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R I A L S E RIES DOWCTNIONS INSIDE

T U TO
INSTRU

L | T R A I NING
I MPERIA

R O U T E R
ROUTER TRAINING TUTORIAL

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Mastercam 2020 Router Training Tutorial
Copyright: 1998 - 2019 In-House Solutions Inc. All rights reserved

Software: Mastercam 2020

Authors: Mariana Lendel

ISBN: 978-1-77146-839-8

Date: August 26, 2019

Notice

In-House Solutions Inc. reserves the right to make improvements to this manual at any time and
without notice.

Disclaimer Of All Warranties And Liability

In-House Solutions Inc. makes no warranties, either express or implied, with respect to this
manual or with respect to the software described in this manual, its quality, performance, mer-
chantability, or fitness for any particular purpose. In-House Solutions Inc. manual is sold or
licensed "as is." The entire risk as to its quality and performance is with the buyer. Should the
manual prove defective following its purchase, the buyer (and not In-House Solutions Inc., its dis-
tributer, or its retailer) assumes the entire cost of all necessary servicing, repair, of correction and
any incidental or consequential damages. In no event will In-House Solutions Inc. be liable for dir-
ect, indirect, or consequential damages resulting from any defect in the manual, even if In-House
Solutions Inc. has been advised of the possibility of such damages. Some jurisdictions do not
allow the exclusion or limitation of implied warranties or liability for incidental or consequential
damages, so the above limitation or exclusion may not apply to you.

Copyrights

This manual is protected under International copyright laws. All rights are reserved. This doc-
ument may not, in whole or part, be copied, photographed, reproduced, translated or reduced
to any electronic medium or machine readable form without prior consent, in writing, from In-
House Solutions Inc.

Trademarks

Mastercam is a registered trademark of CNC Software, Inc.

Microsoft, the Microsoft logo, are registered trademarks of Microsoft Corporation;

Windows 10 is a registered trademarks of Microsoft Corporation.

 Table Of Contents

Router Projects 13

Getting Started 17

Objectives 18

Step 1: Starting Mastercam 18

Step 2: GUI - Graphical User Interface 19

Step 3: Navigate Through Mastercam 20

Step 4: Set The Attributes 22

Step 5: Manager Panels 24

Step 6: Setting Mastercam To Imperial 26

Step 7: Set The Grid 28

Conventions Used In This Book: 29

Mastercam® Work Flow 30

Tutorial 1: Geometry Creation 33

Overview Of Steps Taken To Create The Part Geometry: 34

GEOMETRY CREATION 36

Step 1: Setting Up The Graphic User Interface 36

Step 2: Set The Default Machine To Inch 37

Step 3: Create Construction Lines 38

Step 4: Create A Perpendicular Line 44

Step 5: Create Parallel Lines 46

Step 6: Create A Polar Line 51

Step 7: Trim The Entities 53

Step 8: Create A Line Knowing The Endpoints 57

Step 9: Create A 1/4" Fillet 58

Step 10: Transform Mirror 61

Step 11: Translate - Move A Line 66

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 Step 12: Create The 1/2" Circle 69

Step 13: Create Two Fillets 71

Step 14: Delete The Construction Line 74

Step 15: Create A Rectangle 76

Step 16: Move The Origin 78

Step 17: Save The File 80

Toolpath Creation 81

Setup Sheet: 81

Step 18: Select The Machine And Setup The Stock 82

Step 19: Drill Toolpath 88

Step 20: Backplot The Toolpaths 95

Step 21: Simulate The Toolpath In Verify 96

Step 22: Contour Toolpath 98

Step 23: Post The File 111

Step 24: Save The Updated MCAM File 113

Review Exercise - Student Practice 114

Create The Geometry For Tutorial #1 Exercise 115

Create The Toolpaths For Tutorial #1 Exercise 115

Tutorial #1 Quiz 118

Tutorial 2 119

GEOMETRY CREATION 122

Step 1: Setting Up The Graphic User Interface 122

Step 2: Create The Lines 122

Step 3: Create Two Fillets 129

Step 4: Create Two Arcs Knowing The Endpoints 132

Step 5: Fillet The Sharp Corners 134

Step 6: Save The File 136

Toolpath Creation 137

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 Setup Sheet: 137

Step 7: Select The Machine And Setup The Stock 138

Step 8: Contour Toolpath 142

Step 9: Backplot The Toolpaths 151

Step 10: Simulate The Toolpath In Verify 152

Step 11: Move The Lead In/out 154

Step 12: Post The File 159

Step 13: Save The Updated MCAM File 160

Review Exercise - Student Practice 161

Create The Geometry For Tutorial #2 Exercise 162

Create The Toolpaths For Tutorial #2 Exercise 162

Tutorial #2 Quiz 164

Tutorial 3 165

GEOMETRY CREATION 168

Step 1: Setting Up The Graphic User Interface 168

Step 2: Create A Rectangle 168

Step 3: Create Parallel Lines 170

Step 4: Create 1/4" Holes For The Fixed Shelves 173

Step 5: Create The Holes For The Moving Shelf 175

Step 6: Translate The Holes 176

Step 7: Trim The Lines For The Cut Out 182

Step 8: Delete The Construction Lines 186

Step 9: Save The File 187

Toolpath Creation 188

Setup Sheet: 188

Step 10: Select The Machine And Setup The Stock 189

Step 11: Drill The Through Holes 193

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 Step 12: Backplot The Toolpaths 200

Step 13: Simulate The Toolpath In Verify 202

Step 14: Block Drill The Holes For The Moving Shelf 204

Step 15: Cut The Knock Out 213

Step 16: Cut The Relief For The Backboard 223

Step 17: Post The File 231

Step 18: Save The Updated MCAM File 232

Review Exercise - Student Practice 233

Create The Geometry For Tutorial #3 Exercise 234

Create The Toolpaths For Tutorial #3 Exercise 234

Tutorial #3 Quiz 237

Tutorial 4 239

Overview Of Steps Taken To Create The Final Part: 240

Geometry Creation 242

Step 1: Setting Up The Graphic User Interface 242

Step 2: Create A Door 242

Step 3: Translate The Geometry 245

Step 4: Change The Graphic View And Construction Plane 247

Step 5: Create Parallel Lines 248

Step 6: Create Two Rectangles 251

Step 7: Delete The Construction Lines 254

Step 8: Create Arcs For The Hinges 255

Step 9: Create The Striker 257

Step 10: Create The Striker Holes 259

Step 11: Save The File 262

Toolpath Creation 263

Setup Sheet 263

Step 12: Select The Machine And Setup The Stock 264

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 Step 13: Pocket The Inside Profiles 268

Step 14: Backplot The Toolpaths 276

Step 15: Simulate The Toolpath In Verify 277

Step 16: Chamfer The Pocket Walls 279

Step 17: Change The Plane To The Left 284

Step 18: Machine The Two Hinge Mortises 285

Step 19: Drill The Hinge Holes 290

Step 20: Change The Plane To The Right Side 296

Step 21: Machine The Striker Mortise 297

Step 22: Drill The Striker Holes 302

Step 23: Circle Mill The Striker Hole 310

Step 24: Post The File 317

Step 25: Save The Updated Mcam File 318

Review Exercise - Student Practice 319

Create The Geometry For Tutorial #4 Exercise 320

Create The Toolpaths For Tutorial #4 Exercise 321

Tutorial #4 Quiz 326

Tutorial 5 327

Overview Of Steps Taken To Create The Final Part: 328

GEOMETRY CREATION 330

Step 1: Setting Up The Graphic User Interface 330

Step 2: Open Tutorial #1 Geometry 330

Step 3: Merge Tutorial #2 Geometry 332

Step 4: Change The Wireframe Color 334

Step 5: Option #1 335

Arrange Tutorials 1 & 2 Parts Using Rectangular Nesting 335

Step 6: Save The File 343

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 Toolpath Creation 344

Setup Sheet 344

Step 7: Select The Machine And Setup The Stock 345

Step 8: Drill The 1/2" Holes 349

Step 9: Backplot The Toolpaths 357

Step 10: Simulate The Toolpath In Verify 358

Step 11: Change The Color Of The 1/2" Arcs 360

Step 12: Contour The Parts 362

Step 13: Post The File 372

Step 14: Save The Updated MCAm File 374

Option #2 375

Step 15: Trueshape Nesting 375

Step 16: Save The File 384

Option #3 385

Step 17: Rectangular Nesting The Toolpaths 385

Toolpath Creation 386

Step 18: Translate The Geometry 386

Step 19: Contour The First Part 390

Step 20: Contour The Second Part 398

Step 21: Rectangular Nesting The Toolpaths 401

Step 22: Post The File 409

Step 23: Save The Updated MCAM File 409

Review Exercise - Student Practice 410

Create The Geometry For Tutorial #5 Exercise 411

Create The Toolpaths For Tutorial #5 Exercise 412

Tutorial #5 Quiz 415

Tutorial 6 417

Overview Of Steps Taken To Create The Final Part: 418

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 GEOMETRY CREATION 420

Step 1: Setting Up The Graphic User Interface 420

Step 2: Download The File 420

Step 3: Use Raster To Vector To Open The File 421

Step 4: Create A Point 427

Step 5: Create Text 429

Step 6: Create More Text 434

Step 7: Remove The Point 437

Step 8: Create A Rectangle Around The Graphics 437

Step 9: Move The Origin 439

Step 10: Save The File 440

Toolpath Creation 441

Setup Sheet 441

Step 11: Select The Machine And Setup The Stock 442

Step 12: Machine The Helmet Using Contour Toolpath 447

Step 13: Backplot The Toolpaths 455

Step 14: Simulate The Toolpath In Verify 456

Step 15: Engrave The Letters 458

Step 16: Post The File 467

Step 17: Save The Updated MCAM File 468

Review Exercise - Student Practice 469

Create The Geometry For Tutorial #6 Exercise 470

Create The Toolpaths For Tutorial #6 Exercise 470

Tutorial #6 Quiz 473

Tutorial 7 475

Overview Of Steps Taken To Create The Final Part: 476

GEOMETRY CREATION 478

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 Step 1: Setting Up The Graphic User Interface 478

Step 2: Create A Rectangle 478

Step 3: Create Parallel Lines 480

Step 4: Create Fillets 483

Step 5: Create The Slots In The Desk 487

Step 6: Save The File 491

Step 7: Create A Custom Tool 491

Step 8: Create A Rectangle 492

Step 9: Create Parallel Lines 493

Step 10: Trim Entities 496

Step 11: Create An Arc 498

Step 12: Delete The Construction Lines 500

Step 13: Trim Divide/delete 501

Step 14: Change The Line Style 503

Step 15: Save The Tool Geometry 504

Toolpath Creation 505

Setup Sheet 505

Step 16: Open The Desk Geometry 506

Step 17: Select The Machine And Setup The Stock 506

Step 18: Slot Mill 511

Step 19: Backplot The Toolpaths 521

Step 20: Simulate The Toolpath In Verify 522

Step 21: Cut The Desk Profile 524

Step 22: Post The File 537

Step 23: Save The Updated MCAM File 538

Review Exercise - Student Practice 539

Create The Geometry For Tutorial #7 Exercise 540

Create The Toolpaths For Tutorial #7 Exercise 540

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 Tutorial #7 Quiz 542

Tutorial 8 543

Overview Of Steps Taken To Create The Final Part: 544

GEOMETRY CREATION 546

Step 1: Setting Up The Graphic User Interface 546

Step 2: Download The File 546

Step 3: Open The File 546

Step 4: Save The File 547

Toolpath Creation 548

Setup Sheet 548

Step 5: Select The Machine And Setup The Stock 549

Step 6: Circle Mill The Center Pocket 554

Step 7: Backplot The Toolpaths 563

Step 8: Simulate The Toolpath In Verify 564

Step 9: Drill The Hole 565

Step 10: Engrave The Numbers 571

Step 11: Contour Ramp The Slots 581

Step 12: Pocket Toolpath 588

Step 13: Cut The Through Pockets 595

Step 14: Contour The Outside Of The Clock 605

Step 15: Post The File 613

Step 16: Save The Updated MCAM File 614

Review Exercise - Student Practice 615

Create The Geometry For Tutorial #8 Exercise. 616

Create The Toolpaths For Tutorial #8 Exercise 616

Tutorial #8 Quiz 621

Quiz Answers 623

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 Router Tutorial Quiz Answers 624

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Router Projects

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 Router Projects

Tutorial Geometry Functions Toolpath Creation

#1 Create Polar Line.
Create Perpindicular Line.
Create Parallel Lines.
Trim Entities.
Create a Drilling Toolpath.
Create Fillets.
Create a Contour Toolpath.
Xform Mirror.
Xform Translate.
Create Circle Center Point.
Create Rectangle.
#2

Create Lines.
Create a Contour Toolpath.
Create Fillets.
Create Arcs.

#3
Create Rectangle.
Create Parallel Lines.
Create a Drilling Toolpath.
Create Circle Center Point.
Create a Block Drilling Toolpath.
Xform Rectangular Array.
Create a Contour Toolpath.
Trim Geometry.
Delete Construction Lines.

#4
Create Door.
Xform Translate.
Create a Pocket Toolpath.
Change Graphic View and
Create a Engraving Toolpath.
Construction Plane.
Create Toolpaths on Left and Right
Create Parallel Lines.
Plane.
Create Rectangles.
Create Drilling Toolpaths.
Delete Construction Lines.
Create a Circle Mill Toolpath.
Create Circle Center Point.
Create Rectangular Shapes.

#5
Open Tutorial #1.
Merge Tutorial #2.
Xform Geometry Nesting.
Create Drill Toolpath.
Option #2 (True Shape
Create a Contour Toolpath.
Nesting).
Option #3 (Rectangular
Nesting The Toolpaths).

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Router Projects

Tutorial Geometry Functions Toolpath Creation

#6

Download the File.

Use RAST2VEC.DLL to Open
Create a Contour Toolpath.
The File.
Create an Engraving Toolpath.
Create a Point.
Create Letters.

#7
Create Rectangle.
Create Line Parallel.
Create Fillets.
Create a Slot Mill Toolpath.
Create Rectangular Shapes.
Create Contour Toolpath Using
Create a Custom Tool.
The Custom Tool Created.
Trim Entities.
Create Arc Endpoints.
Delete Construction Lines.

#8
Create a Circle Mill Toolpath.
Create a Drilling Toolpath.
Create a Engraving Toolpath.
Download the File.
Create a Contour (Ramp)
Toolpath. Create a Pocket
Toolpath.

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Tutorial 4

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Tutorial 4 Overview Of Steps Taken To Create The Final Part:

OVERVIEW OF STEPS TAKEN TO CREATE THE FINAL PART:

From Drawing to CAD Model:

♦ The student should examine the drawing on the following page to understand what part is being created in
the tutorial.
♦ From the drawing we can decide how to go about creating the geometry in Mastercam.

Create the CAD Model used to generate Toolpaths from:

♦ The student will create the wireframe needed to create the surfaces.
♦ Create a door using the Door command.
♦ Create side holes.

Create the necessary Toolpaths to machine the part:

♦ The student will set up the stock size and the clamping method used.
♦ Machine the pockets using a straight bit.
♦ Machine the pocket walls using an engraver tool to create a chamfer.
♦ Drill the two side holes.
♦ Use an aggregate to mill the door jam.

Backplot and Verify the file:

♦ Backplot will be used to simulate a step by step process of the tool’s movements.
♦ Verify will be used to watch a tool machine the part out of a solid model.

Post Process the file to generate the G-code:

♦ The student will then post process the file to obtain an NC file containing the necessary code for the machine.

This tutorial takes approximately one hour to complete.

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Tutorial 4 Overview Of Steps Taken To Create The Final Part:

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Tutorial 4 Geometry Creation

GEOMETRY CREATION
STEP 1: SETTING UP THE GRAPHIC USER INTERFACE
Please refer to the Getting Started section to set up the graphics user interface.

STEP 2: CREATE A DOOR

In this step you will learn how to create a door using the Create Door Geometry command. This command automates
the process so you are required to input only a few values to create a door.

Step Preview:

Wireframe

♦ From the Router group, select Create Door Geometry as shown.

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Tutorial 4 Step 2: Create A Door

♦ Select the Door style Notched and modify the door size and inside shape dimensions as shown.

♦ Select the OK button once the parameters have been changed to create the door.

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Tutorial 4 Step 2: Create A Door

♦ To place the lower left corner of the door select the Origin as shown.

♦ Press Alt + F1 to view the geometry.

♦ Press Esc to finish the command.
♦ The geometry should look as shown.

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Tutorial 4 Step 3: Translate The Geometry

STEP 3: TRANSLATE THE GEOMETRY

In this step you will translate the geometry to give the door a 3D appearance. This will help us when we create the holes
for the hinges and striker holes.

Step Preview:

Transform

♦ From the Position group, select the Translate icon as shown.

♦ Hold down the Shift key and select the line as shown.

Note: Holding the Shift key allows you to select multiple entities that are touching each other creating a chain.

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Tutorial 4 Step 3: Translate The Geometry

♦ Once the entities are selected click on the End Selection button or press Enter.
♦ In the Translate dialog box enable Join and enter a Delta Z value of -1.0 as shown.

♦ Select the OK button to exit the Translate panel.

♦ Right mouse click on the graphics window and select the Clear Colors button to reset the color to the system
color.

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Tutorial 4 Step 4: Change The Graphic View And Construction Plane

STEP 4: CHANGE THE GRAPHIC VIEW AND CONSTRUCTION PLANE

You will change the Graphics view to Isometric to view the translation and change the Construction plane to the Right
plane so we can create geometry on the right side of the door.

Step Preview:

♦ Select the Planes tab to open Planes Manager as shown.

♦ Set the Construction plane and the Toolpath plane to the Right as shown.

Note: If you select the Isometric Graphics view at anytime while being in a different plane, the planes will be
reset to Top.

♦ Press Alt + F1 to fit the geometry to the screen.

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Tutorial 4 Step 5: Create Parallel Lines

♦ The grid should look as shown.

STEP 5: CREATE PARALLEL LINES

You will create parallel lines in the right plane, knowing the offset direction and distance. These lines will be used to help
us establish the side pocket locations.

Step Preview:

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Tutorial 4 Step 5: Create Parallel Lines

Wireframe

♦ From the Lines group, select Line Parallel as shown.

♦ [Select a line]: Select Entity A as shown.

♦ [Select the point to place the parallel line through]: Select a point to the right of the selected line.

Note: The color of the line is cyan which means the entity is "live" and you can still change the entities
parameters.

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Tutorial 4 Step 13: Pocket The Inside Profiles

STEP 13: POCKET THE INSIDE PROFILES

Pocket toolpath is used to clean out material from an enclosed boundary. You will create a pocket toolpath to cut the
inside profiles. This will give the door a 3D appearance.

Step Preview:

Toolpaths

♦ From the 2D group, select Pocket as shown.

♦ Make sure that the Chain button is selected in the Chaining dialog box.

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Tutorial 4 Step 13: Pocket The Inside Profiles

♦ Select the four chains in a CW direction and in the order shown.

Note: The arrows shown disappear as you select the next chain. They are showing you the chaining direction.

♦ Select the OK button to exit the Chaining dialog box.

♦ On the Toolpath Type page make sure that Pocket is selected.

13.1 Select a 3/8" Straight Bit from the library and set the tool parameters
♦ Select Tool from the Tree view area.

♦ Click on the Select library tool button.

♦ Then select the Filter button.

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Tutorial 4 Step 13: Pocket The Inside Profiles

♦ Select the None button and then under Tool Types choose the Flat Endmill icon as shown.
♦ Under Tool Diameter, select Equal and enter the value 0.375.

♦ Select the OK button to exit the Tool List Filter.

♦ In the Tool Selection dialog box you should only see a 3/8" Straight Bit.

♦ Select the 3/8" Straight Bit in the Tool Selection page and then select the OK button to exit.

♦ Select the OK button to accept the Tool Settings Modified dialog box.

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Tutorial 4 Step 13: Pocket The Inside Profiles

♦ Make all the necessary changes as shown.

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Tutorial 4 Step 13: Pocket The Inside Profiles

13.2 Set the Cut Parameters

♦ In the Tree view area, select Cut Parameters.
♦ Set the Stock to leave on walls to 0.25 and ensure the rest of the parameters appear as shown.

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Tutorial 4 Step 13: Pocket The Inside Profiles

13.3 Set the Roughing Parameters

♦ Select Roughing in the Tree view area.
♦ Change the Cutting method to Constant Overlap Spiral as shown.

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Tutorial 4 Step 13: Pocket The Inside Profiles

13.4 Set the Entry Motion

♦ Select Entry Motion from the Tree view area.
♦ Set the Entry Motion to Off as shown.

13.5 Set the Finishing Parameters

♦ Select Finishing and disable Finish as shown.

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Tutorial 4 Step 13: Pocket The Inside Profiles

13.6 Set the Linking Parameters

♦ Select Linking Parameters from the Tree view area.
♦ Set the Linking Parameters as shown.

♦ Select the OK button to generate the toolpath.

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Tutorial 4 Step 14: Backplot The Toolpaths

STEP 14: BACKPLOT THE TOOLPATHS

Backplotting shows the path the tools take to cut the part. This display lets you spot errors in the program before you
machine the part. As you backplot toolpaths, Mastercam displays additional information such as the X, Y, and Z
coordinates, the path length, the minimum and maximum coordinates, and the cycle time. It also shows any collisions
between the workpiece and the tool.

♦ Make sure that the toolpath is selected (signified by the green check mark on the folder icon). If the operation
is not selected choose the Select all operations icon.

♦ Select the Backplot selected operations button.

♦ Right mouse click in the graphics window and select Isometric.

♦ To fit the workpiece to the screen, if needed, right mouse click in the graphics window again and select Fit.

♦ You can step through the Backplot by using the Step forward or Step back buttons.
♦ You can adjust the speed of the backplot.

♦ Select the Play button to run Backplot.

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Tutorial 4 Step 15: Simulate The Toolpath In Verify

♦ The toolpath should look as shown.

♦ Select the OK button to exit Backplot.

STEP 15: SIMULATE THE TOOLPATH IN VERIFY

Verify Mode shows the path the tools take to cut the part with material removal. This display lets you spot errors in the
program before you machine the part. As you verify toolpaths, Mastercam displays additional information such as the X, Y,
and Z coordinates, the path length, the minimum and maximum coordinates, and the cycle time. It also shows any
collisions between the workpiece and the tool.

♦ From the Toolpaths Manager, select Verify selected operations icon as shown.

Note: Mastercam launches a new window that allows you to check the part using Verify.

♦ Change the settings for Visibility as shown.

♦ Select the Play (R) button to run Verify.

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Tutorial 4 Step 15: Simulate The Toolpath In Verify

♦ The part should look as shown.

Note: To rotate the part, move the cursor to the center of the part and click and hold the mouse wheel and
slowly move it in one direction.

To Zoom In or Out hold down the mouse wheel and scroll up or down as needed.

♦ To go back to Mastercam window, minimize Mastercam Simulator window as shown.

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