The FaroRUS. Click the Details tab. Note the File version number. The latest RUS version number is 7. Do not put it in a sub-folder. Click the Windows Start menu. In the search field type cmd and press Enter. The Command Prompt window appears. If not, at the prompt type one of these commands and press Enter.

This page will enumerate the steps required to have an approvable MasterCAM files. Staff and TA's are not available to set up users' files for them. A basic workflow for successful MasterCAM setup is as follows:. It is necessary to separate the two, because the material qualities and behaviors vary greatly and require different tooling and parameters for successful milling. A special template is provided for milling flat stock materials, such as single sheets of plywood or MDF. The GSD FabLab does not currently provide templates for less frequently machined materials, though we do maintain tooling to work with the following:.

Rhino File Preparation. Check that geometry fits within the maximum machinable extents of the intended CNC mill. Organize geometry in Rhino by layer, such that each layer will receive similar treatment in MasterCAM e. Building Tops, Draped Surface, etc. Click file in the ribbon menu, and choose merge to open the file picker window. Select the. Click open , and the geometry appears in the MasterCAM model space. Select and then de-select an option from the bottom "Settings' of the Merge Dialog.

This slowdown can be avoided by changing Visibility from shaded to wireframe prior to merging. Because the origin of the file typically corresponds to the origin used on the machine, it is important that your geometry be located relative to the origin such that it is appropriately located on the machine. Working far from the World Top Plane Origin in Rhino or similar applications will often cause the geometry to be located far from the origin in MasterCAM, so it's best to catch this issue early, before getting too far along in MasterCAM.

Your geometry should be located within the positive X, Y, and Z quadrants, with the stock modeled such that it has a corner located at 0,0,0. The gnomon and axes visible on the screen should help to verify whether the geometry needs to move in order to satisfy this condition. Machine dimensions vary, as do the lengths of their respective axes of travel. Make sure your geometry fits within the dimensions of the machine you intend to use. MasterCAM will use the input stock size when simulating, so it is vital to ensure that dimensions are true to the physical material that will be placed on the milling table.

In the toolpath manager pane, expand the properties subgroup. Choose stock setup , and the machine group properties window opens. The stock box is represented by a dashed red rectangular prism.

Enter the as-measured dimensions of your stock into the X, Y, Z fields. Default units are inches. Tick the display checkbox to show stock box in MasterCAM model space.

After defining stock dimensions, u sers MUST manually update machining heights to reflect the stock thickness for each operation individually. MasterCAM will not auto-update these values. Inaccurate values cause collisions during verification. A roughing operation is used to remove large amounts of material rapidly and to produce a part geometry close to the desired shape.

A roughing operation uses large diameter tools and coarse settings, and should not cut all the way down to the drive surface s , instead leaving a small offset for the finishing operations to clean up afterwards.

When stock thickness exceeds the shoulder length of the tools, the surrounding uncut stock may interfere with toolpaths drawn on the perimeter of the part, causing collisions.

In this circumstance, it is necessary to partially clear away the stock outside the part perimeter before proceeding to the finishing operations. The Contour 2D operation may be used for roughing as follows:.

Note that the Contour 2D operation is not context-aware. Nearby parts may be gouged if there are multiple parts being machined from a single stock. The Surface Rough Parallel operation moves the tool in equally spaced parallel passes in the XY plane across the surface, cutting down incrementally in multiple steps.

The toolpath can be drawn as One Way best for anisotropic materials with grain direction, slower or Zigzag best for isotropic materials, faster. Note that all surfaces except stock extents are assigned as Drive surfaces in a typical MasterCAM file. A finishing operation follows roughing and is used to achieve the final geometry and surface finish. Most MasterCAM files need at least one and frequently several separate finishing operations to produce an acceptable part.

Finishing operations clean up the extra material purposefully left behind by the roughing operation. Finishing operations must be employed on a case-by-case basis, as the utility of each operation type varies from one file and geometry to the next. See reference pages linked above for a detailed explanation of concepts and usage that are common across all operation types. Commonly used finishing operations are listed below. Users must review them and determine which operations are appropriate for their geometry.

Figure: 3. You can undo as many steps as needed. To delete unwanted geometry, select the geometry first and then press Delete from the computer keyboard. We are creating the lines to use them as part of the geometry as well as construction lines.

NOTE: The construction plane or the graphics view does not affect the way in which the solid is generated. A Mastercam file can contain separate levels for wireframe, surfaces, drafting entities, solids, and toolpaths. By organizing your files into levels, you can easily control which areas of the drawing are visible at any time and which parts are selectable. By doing so, you will not inadvertently make changes to areas of the drawing you do not want to change. In this step, we will change the Active Level to 2 to create the solid on Level 2.

Mastercam extrudes entities by driving the shapes of the entity along a linear path using a specified direction, distance, and other parameters that further define the results. Chaining is the process of selecting and linking geometry entities such that they form the foundation of a toolpath, a surface, or a solid.

When you chain the geometry, you can select one or more sets of curves lines, arcs, and splines that have adjoining endpoints.

Chaining differs from other selection methods because it assigns order and direction to the selected curves.

Chaining order and direction determine how surfaces, solids, and toolpaths are generated. NOTE: If you did not select the chain correctly, you can use the Unselect button dialog box to undo the previous selection. An arrow will appear on the geometry. This arrow indicates the direction of the extrusion. If the arrow appears upward, click on the Reverse All button as shown in the figure to the right to flip the pointing direction. Press Enter. Extrusion Operation is used to create a solid body, to cut a solid body, or to add a boss to another solid.

Reverse Direction extrudes the solid in the opposite direction from the arrow on the chained geometry. Distance enables controling the outcome of extrusion through various ways: by inputting a value for the extrusion Distance, by extending cuts Through all targeted solids, by extruding in Both directions, or by Trimming to Faces that are selected.

Both Directions allows you to extrude in both the extrusion direction and the opposite direction. Figure: NOTE: In this step, the chaining direction does not matter because the direction of extrusion can be modified afterwards. Change the Type to Cut body and enable Through all as shown in Figure: NOTE: To modify any of the solids operation, double click on the operation. The corresponding dialog box will appear on the screen, and hence the parameters can be modified.

To update the solid after modifying the parameters, please click on the Regen all button from the Solids Manager. Change the Type to Add boss and enable Distance with the specified amount as shown. If the arrow appears downward, click on the Reverse All button to change the direction of the arrow.

Discover other Mastercam Training Solutions at www. While there, be sure to join the conversation! Expand your Mastercam knowledge, anytime and at your own pace, with our selection of step-by-step online video eCourses. Choose a topic below for more information. Wire - When checked, wire is present threaded. Power - When checked, applies voltage to the wire.

Flush - Sets the initial state for the water settings On, Off, or Other. The "Other" setting is specific to the control. Fill tank - Sets the initial state for the fluid tank. Generate stops — Creates a stop point before each tab. For first tab cut of each chain - Outputs a stop code before the tab cut for the first tab cut on each chain. Subsequent tab cuts do not include stop codes. For first tab cut in the operation - Outputs a stop code before the tab cut for the first tab cut of the operation.

Subsequent tab cuts throughout the operation do not include stop codes. Page 17 Infinite look ahead — Examines for wirepath self-intersections along the entire contour before creating the wirepath. If it finds a wirepath self-intersection, Mastercam Wire modifies the wirepath so that it does not cut the portion of the part that comes after the intersection. Land Height — Sets the height at which the wire pivots to the taper angle.

The system can add a line or two, of given lengths and an arc, of given radius and arc sweep to the beginning of each chain. You can set the following options. Line only: Lets you add a line at the beginning of each chain. Line and radius: Lets you add a line and a radius at the beginning of each chain. Page 18 The system can add a line or two, of given lengths and an arc, of given radius and arc sweep to the end of each chain.

Line only: Lets you add a line at the end of each chain. Radius only: Allows the system to add an arc to the end of each chain. Radius and line: Lets you add an arc and a line at the end of each chain. Radius and 2 lines: Allows you to add an arc and two lines at the end of each chain. Maximum Lead Out Length: Allows you to determine the distance that the wire travels toward the cut position on each pass.

Overlap : Lets you set an overlap for the skim cut. Page 19 Linearization tolerance — Sets the tolerance to convert 3D arcs and 2D or 3D splines into lines while creating the wirepath. Smaller linearization tolerance values make more accurate wirepaths, but may take longer to generate and create a longer NC program. Misc values button — Sets the values of the miscellaneous integers and reals that can control some specific machine settings.

Optimize path — Applies an additional check on the no core wirepath that takes additional time to generate but eliminates material dropout. Not available for Morph or True Spiral cutting methods. Output stop code — Sets the types of stop points that can be assigned to a wirepath.

Glue stop - Pauses the wire machine before it cuts the tab only if the "optional" switch on the wire machine is turned on. If the switch is off, the machine cuts the tab without stopping.

A glue stop gstop is also known as an optional stop. Glue stop outputs an M01 code. Stop - Pauses the wire machine until the operator restarts the machine. The stop is also known as a program stop. This stop outputs an M00 code. Power Settings Library - Contains wire EDM machine-specific settings documented by the manufacturer for the material you are cutting. A wire power settings library is organized into 24 "passes. Pass is synonymous with "cut".

A library can contain up to 24 passes, each with unique power settings needed to cut a certain material type on a certain wire EDM machine. For example, Pass 1 in the library may correspond to a rough cut, Pass 2 a tab cut, and Passes 3 — 5 finish cuts also known as skim cuts. Select Library button: - Allows you to choose the power settings library from a list of existing libraries.

Associate to library: - Allows you to associate the selected library to the operation. If it is not checked the system allows you to edit each pass of the existing library. Save Library button: - Allows you to save the changes made in the selected library.

Starting pass: - Sets the first pass to be used by the wirepath. Offsets: - Sets the wire offset number. Refer to your wire machine documentation. Page 20 It depends on material, wire type and thickness. Feedrate: - Sets the speed at which the wire cuts the material in inches per minute or centimetres per minute. Some controllers calculate the feed rate based on material nad thickness.

Other controllers require a value that represents the material and the thickness. Wire diameter: - Sets the width of the wire. Wire radius: - Sets the radius of the wire automatically when you enter the diameter. Wire overburn: - Sets the extra material that can be removed by the wire. Stock to leave: - Sets amount of stock to leave for the finish pass skim cut. Total offset: - Displays the sum of the wire diameter, overburn and stock to leave.

Registers - Values that correspond to the registers in the controller. Pass comment: - Allows you to enter information about the current pass.

Perform rough cut — Enables the rough cut. Additional skim cuts before tab : - Sets the number of skim cuts to be performed before the tab cut. Program — Lets you set the program number for the machines that require a program name. Rapid Height — Sets the Z height of the upper wire guide for rapid moves whether or not the wire is threaded. Reset pass number on tab cuts — Allows you to use Pass 1 rough cut settings when cutting the tab. You use it primarily for inserting arc moves around sharp corners in the wirepath.

This is because some objects in the wirepath do not intersect; in these cases, the computer will automatically add a fillet. Page 21 Cutting method — Sets the patterns Mastercam Wire uses to clean out the no core part. Zigzag Constant overlap spiral Parallel spiral Parallel spiral clean corner Page 22 Start — Lets you set the first line number in the NC program for the machines that require block numbers.

Stepover percentage - Sets the distance the wire shifts over between XY moves as a percentage of wire diameter. Changing the stepover percentage automatically adjusts the stepover distance. Stepover distance - Sets the distance the wire shifts over between XY moves Changing the stepover distance automatically changes the stepover percentage.

Sync option — Synchronizes the upper and lower contours using chain synchronization. When synchronizing the contours, Mastercam Wire breaks each chain into a number of separate subchains then matches up the chains using the Sync mode selection. The Sync option provides a choice of methods that Mastercam Wire can use to place points along the chains, which it matches up when synchronizing the chains. Page 23 The value you enter for Step Size determines how far apart these points are placed.

We recommend that you keep this value small to retain accuracy in the corners. In many cases, the default value of. By branch - Requires branch lines to be added to the geometry to create sync points as shown in the example above. By entity - Matches the endpoints of each entity and requires both chains to have an equal number of entities. By node - Applies only to parametric splines and synchronizes the two chains by nodes on the splines. Linearization tolerance - Provides a factor that Mastercam Wire uses to place sync points along chains when using the by branch, by entity, by node, and by point sync option.

Page 24 Suppress all cut flags — No cut flags will be written in the NCI file. Skim cuts after tab — Allows you to program the finish passes. Together - Sets the number of skim cuts to make before moving to the next contour in the operation. Separate - Sets the number of skim cuts to make, with one made on each chain in the operation separately. Separate is enabled only when you choose Rough, tab, and finish separately.

Subprogram — Creates subprograms called by the main program each time the program repeats the same passes in the XY plane. Used to generate a smaller NC program. STCW — Sets the start, thread, cut and work origin positions for the current operation. Start - Is the home position of the operation. Thread - Is the point where the machine threads the wire, usually a predrilled hole in the material. The wire cuts from the thread position to the start of the chain based on the settings for lead ins and lead outs.

Cut - Is the point where the wire machine cuts the wire before moving to the next thread point. Work origin - Is a reference point for wirepath creation and is set to the system origin by default. Changing the work origin offsets the coordinates for the wirepath. Page 25 Tab — Sets an area of uncut material that keeps the part in place until the machine operator can secure it prior to cutting it free from the rest of the material. Using tabs prevents the part from falling into the tank and possibly damaging the lower wire guide.

Tab width - Sets the tab size. Number of tab cuts - Sets the number of passes the wire machine the tab. Make the tab cutoff move with the skim cut - Make the tab cut at the end of the skim cut or rough cut if there is no skim cut. All cuts together — Allows you to group together all the cuts of a chain rough, skim cut, tab. The method is used when you have multiple contours selected in the operation. Tabs and finish together — Allows you to generate first the roughing cuts on all chains, and then group together all the tab cuts with the finish cuts of each chain.

Page 26 Automatic — Allows you to set the number of tabs to place on each contour in the operation.

Mastercam Wire spaces the tabs equally over the contour. Manual — Allows you to manually select the tabs positions around the contour, by selecting Position button.

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