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 HANDBOOK VOLUME 3

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Mastercam 2020 Handbook Volume 3
Copyright: 1998 - 2020 In-House Solutions Inc. All rights reserved

Software: Mastercam 2020

Author: In-House Solutions

ISBN: 978-1-77146-857-2

Date: August 27, 2019

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This document requires Mastercam Mill 3D.

 Table Of Content

Introduction To Multiaxis Machining 7

Advanced Multiaxis Common Parameters 45

Multiaxis Curve Toolpaths 109

Multiaxis Swarf Milling Toolpaths 147

Multiaxis Parallel Toolpaths 161

Drill Toolpaths Multiaxis Option 169

Multiaxis Along Curve Toolpaths 179

Multiaxis Morph Toolpaths 185

Multiaxis Flow Toolpaths 193

Multiaxis Multisurface Toolpaths 209

Multiaxis Port Toolpaths 219

Multiaxis Triangular Mesh Toolpaths 231

Multiaxis Swarf Toolpaths 253

Multiaxis Rotary Toolpaths 271

Multiaxis Project Curve Toolpaths 287

Multiaxis Roughing Toolpaths 293

Circle Mill Toolpaths Multiaxis Option 299

Multiaxis Port Expert & Blade Expert Toolpaths 303

Handbook Volume 3 Page: 3

 Legend

Page: 4 Handbook Volume 3

CONVENTIONS
Key words and Mastercam menu items are shown in bold the first time they are used. Columns on the outside
edges of each page and note pages at the end of each chapter provide ample space for taking notes.

Useful tips, recommended settings, best practices, and detailed instruction on the most important features are
included when possible.

Extra credit exercises are included on the student CD in PDF format. These will help build your skill to a higher
level.

TERMS
The following terms are used throughout this book.

♦ Left Click means to click once on the left mouse button.

♦ Click means the same as left click.
♦ Right Click means to click once on the right mouse button.
♦ Scroll means to roll the mouse scroll wheel, or move the scroll index in a list.
♦ Options are Mastercam functions selected from the main menu.
♦ Enter means to select the <Enter> key on your computer keyboard.
♦ Press means to press on a keyboard key.
♦ Choose means to select a menu option or button.
♦ Open/Close means to open or close a dialog or information box.
♦ Dialog Box is a window that opens to allow for the input of information and the setting of defaults.
♦ Panel is a window that is locked and opens to allow for the input of information and the setting of defaults.
♦ Drop Down/Flyout Menus are menus that expand down, left, right, or up, to reveal more menu lists.
♦ A Function is the same as a menu option or command.
♦ Help means the Mastercam help files loaded with your software.

Handbook Volume 3 Page: 5

 1 Introduction To Multiaxis Machining
OBJECTIVES
This chapter introduces the basic concepts and principles of multiaxis machining.

Upon completion of this chapter, you should be able to do the following:

♦ Identify common Multiaxis machine tool configurations.

♦ Understand the difference between Multiaxis position and Simultaneous Multiaxis toolpaths.
♦ Understand the different types of Multiaxis toolpaths, and the capabilities and advantages they
provide over conventional toolpaths.
♦ Understand basic setup and programming of Multiaxis machine tools, including collision avoidance
and machine envelope limitations.
♦ Use the Right Hand Rule to determine the correct direction sign of an axis of rotation.
♦ Know how to properly select and set the NC program datum and tool length offsets for different
multi-axis machine tool configurations.

INTRODUCTION
There are many different Multiaxis machine tool configurations. Most control three linear axes (XYZ) plus
two rotational axes. The rotational axes are some combination of the ABC axes, depending on the
machine design.

Multiaxis machines are indispensable for manufacturing parts common in the aerospace, mold, and die
industries.

This chapter presents the basic concepts and knowledge you need to understand Multiaxis machines
and toolpaths. By the time you finish this book, you will have a good understanding of Multiaxis
machines. You will also know how to use Mastercam Multiaxis to program these interesting and versatile
machines.

Handbook Volume 3 Page: 7

CHAPTER 1 Introduction To Multiaxis Machining

MULTIAXIS TOOLPATHS
Multiaxis toolpaths can be classified into two broad categories:

♦ Axis Positioning.
♦ Simultaneous Multiaxis.

AXIS POSITIONING
Axis Positioning involves moving one or more rotary axes to orient a feature towards the spindle. The rotary
axes are then locked in position and only the linear axes are moved simultaneously to machine the feature.

Since three axes move and two are fixed, this type of motion is referred to as "3 plus 2" machining. With the right
post processor, any Mastercam mill toolpath will output 3+2 code. Just set the WCS tool plane to any plane
other than Top.

Mastercam Axis Positioning Multiaxis toolpaths include:

♦ Multiaxis Drill.
♦ Multiaxis Circle Mill.
♦ All the toolpaths that can set the Tool Axis Control to a Plane.

SIMULTANEOUS MULTIAXIS MACHINING

Simultaneous Multiaxis Machining controls up to five axes at once: three linear and one or two rotary.
Mastercam Simultaneous Multiaxis toolpaths include:

♦ Curve.
♦ Swarf Milling.
♦ Parallel
♦ Along Curve.
♦ Morph.
♦ Flow.
♦ Multisurface.
♦ Port.
♦ Triangular Mesh.
♦ Swarf.
♦ Rotary.
♦ Project Curves.
♦ Roughing.
♦ Port Expert.
♦ Blade Expert.
♦ Rotary Advanced.

Most of the 5 axis toolpaths can be set to output in the 3 axis format and use an existing Plane.

Page: 8 Handbook Volume 3

 Introduction To Multiaxis Machining CHAPTER 1

The toolpaths are grouped in two families: Pattern and Application.

The Pattern toolpaths are general toolpaths that can be used to machine any kind of shapes. The Application
toolpaths are designed to machine specific parts or features, automating some of the processes.

♦ From the Pattern family toolpaths:

♦ Curve.
♦ Swarf Milling.
♦ Parallel
♦ Drill.
♦ Along Curve.
♦ Morph.
♦ Flow.
♦ Multisurface.
♦ Port.
♦ Triangular Mesh.
♦ From the Application family toolpaths:
♦ Swarf.
♦ Rotary.
♦ Project Curves.
♦ Roughing.
♦ Deburr.
♦ Circle Mill.
♦ Port Expert.
♦ Blade Expert.
♦ Rotary Advanced.

The Multiaxis toolpaths will be described in this book based on how they are grouped in these two families.

Handbook Volume 3 Page: 9

CHAPTER 1 Introduction To Multiaxis Machining

PATTERN FAMILY TOOLPATHS

Curve
Curve is a 5-axis toolpath that moves the tool tip along a curve while controlling the tool axis.

Mastercam has many methods for controlling the tool axes. The most common is to align the tool axis with the
surface normal at each tool position as the tool moves along the curve.

The tool can also be made to tilt forward or backward in relation to the cut direction. This is called a lead/lag
angle, and it is used to help improve machining efficiency in some cases.

It can also be made to tilt to the left or right in relation to the cut direction. This is called a side tilt angle and is
used to accommodate machine rotary limits or for collision avoidance.

In the illustration below, a 5-axis laser is trimming a formed sheet metal part as shown in Figure: 1. The tip of the
tool moves along the trim curve while two rotary axes keep the tool axis normal to the part surface.

Figure: 1

Page: 10 Handbook Volume 3

 Introduction To Multiaxis Machining CHAPTER 1

Swarf Milling
Swarf Milling (Side Wall Axial Relief Feed) toolpaths allow you to machine wall surfaces with the side of the
tool. The advantage of this 5-axis toolpath is that you can machine the drive surface with a single cut using the
whole flute length of the tool.

The swarf milling toolpath will keep the tool axis aligned between 2 points on the upper and lower curve which
means that the surface to be machined has to be straight between the points. The system tries to get the upper
and lower curves from the surfaces. If this does not work then the user has to provide the upper and lower curve
separately.

The following graphic shows a Swarf Milling toolpath as shown in Figure: 2.

Figure: 2

Handbook Volume 3 Page: 11

CHAPTER 1 Introduction To Multiaxis Machining

Parallel
The Parallel toolpath pattern can be set parallel to Curves, Surfaces or aligned at an Angle.

Parallel To Curves

The Parallel to Curves pattern will align the cut direction with a leading curve. Adjacent cuts are parallel to each
other. It is important to note that the cuts will not simply be copied next to each other. Every new cut is created
at an offset from the previous cut.

The curve must be located exactly on the surface edge, so the best curve would be the edge itself. This is very
important for toolpath generation. If you don't have a proper curve, an incorrect toolpath can be generated.

The following graphic shows a Parallel to Curves pattern used to finish the turbine blade fillets as shown in
Figure: 3.

Figure: 3

Page: 12 Handbook Volume 3

 Introduction To Multiaxis Machining CHAPTER 1

Parallel To Surfaces

The Parallel To Surfaces pattern generates cuts on the drive surface parallel to a check surface. There are special
options for the edge between the check surface and the drive surface. You can define a margin to define the exact
position where the tool is located along the edge, positioned as close as possible to both faces.

The following graphic shows a Parallel to Surfaces pattern used to finish the blade of an impeller as shown in
Figure: 4.

Figure: 4

Parallel To Angle

The Parallel To Angle pattern lets you create tool motions with cuts that are parallel to each other. The direction
of the cuts is defined by the two angles: the Machining angle in X,Y and the Machining angle in Z.

The following graphic shows a Parallel To Angle pattern used to finish a cam as shown in Figure: 5.

Figure: 5

Handbook Volume 3 Page: 13

CHAPTER 1 Introduction To Multiaxis Machining

Along Curve
Along Curve generates the toolpaths orthogonal to a leading curve. This means that when your selected curve is
not a straight line, the cuts are not parallel to each other. The distance between two neighboring cuts (at the
intersection of the curve and toolpath) is the maximum stepover.

The following graphic shows an Along Curve toolpath used to finish an enclosed surface as shown in Figure: 6.

Figure: 6

Page: 14 Handbook Volume 3

 Introduction To Multiaxis Machining CHAPTER 1

Morph
The Morph toolpath allows you to choose between two patterns: From Curves and From Surfaces.

Morph - Pattern From Curves

Morph between 2 curves will create a morphed toolpath between two leading curves. A "morphed" toolpath is
one that is approximated between the tilt curves and evenly spread over the surface. This toolpath will ensure a
better finish with less retraction moves.

The following graphic shows a Morph between 2 curves toolpath used to finish a turbine blade’s surfaces as
shown in Figure: 7.

Figure: 7

Handbook Volume 3 Page: 15

CHAPTER 1 Introduction To Multiaxis Machining

Morph - Pattern From Surfaces

Morph between 2 surfaces toolpaths create a morphed toolpath on the drive surfaces. The drive surface is
enclosed by two check surfaces. A "morphed" toolpath is one that is approximated between the check surfaces
and evenly spread over the drive surface. The main advantage is the possibility to compensate the tool to the
drive surface and check surface in the left and right corner of the workpiece. All you need to do is set the margin,
or distance between the tool center and the surfaces, equal to the tool radius.

The following graphic shows a Morph between 2 surfaces toolpath as shown in Figure: 8.

Figure: 8

Page: 16 Handbook Volume 3

 Introduction To Multiaxis Machining CHAPTER 1

Flow
Flow 5-axis toolpaths follow the UV Curves of a surface or row of surfaces.

While mostly used to machine a single surface, Flow can sometimes be used to machine across multiple surfaces.
Because they can be very efficient and allow a lot of control, Flow is a widely used toolpath strategy.

Flow provides extensive tool axis and cut control, including lead/lag, side tilt, axis limits and more. It also provides
scallop height stepover control.

The following graphic shows a 5-axis Flow toolpath used to finish machine an aircraft turbine blade as shown in
Figure: 9.

Figure: 9

Handbook Volume 3 Page: 17

 3 Multiaxis Curve Toolpaths
OBJECTIVES
The purpose of this chapter is to introduce Multiaxis Curve toolpaths.

Upon completion of this chapter, you should be able to do the following:

♦ Understand concepts related to Multiaxis Curve toolpaths and recognize applications where they
should be considered.
♦ Understand the difference between 3, 4, and 5-axis output formats.
♦ Know how to control the toolpath using 3D curves or surface edges.
♦ Know how to control the tool axis orientation using all available methods.
♦ Understand tool tip compensation as it relates to Multiaxis curve machining.
♦ Know the difference between Surface and Plane projections.
♦ Be able to define and set the tool lead/lag and side tilt angles.
♦ Understand all parameters and settings related to Entry/Exit and be proficient with them.

INTRODUCTION
Curve toolpaths are used to move the tip of the tool along a 3D curve while controlling the tool axis as
shown in Figure: 1. This toolpath has many applications. The illustration below shows a Curve toolpath
being used to control a laser to trim cut a molded manifold.

Figure: 1

Handbook Volume 3 Page: 109

CHAPTER 3 Multiaxis Curve Toolpaths

CURVE TOOLPATH
To start the toolpath, select the TOOLPATHS tab and, from the Multiaxis group, select the Curve icon as shown.

Toolpath Type
Toolpath Type controls the options available as you proceed down the tree structure. The options are based on
the toolpath you previously selected, as well as the toolpath family (Pattern or Application).

Page: 110 Handbook Volume 3

 Multiaxis Curve Toolpaths CHAPTER 3

Mastercam toolpath dialog boxes have three distinct areas: Tree View list, Page, and Quick View Settings as
shown in Figure: 2.

Figure: 2

Handbook Volume 3 Page: 111

CHAPTER 3 Multiaxis Curve Toolpaths

Tool
The Tool page allows you to select a tool, set the feeds and speeds, enter a comment about the operation, and
set other general toolpath parameters as shown in Figure: 3. This page is identical to the Tool page used
throughout Mastercam 2D toolpaths. For questions regarding parameters on this page, consult the online help
(Alt + H) or refer to the Mastercam Handbook Volume 1 or Volume 2.

Figure: 3

Page: 112 Handbook Volume 3

 Multiaxis Curve Toolpaths CHAPTER 3

Cut Pattern
Cut Pattern settings determine the geometry the tool follows and how it travels along that geometry as shown in
Figure: 4.

Figure: 4

Term Definition
Curve type can be set to 3D curves (lines, arcs or splines) or Surface edges when you
Curve type
are not using chained geometry.
Allows you to specify how you want to handle cutter compensation. This option is
Compensation type
identical to that used in 2D and 3D toolpaths.
Compensation
Gives you the choice to offset the tool to the right or left of the toolpath.
direction
Tip compensation Sets the offset to be used relative to the tool's center or tip.
Sets the distance that the center of the tool is offset (left or right) based on the
Radial offset
Compensation direction.
This value is a linear distance along the path taken by the tool. An additional vector
Distance increment will be added to the toolpath when the distance between calculated vectors is
greater than the distance increment value.
Enable this option to use a distance value to limit tool motion. The specified value is
Distance
the distance between generated vectors along the selected geometry.
Cut tolerance Cut tolerance determines the accuracy of the Multiaxis toolpath.

Handbook Volume 3 Page: 113

CHAPTER 3 Multiaxis Curve Toolpaths

Term Definition
Maximum step sets the largest step that can be made between tool moves so that
Maximum step
the tool moves can be kept closer together in flat areas of the part.
Projection set to Normal to plane projects the curves to the surface normal to the
current construction plane.
Projection
Projection set to Normal to surface projects the curves to the surface along the
surface normals.

Curve Type 3D Curves

The path of the tool is controlled by the Curve type group. Clicking on the 3D Curves Select button brings up the
Mastercam chaining menu. Use this menu to select the curves to machine.

Curves can be composed of lines, arcs, and NURBS splines. Parametric splines and surface curves are not allowed
as shown in Figure: 5.

Figure: 5

Page: 114 Handbook Volume 3

 Multiaxis Curve Toolpaths CHAPTER 3

The best results are achieved using quality data. When possible, model the curves using the simplest geometry
possible i.e. using lines instead of straight splines, arcs instead of circular splines, etc.

Avoid splines with excessive control points, reversals, or other undesirable characteristics. If necessary, reduce
the splines or remodel them. The Mastercam Handbook Volume 2, Chapter 1: Splines provides information
on spline modeling and troubleshooting.

Curve Type Surface Edge

The Surface edge - single option allows you to control the toolpath using a selected surface edge instead of 3D
curves.

The Surface edge - all option drives the tool around all surface edges. The system prompts you to select the
surface, and then to select the cut direction as shown in Figure: 6.

Figure: 6

Handbook Volume 3 Page: 115

CHAPTER 3 Multiaxis Curve Toolpaths

Use the Single setting to drive the tool around one edge of a surface or group of surfaces as shown in Figure: 7.

Figure: 7

When more than one surface is selected, the system prompts you to pick the first surface, and then the edge to
start on as shown in Figure: 8. It then prompts you to select the edge to use for the next adjacent surface. This is
repeated for each subsequent surface until one edge of each surface is selected.

Figure: 8

Page: 116 Handbook Volume 3

 Multiaxis Curve Toolpaths CHAPTER 3

In cases where multiple edges of a single surface are used as edges, first split the surface using the SURFACES/Split
function as shown in Figure: 9.

Figure: 9

Surfaces With Seams

Surfaces generated from cross sections, such as Revolved or Net surfaces, have a seam as shown in Figure: 10.

The toolpath will drive along this seam and the perimeter of the surface when using the Surface Edge function.

Consider using the 3D Curves option rather than Surface Edge to avoid machining the surface seam.

Figure: 10

Handbook Volume 3 Page: 117

CHAPTER 3 Multiaxis Curve Toolpaths

Radial Offset
Radial offset is related to the cut direction as shown in Figure: 11. Set this parameter to the radius of the tool.

Figure: 11

Curve Following Method

The Curve following method allows you to set the accuracy of the Multiaxis toolpath.

Term Definition
Enable this option to use a distance value to limit tool motion. The specified value is
the distance between generated vectors along the selected geometry. A smaller
Distance
value creates a more accurate toolpath, but may take longer to generate and may
create a longer NC program.
Cut tolerance determines the accuracy of the Multiaxis toolpath. A smaller cut
tolerance value creates a more accurate toolpath but may take longer to generate
and create a longer NC program. This value is also used to eliminate duplicate
positions and as a tolerance when compensating to surfaces. When the Distance
Cut tolerance
check box is deselected, Mastercam uses the cut tolerance you specify as a tolerance
to fit tool positions to the surface based on the curvature of the surface. Otherwise,
Mastercam uses the Distance value as an absolute distance for the space between
each tool position.
Maximum step sets the largest step that can be made between tool moves so that
Maximum step
the tool moves can be kept closer together in flat areas of the part.

Page: 118 Handbook Volume 3

 Multiaxis Curve Toolpaths CHAPTER 3

Projection
Projection determines how the curves are projected onto the surface.

Term Definition
Normal to plane Causes the curve to be projected normal to the active construction plane.
Normal to surface Projects the curve onto the surface along the surface normals.
Controls how far the system looks to find the surface on which to project the curve.

To reduce calculation time, set this value to a little more than the maximum distance
between the curve and the surface it is projected onto. If the curve lies directly on
Maximum distance the surface, a setting of 0.05 inches or less may be used.

Use this setting to prevent extra projections that could occur when the projected
curve intersects a surface more than once. For example, a curve projected through a
cylinder.

Handbook Volume 3 Page: 119

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