.

3. Use a ½� end mill.

4. Backplot the toolpaths to verify on the screen.

Step 1. Open the draft surface model drafts2.Select MAIN MENU à File à GetFile name: drafts2The draft surface appears as in Figure 16.71.

Figure 16.71

Step 2. Initiate the Swarf5ax function.Select MAIN MENU à Toolpaths à Multiaxis à Swarf5axFile name for toolpath: swarfsSelect Plane à z = constEnter z-coordinate of plane = -1Select Slct walls, then pick the surface

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Set the parameters as below:

Wire/surf = SOpen pock = NStep cmr = NFan wall = YRadius = 0.55Fan distance = 0.2

Select Do itSet the 5-axis Swarf parameters as below.

Screen � step 2

Step 3. Define the NC parameters.Select the NC buttonSet the NC parameters as below.

Screen � step 3

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Figure 16.72

Step 4. Backplot the toolpath.Select MAIN MENU à NC utils à BackplotSelect Yes to �Operations have been modified. Create the NCI text file?�Select Run to verify the toolpaths on the screen

16.12 Flowline 5-Axis Function

The Flowline 5-axis function generates 5-axis toolpaths for cutting a surface model (Figure16.73). This function can produce very precise and smooth finish with accurate control of the scallopheight left on the part. The flowline parameter dialog box appears as below.

Figure 16.73

Screen � flowline parameter dialog box

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: Project 10. Generating 5-axis flowline toolpathsThis project uses the 5-axis flowline function to generate 5-axis toolpaths to cut three surfaces

in the pocket of the car wheel model. These three surfaces include two fillet surfaces and one sweptsurface. Figure 16.74 shows the surface model and flowline toolpaths.

Figure 16.74a Surface model Figure 16.74b Toolpaths

6Tips 1. Open the surface model file wheels.

2. Use the flow5ax function to generate toolpaths.

3. Select three surfaces in the concave pocket.

4. Backplot the toolpaths to verify on the screen.

Step 1.Open the surface model file wheels.Select MAIN MENU à File à GetFile name: wheelsThe car wheel surface model appears as Figure 16.75.

Figure 16.75

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Step 2.Initiate the flow5ax function.Use the pick points in Figure 16.75.Select Cplane à TopSelect MAIN MENU à Toolpaths à Multiaxis à Flow5axFile name for toolpath: flow5axPick P1, P2, and P3 to select three surfacesSelect DoneClick the right mouse button, then select Get tool from librarySelect tool number 254 (3/8 sphere end mill)Select OK

Set the tool parameters as below.

Screen � step 2

Step 3.Define the finish parameters.Click �Finish parameters� buttonSet the finish parameters as below.

Screen � step 3

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Step 4.Define the flow5ax parameters.Click �Flow5ax parameters� buttonSet the flow5ax parameters as below.

Screen � step 4

Select OKSelect Do it to generate toolpaths as shown in Figure 16.76.

Figure 16.76

Step 5. Backplot the toolpaths.Select MAIN MENU à NC utils à BackplotSelect Yes to �Operations have been modified. Create the NCI text file?�Select Run to verify the toolpaths on the screen

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16.13 Exercises

1. List the four 5-axis machining functions available in Mastercam.

2. How many axes are defined by the EIA-267-B standard?

3. Use a drawing to explain how to define the three primary rotary axes and their rotation directions.

4. Use a drawing to describe the thumb rule for determining the direction of the rotation.

5. Can the rotary 4-axis function cut multiple surfaces in one operation?

6. Use a drawing to define the lead angle in rotary 4-axis function.

7. When to use curve 5-axis function?

8. List the three options of curve 5-axis function and describe what they are.

9. Describe the difference of two tool types, 3-axis and 5-axis, in curve 5-axis function.

10. Use drawings to describe how the side angle affecting the tool axis orientation.

11. Use drawings to describe how the lead angle affecting the tool axis orientation.

12. List the two stepping methods used in outer edge function and describe what they are.

13. Use a drawing to describe the working principle of the chain curves function.

14. What are the two methods of projecting chained entities onto the surface(s)?

15. List the two methods for specifying the location and direction of the drilling in drill 5-axis function.

16. What are the main features of swarf 5-axis function?

17. List the two methods of specifying the toolpath floor in using swarf 5-axis function.

18. What is the flowline 5-axis function?

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