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What’s
New in Mastercam Mill and Design Version 9.1
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Welcome
Version 9.1 of Design, Lathe, Mill, and Wire have been developed in conjunction with the Router 9 project, with the majority of changes during the 9.1 development cycle focused in the Router product. At the same time, CNC Software has taken advantage of the time to include new options in Mastercam Design, Lathe, Mill, and Wire. The following sections list what additions have been made in each product - additions that will enhance your productivity. This version release is part of our ongoing software improvement plan as we progress toward Mastercam X.
Listed below are the Mill and Design V9.1 product enhancements.
· Solids
· Verify
Visual Basic® Support
Now all Mastercam products (except Entry) can support scripts written in Microsoft Visual Basic. Press [Alt+C] and select MCAMVB.DLL. When prompted for a VBS file, select EXAMPLE.VBS from the Data directory. This very simple example requires at least one entity to be on the screen.
You will see this dialog box with options to create a new VB Script, edit an existing script, or run the current script. You can also assign VB Scripts to keystroke sequences and the toolbar in the Screen, Configure, Toolbar/Keys dialog box.
Mouse Wheel Support for Zooming
Version 9.1 now supports the ability to zoom in and out by simply rolling the mouse wheel on mice equipped with this device. The Home key also acts as a “Fit” command.
Support for Specific Line Widths in Printing and Plotting
You now have the ability to control the width of lines created during printing and plotting. A simple interface lets you set the desired width by color to allow for different widths on your plots and prints.
The printed widths correspond to the current graphical widths as follows:
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Graphical
Width |
Printed
Width |
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1 |
1 pixel |
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2 |
0.15mm |
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3 |
0.3mm |
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4 |
0.5mm |
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5 |
0.7mm |
Mastercam’s file translators undergo constant change and improvement. With the release of 9.1, the translators have been updated to support the latest software releases. Here is a list of the updated translators and the current version supported.
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Parasolids |
Version 14.1 |
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ACIS |
Version 10 SP2 |
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STEP |
Newest engine release |
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Autodesk Inventor |
Version 6 (Windows 98 and higher OS) |
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Solid Edge |
Version 12 |
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SolidWorks |
2003 |
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ProE |
Granite 2 |
Numerous requests from users have brought about a new option on the Solid, Boolean menu. This option enables the creation of non-associative solids. When the Associative option is set to N, additional options to keep the Target and the Tool bodies are available. In the above example, the yellow tool solid is subtracted from the green target to form a mold cavity and not deleted. This allows it to be used multiple times.
Updating Posts From Previous Versions
Since Version 9 is a major release, posts that have been written for any earlier version must be updated to ensure proper functionality and safety. Even if your post was previously updated for use with Version 9.0, you do want to update it again for use with Mastercam Version 9.1. If a post from a release prior to v9.0 is used, Mastercam will issue a warning to you with instructions to run this DLL file. This function is found under the NC utils, Post processor menu.
For information on what this update procedure does to the post processor, see the UPDATEPST9.HLP help file in the Chooks directory.
Compensation in Control Error Messages and Post Question 1520
An important change has been made to the way compensation in control is being handled that will affect a small number of users. This change is being made because of the number of calls received by our Technical Support department and Resellers. Prior to 9.1, users would receive an error message like this when the software determined an arc move would be less than the cutter radius, and would end up resulting in a 0 (zero) radius arc in the control. This error frustrated many users whose controls automatically handle this.
In Version 9.1, checking for those corner conditions and reporting those errors has been tied to question number 1520 in the post. Prior to 9.1, this question was used only to warn the user of this case. If a user has this type of control, they need to edit question 1520 and set it to Y to check for this condition. If they have this question enabled and encounter this type of condition, the following error message will be displayed.
The Optimize option found in the Contour parameters tab will continue to override this post question.
Other Post Additions/Changes
This new post switch variable is
added to all posts (except Wire posts):
skp_lead_flgs : 1 #Do NOT use v9 style contour flags
This "demotes" the new
style contour flags (like Wire has had) so the post does not see any different
values than it was used to. If you alter your post to use the new style contour
flags in Version 9.1 Mill, be sure to change the answer for
"skip_lead_flgs" to 0 (zero).The
addition of this flag is very important.
Questions 159, 1503, 1520, 1521,
and 1530 are added to all post processors.
159. Show first and last
position as fully compensated in simulation? n
1503. Write transform
operations (0=transform ops, 1=source ops, 2=both)? 1
1520. Display a warning when
cutter compensation in control simulation finds an error? n
1521. Number of controller
look-ahead blocks for CDC in control? 2
(Note: The 1521 question is for future use.)
1530. Ignore work offset
numbers when processing subprograms? Y
The 1530 question directs Mastercam to ignore the work offset numbers when processing transform operations for subprograms. If the response to this question is Y (yes), transform toolpaths will create a single subprogram number even if the work offset numbers do not match in copied patterns. This happens frequently with rotate transform toolpaths. Ignoring the work offset number prevents identical subprograms from being generated.
Post Numbered Questions Information
The new names for these files are Mill9.PNQ, Lathe9.PNQ, Wire9.PNQ and Router9.PNQ. PNQ = Post Numbered Questions. These files provide additional information about the numbered questions in the post processor.
Support for Full 360 Degree Arcs
With some simple changes to the post, it is now possible to output full circles as a single 360-degree arc move instead of two 180-degree moves. Refer to the Post update documentation mentioned below for details.
Additional Post Changes
All new post information specific to Version 9 is documented in a file called Post Processors - What's New in V9.PDF. This file is installed in the same directory as the What's New files for each product (C:\Mcam9\Whats New).
The transition from the Sirius engine to the MachineWorks® engine for toolpath verification has been completed. Now only LightWorks code is being used and we can focus on addressing more requests and fixing more bugs. In this release, you will find that the speed and quality of TrueSolid verification are significantly improved.
The following table shows speeds measured on a DellTM Pentium® 3 notebook computer with Microsoft® Windows® 2000 running at 1.2 Mhz with 256MB of RAM. The graphics card in the test machine is the ATI Mobility M4 with the hardware acceleration set to 5 of 6. “Q” indicates the quality setting 1 to 5 with 5 being the highest. The “1/1” indicates that the moves per step and moves per refresh are equal to 1. “Q5” with “1/1” indicates the highest possible setting and puts the most stress on the CPU and the graphics card. “FF” at the end of some of the wireframe tests indicates the time was taken from Fast Forward mode, thus eliminating all graphics changes until the toolpath is completely processed. All times measured during the testing of Version 9.1 were from completed tests. Three of the tests measured against Version 9.0 SP1 were stopped before completion - the percentage of the completed test is given with the elapsed time it took to complete it to that point.
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9 SP1 |
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9.1 |
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Constant-Z 140.8k |
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Turbo Q5 1/100000 |
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:13.2 |
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:3.4 |
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Wireframe Q5 1/1 |
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18:16.7 |
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:46.5 |
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Wireframe Q5 1/1 FF |
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:09.2 |
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:04.8 |
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Turbo Q3 1/100000 |
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:01.9 |
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:01.1 |
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Wireframe Q3 1/1 |
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* 20% 03:22 |
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*100% :40.9 |
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Wireframe Q3 FF |
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:04.7 |
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:03.5 |
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Scallop 177k |
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Turbo Q5 1/100000 |
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:11 |
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:03.9 |
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Wireframe Q5 1/1 |
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* 20% 5:23 |
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*100% 4:00 |
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Wireframe Q5 1/1 FF |
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3:19 |
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1:03 |
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Turbo Q3 1/100000 |
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:01.9 |
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:01.4 |
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Wireframe Q3 1/1 |
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*15% 3:21 |
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*100% 2:30 |
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Wireframe Q3 FF |
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:43.8 |
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:30.7 |
View Information Retained
Now when entering Verify, the current
view information from the Mastercam graphics window will be seen in Verify.
Contour – Lead In/Out Controls
Significant additions have been made to the lead in/out capabilities based on customer requests. Each enhancement addresses needs that used to require significant workarounds to achieve.
Plunge After First and Before Last Move
This option is useful when working in tight spaces where there is not enough room to turn cutter compensation on when the tool is at the cut depth. When enabled, cutter compensation occurs at the highest defined plane, and then the tool plunges to the desired depth and performs the second lead-in move. When used before the last move, the tool moves off the part, and then retracts to the highest defined plane and turns compensation off. The following picture shows the tool motion when cutting a slot that is too narrow to allow compensation to be turned on at the cut depth.
Override Feed Rate
You now have greater control over the feed rate on the lead-in and lead-out moves, which lets you dial in the best speed for the finish you need.
Adjust Start/End of Contour
This new idea came from a couple of European dealers who needed greater control of toolpaths with solids. This option allows you to extend or shorten the chain before making the entry and exit moves. This is especially helpful when working with compensation in control. Enter a percentage of the tool diameter to control the distance.
The following example shows the toolpath being extended by 50% of the tool diameter with a tangent entry motion, so that compensation is turned on completely before the cutter gets close to the part. The exit extends the contour by 50% so that the tool is clear of the material before compensation is turned off.
The next example shows a contour being shortened by 75% of the cutter diameter, so an edge break can be cut without modifying or creating any additional geometry.
Pocketing – Finish Pass Controls
Several enhancements have been added to give greater control and flexibility.
Spring Passes
This feature forces additional passes to be made around the part, identical to the last finish pass, to pick up any additional material that may have been deflected by the tool during the last finish pass.
Override Feed/Speed
This allows you to set a
different feed and speed for the tool during the finish pass to better control
the part finish.
Pocket Lead In/Out
New lead in/out options (developed for Contour toolpaths) to control the plane where compensation is turned on and the ability to override the feed rate of the finish passes have been added to Pocket finish passes.
Thin Wall Pockets
This new option gives greater control for finishing thin wall pockets. It allows you to control the depth of each finish pass relative to the depth cut. To enable these options, you must be using Depth Cuts so there is more than one roughing pass in the pocket toolpath. You must also deselect the “Machine finish passes after roughing all pockets” check box. Then select on the Thinwall check box and open the dialog box. The following dialog box screen shots shows the system taking two finish passes in Z for every roughing pass, which automatically displays the maximum calculated finish depth.
Rough Pocket Finish Parameters
The new finish options created for 2D pocketing have been added to 3D pocketing as well. This includes spring passes, overriding feeds and speeds for the finish pass and the lead in/out moves, and thin wall pocketing. Another new option is using Wear or Reverse Wear compensation for the finish passes. See “cutter compensation, Mill” in the online Help Index for more information.
New Gap Setting for High Speed Contour and Restmill Toolpaths
In High speed machining, the stepdown in Z is often much smaller than that used in traditional machining. This means the gap size will be smaller, and subsequently the tool will retract more often. By adding an option to set gap size by a percentage of the tool diameter, you will have greater control over the frequency of rapid moves.
Tangent Entry and Exit Lines Added in Restmill and Contour
Now you have the additional benefit of defining lines, along with arcs, for tangent entry and exit moves in Restmill and Contour toolpaths.
New Project Blend Controls
There are three new features in Project Blend that make it an even better toolpath. These new controls will give greater control to rival the quality of a Flowline toolpath without the concerns of aligning surfaces.
Along Cut Resolution
This option lets you set a distance that controls how far apart the across scans are created along the blend curves. For parts with significant change in curvature, a smaller value yields better results.
Quick vs. Thorough Projection Methods
This switch allows parts with no vertical walls to do the quickest scans and get excellent results. Use the Thorough method when the part contains vertical and steep walls - it will take longer, but the quality will be very good.
Support for a Spiral Cut Method
This new option keeps the tool down and eliminates stepover, creating an even better finish.
Retract Between Cuts
The Project Blend toolpath works well for many different applications. With the addition of this new option, it will work well for Engraving as well. When selected, this option forces the cutter to retract between contours, which is perfect for engraving applications.
Pocket and Contour - Support for Undercuts with Slot, Dove, and Lollipop Cutters
The ability to machine undercuts in Rough Pocket, Rough Contour, and Finish Contour has been added. Using Slot, Dove, and Lollipop mills, you can now create gouge-protected undercuts. Version 9.1 can compensate to the tool shape and protect the shank of the tool from hitting the material.
Minimize Burial Option Added to Rough and Finish Contour
When the Optimize option is selected in Finish or Rough Contour, you can select the Minimize Burial option. This option will retract the tool in cases where it could be encountering stock on both sides as it works itself around bosses. With Optimize deselected, Mastercam cuts parts by Z level and may produce more retracts than desired. Optimize keeps Mastercam in one region until all of the Z level cuts are made. With Minimize Burial selected, the tool will stay in an area and make as many Z cuts as possible until it encounters stock from another region. Then it will retract and reposition.
Finish Shallow – Ordered Cuts by Minimum Distance
This new option creates more efficient toolpaths for certain geometry conditions.
Simplified Entry and Exit
The Entry/Exit dialog has been simplified by removing the Approach Height and Retract Height options. Entry and exit moves will now use the Clearance, Retract, and Feed planes like other toolpaths.
New Backplot Controls
You can now see the tool tip motion in the backplot of 4- and 5-axis toolpaths, with an additional option to display the tool axis vectors.
Curve 5-axis Additions
· Support for check surfaces.
· Depth Cut control (similar to 2D Contour and Pocket) allows for multiple passes along the tool vector, simplifying control over the amount of material to be removed on each pass.
· Multi Passes controls (similar to 2D Contour) enable multiple stepovers of the tool, allowing for greater control of stock removal.
· Axis limits, similar to those found in the Msurf 5ax functionality introduced in Version 9.0, are now included in Curve 5-axis. This functionality produces toolpath output that will not exceed your machine’s axis rotation limits.
· Point Generators, introduced in Version 9.0 Msurf 5-axis, have also been added to Curve 5-axis for Version 9.1. This option gives you greater control in areas where the normal vector changes angles dramatically.
Swarf 5-axis Additions
· Support for check surfaces.
· Depth Cut control (similar to 2D Contour and Pocket) allows for multiple passes along the tool vector, simplifying control over the amount of material to be removed on each pass.
· Multi Passes controls (similar to 2D Contour) enable multiple stepovers of the tool, allowing for greater control of stock removal.
· Axis limits, similar to those found in the Msurf 5ax functionality introduced in Version 9.0, are now included in Curve 5-axis. This functionality produces toolpath output that will not exceed your machine’s axis rotation limits.
· Options to cut One way or Zigzag when Depth Cuts or Multi Passes are enabled.
· Point Generators, introduced in Version 9.0 Msurf 5-axis, have also been added to Curve 5-axis for Version 9.1. This option gives you greater control in areas where the normal vector changes angles dramatically.
Flow 5-axis Additions
· Depth Cut control (similar to 2D Contour and Pocket) allows for multiple passes along the tool vector, simplifying control over the amount of material to be removed on each pass.
· Point Generators, introduced in Version 9.0 Msurf 5-axis, have also been added to Curve 5-axis for Version 9.1. This option gives you greater control in areas where the normal vector changes angles dramatically.
Multisurface 5-axis Additions
· Depth Cut control (similar to 2D Contour and Pocket) allows for multiple passes along the tool vector, simplifying control over the amount of material to be removed on each pass.
MCU Light v2.1 (a substantial sub-set of the MetaCut Utilities) is included at no charge with Version 9.1. The MCU Light OEM version for Mastercam requires a Mastercam security device (SIM). MCU Light is not included with Design.
MCU is a powerful set of utilities for your toolpaths that will quickly become an essential tool throughout your shop. MCU integrates directly with Mastercam, and also works as a stand-alone application, that helps you problem-solve and analyze your toolpaths both before and after post processing.
Free Trials of Current and Future MCU Features
As an MCU Light user, you will automatically receive a free 30-day trial of the full MCU v2.1 software. The full version of MCU includes G-code verification, graphical editing and comparison, multiaxis backplot of NCI files, and much more. As new features are released for MCU, you can try them for free just by downloading and requesting a trial version. Talk to your Mastercam Reseller or check the MetaCut Web site for newly released MCU features and versions.