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Mastercam is easy and intuitive to use, but maintains a depth of features to support the most complicated jobs. Our toolpaths are elegant and remarkably efficient. We help connect the largest CAM community worldwide, and our success is a direct result of listening and responding to industry needs for productivity solutions from job set up to job completion. Our dedication to the manufacturing community drives Mastercam innovation.

We collaborate with leading tooling, software, and machine tool manufacturers to develop new technologies. Opportunities to drive down costs and increase profits can be found across the entire shop. Mastercam supports improved use of data-driven manufacturing in the digital age. Mastercam supports programs and competitions for students to develop practical skills and experience.

Figure: 6 Angles are measured in degrees from the position as shown in Figure: 7. CW angles are negative. For example, the angle is the same as Reference position for the polar coordinates. Angles can be expressed in degrees, minutes and seconds, which is abbreviated, DMS. It's important to know which quadrant the part is in because the sign of the coordinates changes based on the quadrant.

As shown in Figure: 8, all points in quadrant I , have positive X and Y values. Points falling in quadrant II have negative X and positive Y values, and so on. Figure: 8 Turn to the end of this chapter and complete; l l Exercise , Cartesian Coordinate System. Exercise , Incremental Positioning. The drawing below shows the datum in the lower-left corner, locating the part in the first quadrant as shown in Figure: 9.

Figure: 9 Note: Even though part prints do not show dimensions as negative numbers, you must input negative values when appropriate. For example, the hole in the upper left corner in the drawing below is at the coordinate: X. The following drawing shows the same part with the datum in the upper-left corner, locating the part in the fourth quadrant.

For example, it is common to place the Datum at the center of round parts as shown in Figure: Figure: 10 Since most parts get installed into an assembly, the Datum ensures that critical dimensions are held for proper fit and function. In the example below, the critical dimensions are between hole centers in reference to the 0.

Thus, the engineer selected the center of this hole as the Datum as shown in Figure: Figure: 11 Note: Attention to the datum is essential to part quality. Usually the same datum used to dimension the part is also used for machining. It extends, for all practical purposes, infinitely in all directions. Its position and orientation never change. Within this coordinate system, any number of Planes, called Construction Planes, can be defined.

A Plane can be located and oriented anywhere within the coordinate system. Planes make drawing easier and are required to define certain 2D entities. Figure: 12 Examples in this chapter use the predefined plane, Top. Select the Top Plane by clicking on Plane on the status bar and picking Top from the list. Note: You can view the coordinate system axes by selecting F9 or File, Configuration, Screen, Display part information. Screen Grid shows the position and orientation of the active Cplane.

Wireframe geometry includes information only about the edges of a part. Wireframe models cannot be shaded. A surface can be thought of as an infinitely thin shell stretched over a wireframe. Surface geometry includes information about the faces and edges of a part. There are many types of surfaces; each suited to model a specific type of shape. Surfaces are used to model complex, freeform organic shapes common in the automotive, aircraft, mold, and consumer goods industries.

Surface modeling is covered in the Mastercam Handbook, Volume 2. Solids contain information about the edges, faces, and interior of the part. Solids are able to model many parts, but some highly sculpted shapes, like car bodies, may still require surfaces.

All Solids start with profiles of wireframe geometry. Solids are covered in Chapter 5, Solid Modeling. Entity Definition Point A point occupies a single set of coordinates in space.

It has no length, depth, or width; it is infinitesimally small. Line Arc Spline Drafting A line is an entity defined by any two points in space, called endpoints. Lines have length, but no width or depth; they are infinitely thin. An arc is an entity that is equidistant from a point in space, called a center point. Arcs are "2D" entities, meaning that they must lie on a plane.

A Spline is a curve that travels, usually smoothly, through a set of points, called Control Points. There are two types of splines; 2D and 3D. Drafting entities include notes, text, leader lines, witness lines, and hatchs. They are used to annotate a drawing. Drafting text and notes are stored as a special entity type called a font, which allows lettering to be stored in an efficient format. Wireframe geometry includes other geometry types, such as a helix, ellipse, and rectangle.

However, these are modeled using one of the basic entity types described above. For example, an ellipse is modeled using a spline, and a rectangle is modeled using four individual lines. This chapter deals with how to create basic wireframe geometry types listed in the table above.

Once you understand these, it will be easy for you to create other types. Figure: 13 shows the commands used to create wireframe geometry. The commands are arranged in groups based on entity types or specific activity. The groups are displayed in the ribbon from basic to more complex functions.

A line can start and end anywhere in the Mastercam Coordinate System as shownFigure: Full length of the line, regardless of the view. If the line lies in the same plane that it is being viewed, the 2D and 3D lengths are the same. The angle of a line is measured from the position. Counterclockwise CCW angles are positive. Clockwise CW angles are negative. A line that splits two other lines equally.

The coordinates of the either end of a line. A line along or parallel to the X-axis. Point equidistant from the end points. A series of lines that are connected. A line offset an equal distance from another line. A line 90 degrees to another line or arc. Sometimes referred to as a normal line.

A line defined by its start point, length and angle. Lines have a direction. The Start point is the x,y,z coordinates of the first endpoint. A line that intersects an arc or spline at one point only.

A line along or parallel to the Y-axis. Figure: 15 Perpendicular Perpendicular lines pierce a line or curve at a 90 degree angle all around as shown in Figure: In other words, a perpendicular line is a tangent line rotated 90 degrees. This type of line is also called a Normal line when referring to arcs, splines, or surfaces.

Mastercam can create a perpendicular line passing through some point on the curve or a point in space. Mastercam can define a parallel line given an offset distance from an existing line or a through point. Burn finish passes after roughing all pockets - Used multiple no core wirepaths exist in a single operation, Mastercam Wire can cut the roughing pass on each no core first.

After completing all the roughing passes, Mastercam Wire then cuts the finish pass on each no core wirepath. Format — Controls how the arcs and lines in 4-axis wirepath are handled as data for the control. All circular moves arcs are broken into linear moves based on the linearization tolerance set in the 4-axis parameters dialog box tab. Direct 4-axis requires that the XY and UV contours have an equal number of entities. General — Controls cutting method, wire EDM machine initial settings and other parameters.

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. Use square point for tab position — Automatically places a tab at each location marked by a square point. You have to previously create points using square style along the geometry. If you use the square point method, select Start, Midpoint or End to indicate what square point marks. Tab Cuts no dropout method — Used to eliminate sliver or slug material when using either the line and radius or 2 lines and radius moves combined with overlap.

Page 27 With 3D tracking, the wire guides on the machine follow the nonplanar geometry. UV Extension - Used for geometry with variable depths that not lie completely in a single plane when 3D tracking is supported by the wire EDM machine. Give a positive incremental value to lift the extension above the UV height and trim planes.

UV Height — Sets the height of the part, the upper contour of the wirepath. Absolute locates the UV plane relative to absolute 0,0,0.

Incremental locates the plane relative to the Z depth of the chained geometry. Page 28 When is not required it should be set to the same height as the UV Height. XY Extension - Used for geometry with variable depths that not lie completely in a single plane when 3D tracking is supported by the wire EDM machine.

Give a negative incremental value to locate the extension below the XY height and trim planes. XY Height — Sets the bottom of the part, the lower contour of the wirepath. Absolute locates the XY plane relative to absolute 0,0,0. When is not required it should be set to the same height as the XY Height. Page 29 It is used by many full-scale CAD systems. The IGES standard is considerably more complex than other file formats. The IGES interface is three dimensional. IGES files are written in five sections: the start section a comment , the global section, the directory section, the parameter section and the terminate section.

The parameters for the global section cannot be changed. The default delimiter and end of record comma and semicolon are used. A comment is solicited and written in the start section. Use this feature based on the following descriptions.

Trim Surface Handling Use this setting based on the following descriptions. If there is no flag, Mastercam uses XYZ co-ordinates to trim surfaces. If there is no flag, Mastercam uses UV co-ordinates to trim surfaces. Type the level that you want Mastercam to use in the Level Number text box. Override with File Values Page 30