SOLIDWORKS 15 MCX9 fOR SW TOOLpaThS CO2 ShELL CaR pagE 21-1
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 on the Standard Views toolbar. (Ctrl-7)
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 Copyunder Rotate
X Rotation Origin 0
Y Rotation Origin 0
Z Rotation Origin 0
Y Rotation Angle 90 press ENTER key on keyboard click OK .
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C. Create Plane for Check Body.Step 1. Click Right Plane in the Feature Manager to
select plane, Fig. 4.
Step 2. Click Reference Geometry on the Fea-tures 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
and click OK .
D. Create Check Body.Step 1. Hide Plane1 . To hide, click
Plane1 and Hide on the Context toolbar, Fig. 7.
Step 2. Click Plane1 in the Feature
Manager and click Sketch on the Context toolbar, Fig. 8.
Fig. 4
Fig. 5
Fig. 6
Vertex
Fig. 8Fig. 7
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Step 3. Click Center Rectangle (S) in the Rectangle flyout on the Sketch toolbar.
Step 4. Draw a rectangle starting at Origin or most forward vertex of the Body, Fig. 9.
Step 5. Click Smart Dimension (S) on the Sketch toolbar.
Step 6. Add dimensions, 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
click Reverse direction The Direction arrow should point back toward the Body, Fig. 11.
Click OK .
Fig. 9
Fig. 10
Fig. 11
Direction arrow
Origin
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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.
Step 3. Click Pin/UnPin in Orientation dialog box to pin the dialog box, Fig. 13.
Step 4. Click New View to display Named View dialog, Fig. 13.
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. 12
Fig. 14
Fig. 15
Fig. 13
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F. Create LEFT CUT WCS and Tool Plane.Step 1. Click Mastercam X9
on the Command Manager toolbar.
Step 2. Click Plane Man-
ager on the Mastercam toolbar.
Step 3. With the Mastercam Top plane selected, click Create From button in the Plane Manager dia-log box, 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. 16
Fig. 17
Fig. 18
BEFORE rotating Origin
Fig. 19
AFTER rotating Origin
SOLIDWORKS 15 MCX9 fOR SW TOOLpaThS CO2 ShELL CaR pagE 21-6
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.
Step 2. Click New View to display Named View dialog, Fig. 23.
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. 20
Fig. 21
LEFT CUT Mastercam Origin
Fig. 24
Fig. 23
Fig. 22
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H. Create BOTTOM CUT WCS and Tool Plane.Step 1. Click Plane Man-
ager on the Mastercam toolbar.
Step 2. Click Mastercam Top plane from list of named planes in the Plane Man-ager dialog box, Fig. 25.
Step 3. Click Create From but-ton 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 .
Step 5. In the Plane Manager, under Origin (in view coordinates) set, Fig. 28 X to -305 Y to 0 Z to 0.
Step 6. Click Set All button
and click OK .
Step 7. Confirm axis, Fig. 29.
Fig. 25
Fig. 26
Fig. 28
AFTER rotating Origin
Fig. 27
Fig. 29
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I. Stock Setup.Step 1. Click Mastercam Toolpath Manager tab in the Property
Manager, Fig. 30.
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.
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
Step 8. Click OK in Machine Group Prop-erties. The Stock is displayed as red wire-frame, Fig. 32.
Step 9. Save. Use Ctrl-S. Fig. 31
Fig. 30
Click corner to move arrow
Fig. 32
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J. REAR SHELL Area Roughing Toolpath.
Step 1. Click 3D High Speed Toolpaths on the Mastercam toolbar and Area Rough from the menu.
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 expand Containment Boundary
select Edge select Propagate along Tangent edges click edge of rear wheel shell, Fig. 35 click OK .
Fig. 33
Fig. 34
Fig. 35
Chain shell edge
Solid car body
SOLIDWORKS 15 MCX9 fOR SW TOOLpaThS CO2 ShELL CaR pagE 21-10
Step 4. Select Tool-path Type from the tree control and confirm: Area roughing toolpath Drive and Containment boundary Fig. 36.
Step 5. Select Tool from tree con-trol and: Click Select library tool Fig. 37.
Fig. 36
Fig. 37
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Step 6. Click Fil-ter button, Fig. 38.
Step 7. Click None button under Tool Types,Fig. 39.
Step 8. Click Endmill2 Sphere button (second button top row) and click OK, Fig. 39.
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Step 10. Back in Tool page set: Feed rate 300
Plunge rate 200 Fig. 41.
Step 11. Select Cut Pa-rameters from tree control and set: Cutting meth-od Climb Stepdown 12.5 Stock to leave on walls and floors 1 XY stepover 50% Minimum 2 Maximum 3 Fig. 42.
Fig. 41
Fig. 42
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Step 12. Select Trochoidal motion from tree control and set: Minimize burialFig. 43.
Step 13. Select Toolcontainment from tree con-trol and set: Compensate to Inside Uncheck Add offset distance to tool radius Fig. 44.
Fig. 43
Fig. 44
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Step 14. Select Transitions from tree con-trol 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. 46.
Fig. 45
Fig. 46
Negative -35Negative -9
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Step 16. Select Linking Parameters from tree con-trol and set: Clearance plane 0 SelectMinimum Vertical Retract Part clearance 0 All Leads 0 Fig. 47.
Step 17. Click OK in Area Roughing dialog box.
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.
Step 4. Switch back to Mastercam (Alt-Tab).
Fig. 47
Fig. 51Fig. 50
Fig. 49
Fig. 48
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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.
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. 52
Fig. 53
Fig. 55
Chain shell edge
Fig. 54 Fig. 56
Fig. 57
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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 Contain-ment boundary, click Select Containment Boundaries
Fig. 60.
Fig. 60
Fig. 58
Fig. 59
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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 Pa-rameters from tree control and set: Cutting method Zigzag Stepover .5 Stock to leave on walls 0 Stock to leave on floors 0 Fig. 63.
Fig. 62
Chain shell edge
Fig. 61
Fig. 63
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Step 6. Select Toolcontainment from tree con-trol 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. 65.
Step 8. Click OK
inRaster dialog box.
Step 9. Save. Use Ctrl-S.
Fig. 64
Fig. 65
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N. Verify Finish BOTTOM CUT.Step 1. In the Toolpaths Manager, click Regenerate all dirty opera-
tions , 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 To-tal Time to run program (31min 42.03s), Fig. 68.
Step 6. Switch back to Mastercam (Alt-Tab).
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. 66
Fig. 68
Fig. 67
Fig. 70Fig. 70
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Step 3. Insert a new Tool-path group. To insert group, right click Machine Group 1 at the very top and click Groups > New Tool-path 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 on the Mastercam toolbar.
Step 2. In Plane Manager, click LEFT CUT from list of planes, Set All and click OK , Fig. 73.
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.
Fig. 72Fig. 71
Fig. 74
Fig. 73
Fig. 75
LEFT CUT Mastercam Origin
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Q. Left Cut Finish Hybrid Toolpath.
Step 1. Click 3D High Speed Toolpaths on the Mastercam toolbar and Hybrid from the menu.
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 click the flat face on the underside of Body and flat face at rear, Fig. 79 click OK .
Fig. 76
Fig. 77
Fig. 78
Check surface
Check surface
Solid car body
Check solid
Fig. 79
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Step 3. Select Tool-path Type from the tree control and confirm: Hybrid tool-path Drive andChecks Fig. 80.
Step 4. Select Tool from tree con-trol and set: Feed rate 300
Plunge rate 200 Fig. 81.
Fig. 80
Fig. 81
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Step 5. Select Cut Pa-rameters from tree control and set: Open contour direction Zigzag Z stepdown 3
Limiting angle 34 3D stepover 1.2 CheckPreserve Z passes Offset method Upper to lower Keep tool down within 80% Stock to leave on walls and floors 0 Check sur-faces .01 Fig. 82.
Step 6. Select Steep/Shallow from tree control and set: Check Use Z depths Minimum 0 Maximum -37 Click Apply Fig. 83.
Fig. 82
Fig. 83
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Step 7. Select Linking Parameters from tree con-trol and set: Clearance plane 2 selectMinimum Vertical Retract Part clearance 2 All Leads 0 Fig. 84.
Step 8. Select Arc Filter/Toler-ance from tree control and set: Total tolerance .0625 check Line/Arc Filtering Settings uncheck Cre-ate arcs in XY check One way filtering set Minimum arc radius .0625
Cut tolerance 10%Fig. 85.
Step 9. Click OK in Hybrid dialog box and allow Mastercam to calculate toolpath Save. Use Ctrl-S.
Fig. 84
Fig. 85
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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).
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.
Step 2. Rename new Toolpath Group RIGHT CUT, Fig. 90.
Fig. 86
Fig. 87
Fig. 88
Fig. 90Fig. 89
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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 op-erations LEFT CUT toolpath group, select Surface High Speed (Hybrid), 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. 91
Fig. 92
Fig. 93
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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 (R) in VCR bar.
Step 4. Click Close to close Mastercam Simulation.
