1. ME 418 M8, M9, & M10 2014 Robert Peace rob.peace@usask.ca

2. Before launching Mastercam for the 1 st time:  Open Windows Explorer & Navigate to:  Computer  Windows (C:)  Users  NSID  Default  Copy my mcamx7 folder  H:  My Documents  Paste my mcamx7 folder M8

3. Dimensioned Drawing

4. Set-Up Sheet

5.  Things to Ensure:  Coordinates are: D+, Z (diameter and Z)  Units are Metric  Machine Type is Baxter Lathe (Operations Manager)  File Save location is H: drive (if it is left on C:, you won’t be able to access it).  If undo is unavailable, Esc the function and it will be available. M8 – Drawing in MasterCam

6. M8 – Stock Set-Up Origin ZW= 47.3+1.7+3+4=56.0 Jaw Width = 47.3 mm Part-off Tool W=4.0 mm B=3.0 mm Safety Clearance ~2mm, round to 1.7 mm Grip Length ~ 20 mm (technically 20.3 (29-8.7) Position along Axis, Z: -29.0 (20+8.7~29) Chucking ~1/3 of finished length: 65/3 ~ 20 mm Total Length: 20+8.7+65+2 = 95.7 Round to 96.0 mm Facing pass allowance, after rounding = 2.3 mm Important measurement: =8.7+65+2.3=75 mm

7.  First is Always a Facing Pass with tool ID#5  Leave stock behind for finishing passes.  Always “From Tool”  Reference points to ensure safe tool paths.  Lead in/Lead out parameters for some tools are required.  Cut-off tool is always tool ID#130 and in position 8. M8 – Tool paths

8. Cup Reference Points (D, Z) (0,40) (20,40) (20,62.5) (30,62.5) (42,50) (38,32) (48,28) (48,0) (54,0) (54,30) (58,38) (58,45) (58,55) (44,43) (54,70) (200,0) (54,41) (33,70) (18,70) (0,70) Barstock

9.  A printed, dimensioned (METRIC) drawing of your work-piece. SEE PAGE 6 for Details.  A printed listing of all tools used, in sequence, maximum of 8 tools.  Draw your part in AutoCAD, as it is a smoother import than Solidworks.  Draw part to Full Scale.  Drawing already imported into MasterCam, and origin set (see page 68 of the lab manual).  All Roughing passes attempted in MasterCam.  Templates for set-up sheet, drawing and Job Card can be found on the ME 418 website. For M9

10.  Design Considerations (see lab manual 6-9).  Maximum diameter = 50.8 mm  Maximum length <= 2.5* stock diameter  Keep the bar-stock as thick as possible close to the chuck for as long as possible.  Very small diameters can result in unstable work pieces and chattering (poor surface finish).  Design should include circular arcs and straight lines.  Tool #1 must be the reference tool – Tool ID#5 (T0501)  Tool #8 must be the part-off tool – Tool ID#130 (T13001)  Tool library is in the Lab Manual  Late Penalties & Marking Scheme supplied on pages 3-6 of the lab manual. For M9

11.  If these are not correct, collisions or “Machining Air” can occur.  Says where the cutting edge is in space relative to the workpiece datum (Origin).  When a tool change occurs, the Turret does not move, but the coordinates X, Y change.  This is because the tools cutting edge is in a different location.  Description of calculations: Page 61 of lab manual  Values for “cup” example: Page 63 Work Piece Datum & Tool Change Positions, G50’s

12. Tool Change Video

13.  Unmodified Code found on page 56  Debugging Tools:  Mastercam Backplot  Shows tool path, rapid moves, tool and holder  Can be expanded (double blue triangles) to show coordinates D, Z, Y of leading edge of tool during run through, rapids and feeds different colors.  Can set to stop at any change in XYZ, (stop sign to right of progress bar).  Mastercam Simulation  Shows tool position using X, Y, Z coordinate system, not the coordinate system used in the drawing process.  X  Z in drawing  Y  Radius in drawing (even though we used diameter programing)  Z  Y in drawing (always 0.0 for our case)  Plot.exe (similar to Backplot)  Custom made DOS program to assist with student code debugging.  Space.exe  Custom made DOS program to space out CNC code to assist with student debugging. CNC Code Debugging

14.  See Page 4-5 of lab manual.  Two weeks after M9:  Completed Mastercam file - digital  Completed CNC Set-up sheet – hard copy  Completed Engineer’s Drawing – hard copy  Work Piece Datum & Tool Change Position (G50’s) - digital  3 School Days before M10:  Debugged CNC code – MUST have been run through SPACE.exe - digital  Any corrections to G50’s, drawing or set-up sheet.  Drawing and set-up sheet – hard copy (only if significant changes). Due Before M10