Hello All, In Mastercam 2021 when loading a file created in a previous version of Mastercam, in the Threadmill programs the Retract value has changed to 0 and the Thread depth has changed to 0 as well. This is happening on every part that has a threadmill program. The same problem happens when Importing a thread mill programs the Retract value is changed to 0 and the Thread depth is changed to 0. Anyone seen this problem? Thx, Greg

I have a Integrex J400 with smooth control it does milling and turning. Below is our EIA programs for turning, obviously it's not the same machine but maybe there is something in it that can solve your problem. Boring program. N3 (T54 | .75 DPMT 321 | DIA. - 7. ) (ROUGH BORE +.040 STOCK) (TOOLPATH GROUP - SETUP-1) M202 G10.9 X1. G20 G40 G80 G18 G91 G28 X0. Y0. G91 G28 Z0. G90 T54 M6 G91 G28 X0. Y0. G91 G28 Z0. G90 M901 M202 M108 G0 G90 B0. M107 G92 S800 R1 G96 S250 M204 R1 G54 G18 G90 G43 P1 G0 X20. Y0. Z1. M51 X1.46 Z.105 G95 G1 Z.005 F.01 Z-1.1175 X1.375 X1.3467 Z-1.1034 G0 Z.105 X1.56 G1 Z.005 Z-.0317 X1.4816 Z-.0996 G2 X1.46 Z-.1399 I.0698 K-.0403 G1 X1.4317 Z-.1258 G0 Z.105 X1.647 G1 Z.005 G2 X1.5801 Z-.0143 I0. K-.0386 G1 X1.56 Z-.0317 X1.5317 Z-.0176 G0 Z1. X20. M9 M205 G91 G28 X0. Y0. G91 G28 Z0. G90 M01 Facing program. N1 (T41 | CNMG-543 | DIA. - 41.) (FACE) (TOOLPATH GROUP - SETUP-1) M202 G10.9 X1. G20 G40 G80 G18 G91 G28 X0. Y0. G91 G28 Z0. G90 T41 T63 M6 G91 G28 X0. Y0. G91 G28 Z0. G90 M901 M202 M108 G0 G90 B45. M107 G92 S800 R1 G96 S600 M204 R1 G54 G18 G90 G43 P1 G0 X20. Y0. Z1. M51 X5.2 Z.15 G95 G1 X-.2137 F.012 G0 Z.25 X5.2 Z.1 G1 X-.2137 G0 Z.2 X5.2 Z.05 G1 X-.2137 G0 Z.15 X5.2 Z0. G1 X-.2137 F.008 G0 Z.1 Z1. X20. M9 M205 G91 G28 X0. Y0. G91 G28 Z0. G90 M01

The nickel content of Mar-M 247 is way higher than the material I've been working with, it also has tungsten in it. So it's not quite the same beast that I've been dealing with it looks much worse. 80-125 SFPM .010 FPT .10 RDOC - Rough Turning my best guess. 80-125 SFPM .005-.008 FPT .03 DOC (DEPENDS ON THE SIZE) 10% Coolant concentration. Give ceramics a try we have had great success.

What is the ending designation? MAR M-247? 246, 509 ,302 I'm trying to compare it to a Nickel Super alloy we work with. How hard is it?

Another good feature that the Mazak Smooth Control has that I wish every machine would have is that it has mode selection button that changed between 2d (Just code) and the code displayed in 3D. You then can touch any part of the 3D code and it will take you to that place in the program, you can also do the reverse touch the line of code and the motion will be highlighted in the 3D viewer. It's just like having Cimco back plot built into the control. The control is touch screen so you can use gestures to view the 3D program, you can pan by sliding two fingers on the screen, zoom in by pinching in ward on the place you want to zoom to or pinch outward to zoom out. I use this feature all the time but it's not perfect, for instance rotary moves do not display correctly and the odd time there may be too much to see on the screen.

Hello, We have two Mazak J400 machines with the smooth G control. https://www.mazakcanada.com/machines/integrex-j-400/ It's not a full 5 axis machine it's more a 4+1, no matter it has certainly increased out productivity, C6 holders and a 72 tool changer. Very happy with it's turning capabilities we can easily take a .22 radial doc at .018/rev in 4140. For that machine there was no reason to purchase the Mill-Turn Environment, for me it's a lathe when I need a lathe and a 4+1 mill when I need a mill. It took a little time to iron out the post, we use plane shift G68 not TCPC because it's not a true 5 axis machine. There was some minor axis substitution issues as well. I had Inhouse add a switch to move in the Z before the X and Y after a tool change for longer parts where the Z home/tool change position was in the Z- position. Some of the machines conversational features are not useable because the machine is running EIA programs not Mazatrol programs.

I definitely run with multiple sessions open. I'll try and see if running one session makes a difference. Thanks Leigh.

Thanks Ron. At least I know it's not just me.

Hello, I'm having issues with the Simulation Stock settings resetting randomly. I would set it to a stock model or a pmesh but randomly it resets to the default stock settings. Does anyone know how to stop this from happening and stay on the stock I've selected? Thanks, Greg

What cures the tessellation message and wait time?

Anyone have working a link to the 3.0 file? I found the file, there was a link with the Cam Instructor Youtube video.

Bullnose, it was a 3.0/.121 high feed cuter with a 1.0/.032 tool for picking the corners.

Yon need a machine with the rpm, many of our mills only have 4k spindles but we have two new Mazak J400 that have 12k spindles so I would like to give it a try. When it comes to turning it spins too fast to not use a tailstock, it would have to be application specific. GreenLeaf seems to have impressive speeds and feeds in Incoloy. Turning 600-700SFM / .008”-.010” IPR / .050” - .080” DOC - 7-8mins of tool life Milling 2000SFM / .004” - .005” IPT / .050” - .080” IPT.

It does not warp, due to the high nickel content. I've roughed large amounts from a billet/forging and it's very stable. We turn many of the parts and we will finish with .500 wall thickness and there is no noticeable changes any thing thinner and I'm not too sure. I plan to use ceramics on the next batch of parts that come through I hope to decrease the roughing cycles like we did on the mills using endmills.

I agree, I like to quote 8 to 9 times the cost of the part in 4140. If parts made in 4140 run at 600 sfpm and Incoloy 100 sfpm so that's 6 times slower and then indexing time, operators are constantly changing inserts then there is "pucker factor". The cost of the part operators are measuring and remeasuring the part to make sure its right, it all adds up.

My experience is with Incoloy 925 but I'm sure it similar enough. I would use solid carbide endmills Incoloy likes sharp tools so if you have to use inserts get ones with positive geometry. I've switched from indexable cutters to endmills and shaved hours and hours off of the parts we make. When using indexable because your cutting so slow if your machine can handle it increase the depth of cut if possible. Be prepared to use a lot of inserts. For example: Standard Z level roughing took 30 hours, same feature using Dynamic OptiRest took 7.5 hours. Huge difference. The endmill lasted the entire time never had to change it, in fact it's still in the machine. It was Kennametal Harvi 1 HPHV1000S4400 KCPM15. I didn't even have the best coating for Incoloy on that endmill. 110SFPM at .005 fpt

Fanuc 31i and I don't know if it has DFO, I'll have to look into that. What does it do? There is already a hole/bore in the center of the table I was hoping to work with that but I would have to check if its accurately placed, It looks like part of the mounting mechanism. We do use the twin boring head from Seco to rough and Sandvik devibe to finish, no drag marks allowed G76 boring cycle.

Do you have a link to a twin bore? We currently use Sandvik Divibe bars, not cheap. Those parts we make have single, double, triple and quad bores through ranging in size from 3.500 to 8,000 with a +/- .001 and 32 surface finish. We made a triple out of solid incoloy 925 last month, 330 hours machine time, fortunately it was one of our smaller size parts. Unfortunately we do not have probing on our Toyoda 1250 machine we use dial probe and it would be very touch reaching to center of the table, I was thinking of putting tooling ball locations on the 4 corners and referencing them when needed. I really do like the G52 suggestion and making minor adjustments on G54.

We use Earth-Chain ECB-210 permanent magnet, each magnet has the ability to hold up to 2100kgf with the correct surface finish. https://www.earth-chain.com/ecb.html?cid=29 In my setup we use 4 magnets horizontally mounted to a tomb stone with 2x4x6 block under the forging. Our forging sizes range from 2500 lbs. to 12000 lbs. I've been using them for 12+ years now and we have never had the part move while machining. We run a 3" high feed cutter taking .08 doc up to 600 ipm and a 4" face mill taking .25 doc at 60 ipm on these parts with no issues.

Thanks Ron. We have pretty open tolerances. The biggest concern is the bores which we bore half and half and we would adjust the X value of the work offset after each cut to keep the concentricity with in tolerance and minimize miss match. Not sure how that will work out using fixture plates, we don't take one finish cut we take several and adjust them after each pass.

Hello, I have a 4 axis HMC that we manufacture a part family on and over the years the parts have become more complex. We make the part in 3 setups. First setup is on magnets on a tombstone and we use G54 B0. and we machine whiteness marks for part pickup on setup 2. Second setup we mount fixture plates to the finished faces from setup 1 that use a Schunk clamping system mounted to 4 legs that we and lay the part down so we can machine features at B0, B26, B90, B180 and B270 each angle having its own work offset G55-G59, Third setup, we take off the pull stud used by the Schunk and set the part back up on the magnets and complete the 3rd setup. Unfortunately the fixture holes get milled away on this setup so to aid in work holding we use a bar clamp over the part. This setup uses G54 and B0. I want to change the second setup. I want to machine the part on the center of rotation so I can machine on any angle with one work offset instead of the angles and offsets listed above, I can use shorter tools and reach into areas that are harder to reach. I would make a plate that would accurately mount to the machine table and that would have pockets that would match the size and shape of the fixture legs. I would engrave the part number in the pockets for easy identification for the operators and engrave the orientation. The center of the part would be center of rotation (X and Z origin) and they would only have to set the Y axis origin for each part and make sure the part was in the correct orientation to B0. It all sounds good to me because we do it on our VMC that have a rotary axis less the fixture plate we just use a chuck, but is there anything that I am missing? What sort of issues happen with setup like this? I may be overly optimistic about this change? Accuracy matters so if the parts are too accurate they parts are tough to fit together, which would take more time to setup. Any help, ideas or criticisms would be appreciated. See reference image below. Greg

In your Machine Group Properties under the Tool Settings tab in the Feed Calculation section what do you have selected? Should be from tool. or Maybe it's in your post? There is a max feed in the General Output Settings section?

Every time I post a program, Every time. I search for G55, G56, G57, G58 and G59 in Cimco. That's how I catch my mistakes.

Does auto save work well? I disabled it back in X2 days because I would save at the worse time and seem to lock up MC for a while. Hence the mantra "save and save often".

I've noticed that when creating a custom lathe tool the Cutting Plane moves on you and needs to be adjust back to the center of the tool or a value added to the offeset. I don't know if that's your problem but it was causing me issues.