Chapter 21 CO2 Shell Car Mastercam X9 for SOLIDWORKS A. Enable Mastercam for SOLIDWORKS. Step 1. If necessary, turn on Mastercam for SOLIDWORKS, click the flyout of Options on the Standard toolbar and click Add-Ins. Step 2. In the dialog box scroll down to Mastercam for SOLIDWORKS and place a check in the check box under Active Add-Ins and Start-Up, Fig. 1. Click OK. B. Rotate Body. Step 1. Open your car Body file. Step 2. Click Isometric (Ctrl-7) on the Standard Views toolbar. Step 3. Click Insert Menu > Features > Move/Copy. Step 4. In the Property Manager set: under Bodies to Move/Copy, Fig. 2 click car Body, Fig. 3 uncheck Copy under Rotate Fig. 1 X Rotation Origin 0 Y Rotation Origin 0 Z Rotation Origin 0 Y Rotation Angle 90 press ENTER key on keyboard click OK. Body Fig. 2 Fig. 3 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-1 Cudacountry.net Tech Ed http://www.cudacountry.net email:cudacountry@hotmail.com 9/10/15
C. Create Plane for Check Body. Step 1. Click Right Plane select plane, Fig. 4. in the Feature Manager to Step 2. Click Reference Geometry on the Features toolbar and Plane from the menu. Step 3. In the Plane Property Manager set: under First Reference, Fig. 5 Right Plane is selected under Second Reference click the most forward vertex of the Body, Fig. 6 Fig. 4 and click OK. D. Create Check Body. Step 1. Hide Plane1. To hide, click Plane1 and Hide on the Context toolbar, Fig. 7. Fig. 5 Step 2. Click Plane1 in the Feature Manager and click Sketch on the Context toolbar, Fig. 8. Fig. 6 Vertex Fig. 7 Fig. 8 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-2
Step 3. Click Center Rectangle Rectangle flyout toolbar. (S) in the on the Sketch Step 4. Draw a rectangle starting at Origin or most forward vertex of the Body, Fig. 9. Origin Step 5. Click Smart Dimension the Sketch toolbar. Step 6. Add dimensions, Fig. 9. (S) on Fig. 9 Step 7. Click Features on the Command Manager toolbar. Step 8. Click Extruded Cut on the Features toolbar. Step 9. In the Cut-Extrude Property Manager set: under Direction 1, Fig. 10 Depth 5 uncheck Merge result Fig. 10 click Reverse direction The Direction arrow should point back toward the Body, Fig. 11. Click OK. Fig. 11 Direction arrow SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-3
E. Create LEFT CUT View. Step 1. Rotate view to view side of Body, Fig. 12. Hold down middle mouse button (wheel) and drag to rotate view. Step 2. Press the Space Bar on the keyboard to display the Orientation dialog box. Drag the dialog box to the top left corner of the drawing area, Fig. 13. Fig. 12 Step 3. Click Pin/UnPin in Orientation dialog box to pin the dialog box, Fig. 13. Step 4. Click New View View dialog, Fig. 13. to display Named Step 5. In the New View dialog box key-in LEFT CUT and click OK, Fig. 14. Later, to display new LEFT CUT view, click LEFT CUT, Fig. 15. Step 6. Save. Use Ctrl-S. Fig. 13 Fig. 14 Fig. 15 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-4
F. Create LEFT CUT WCS and Tool Plane. Step 1. Click Mastercam X9 on the Command Manager toolbar. Step 2. Click Plane Manager on the Mastercam toolbar. Step 3. With the Mastercam Top plane selected, click Create From button in the Plane Manager dialog box, Fig. 16. Fig. 16 Step 4. In the Define Mastercam Plane Property Manager: under New Plane Geometry, Fig. 17 in the Plane name box, key-in LEFT CUT under Orientation Options About X 180º click in another About box confirm rotation of Mastercam Origin, Fig. 18 and Fig. 19 click OK. Tip: Mastercam origins in all CO2 Car Bodies; X runs positive from rear of Body forward. Y left to right. Z always points up, Fig. 19. Fig. 18 BEFORE rotating Origin AFTER rotating Origin Fig. 17 Fig. 19 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-5
Step 5. Back in the Plane Manager, under Origin (in view coordinates) set, Fig. 20 X -305 Y -34 Z 34. Step 6. Click the Set All button, Fig. 20. Step 7. Click OK. Step 8. Confirm axis moved and rotated, Fig. 21. Step 9. Save. Use Ctrl-S. G. Create BOTTOM CUT View. Step 1. Rotate view to view bottom of Body, Fig. 22. Hold down middle mouse button (wheel) and drag to rotate view. Fig. 20 LEFT CUT Mastercam Origin Step 2. Click New View to display Named View dialog, Fig. 23. Fig. 21 Step 3. In the New View dialog box key-in BOTTOM CUT and click OK, Fig. 24. Later, to display this new BOTTOM CUT view, click BOTTOM CUT view. Fig. 22 Fig. 23 Fig. 24 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-6
H. Create BOTTOM CUT WCS and Tool Plane. Step 1. Click Plane Manager on the Mastercam toolbar. Step 2. Click Mastercam Top plane from list of named planes in the Plane Manager dialog box, Fig. 25. Step 3. Click Create From button in the Plane Manager dialog box, Fig. 25. Step 4. In the Define Mastercam Plane Property Manager: under New Plane Geometry, Fig. 26 in the Plane name box, key-in BOTTOM CUT under Orientation Options About X 180º click in another About box confirm rotation of Mastercam Origin, Fig. 27 click OK. Fig. 27 Fig. 25 AFTER rotating Origin Step 5. In the Plane Manager, under Origin (in view coordinates) set, Fig. 28 X to -305 Y to 0 Z to 0. Fig. 26 Step 6. Click Set All button and click OK. Step 7. Confirm axis, Fig. 29. Fig. 28 Fig. 29 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-7
I. Stock Setup. Step 1. Click Mastercam Toolpath Manager tab Manager, Fig. 30. in the Property Step 2. Expand Properties in the Toolpath Manager, Fig. 30. Step 3. Click Stock Setup in the Toolpath Manager. Step 4. Confirm Stock Plane is Mastercam Top, Fig. 31. Fig. 30 Step 5. Click the left front top corner of the stock to move the origin. After you click corner the arrow will point to corner. Step 6. Key-in X, Y and Z stock dimension into the fields X 305 Y 42 Z 70 Step 7. Key-in Stock Origin coordinates: X -305 Y -21 Z 70 Click corner to move arrow Step 8. Click OK in Machine Group Properties. The Stock is displayed as red wireframe, Fig. 32. Step 9. Save. Use Ctrl-S. Fig. 31 Fig. 32 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-8
J. REAR SHELL Area Roughing Toolpath. Step 1. Click 3D High Speed Toolpaths the menu. on the Mastercam toolbar and Area Rough from Step 2. Click OK in the NC name dialog, Fig. 33. Step 3. In the Selection Manager set: under Faces and Bodies, Fig. 34 select Solid body click the solid car Body, Fig. 35 Fig. 33 expand Containment Boundary select Edge select Propagate along Tangent edges click edge of rear wheel shell, Fig. 35 click OK. Chain shell edge Solid car body Fig. 35 Fig. 34 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-9
Step 4. Select Toolpath Type from the tree control and confirm: Area roughing toolpath Drive and Containment boundary Fig. 36. Step 5. Select Tool from tree control and: Click Select library tool Fig. 37. Fig. 36 Fig. 37 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-10
Step 6. Click Filter button, Fig. 38. Step 7. Click None button under Tool Types, Fig. 39. Fig. 38 Step 8. Click Endmill2 Sphere button (second button top row) and click OK, Fig. 39. Step 9. Click 491 BALL END- MILL 6mm and click OK, Fig. 40. Fig. 39 Fig. 40 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-11
Step 10. Back in Tool page set: Feed rate 300 Plunge rate 200 Fig. 41. Step 11. Select Cut Parameters from tree control and set: Cutting method Climb Stepdown 12.5 Stock to leave on walls and floors 1 Fig. 41 XY stepover 50% Minimum 2 Maximum 3 Fig. 42. Fig. 42 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-12
Step 12. Select Trochoidal motion from tree control and set: Minimize burial Fig. 43. Step 13. Select Tool containment from tree control and set: Compensate to Inside Uncheck Add offset distance to tool radius Fig. 44. Fig. 43 Fig. 44 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-13
Step 14. Select Transitions from tree control and set: Entry helix Radius 3 Fig. 45. Step 15. Select Steep/ Shallow from tree control and set: Check Z depths Minimum -9 Maximum -35 Click Apply Fig. 45 Fig. 46. Negative -9 Negative -35 Fig. 46 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-14
Step 16. Select Linking Parameters from tree control and set: Clearance plane 0 Select Minimum Vertical Retract Part clearance 0 All Leads 0 Fig. 47. Step 17. Click OK in Area Roughing dialog box. Fig. 47 Step 18. Allow Mastercam to calculate toolpath. Step 19. Save. Use Ctrl-S. K. Verify REAR SHELL Rough Area Toolpath. Step 1. Click Verify in the Toolpath Manager, Fig. 48. Step 2. Click Play (R) in VCR bar along bottom of the window, Fig. 49. Step 3. Note Total Time to run program under Toolpath Info in Move List panel (9min 13.24s), Fig. 51. Fig. 48 Fig. 49 Step 4. Switch back to Mastercam (Alt-Tab). Fig. 51 Fig. 50 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-15
L. FRONT SHELL Area Roughing HST Surface Toolpath. Step 1. Toggle toolpath display in Toolpath Manager to toggle toolpath display, Fig. 52. Step 2. Copy Roughing toolpath in the Toolpaths Manager. To copy, hold right mouse button and drag the Surface High Speed toolpath down under the operations. Release the mouse button and click Copy After from menu, Fig. 52. Step 3. Expand the copied 2 - Surface High Speed, expand Geometry and click Geometry - Containment, Fig. 53. Fig. 52 Fig. 53 Step 4. In the Selection Property Manager set: under Containment Boundary, Fig. 54 right click Edge1 in Containment Boundary box and click Clear Selections click an edge of front wheel shell, Fig. 55 confirm Edge 2 is selected, Fig. 56 click OK. Step 5. In the Toolpath manager, click Regenerate all dirty operations, Fig. 57. Step 6. Save. Use Ctrl-S. Fig. 54 Fig. 56 Chain shell edge Fig. 55 Fig. 57 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-16
M. BOTH SHELLS Finish Raster HST Toolpath. Step 1. Copy the second Roughing toolpath in the Toolpath manager. To copy, hold with the right mouse button and drag the Surface High Speed toolpath down under the operations. Release the mouse button and click Copy After from menu, Fig. 58. Step 2. Expand 3 - Surface High Speed and click Parameters, Fig. 59. Step 3. Select Toolpath Type from the tree control and select: Finishing Raster Under Containment boundary, click Select Containment Boundaries Fig. 58 Fig. 59 Fig. 60. Fig. 60 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-17
Step 4. In the Selection Manager set: under Containment Boundary, Fig. 61 select Edge select Propagate along Tangent edges click edge of rear wheel shell, Fig. 62 click OK. Step 5. Select Cut Parameters from tree control and set: Chain shell edge Cutting method Zigzag Stepover.5 Stock to leave on walls 0 Stock to leave on floors 0 Fig. 63. Fig. 62 Fig. 61 Fig. 63 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-18
Step 6. Select Tool containment from tree control and set: select Tool contact point Compensate to Inside Fig. 64. Step 7. Select Steep/ Shallow from tree control and set: Uncheck Use Z depths Click Apply Fig. 64 Fig. 65. Step 8. Click OK in Raster dialog box. Step 9. Save. Use Ctrl-S. Fig. 65 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-19
N. Verify Finish BOTTOM CUT. Step 1. In the Toolpaths Manager, click Regenerate all dirty operations, Fig. 66. Step 2. Click Toolpath Group-1 to select all three shell toolpaths, Fig. 66. Step 3. Click Verify in the Toolpaths Manager. Step 4. Click Play (R) in VCR bar. Step 5. Note Total Time to run program (31min 42.03s), Fig. 68. Fig. 66 Step 6. Switch back to Mastercam (Alt-Tab). Fig. 67 O. Set-up Toolpath Groups. Step 1. Rename Toolpath Group 1 to WHEEL SHELLS. To Rename group, right click Toolpath Group 1 and click Groups > Rename from the menu, Fig. 69. Step 2. Key-in WHEEL SHELLS for new group name, Fig. 69. Fig. 68 Fig. 70 Fig. 70 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-20
Step 3. Insert a new Toolpath group. To insert group, right click Machine Group 1 at the very top and click Groups > New Toolpath group from the menu, Fig. 71. Step 4. Key-in LEFT CUT for Group name, Fig. 72. Step 5. Save. Use Ctrl-S. P. Set WCS to LEFT CUT. Step 1. Click Plane Manager Fig. 71 on the Mastercam toolbar. Fig. 72 Step 2. In Plane Manager, click LEFT CUT from list of planes, Set All, Fig. 73. and click OK Step 3. Click LEFT CUT in Orientation dialog box to change to your left cut view, Fig. 74. Step 4. Confirm Left Cut Origin, Fig. 75. LEFT CUT Mastercam Origin Fig. 73 Fig. 75 Fig. 74 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-21
Q. Left Cut Finish Hybrid Toolpath. Step 1. Click 3D High Speed Toolpaths and Hybrid from the menu. on the Mastercam toolbar Step 2. In the Selection Manager set: under Faces and Bodies, Fig. 76 select Solid body click the solid car Body, Fig. 77 expand Check surfaces select Solid body click the extruded body, Fig. 77 select Face, Fig. 78 rotate view to view underside of Body and rear of Cartridge hole, hold down middle mouse button (wheel) and drag to rotate view, Fig. 79 Fig. 76 click the flat face on the underside of Body and flat face at rear, Fig. 79 click OK. Solid car body Check solid Fig. 77 Check surface Fig. 78 Fig. 79 Check surface SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-22
Step 3. Select Toolpath Type from the tree control and confirm: Hybrid toolpath Drive and Checks Fig. 80. Step 4. Select Tool from tree control and set: Feed rate 300 Plunge rate 200 Fig. 81. Fig. 80 Fig. 81 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-23
Step 5. Select Cut Parameters from tree control and set: Open contour direction Zigzag Z stepdown 3 Limiting angle 34 3D stepover 1.2 Check Preserve Z passes Offset method Upper to lower Fig. 82 Keep tool down within 80% Stock to leave on walls and floors 0 Check surfaces.01 Fig. 82. Step 6. Select Steep/ Shallow from tree control and set: Check Use Z depths Minimum 0 Maximum -37 Fig. 83 Click Apply Fig. 83. SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-24
Step 7. Select Linking Parameters from tree control and set: Clearance plane 2 select Minimum Vertical Retract Part clearance 2 All Leads 0 Fig. 84. Step 8. Select Arc Filter/Tolerance from tree control and set: Fig. 84 Total tolerance.0625 check Line/ Arc Filtering Settings uncheck Create arcs in XY check One way filtering set Minimum arc radius.0625 Cut tolerance 10% Fig. 85. Fig. 85 Step 9. Click OK in Hybrid dialog box and allow Mastercam to calculate toolpath Save. Use Ctrl-S. SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-25
R. Verify Finish LEFT CUT. Step 1. In the Toolpaths Manager, click the LEFT CUT Toolpath group to select toolpath and click Verify, Fig. 86. Step 2. Click Play (R) in VCR bar. Step 3. Note Total Time to run program (41min 9.66s), Fig. 88. Step 4. Switch back to Mastercam (Alt-Tab). Fig. 86 Fig. 87 S. Insert RIGHT CUT Toolpath Group. Step 1. Insert another Toolpath group. To insert group, right click Machine Group 1 at the very top of Ops Manager and click Groups > New Toolpath group, Fig. 89. Fig. 88 Step 2. Rename new Toolpath Group RIGHT CUT, Fig. 90. Fig. 89 Fig. 90 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-26
T. Mirror LEFT CUT to RIGHT CUT Hybrid Toolpath. Step 1. Click LEFT CUT view in Orientation dialog box to change to your left cut view. Step 2. Click Transform on the Mastercam toolbar. Step 3. Under Type, select Mirror, Fig. 91. Step 4. Under Source operations LEFT CUT toolpath group, select Surface High Speed (Hybrid), Fig. 91. Fig. 91 Step 5. Click the Mirror tab at the top of the dialog box, Fig. 91. Step 6. Under Method, select Mirror about X axis, Fig. 92. Step 7. Click OK in Transform Operation Params dialog box. Step 8. Allow Mastercam to calculate toolpath. Fig. 92 Fig. 93 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-27
U. Verify RIGHT CUT. Step 1. In Toolpaths Manager, click the Transform/Mirror toolpath, Fig. 94. Step 2. Click Verify in Toolpaths Manager, Fig. 94. Step 3. Click Play Step 4. Click Close (R) in VCR bar. to close Mastercam Simulation. Step 5. Save. Use Ctrl-S. Fig. 94 Fig. 95 SOLIDWORKS 15 MCX9 for SW Toolpaths CO2 SHELL CAR Page 21-28