TRAINING

GUIDE

5-AXIS INTRO-LESSON-1
FACE AND POCKET
TRUNNION-TABLE – 3+2 POSITIONAL
Mastercam Training Guide

Objectives
For 5-Axis Intro-Lesson-1 you will generate the toolpaths to machine the part on a CNC
vertical milling machine with multi-axis capability. The part will be held in a machine vise and a
Trunnion table as shown below will be utilized to machine the angled face and pocket. This
Lesson covers the following topics:

 Open an existing file containing:

The solid geometry for the machine vise and
Wireframe geometry for the part

 Establish Stock Setup settings:

Stock size
Create points to be used for Trim toolpath
Material for the part
Feed calculation

 Generate milling toolpath consisting of:

Using the Plane Manager
Using Views, Tool Planes and Construction Planes
Create Face and Pocket toolpaths

 Inspect the toolpath using Mastercam’s Verify and Backplot by:

Launching the Verify function to machine the part on the screen
Generating the NC- code

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5-AXIS INTRO-LESSON-1 DRAWING

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TOOL LIST
 Two cutters will be used to create this part.
 3.0 diameter face mill to machine the 30 degree angled face.
 0.375 diameter flat end mill to machine the pocket. The pocket depth is 0.125.

5-AXIS INTRO-LESSON-1 - THE PROCESS

Toolpath Creation

TASK 1: Setting the environment

TASK 2: Introduction - Watch the video
TASK 3: Open an Existing file from the Multimedia DVD
TASK 4: Define the rough stock using stock setup and create points that
will be used for Trim toolpath
TASK 5: Use Plane Manager to set up new Cplanes and Tplanes
TASK 6: Face Mill 30 Degree angle
TASK 7: Use Trim toolpath to edit the facing toolpath
TASK 8: Pocket slot on 30 degree face. The pocket depth is 0.125.
TASK 9: Backplot the toolpath
TASK 10: Verify toolpaths
TASK 11: Post and create the CNC code file

EXAMPLES OF HAAS
ROTARY TRUNNION TABLES

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Toolpath Creation
TASK 1:
SETTING THE ENVIRONMENT
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. Load the Workspace – SETTINGS>Load Workspace>4-5 Axis Toolpaths to machine a 4-
5 axis part.

SET THE DISPLAY OF THE GRID:

1. Launch Mastercam.
2. Select from the pull down menu Settings>Configuration.

3. From the window on the left side of this window expand the Screen topic by selecting the +
sign and then select Grid Settings.
4. Enable the Visible Grid and change the Size to 1.
5. Select the OK button to complete this function.

6. When prompted to “Save settings to configuration file” select Yes.

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SET THE TOOLBARS REQUIRED FOR A 4-5 AXIS PART:

1. Select from the pull down menu Settings> Load Workspace.
2. Select 4-5 Axis Toolpaths.

 To toggle on or off the display of the Toolpath/Solids Manager.

 You can close the Toolpath/Solids Manager by clicking the Close button in the upper right
corner. To open the Managers again, choose View, Toggle Toolpaths Manager or View,
Toggle Solids Manager.
3. To Show or Hide the Toolpaths Manager pane on the left of the screen press Alt + O.
Pressing Alt + O acts like a toggle switch between Show and Hide. The Mastercam
interface will be displayed as shown below when the Toolpaths Manager is hidden.

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TASK 2: INTRODUCTION – WATCH THE VIDEO

1. Before you start to work on this Lesson review the Introduction video on the multimedia DVD
that came with this text. You will find the video in the “Lesson-1” section, it is entitled
Introduction - 10 Minutes.
 The video will review the techniques that will be used to generate the two toolpaths for the
face and pocket toolpaths utilizing the Trunnion table.

TASK 3:
OPEN EXISTING FILE FROM THE MULTIMEDIA DVD
 On the multimedia DVD that came with this text is a folder called Mastercam-Files. The file
will contain the wireframe geometry of the part and the vise constructed as a solid. The
part is already setup for a: GENERIC HAAS VF-TR_SERIES 5X MILL.

1. Select FILE>Open… 5-Axis-Intro-Lesson-1.

2. Activate a shaded view by selecting the icon at the top of the screen. The file should appear
as below. The vise is made up of solid features, the part is wireframe geometry.

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TASK 4:
DEFINE THE ROUGH STOCK USING STOCK SETUP
 Define the Rough Stock sizes and material type using stock setup.
 Before you use Stock Setup the Levels that contain the vice will be turned off, it will
make it a lot easier to select the entities in this next set of instructions.
 During this lesson you will turn the visibility of Levels off and on.

 Levels are a primary organizational tool in Mastercam. A Mastercam file can contain
separate levels for wireframe, surfaces, drafting entities, and toolpaths.
 By organizing your files into levels, you can more easily control which areas of the drawing
are visible at any time and which parts are selectable so that you do not inadvertently make
changes to areas of the drawing you do not want to change.

1. Activate a wireframe view by selecting the icon at the top of the screen.
2. From the Status bar at the bottom of the screen select Level.

3. The Level Manager dialog window will now appear. In the Visible column click on the X
for Level Number 100.

4. Ensure the Level Manager dialog window appears as below, with the X for Level Number
100 removed. This makes the entities on that level invisible. Click on the OK button when
done .

5. Select the plus in front of Properties to expand the Toolpaths Group Properties. Alt-O will
Show/hide Toolpaths Manager pane.

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6. Select Stock setup in the toolpath manager window.

7. To begin with set the Stock Origin arrow to the lower left corner.

8. On the Stock Setup page select Bounding box.

9. You are now prompted to Select Entities. Select the three lines as shown on the right; you
can select the lines in any order. The stock size needs to be the same size as the part,
picking these three lines defines the X, Y and Z values of the stock.

10. Click on End Selection to move onto the next step. The Bounding box window
appears.

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11. In the Bounding Box dialog box scroll down and activate Points.

12. Now click on the OK icon in the Bounding box window.

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13. Your stock sizes should now be X6.0, Y3.0, and Z3.0 as shown on the right. Complete the
remaining parameters to match the Stock Setup screenshot below if required.

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14. Select the Tool Settings tab and change the

parameters to match the Tool Settings
screenshot below. To change the Material
type follow the next set of instructions.
15. To change the Material type to Aluminum 6061
pick the Select button at the bottom of the Tool
Settings page.
16. At the Material List dialog box open the
Source drop down list and select Mill –
library.
17. From the Default Materials list select
ALUMINUM inch -6061 and then select .

18. Select the OK button again to complete this Stock Setup function.

 Your part should look similar to the screen shot below. Note the points on the
corners of the stock. These points will be used later on in this lesson when you use
the Trim toolpath function.

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TASK 5:
USE PLANE MANAGER TO SET UP NEW CPLANES AND TPLANES

 Cplane is an abbreviation for construction plane; the plane where geometry is created.
 Typically, this is used in connection with drafting when you draw entities, select a Cplane to
orient the geometry in space. When you create a toolpath, the construction plane is the
plane in which the tool is compensated. For almost all toolpaths, the construction plane
should be the same as the tool plane (which is the plane normal to Z, or to the vertical tool
axis). However, it is possible to have them differ for advanced contour applications or Swiss
machining.

 Tplane is an abbreviation for tool plane; a 2D plane that represents the CNC machine’s XY
axis and origin.
 For most typical toolpaths, this is the plane in which cutting moves (G1/G2/G3) take place.
The tool typically approaches and retracts from the part normal to the tool plane in the Z
axis. You can align the Tplane with any of the standard planes or a custom orientation.
Changing the Tplane typically produces a rotary motion code when you post your toolpath.
The exact effect depends on your machine tool and post processor; for example, rotating
the tool plane 30 degrees about the X-axis might tilt the tool axis on a 5-axis machining
center, or could rotate a fixture on a table, depending on how your post is written.

1. Select WCS>Plane Manager from the Status bar.

2. From the Plane Manager Dialog box select the Geometry button as shown below.

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3. You will be returned to the graphics screen with a prompt to: Select construction plane by
geometry. Cplane by geometry. Select the two lines shown below. Note: pick the
horizontal line first, this is the line pointing along the X axis. Make sure the XYZ tripod
is the same as the example below with the Z axis arrow pointing up from angled face. If
required use the arrow buttons in the Select plane screen to cycle through to the correct
coordinate system.

4. Select the green check mark for OK.

5. In the New Plane dialog box enter PLANE-30-DEGREES in the name section.

6. Click on the OK icon to complete this feature.

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7. Now you are back in the Plane Manager dialog box pick in the C (Cplane) column and T
(Tplane) column of the PLANE-30-DEGREES row as shown below, if required.

8. In the lower right of the Plane Manager dialog window change the origin coordinates to X0
Y0 Z0.

9. Click on the OK icon to complete this feature.

10. Select on your keyboard ALT and F9. This displays on the screen the orientation of the
Cplane, Tplane and the WCS.
11. Select on your keyboard ALT and F9 to turn off the display.
12. Now you will make the Level visible that contains the geometry for the vise. From the
Status bar at the bottom of the screen select Level.

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13. The Level Manager dialog window will now appear. In the Visible column click on the
visible column for Level Number 100 so the X appears to make this level visible.

14. Click on the OK button when done .

15. Activate a shaded view by selecting the icon at the top of the screen.

 Your part should look similar to the screen shot below.

 Notice at the bottom of the graphics screen the status of the Tool and Construction plane,
it is set to PLANE-30-DEGREES. Before you start to work on the toolpath for the pocket
you need to understand what happens when you start to display different views of the part,
such as an Isometric or Front view and how it affects the Cplane and Tplane.

16. Set the graphics view to Isometric View.

17. Select the Screen Fit icon found at the top of the screen to fit the part to the screen .
 Notice at the bottom of the graphics screen the status of the Tool and Construction plane, it
is now set to TOP as shown below.
 If you had dynamically moved the view around the T/Cplane would have stayed at PLANE-
30-DEGREES
 Before you start to work on the toolpaths you need to change the T/Cplane to the PLANE-
30-DEGREES created earlier.

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18. Select Planes from the Status bar and then select Named planes and select PLANE-30-
DEGREES.

19. At the bottom of the graphics screen you will now see T/Cplane:PLANE-30-DEGREES.

20. Another method of setting the T/Cplane to PLANE-30-DEGREES would be to select the
drop down menu at the top of the screen and select Plane List.

21. From the Plane Selection dialog window click on PLANE-30-DEGREES and then select the
OK button to exit

Plane Selection dialog box

Each plane has a name and origin, or zero point,
associated with it. Use the Plane Manager to rename a
plane or change its origin.

Use this dialog box anywhere in Mastercam when you

are prompted to select a plane.
Most often, this happens when you choose to set the
Cplane, Tplane, or Gview to a named plane, or when
you need to select a new Tplane from the Toolpath
Coordinate System dialog box when creating a toolpath.

When the dialog box appears, a list of planes is

displayed, showing the plane name, origin, and work
offset number.

Choose the Select button in the dialog box to select a

plane by clicking on its gnomon in the graphics window.

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22. At the bottom of the graphics screen you will now see T/Cplane:PLANE-30-DEGREES.

Please Note:

 Before you start to work on any of the toolpaths in this lesson look at the bottom of the
graphic screen and ensure the status of the T/Cplane is set to PLANE-30-DEGREES as the
picture above shows.

 If it is not set to PLANE-30-DEGREES use the steps just prescribed, for example:

1. On the Status bar select Planes

2. Plane List

3. Click on PLANE-30-DEGREES

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TASK 6:
FACE MILL 30 DEGREE ANGLE
 In this task you will use a 2.0 diameter face mill to face the 30 degree angle. The tool
axis will be perpendicular to this 30 degree machined face.
 Before you create the toolpath the Level that contain the vice will be turned off, it will
make it a lot easier to select the entities in this next set of instructions.

1. From the Status bar at the bottom of the screen select Level.

2. The Level Manager dialog window will now appear. In the Visible column click on the X
for Level Number 100.

3. Ensure the Level Manage dialog window appears as below, with the X for Level Number
100 removed. This makes the entities on that level invisible. Click on the OK button when
done .

4. From the menu bar select TOOLPATHS>Face…

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5. When prompted to Enter new NC name ensure 5-Axis-Intro-Lesson-1 is displayed and

then select the OK button . If not prompted then continue to the next step.
6. On the screen you will now see the Chaining dialog box with Chain set and in the graphics
screen a prompt to Select OK to use defined stock or select chain 1.
7. Activate the C-plane radio button.
8. Select the line as shown below to chain the area being faced.

 Cplane
Chains only entities that are parallel to the current construction plane and at the same Z depth
as the first entity you chain.
In Window, Area, or Polygon chaining, chains only entities that are on the current construction
plane and at the current Z depth.
Mastercam uses the Plane tolerance setting in the Chaining Options dialog box to determine
whether or not an entity lies in the Construction plane.
 3D
Chains entities defined in the X, Y, and Z axes simultaneously.
3D recognizes co-planar as well as non-planar branches. At branch points, Mastercam prompts
you to select the next entity in the chain.

9. Select the OK button to exit the chaining dialog box.

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10. On the Tool page, select the 2” Face Mill and make changes to this page as shown below:

11. Select the Linking parameters page and first activate Clearance then change the
Clearance, Retract and Feed plane to Incremental. Now set the remaining values as
shown below;
Absolute and incremental values
Most toolpaths provide Clearance, Retract, Feed
plane, Top of stock, and Depth parameters that
can be entered in either absolute or incremental
values.
Absolute values are always measured from the
origin 0,0,0. If you were to translate geometry
associated with a toolpath, and the toolpath
depth were set to an absolute value, the tool will
try to cut to that same absolute depth value no
matter where the geometry is located.
Incremental
Incremental values are relative to other
parameters or chained geometry. Depth and Top
of Stock parameters are relative to the location of
the chained geometry. Clearance, Retract, and
Feed plane are relative to the Top of stock.
If you were to translate geometry associated with
a toolpath and the toolpath depths were set to an
incremental value, then the toolpath would be cut
at the depth relative to the geometry location.
Note: In a multiaxis toolpath, the Clearance,
Retract, and Feed plane options on the Multiaxis
parameters section are automatically set to
Incremental.

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12. Still on the Facing parameters page change the Depth and Top of Stock to Incremental
and set the Depth value to 0.

13. Now click on the Top of stock button. When prompted to Select point select the point on
the top of the stock as shown below. This is one of the points you created earlier using
Bonding Box. Ensure the visual cue for point appears before you select the point.

14. Notice the Top of Stock has now changed to 2.126855 after picking the point.

Top of stock
 Sets the height of the material in the Z axis.
 Many other toolpath parameters are measured from this position in incremental mode, such
as Clearance, Retract, and Feed planes.

 Choose the Top of stock button and select a point on the geometry or enter a value.
 Incremental values are measured from the chained geometry.

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15. On the Cut Parameters page review and make the remaining changes as shown below:

16. Select the Depth Cuts page and select the Depth Cuts button and make changes as
shown below:

17. Select the OK button to exit Face parameters.

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TASK 7:
USE TRIM TOOLPATH TO EDIT THE FACING TOOLPATH
 In this task you will trim the facing toolpath to remove the fresh air cutting. This Trim
function allows you to create a Trim operation, which trims an existing toolpath to
one or more closed boundaries that you select.
 To accomplish this we need to create a trim containment area. One of the points you
created earlier in Stock setup will now be used to create a couple of lines for the
boundary for this trim operation.

1. Set the graphics view to the Front View by using the toolbar icon at the top of the screen.

2. Select the Screen Fit icon found at the top of the screen to fit the part to the screen and
zoom as required to display the toolpath as shown below.

 As you can see there are lot of fresh air moves, as shown below:

3. Set the graphics view to the Isometric View by using the toolbar icon at the top of the

screen.
4. Select Alt-T on your keyboard to hide the display of toolpaths.
5. To make it easier to select the entities in this next set of instructions move into Stock Setup
and turn off the display of stock.

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6. Select from the pull down menu: CREATE>Line>Endpoint…

7. Activate Multi-Line on the line ribbon bar.

8. When prompted to Specify the first point pick at position 1. This point is the intersection
or endpoint of the lines shown below at position 1. Ensure the visual cue for end point or
intersection displays before you select the position. Zoom in as required.

9. When prompted to Specify the second point pick at position 2. This point is the Point
that was created earlier in Stock setup. You may wish to dynamically rotate the display by
holding the middle mouse button down and rotating the display to better view the point.
Ensure the visual cue for Point displays before you select the position.

10. When prompted to Specify the second point again pick at position 3. This point is the
intersection or endpoint of the lines shown below at position 3. Ensure the visual cue for
end point or intersection displays before you select the position.

11. Click on the OK icon to complete this feature.

12. Set the graphics view to the Front View by using the toolbar icon at the top of the screen.

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 To ensure the 2.0” face mill does not hit the material when it plunges to depth we will
now use Xform Translate to move the vertical line just created 1.25” in the positive X
direction.

13. Select XFORM>Translate…

14. You are first prompted to Translate: select entities to translate. Select the vertical line
shown below:

15. Click on the End Selection icon

16. In the Translate dialog window activate Move and set the Delta X to 1.25.

17. Click on the OK button .

18. Click on the Clear Colors at the top right hand corner of the screen.
19. The vertical line is translated as shown below:

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 Next you will use Trim two entity to join the two lines

20. Select EDIT>Trim/Break>Trim/Break/Extend.

 The Trim / Extend / Break ribbon bar appears and you are prompted to Select the
entity to trim/extend.

21. Click on the Trim 2 entity icon to activate it as shown above.

22. Select the two lines shown below left:

The lines are now trimmed to each other as shown above right:
23. Click on OK to exit trim.
24. From the menu bar select TOOLPATHS>Trim…

25. In the Chaining dialog window activate Cplane and ensure Chain is set. When prompted
to Select trimming boundaries 1 – select the horizontal line shown below that was
created earlier. This will then chain the two lines shown below.
26. If the arrows are not pointing as shown below select the reverse arrow from the
Chaining dialog box to reverse the direction.

27. Select the OK button to exit Chaining.

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28. When next prompted to Enter a point on the side to keep pick a point approximately
where shown below by the arrow.

29. After picking this point the Trimmed dialog window appears. Select the Facing operation
from the list of Operations to trim on the left. Ensure you have a check mark on this
Facing operation. Next activate Keep tool down.

30. Select the OK button to exit the Trimmed dialog window.

31. Select Alt-T on your keyboard to display toolpaths. The Trimmed facing toolpath should
look as below, with the fresh air moves removed

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TASK 8:
POCKET SLOT ON 30 DEGREE FACE
 In this task you will use a 0.375 diameter flat end mill to machine the pocket on the 30
degree angled face.
 The pocket depth is 0.125.

1. Set the graphics view to Isometric View.

2. Select the Screen Fit icon found at the top of the screen to fit the part to the screen .

3. Turn off the display of toolpaths by selecting Alt-T on your keyboard.

 Notice at the bottom of the graphics screen the status of the Tool and Construction plane, it
is set to TOP as shown below. Before you start to work on the toolpath for the pocket you
need to change this to the PLANE-30-DEGREES created earlier.

4. Select Planes from the Status bar and then select Named planes and select PLANE-30-
DEGREES.

5. At the bottom of the graphics screen you will now see T/Cplane:PLANE-30-DEGREES.

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6. From the menu bar select TOOLPATHS>Pocket…

7. On the screen you will now see the Chaining dialog box with Chain set and in the graphics
screen a prompt to Select Pocket chain 1.
8. Activate the C-plane radio button in the Chaining dialog box.
9. Select the angled line for the pocket as shown below to chain the slot.

10. After selecting the line the arrows should be pointing upwards, if not see below.
11. If the arrow is not pointing upwards select the arrow from the Chaining dialog box shown
below to reverse the direction.

12. After the pocket has been successfully chained select the OK button at the bottom of
the Chaining dialog box.

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13. Select 3/8 FLAT ENDMILL and make changes to the Tool page as shown below:

14. Select the Linking Parameters page and if required activate Clearance then change the
Clearance, Retract and Feed plane to Incremental and set the remaining values as shown
below;

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15. Still on the Linking Parameters page change the Depth and Top of Stock to Incremental
and set the Depth to -0.125.

16. Now click on the Top of stock button. When prompted to Select point select the point on
the top of the stock as shown below. This is one of the points you created earlier using
Bonding Box. Ensure the visual cue for end point, intersection or point appears before
you select this point.

17. Note the Top of Stock and Depth should be as shown below:

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18. On the Cut Parameters page make the changes as shown below:

19. Expand the Cut Parameters menu and select the Roughing page. Make the changes as
shown below:

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20. Expand the Roughing menu and select the Entry Motion page. Make the changes as
shown below if required:

21. Select the Finishing page. Make the changes as shown below:

22. Select the OK button to exit Pocket parameters.

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TASK 9:
BACKPLOT THE TOOLPATH
 In this task you will use Mastercam’s Backplot function to view the path the tools take to cut
this part.
 Backplot will enable you to review the cutting motions and identify any problem areas when
cutting the part.

1. Now you will make the Level visible that contains the geometry for the vise. From the
Status bar at the bottom of the screen select Level.

2. The Level Manager dialog window will now appear. In the Visible column click on the
visible column for Level Number 100 so the X appears to make this level visible.

3. Click on the OK button when done .

4. Select the Screen Fit icon found at the top of the screen to fit the part to the screen .
5. Select Alt-T on your keyboard to display toolpaths.
6. Activate a shaded view by selecting the icon at the top of the screen.

 Your part should look similar to the screen shot below.

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7. To pick all the operations to Backplot pick the Select All icon .
8. The next step is to select the Backplot selected operations icon shown below:

9. Maximize the Backplot/Verify window if required.

10. Select the Home Tab if required.
11. Activate the options shown below in the Visibility section of the Home tab.

12. Click on the Backplot tab at the top left of the screen.

13. Activate the Both option in the Toolpath section of the Backplot tab.

14. In the lower right corner of the screen now set the run Speed to slow by moving the slider
bar pointer over to the left as shown below.

15. Now select the Play Simulation button to review the toolpaths.

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16. After reviewing the Backplot of the toolpaths use the Close button to exit Backplot.
 Your part should look similar to the screen shot below.

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TASK 10:
VERIFY THE TOOLPATHS
1. In the Toolpath Manager pick all the operations to verify by picking the Select All icon .
2. Select the Verify selected operations button shown below:

3. Maximize the Backplot/Verify window if required.

4. Activate the options shown below in the Visibility section of the Home tab. Initial Stock and
Toolpath not activated.

5. Activate the Color Loop to change the color of the tools for the verified part.
6. In the lower right corner of the screen now set the run Speed to slow by moving the slider
bar pointer over to the left as shown below.

7. Now select the Play Simulation button to review the toolpaths.

8. After reviewing the toolpaths use the Close button to exit Verify.
 Your part should look similar to the screen shot below.

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TASK 11:
POST AND CREATE THE CNC CODE FILE
1. Ensure all the operations are selected by picking the Select All icon from the
Toolpath manager.
2. Select the Post selected operations button from the Toolpath manager.
3. Please Note: If you cannot see G1 click on the right pane of the Toolpath manger window
and expand the window to the right.

4. In the Post processing window, make the necessary changes as shown below:

5. Select the OK button to continue.

6. Enter the same name as your Mastercam part file name in the NC File name field 5-AXIS-
INTRO-LESSON-1.
7. Select the Save button.

8. Select the in the top right corner to exit the CNC editor.
9. This completes 5-Axis Intro-Lesson-1.

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5 AXIS INTRO-LESSON-1 EXERCISE #1

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5 AXIS INTRO-LESSON-1 EXERCISE #1

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5 AXIS INTRO-LESSON-1 EXERCISE #2

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5 AXIS INTRO-LESSON-1 EXERCISE #2

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