TRAINING

GUIDE

MULTI-AXIS-LESSON-7
TRUNNION-TABLE FLOW 5 AXIS

Mastercam Training Guide

Objectives
For Multi-Axis-Lesson-7 you will generate the toolpaths to machine the propeller part shown
below on a CNC vertical milling machine with multi-axis capability. The raw material for the
propeller is a casting. The part will be initially machined using the Flowline 5-axis toolpath.
Following this the Advanced Multiaxis toolpath will be used to finish machine. Finally the
Toolpath Transform feature will be used to copy the toolpaths to and machine the remaining two
vanes of the propeller. The part is in inch units. The part will be held on a fixture using a socket
head cap screw through the centre hole. This setup will be located on a Trunnion table.
This Lesson covers the following topics:
Open an existing file containing:
Solid geometry for the part
Generate toolpaths consisting of:
Flowline 5-axis toolpath
Advanced Multiaxis toolpath
Inspect the toolpath using Mastercams
Backplot by:
Launching the Backplot function to machine the
part on the screen
Generating the NC- code

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TOOL LIST

MULTI-AXIS-LESSON-7 - THE PROCESS

Toolpath Creation
TASK 1:
TASK 2:
TASK 3:
TASK 4:
TASK 5:
TASK 6:
TASK 7:
TASK 8:
TASK 9:
TASK 10:

Setting the environment

Introduction - Watch the video
Open an existing file from the Multimedia CD
Identify the entities on each Level
Machine first vane Flowline 5-axis
Machine fillet radii between vane and main hub
Transform and Rotate toolpaths
Backplot the toolpath
Verify the toolpath
Post and create the CNC code file

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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: Size= 1.0, X & Y Spacing= 0.25. This will help identify the location of the
origin.
2. Customize the toolbars to machine a 4-5 Axis part.

TASK 2: INTRODUCTION WATCH THE VIDEO

1. Before you start to work on this Lesson review the Introduction video on the multimedia CD
that came with this text. You will find the video in the Lesson-7 section, it is entitled
Introduction - 10 Minutes.
The video will review the techniques that will be used to generate the toolpaths to cut this
part.

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TASK 3:
OPEN EXISTING FILE FROM THE MULTIMEDIA CD
On the multimedia CD that came with this text is a folder called Mastercam-Files. The file
is in inch units and contains the wireframe and surface (solid) geometry of the part.
The part is already setup for a: GENERIC HAAS VF-TR_SERIES 5X MILL.
1. Select File>Open> Multi-Axis-Lesson-7.MCX.
2. If confronted with the System Configuration dialog box activate the radio button for All
settings.

System Configuration (switch units) dialog box

When you open a part file that uses different units (English or metric) from those currently in
use, Mastercam automatically displays this dialog box, which informs you that Mastercam is
switching units and loading an alternate default configuration file. In order to complete the
operation, select one of the following options:
Units: Tells Mastercam to use only the units from the new configuration file. (default)
All settings: Tells Mastercam to load all settings from the new configuration file.
3. Select the OK button
to exit the System Configuration dialog box.
4. Activate a shaded view by selecting the icon at the top of the screen. The file should appear
as below. The Stock setup has already been setup.

5. Display the Operations Manager. Selecting Alt-O will Show/hide the Operations Manager
pane.

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TASK 4:
IDENTIFY THE ENTITIES ON EACH LEVEL
Before you start to work on the two toolpaths lets first identify the entities on each Level.
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. From the Status bar at the bottom of the screen select Level.
Note that the Z depth is set to 0.575

The Level Manager dialog window will now appear.

As you can see in the picture below there is only one Level in this part Level 1.
Level 1 contains the part geometry
Level 1 is visible as noted by the X in the Visible column.

2. Select the OK button

to exit the Level Manager dialog box.

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TASK 5:
MACHINE FIRST VANE FLOWLINE 5-AXIS
In this task you will use a 0.5 diameter ball end mil to machine the first vane using Flowline
5-axis.
Flow 5-axis toolpaths allow either precise control of the scallops left on the part or constant
distance stepovers, creating an exact, smooth finish.
The 5-axis output provides 2 degrees of freedom for the tool vectors. You can use flow 5axis toolpaths on a row of adjacent drive surfaces or on a single surface.
Flow 5-axis toolpaths can use ball, bull, flat, or tapered tools.

1. Before you start to work on this Task review the Lesson-7 Task 5 video on the multimedia
CD that came with this text. You will find the video in the Lesson-7 section; there is some
tricky selection of surfaces in this task so please check out the video before you proceed.
2.
3.
4.
5.

Activate a wireframe view by selecting the icon at the top of the screen.
Set the graphics view to Isometric View and then select the Screen Fit icon.
From the menu bar select Toolpaths> Multiaxis>Flowline 5-axis
When prompted to Enter new NC name Input Multi-Axis-Lesson-7 and then select the OK
button
.

6. At the Flow 5-axis dialog box activate the 5-axis radio button and the remaining radio
buttons shown below.
Cut Pattern Surfaces
Select surfaces to define the drive
surfaces for the operation. Multiple
surfaces can be selected provided
that surfaces form a contiguous
row, or where the surface
directions are not in conflict with
one another.
Tool Axis Control Pattern
Surface
Keeps the tool axis vector normal
to a selected surface. For
Multisurface 5-axis toolpaths,
keeps the tool axis vectors normal
to the surfaces selected for the cut
pattern. The cut pattern is a set of
surfaces that best defines the
general machining area for the
operation and defines the general
flow of tool motion.
7. Now click on the Surfaces button in the Cut Pattern section.
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8. On the graphics screen you will be prompted Select Tool Pattern Surface(s). Before you
select the surfaces you need to set up the appropriate selection options on the General
Selection Toolbar.
9. On the General Selection toolbar select the icon to toggle Activate solid selection. Do this
by clicking on the Activate solid selection icon shown below so it is greyed out.

10. After picking the Activate solid selection icon it should be greyed out as shown below.
Now click on the Select Face icon so it is greyed out. Ensure your General Selection
Toolbar is setup as below:

Activate solid selection

This activates solid selection functions appropriate for the current solid and operation. In cases
where you initiate a Mastercam function that might apply to solids in addition to other types of
entities, you can use this button to switch from the default Standard Selection mode to the Solid
Selection mode.
Select face
Toggles face selection on or off. When chosen, you can select solid faces on a model. When
not chosen, you exclude solid face selection.
Select edge
Toggles edge selection on or off. When chosen, you can select solid edges on a model. When
not chosen, you exclude solid edge selection.
Select body
Toggles whole solid body selection on or off. When chosen, you can select whole solids on a
model. When not chosen, you exclude whole solid body selection.
From back
Toggles "from back" selection on or off. When chosen, you can select solid edges or faces only
on the back of a model. When not chosen, you can select solid edges or faces only on the front
of a model.

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11. Now select the surface on the propeller vane shown below.

12. Click on the End Selection icon.

.
13. The Flowline data dialog box appears and the graphic screen displays as below. Nothing
to change here, select the OK button

to exit the Flowline data dialog box.

Use this dialog box to change the direction, offset, tolerance, or step direction for Flowline
geometry.

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14. Now back at the Flowline data dialog box click on the Check Surfaces button.

15. The Toolpath/surface selection dialog box will appear now select the selection arrow
shown below left:

16. On the graphics screen you will be prompted Select Check Surfaces. Before you select
the surfaces you need to set up the appropriate selection options on the General Selection
Toolbar.
17. On the General Selection toolbar select the icon to toggle Activate solid selection. Do this
by clicking on the Activate solid selection icon shown below so it is greyed out.

18. After picking the Activate solid selection icon it should be greyed out as shown below.
Now click on the Select Face icon so it is greyed out. Ensure your General Selection
Toolbar is setup as below:

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

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20. The prompt now changes to Select Solid Body of Face. Select the four check surfaces
shown below. For the four check surfaces, pick the 3 fillets 1, 2 and 3 from the vane to
the hub, then the hub - 4 (conical). Zoom as required.

21. After selecting the check surfaces click on the End Selection icon.
.
22. At the Toolpath/surface selection dialog box take note that it indicates (4) check surfaces
as shown below. Select the OK button
box.

23. Select the OK button

to exit the Toolpath/surface selection dialog

to exit the Flow 5-axis dialog box.

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24. Select the 1/2 ball end mill and make changes to this page as shown below.

25. Select the Multiaxis parameters page and set the values as shown below:

Stock to leave on check surfaces

For check surfaces, the stock to leave parameter provides an additional margin of clearance.
Check surfaces are surfaces that are not cut, but are selected to identify areas for Mastercam to
avoid when creating motion that could gouge these surfaces.
Stock to leave on check surfaces can be entered as a positive or negative amount. A positive
amount leaves stock on the normal side of the surface. A negative amount is applied to the
opposite side of the surface and allows cutting into the check surface.

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26. Select the Flowline 5ax Parameters page and set the values as shown below:
Flowline 5ax Parameters
Use this dialog box to:
Refine the tool axis vectors.
Set the cut tolerance, the size of
the stepover and step along.
Set flowline parameters for the cut
surfaces.
Set the gap settings to control
retract motion between surfaces in
the toolpaths.

27. Select the Edges page and set the values as shown below:
Edges
Use this tab to control blending
between surface edges on the first
and last passes.
Edge Blend Options
Choose one from the list.
Normal Surface Edge: No edge
modification (default).
Skip Pass: Removes the selected
cutting pass or passes from the
toolpath.
Apply Blend: Adds the selected
blending pass or passes to the
toolpath, using the Blend
Parameters you specify.

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28. Select the Axis limits page and set the values as shown below:
Axis limits
Axis limits set a range of tool
motion for a rotary axis that limits
the amount of head tilt relative to
the tool position.
Using axis limits provides
protection against axis over-travel,
and lets you select the action to
take were axis over-travel to
occur.
Note: Axis limits are not available
for Rotary 4-axis toolpaths.

29. Select the Point Generator page and set the values as shown below:
Point Generators
Add additional tool positions for a more
accurate final toolpath and improved
surface finish. Mastercam supports two
point generators for multiaxis toolpaths:
Angle
Mastercam evaluates the tool moves using
an angle measurement. When the tool axis
angle between any two vectors in the
toolpath exceeds the value entered,
Mastercam inserts one or more additional
vectors. Can be used concurrently with
Distance.
Distance
Mastercam evaluates the tool moves using
a linear distance measurement. When the
distance between any two vectors in the
toolpath exceeds the value entered,
Mastercam inserts one or more additional
vectors. Can be used concurrently with
Angle.
30. Select the OK button

to exit Flow 5-axis.

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31. Activate a wireframe view by selecting the icon at the top of the screen.
32. If required set the graphics view to Isometric View and then select the Screen Fit icon.
33. Save your file.
34. Backplot the toolpath you have just created. Your backplot should be similar to the image
shown below.
35. Backplot the toolpath you have just created. Your backplot should be similar to the image
shown below.

36. Now verify the toolpath. Your verified part should be similar to the image shown below.

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TASK 6:
MACHINE FILLET RADII BETWEEN VANE AND MAIN HUB
In this task you will use a 0.5 diameter ball end mil to machine the fillet radii between the
vane and the main hub using the Advanced Multiaxis option.

The Advanced Multiaxis option on the Toolpaths menu provides enhanced 5-axis
multisurface machining strategies. You can choose to work with the advanced multiaxis
toolpaths in either of two ways:

Option 1.
You can choose to work with the full interface that gives you access to all the available
parameters and options. These are organized in several tabs as shown in the following picture.

Setting Up:
To access the full interface, select Toolpaths, Advanced Multiaxis from the Mastercam menu. In
the Select User Interface dialog box, click the 5 ax Multi Surface button

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Option 2.
You can choose from a number of simplified interfaces that have been customized for specific
applications and machining strategies. In this case, Mastercam only shows you a small subset
of the options, organized in a customized, easy-to-use tab: All the options that are hidden have
been preset to values appropriate for the selected application.
The following picture below left shows the custom interface for the Impeller application and
Floor Surface - Without tilt curve machining application.

Setting Up:
To access a customized interface, select the appropriate application and machining strategy
buttons in the Select User Interface dialog box.
Once you become familiar with parameters in the advanced interface, you will find the
customized interface easy to learn. You can switch from a customized interface to the advanced
interface by clicking the Switch to advanced interface button on the Misc tab.
However, once you switch from the customized interface to the advanced interface, you cannot
return to the customized interface for that operation.
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1. Before you start to work on this Task review the Lesson-7 Task 6 video on the multimedia
CD that came with this text. You will find the video in the Lesson-7 section; there is some
tricky selection of surfaces in this task so please check out the video before you proceed.
2. If required activate a wireframe view by selecting the icon at the top of the screen.

3. Set the graphics view to Isometric View and then select the Screen Fit icon.
4. Turn off the display of toolpaths by selecting Alt-T on your keyboard.
5. From the menu bar select Toolpaths>Advanced Multiaxis
6. At the Select User Interface dialog box select the 5 Ax Multi Surface tool box icon
Setting Up:
As you will be using the full interface for Advanced Multiaxis the 5 ax Multi
Surface button will enable access to the flowing options:

7. After selecting the toolbox icon on the left pick the toolbox icon on the right.

8. Select the 1/2 ball end mill and make changes to this page as shown below.

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9. Select the Surface paths page and set the Pattern to Parallel to curve. Set the remaining
values as shown below:

Parallel to curve
The Parallel to curve toolpath 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.
There are special options for the first and last cut. You can define a margin to get the exact
position where the tool is located at the edge within a certain distance.
Settings:
The distance between two neighboring cuts is the maximum stepover.
Define the area to be machined in the Area section.
Note:
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.
You can use only ONE curve. If you select multiple curves, only the first curve selected will be
used. For more complex face models, this means that the curve cannot be intermitted.

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10. Click on the Single edge button in the Edit cures section

11. In the chaining box set to single chain.

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

13. In the graphics window you will now be prompted to Add Chain: 1. Zoom as required and
select the curve shown below. If the arrow is not pointing to the right select the arrow from
the Chaining dialog box to reverse the direction:

14. Select the OK button

to exit chaining.

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15. Back at the Surfaces paths parameter pace click on the Drive surfaces button.

16. On the graphics screen you will be prompted Select surface for machining (watch your
surface normals. Before you select the surfaces you need to set up the appropriate
selection options on the General Selection Toolbar.
17. On the General Selection toolbar select the icon to toggle Activate solid selection. Do this
by clicking on the Activate solid selection icon shown below so it is greyed out.

18. After picking the Activate solid selection icon it should be greyed out as shown below.
Now click on the Select Face icon so it is greyed out. Ensure your General Selection
Toolbar is setup as below:

19. In the graphics window you will now be prompted to Select Solid Body or face: Pick the
surface shown below. The fillet between the main body and vane.

20. Click on the End Selection icon.

21. Click on the Done button

.
,

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22. Select the Tool axis control page and set the values as shown below:
Maximum angle step
The Maximum angle step value
sets the maximum allowed angle
change between two consecutive
toolpath positions. The calculation
engine outputs 5-axis toolpath
data that contains the tool tip
position and the direction vector of
the tool. The direction vectors are
not allowed to have an angle
change larger than the value
specified here.
Tool axis will be tilted
relative to cutting direction
With this strategy you can assign
a lead/lag angle to the cutting
direction and a tilt angle at the
side of the cutting direction.

23. Select the Gouge check page and set the values as shown below:

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24. Select the Link page and set the values as shown below:
First entry
First entry is the first approach of
the tool towards the part.
You can specify from where the
tool should approach (enter) the
part and whether there will be a
lead-in move when entering the
part.
The default setting is From
clearance area. In this entry
method, the tool comes from the
clearance area, moves to the
rapid distance, and enters the
surface to the feed distance.
If you select Use rapid distance or
Use feed distance, your tool will
start closer to your part.
25. Select the Roughing page and set the values as shown below:

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26. Select the Utility page and set the values as shown below:

27. Select the Machine definition page and set the values as shown below:
Machine definition tab
The machine information entered
into this tab is used only if you
have the machine simulation
module (available separately).
These values are not read from
Mastercam's Machine Definition
Manager.
See your Mastercam Reseller for
more information about machine
simulation.

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28. Select the Misc page and set the values as shown below:
Simulation
Select the Save toolpath as
geometry (delete: undo) to save
the toolpath as geometry in your
part file. Click the () button to
open the Options to create
geometry dialog box.
Tip comp
Use this option to control whether
the locations that are output to the
NCI file will be the tool center or
tool tip coordinates.

29. Select the OK button

to exit 5-Axis Multi Surface.

30. Activate a wireframe view by selecting the icon at the top of the screen.
31. If required set the graphics view to Isometric View and then select the Screen Fit icon.
32. Save your file.
33. Backplot the toolpath you have just created. Your backplot should be similar to the image
shown below left.

34. Verify the toolpath you have just created. Your verified toolpath should be similar to the
image shown above right.

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TASK 7:
TRANSFORM AND ROTATE TOOLPATHS
In this task you will use Transform Toolpath to rotate the initial two toolpaths to complete the
machining of the remaining two vanes on the propeller.
1. Before you start to work on this Task review the Lesson-7 Task 7 video on the multimedia
CD that came with this text. You will find the video in the Lesson-7 section.
2. If required set the graphics view to Isometric View and then select the Screen Fit icon.
3. If required turn off the display of toolpaths by selecting Alt-T on your keyboard.
4. From the menu bar select Toolpaths>Transform
5. On the Types and Methods page set the following. Ensure there is a check for both
operations in the Source operations list, both operations should be selcted.. To select both
operation hold the CTRL key down on your keyboard and select both folders in the Source
operations list.

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6. Now click on the Rotate tab and set the following:

7. Select the OK button

8. Save your file.

to exit the Transform Operations Parameters dialog box.

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TASK 8:
BACKPLOT THE TOOLPATHS
In this task you will use Mastercams Backplot function to view the path the tools take to cut
this part.
1. Set the graphics view to Isometric View and then select the Screen Fit icon.
2. Un-zoom .8
3. Activate a shaded view by selecting the icon at the top of the screen.

4. In the Toolpath Manager only select the third operation to Plot, the transformed toolpaths.
5. The next step is to select the Backplot selected operations icon shown below:

6. After reviewing the backplot of the toolpaths select the OK button

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to exit Backplot.

Multi-Axis-Lesson-7
TASK 9:
VERIFY THE TOOLPATHS
In this task you will verify all the toolpaths.
1. In the Toolpath Manager only select the third operation to verify, the transformed toolpaths.
2. Select the Verify selected operations button circled below and hit the play button:

3. At the Verify dialog window activate Simulate Tool.

4. Next click on the Verify options icon as shown below:

5. At the Verify Options dialog window set the Miscellaneous options as shown below:
Stock Shape - Solid
Choose this option to use a solid
model in the current part file as
the stock. Then click the Select
button to return to the graphics
window and select the solid.
This part is already setup to use a
solid as the stock.

6. Select the OK button

to exit Verify options.

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7. Select the play button to verify the toolpath.

8. Select the OK button

to exit Verify.

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TASK 10:
POST AND CREATE THE CNC CODE FILE
1. In the Toolpath Manager only select the third operation to post.

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.

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6. Enter the same name as your Mastercam part file name in the NC File name field MULTIAXIS-LESSON-7 and select the Save button
7. Select the Save button and review the CNC code.

in the top right corner to exit the CNC editor.

8. Select the
9. This completes Multi-Axis-Lesson-7.

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MULTI-AXIS-LESSON-7 EXERCISE #1: THREE-BLADE PROPELLER
MULTI-AXIS-LESSON-7-EX-1.MCX

MULTI-AXIS-LESSON-7 EXERCISE #2: TWO-BLADE PROPELLER

MULTI-AXIS-LESSON-7-EX-2.MCX

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