Gap settings is the best bet. I set mine to 500% for small cutters and 300% for cutters bigger than 3/8.

Try turning off your arc filter. I had this problem a while back and that was the fix. I always leave the gouge checks on. Also try rough contour. I use rough contour for all my undercutting. I use multiple surfaces with several blended surfaces and fillets and flowline doesn't work very well. The update with V9.1 said you could use rough pocket but I can't get it to work properly with a lolipop. I have had some lolipip cutters custom made by Melin (1/2 with .340 shank) that I use every day.

Thanks for the help Mick and Bullines. I will watch this post for updates.

Thanks for the reply in an earlier post. I am having a problem with a script that you wrote for me a while back now that I am using V10. The script will run, but when I am promped for an entity I cannot select one. Not to be too forward but if you could look at the code and mabey tell me what to change I would appreciate it. Here is the code: '//////////////////////////////////////////////////////////////////////////////// '// '// Author: Mick George [email protected] '// Date: 05/11/2003 04:42 PM '// File Name: Copy Entities to Level.vbs '// '// Description: '// '// Comments: Select an entity to get its level, prompt for a new level and copy all '// entities from current level to new level. '// '//////////////////////////////////////////////////////////////////////////////// ' Const DEF_GIVE_ME_EVERYTHING = -1 Public Const DEF_PANEL = "MAND FACE" Public Const DEF_PANELA = "MAND BACK" Public Const DEF_PANELB = "CAP FACE" Public Const DEF_PANELC = "CAP BACK" Public Const DEF_PANELD = "BACKER FACE" Public Const DEF_PANELE = "FEEDER BACK" Public Const DEF_LEVEL_NUMBER = 10 Public Const DEF_LEVEL_NUMBERA = 11 Public Const DEF_LEVEL_NUMBERB = 12 Public Const DEF_LEVEL_NUMBERC = 13 Public Const DEF_LEVEL_NUMBERD = 14 Public Const DEF_LEVEL_NUMBERE = 9 ' -- Start Script Call Main() ' //////////////////// ' Sub Declaration ' //////////////////// Sub Main() Dim CArc, CLine, CPoint, CRect Dim CArcCopy, CLineCopy, CPointCopy, CRectCopy Dim intOriginalLevel, intNewLevel Dim bRet Dim intColor,intNewColor Dim intlevel Call SetLevelName(DEF_LEVEL_NUMBER, DEF_PANEL) Call SetLevelName(DEF_LEVEL_NUMBERA, DEF_PANELA) Call SetLevelName(DEF_LEVEL_NUMBERB, DEF_PANELB) Call SetLevelName(DEF_LEVEL_NUMBERC, DEF_PANELC) Call SetLevelName(DEF_LEVEL_NUMBERD, DEF_PANELD) Call SetLevelName(DEF_LEVEL_NUMBERE, DEF_PANELE) If Not IsDrawing Then ShowString "We need a drawing": Exit Sub If AskForEntity("**** SELECT AN ENTITY ****", mc_arctype + mc_linetype + mc_recttype + mc_pointtype) Then ' -- Store this entities level for eval intOriginalLevel = GetEntityLevel intnewlevel = 10 If (intNewLevel) Then ' -- Loop through all entities on original level and ' -- make a copy of it on the new level. bRet = StartDBSearch(mc_alive, DEF_GIVE_ME_EVERYTHING) Do Select Case GetEntityType Case mc_arctype ' -- Is this arc on the same level? If intOriginalLevel = GetEntityLevel Then Set CArc = New McAr Set CArcCopy = New McAr ' -- Get this arc If GetArcData(GetEntityEptr, CARC) Then ' -- Copy properties to our new arc With CArcCopy .X = CArc.X .Y = CArc.Y .Z = CArc.Z .R = CArc.R .SA = CArc.SA .SW = CArc.SW .VIEW = mcVIEW_TOP ' -- Bug Alert!! hard code for now fix pending End With ' -- Create our new arc on our new level intColor = GetEntityColor() If CreateArc(CArcCopy, intColor, intNewLevel) = mcENTITY_INVALID Then ' -- Call the police, we have a situation... ShowString "Could not create copy of Arc" Exit Sub End If Else ' -- OMG ShowString "Could not get current Arc" Exit Sub End If End If Case mc_linetype ' -- Is this line on the same level? If intOriginalLevel = GetEntityLevel Then Set CLine = New McLn Set CLineCopy = New McLn ' -- Get this line If GetLineData(GetEntityEptr, CLine) Then ' -- Copy properties to our new line With CLineCopy .X1 = CLine.X1 .Y1 = CLine.Y1 .Z1 = CLine.Z1 .X2 = CLine.X2 .Y2 = CLine.Y2 .Z2 = CLine.Z2 End With ' -- Create our new arc on our new level intColor = GetEntityColor() If CreateLine(CLineCopy, intColor, intNewLevel) = mcENTITY_INVALID Then ' -- Call the police, we have a situation... ShowString "Could not create copy of Line" Exit Sub End If Else ' -- OMG ShowString "Could not get current Line" Exit Sub End If End If Case mc_pointtype ' -- Is this point on the same level? If intOriginalLevel = GetEntityLevel Then Set CPoint = New McLn Set CPointCopy = New McLn ' -- Get this point If GetPointData(GetEntityEptr, CPoint) Then ' -- Copy properties to our new point With CPointCopy .X = CPoint.X .Y = CPoint.Y .Z = CPoint.Z End With ' -- Create our new arc on our new level intColor = GetEntityColor() If CreatePoint(CPointCopy, intColor, intNewLevel) = mcENTITY_INVALID Then ' -- Call the police, we have a situation... ShowString "Could not create copy of Point" Exit Sub End If Else ' -- OMG ShowString "Could not get current Point" Exit Sub End If End If Case mc_recttype ' -- Is this rectangle on the same level? If intOriginalLevel = GetEntityLevel Then Set CRect = New McLn Set CRectCopy = New McLn ' -- Get this rect If GetRectangleData(GetEntityEptr, CRect) Then ' -- Copy properties to our new rect With CRectCopy .X1 = CRect.X1 .Y1 = CRect.Y1 .X2 = CRect.X2 .Y2 = CRect.Y2 .Z = CRect.Z End With ' -- Create our new arc on our new level intColor = GetEntityColor() If CreateRectangle(CRectCopy, intColor, intNewLevel) = mcENTITY_INVALID Then ' -- Call the police, we have a situation... ShowString "Could not create copy of Rectangle" Exit Sub End If Else ' -- OMG ShowString "Could not get current Rectangle" Exit Sub End If End If End Select bRet = NextDBSearch Loop While bRet Call UnselectAll Call RepaintScreen(True) Else ' -- Bail... Exit Sub End If Else End If End Sub ' //////////////////// ' Function Declaration ' //////////////////// Function IsDrawing() Dim Ret Ret = StartDBSearch(mc_alive, -1) UnselectAll IsDrawing = Ret End Function I did revise it a little to get my colors to stay the same. I am not sure if I got all of it as I copied it several times to copy to several levels. Any help would be great! Thanks

I've had X for a couple of weeks now (my boss is a beta tester) and I am very suprised at the stability of it. My backplot still isn't working as it should, but I have not had one crash the whole time. The new ribbon bar style for selecting is really wierd at first, but I think after I get used to it I will be able to program faster than V9. I DO NOT like the new posting situation, however. The toolpaths are tied to a machine definition and the select post option is greyed out. I post toolpaths straight to machines over our network by using the numbered question at the end of the posts. X sets this in the machine def and to post to several machines the only way I can find is to change the machine and then go back and post again or search in the windows save box for the proper mapped drive to get it to the machine. My VB scripts are not working properly. When I am promped for an entity I cannot select one because the selection tool bar is greyed out. My MRU function bar dissapears every time I exit and come back and I have to turn it off in config and then turn it back on every session. Other than these few problems it's great. I remember changing from V6 to V7 was a pain for about a month, but looking back at V6 I wondered how we ever got anything done with it. I think X will be the same way very shortly.

I have been having a problem with MR0105 crashing to desktop with no warning. I have a Dell workstation w/dual 2.2 intel xeon (?) running Win XP pro fully updated to latest service packs and patches. I have only pinpointed the cause of one crash: ALT + S . I have had crashes at other times doing various tasks at a fast pace where I lost MC while I was looking away at my print. When I looked back I was looking at desktop. I have an ATI Fire GL2 Video card, SCSI hard drive, 2 gig RAM. If anyone can point me toward any possible causes I would be grateful. Thanks

Where are the resellers that come in here??????? I have a copy of the intro video that will be on the first release of X. My reseller sent it to us last week.

My boss is a beta tester. He tells me we better wait for VX.1 because...... I better not say. {I have a secret, ha ha ha)

I assumed you mean the top view after I saw the 1/4 lollipop. In V8 I would use create curve flowline to make multiple arcs concentric to the cylinder and use a simple 3D contour routine to cut the flowlines. Change the number of slices to get a better finish. In V9 use surface rough contour and it will undercut the surfaces.

The part came in as a half cylinder centered on the x axis. Are you cutting from the red line side as the top or from the top view?

I have done what you are talking about using a file from Mastercam, but I used the machine offsets to widen the thread to get what I wanted. I'm sure you could do it with multiple ops and get the same result. Make your thread program as you normally would in MC but split the middle of the desired thread width. Start and stop short by the amount of "movement" you need to get the desired width (I used a .236 grooving tool to cut a .750 wide spiral groove for coolant on a sleeve. Vary the offset plus and minus.257 in as big an increment as your machine can handle. Allow .257 at the beginning and the end). The trick is knowing your machine and making correct increments so that the profile of the groove/thread stays smooth. I also used a finish pass thread program and backed everything off and came in one cut at a time. My groove was .500/side deep and .750 wide in a thread form of 2.5inches per thread (.4 threads/inch). Hope this helps.

A1, here is the output of my set-up sheet. If you want me to I will send it to you. I use mine as a post file because of a bug in an earlier version. Here it is: T10 1/8 FLAT ENDMILL SPINDLE = 5000 FEEDRATE = 10. STOCK (XY)= -.034 Max Z Depth = +1.7900 T16 3/4 SHEAR EDGE TALL SPINDLE = 450 FEEDRATE = .5 STOCK (XY)= -.05 Max Z Depth = +0.6500 T12 1/2 FLAT ENDMILL SPINDLE = 550 FEEDRATE = 3. STOCK (XY)= .02 Max Z Depth = +1.4000 E-mail me at [email protected] if you want me to send it to you. I used the mill.set and blocked some of the outputs to get what I wanted. If you need Z stock I can revise the file and send it to you with Z stock output.

It may not seem like it when you select geometry but the size of the hole makes a difference in the toolpath. Depending on your tool, you may need to fudge the "number of active teeth" at the top to make only one pass. Sometimes the tool will make one pass at the bottom and then move up to make another pass to cover the full depth of the hole if your hole depth needs more threads than your parameter number. I make several passes in different ops and add to the "allowance(overcut)" option to finish holes that need to be fit to a guage. Make your hole slightly smaller than the finish size (.735 hole for 3/4 threads) until you know how your tool is going to cut, then increase the overcut until you get the desired size.

I have to protect the surfaces above the undercut. I haven't tried flowline. I have been using rough contour. The output has always been correct with contour. I have tried rough pocket with the lolipop tool but it sometimes retracts through the upper surface causing a gouge. I can't remember if flowline is supported with undercut. I'll look into it. One problem with flowline is that all the surfaces need to flow in the same direction. I am using geometry with multiple surfaces. Think of a square boss 2 inches tall, 1 across from 1.5 up and .875 across down from 1.5. I have to cut all the way around the boss while protecting the top and other surfaces around the sides and bottom. (extrusion hollow die). Thanks

I am having great success with the new undercutting abilities of V9. I have hade some lolipop tools special made to cut about .080 under surfaces to finish parts 100% on cnc with a three axis machines. The only problem is the long processing time. I have come across an insert tool that will cut about .125 under but I have to define it as a slotmill (.600 flute w/.060R). This definition causes the process time to go through the roof (1.5 to 2 hrs for a 1 meg nci file). Anyone defining tools differently to speed up processing time?

What type of machines??? I have my Bridgeport's and my newer mazak fusion controls connected directly to our network and use mapped network drives to post straight to the machines. I have a laptop next to my old mazaks with M-32's and drip feed via rs232 in tape mode to run large programs.

We have two Mazak VCN 510-c's. They are excelent machines. We opted for the 510 because of the extra travel (20,40,20). Have had one for 2 years with only a small problem with a cooling fan on a drive. We are looking at the Dekel 5 axis machine mabey later this year. We wanted the Mazak Angulax, but we are told this a Europe only machine.

Thanks for the info guys. I may do a few more tests in the near future and get back to let everyone know how it turns out.

Thanks for the input guys. Code-Breaker, I am using Carboly feed mills and super turbo mills .75 to 1.5 tool diameter. We ran some tests taking cuts at .250 step over feeding about 25 inches/min. The tool did well with very little spindle or z load. Every one else: The supervisor in our sister company swears that the offset load caused by only plunging with one side of the tool causes excessive wear on the spindle bearings. If anyone is plunging on a machine EVERY DAY and not trashing spindles please let me know as I can save loads of machine time by plunging out rough stock. Thanks

I occasionally plunge mill when cutting deep pockets, but I don't use it very often because of the wear it puts on the machine spindle. The Carboloy rep came by recently and asked why I wasn't plunging everything with their feed mill. I told him if he will send me a new spindle every six months or so I would be glad to. Is anybody out their plunging on a regular basis with a 40 taper machine and not trashing spindles? Thanks

Look up a company called velocity. I have only recently come across this company. They sell tapered end mills used for cutting ribs in tool steel for mold industry. We cut ribbs on the mills instead of elox. Saves time and money for carbon. check it out. 1 degree cutter with .070 bottom cutting 2 inches deep in ribs. I'm not sure about cutters that big to cut 5 inches deep though.

I figured up: (yearly total/52) = avg weekly pay. avg weekly pay-40hr pay = ovtime pay per week. ovtime pay/1.5 wage = ovtime hrs. (40+ovtime hrs)x52 = hours per year. So I worked ~ 2960 hours. quote: If you want it to be good expect it to be perfect!

I agree with CNCme about paying good people. The job I am at now is paying me very well for the area I'm in (NW Alabama), but not because they want to, because I showed them I am worth it! They made promises when I hired in and when I did the job they didn't want to live up to the deal. I got out and got a good offer from a competitor and then they had to get right. Most companies will try to pay as little as you will work for to maximize profit ( I guess I would too). But if you are good enough they will pay.

I am wondering if anyone is using Mastercam Solids to draw geometry from a 2D file (autocad). I now am manipulating cross sections and contours to draw multiple surfaces to creat a part in 3D before I can put tools to it. I talked to some people about using Solids to draw these parts instead of surfaces and most say that Solids is easier than drawing surfaces, but the process is different in Solids. I have played with it a little on a co-workers seat of Solids in the die-cast department, but I had a little trouble blending corners and making fillets. Is anyone using Solids or do most draw or get the solids from SolidWorks? Any input is appreciated.

I'll bring up the rear being a programmer for an Extrusion die shop. Use V9.1sp2 level 3. I do hollow dies for extruding tubes and housings of several types using 3D surfaces. I build hollows from lathe to finished stack on CNC mills. I program 3D contours for shapes on flat dies and drop bearings on CNC. Most dies go from lathe to CNC mill to run complete. Heat treat dies and wire cut the shapes, polish and ship. We have 4 VMC's, 2 Bridgeports, 2 Mazaks (soon 3 Mazaks for a total of 5). My day shift guy has been off lately, and when he is off I program for 3 shifts and run mills all day too. Normally I program all day. One day guy, one night guy, and one weekend guy for operators. Most of my work is quick (2-4 hours on the mill) so I set-up around 20 times a day. Makes for a hectic day.