OVERVIEW:

This part is a prismatic-to-freeform machined component featuring a sloped body, blended curved surfaces, and a circular through-bore on the inclined face. The geometry combines 2D machining features with 3D surface machining, making it suitable for demonstrating intermediate to advanced Mastercam toolpath strategies.

The base of the part is rectangular with vertical side walls, transitioning into an inclined top face that blends smoothly into a rounded cylindrical surface. A circular bore is machined normal to the inclined face, and an additional circular feature is present on the upper surface. The overall design emphasizes smooth surface continuity and controlled scallop height for finishing.

Machining Operations Performed

1. Facing

• Establishes a flat and uniform reference surface on the stock
• Ensures consistent Z-zero and proper stock preparation

2. 2D Contour

• Defines the external profile of the part
• Machines vertical walls and overall outer geometry to final dimensions

3. Surface Roughing

• Removes bulk material from inclined and curved surfaces
• Leaves a uniform allowance for finishing
• Demonstrates efficient material removal on complex geometry

4. Surface Finish – Constant Scallop

• Finishes all contoured and freeform surfaces
• Maintains a consistent scallop height across varying surface angles
• Produces a smooth, high-quality surface finish

HOW THIS CAN BE FURTHER IMPROVED: During my explanation video, I made a mistake in the planning toolpath for the finishing scallop operation as it collided with the workpiece which is obviously not something that we want!! Simple fix to this is to intentionally lift end mill and create a toolpath to change toolbit before it collides with product.

I dont own a 3-axis machine also (figures haha) but this project was ended to simulate the needed CNC milling operations to achieve the end product that was given to me. Of course, I provided the typical feed rate and milling speed but in actual operations we can cut corners here and there to optimize our cycle time!