In this tutorial, we will show you how to complete a relatively complicated fourth axis work piece using axis substitution and Swarf 5 axis on a Haas VMC with a Haas 4th axis Rotary Table. The Swarf 5 axis cut will be completed in four axis format. 


This part requires a 5axis operation (4axis format) in Mastercam as the walls of the slot are angled such that axis substitution cannot complete the machining properly.  The work piece must be tilted appropriately in the Swarf  operation.  See below for images of the angled walls.


The first step is to rough the cut out using axis substitution.  This could be done with 5axis operations but is much easier using axis substitution with a simple 2D pocket.  This can be completed a few different ways but we are going to stick with the most common method.


Execute Xform Roll and select chain as shown below.


Clean geometry up as required.  It may be necessary to re-trim etc. Keep in mind that when using the unroll function the geometry may be placed one circumference away than required.  Simply translate the geometry in Y by Pi*D.


Create a standard 2-D pocket on the unrolled geometry.  Enable the rotary axis substitution at shown.




We are now ready to take the finished cuts using Swarf 5axis.  Prepare geometry as shown on a separate layer.  This is simply the wireframe copied over and surfaces created on the walls by using the create surface from solid function.  This is so that we can check the backplot for accuracy.  By the way, the wall on the right side was finished in a prior operation.



This particular job required extremely close tolerances.  This was achieved by using a very tight step increment of .0015.


The final step was to create the other two slots by using toolpath transform (tool plane). The back plotted image is shown below.



Note-Multi Axis toolpaths is an advanced Mastercam module, that must be purchased seperately.

If you would like to follow along with the tutorial you can download the model here in parasolid form.

Michael Whitten is an independent CNC Programmer in Carson City Nevada. He does contract programming utilizing Mastercam, Solidworks and Predator Machine Tool simulation.