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Handbook Volume 2
Notice
In-House Solutions Inc. reserves the right to make improvements to this manual at any time and without
notice.
Disclaimer Of All Warranties And Liability
In-House Solutions Inc. makes no warranties, either express or implied, with respect to this manual or
with respect to the software described in this manual, its quality, performance, merchantability, or
fitness for any particular purpose. In-House Solutions Inc. manual is sold or licensed "as is." The entire risk
as to its quality and performance is with the buyer. Should the manual prove defective following its
purchase, the buyer (and not In-House Solutions Inc., its distributer, or its retailer) assumes the entire
cost of all necessary servicing, repair, of correction and any incidental or consequential damages. In no
event will In-House Solutions Inc. be liable for direct, indirect, or consequential damages resulting from
any defect in the manual, even if In-House Solutions Inc. has been advised of the possibility of such
damages. Some jurisdictions do not allow the exclusion or limitation of implied warranties or liability for
incidental or consequential damages, so the above limitation or exclusion may not apply to you.
Copyrights
This manual is protected under International copyright laws. All rights are reserved. This document may
not, in whole or part, be copied, photographed, reproduced, translated or reduced to any electronic
medium or machine readable form without prior consent, in writing, from In-House Solutions Inc.
Trademarks
Mastercam is a registered trademark of CNC Software, Inc.
Microsoft, the Microsoft logo, MS, and MS-DOS are registered trademarks of Microsoft Corporation;
Windows 7 and Windows 8 are registered trademarks of Microsoft Corporation.
This document requires Mastercam Mill Essentials.
Table of Contents
Legend ........................................................................................................................ 1
Chapters
Introduction To 3D Workspace .............................................................................................................. 3
Splines ..................................................................................................................................................27
Surface Modeling .................................................................................................................................57
Surface Rough Machining ..................................................................................................................117
Surface Finish Machining ...................................................................................................................193
Surface High Speed Machining ..........................................................................................................237
Mold Project ......................................................................................................................................283
Prototype Project ..............................................................................................................................297
Handbook Volume 2
Handbook Volume 2
LEGEND
Legend
Conventions
Key words and Mastercam menu items are shown in bold the first time they are used. Columns on the outside
edges of each page and note pages at the end of each chapter provide ample space for taking notes.
Useful tips, recommended settings, best practices, and detailed instruction on the most important features are
included when possible.
An accompanying CD ROM contains files needed to complete all exercises in this handbook.
The following terms are used throughout this book.
Handbook Volume 2
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LEGEND
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Handbook Volume 2
Introduction To 3D Workspace
CHAPTER 11
Introduction To 3D Workspace
OBJECTIVES
This chapter introduces the 3D Cartesian coordinate system and how to create and manipulate 3D wireframe
drawings.
Upon completion of this chapter, you should able to do the following:
INTRODUCTION
Surface modeling and machining requires the ability to visualize parts in three dimensions. You must also be able
to visualize the entire machining process from start to finish. How will the part be held while being machined?
What it will look like as it goes from one machining operation to the next? This spatial ability is, to some degree,
a natural talent, but it can be developed with training and experience.
You must also be able to work efficiently and accurately in the Mastercam 3D workspace. This includes being
able to create wireframe, surface, and solid entities, and to define and manipulate views and 2D work planes
within this space. You have to be able to move the part between any two points in space and rotate it precisely
about any axis.
This chapter provides the basic knowledge and skills you will need to accomplish all of these tasks. Study the
information and examples in this chapter carefully. They form the foundation that will help you work with
speed, confidence, and precision.
Handbook Volume 2
Page |3
CHAPTER 11
Introduction To 3D Workspace
MASTERCAM WORKSPACE
An illustration of the Mastercam workspace is shown below. Because this workspace is dynamic and
customizable, your screen may appear somewhat different from that shown.
For instructional purposes, this example shows notes and interface components that are not normally displayed
together. For example, the Screen Grid and RMB menus are active, and Drop Down/Fly Out menus are shown
offset from their normal position for clarity.
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Handbook Volume 2
Introduction To 3D Workspace
Item
Product ID
Window Control
Menu
Ribbon Bar
Toolbars
Drop Down Menu
CHAPTER 11
Definition
Name of the active Mastercam application.
Minimize, Restore Down or Close Mastercam.
The Menu allows you to select all Mastercam functions from a list of words
across the top of the workspace. These words open drop down/fly out menus.
Controls values and relations of geometric entities.
Groups of related functions, displayed as Icons. Icons are picture
representations of functions.
Menus that expand downward.
Graphic Area
Area where geometry and toolpaths are created, edited and displayed.
Origin
Mouse Cursor
RMB
X/Y Axes
Function Prompt
Status Bar
Viewport Axes
Prompt Line
View/Plane Information
Toolpaths/Solids Manager
Keyboard Command
MRU Toolbar
Dialog Box
Intersection of X, Y, Z axes.
Shows mouse location. Appears as a cross hair over the graphic area and as
arrow when over a menu item.
Right Mouse Button. Clicking on Right Mouse Button with cursor in the
graphics area opens the RMB menu.
This is how the screen appears with the Selection Grid on. Dashed lines show
the axes orientation.
Prompts for user input.
Sets default geometry and system attributes.
Shows orientation of the view in relation to the global coordinate system.
Provide information and prompts for next expected action.
Information regarding the units (Inch or Metric), active view, planes and WCS
(Work Coordinate System).
History manager for toolpath operations and solids bodies.
Not shown. Keyboard Function keys [F1-F12] and other key combinations can
be assigned to options.
List of the most recently used functions.
A window that opens to allow input of information and setting options. Dialog
boxes are tailored for specific functions and often feature descriptive graphics
to simplify user input.
Handbook Volume 2
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CHAPTER 11
Introduction To 3D Workspace
Any point in this workspace is precisely defined given its axes label, sign, and value. For example, the point "X3,
Y2, Z4" is located by counting, from the Origin, three units along the X+ axis, then up two units parallel to the
Y+ axis, and then up four units parallel to the Z+ axis.
3D Cartesian coordinates may be written two different ways. One way uses the axis label, sign and value. For
example: X3, Y2, Z4.
The other writes coordinates as an ordered pair. Numbers are written in a specific order (X, Y, Z) separated by
commas. For example: 3, 2, and 4.
Within the Mastercam coordinate system, any number of Construction Planes (Cplanes) can exist. A Cplane is a
flat working plane that can be located in any position or orientation in the Mastercam coordinate system.
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Handbook Volume 2
Introduction To 3D Workspace
CHAPTER 11
Screen Grid (Alt-G) shows the position and orientation of the active Cplane.
Handbook Volume 2
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CHAPTER 11
Introduction To 3D Workspace
Arcs and 2D Splines are 2D entities and must exist on a Cplane. If needed, Mastercam will automatically create
Cplanes to support these entities.
For example, if an arc is rotated such that it is not parallel to an existing Cplane, Mastercam will create one for
it. These Cplanes are assigned a number (8, 9, 10, etc.) or can be given a name.
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Handbook Volume 2
Introduction To 3D Workspace
CHAPTER 11
By default, Z: 0.0. This means geometry is created on the active Cplane. To change the construction depth, do
any of the following:
Enter the value in the field next to the Z: setting. Positive values move the construction depth above the
active Cplane. Negative values move it below the active Cplane.
Pick a previously entered value from the Z: drop down list.
Click on Z: to pick a Z-value from screen geometry.
Right click on Z: and use the menu.
Handbook Volume 2
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CHAPTER 11
Introduction To 3D Workspace
Construction Depth
Practice how construction depth works by completing the following example:
Start with the part, GussetPlate.MCX-9 which is included on your student CD. Extrude the 2D profile to create a
3D wireframe model using the Xform, Translate, Join function and setting Z: -0.5.
Add the rectangular shape at the bottom of the part as follows:
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Handbook Volume 2
Introduction To 3D Workspace
CHAPTER 11
After Step 6: above, you may want to create a diagonal line across the face. This allows you to place the arc at
the center of the face by picking the midpoint of the diagonal line. This construction geometry can be deleted
after all arcs are drawn.
Handbook Volume 2
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CHAPTER 11
Introduction To 3D Workspace
2D Mode:
Wireframe geometry is created on the active Cplane.
Z-values are set by the Z: setting on the Status Bar.
Z-value input selections from the mouse are ignored.
3D Mode:
Z-values in the Z: settings on the Status Bar are ignored.
Z-value inputs are retrieved from geometric features selected by the mouse.
Practice using the 3D drawing mode by completing the following example:
Create a one-inch cube. Then draw lines between endpoints and midpoints in a zigzag pattern as shown. Try this
using the 3D mode and then the 2D mode to see how the two methods differ.
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Handbook Volume 2
Introduction To 3D Workspace
CHAPTER 11
Two Lines.
Flat Entity.
Rotate.
Normal.
Handbook Volume 2
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CHAPTER 11
Introduction To 3D Workspace
Creating Cplanes
Create a Cplane by selecting the Planes menu from the Status Bar.
Item
Named Planes
Definition
Select a named Cplane.
Planes By Geometry
Define a Cplane by selecting a flat entity, two lines, or three points. A Flat
Entity is an arc, 2D spline, Flat surface or flat solid face.
Dynamic Planes
Use the Dynamic Plane to create a plane through the use of an interactive
gnomon in the graphic window.
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Handbook Volume 2
Introduction To 3D Workspace
CHAPTER 11
Cplane 2 Lines
Any two lines that intersect can define a Cplane. Ideally, the lines intersect at a 90-degree angle and share an
endpoint. This is a preferred way to define Cplanes since it is easy to set the orientation, origin, and axes
directions based on how the entities are selected.
Step 3: Observe the axes indicator. Use the arrows to toggle through the possible solutions until you see the
one you want and then click on the green checkmark.
Step 4: By default, the new Cplane is assigned a number. Name the Cplane by entering it in the Name field.
The origin of the new plane is where the two lines intersect. Shift the origin by clicking on the arrow below
the origin field and then picking a point on the part.
Handbook Volume 2
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CHAPTER 11
Introduction To 3D Workspace
Flat Entity
This option is easy to use, but it is more difficult to control the Cplane X-Y axes direction. Simply click on a flat
entity to set the new plane Z-axis normal (piercing at 90 degree angle all-around) to the flat entity. A flat entity is
a:
Arc.
2D Spline.
Flat Surface.
Flat Solid Face.
Item
Arc
Definition
An arc must exist on a plane. This method sets the new plane Z-axis normal to
this plane.
2D Spline
2D splines lie on a plane. Certain geometric shapes, such as an ellipse and some
arcs, are modeled using 2D splines.
Flat Surface
A flat surface has an infinite radius of curvature. Check the radius of curvature
using Analyze, Dynamic.
Solid Face
Page |16
Any flat face on a Solid can be used to set a Cplane similar to the Flat Surface
method.
Handbook Volume 2
Introduction To 3D Workspace
CHAPTER 11
Rotate Plane
Rotate defines a new Cplane by rotating the active Cplane about its X, Y, or Z-axis.
Step 1: Select an existing plane (the reference plane to be rotated to create the new plane).
Step 2: Select Cplane, Rotate from the Status Bar.
Step 3: Enter the rotation angle in the appropriate field. In the example, the reference plane is rotated +15
degrees about the X - axis.
Handbook Volume 2
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CHAPTER 11
Introduction To 3D Workspace
Normal Line
A Normal line is a line that pierces an entity at 90 degrees all-around. Click on a line to set the
Z-axis of the new Cplane along the line.
After picking the Normal line, you will be prompted to select another entity to define the new plane X-axis.
Choose <Enter> to skip this option.
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Handbook Volume 2
Introduction To 3D Workspace
CHAPTER 11
Translate 3D
Translate 3D is used to move geometry from one Cplane to another. It both moves the part along all three axes
and rotates about them to easily and accurately move the part from one location and orientation in the
coordinate system to another.
For example, an imported CAD model may need to be moved and reoriented for machining. Translate 3D
performs all rotations and transformations needed to align and orient the part in one step.
To use Translate 3D, you need to know four things:
Handbook Volume 2
Page |19
CHAPTER 11
Introduction To 3D Workspace
Item
Select Geometry
Source Plane
Destination Plane
From Point
To Point
Definition
Pick geometry to move.
Reference plane for move. Brings up plane selection.
Plane to move to.
Reference (handle) point to move from.
Point to move to.
Follow the steps below to move and reorient the part Translate3D.MCX-9.
Step 1: Create a Cplane using the Geometry option and picking two lines as shown by (1) and (2)
in the illustration below. Give this plane a name (example: From Plane).
Step 2: Select Translate 3D from the Xform menu or Transform toolbar. Click on the Select Geometry
button and pick the geometry to translate.
Step 3: Set the source plane by clicking on the Source Plane icon and picking the plane defined in Step 1
above.
Step 4: Set the Destination Plane to Top.
Step 5: Make sure you are in the 3D Drawing Mode, and pick the Move to Origin from the Xform menu.
Step 6: Pick the From Point as shown and the part will be moved to the origin.
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Handbook Volume 2
Introduction To 3D Workspace
CHAPTER 11
Handbook Volume 2
Page |21
CHAPTER 11
Introduction To 3D Workspace
Exercise 1-1: 5 x 5 x 5
Draw and Dimension the drawing.
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Handbook Volume 2
Introduction To 3D Workspace
CHAPTER 11
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CHAPTER 11
Introduction To 3D Workspace
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Handbook Volume 2
Introduction To 3D Workspace
CHAPTER 11
Handbook Volume 2
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CHAPTER 11
Introduction To 3D Workspace
NOTES:
Page |26
Handbook Volume 2
INDEX
Numerics
2 Surface Blend ............................................. 107
3 Fillet Blend ................................................. 111
3 Surface Blend ............................................. 109
3D Contour Toolpath ...................................... 47
3D Cutter Compensation ................................ 46
3D Mode ......................................................... 12
3D splines ....................................................... 45
A
Advanced Settings ........................................ 151
Analyze Test Surfaces ................................... 127
Automatic Spline ............................................ 33
B
Ball Nose Mil ................................................. 118
Blended spline ................................................ 36
Boss ............................................................... 118
Break many places .......................................... 40
Bull Nose ....................................................... 118
C
cad geometry types ........................................ 58
Cavity ............................................................ 118
Check Surfaces .............................................. 118
Chordal Deviation ......................................... 118
Chordal deviation ........................................... 34
Climb vs. Conventional Machining ............... 142
Construction Depth (Z
9
Continuity ....................................................... 30
Core .............................................................. 118
Cplane 2 Lines ................................................. 15
Cplanes ............................................................. 8
Create Automatic Spline ................................. 31
Create Blended Spline .................................... 31
Create Curves Spline ....................................... 31
Create Manual Spline ..................................... 31
Curve ............................................................... 27
Curves Spline .................................................. 34
Cut Depths .................................................... 146
Cut Tolerance ................................................ 118
Cutting Methods ........................................... 154
Cutting Speeds & Feeds ................................ 122
D
Dialog Box ......................................................... 5
Direction ....................................................... 159
Draft .............................................................. 118
Draft surface ................................................... 69
Drive Curves .................................................... 60
E
Entry Options ................................................ 143
Extruded Surface ............................................ 71
F
Facing ............................................................ 145
Fence Surface ................................................. 77
Fill holes .......................................................... 95
Fillet Surface ................................................... 98
Fillet Surfaces To Surfaces .............................. 98
Fillet to curves .............................................. 106
Fillet To Plane ............................................... 105
Filter ................................................................ 43
Flat Boundary Surfaces ................................... 93
Flat Endmill ................................................... 118
Flat Entity ........................................................ 16
Flats .............................................................. 166
Flowline Data ................................................ 175
Fly Out Menu .................................................... 5
Function Prompt ............................................... 5
G
Gap Settings .................................................. 149
Graphic Area ..................................................... 5
H
Helix Parameters .......................................... 163
High Speed Machining .................................. 118
High Speed Parameters ................................ 156
K
Keyboard Command ......................................... 5
L
Last Planes ...................................................... 14
Lathe Radius Lathe Diameter .......................... 14
Lofted Surface ................................................. 65
M
Menu ................................................................ 5
Modify spline .................................................. 37
Mouse Cursor ................................................... 5
MRU Toolbar ..................................................... 5
N
Named Views .................................................. 14
Net Surface ..................................................... 80
Normal Line .................................................... 18
Nurbs Splines .................................................. 29
Handbook Volume 2
Page|299
INDEX
O
Offset Surface ................................................. 97
Origin ................................................................ 5
P
Parametric Splines .......................................... 28
Planes = Gview ................................................ 14
Planes = WCS .................................................. 14
Planes Always = WCS ...................................... 14
Planes By Geometry ....................................... 14
Planes By Normal ............................................ 14
Planes By Solid Face ........................................ 14
Plunge Control .............................................. 170
Pocket Parameters ....................................... 152
Product ID ......................................................... 5
Prompt Line ...................................................... 5
R
Refine Toopath ............................................. 140
Remove Bounday ............................................ 94
Revolved Surface ............................................ 66
Ribbon Bar ........................................................ 5
Right Hand Rule .............................................. 18
RMB .................................................................. 5
Rotate Planes .................................................. 14
Rough Contour ......................................131, 157
Rough Contour Parameters .......................... 161
Rough Flowline .....................................131, 174
Rough Parallel .......................................131, 167
Rough Parallel Parameters ........................... 168
Rough Plunge ................................................ 131
Rough Pocket ........................................131, 137
Rough Project ............................................... 131
Rough Radial .........................................131, 171
Rough Restmill .............................................. 131
Ruled Surface .................................................. 62
Runoff Surface .............................................. 118
T
Tapered End Mill ........................................... 118
Tip Comp ....................................................... 119
Tool Center Boundary ................................... 119
Tool Parameters ........................................... 133
Tool Selection ............................................... 120
Tool Tip Compensation ................................. 123
Toolbars ............................................................ 5
Toolpath/Surface Selection .......................... 132
Toolpaths/Solids Manager ................................ 5
Translate 3D .................................................... 19
Translucent ..................................................... 60
Trim Surfaces To A Plane ................................ 89
Trim Surfaces To Curves ................................. 86
Trim Surfaces To Surfaces ............................... 91
Trimmed Surfaces ........................................... 84
troubleshooting splines .................................. 41
U
Un-Trim Surfaces ............................................ 93
User Defined Cplanes ..................................... 13
UV Curves ....................................................... 60
UV curves ........................................................ 59
V
Variable Fillet Indicators ............................... 102
View/Plane Information ................................... 5
Viewport Axes ................................................... 5
Page |300
X
X/Y Axes ............................................................ 5
Handbook Volume 2
Handbook Volume 2