Mastercam Instructions. KTH School of Architecture Digital Fabrication Lab - CNC Router Version

Transcription

1 Mastercam Instructions KTH School of Architecture Digital Fabrication Lab - CNC Router Version

2 CONTENTS: 1. Setup in Rhino and Mastercam 2. Creating A Drilling Operation 3. Creating A Contour Operation 4. Creating A Surface Rough Operation 5. Creating A Surface Finishing Operation 6. Posting Toolpath Acknowledgements These instructions are based on material developed at dfab of Carnegie Mellon University. 2

3 1 SETUP IN RHINO AND MASTERCAM 1A. Create a 3d model file a) The DFL s preferred modeling program is Rhinoceros. Mastercam will also work with other modeling programs - Maya, 3DS, and Solidwork are all supported. b) We will begin in Rhino. Please prepare your model as much as possible to avoid having to edit any imperfections later on in MasterCam. While this program provides numerous possibilities as a CAD/ CAM gateway, simple tasks such as moving a point from one area to another proves to be very difficult. With time you will begin to understand how this program works, and you will learn to complete these tasks; but for the time being- stick with what you know! Origin Point The origin point in any program should be 0,0,0. This is a screen shot from Rhinoceros. It displays a rectangle with its upper left corner positioned on the origin point. This should also be the case with your model; with it s upper left most point located at the origin. This is very important - all jobs run in the KTH DFL CNC Router should have Top of Stock set to Zero. Levels/ Layers Feel free to create geometries on different layers. Mastercam will convert your layers to levels.- and function very similar. See Figure 1.2a and 1.2b Once you have your file created, save as a.3dm and open Mastercam. 3

4 1B Mastercam a. Once Mastercam is open, we will immediately open your file. File/ Open/ and load your Rhino Model. We may have to hit Enter afterwards to approve a new Machine Group. Before we even begin creating toolpaths, we will first select the equipment that will be used. b. At the top of your screen, please select Machine Type/ Router/Multicam Generic 4x Router MM. Hit Enter to accept a new Machine Group ; and be sure to delete your previous Machine Group. Feel free to title these as you please; make sure no spaces are used. Towards the bottom of your screen you may control your layers. Left click on Level, and the Level Manager will open. Here you can control your Layers from Rhino. You must always have a Main Layer - so if you are looking to turn off one of your layers, and cannot do so; you may have to right clock on another layer and make it your Main Layer. Operations Manager The Operations Manager contains all the tools you will need to create toolpaths, edit, and back-plot. ALT-O closes and opens this window. Your Machine Group contains all the external properties; such as; stock size and origin, equipment, and tool settings. We will first set our stock size. Select Stock Setup in your Ops Manager. 4

5 1C Stock Setup a. Much of Stock Setup is self explanatory. Here you will set up your stock size for simulation and post processing purposes. You should have a window similar to the one shown in the figures on the right on your screen. Stock Size and Origin In the gray window, insert the dimensions of your stock. More importantly, set your origin. This can be done by clicking the top left corner (As shown above). Make sure you insert your origin values as well in the Stock Origin area. (0,0,0). We can also choose how our Stock is displayed with the Display Options. Click on the Display box next, and choose Wireframe or Solid. Stock When you are finished, select the checkmark button at the bottom of the window to apply the options. If at any point you are confused on certain options, click the help button in the bottom of any window. The help menus are very intuitive! to your right, you will see a 300 x 321 x 6,5 Solid (Display) Stock positioned on the correct origin. 5

6 2 1D Drilling Operations a. Next, select Toolpath, at the top of your screen, and choose the Drill option. You will be prompted to assign a Toolpath Name, and NC name please do not use spaces. DRILLING OPERATIONS Drill Point Selection With the Drill Point Selection window now open; you have multiple ways to select your geometry. For your Drilling Purposes, the Entities option, or the Window Points option will work well. Window points allow you to draw a window over all of the points you would like to select, whereas Entities allows you to select them singly -or- with a window. You also have the option of choosing how your points are Sorted - or the order in which they are milled. Click on the Sorting option and browse through the different options. The Mask on Arc option is used when holes to be drilled are modeled as circles (rather than points). Diameter displays the diameter of the arc (circle) selected for the Mask on Arc function. All circles of this diameter will be automatically selected. The preferable way to set holes is to locate points as centerpoints already in your modelling software. Sorting Sorting allows the user to change the order in which their geometry is milled. For large complex jobs this may speed up your milling time. 6

7 After selecting our Drilling points, we move on to the toolpath menu. (Figure 1.8) Here we will set our parameters for milling. On the far left of the menu are the Parameters and Settings; in the center are visualizations of what you are creating. For normal operation, one would use the Drill option as our toolpath type - in which the tool diameter must be the same as the hole. Alternate options would allow drilling bigger holes with smaller diameter tools. Tool Moving on to the Tool option, we must select a tool to use. We can find our tools by selecting the Select Library Tool button. Once the tool library window opens, browse the DFL Tool Library by selecting the New Library button located near the top of the window, and locate KTH AR- CHITECTURE TOOLS. Hit ok and select your tool. The correct tool library may be available only at the workstation in the Lab (not in the computer room). You may later need to select tools and rerun the job in the Lab. Cut Parameters Under the Cut Parameters area, we can select how we would like our bit to Drill. In order to save your material and any bits used, Chip Break is a safe method to Drill. This option allows us to drill in pecks. The bit drills a predefined increment, and then another until we reach our desired depth. As default it is suggested to set 1st Peck, Subsequent Peck, and Peck Clearance to 5 mm. All other operations receive a value of Zero

8 Linking Parameters Linking Parameters allows us to define important processing values. Clearance should be set to ca 50 mm. Retract sets the height in which the tool moves before the next tool pass. Top of Stock should be set to Zero. Depth is the final option. Allowing us to set the final machining depth. This should be set to the depth of the stock used. Home/ Ref. Points and Planes (WCS) The Home / Ref. Points window, gives us the option of setting a Home Position, A spot in the operation where the tool can begin from, and finish with. This can be anywhere on the table so long as it clears your stock! X0, Y0, Z5 should work fine. Lastly, select the Planes (WCS) window, and make sure that all planed are set to a TOP view. Double check your settings, and hit the checkmark button to apply your settings. A reference point is a location that the tool moves to between the home position and the start or end of the toolpath. The home position is typically where the tool moves for tool changes and at the end of the NC program. You can create separate reference points for approach and retract moves. The next move between the reference position and your part is typically the clearance plane, defined on the Linking parameters page. 8

9 1E Finalization a. After applying our settings, we should find a new toolpath created in our Operations Manager Window. If the icon next to Toolpath appears to have an X over it, you may have to correct a thing or two, not if you have a clean icon- then you are ready to simulate your operation. CLEAN OPERATION Back plotting and Verification If we left click on Toolpath in our Operations Manager, we can view our toolpaths that we have just created parameters for. You can simulate the entire operation by doing so. However, if you would like a more realistic simulation, you can right click on Toolpath, and a Verify window appears. You may simulate your operation with your stock displayed. Both of these simulation options will also regenerate your toolpaths. So if you happen to have a Dirty Operation this may be a quick way to solve it. Finally we post our operation by selecting the G1 icon at the top of your Op. Manager. Congratulations, you may now run your file! DIRTY OPERATION Post Post your operation by selecting the G1 icon at the top of your Operations Manager. This step and onwards can only be done on the workstation in the DFL CNC Lab! 9

10 Post processing Make sure that the settings in the Post processing window follow the image to the right. Make sure to set extension to.cnc! When you save the NC-file, make sure that you save to C://DncFiles. When you do, the output code will be immediately available to the Router. This step and onwards can only be done on the workstation in the DFL CNC Lab! Post processing Once this window opens, you can continue at the CNC Router. 10

11 3 Contours It is important that you understand what Mastercam considers a contour. Contours can be 3D Lines or 2D Lines. 2D lines typically are used for cutting profiles; where their Z-axis location remains constant, whereas 3D lines work on the X.Y and Z-axis instead. The following instructions are partially based on the set up done in the previous instruction - Drilling Operation. CONTOURS Toolpaths Select Toolpath from the Menu bar at the top of your screen, and select Contour Select a name for your toolpath WITHOUT spaces; and begin chaining your geometry. 11

12 2B Chaining Chaining is Mastercam s way of grouping Entities. Entities are any type of geometry that you bring into Mastercam. In general, when you are prompted to Chain your geometry; you will be using lines or points. Chaining When you are prompted to chain your geometry, Mastercam gives you multiple options to do so. Because Mastercam is used for such a wide array of applications, a lot of these options will not appeal to your needs. You may simply select each line singly, or you can choose the Window option; which allows you to drag a window over all of your lines. After drawing your window, you may be prompted to select a start point; this option is used for sorting, and gives Mastercam an idea of where to begin milling. Choose wisely! Setting Contour Options Once you have selected your geometry, select the Check Mark box located in the bottom of the Chaining Dialogue Box. You will begin setting parameters for your Milling operation; you will also notice that the set up is much like the previous Drilling Operations from your first project. Set your Toolpath Type to Contour and select your bit from the tool Menu. 12

13 2C Contour Parameters Cut parameters features different options on how the bit will mill through your operation; but more importantly- it allows you to determine what type of lines you will be milling. It should automatically discover that these lines are 3D Contours, but if not please select 3D from the drop down menu in the top right. Please note that the Max Depth parameter is only available if 3D curves are present in the model file! Depth Cuts Max rough step sets the maximum amount of material removed in the Z axis with each rough cut. Mastercam will calculate equal rough cuts no larger than the maximum rough step until it reaches the final Z depth. The value is calculated as a percentage of the tool diameter if you select the Use tool s step, peck, coolant option in the Tool settings tab, Machine Group Properties dialog box. Finish cuts sets the number of finish cuts for the toolpath. This number multiplied by the finish step value equals the total amount of stock cut by the finish passes. Setting the number of finish cuts to 0 creates no finish cuts. Finish step sets the amount of material removed in the Z axis with each finish cut. This number multiplied by the number of finish passes equals the total amount of stock cut by the finish passes. The value is calculated as a percentage of the tool diameter if you select the Use tool s step, peck, coolant option in the Tool settings tab, Machine Group Properties dialog box. Keep Tool Down - use only when you have closed toolpaths, with an end point similar to the start point. 13

14 Lead In/Out This direct how the tool will approach the geometry to be cut. Enter setting as per image. You can enter the left side parameters, then click the right arrow to copy to right side. Linking Parameters For this operation we will set our clearance at an Absolute height of 50 mm. Retract can be set to 10 mm Incrementally; and the feed Plane is set to 0.1 Incrementally. It is important that you create your Top of Stock at an Absolute Height of 0 mm - as your Depth Cuts will rely on this number. For a cut through of the material, set Depth to material thickness, in this example mm. This indicates the maximum depth the tool will go into the material. Incremental values are relative to the chained geometry - not to the Top of Stock! Clearence, Retract and Feedplanes are measured from Top of Stock in incremental mode. Retract sets the height that the tool moves up to before the next tool pass. Select the checkbox to activate the retract plane, then click the button and select a point on the geometry or enter a value. This option is off by default. The retract height should be set above the feed plane. If you do not enter a Clearance height, the tool will move to the retract height between operations. In multiaxis toolpaths, Retract is an incremental distance from the current tool position. 14

15 Home/ Ref. Points and Planes (WCS) The Home / Ref. Points window, gives us the option of setting a Home Position, A spot in the operation where the tool can begin from, and finish with. This can be anywhere on the table so long as it clears your stock! X0, Y0, Z5 should work fine. Lastly, select the Planes (WCS) window, and make sure that all planed are set to a TOP view. Double check your settings, and hit the checkmark button to apply your settings. A reference point is a location that the tool moves to between the home position and the start or end of the toolpath. The home position is typically where the tool moves for tool changes and at the end of the NC program. You can create separate reference points for approach and retract moves. The next move between the reference position and your part is typically the clearance plane, defined on the Linking parameters page. 15

16 4 CREATING A SURFACE ROUGH OPERATION 3A Prerequisites Please note that this tutorial was created in coordination with ARCH Digital Tectonics Robotic Fabrication. You must read and attempt the Contour Operations Tutorials before continuing. Toolpaths Surface Rough Parallel Begin by opening Mastercam and opening your model. Turn on the rendered view to be abel to examen your model. If the geometry look strange in anyway it has probably been some kind of conversion problem. The for now best solution is to go back to Rhino and mesh your geometry and then reopen in Mastercam. Next, you will create a Parallel Roughing Surface Toolpath by selecting Toolpath from the Mastercam Menu Bar; Surface Rough ; and lastly Parallel. Surface Selection Boss/ Cavity You will immediately be prompted by promoted to choose whether your geometry resembles a Cavity or a Boss object. In general, Boss objects tend to be extruded parts of geometry surrounded by a cavity. Best to think of them as islands. For the most part you will usually be using subtractive processes. Next, create your NC Name and select your Drive Surface. Your Drive Surface/s is the Surface/s you would like to mill. After you select your Drive Surface/s, you may hit Enter, and a new window appears. You now have the option of selecting Check Surfaces and Containment geometries. Check Surfaces are any surfaces you would not like to be milled, while Containment offers you an option to Mill within a selected 2D Closed Line. These will be important features when Robotic Milling. 16

17 3B Parameters a. Once we continue, we will find that our Parameters Window is a little different than our 2.5 Axix Options. Get familiar with this new appearance; as it will be a template for Robotic Milling in the future. Toolpath Parameters By now, you should be apt in figuring your Toolpath Parameters. Be sure to select your tool of choice; reset the tool number, set your Feed, Plunge, and Spindle Speed accordingly. Lastly, you may set your own Retract Rate, or simply select the Rapid Retract box option right below it. Our Retract motions and speeds depict how our tool moves from point to point between operations. Rapid Retract will reference the Post Processor for the max speed allowed. (500 is always safe) Before you continue, be sure to set your Home Position ; 0,0,5 is always safe. Also, find the Planes box; select, and make sure all planes are set to TOP. Recommended settings: FEED: max for wood, 5000 for foam SPINDEL SPEED: about with a smal tool about 8000 with a thicker tool (e.g. 16mm) See separate sheet for more detailes. Surface Parameters In the Surface Parameters tab we set our Linking Parameters; and a few other options gives us a little more versatility with how our part is milled. Stock to leave on... If we seek a better finish for our part, we may choose to leave a tiny portion of material left on our part for the Finishing Pass to mill. We also have this option for our Check Surfaces. Tool Containment If we have selected a 2D Closed Line for our Containment or- Region ; we can set how our bit interacts with this line. Is the bit limited to its TCP? (Tool Center Point) We can choose, different options and see what will best for our part. 17

18 Rough Parallel Parameters Finally we reach the Rough Parallel Parameters tab. Here we can set a variety of options. First and foremost, our step over and step down. Your Max Step over should not exceed a value half of your bit diameter. Max Step down should not be so large that it creates and excessive load on the bit. Recommended for wood is maximum 5 mm. For foam it is a lot more. Foam is a very forgiving material. Machining Angle Our Machining Angle is relative to the X Axis ; where a value of 0 Degrees creates toolpaths parallel with the X Axis. Other options Our Cutting Method usually works a little faster f we run in a Zig-Zag motion. Unless we are cutting a material with a grain, Zig-Zag is a preferred method. The name should give you an idea of what type of toolpaths this option outputs. We can also select options like Allow Negative/ Positive Z motion Along Surface. All Spiral Bits have a Z Cutting Direction. Down Spiral Bits push material downward, while Up Spiral pulls material up and out. Deselect the Negative Z option if you do not have a bit that cuts Downward; and vice versa. 18

19 5 CREATING A SURFACE ROUGH OPERATION 3C Finishing Toolpaths a. After we have Back plotted and Verified our Roughing Operation; we will mimic all instructions thus far and created a Surface Finishing Toolpath. Please select Toolpath Surface Finishing Parallel from the menu bar at the top of your screen. Finishing Parallel Parameters We select our Driving Surfaces, just as before; and being setting up our Finishing Operation. All instructions remain nearly identical until we arrive at the Finish Parallel Parameters Tab. Other Options For the most part, this tab is self-explanatory; we set our Max Stepover to our desired value, our Cutting Method ; and lastly our Machining Angle. However, we must set our final option to its correct values. Select the checkbox next to the Depth Limits option. You ll find it is much like the Depth Cuts option from our surface Rough operation. Set these values accordingly and use the checkmark boxes to make your way back to the Mastercam Interface. Backplot, Verify, then Post! 19

20 6 POSTING TOOLPATH Operations must be run through a post processor in order to be usable by your machine. This process is commonly referred to as posting. This lesson will guide you through selecting and posting all of your operations. Communicating the posted code to your machine is the last step of the toolpathing process in Masercam. 1. In the Toolpath Manager, click the Select All Operations button. 2. Click the Post Selected Operations button. The post processing dialog box opens. 3. Set the post processing options as shown. 4. Click OK. The Save As dialog box opens. 5. Click Save to save the NC file in the default location with the recommended file name. Note: Producing the correct NC code for your machine and application depends on properly configuring the machine definition, control definition, and.pst file. For detailed information on machine definition, control definition, and posting, please see Mastercam Help. 20

21 6. Your chosen editor opens (in this case, Mastercam Editor), displaying the posted NC code similar to thr image below. 7. Scroll through the NC code to verify that each line of code meets your expectations. Edit and save as necessary. After the NC file is reviewd, edited, and saved, you can set up your machine control to accept the NC file. This is done according to your machine and control manufacturer s procedures. When the machine control is ready to receive the NC file, configure your preferred editor or communications program documentation for details. Send the NC code to your machine control according to your machine and control manufacturer s documentation. Once you start the communication process, the send/ receive data processing is mostly managed by your machine control. Congratulations! You have now completed the Basic 3D Machining tutorial and have now the skill to run your job on the mill. Happy Milling! 21