Truongmill Lesson 13

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TRAINING
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GUIDE
MILL-LESSON-13
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ROUGH PLUNGE, FINISH CONTOUR

& FINISH SHALLOW TOOLPATHS
www.mastercam.webs.com and cokhitruong.webs.com
Objectives
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Mastercam Training Guide
You will create the geometry for Mill-Lesson-13, and then generate the toolpaths to machine the
part on a CNC vertical milling machine. This Lesson covers the following topics:
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Establish Stock Setup settings:

Stock size using Bounding Box.
Material for the part.
Feed calculation.
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Create a 3-dimensional drawing by:

Creating lines.
Creating arcs.
Trimming geometry.
Creating a ruled surface.
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Generate a 3-dimensional milling toolpath consisting of:

Surface rough plunge Toolpath.
Surface finish contour Toolpath.
Surface finish shallow Toolpath.
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Inspect the toolpath using Mastercams Verify and Backplot by:

Launching the Verify function to machine the part on the screen.
Generating the NC- code.
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TRAINING
GUIDE
Mill-Lesson-13 Page - 1
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Mill-Lesson-13
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MILL-LESSON-13 DRAWING
TOOL LIST
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0.500 diameter flat end mill to rough machine.

0.500 diameter ball end mill to finish machine.
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MILL-LESSON-13 - THE PROCESS

Geometry Creation
Setting the environment

Create geometry for bottom of pocket
Create geometry for top of pocket
Trim geometry top of pocket
Create geometry material blank 4.625 x 2.5 x 1.0
Translate geometry to bottom of pocket
Create the ruled surface
Create the flat boundary surface bottom of pocket
Create the surface fillet at bottom of pocket
Save the drawing
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TASK 1:
TASK 2:
TASK 3:
TASK 4:
TASK 5:
TASK 6:
TASK 7:
TASK 8:
TASK 9:
TASK 10:
Toolpath Creation
TASK 11:
TASK 12:
TASK 13:
TASK 14:
TASK 15:
TASK 16:
TASK 17:
Define the rough stock using stock setup

Rough out surface using surface rough plunge
Finish using surface finish contour
Finish bottom surface using finish shallow toolpath
Verify the toolpath
Save the updated MCX file
Post and create the CNC code file
Mill-Lesson-13
TASK 1:
SETTING THE ENVIRONMENT
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Before starting the geometry creation you should set up the grid, toolbars and machine type as
outlined in the Setting the environment section at the beginning of this text:
1. Set up the Grid. This will help identify the location of the origin.
2. Customize the toolbars to machine a 3D part.
3. Set the machine type to a Haas Vertical Spindle CNC machine.
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TASK 2:
CREATE GEOMETRY FOR BOTTOM OF POCKET
X0 Y0 CENTER OF PART Z0 TOP OF PART
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The top of the material is at Z 0. The material has been previously machined to size: 4.625
x 2.5 x 1.0.
Later in this lesson you will use Xform Translate to translate the bottom of the pocket
geometry down to a Z level of -0.5.
Create bottom of pocket section
1. Use Alt-O to hide the Operations Manager pane.
2. Select from the pull down menu Create>Rectangular Shapes
3. The Rectangular Shapes Options dialog box appears and you are prompted to Select
position of base point.
4. Set the following values shown below left:
5. Now you need to Select position of base point. Move the

cursor over to the graphics screen and position the cursor at
the center of the grid and pick the origin.
6. Click on the OK icon

to complete this feature.
7. Change the graphics view to Isometric.
8. Now select the Fit to screen icon.
The completed geometry is shown below:
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TASK 3:
CREATE GEOMETRY FOR TOP OF POCKET
1. Select from the pull down menu Create>Rectangle

2. Click in the space for Width and enter a value of 3.25 and then hit the tab key. In the space
for Height enter a value of 1.75 and hit enter.
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3. Activate the Anchor to center icon as shown above:

4. Now you need to Select position of base point. Move the cursor over to the graphics
screen and position the cursor at the center of the grid and pick the origin.
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Create Circle #1 & #2

6. Change the graphics view to Top.
7. Now select the Fit to screen icon and then Un-zoom .8.
8. Select Create>Arc>Circle Center Point
9. Enter .375 for the radius and hit enter .
10. To satisfy the prompt Enter the center point move the cursor over the midpoint of the line
shown below left. Ensure the visual cue for midpoint is being displayed and click on this
point.
11. Click on Apply
to fix the entity.
Mill-Lesson-13
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12. On the circle ribbon bar enter .375 for the radius and hit enter.
13. To satisfy the prompt Enter the center point move the cursor over the midpoint of the line
shown below left. Ensure the visual cue for midpoint is being displayed and click on this
point.
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Create Line #1,2,3 & 4

Create Line #1
15. Now select the Fit to screen icon and then Un-zoom .8.
16. Select from the pull down menu: Create>Line>Endpoint
17. First click in the space for Length and enter a value of 1.0 and then hit the tab key. In the
space for Angle enter a value of 45 and hit enter.
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18. On the graphics screen you are prompted: Specify the first endpoint and the Line ribbon
bar appears. Note that the Tangent function is activated.
19. To satisfy the prompt Specify the first endpoint move the cursor over the area of the circle
shown below left. Ensure there is no visual cue being displayed and click on this point.
After selecting the circle you will be prompted to Select the line pick the line shown below:
20. Click on Apply
to fix the entity.
Create Line #2
21. Click on the icon for Length to lock this 1.0 value and in the space for Angle enter a value
of -45 and hit enter.
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23. Click on Apply
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to fix the entity.
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Create Line #3
24. In the space for Angle enter a value of 45 and hit enter.
26. Click on Apply
to fix the entity.
Create Line #4
27. In the space for Angle enter a value of 90+45 and hit enter.
Mill-Lesson-13
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Create Fillets
30. Select Create>Fillet>Entities
31. On the Fillet ribbon bar enter .375 for the radius. Ensure the Style of radius is set to
normal and the trim button is depressed to turn the trim on.
32. When prompted to Fillet: Select an entity, select entity 1 and 2 as shown below. To
complete the remaining fillet select: entities 3 and 4, entities 4 and 5. entities 6 and 1. The
completed geometry is shown below right:
TASK 4:
TRIM GEOMETRY TOP OF POCKET
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In this task you will first delete two lines and then trim the geometry using Divide / Delete.
1. Delete the two lines shown below by clicking on the lines and hitting the delete key on the
keyboard.
2. Select Edit>Trim/Break>Trim/Break/Extend
3. The Trim / Extend / Break ribbon bar appears and you are prompted to Select the entity to
trim/extend.
icon to activate it as shown above. Ensure the icon is

4. Click on the Divide / Delete
pressed down to signal that it is activated.
5. The prompt changes to Select the curve to divide / delete. Move the cursor over the
various entities and select in order and position as shown below left:

TASK 5:
CREATE GEOMETRY MATERIAL BLANK 4.625 X 2.5 X 1.0
1. Select from the pull down menu Create>Rectangle
2. Click in the space for Width and enter a value of 4.625 and then hit the tab key. In the
space for Height enter a value of 2.5 and hit enter. Anchor to center should be activated.
3. Now you need to Select position of base point. Move the cursor over to the graphics
screen and position the cursor at the center of the grid and pick the origin.
5. Change the graphics view to Isometric.
The completed rectangle is shown below:
Create the 3D box to represent the material blank

7. Select from the pull down menu Xform>Translate
8. You are now prompted to Translate: select entities to translate. Hold the shift key down
and select one of the lines of the rectangle you just created. This process then selects all
four lines.
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Mill-Lesson-13
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9. Pick the End Selection icon
10. Set the following values shown below left. Ensure Join is activated:

to complete this feature. The completed geometry is shown
above.
12. Click on the Clear Colors at the top right hand corner of the screen.
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TASK 6:
TRANSLATE GEOMETRY TO BOTTOM OF POCKET
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Translate the geometry at Z0 down to Z-0.5

1. Select from the pull down menu Xform>Translate
2. You are now prompted to Translate: select entities to translate. Hold the shift key down
and select the line shown below. This process then selects the complete chain.
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3. Pick the End Selection icon
4. Set the following values shown below left. Ensure Move is activated, deselect Fit:

to complete this feature. The completed geometry is shown
above.
6. Click on the Clear Colors at the top right hand corner of the screen.
7. Fit to Screen.
TASK 7:
CREATE THE RULED SURFACE
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Mill-Lesson-13
In this task you will create a ruled surface using the geometry you have just created.
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Create Ruled Surface

Select from the pull down menu: Create>Surface>Ruled/Lofted
On the graphics screen you are prompted: Lofted surface: define contour 1.
Select in order, contour 1 and 2 as shown below. Note: When you select contours 1 and 2
ensure the arrow is pointing to the right for both contours. If not use the Reverse button in
the chaining dialog box.
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1.
2.
3.
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in the Chaining dialog window.
5. Ensure the Ruled icon is activated as shown below:
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below:
to complete this feature. The completed ruled surface is shown

TASK 8:
CREATE THE FLAT BOUNDARY SURFACE BOTTOM OF POCKET
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Create Surface at bottom of pocket

Select from the pull down menu: Create>Surface>Flat Boundary
In the Chaining dialog box set to Chain.
On the graphics screen you are prompted: Select chains to define flat boundary 1. Select
the chain by selecting the line shown below:
1.
2.
3.
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in the Chaining dialog window.
5. Click on the OK icon to complete this feature. The completed boundary surface is shown
below:
Mill-Lesson-13
TASK 9:
CREATE THE SURFACE FILLET AT BOTTOM OF POCKET
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1. Select from the pull down menu: Create>Surface>Fillet >To Surfaces

2. On the graphics screen you are prompted: Select first set of surfaces and press <enter>
to continue. Select the first surface (Ruled surface) as shown below and then hit enter.
3. Next you are prompted: Select second set of surfaces and press <enter> to continue.
Select the second surface (Flat boundary surface) as shown below and then hit enter.
4. The Fillet Surfaces to Surfaces dialog box appears set the radius to 0.25 and other values
set the values as shown below:
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as shown below left. Click on the options button

to exit Options and then exit Fillet Surfaces to Surfaces.
The completed Fillet surface is shown above:
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TASK 10:
SAVE THE DRAWING
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3.
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Select File.
Select Save as.
In the File name box, ensure Mill-Lesson-13 is the name of the file to be saved.
Save to an appropriate location.
to save the file and complete this function.
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5. Select the green check mark button
Toolpath Creation
TASK 11:
DEFINE THE ROUGH STOCK USING STOCK SETUP
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1. Select the plus in front of Properties to expand the Toolpaths Group Properties. Alt-O will
Show/hide Operations Manager pane.
2. Select Stock setup in the toolpath manager window.
3. Select the Bounding box button.
4. Set the parameters to match the Bounding Box screenshot below:
5. Select the OK button
again to complete this function.

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Mill-Lesson-13
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6. Bounding box calculates the sizes and is then input into the X, Y and Z values. The top of
the material is at Z 0. The material has been pre-machined to size. The parameters have
been set by the bounding box feature as shown below:
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7. Select the Tool Settings tab and change the parameters to match the Tool Settings
screenshot below. To change the Material type follow the instructions below:
8. To change the Material type to Aluminium

6061 pick the Select button at the bottom
of the Tool Settings page.
9. At the Material List dialog box open the
Source drop down list and select Mill
library.
10. From the Default Materials list select
ALUMINIUM inch -6061 and then select
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again to complete this function.

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Your part should look similar to the screen shot below. With X0 Y0 at the center and Z zero
on top of the stock.
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TASK 12:
ROUGH OUT SURFACE USING SURFACE ROUGH PLUNGE
In this task you will use a 0.5 diameter center cutting flat end mill to rough the pocket.
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Rough Plunge Toolpaths machine surfaces quickly with a drilling-type motion. One application
for rough plunge is to clean out a deep cavity using special plunge milling tools often with
through-tool coolant to help evacuate chips.
Rough plunge can project a toolpath onto the drive geometry and create plunge points in that
pattern. Selecting NCI requires that you have the pattern operation already present in the file.
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In this task you will first create a 2D pocket to provide the pattern for the rough plunge toolpath.
This 2D toolpath will only be used as a pattern it will not be used to machine the part.
1. From the menu bar select Toolpaths>Pocket
2. When prompted to Enter new NC name ensure Mill-LESSON-13 is entered and then select
the OK button
.
3. On the screen you will now see the Chaining dialog box with Chain set. Activate the radio
button for C-Plane.
Cplane: Chains only entities that are parallel to the current construction plane and at the same
Z depth as the first entity you chain.
Mill-Lesson-13
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4. For the prompt to Select Pocket chain 1. Select the line as shown below:
5. After selecting the line your graphics screen should look like the screenshot above, with the
green arrow pointing to the right.
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6. After the pocket has been successfully chained select the OK button
at the bottom of
the Chaining dialog box.
7. Selct Tool from the list on the let. In the lower left corner of the Tool parameters page select
the Select library tool button.
8. Use the slider bar on the right of this dialog box to scroll down and locate a 0.5 diameter
flat end mill. Select the 0.5 diameter flat end mill by picking anywhere along the 0.5 end
mill row, as shown below:
to complete the selection of this tool.

10. Make changes to the Toolpath parameters page as shown below.
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11. Select the Cut Parameters>Roughing parameters page and make changes to this page as
shown:
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Mill-Lesson-13
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12. Select the plus sign to the left of Roughing from the list on the left and then select Entry
Motion. On the Entry Motion parameters page turn the entry motion off.
13. Select the Cut Parameters>Finishing parameters page and uncheck finishing.
to exit Pocket parameters.
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Rough Plunge Toolpath

15. From the menu bar select Toolpaths>Surface Rough>Plunge
16. You are first prompted to Select Drive surfaces, select the All button on the General
Selection ribbon bar as shown below:
17. The Select All dialog box appears on the screen. Click on the OK icon
and exit this feature.
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18. To move onto the next step you now need to pick the End Selection icon
to complete
.
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to exit the Toolpath/surface selection dialog box.

20. Select the 0.5 diameter end mill and make changes to the Toolpath parameters page as
shown below. Set coolant on.
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21. Select the Surface parameters page and make changes to this page as shown below:
Stock to leave on drive is set to 0.050.
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22. Select the Rough plunge parameters page and make changes to this page as shown
below. Ensure NCI is activated and the Pocket is selected in the Source operations.
Mill-Lesson-13
23. Select the Cut depths button make the necessary changes. Note: both depths are negative
values.
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to exit Rough plunge parameters.

26. Verify the new toolpath operation.
27. Your screen should look similar to the image below.

TASK 13:
FINISH USING SURFACE FINISH CONTOUR
In this task you will use a 0.5 diameter ball end mill to finish the pocket.
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1. In the Toolpath Manager pick all the operations by picking the Select All icon
then select the Toggle toolpath display on selected operations to hide the toolpaths.
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2. From the menu bar select Toolpaths>Surface Finish>Contour

4. The Select All dialog box appears on the left of the screen. Click on the OK icon
complete and exit this feature.
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6. Click on the Containment button on the Toolpath/surface selection dialog box. In the
chaining dialog box activate C-plane and then select the line shown below to chain the top
of the pocket.
to exit the chaining dialog box.

Mill-Lesson-13
in the Toolpath/surface selection dialog box.
8. Select the OK icon
9. In the lower left corner of the Toolpath parameters page select the Select library tool
button.
10. Use the Filter function to filter out a selection of cutters. Select the Filter button on the right
side of the Tool selection dialog box.
11. Select the None button in the Tool Types section.
12. Click on the Endmill2 Sphere type icon, first row, and second icon from the left.
13. Select the drop down arrow in the Tool diameter field and set it to Equal. Input the tool
diameter as 0.5.
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to complete the selection of this tool.
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to exit.
15. Select the 0.5 ball end mill.
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17. Make changes to the Toolpath parameters page as shown below:
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Mill-Lesson-13
19. Next on the Finish contour parameters page make changes to this page as shown below:
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to exit Finish contour parameters.
21. Verify the toolpaths.
22. Your screen should look similar to the image below.
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This last toolpath did not machine the bottom surface of the pocket.
Rough and Finish contour toolpaths make multiple cuts using constant Z steps. Rough and
finish contour can be used for parts with steep bosses.
To finish machine the bottom surface you will use Surface finish shallow toolpath.
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TASK 14:
FINISH BOTTOM SURFACE USING FINISH SHALLOW TOOLPATH
A finish shallow toolpath removes material from surfaces that fall between two slope angles.
In this task you will use a 0.5 diameter ball end mill to finish the bottom of the pocket.
and then
select the Toggle toolpath display on selected operations twice to hide the toolpaths.
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2. From the menu bar select Toolpaths>Surface Finish>Shallow

4. The Select All dialog box appears on the left of the screen. Click on the OK icon
complete and exit this feature.
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6. Click on the Containment button on the Toolpath/surface selection dialog box. In the
chaining dialog box activate C-plane and then select the line shown below to chain the top
of the pocket.

8. Select the OK icon
to exit the chaining dialog box.

in the Toolpath/surface selection dialog box.
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9. Select the 0.5 ball end mill.

10. Make changes to the Toolpath parameters page as shown below:
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Mill-Lesson-13
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Change the Tool Containment to Inside.
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12. Next on the Finish shallow parameters page make changes to this page as shown below:
to exit Finish shallow parameters.
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Mill-Lesson-13
TASK 15:
VERIFY THE TOOLPATH
and
then select the Toggle toolpath display on selected operations to display the toolpaths.
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2. Select the Verify selected operations button circled below:
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3. Select the Turbo button. Turbo displays no tool. This is generally the fastest option.
4. Adjust the Verify speed to maximum on the speed control bar.
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5. Select the machine button to verify the toolpaths.
to exit Verify.
TASK 17:
POST AND CREATE THE CNC CODE FILE
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1. Select the save icon from the toolbar
TASK 16:
SAVE THE UPDATED MCX FILE
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1. You only need to post operations 2 through 4, as operation 1 is not part of the machining
operations. To do this pick the second operation folder in the Toolpath manager then hold
the shift key down and select the operation 4 folder. If you do not wish to select operations
for posting manually, you can turn posting off for an operation by selecting the operation,
then selecting the ghost icon above.
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2. Select the Post selected operations button from the Toolpath manager as shown below:
3. In the Post processing window, make the necessary changes as shown below:
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Mill-Lesson-13
to continue.
5. If you did not use the ghost to disable posting and manually selected the operations, you are
warned that Not all operations have been selected for posting, Post all? Select No only
operations 2 through 4 are required.
6. Ensure the same name as your Mastercam part file name is in the NC File name field MillLesson-13.
7. Select the Save button.
8. The CNC code file opens up in the default editor.
9. Select the
This completes Mill-Lesson-13.
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in the top right corner to exit the CNC editor.
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MILL-LESSON-13 EXERCISE
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GUIDE
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TRAINING
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Truongmill Lesson 13

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Truongmill Lesson 13

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ROUGH PLUNGE, FINISH CONTOUR

Mastercam Training Guide

Establish Stock Setup settings:

Create a 3-dimensional drawing by:

Generate a 3-dimensional milling toolpath consisting of:

Inspect the toolpath using Mastercams Verify and Backplot by:

www.mastercam.webs.com and cokhitruong.webs.com

0.500 diameter flat end mill to rough machine.

Mastercam Training Guide

MILL-LESSON-13 - THE PROCESS

Setting the environment

Define the rough stock using stock setup

5. Now you need to Select position of base point. Move the

6. Click on the OK icon

Mastercam Training Guide

1. Select from the pull down menu Create>Rectangle

3. Activate the Anchor to center icon as shown above:

5. Click on the OK icon

Create Circle #1 & #2

11. Click on Apply

to fix the entity.

14. Click on the OK icon

to complete this feature.

Create Line #1,2,3 & 4

20. Click on Apply

to fix the entity.

Mastercam Training Guide

23. Click on Apply

to fix the entity.

26. Click on Apply

to fix the entity.

29. Click on the OK icon

to complete this feature.

to complete this feature.

33. Click on the OK icon

icon to activate it as shown above. Ensure the icon is

6. Click on the OK icon

to complete this feature.

Mastercam Training Guide

Create the 3D box to represent the material blank

11. Click on the OK icon

Mastercam Training Guide

Translate the geometry at Z0 down to Z-0.5

5. Click on the OK icon

Create Ruled Surface

4. Click on the OK icon

6. Click on the OK icon

to complete this feature. The completed ruled surface is shown

Mastercam Training Guide

Create Surface at bottom of pocket

4. Click on the OK icon

1. Select from the pull down menu: Create>Surface>Fillet >To Surfaces

as shown below left. Click on the options button

5. Click on the OK icon

Mastercam Training Guide

5. Select the green check mark button

4. Set the parameters to match the Bounding Box screenshot below:

5. Select the OK button

again to complete this function.

8. To change the Material type to Aluminium

11. Select the OK button

again to complete this function.

Mastercam Training Guide

12. Now select the Fit to screen icon.

9. Select the OK button