Mastercam Mill 3D OptiRoughing

Features

• Machining and avoidance surfaces: In OptiRough, you can select multiple machining and avoidance surfaces and assign separate stock allowances for the floor and walls.
• Automatic fixture detection: The software detects fixtures and automatically avoids them using the stock allowance defined by the user.
• Boundary options: The toolpath can be bounded manually or automatically using a contour, bounding rectangle, or bounding circle. The boundary compensation direction can be set inward, centered, or outward, and offset distances can be assigned.
• Pocket skipping: The user can skip all pockets or only those below a specified size. This reduces unnecessary movements.
• OptiRest: The operation can be used to remove remaining material with a smaller tool. It identifies material removed during previous operations, significantly reducing machining time, especially on complex parts.
• Machining methods: Climb milling, conventional milling, or zigzag milling can be used. A separate feed rate can be assigned for conventional milling.
• Stepover and engagement angle: The stepover can be specified as a percentage of the tool diameter, in millimeters, or as an engagement angle. The Maximize Engagement function ensures efficient tool engagement.
• Depth cuts: Depth steps can be specified as a percentage of the tool diameter, in millimeters, or calculated automatically by the software. The Step Up function makes it possible to take advantage of the tool’s maximum cutting depth and save time. Additional cuts can also be added at critical depths.
• Steep/Shallow function: Enables machining boundaries to be defined automatically or manually.
• Transitions and retracts: Tool retracts can be defined as a full vertical retract, a minimum vertical retract, or based on a minimum distance. Micro-lifts allow the tool to return without retracting to the clearance level, speeding up machining.
• Arc fitting and feeds: On modern machines, arc fitting and feed-controlled transitions are recommended to create smoother movements and more fluid machining.
• Entry movements: For internal pockets, the plunge angle can be specified according to the tool manufacturer’s recommendations. The helix radius should be kept slightly smaller than the tool. In deep features, a tapered helix can also be used to improve chip evacuation.

Applications

• Roughing complex 3D shapes, such as molds, castings, and forgings.
• Removing remaining material from previous operations.
• Rapidly removing large amounts of material before finishing.
• Machining complex parts where fixtures and avoidance areas must be taken into account.

Benefits

• Efficient material removal with deep cuts from the bottom upward.
• Significant machining time savings compared with conventional roughing toolpaths.
• Longer tool life thanks to consistent tool loading.
• A safe and predictable process that accounts for fixtures and areas to be avoided.
• Consistent remaining stock makes finishing easier.

Tips

• Use solid-carbide end mills designed for dynamic milling.
• Take advantage of arc fitting for transitions and simulate the toolpath before running it.
• Verify plunge angles and ramps according to the tool manufacturer’s recommendations.
• Use OptiRest Machining after previous operations to remove remaining stock.
• Ensure stable workholding, especially when making deep cuts.

Summary

Mastercam Mill 3D OptiRoughing applies the principles of 2D dynamic milling to 3D machining, providing a highly efficient solution for roughing complex parts. Its extensive settings—from controlling machining and avoidance areas to OptiRest Machining and arc fitting—make it a flexible and safe method. OptiRoughing delivers significant time savings, extends tool life, and ensures consistent results in all 3D roughing applications.