Thanks for all the help. The result of what Thad suggested worked exactly as I needed.

Thanks for all the help. I did what Thad suggested and reposted the file with the TRIM to the FTP site as MC9 FlesCAST TEST.MC9. I tried your file Beej, but got an error on the restmill operation when I tried to regenerate - "problem with solid face"??? Thanks anyway.

Thanks for the quick response. I will try this as soon as I get back in the office and let you know how it worked out.

I have uploaded a file named CAST TEST.MC9 to the MC9 directory on the FTP site( Cast Test MC9 File ). I am trying to rough machine the interior pocket surface where the stock is a casting with the top of stock at an angle rather than horizontal. Is there a way that I can reduce the amount of "air cuts" (look at the front view to see how the toolpaths spend a lot of time in the air)? I quickly made this file as a test piece (I know that I could cut this with a standard pocket cut, and not use surface, however I would have the same problem with the pocket cuts). I already searched the forum and downloaded Iskander's Lazy Tricks for Remachining, checked using STL files for stock in verify, and looked at trimming toolpaths. I can trim the toolpaths to a boundary, but I would like to trim these to an angled top of stock. So far the only method I found was to manually edit the toolpath once it was created. Thanks in advance for any help.

You have mail.

I am not sure I understand. Could you e-mail a print or sketch including the helix note?

I might not understand your layout correctly, but I believe that if the lead is 3.125", then the form on the roll should "feed" 3.125" per revolution of the roll. Along the 36" roll will be approximately (just under)12 full turns. I am not sure what else they could mean by a 3.125 lead helix in 36 inches. You only need to use the circumference to calculate the flat pattern of the helix.

I have used Agie posts for years, and have used Mastercam's MPWAGIE.PST to work some custom changes. If I can be of any help, please e-mail me and I will do what I can.

Fadal also uses a G17 Q#### to provide A axis mapping. The Y axis is mapped to the A axis. I have used this in the past with good success. Programming in Mastercam is simply XY 2D, and then the G17 Q#### makes the conversion. I have found that this gives the smallest file size while allowing simple modifications to the toolpath. If this works for you, contact me and we could talk about the post that I modified for a customer. It's not perfect, but it works well for them. If you would like, e-mail me and I can get you more information. HTH.

Sorry I did not get back an answser sooner - I have been out of the office on a job (working split 3rd - 1st shift times) and only have a slow dialup internet access in my room. Work at night and sleep during the day. MCAM Newbie explained it better than I did. Any other questions, I will try to get back to you sooner. HTH

Zero Return - "Homes" the machine (X, Y, Z axes). On HMC - this is usually the pallet change position. On VMC's and Turning Centers, this is machine home (usually all axes at a maximum travel position). G28 will send a machine home, but it must be used along with other commands or the results can be disastrous. G28 X0 Y0 Z0 - sends the machine home in the XYZ directions after FIRST moving TO the point X0, Y0, and Z0. If Z zero is the face of the fixture or chuck, the tool can be driven through the part before returning home. X0/Y0/Z0 does not cause the tool to move home, this is a point to move through prior to going home. G91 G28 X0 Y0 Z0 - puts the machine into incremental / relative which tells the machine to first move zero in the X Y and Z direction and then go home. This zero incremental move will not crash, it just causes the tool to go directly home (the X0,Y0,Z0 is used to tell the machine which axis should be homed - a G91 G28 Z0 would ONLY home the Z axis). Turning centers often use G28 U0 W0 to send the X and Z axis home after an incremental zero move. On a HMC or VMC, G53 G28 X0 Y0 Z0 is used to send the axes directly home by using the Machine Coordinate System to tell the machine to move home after first going through the point X0 Y0 Z0 measured from the Machine Zero (Home). Finally, the G50 command is used to both clamp the maximum spindle speed on a turning center when using Constant Surface Speed, or to set the current position display. G50 S2000 clamps the maximum spindle speed at 2000 rpm. G50 X1.0 Z2.0 sets the current display to show X1.000 Z2.000. This is the same as the G92 command on some controllers (FANUC). Sorry this got so long, but it is critical that you understand this command - it can quickly CRASH. HTH

I'm in. Thanks for a great service. I am glad to help keep it going.

The following web page has information on bottle thread design. I used this for a project that I worked on last year. http://www.plasticbottle.com/techinfo/spi.html

I've programmed both Allen Bradley and PLC Direct PLC's. By far, Allen Bradley is my choice - local and corporate support is excellent and the product quality is second to none. Would be glad to help out if you have questions.

I would think an EDM finish. I have seen charts that show the finish at various power settings. HTH.

None that I am aware of. Mastercam does have a Dyna Post for the mills, but no reverse post that I have seen.

WinLINE makes windows plotter drivers for older plotters. I currently use it for an HP Draftpro EXL, and it works great. Look up WinLINE on the web. Price is around $200.00. If you want, I can try to print to a file and give you HPGL code. If you want me to try, let me know what plotter you have, and e-mail me the PDF file. You should then be able to send that to your plotter with DOS commands.

I have used a Dyna 4400 vertical mill with a 10 tool changer since 1992 for training. (The place I train for has this unit, not my choice). This mill does NOT use standard G/M code. It uses its own Dyna lanquage, and the memory on the machine is very limited (around 900 lines of code). For longer programs, the machine must be drip fed, and I have had a lot of trouble with stable communications with this unit. The last time I spoke to service they indicated that the latest version of Windows that they supported with their communications software was WIN 3.1. Even some older DOS programs that I used for communication would not transfer files reliably. It has a few useful subroutines, but everything else must be coded longhand. For drilling, it has a peck cycle , but no dwell for counterboring / countersinking. Also, the last few times I needed service, I was unable to contact any factory rep's (I believe that they are out of business). If you need any more specifics, please e-mail me, and I will help whatever I can. Personally, I would stay away from this machine.

Additional info - G73 - High Speed Peck Drill Cycle (Also called chip break cycle) will only retract a set amount between pecks (usually set up on the parameter page of the controller, and not on the G73 code line). Used where the flutes of the tool are not buried, allowing the chips to flow out of the hole while drilling. This is a very fast cycle and can save a lot of time / machine motion when used properly. G83 - Deep Hole Peck Drill Cycle is used where the flutes of the tool would be buried in the workpiece during drilling. This cycle retracts all the way back to the Z height specified as "R". This cycle is slower but will clear the chips better on a deep hole. HTH.

Once you have the centerline path of the 4" diameter cutter, you could create a solid of your cam blank and then use the centerline path to sweep the cam track surfaces. Now you have an inside and outside face of the cam track generated by the 4" dia. cutter, and you can run any tool diameter to finish the track. The trick is to not try to generate the original cam track from a tool that is smaller than the roller, or you could create undercut areas that the larger roller cannot follow. Is sounds like you have a good post to create the modified sine geometry. I have never used the post that you referred to, but I have several other programs that can create cam geometry if you have any trouble generating the initial path. E-mail me if I can be of any help. I have been on the receiving end of much help on this forum and would be happy to repay some.

Sorry for the "dumb" question. It was drawn in inch, but when I translated it, the default STL option was millimeter. Thanks for your time.

I have tried to use STL files with Mill Verify to show cast / forged parts. Hardmill, thanks for the info on just using the Parasolid file. That worked the best (although it gives me a message that "LW found the STL file to not be watertight, will use an approximation of the model"). However, if I convert from Solidworks to STL first, and then import the STL file the file comes in watertight, but appears way out of scale and off locatioon from the toolpath geometry. What am I doing wrong? Thanks in advance.

Well Done !!! Thanks for Posting!

LN1 is a Locational Interference Fit (Light Press Fit). There are many sites on the web that will give the tolerance for this class of fit. Also, information can be found in the Machinist's Handbook (look under Fits / ANSI). The note LN1 fit to pin, indicates that the hole should provide a light press fit with the mating pin, and you will need the pin to get the actual dimensions. HTH.

I just bought a Dell Precision Workstation (M60 Laptop). VERY EXPENSIVE BUT....... I had been following this forum for quite awhile and wanted desperately to stay away from ATI cards. Also, I had a need for legacy ports due to some older programs that I use to communicate with PLC's and DOS based programs. This basically ruled out all systems that I found except for the DELL M60. Need to look on the Small Business site since this unit will not show up on the Home and Home Office site. Select Precision Workstation M60 Laptop. The only drawback other than price is no full keyboard, but I use the docking station whenever I am not on the road. I bought my unit from the Dell Outlet site (it was a returned / refurbished unit). The system has 2Gb RAM, 60 Gb Hard Drive, Nvidia Fx1000 with 128 Mb Video Ram, and a Centrino 1.7 processor. I am very happy with the system and it is running both Mastercam and Solidworks without any problems. Running Windows XP Pro. I created a dual boot with DOS so that I could separate all of my old programs, and so far everything is working better than I could have expected. HTH.