User Manual Mayka v7 Model - PicaSoft · User Manual Mayka Model V7.0 – page 1 User Manual Mayka v7 Model (showing optional Plus 2D) Innovative tools to compliment the Creative

User Manual Mayka Model V7.0 – page 1

User Manual Mayka v7 Model

(showing optional Plus 2D)

Innovative tools to compliment the Creative

Beauzy – Route de Châtres sur Cher – 41300 THEILLAY

Email: info@ picasoft.com – web: www.picasoft.com


Copyright © 2001-2006 PICASOFT sas ® - All rights reserved

The content of this manual and software describe is protected by the international laws of the author’s right. Neither the software nor the manual can be reproduced, saved or transmitted or otherwise, without prior written permission of PICASOFT SAS (11 March 1957 law and 3 of July 1985 law on the author’s right).

Limitation of guarantee and responsibility

Even if the programme described in this manual, being well tested, neither PICASOFT nor its suppliers can offer a guarantee, implicit or clear, on its qualities, its performances or its capacity in satisfying the user needs. The user assumes the risks of the utilisation and its possible consequences. In any case, PICASOFT or its suppliers cannot be responsible for some direct or indirect consequences, from whatever nature it can be, resulting from a defect of the programme or in the manual, or from the utilisation, even if they were or were not told about the possibility of that sort of injuries. However the buyer has the right to the legal guarantee, only in the case and in the measure we can apply the legal guarantee, not withstanding all exclusions or limitations.

More, PICASOFT keeps the right to modify the product characteristics or the content of its documentation without telling the users.

By the use of that product you accept the above clauses.

PICASOFT®, the logo PICASOFT, and the names and the logo’s Mayka™, Maquette Volume™ , Stenza™ are trade marks of PICASOFT SAS.

Apple®, logo Apple, Macintosh®, logo Macintosh™, Mac™OS are trademarks of © Apple Computer, Inc.

Microsoft™, Windows™, logo Windows™, are trademarks of Microsoft Corporation.

All the other products quoted in the manual are trademarks:

AutoCAD & DXF are trademarks of Autodesk.

CAMM-2, CAMM-3, Modela, Picza & PIX are trademarks of Roland Digital Group Corp.

IGN © BDALTI ® is a trademark of the National Geographic Institute.

Photoshop & Illustrator are trademarks of Adobe Systems Incorporated.

Canvas is a trademark of Deneba Systems.

Corel Draw & Corel Paint are trademarks of Corel Corporation.

HPGL is a trademark of Hewlett Packard Inc

All the other products or trademarks quoted in this manual are acknowledged trademarks of their respective owners.

Note due to the different versions of Mayka, some of the graphics in the manual may not be exact replications from the specific version this manual relates to.

Compiled by Patrick Thorn. 09 April 2006. E&OE


Contents 1 Definitions ................................................................................................................ 11

1.1 CAD....................................................................................................................................... 11

1.2 CAD: 2D Geometry ............................................................................................................. 11

1.3 CAD: Polyhedral models ..................................................................................................... 11

1.4 CAD: Surface models ........................................................................................................... 11

1.5 CAD : Solid models............................................................................................................... 11

1.6 CAD : BITMAP images........................................................................................................ 11

1.7 CAM...................................................................................................................................... 12

1.8 CAM 2D ½ ............................................................................................................................ 12

1.9 CAM 3 axis............................................................................................................................ 12

1.10 CAM 4 axis............................................................................................................................ 12

1.11 CAM 5 axis............................................................................................................................ 12

2 Installation of Mayka .............................................................................................. 13

2.1 Hardware requirements ....................................................................................................... 13 Suggested computer configuration Windows .................................................................................. 13

2.2 Installing the software .......................................................................................................... 13

2.3 Enter your user licence......................................................................................................... 13 2.3.1 Education version ........................................................................................................... 15 2.3.2 Contract OEM versions................................................................................................... 15 2.3.3 Demonstration mode....................................................................................................... 15 2.3.4 Evaluation Mode............................................................................................................. 15 2.3.5 Multi-licence................................................................................................................... 15

3 Mayka Toolbar ........................................................................................................ 16

3.1 Cursor icon ........................................................................................................................... 16

3.2 Rotate view icon.................................................................................................................... 16

3.3 Pan Screen icon..................................................................................................................... 16

3.4 Zoom icon.............................................................................................................................. 17

3.5 Measure icon......................................................................................................................... 17

3.6 Fit to view.............................................................................................................................. 17

3.7 Contour Editing tools ........................................................................................................... 17

3.8 Display undercut faces.......................................................................................................... 18

3.9 Shading view ......................................................................................................................... 18

3.10 Shading Contour Outlines.................................................................................................... 19

3.11 Shading with transparency................................................................................................... 19

3.12 Wireframe view .................................................................................................................... 20


3.13 Isometric view ....................................................................................................................... 20

3.14 Orthogonal views .................................................................................................................. 20 3.14.1 Front face........................................................................................................................ 20 3.14.2 Top face.......................................................................................................................... 20 3.14.3 Right view ...................................................................................................................... 21

3.15 Align objects icon.................................................................................................................. 21

3.16 Align to machine origin icon................................................................................................. 21

3.17 Create cutting method icon .................................................................................................. 22

3.18 Cutting icon........................................................................................................................... 22

3.19 Animation / Simulation icon................................................................................................. 22 3.19.1 Animation....................................................................................................................... 22 3.19.2 Simulation....................................................................................................................... 22

3.20 Information icon ................................................................................................................... 22

4 Objects in Mayka .................................................................................................... 24

4.1 List of objects ........................................................................................................................ 24

4.2 Displaying the objects........................................................................................................... 24

4.3 Selection of objects................................................................................................................ 24 4.3.1 Object sub-menus............................................................................................................ 25

4.3.1.1 Colour......................................................................................................................... 26 4.3.1.2 Rename....................................................................................................................... 26 4.3.1.3 Hide ............................................................................................................................ 27 4.3.1.4 Duplicate..................................................................................................................... 27 4.3.1.5 Copy ........................................................................................................................... 27 4.3.1.6 Paste ........................................................................................................................... 27 4.3.1.7 Delete.......................................................................................................................... 27 4.3.1.8 Ungroup...................................................................................................................... 27 4.3.1.9 Show normals ............................................................................................................. 27 4.3.1.10 Length of normals ................................................................................................... 27 4.3.1.11 Top side view.......................................................................................................... 27 4.3.1.12 Front side view........................................................................................................ 27 4.3.1.13 Right side view........................................................................................................ 27 4.3.1.14 Offset ...................................................................................................................... 27 4.3.1.15 Export ..................................................................................................................... 27 4.3.1.16 Properties ................................................................................................................ 27

4.3.2 Multiple selection............................................................................................................ 28 4.3.3 Order of the objects in the list ......................................................................................... 28

4.4 Screen icons........................................................................................................................... 28 4.4.1 Datum point X0, Y0, Z0.................................................................................................. 28 4.4.2 Screen orientation ........................................................................................................... 29

5 Menus of Mayka...................................................................................................... 30

5.1 File......................................................................................................................................... 30 5.1.1 New ................................................................................................................................ 30 5.1.2 Open ............................................................................................................................... 30

5.1.2.1 DXF 3D file format..................................................................................................... 31 5.1.2.2 DXF 2D file format (optional)..................................................................................... 31


5.1.2.3 STL file format ........................................................................................................... 32 5.1.2.4 Point file format 1 ....................................................................................................... 32 5.1.2.5 Point file format 2 ....................................................................................................... 33 5.1.2.6 Grid format ................................................................................................................. 33 5.1.2.7 Bitmap file BMP......................................................................................................... 34 5.1.2.8 Bitmap file JPEG ........................................................................................................ 34 5.1.2.9 File format PIX .......................................................................................................... 34 5.1.2.10 File format EPS (optional)...................................................................................... 35 5.1.2.11 File format AI (optional) ........................................................................................ 35 5.1.2.12 File format Scene .................................................................................................... 35 5.1.2.13 File format 3DS....................................................................................................... 35 5.1.2.14 File format 3DM ..................................................................................................... 35 5.1.2.15 File format Tool path............................................................................................... 35

5.1.3 Save................................................................................................................................ 36 5.1.4 Save as…........................................................................................................................ 36 5.1.5 Export............................................................................................................................. 36

5.1.5.1 Export a model............................................................................................................ 36 5.1.5.2 Export a grid ............................................................................................................... 37 5.1.5.3 Export a tool path........................................................................................................ 38

5.1.6 Transmit ......................................................................................................................... 39 5.1.7 Machine Configuration ................................................................................................... 40 5.1.8 Quit ................................................................................................................................ 42

5.2 Edit ........................................................................................................................................ 43 5.2.1 Undo Ctrl+Z ................................................................................................................. 43 5.2.2 Redo Ctrl+Y ................................................................................................................. 43 5.2.3 Free memory Ctrl+L ..................................................................................................... 43 5.2.4 Duplicate Ctrl+D........................................................................................................... 43 5.2.5 Copy Ctrl+C ................................................................................................................ 43 5.2.6 Paste Ctrl+V ................................................................................................................ 43 5.2.7 Delete Del..................................................................................................................... 43 5.2.8 Configure ....................................................................................................................... 43 5.2.9 Redraw Crtl+R.............................................................................................................. 43 5.2.10 Quit Process Esc ........................................................................................................... 43 5.2.11 Preferences ..................................................................................................................... 44

5.2.11.1 Display.................................................................................................................... 44 5.2.11.2 Units ....................................................................................................................... 45 5.2.11.3 Files ........................................................................................................................ 45 5.2.11.4 Communication....................................................................................................... 45 5.2.11.5 Modelling................................................................................................................ 47

5.3 Display................................................................................................................................... 47 5.3.1 ZOOM............................................................................................................................ 48 5.3.2 View ............................................................................................................................... 48 5.3.3 Normal............................................................................................................................ 48 5.3.4 Undercut ......................................................................................................................... 49 5.3.5 Animation....................................................................................................................... 49 5.3.6 Simulation ...................................................................................................................... 50

5.4 Transformation..................................................................................................................... 52 5.4.1 Translation...................................................................................................................... 52 5.4.2 Rotation .......................................................................................................................... 53 5.4.3 Scale ............................................................................................................................... 55 5.4.4 Symmetry ....................................................................................................................... 56


5.4.5 Invert .............................................................................................................................. 57 5.4.6 Array .............................................................................................................................. 58 5.4.7 Align objects................................................................................................................... 59 5.4.8 Align to origin................................................................................................................. 60 5.4.9 Group.............................................................................................................................. 60 5.4.10 Ungroup.......................................................................................................................... 61

5.5 Cutting .................................................................................................................................. 61 5.5.1 Create a method .............................................................................................................. 61

5.5.1.1 Definition of a method ................................................................................................ 61 5.5.1.2 Creating a method ....................................................................................................... 61 5.5.1.3 Manipulating a method in 3D ...................................................................................... 61 5.5.1.4 Editing a method ......................................................................................................... 62 5.5.1.5 Calculate now ............................................................................................................. 63

5.5.2 Raised angles (optional with Mayka Model).................................................................... 64 5.5.2.1 The raised angle cutting parameters............................................................................. 64 5.5.2.2 Complete carving ........................................................................................................ 65 5.5.2.3 Incomplete carving...................................................................................................... 65 5.5.2.4 Raised angle example to full depth .............................................................................. 66 5.5.2.5 Raised angle example insufficient depth...................................................................... 66

5.5.3 Cutting............................................................................................................................ 67 5.5.3.1 Cutting a block............................................................................................................ 67 5.5.3.2 Processing a method.................................................................................................... 69 5.5.3.3 Roughing a tool path ................................................................................................... 69

5.5.4 Configure …................................................................................................................... 70 5.5.4.1 Configure a method..................................................................................................... 70 5.5.4.2 Configure a block........................................................................................................ 70 5.5.4.3 Configure a attachment ............................................................................................... 70

5.5.5 Tool library..................................................................................................................... 71

5.6 Model menu .......................................................................................................................... 71 5.6.1 Define attachment ........................................................................................................... 71 5.6.2 Define block ................................................................................................................... 73

5.7 Grid menu ............................................................................................................................. 74 5.7.1 Display ........................................................................................................................... 74

5.8 Contour menu (optional with Mayka Model)...................................................................... 75 5.8.1 Draw............................................................................................................................... 75

5.8.1.1 Draw........................................................................................................................... 76 5.8.2 Text ................................................................................................................................ 76 5.8.3 Simplify.......................................................................................................................... 77 5.8.4 Close............................................................................................................................... 77 5.8.5 Invert winding................................................................................................................. 77 5.8.6 Cut.................................................................................................................................. 77 5.8.7 Modify entry point ......................................................................................................... 77 5.8.8 Contour offsetting ........................................................................................................... 77 5.8.9 Chain .............................................................................................................................. 78 5.8.10 Copy in new object ......................................................................................................... 78 5.8.11 Move to new object......................................................................................................... 78

5.9 Window ................................................................................................................................. 78 5.9.1 Toolbar ........................................................................................................................... 78 5.9.2 Object list ....................................................................................................................... 78 5.9.3 Object Selection.............................................................................................................. 79


5.9.4 Information. .................................................................................................................... 79 5.9.4.1 The model: .................................................................................................................. 79 5.9.4.2 The grid: ..................................................................................................................... 79 5.9.4.3 The tool path: .............................................................................................................. 80 5.9.4.4 Information print ......................................................................................................... 80

5.9.5 Edit contours................................................................................................................... 81

5.10 ? menu................................................................................................................................... 82 5.10.1 Personnal code................................................................................................................ 82 5.10.2 Manual............................................................................................................................ 82 5.10.3 Documentation................................................................................................................ 82 5.10.4 www.picasoft.com .......................................................................................................... 82 5.10.5 About.............................................................................................................................. 82

6 Types of cutting methods ........................................................................................ 84

6.1 Sweeping method .................................................................................................................. 84 6.1.1 Objects............................................................................................................................ 84 6.1.2 Zone ............................................................................................................................... 85

6.1.2.1 Cartesian zone............................................................................................................. 86 6.1.2.2 Zone cylindrical .......................................................................................................... 87

6.1.3 Tool Definition ............................................................................................................... 88 6.1.4 Cutting parameters.......................................................................................................... 90

6.1.4.1 Tool path type ............................................................................................................. 90 6.1.4.2 Finishing ..................................................................................................................... 90 6.1.4.3 Roughing .................................................................................................................... 92

6.1.5 Machine parameters ........................................................................................................ 99

6.2 Contouring a model ............................................................................................................ 100 6.2.1 Objects.......................................................................................................................... 100 6.2.2 Zone ............................................................................................................................. 100 6.2.3 Tool Definition ............................................................................................................. 101 6.2.4 Cutting parameters........................................................................................................ 101

6.2.4.1 Toolpath type - Finishing: ......................................................................................... 101 6.2.4.2 Toolpath type - Roughing:......................................................................................... 101 6.2.4.3 Clearance .................................................................................................................. 102 6.2.4.4 Increment.................................................................................................................. 102 6.2.4.5 Depth cut pass........................................................................................................... 102 6.2.4.6 Milling direction ....................................................................................................... 102 6.2.4.7 Offset count .............................................................................................................. 103 6.2.4.8 Rapid plane ............................................................................................................... 103

6.2.5 Finishing....................................................................................................................... 103 6.2.6 Entry / Exit ................................................................................................................... 104

6.2.6.1 Linear ....................................................................................................................... 104 6.2.6.2 Circular ..................................................................................................................... 105

6.2.7 Machine parameters ...................................................................................................... 105

6.3 Contours (Contouring) (additional option)............................................................................. 106 6.3.1 Contours ....................................................................................................................... 106 6.3.2 Objects.......................................................................................................................... 107 6.3.3 Zone ............................................................................................................................. 107 6.3.4 Tool Definition ............................................................................................................. 107 6.3.5 Cutting parameters........................................................................................................ 107

6.3.5.1 Toolpath type ............................................................................................................ 107 6.3.5.1 Cutting height ........................................................................................................... 108


6.3.5.2 - Absolute ................................................................................................................. 108 6.3.5.3 Cutting height – Relative to the contour .................................................................... 108 6.3.5.4 Type of cutting - Contouring ..................................................................................... 108 6.3.5.5 Offset count .............................................................................................................. 109 6.3.5.6 XY Clearance............................................................................................................ 110 6.3.5.7 Z Clearance............................................................................................................... 110 6.3.5.8 Increment .................................................................................................................. 110 6.3.5.9 Milling direction ....................................................................................................... 110 6.3.5.10 Type of plunge ...................................................................................................... 110 6.3.5.11 Entry/Exit.............................................................................................................. 110


6.4 Contours (Pocket) (additional option)..................................................................................... 111 6.4.1 Contours ....................................................................................................................... 112 6.4.2 Objects.......................................................................................................................... 112 6.4.3 Zone ............................................................................................................................. 112 6.4.4 Tool Definition ............................................................................................................. 112 6.4.5 Cutting parameters ........................................................................................................ 113

6.4.5.1 Toolpath type ............................................................................................................ 113 6.4.5.2 Cutting height - Absolute .......................................................................................... 113 6.4.5.3 Cutting height – Relative to the contour .................................................................... 113 6.4.5.4 XY Clearance............................................................................................................ 113 6.4.5.5 Z Clearance............................................................................................................... 113 6.4.5.6 Increment .................................................................................................................. 113 6.4.5.7 Milling direction ....................................................................................................... 113 6.4.5.8 Type of plunge .......................................................................................................... 113 6.4.5.9 Entry/Exit.................................................................................................................. 114


6.5 Contours (Sweeping) (additional option) ................................................................................ 114 6.5.1 Contours ....................................................................................................................... 115 6.5.2 Objects.......................................................................................................................... 115 6.5.3 Zone ............................................................................................................................. 115 6.5.4 Tool Definition ............................................................................................................. 115 6.5.5 Cutting parameters ........................................................................................................ 115

6.5.5.1 Toolpath type ............................................................................................................ 116 6.5.5.2 Cutting height - Absolute .......................................................................................... 116 6.5.5.3 Cutting height – Relative to the contour .................................................................... 116 6.5.5.4 XY Clearance............................................................................................................ 116 6.5.5.5 Z Clearance............................................................................................................... 116 6.5.5.6 Increment .................................................................................................................. 116 6.5.5.7 Milling direction ....................................................................................................... 116 6.5.5.8 Sweeping angle ......................................................................................................... 116 6.5.5.9 Type of plunge .......................................................................................................... 117 6.5.5.10 Entry/Exit.............................................................................................................. 117


7 Post processing ...................................................................................................... 118

7.1 Exporting ............................................................................................................................ 118

7.2 Security Plane ..................................................................................................................... 119 7.2.1 Post processing of 3 and 4 axis tool paths...................................................................... 120

8 Basic concepts ........................................................................................................ 122


8.1 Basics to getting started with models ................................................................................. 122 8.1.1 Launch the software...................................................................................................... 122 8.1.2 Select your machine configuration ................................................................................ 122 8.1.3 Check Preferences......................................................................................................... 123 8.1.4 Open a model object ..................................................................................................... 123 8.1.5 Prepare the method (Roughing)..................................................................................... 125 8.1.6 Save the Scene .............................................................................................................. 128 8.1.7 Start the roughing cutting process ................................................................................. 128 8.1.8 Prepare the method and cut (Finishing) ......................................................................... 130 8.1.9 Exporting the NC tool paths.......................................................................................... 132 8.1.10 Setting the Machine tool ............................................................................................... 133

8.2 Basics to getting started with contours (optional witn Model Plus 2D).................................... 135 8.2.1 Launch the software...................................................................................................... 135 8.2.2 Select your machine configuration ................................................................................ 135 8.2.3 Open a contour object ................................................................................................... 135 8.2.4 Align the contours in respect to the datum..................................................................... 137 8.2.5 Prepare the method (Roughing)..................................................................................... 138 8.2.6 Save the Scene .............................................................................................................. 140 8.2.7 Start the roughing cutting process ................................................................................. 140 8.2.8 Prepare the method and cut (Finishing) ......................................................................... 142 8.2.9 Exporting the NC tool paths.......................................................................................... 144 8.2.10 Setting the Machine tool ............................................................................................... 145

8.3 Basics to getting started with a BMP image ..................................................................... 146 8.3.1 Open a BMP file ........................................................................................................... 146 8.3.2 Cutting the grid ............................................................................................................. 147 8.3.3 Export the tool path....................................................................................................... 149

8.4 Basics to getting started with 4 axis ................................................................................... 150 8.4.1 Machine configuration .................................................................................................. 150 8.4.2 Open a Model or Scene ................................................................................................. 150 8.4.3 Configure the method.................................................................................................... 150 8.4.4 Export your NC toolpaths ............................................................................................. 153

8.5 Cutting techniques.............................................................................................................. 154 8.5.1 Multi-plane cutting........................................................................................................ 154 8.5.2 Internal cylindrical cutting ............................................................................................ 155 8.5.3 Choosing Contours (Optionin Model)................................................................................ 155

8.5.3.1 Seperating the contours ............................................................................................. 156 8.5.3.2 Cutting the contours .................................................................................................. 157

8.5.4 Grouping NC FILES ..................................................................................................... 159 8.5.4.1 Selecting the objects.................................................................................................. 159 8.5.4.2 Grouping the objects ................................................................................................. 159

8.5.5 2 sided cutting using inversion ...................................................................................... 160 8.5.5.1 Placing the attachments............................................................................................. 160 8.5.5.2 Create the block ........................................................................................................ 162 8.5.5.3 Prepare the block....................................................................................................... 163 8.5.5.4 Configuration of the cutting method.......................................................................... 164 8.5.5.5 Invert the model ........................................................................................................ 165


Welcome to Mayka™

Congratulations on your purchase of this Mayka™ (phonetic:- Make ah) software, that allows you to easily cut 3D models from all 3D CAD/Design software’s and Digitising/Scanning systems that produce 3D mesh data like DXF and STL files. Mayka™ also provides unique tools and options related to cutting point cloud and bitmap (picture) data.

We hope that this software will be the answer to your needs. It is important for you to fully understand Mayka™’s functions to exploit your creativity.

Read carefully this general reference manual and contact your supplier for any further training and specific information. Please note that this manual has been produced to outline the facilities and due to software developments, the documentation may have possible discrepancies, so please contact your supplier if anything is unclear. This handbook refers to Mayka version 7.0. If you have a later version, check the website http://www.picasoft.com for further information.

If you have any suggestions or remarks concerning the Mayka™ software, we will be pleased to receive them, via your supplier, or via our website http://www.picasoft.com

The PicaSoft Team


Beauzy – Route de Châtres sur Cher – 41300 THEILLAY

email : info@ picasoft.com – web : www.picasoft.com


1 Definitions

1.1 CAD Computer software that assists with the conveying of designs. Many geometrical entity types describe the designs and models drawn with these software products. (see below)

1.2 CAD: 2D Geometry Lines, arc, circles and splines are the basis for 2D drawings and illustrations. Mayka provides options to utilise this data for 2.5D machining and engraving.

1.3 CAD: Polyhedral models We speak about a polyhedral model when the geometrical definition of the surface of the CAD model is composed by lots of small faces. Each face is defined by points linked together by a line or series of lines, that makes the model look like a net. The true mathematic description of a surface does not normally exist in this kind of model.

This type of modelling is often used in the softwares that create synthetic images. The output formats used are usually DXF and STL.

Mayka™ is designed to allow you to reproduce these kind of model’s on a various CNC machine tools. Mayka™ can also generate certain types of polyhedral models from picture and point data.

1.4 CAD: Surface models We speak about surface models when the geometrical definition of the CAD model surface is composed by mathematical surfaces. They can be; plane surfaces, surfaces of revolution, coons patch, beziers, splines, parametric or NURBS surfaces, etc.

These types of modelling software’s are often used in mould production, calculation of the flowing of fluids or materials stress analysys etc.

The standard exchange format used is usually the IGES format. This format cannot be read or processed by Mayka™. Most softwares allow the conversion to STL and 3D-DXF polyhedral data before exporting.

1.5 CAD : Solid models Solid models geometry elements are normally based on CAD volumes to define the shape of the part.

Programmes using this type of solid data usually can export to rapid prototyping format STL, which is compatible with all systems and recommended for Mayka.

1.6 CAD : BITMAP images Images or photographs stored on a computer are termed as Bitmap files.


This format defines the number and the colour of all the pixels that compose the image. A screen shot copy of your PC's screen is saved as a bitmap. In Windows this is BMP.

Software like Photoshop, Paint, etc. utilise these formats and can be used to convert and save images to the correct format.

Many BITMAP formats exist, such as: BMP, JPEG, PICT, PIX, TIFF, EPS, etc

Mayka™ recognises the format BMP, JPEG ).

1.7 CAM Computer software that allows the generation of numerical data to pilot computer numerically controlled machine tools utilising CAD data.

1.8 CAM 2D ½ The CAM 2-1/2 D softwares calculate the tool paths parallel to the machine axis planes by working with the geometrical contours of the CAD model. This is the case for the software’s which are often used for general machining of mechanical parts. The tool is placed on the Z axis with a given height and then works on two axis at the same time.

The Z height is defined by the operator for a CAD 2D model, where as the Z height is automatically defined for a 3D CAD model. Mayka offers 2D cutting routines.

1.9 CAM 3 axis The 3 axis CAM softwares calculate the 3D tool paths by working with 3D surfaces and geometrical contours. The 3 axis of the machine X, Y & Z can move at the same time to go from a point to another one of the tool path. This is the case for the 3D mould fabrication softwares.

1.10 CAM 4 axis The CAM softwares that produce 4 axis tool paths usually offer 2 distinct options. 4th axis where the actually rotary axis is the 4th axis of the machine and is based on a rotary indexer sited parallel to one of the main XYZ axis. Either the software facilitates the movement of the 4th axis in conjuction with 3 other axis to product continuous movement, or the software can only index the 4th axis and cut in 3 axis in that plane.

1.11 CAM 5 axis The CAM 5 axis softwares calculate the 3D or surfaces tool paths by working with geometrical contours. The tool inclination in comparison with the model is taken into consideration in its tool path calculation and the software allows for all 5 axis movement and or indexing of the rotary axis to position the 3 axis cutting plane.

Reference manual for Mayka Model V7.0 – page 13

2 Installation of Mayka

2.1 Hardware requirements

Suggested computer configuration Windows

Intel Pentium PC with Windows XP or 2000 Professional, 256 Mb RAM, 10Mb of hard disk space, 19" Colour Screen, keyboard and mouse. OpenGL graphics card eg NVIDIA GeForce2.

The software may run with some other makes of processors, running Windows NT-4 and XP with 128Mb RAM and 15" Colour Screen.

If your data files are very large, such as 250Mb upwards, we recommend you will get the most from having a fast single processor with a lot of RAM and a fast hard disk.

2.2 Installing the software You are either provided with a CD that contains the software installer application, examples and documentation. Or you have downloaded the software installer.

• You will need a software licence.

• The software operates with Microsoft Windows 2000 and XP.

Insert the CD to the drive in your computer. It contains:-

• Installer for different Picasoft applications

• Installer for example files

• Installer for documentation.

Click the icon to suit your choice and follow the instructions to make the installation.

So you can utilise MAYKA fully you must perform the following steps:

1. Run the MAYKA installer and the installer application will guide you through the steps, similar to any other application.

2. Run MAYKA and enter your user name and software licence code.

3. Exit MAYKA, the start again MAYKA to activate your authorization

During the installation data will need to be added to the preferences, therefore, the user will need full access to the computers operating system so these files can be saved to the computer. It is therefore important that all restrictive software is disabled. ie Administrator access is required.

Note: If you have previously installed, then re-install an updated version of Mayka, it is not usually necessary to re-install drivers for the protection key.

2.3 Enter your user licence


From the Windows Start menu select the Programs folder, then the Picasoft folder, then the Mayka™ software icon.

When you first start Mayka™, a dialog box appears. If you cannot see this dialog, then select Personnel Code from the ? menu.

Enter your name and personal code, which is written on your licence notice, then click on OK to validate your personal code. Note exact characters are required.


Then click on OK to confirm your choice, then Quit Mayka™, this will authorise your code.

Should you need to change your code, or enter it at a later date, then select “Personal Code” from the ? menu.

If the software started in “demonstration” mode and you have entered a code, you will need to quit the application and re-launch for the code to take effect.

2.3.1 Education version

There is a software version for National Education School users. Which has some limitations.

2.3.2 Contract OEM versions

The OEM versions is a contract for distribution of Mayka ™ passed on with a machine tool manufacturer, possibly under another trade name. There are particular versions of the software, limited to functions and to the type of machines tools which are sold by various OEM’s

2.3.3 Demonstration mode

The demonstration mode allows you to use all the functions of the software. But you cannot save your work.

Mayka™ works in the demonstration mode when:

• your personal code is not correct.

• you have entered your personal code and you clicked on Cancel.

Note: Drivers for protection key (dongle) are not needed in demonstration mode.

2.3.4 Evaluation Mode

An evaluation version of Mayka ™ is available. It allows you to get access to all the functions and to save your work, but the number of savings is limited. After the limited saves the program will only work in demonstration mode.

2.3.5 Multi-licence

For registered users it is possible to purchase a multi-licence for multiple users on one site location.


3 Mayka Toolbar

This tool pallet is similar in all versions of the software, however within Microsoft Windows, dragging the pallet within the main application window will change the pallets appearance. If you cannot see it select toolbar in the Window menu.

3.1 Cursor icon

This icon allows you to use the cursor arrow to select and modify objects with the left mouse button in the main graphic window. In addition there are other options available with the right mouse button in other windows and dialogs like the object list window. If you have a 2 button mouse with a wheel button, some other features such as zoom +/- with the wheel are available.

3.2 Rotate view icon

This icon allows you to rotate the display of the object from different angles on the screen.

To use this function:

• Click on the rotation icon with the left mouse button once.

• Position the cursor on the working screen then click and drag the mouse without releasing the button.

The rotation is performed around the centre of gravity of the selected object, and not around the reference point. This only modifies the screen display of the objects, it will not modify the position of the objects in the reference system.

You have this same function available to rotate the screen by using the right mouse button without selecting using this icon.

Note: When rotating a large model in shades mode the performance of the screen display is related to the power and memory of the OpenGL support your PC is using. You can adjust the performance within Mayka's preferences so as to reduce the number of polygons displayed during movement of the screen. This performance value is only related to the display of your model and does not effect the quality of the machining calculations.

3.3 Pan Screen icon

This icon will move the view of the object both horizontally and vertically on the screen. To use this function :


• Click on the direction icon.

• Move the cursor on the working screen.

• Click and hold the mouse without releasing, then drag the screen.

• Release the mouse to stop.

Important : Only the view of the object on the screen changes, not the position of the object in the coordinate reference system.

3.4 Zoom icon

This icon will move the view of the object both horizontally and vertically on the screen.

• Click once on the main screen and the display scale is multiplied by 2.

• Hold down the CTRL key and click once on the main screen and the display scale is divided by 2.

• Click and drag over the display screen and this will enlarge the selected area to fit the screen.

Note a Windows mouse scroll wheel will perform Zoom +/-, even without this icon being active.

3.5 Measure icon

This tool allows you to measure: the position of a point, the distance between two points, the angle between 3 points. The points can be points on the CAD object or points the tool path.

To use this feature click on geometrical points whose you wish to measure. This tool works equally in shaded and wireframe display modes. The tool remembers upto 3 points in memory, information is displayed at the bottom of the screen.

3.6 Fit to view

This icon adapts the screen dimensions to display all of the visible objects on the screen.

3.7 Contour Editing tools

Clicking this icon displays the 2D contour editing tools.


3.8 Display undercut faces

Clicking this icon displays the model’s undercut faces (areas the tool cannot reach) in relation to the active cutting method.

3.9 Shading view

Clicking this icon displays the screen in OpenGL mode to show a realistic representation of your parts, methods, grids and tool paths. There are 3 modes to choose from as you wish.


Normal Gloss Fog

3.10 Shading Contour Outlines

Clicking this icon displays model in a shaded view with all the contour edges shown.

3.11 Shading with transparency

Clicking this icon displays the screen in OpenGL mode to show the parts transparently.


3.12 Wireframe view

Displays an exact representation of your geometry.

3.13 Isometric view

Positions the screen to view the objects in a perspective view.

3.14 Orthogonal views

3.14.1 Front face

Clicking the icon positions the screen view so your object viewed from the front face.

Clicking on the small arrow to the right of the icon allows you to display other related views depending on the working zone and the axis configuration.

3.14.2 Top face

Clicking the icon positions the screen view so your object viewed from the top face.



3.14.3 Right view

Clicking the icon positions the screen view so your object viewed from the right face.


3.15 Align objects icon

Aligns at least two or more selected objects to the first object selected in the list from the top.

The next window defines the type of alignment. You have to indicate position criteria of the objects in all three directions XYZ.

None: means that nothing is displaced in this axis.

3.16 Align to machine origin icon

This icon allows, an object or several selected objects to be aligned on the last defined machine origin.


3.17 Create cutting method icon

Selecting this icon creates a new method in the object list. It is equivalent to create method in the modelling menu.

3.18 Cutting icon

This icon allows the cutting of the model or the grid of points selected. It is equivalent to process cutting of the Modelling menu. To activate this function, a cutting method has to be selected in the object list first. When it is activated it calculates the cutting parameters of the method.

If a block is selected first, then this icon will display the block preperation machining options for facing, contouring and location drilling.

3.19 Animation / Simulation icon

This icon allows the selection of either the animation or simulation of the selected tool path in the object list. It is equivalent to animation or simulation of the Display menu. To activate this function, a tool path has to be selected in the object list first. When it is activated, it opens a control window that allows you to navigate the tool path, forward, back, pause, stop etc.

3.19.1 Animation

This activates the animation mode as described in the menu section. Basically with a tool path selected, you can view the tool movements over the part. In this mode you can change the screen orientation with the mouse.

3.19.2 Simulation

This activates the simulation mode as earlier in the menu section. Simulation shows the part being machined from a block. This mode does not allow screen manipulation whilst processing.

3.20 Information icon


This tool displays a window of the relative information relating to objects selected. To access the information on a given object, select it in the list and click this icon or choose the function Information from the Window menu.

Information displayed depends on the type of object or objects selected. You can simultaneously select several objects in the list and see them in this window. Selecting “Print” will print this information and a screen shot to your selected printer. An ideal job sheet. Text copy using the control and C key will allow you to copy the text to another application.


4 Objects in Mayka

4.1 List of objects Several types of objects can exist in Mayka:

• Models,

• Grid of points,

• Point clouds,

• Methods of cutting,

• Tool paths,

• Blocks,

• Attatchments,

• Contours.

The list of the objects appears in the object list in order of their creation.

4.2 Displaying the objects The small icons adjacent to the objects in the list can be made visible or invisible :

• Blue icon: object visible

• Red icon: object invisible.

To change the visibility, click the mouse pointer on the blue or red icon.

4.3 Selection of objects


To select a visible object, just left click on its name: it appears highlighted. You cannot select an invisible object, so make it visible first by clicking its red icon first.

Each object can undergo a certain number of functions (transformations, conversions, etc..). The former differ depending on the type of entity selected (model, grid, tool path etc) and are authorised, or not, automatically by Mayka. If the function of the menu is greyed then the function you are selecting is not available for the object that you have selected.

4.3.1 Object sub-menus

With the right mouse button clicked on an object in the list a pop down menu appears. It is different depending on the type of object selected.

In the case of a grid, for example, one can modify the number from points displayed on the screen using the right mouse button. This affects the speed of screen functions, but not the precision of the grid.

Options vary when you right click on the objects, as shown in the list as shown below:-


4.3.1.1 Colour

You have here the possibility to modify the colour of the object selected. If you wish to permanently change the colour of all objects, you can modify the values of these parameters in the preference/ display menu.

4.3.1.2 Rename

You can change the name of the object. Edit the name and click OK.


4.3.1.3 Hide

You can hide this object, which makes its icon go red. (Keystroke Ctrl+H)

4.3.1.4 Duplicate

This makes a duplicate of the selected object in the object list. . (Keystroke Ctrl+D). Methods hold all the same parameters so you only need to change the ones you want. eg Roughing to Finishing, so this is really useful.

4.3.1.5 Copy

This copies the object, making a duplicate in the object list. . (Keystroke Ctrl+C).

4.3.1.6 Paste

This pastes the previously copied object into the object list. . (Keystroke Ctrl+V).

4.3.1.7 Delete

This deletes the object from the list. (Keystroke Del). Edit > Undo will reverse this.

4.3.1.8 Ungroup

When a object consists on more than one object grouped together, you can ungroup it.

4.3.1.9 Show normals

Normals are the vector orientation the tool. In the case of 3 axis tool paths, this vector is parallel to the axis Z.

4.3.1.10 Length of normals

You can change the length of the vector. This function has no influence on the tool path. You can visualise only a selection of the normals by using the next values:

4.3.1.11 Top side view

This changes the current view to be looking at the local top view of this object.

4.3.1.12 Front side view

This changes the current view to be looking at the local front view of this object.

4.3.1.13 Right side view

This changes the current view to be looking at the local right view of this object.

4.3.1.14 Offset

This function creates a parallel path offset from the selected path of the value that you indicate. Note this value can deform the path.You do not have to use this function to offset the tool for normal cutting.

4.3.1.15 Export

To reduce your mouse movements up to the file menu, here you have the File > Export option to export your selected file in the object list.

4.3.1.16 Properties


You can change various properties of the object. Double clicking an object in the object list also shows the properties.

4.3.2 Multiple selection

To select several objects simultaneously, you have three possibilities:

• Click on the object name whilst holding "Shift" key on the keyboard.

• Click on the object name whilst holding "CTRL" key on the keyboard, this allows different objects to be selected with unselected objects in between.

• Click and drag the mouse over several objects in the list.

To deselect specific objects in a selected list, hold the CTRL key and click on those objects.

4.3.3 Order of the objects in the list

The order of objects is defined by their place in the list of objects from the top to the bottom.

This order is important for some functions (for example: to align) and can be easily modified:

• Click the name of the object that you want to move.

• Drag the object to the new place in the list.

The order of tool paths in the list will be the way that they are cut on the machine tool. If you group them together you will generate a combined cutting program. ie Group Roughing and Finishing to equal your total process.

4.4 Screen icons When working with object, you will want to orientate, scale, move etc in relation to the axis and the datum point. The following icons are displayed to help you.

4.4.1 Datum point X0, Y0, Z0

This icon represents the Datum point where the axis are X0, Y0 and Z0. This corresponds to the axis of your machine tool in absolute coordinates. It is important to align your parts in relation to this point.


Datum in shaded mode Datum in wireframe mode

4.4.2 Screen orientation

This icon is permanently displayed in the bottom left corner of your Mayka window to show you the orientation of the screen you are viewing. This orientation is displayed as a visual guide based on a standard geometrical format.

X related items are in Red

Y related items are in Green

Z related items are in Blue

This indicates + rotation around Z is anticlockwise.

This indicates + rotation around Y is clockwise.

This indicates + rotation around X is anticlockwise.

In a lot of the dialogs, the Red, Green and Blue is used to help you.


5 Menus of Mayka

5.1 File

5.1.1 New

This function allows the creating of a new window in Mayka™ after the closing of the previous one without being forced to quit the application.

Note: Opening of a new working window will erase the previous one and all the files in the list make sure you save your work first.

5.1.2 Open

This function allows you to open and process files in the following formats:-

• DXF 3D face & Polyline

• STL ASCII & Binary

• BMP

• JPEG


• File of Points PTS & RLF

• PIX (format of Roland)

• VNA (format of Type 3)

• Tool path ISO G-Code (G00 & G01) by Mayka

• EPS & AI Contour paths

• Mayka Scene format

• 3DS

• Rhino .3dm

5.1.2.1 DXF 3D file format

File extension : .DXF

DXF is a CAD file format that is defined by and, is the property of Autodesk Inc.

It allows the exchange of data between different CAD ans CAM.

This format describes several geometrical entity types such that lines, arcs, polylines, etc... It does not normally allow a mathematical surface definition. In file DXF, surfaces of models are normally described by a quantity of facets that form a mesh that is commonly known as a polyhedral mesh. Mayka processes facets on the mesh in DXF files and ignores all other entities:

Format DXF 3D Faces: facets of 3 or 4 points.

Format DXF polylines: from a number of points to describe each facet.

Note: A binary DXF format exists, but this is not interpreted by Mayka.

5.1.2.2 DXF 2D file format (optional)

File extension : .DXF

DXF is a CAD file format that is defined by and, is the property of Autodesk Inc.

It allows the exchange of data between different CAD and CAM.

This format describes several geometrical entity types such that lines, arcs, polylines, etc. Mayka can open these as 2D contour entities.

Note: A binary DXF format exists, but this is not interpreted by Mayka.


5.1.2.3 STL file format

File extension : .STL

It is a format of CAD file used for the manufacture of models with stereolithography machines.

It is the format it most used in rapid prototyping and, consequently, most CAD software can generate the STL file format.

The CAD file description of the model is a polyhedral type that describes the skin of the model in a multitude of facets. In this format the facets are all triangular with 3 points describing the corners.

There exist’s two types of STL formats: Binary and ASCII.

Mayka processes the two formats indifferently. The binary format is more compact and therefore opens more rapidly than ASCII files. Concerning the cutting process, there is no difference in the time or the precision of calculation.

Note:

The name of the stereolithography file has to have the suffix .STL in order that it is recognised by Mayka (Examples: motorbike.stl or motorbike.STL are both valid).

5.1.2.4 Point file format 1

File extension: .pts

There is no standard in formats of 3D point cloud files.

The object generated in MAYKA is called "cloud of points"

It is necessary therefore to insert in the head of point files the words "POINT MAYKA" to indicate it is a points file, then put the file extension .pts. The values of XYZ should be preceeded with the letters X Y Z and the seperators between values can be space characters, commas, semi-colons, etc.. Each point must be on a separate line, decimal point is assumed if not entered.

example 1 (Comma) :

POINTS MAYKA

X20.1274867, Y10.922, Z45.356

X22.68, Y43.784574, Z25.77856

...


...

example 2 (Space) :

POINTS MAYKA

X20 Y10 Z45

X22 Y43 Z25

...

...

example 3 (Semi-colon) :

POINTS MAYKA

X20; Y10; Z45

X22; Y43; Z25

5.1.2.5 Point file format 2

File extension: .rlf

Use this extension when point files describe a form as a rectangular set points in lines and columns. If the interval of these lines and columns is constant, Mayka will try to translate them and will convert the file from ASCII points into Mayka's Grid of point format.

Specific developments to make other point formats compatible with Mayka are available to order from Picasoft. Contact your dealer or PICASOFT for a quotation.

5.1.2.6 Grid format

File extension: .MVGrid

This is a specific internal format of Mayka.

It is a file from points, written in binary, that contains a number of points on X and on Y, with a list of values in Z.

The number of points in X and Y can be different.

The grid file is created from:

• The conversion of a bitmap (BMP) image.

• The projection of grid on a model.


• The opening of a file from points.

• The conversion of a model to grid.

The grid format offers several advantages over the standard CLOUD OF POINTS:

• File compression of important data.

• Rapid cutting calculations.

• Conversion to image.

• Display in OpenGL.

• Conversion to model.

Application developers can ask to licence the description of the GRID format from PICASOFT.

There are several types of grid formats:

• Cartesian, Cylindrical, Polar and Spherical

5.1.2.7 Bitmap file BMP

File extension: .bmp

This is the most common image format used on the PC.

Mayka reads these bitmap files in and converts the pixels of the image into XY coordinate points with altitude Z proportional to the level of grey. BMP 16 bit is the prefered format.

Mayka therefore transforms the image into a cloud of orderly points into a grid.

5.1.2.8 Bitmap file JPEG

File extension: .jpg

This is another format which works like other bitmaps.

5.1.2.9 File format PIX

The PIX format is produced by digitisers made by Roland DG.(PICZA)

Roland uses PIX variants on different equipment that maybe invalid.

(Models Picza PIX-3, PIX-4 and PIX-30 all work)

MAYKA converts this into its grid format. File extension: .pix


5.1.2.10 File format EPS (optional)

Format EPS is the format for postscript printers and contains 2 entity types. Points (Raster) and curves (vectorial). Mayka can only read the curved entities in the file. This format can be generated by Adobe Illustrator, Corel Draw, Vellum, Concept, Autocad and Rhino3D for example?

Illustrator eps formats of version 8 or below can be read by Mayka.

MAYKA opens this as Contours. File extension : . EPS

5.1.2.11 File format AI (optional)

Format AI is the native format defined by Adobe systems. Points (Raster) and curves (vectorial). Mayka can only read the vector entities in the file. This format can be exported various vectorial packages.

Illustrator formats of version 8 or below can be read by Mayka.

MAYKA opens this as Contours. File extension : .AI

5.1.2.12 File format Scene

The proprietary internal format of MAYKA. File extension: . MVSCN

This format includes the total job you are working on including objects, models, methods, attachments, blocks, methods, tool paths and defered processes. To create a scene file, you must do this insde Mayka.

5.1.2.13 File format 3DS

The proprietary format from 3D Studio Max. Supporting mesh data and curves.

5.1.2.14 File format 3DM

The proprietary format of Rhino3D CAD. File extension: . 3dm

Mayka can open Rhino3D files that contain mesh and curve entities.

Picasoft provide a free Rhino Plug-in to export directly from Rhino into Mayka.

5.1.2.15 File format Tool path

Mayka knows how to read NC cutting files, typically these are CM3, Mimaki, HPGL and ISO (G code) by default, some NC toolpaths exported by Mayka can also be opened.

The CAMM-3 and HPGL are special formats, all other ISO cutting files are initially detected with beginning % character.


Mayka does not interpret the ISO codes: G2, G3, G41, G42, G43.

You can open and import cutting files described with codes G0 and G1, or any file internally generated by one of Mayka's built in post processors.

The plot file format HPGL™ of Hewlett Packard, that consists of PU (Pen Up) and PD (Pen Down) commands followed by linear step moves on separate lines, can be read by Mayka, as a tool path. No other commands are recognised. ie

PU0,0;

PD100,0;

PU...........etc

Utilisation of files after opening:

During the export of CAD files in the format DXF, the parameters of the scale may have been lost. (to change this see Scale function of the Transform menu ).

To have a quick idea of the size of the model that you have openned, the size of the X0,Y0, Z0 axis origin marker shown on Mayka's screen is defined in the Preference option under display. The default value of 10 mm is initially entered:

Note:

The display of the model to the screen can be interrupted if it takes too long to redraw. To do this press the ESC key or click the mouse. The amount of model displayed will not affect the amount of model processed. Pressing the ESC key when a calculation is being performed will stop the calculation.

The indicator at the bottom of Mayka's screen indicates to time to open the file.

5.1.3 Save This function allows you to save a Mayka Scene with all the features of the total job you are working on including objects, models, methods, attachments, contours, blocks, methods, tool path’s and deferred processes.

5.1.4 Save as… This function lets you save your scene as a new named scene.

5.1.5 Export

The format you export depends on the object you have selected in the object list.

5.1.5.1 Export a model


The default saved format is binary STL.

To choose an other format to save, click on the arrow or on the name.

A choice of valid file formats are displayed in the list:

• DXF 3DFACE

• DXF POLYLINE

• STL ASCII Text

• STL Binary

Drag the cursor to the format you require, when it is highlighted, click the format and the list will disappear leaving your choice displayed. Enter the filename you require and then click the Save button.

STL formats can only contain 3 points per face, so if the file does not conform to this the formats will be greyed out in the list.

You may require to save your model when:

• You have change the position or size (translate, scale, rotate, duplicate etc.)

• You have created a model from a grid from points.

Note:

The format you save depends on the object you have selected in the object list.

5.1.5.2 Export a grid


To save a grid, first select it in the object list.

You can choose one of the formats to save:

• Image BMP: Mayka converts the grid into a BMP image where the pixels of the image represent the XY coordinate points with altitude in Z proportional to the level of gray in the image.

• Mayka Grid, the internal Mayka grid format.

• Point Cloud, in text format.

Note:

The format you save depends on the grid object you have selected in the object list.

5.1.5.3 Export a tool path


When saving the cutting tool path, the attributes and file extension will be configured depending on the post processor selected.

The available post processor format take into account the configuration of the machine that you have initially chosen.

Note:

The format you save depends on the tool path object you have selected in the object list. The save process makes the final calculation to generate the tool path in the correct post-processor format.

5.1.6 Transmit

This function is used for sending a cutting file to the CNC machine directly via a serial or parallel port of your PC (Normally COM1 or COM2, LPT1 is available for some machines). In addition the file can be sent to a printer driver that spools the NC data to the machine. This is common with machines like Roland and Mimaki milling machines.

The interface cable is specific for each type of CNC machine and the parameters of communication.

In case of possible communication problems, contact your machine supplier. Some machines do not support standard communication setting and need their own transfer software.

It is not necessary to open the file on the Mayka screen to use the Transmit command. Transmit also works in demonstration mode.

To control the parameters of this function, choose Preferences/Communications from the Edit menu.

When the Transmit function is selected, the next dialogue window appears:


Choose the cutting tool path file and click open, you then can choose where to send the file.

Select the method of transmission and click OK. The next dialog asks to confirm the transmission.

Make sure your machine is ready to receive the data before clicking OK.

Note :

A % appears in the bottom right side of the screen to give you the progress of the communication.

You can select Stop transmission from the File menu to terminate the communication process, if it is a direct transmission to a port. If it is via a printer driver, you will need to open the printer driver from the Windows start menu and cancel the document.

5.1.7 Machine Configuration


Mayka has the options to drive 3 and 4 axis machines.

You have to begin by defining the type of machine that you wish to drive before doing any work. The machine configuration sets parameters so that you can only work within your machine tools axis.

Choose the configuration schematic corresponding to axis of the machine that you are using.

The cutting functions and the display of the software will be adapted to the capacity of the chosen machine to realise these functions for you. Similarly the valid post processors will be displayed. Some machine configurations have limitations such as rotational limits, these will be displayed here. Consult your supplier to enter these values correctly.


If the post processor for your machine does not exist, contact your retailer for a quotation.

5.1.8 Quit

This is a function of the software which allows you to exit the Mayka™ application when you have finished and return to Windows™.

Mayka™ does not automatically save your work when you quit the software. It will ask if you wish to save the scene. If you choose not to save all work is lost unless previously saved.


5.2 Edit

5.2.1 Undo Ctrl+Z

This function cancels or reverts the effect of your last single operation.

5.2.2 Redo Ctrl+Y

This reverses the Undo function.

5.2.3 Free memory Ctrl+L

In some cases when many manipulations have taken place the internal memory can need clearing. You can free up the memory used by Mayka with this function. You will lose the possibility to undo any preceding functions, but the files you have open will not be affected. We recommend you save your work regularly.

5.2.4 Duplicate Ctrl+D

Duplicate the object selected in the object list.

5.2.5 Copy Ctrl+C

Copy the object selected in the object list.

5.2.6 Paste Ctrl+V

Copy the object selected in the object list.

5.2.7 Delete Del

Delete all objects selected in the object list.

5.2.8 Configure ..

The configure menu allows you edit the selected object. It can also be accessed by double clicking on an object in the list of objects.

5.2.9 Redraw Crtl+R

Redraws all the visible objects on the screen.

5.2.10 Quit Process Esc

This function interrupts the cutting process calculations.


5.2.11 Preferences

These are general adjustments that can be made to the software and the way it works.

5.2.11.1 Display

Objects colour

This allows you to choose the object types, background and selection colours in Mayka.

Activate hidden selection

Objects in the object list cannot normally be selected if they are hidden, with this option selected you can override this limitation. Default is off.

Simplify model when moving it

Simplify the model when moving it, allows you to change the number of polygons displayed, during screen manipulation and in shading mode so as to make the display faster. Varying this value in the Resolution will depend on the level of your OpenGL graphics support within your computer. This will not affect the finish of the cutting process, just the display you see on the screen.

Line thickness

Lines and contours are usually displayed as 1 pixel wide, you can adjust this if required.

Diamter of origin

In order to have a rough idea of the model size, you can give a dimension to the origin (Mayka™ defaults to 10 mm automatically).


Transparency

You can change the level of transparency in shading transparent mode.

5.2.11.2 Units

Mayka™ offers you the possibility of choosing your units of length (mm, cm, inch), angle ( degree, radian), feedrate (mm/s, mm/mn, m/mn, inch/s, inch/mn ). Click and drag the pop-up to the unit you want.

Note: Do not change units in the middle of a process, otherwise your results will be incorrect.

5.2.11.3 Files

Mayka™ offers you the possibility of closing the open polylines found in some DXF files. Also you determine the scale factor which Mayka opens your files. This is sometimes needed when your CAD outputs different units to Mayka. It is preferred to set this value rather than use the scale function every time you open a part.

5.2.11.4 Communication


This dialog box allows you to define the different communication parameters between your computer and the modelling/cutting machine. The transfer of the cutting tool path programme to your CNC will be achieved by way of an interface cable connected to a computer port.

Your PC usually has two serial ports (DIN 9 pins) situated behind the central unit (COM1 or COM2). There is an option for Parallel interface (LPT1), but this only works with certain machines.

In addition the file can be sent to a printer driver that spools the NC data to the machine. This is common with machines like Roland and Mimaki milling machines.

The interface cable is specific for each type of CNC machine and the parameters of communication.

In case of possible communication problems, contact your machine supplier. Some machines do not support standard communication setting and need their own transfer software.

It is not necessary to open the file on the Mayka screen to use the Transmit command. Transmit also works in demonstration mode.

To control the parameters of this function, choose Preferences/Communications from the Edit menu.

You must define the following to match your machine tool:

• Baudrate of transfer,

• Parity,

• Transmission protocol,

• Communication (COM1 or COM2, etc..),

• End of Block separator (This is saved in the tool path file)

Note :

The different machine tool parameter should be obtained from your machine tool supplier. Mayka cannot perform special protocols that do not conform to the Microsoft communications ports. Other 3rd party software maybe needed to transmit data to your machine tool.


5.2.11.5 Modelling

The value of the toolpath optimisation parameter is taken in account when the software calculates the tool path. It affects the length of each block segment and corresponds to the Maximum error that you will tolerate as compared to the exact path.

This value compromises between the capacity of the CNC controller of your machine to execute the small segments of program at a constant speed and at the precision that you wish. He default is 0.010mm. (e.g. If the toolpath was moving over a flat area and the calculated moves only deviated less than the value entered, the resultant NC code would output the start and end point.).

Rapid movement discretion angle. This value is defaulted to 1 degree. Changing this value affects the rapid moves around a rotary axis.

Toolpath optimisation angle. This value is defaulted to 1 degree. Changing this value affects the cutting optimisation around a rotary axis.

The default boarder value is the value displayed when setting a working zone.

Create a method while loading the first object is the default. So when opening your first model object, a sweeping method is created around your object.

Align this method to the origin is useful, if you always do this for your parts.

Enable ‘Changing the type of cutting’ dialog box. By default Mayka warns you when you change between methods that will change the types of parameters. If you are aware of this, then this option can be turned off.

5.3 Display


5.3.1 ZOOM

All the functions of the menu do not affect the real dimension of the model, but only the visible dimensions of the screen.

• Zoom Out: decrease the view.

• Zoom In: increase the view.

• Fit screen: adjusts the size of the model so that it just fits in the current window.

Note: a Windows mouse scroll wheel will perform Zoom +/-.

Note: Each function of the zoom commands a new display of the screen. If the time of the new display seems too long, you can stop it by clicking on the ESC key of the keyboard. The shortcut keys relate to the keypad on extended keyboards when « Number lock » is pressed on.

5.3.2 View

You can select the views from this menu the same as clicking on the view buttons: Perspective, Top, Front, Right.

Along a vector allows you to select two points on an object. The view of the object will be oriented to follow this vector.

Normal to a plane allows you to define a plane by 3 points. The view of the object will then orientate to this view.

5.3.3 Normal

This is the mode of normal display. Choose this to cancel Undercut faces display modes.


5.3.4 Undercut

This mode displays all the undercut faces on the selected model

Same as clicking the icon

If no method is selected in the object list, the cutter axis is considered vertical.

.

If a method is selected then the display is according to the orientation of the selected method. This feature is very helpful in multi axis set-ups.

5.3.5 Animation

Animation allows you to display the tool path movements over the actual model. Changing tool paths by clicking on then in the object list, view rotation, zoom, pan etc are all active with the mouse. Control of the tool path movements can be animated forwards and backward, step by step etc., via the animation control dialog. This is similar to a movie player apart from the steps processed. This feature displays between 1 and 200 steps of tool path per movement of the tool displayed.


Clicking the end button returns you to the normal view.

5.3.6 Simulation

Simulation copies the selected view port to a new display, where you can see the actual machining movements from a solid graphical block. The tool paths are representative of your actual part and the surface finish. You are prompted to choose a tool path to simulate and a block. The block can either be the limitation of the tool path movements or a block you have defined previously.

The control of tool path movements is similar to animation although you can only play the tool paths in a forward direction. The Block size represents the number of tool path blocks of data that will be processed before a piece of the graphic simulation is updated. If the display tool is turned off the simulation will be slightly quicker.


In simulation you cannot change the view, this should be selected before using this function. Simulation relies on the graphic processing power of you computer, therefore, on slower computers, animation is quicker to view than simulation. If you reduce the window size and the view of your part, simulation will be quicker than on a higher resolution large screen.

Clicking the end button returns you to the normal view. If the simulation is only in standard 3 axis control, then the “Display Result” button is shown. Clicking this will exit the simulation and then Mayka will calculate a grid of the tool path, which is a true representation of the cutting result.


If you colour your tool paths differently in the object list, then group them together as one object, you will see the different colours in the simulation.

5.4 Transformation

Mayka allows you to undertake various geometrical transformations on your objects.

Functions of the Transformation menu work on the objects selected in the object list.

All selected objects can undergo geometrical transformations. Mayka controls the coherence of the transformation within the possibilities of the selected machine and zone configurations.

For example it will be forbidden to rotate a tool path other than in the Z axis if the machine is limited to 3 axis.

Note :

More than one object can be selected to be moved.

5.4.1 Translation

Transformation applies to everything you have selected in the object list. Do the translation by entering the value of the movement of each axis. If you enter a number greater than 0 in the Number of copies dialog box, the translation will produce this number of copies in addition to your original object.


Example of a translation of 10 mm on X and Y and 20 mm on Z, without duplication:

with duplication:

Note :

The duplication keeps the initial object and calculates other objects according to the transformation and the number of objects you have to duplicate.

5.4.2 Rotation


The model, adaptive grid and tool path objects can undergo rotation.

Choose the rotation axis (X, Y or Z) and indicate the rotation angle. It can be either positive or negative. You can make rotations with or without duplications.

Example of rotation around the X axis -90°.

The rotation axis can also be arbitrary. In that case, define the axis of rotation by giving the coordinates of two points. For that, click on Two points then on the OK, the following window appears:


Enter the coordinates of the first point and click OK, a second window will appear for the second point enter this and click OK.

Do not forget that the transformation applies to all the objects you have selected.

5.4.3 Scale

The dialog displays the original “previous” dimension of your selected object and allow you to either enter a “new” dimension or “scale” factor. If the “keep aspect ratio” is selected all axis are scaled together otherwise the scale factor applies to each axis separately, so you can distort your objects with this tool.

In most of the numerical fields Mayka accepts formula for calculation with the operators: + - X /. etc for plus, minus, multiply and divide. Pressing the TAB key will calculate the expression.

For example a scale factor can be written: 127.5/ 25.4


Note:

The scale factor modifies the dimensions of the objects selected.

5.4.4 Symmetry

Choose the plane of symmetry to reflect the selected object in. Otherwise known as mirror.

Example:

Example of a symmetry according to the XZ plane situated at y = 0


Example of a symmetry according to the XZ plane situated at the middle of the object

If the plane of symmetry is out of the ordinary, give it’s coordinates of three points of that make a plane (enter the coordinates in the same way as the rotation, but with three points).

If the duplication option was selected a copy of the object is made symmetrically across the plane, else the object is moved symmetrically.

5.4.5 Invert


This function is most often used in the case when you wish to manufacture the two sides of a model. (see example section)

This function facilitates the inversion of the part and all its block and attachment objects so that tooling paths will be aligned correctly to the machine tool and the part.

This corresponds to a 180 rotation of the model around an axis. The inversion can made on the X axis or Y axis.

Selecting this function displays the following dialog:

Inversion without a block works from to the centre of gravity of the selected model.

Inversion with a block and model, works from to the centre of gravity of the block.

Example of an inversion according to the Y axis

5.4.6 Array


This function allows you to make multiple copies of a selected object in the object list.

Number of objects specifies how many total objects you require.

Vector is the size of the selected object.

Offset is the space you require between objects.

In this example a tool path object has been copied with 3 sets in X and 2 sets inY. This is a faster way to make 6 identical tool paths, rather than processing 6 copies of the model. The tool paths can be grouped together as one file.

5.4.7 Align objects

This function permits the alignment of several objects to in relation to each other.

When several objects are selected in the object list, this function aligns each object based on the first in the list (nearest the top). Options to align the objects either end to end or stacked on each other are also available. Alignment parameters can be selected for each axis in the following window.


When the end to end option, or stacked option is selected, you have the choice to enter an offset between the selected objects. The default is a zero offset.

You can choose if you want attachments to be included or not.

5.4.8 Align to origin

This function allows you to align objects selected in the object list with respect to the absolute origin, which normally corresponds to the machine tool origin for cutting.

Note:

It is usually necessary to make this setting because it determines the origin of your model on the machine tool. Placing the object so as the origin corresponds to your milling machine is the easiest and the fastest method to use.

5.4.9 Group

The Group function is available only with model objects, grids and tool paths.

A group is one object containing multiple objects of the same type.

To group several objects:

Select several objects in the object list.

Choose the Group function.

The list of the selected objects disappears to display the resulting object, which has the name of the first object of the list. You can change that name by clicking on it in the object list.


5.4.10 Ungroup

This is the reverse function to group.

5.5 Cutting

Mayka Model Mayka Model+2D option

5.5.1 Create a method

5.5.1.1 Definition of a method

The method is a principal object of MAYKA and contains all the parameters which are needed to control the cutting process. This object is stored in the object list.

The method defines:

The objects that will be process with their specific actions.

The working zone on the model.

The cutting strategies.

All the parameters for the tool definition and cutting attributes.

The method is orientated in 3D space with its own local coordinates.

In shading mode a tool is displayed to exact scale at the top of the method.

In other display modes the method top is outlined with a thicker line.

5.5.1.2 Creating a method

Selecting this menu item in the modelling menu or this icon,

creates a new method in the object list and presents a method dialog on the screen.

If the method dialog is not displayed, select the method in the object list and either:- right click the mouse and select properties, double click the method name, or select configure from the modelling menu

5.5.1.3 Manipulating a method in 3D

Several geometrical forms are available: Rectangular, or Cylindrical. The utilisation of each manipulation is very similar in each method.


You can reposition the method using the translation and rotation features. The zone can also be manipulated using the mouse pointer in the same way as a selection zone.

Transformation

With the method selected in the object list and using the transformation menu, you can change the position and orientation on the method.

Translation by mouse

Using the mouse button with the CTRL key you can move the method in the view by clicking on a handle or corner and dragging. The eight corners of the zone of the method are not displayed so as to not to overload the screen, they are never the less all active. The function only works with the cursor arrow selected in the toolbar.

Rotation by mouse

Using the mouse button with the SHIFT key you can rotate the zone in the view by clicking on a handle or corner and dragging. The eight corners of the zone of the method are not displayed so as to not to overload the screen, they are never the less all active. The function only works with the cursor arrow selected in the toolbar.

Edit sizes

To move a control point (centre on each side) of the zone with the mouse, click these points and drag. Selecting between shaded and wireframe view makes these features easier to use.

Placement

You can place a method in any selected view:

• Define your view point (Display >View, or with the mouse),

• Select the zone in the list of objects.

Use the transformation menu > Rotate according to view.

5.5.1.4 Editing a method

The configure menu under the modelling menu allows you edit the selected method. Double clicking on a method in the list of objects can also access it.

With the right click of the mouse can change the properties of the method.


When the method parameters dialog is displayed, there are several tabs shown across the top to allow you to access the necessary information help in the method you are working on. These tabs vary depending on the type of method and the version of Mayka. In Mayka Model the Contours section are an optional extra.

5.5.1.5 Calculate now

This button allows you start the calculation immediately.

The dialog will be closed and the process will begin. Pressing the ESC key will terminate the calculation.


5.5.2 Raised angles (optional with Mayka Model)

This type of cutting makes it possible to cut out sharp interior angled corners and is very useful in the case cutting quality lettering. It is necessary to use a conical tool (or ball) for this function to perform correctly.

If one uses a standard pocket cutting routine, then the internal corners are left with a radius equal to the cutters radius, plus certain parts of contours are not reached. This feature will help correct this problem.

5.5.2.1 The raised angle cutting parameters

Select the contours in the object list and then choose Raised angles from the Modelling menu. The following dialog appears:

For this example we have pre selected a 6mm conical tool with a 15 degree angle and a 0.5mm radius, then selected finishing and indicate the same depth that would be used for pocket cutting of the contours. Tool definition and Machine parameters are the same as in other methods.

The conical tool will rise up in the corners and at the constricted places that the cutter cannot pass. The trajectory of the cutter is a 3D curve.


The tool path is calculated where the cutter goes up in the angled and constricted places.

5.5.2.2 Complete carving

If the depth of required cutting is rather deep or if the cutter is wide enough and of sufficient diameter, it is possible that the tool paths and raised angles will be continuous and pocketing will not be required.

5.5.2.3 Incomplete carving

Depending on the contours and the cutter sizes, in some cases small islands of material are left behind.


Use the option "Build pocket contour" to create contours where residual material is left behind. You can then mill this contour with the contouring and pocketing method using the same tool or another one.

5.5.2.4 Raised angle example to full depth

Plan Side

5.5.2.5 Raised angle example insufficient depth

Here its shape and the contour sizes have restricted the tool depth.

With the option "Build pocket contour" a new contour is created for the residual area.

The resulting contours can be machined with the pocket contour method.


The two tool paths can be grouped together if required to machine a complete part.

5.5.3 Cutting

5.5.3.1 Cutting a block

Select the block in the object list.In the Modelling menu choose Cutting Block, the following window appears.

Diameter of cylindrical tool: enter the size of the cylindrical tool to use.

Rapid Plane: enter the rapid clearance distance above the block.

Depending on your selection the following options exist to surface, contour the edges or drill location holes. You can select each tool path in the object list and group them together to make one file if you wish.


Surfacing

This operation is necessary if you want to be sure the top of the block is flat for use when inverting a part.

Contour edges

This operation is necessary if you want to be sure the block is square. If you drill location holes you do not normally need to contour the block.

Drilling

This allows you to drill the location holes on the centreline of the block to aid the inversion of your part. Using this technique of location holes and locating pins requires you to have a fixture board on which to locate the part. The fixture board should not be securely attached to the machine so as to keep the same reference points. You can use this drilling feature to drill the block and the fixture board. The depth of block denotes the drilling depth.


5.5.3.2 Processing a method

Selecting a method in the object list, followed by this menu item, will process the tool path of the method immediately.

5.5.3.3 Roughing a tool path

A tool path displayed with shading on.

You can easily make multiple roughing cuts from an existing tool path:

• Select the tool path in the object list.

• Select roughing a tool path from the modelling menu or click on the cutting icon in the toolbar, the following will be displayed.


Selecting the minimum and maximum cut heights, plus the depth of each cut and the desired rapid plane followed by the machine parameters, Mayka will calculate the new roughing tool paths.

5.5.4 Configure …

This menu changes depending on the object type selected in the object list.

5.5.4.1 Configure a method

The menu "configure a method" appears when a method is selected. When you activate this function, you display the parameters window to adjust the values in the method. This function is equivalent to double clicking on the method in the object list.

5.5.4.2 Configure a block

The menu "configure a block" appears when a block is selected. When you activate this function, you display the parameters window to adjust the values of the block. This function is equivalent to double clicking on the block in the object list.

5.5.4.3 Configure a attachment

The menu "configure a attachment" appears when a attachment is selected. When you activate this function, you display the parameters window to adjust the values of the attachment. This function is equivalent to double clicking on the attachment in the object.list.


5.5.5 Tool library

The tool library is a place where you can define tools that you most commonly use during the creation on your toolpaths. Selecting this menu displays the following dialog:-

Within the dialog you can create and delete tools and manage all the parameters relating to the tool geometry.

This tool library is stored in a file “ToolLibrary.tools” in the Mayka folder inside your programs folder, if you make a lot of changes it is worth making a copy of this file to preserve your work.

5.6 Model menu

5.6.1 Define attachment

Attachments are small rectangular, oval or cylindrical CAD block models.

They generally are used when inversion cutting is used for modelling both sides of an object. They allow you to fix the model so as to avoid it falling away during cutting. (the model or


machine could be damaged if the part comes loose). Therefore, creating attachment’s to tie the model to the material block is a feature Mayka can help you with.

Images above illustrate the placement of attachments in the software as well as on the finished object.

Mayka facilitates the interactive placement and the dimensions of these attachments. Once defined it is also easy to orientate these attachments.

To easily see their positions they are displayed semi-transparent in the shaded view.

They can be used equally to block a hole or to create a zone you do not want to be cut. Some customers use them to shield a fixture or clamp to prevent tool collision.

Operations to create an attachment

Display the model and view from the top in X and Yaxis (other orthographic views can be used).

Select Define Attachment in the model menu.

The mouse cursor changes to a cross.

In the main screen window, click and drag the mouse so as to draw a rectangle where you require it. Ideally make sure the attachment is intersecting the model and the block.


Holding down the CTRL key will allow you to click and drag several attachments. Release the CTRL key before drawing the last attachment.

Selecting your attachments in the object list allows your edit the values. In any view you can drag any of the eight corners to easily change its size. In shaded mode you can also use the six marker points.

Enter the attachments coordinates and click OK.

If you are in shaded mode or perspective view, you will be prompted to enter its dimensions in the preceding window.

You can select attachments in the object list, or if you are in a shaded mode you can click on them.

Using the SHIFT key will allow you to rotate the attachment by dragging one of its corners. Using the CTRL key will allow you to drag it to a new position.

In some views the control points are not easily visible, but they are still active if the attachment is selected in the object list.

5.6.2 Define block

The block feature in Mayka is a rectangular CAD model specifically created to help represent the block of material you are going to make your model from. It is most commonly used when cutting two sides of the model using the invert feature.

Note:


It is not necessary to define a block to make your model.

Click Define block in the modelling menu and the following dialog is displayed:

You can define the size of the block numerically by entering the values you require, or depending on the objects you want selected you can define a border around these. Clicking the compute button will calculate the block sizes required.

If you want to align the block to the origin, use the “align to origin” button.

Clicking Ok will create the block on the screen and show it in the object list.

Modifying a block:

- Select the block object on the list and then choose configure block from the modelling menu, the list of values will be displayed.

- Or double click the block in the object list.

5.7 Grid menu

Grids are created when opening bitmap files.

5.7.1 Display


You can view the grid in 3 different shading views:

5.8 Contour menu (optional with Mayka Model)

5.8.1 Draw

This function gives you certain numbers editing tools to draw, clean, erase and modify curves. The curves can be either imported EPS vectors or contours extracted from a model.

Select contour

Modify start point

Chain contours

Cut

Move to new object

Text tool

Draw

Close path

Chain automatic

Invert direction

Copy to other

Offset curve


The selection of the curves is done with the mouse. Multi-selection can be made with the SHIFT key presses whilst clicking the contours. Selected curves are displayed in red. Although the edit menu is not displayed, the keyboard function Control+Z will undo the last of these actions.

5.8.1.1 Draw

This function allows you to draw a curve with the mouse. Select Top view, click the draw button then click on the screen for your first point. The next place you click will draw the first segment of your curve, the click the next point and so on. When you have drawn the last point, right click the mouse and drawing will stop, then a contour will be added to the object list. To close the curve, use the “close” button.

Holding the SHIFT key whilst drawing will constrain the curve to horizontal and vertical positions.

5.8.2 Text

This function allows you to create text contours based on Truetype fonts.

When you first select this function there will be a small delay whilst Mayka reads you system fonts. In the dialog the left-hand column displays all the Truetype fonts installed on your PC, on the right are the font styles. You can indicate the approximate height of the letters, but this will vary slightly with different font styles. Type your text in the box provided. By clicking Ok the text is generated as contours at the origin point and added to the object list. You can apply all the editing and cutting functions like other contours.


5.8.3 Simplify

This function allows you to reduce the control points in the selected curve. The higher the number the less points.

5.8.4 Close

An open curve has a green round point at the starting point of the curve with an arrow at the other end. The close function connects the arrow to the green point by creating a segment of curve.

5.8.5 Invert winding

Inverts the direction of the selected curves. This is indicated with a small arrow head on the curve.

5.8.6 Cut

Cuts a curve at a designated position. With a curve selected, click this button and then the place to cut the curve.

5.8.7 Modify entry point

The entry point of a complete curve can be changed. Click the selected curve where you want the new entry point to be.

5.8.8 Contour offsetting

Select a contour in the object list and check the direction of contour by looking at the orientation of the arrow. Choose the function contour offsetting from the contour menu. The following window appears:

The offset side is determined by the direction of the curve from the start point (green point) to the end point (arrow). On closed curves a counter clockwise direction will work as inside and


outside by convention. Pocket will determine the number of offset counts when it works to the inside of a closed curve until it reaches the centre. Choose the option and set the offset distance.

Clicking Ok will create the new contours.

5.8.9 Chain

This function enables you to connect two curves and to amalgamate them into one.

You must:

Check that the direction of the arrows of each curve is in a good direction.

To select the first curve with the mouse, then with the shift key pressed select the second curve.

Click the chain option end to end or shortest distance to connect them.

5.8.10 Copy in new object

This function lets the selected curve to be copied.

5.8.11 Move to new object

This function lets the selected curve be moved into a new object.

5.9 Window This menu allows you to select windows that you are using by bringing them to the front of the screen display.

5.9.1 Toolbar

This displays the screen tool pallet.

5.9.2 Object list


This displays the Object List to handle the different types of objects (models, methods, grids and tool paths).

5.9.3 Object Selection

This displays the Object selection filter . This sets different types of objects that can be selected on the main screen with the mouse pointer. Turning all the check boxes off and closing the window will mean you will have to user the object list only to select objects.

5.9.4 Information.

The Information window gives you all the instructions (dimensions, number of points, number of faces, cutting time, …) on the selected object or multiple objects:

Information concerning:

5.9.4.1 The model:

Data relating to the number of points, faces, groups, dimensions and their differences are displayed.

5.9.4.2 The grid:


Data relating to the number of points in X and Y, the precision and the distance between them.

5.9.4.3 The tool path:

Data relating to the maximum sizes, the cutting time, tool used and tooling parameters.

The saving on the cutting file adds the parameters of the post processor that has been selected and calculates the correct tooling sequences.

5.9.4.4 Information print

If you have a printer connected to your computer, you can print the information. A basic report sheet will be made with a picture of your screen part and the text.


If you do not have a printer, you can drag your mouse over the text and use Control + C keys to copy the information, then paste it in another text application.

5.9.5 Edit contours

This displays the contour editing tools window.


5.10 ? menu

5.10.1 Personnal code

The function displays the following:

Enter your name and personal code, which is written on your licence notice, then click on OK to validate your personal code. Note exact characters are required.

Then click on Yes to confirm your choice, then quit Mayka for the setting to take effect. Should you need to change or update your code, or enter it at a later date, then select “Personal Code” from the ? menu.

If the software started in “demonstration” mode and you have entered a code, you will need to quit the application and re-launch for the code to take effect.

5.10.2 Manual

This item will launch the PDF user manual.

5.10.3 Documentation

This item will open the documentation folder in Mayka’s program folder.

5.10.4 www.picasoft.com

This item will launch Internet Explorer and link to the Picasoft web site.

5.10.5 About


When the software starts a window displaying the software name placed on the screen for a few seconds. Selecting this option displays that window with other information. The modes of operation of Mayka are:

• Normal commercial licence information

• Demonstration (saving is disabled)

• NFR (Not for Resale, available only to authorised dealers for support)

• Education licence information

• The build version. For upgrades and support you will be asked for from this information.


6 Types of cutting methods

The different types of method enable you to choose the best cutting strategy that adapts to the topology of the model you wish to manufacture. Each type of method requires slightly different attributes. The tabs for objects, zone, tool definition, cutting parameters, machine parameters hold different information according to the selected type of cutting method. You can enter the information in these tabs in any order you wish, although they do follow a logical order from left to right to help you process your part. Changing the type of cutting tab will change the other tabs information.

Each type of method creates a specific object of Mayka that holds all the information on the cutting zone, tools and parameters linked to a model to perform a process.

To create a method click the method icon:

or select the modelling menu : " Create a method "

Mayka displays the method parameters.

6.1 Sweeping method This cutting method machines models based on an assembly of facets, by successive passes back and forth across the defined cutting zone. This strategy can be applied with all types of 3D models. This method can generate long cutting times, but the algorithms of sweeping will support the cutting of bad quality CAD models such as scanned 3D data. This method is used when the other strategies are not suitable or for models that may fail due to geometrical errors. This method is available for 3 and 4 axis machining.

6.1.1 Objects


Defines the objects you wish to include in the method.

In the left-hand side list are the objects, which can be taken into account by this method. In the list on the right-hand side you place the objects of your choice. Only, the models placed in the right-hand list "Objects to cut" will be taken into account for cutting with this method. You can select all the objects of the scene if you wish by clicking the check box "cut whole scene". Un- check the check box "cut whole scene" will move all objects to the right-hand side list. Select an object in the list and use the buttons "add", "remove", “add all” and “remove all” to move objects from list to lists. You can also double click on an object to transfer it from one side to the opposite list.

Note:- If you are working on a scene with models you want to cut separately, it is best to un- check the check box "cut whole scene" and select the items you want to work on.

6.1.2 Zone

Zones define the volume to manufacture and the geometrical shape of the cutting zone. Several cutting zones are proposed depending on the machine axis configuration options.


On a linear 3-axis machine: Cartesian, Polar

On a 3-axis machine with 2 linear and 1 rotary axis: Cylindrical.

On a 4-axis machine with 3 linear and 1 rotary axis: Cartesian, Cylindrical.

The greyed out zones are only available in Mayka Pro and Expert versions

On a linear 3-axis machine: Cartesian, Polar

On a 4-axis machine with 3 linear and 1 rotary axis: Cartesian, Polar and Cylindrical.

On a 4-axis machine with manually inclined spindle: Cartesian, Polar, Cylindrical, Conical.

On a 5-axis machine: Cartesian, Polar, Cylindrical, Conical and Spherical.

Zone dimensions are displayed according to the shape and size of the zone. In many cases it is easier to position and resize the zone using the mouse on the main screen.

Border around the object will allow you to add a border around the objects selected. Entering a value and pressing set will compute a new zone area.

6.1.2.1 Cartesian zone

It is the most commonly used feature to drive 3 and optionally 5 axis machines in Pro and Expert versions.

You can indicate dimensions of the method numerically either manually or by using the border set feature. Click the Set button to update the values.


In shading mode you can change the zone using the mouse in any view. You can drag any of the eight corners or six marker points to easily change its size. The six maker points are show in red, green and blue to relate to the axis.

6.1.2.2 Zone cylindrical

This method cannot be used on a machine that does not have a rotary table (normally a 4th axis) or full 5-axis movement. With a 3-axis machine configuration you will not be allowed access to this method.

The cylindrical zone is defined around the rotational axis.


In shading mode you can change the zone using the mouse in any view. You can drag any of the eight marker points to easily change its size.

6.1.3 Tool Definition

Select the shape and sizes of tool that you wish to use. Each tool form is accompanied by a graphical representation allowing you to easily identify the parameters required.

Make sure you use the same tool description in MAYKA as intend to use on your milling machine otherwise the cutting will not be a true representation of your model.

Hemispherical (ball end)

Enter the tool diameter.


Cylindrical (end mill)

Enter the tool diameter

Conical

Enter the tool diameter, the tool angle and the radius on the end of the tool.

Conical flat


Enter the tool diameter, the tool angle and the flat on the end of the tool.

Bullnose

Enter the tool diameter and the radius on the corner of the tool..

6.1.4 Cutting parameters

6.1.4.1 Tool path type

There are two main types of cutting with this method:

• Finishing,

• Roughing,

6.1.4.2 Finishing

Clearance


You can specify a clearance value over your part. This therefore leaves an amount on the part for fine finishing later, if required.

Increment is the distance between each sweeping pass over the model.

The increment value corresponds to the surface finish of your part and is selected by one of the suggested values from the pop-up arrow.

- Extra fine:

- Fine:

- Medium:

- Course:

Remark

With constant increment, the ridge value is not the same everywhere on the model.

The ridge value of sweeping is calculated with reference to the orientation of the models faces.

The nearer the trajectory of the tool path is perpendicular to the faces, better the ridge. The opposite is such when the tool is cutting parallel with the faces.

You should choose the sweeping direction in the zone "tool path direction" according to this criterion. In certain cases you will have to carry out several sweeping procedures.


With a rectangular zone, angled sweeping is adapted to avoid most of the crossing the trajectories.

6.1.4.3 Roughing

You can specify a clearance value over your part, this therefore leaves an amount on the part for finishing.

The increment of each roughing pass is automatically calculated by Mayka.

Specify the depth cut pass of each cut in depth. You will need to change this value depending on the material you are cutting.

depth cut pass

Mayka reorganises the tool path trajectories so as to reduce the number of tool retraction moves and therefore, produce a faster cutting cycle.


Normal non-optimised tool path

Optimised tool path

Another example:

Limits of Cutting:

Mayka offers several possibilities to limit the area of cutting:


• Cutting zone.

• Strictly object.

• Object.

• Partition line.

Cutting Zone:

Cutting is performed to the limits of the defined cutting zone. Depending on where you place the zone, all of your model and the surrounding area within the zone will be cut.

Strictly object:

The cutting is performed strictly within the maximum limits of the models perimeter as viewed from the top of the working zone.

This function allows is ideal when cutting a part where you do not want to cut outside its limits. Also when cutting a grid that has been inverted and you do not want to cut over the edge. The tool will not go outside these limits.

Object:

Cutting is limited to the models silhouette plus the radius of the tool. The depth of cut will be the bottom limit of the defined working zone.


Partition line :

Cutting is limited to the models silhouette plus the radius of the tool. The depth of cut is limited to the position that would be the widest point of the model in the view of the zone, normally referred to as the partition line or seam line.

Using the menu, display / undercut will show a coloured view of the visible parts where the partition line is.

Rapid plane

The Rapid plane is the level that the cutter will raise up to at the end of the cutting sequence or between cutting different model areas. The indicate amount will be a height that will be relative to the top of the selected working zone. This value is always relative to the zone, so in the case of 5 axis cutting it is a retract value only when cutting in that particular zone. The direction of retracting the tool is normal to the method. In the case of Spherical and Cylindrical methods the tool retracts along the tool normal at the point of retraction.

When using a zone that is lower that your part, make sure to enter a rapid plane distance that will be clear of the top of your model and any fixed items such as a vice or clamping device.

Tool path direction

With the aid of selecting different tool path cutting directions, you can achieve varying results that may benefit your particular part of machine tool. For example when cutting detailed relief work like medals and jewellery, then the spiral tool paths generally give a better looking


machine finish to the eye of the viewer. On large 5 axis machines, changing from one direction to another can be faster and more beneficial for the machines structure.

Choose a direction for cutting:

Some of the cutting directions are drawn on the top surface of the selected method to help you visualise the process. These are schematic and do not represent the actual tool paths that will be calculated by the method.

An example of a sweeping method display in X direction.

Cartessian zone

For Cartesian zones Mayka offers you the following direction possibilities:

• In X

• In Y

• In X then in Y



Zone cylindrique

For Cylindrical zones Mayka offers you the following direction possibilities:

• Rotary

• Linear

• Rotary then Linear

• Helical

Rotary Linear

Helical Rotary then Linear


6.1.5 Machine parameters

This window of machine tool related parameters offers options to enter parameters that some machine tools require. When saving your tool paths the post processor will ignore values that are not related to your specific machine.

Programme number

• Indicate the programme number.

Tool number

• Indicate the tool number of your machine to use. (Manual or Automatic)

Tool Length corrector

• Indicate the tool corrector number of your machines tool offset table to be used.

Tool Length value

• Indicate the actual tool length value in certain machines without tool offset tables.

Option M-Function

• Indicate a String of characters that can be entered as a special function in your post processor. Ask your supplier about this.

Spindle speed

• Indicate the numeric rotation speed of the spindle in rpm.

Feedrate

• Indicate the side feed velocity of the cutter in the material in the displayed units (eg mm/s), in the respective axis.

Note:

This feedrate depends on the material, on the diameter of the chosen cutter, the cutting depth and the spindle power and feedrate


Plunge feedrate

• Indicate the feed velocity of the cutter in the axis parallel to the cutter (Z axis in 3 axis cutting) into the material in the displayed units (eg mm/s selectable in preferences). Depending on the cutter form and material, this feed usually is much slower that the side feed. Something like 20% or 30% of the side feed would be a guide.

6.2 Contouring a model

The cutter profiles the silhouette’s of the model.

This type of milling makes it possible to make a models profile edges cleaner than using the sweeping method. If is also useful when a 2D design has been extruded in Z only, therefore, this feature will contour all the edges.

The detection of the horizontal faces in a model requires the model to be a clean and coherent CAD file. This method can be applied in a Cartesian zone.

6.2.1 Objects

All options in this tab are the same ones as in the sweeping method.

6.2.2 Zone


The working zone will limit the contour. After each pass the tool will retract to the rapid plane.



All options in this tab are the same ones as in the sweeping method


6.2.4.1 Toolpath type - Finishing:

All features are the same ones as in the sweeping method.

6.2.4.2 Toolpath type - Roughing:

All features are the same ones as in the previous method.


6.2.4.3 Clearance

See the previous methods definitions.

6.2.4.4 Increment


6.2.4.5 Depth cut pass

This value corresponds to the distance that separates each of the layers that will be cut with each plunge of the tool.

In this case finishing has the option for a depth of cut value. If entered the cutter contours the silhouette at each cut value layer until the bottom of the zone is reached. Note that roughing should have been performed first..

6.2.4.6 Milling direction

The direction of the cutting paths will influence the surface finish and the quality of the chips and the life of the cutter.

Conventional Climb

Conventional cutting has been the most commonly used method of milling as it is working in opposition to the machines axis, therefore, any limitations in the machines rigidity will not draw the cutter forward and break it. Machines that have virtually no mechanical backlash and are


rigid will allow climb cutting and the results of finish can be much better. Materials hardness, angles of cut of the cutter, numbers teeth of the cutter and other factors will effect your choice of cutting direction. Generally your own experimentation will be the best solution for your application.

6.2.4.7 Offset count

This function allows you to specify several offset cuts away from the profile. The default value is 1 and the offset amount is based on the radius of the tool being used. Here the offset is 2.

With roughing the offset count is very useful to remove material around the outside of your part to facilitate clearance for other cutting methods.

6.2.4.8 Rapid plane


6.2.5 Finishing

The contour profile is only effective at the bottom level of the methods zone after roughing.


6.2.6 Entry / Exit

These parameters will be used each time the cutter begins a sideways movement towards the start point of a 2D contour and away from the exit point.

In different applications, the default of plunging at the start point can sometimes make a cutter mark on the part due to the way the cutter works. Mayka offers 3 options.

6.2.6.1 Linear

The length parameter specifies the length of the segment before the start point and after the exit point of the contour.


6.2.6.2 Circular

The length parameter specifies the length of the segment before the start point and after the exit point of the contour. The radius parameter specifies the arc radius before and after the start and exit points.

If you only wish to use an arc, then set the length equal to 0. Note if your zone is not far enough away from the entry/exit points then the paths will be truncated by the zones limits.

These parameters can be combined with the plunge parameters if required.


All options in this tab are the same ones as in the previous method.


6.3 Contours (Contouring) (additional option)

This method allows the cutting of 2D contours by either following their centreline, or offset to either of their sides. You have the facility to cut the contours in 2.5D by defining the Z depth .

If the option on the model is selected then the cutting tool paths of the contours are projected onto a model making a 3D contoured path. Therefore in this method options there is an extra tab for selecting the model to work with.

6.3.1 Contours

The contours to be cut with this method are selected with this tab. It displays the contours that are listed in the object list.


6.3.2 Objects

As with all the other methods models can be selected. If a model is selected and below the contours in the working zone, then the resulting tool path from the contours will be projected onto the models and thus making a 3D tool path.

6.3.3 Zone

Similar to other methods described before.

.




6.3.5.1 Toolpath type

The same as in the sweeping method.


6.3.5.2 Cutting height - Absolute

The value entered in “Absolute” is the starting position relative to the “origin”. The real Z position of the contour is not taken into account. If contour is with the actual height Z=0 and you enter 0, then the result is the same in both cases.

“Total depth” is the depth of all cutting in the Z direction of the zone. . Note the working zone is only used in X and Y to limit the cutting.

“Depth cut pass” is the pecking depth to reach the “Total depth” used in “Roughing”

6.3.5.3 Cutting height – Relative to the contour

“Total depth” is the relative depth of all the cutting in the Z direction of the zone relative to the contours actual position. Note the working zone is only used in X and Y to limit the cutting.

In “Finishing” no “Depth cut pass” is used.

6.3.5.4 Type of cutting - Contouring


Inside Outside

Tool centre

6.3.5.5 Offset count

This function allows you to specify several offset cuts away from the profile. The default value is 1 and the offset amount is based on the radius of the tool being used. Here the offset is 3.


6.3.5.6 XY Clearance

The same as in the previous method.

6.3.5.7 Z Clearance


6.3.5.8 Increment




6.3.5.10 Type of plunge


6.3.5.11 Entry/Exit


Example Contour on Model

Contour above model Simulation of contour 2mm into model

.


Another contour projected onto a model



6.4 Contours (Pocket) (additional option)

This method allows the cutting of 2D contours by pocketing. You have the facility to cut the contours in 2.5D by defining the Z depth .



6.4.1 Contours

All options in this tab are the same ones as in the contouring method.

Note that to successfully pocket a set of contours that are inside each other, the contours need to be closed.

6.4.2 Objects


6.4.3 Zone


.








The same as in the contouring method.


The same as in the contouring method.



6.4.5.5 Z Clearance


6.4.5.6 Increment



The same as in the previous method




6.4.5.9 Entry/Exit




6.5 Contours (Sweeping) (additional option)

This method allows the cutting of 2D contours by sweeping. You have the facility to cut the contours in 2.5D by defining the Z depth .



6.5.1 Contours


6.5.2 Objects


6.5.3 Zone


.













6.5.5.5 Z Clearance


6.5.5.6 Increment



The same as in the sweeping method with the addition of Zig-Zag and No Zig-Zag.

6.5.5.8 Sweeping angle

This angle defines the direction of sweeping relative to the X+ direction of the method.




6.5.5.10 Entry/Exit





7 Post processing

When that you want to save your tool path for your particular machine tool you will perform the following steps. These will vary slightly depending on the machine tool configuration you selected.

7.1 Exporting • Click on the visible tool path object you wish to export in the object list.

• Select Export from the File menu, or right click on the toolpath in the object list and select Export.

• Select the folder to export and save your work to, then enter a file name, then select the post processor format you require. Click Save.


• Next you will be prompted to enter the “Security plane” height. This dialog will vary depending on the machine configuration and the maximum height of all the objects in your scene. When using a machine with restricted height, please make not of the tool security height you want to be safe, not necessarily Mayka suggested height.

• The tool path file will be formatted for your machine and saved to disk so you can take them to your machine tool, or use Mayka’s Transfer feature for direct sending to the machine tool.

7.2 Security Plane


This value fixes the height as an absolute value compared to machine origin, where the cutter will safely retract to between one or several methods.

7.2.1 Post processing of 3 and 4 axis tool paths

The “security height” is requested in the following dialog:

The process of movements are summarised in the following diagram.

1. From the initial start position “T”, the movements of the machine axis are safely made at the “security plane” at fast traverse speed (G00 by default) with the tool vertical to avoid the risk of collision between the tool and the work piece.

2. The tool then goes down to the “rapid plane” at fast traverse speed (G00 by default). The “rapid plane” is located at a distance, which corresponds to the value of the safe withdrawal of the tool compared to the top of the method. (The value of the “rapid plane” is defined in the methods cutting parameters.)

3. Cutting within the working zone as defined within the method.

4. When cutting is finished in the method the tool withdraws at rapid speed to the “rapid plane”, local to the zone.

5. The “security plane” is reached.

6. If there is another tool path grouped with the current tool path then the machine will move to the beginning of the next methods zone. Otherwise the program end sequence will move the tool away and back to the initial start position “T”.

Key


� T Represents to position the machine tool starts from. Sometimes referred to as the tool change position. This is controlled in the post processors tool start up.

� S This is the “security height” and is an absolute distance from the origin in Mayka, which is also the part origin (datum), or work offset, set in your machine tool.

� R “Rapid plane”, this is the incremental distance above the top each specific methods working zone.

� Origin (datum).


8 Basic concepts

8.1 Basics to getting started with models This is a quick overview on using Mayka™ to produce 3D cutting data for your machine tool. In this example we show you how to make a roughing then a finish cut in soft modelling foam. For harder materials you will need to use smaller increments and slower feedrates. The principles here are similar for most parts. Your supplier will be able to train you as to which method will be suitable for your part.

Note: We are assuming that you have been instructed on the features of the Microsoft Windows environment, which are detailed in the Windows documentation, supplied with your computer. Also you should understand on how to use your machine tool. If you are unsure please contact your dealer.

8.1.1 Launch the software

• From the Windows Start menu select the Picasoft folder then the Mayka™ software.

8.1.2 Select your machine configuration

• Select Machine Configuration from the File menu.


8.1.3 Check Preferences

• Select Preferences > Cutting from the Mayka™ Edit menu.

Check that the bottom 3 items are ticked on. This will make things easier to understand to start with.

8.1.4 Open a model object

• Select Open from the Mayka™ File menu.


• Navigate to Open the model you want to cut, then click Open.

• Mayka™ will open the file and display it on the screen. The progress of opening is displayed at the bottom of the screen window, like this:-

This is what you will see when the model file is opened. There will be the model file and a method in the object list, plus the origin will have been set. (Due to the Preferences setting)


8.1.5 Prepare the method (Roughing)

• Double click on the Sweping Method in the object list.

Edit the values as shown in the following dialogs.

• Type of Cutting = Model > Sweeping


• Nothing to change in Objects. Just your model selected as the object to cut.

• Nothing to change in the Zone, unless you only want to cut part of your model.

• Tool definition. Select a suitable tool for your job.


• Cutting Parameters.

Here we need to select Rough Cutting, allow a Clearance to finish later, an Increment medium, and the other parameters can be as shown below.

• Machine parameters

These depend on your machine tool, the cutting tool and the material you are cutting.


• Click OK and the window will close

8.1.6 Save the Scene

• Regularly save the Scene of all your work. Mayka keeps this all in one compact file..

8.1.7 Start the roughing cutting process

• With the method still selected in the object list, click the Cutting icon.

• The tool path will be calculated, placed in the object list and displayed on the screen over the model. As the tool path is created you will see red/blue lines that indicate the tool path. Should you have made a mistake or want to abort the calculations, press the ESC key.


You can use Simulation or Animation to follow the toolpath progress.


8.1.8 Prepare the method and cut (Finishing)

• Right click on the Sweeping Method in the object list and choose duplicate.

• Now double click on the duplicated method. We will use this for finishing, using the same tool.

• We use the same cutting zone for this part.


• Change the Cutting parameters to Finishing and choose a Extra Fine Increment and limit the cutting to the object, which will save time. You could have use Object for the Roughing as well.

• Then adjust the machine parameters and click OK or the Calculate Now.

• If you clicked ok, now Click the Cutting icon.


• Animation is a useful facility to check the progress of the cut through the block. Also as we selected the limit to object you can see we do not cut all the area around the part.

8.1.9 Exporting the NC tool paths

• Clicking on the visible tool path object you wish to export in the object list will allow you to save that file in the format for your NC machine.

• Select a too path object.


• Select Export from the File menu or the right click menu in the object list.

• Select the folder to save your work then enter a file name followed by the postprocessor format you require. Click Save.

You can repeat this process for each toolpath.

• Next you will be prompted to enter the “Security Height”. This dialog will vary depending on the machine configuration. Here we have chosen 10mm above the origin.

• The tool path file will be formatted for your machine and saved to disk so you can take them to your machine tool.

8.1.10 Setting the Machine tool

• Assuming you did not re-align the part datum when in Mayka™, you need to set up you part on the machine as follows. Each machine tool is different and we cannot anticipate for that, nor do we take any responsibility for your actions. This is just an illustration so you understand the principles.


• Fix a piece of modelling foam to your machine with the approximate size of X110mm x Y110mm x Z20mm.

• Securely fit a 3mm ball end cutter into your machine, with approximately 20mm of cutting flute.

• Using the axis jog controls, set the datum at the front left corner of the block of foam in X and Y with the tool tip Z0 point set to the top.

• When the machine is set as instructed by your machine tool supplier, you can download the Mayka™ NC file you have made either using the Makya File>Transmit function, or your own NC transfer software.


8.2 Basics to getting started with contours (optional witn Model Plus 2D) This is a quick overview on using Mayka™ to produce 2D cutting data for your machine tool. In this example we show you how to make a roughing then a finish cut in soft modelling foam. For harder materials you will need to use smaller increments and slower feedrates. The principles here are similar for most parts. Your supplier will be able to train you as to which method will be suitable for your part.

8.2.1 Launch the software

• From the Windows Start menu select the Picasoft folder then the Mayka™ software.

8.2.2 Select your machine configuration

• Select your post processor from Machine Configuration under the File menu.

8.2.3 Open a contour object

• Select Open from the Mayka™ File menu.


• Navigate to Open the contours you want to cut, then click Open.

• Mayka™ will open the file and display it on the screen. The progress of opening is displayed at the bottom of the screen window, like this:-

This is what you will see when the model file is opened.


8.2.4 Align the contours in respect to the datum

• Click on the Method Icon in the toolbar.

• Choose the settings as shown and click OK.


8.2.5 Prepare the method (Roughing)

• Click on the Method Icon in the toolbar.

Edit the values as shown in the following dialogs.

• Type of Cutting = Pocket

• In Contours select your contours to process and to cut, in the drop down menu.

• In the Zone enter 5mm in the add border around objects and click the apply.


• Tool definition. Select a suitable tool for your job.

• Cutting Parameters.

Here we need to select Rough Cutting, allow a Clearance to finish later, an Increment auto, and the other parameters can be as shown below.


• Machine parameters

These depend on your machine tool, the cutting tool and the material you are cutting.

• Click OK and the window will close

8.2.6 Save the Scene

• Regularly save the Scene of all your work. Mayka keeps this all in one compact file..

8.2.7 Start the roughing cutting process

• With the method still selected in the object list, click the Cutting icon.

• The tool path will be calculated, placed in the object list and displayed on the screen over the model. As the tool path is created you will see red/blue lines that indicate the tool path. Should you have made a mistake or want to abort the calculations, press the ESC key.


You can use Simulation or Animation to follow the toolpath progress.

We suggest you make the method zone a little deeper so as to see what is happening.

Click OK and view the Simulation.


8.2.8 Prepare the method and cut (Finishing)

• Right click on the Sweeping Method in the object list and choose duplicate.

• Now double click on the duplicated method. We will use this for finishing, using the same tool.

• We use the same cutting zone for this part.


• Change the Cutting parameters to Finishing and choose zero clearance in XY and Z.

• Then adjust the machine parameters and click OK or the Calculate Now.

• If you clicked ok, now click the Cutting icon.


• Animation is a useful facility to check the progress of the cut through the block. Also as we selected the limit to object you can see we do not cut all the area around the part.

8.2.9 Exporting the NC tool paths

• Clicking on the visible tool path object you wish to export in the object list will allow you to save that file in the format for your NC machine.

• Select a too path object.

• Select Export from the File menu or the right click menu in the object list.

• Select the folder to save your work then enter a file name followed by the postprocessor format you require. Click Save.

You can repeat this process for each toolpath.

• Next you will be prompted to enter the “Security Height”. This dialog will vary depending on the machine configuration. Here we have chosen 10mm above the origin.


• The tool path file will be formatted for your machine and saved to disk so you can take them to your machine tool.

8.2.10 Setting the Machine tool

• Assuming you did re-align the part datum when in Mayka™, you need to set up you part on the machine as follows. Each machine tool is different and we cannot anticipate for that, nor do we take any responsibility for your actions. This is just an illustration so you understand the principles.

• Fix a piece of modelling foam to your machine with the approximate size of X185mm x Y122mm x Z5mm.

• Securely fit a 3mm ball end cutter into your machine, with approximately 10mm of cutting flute.

• Using the axis jog controls, set the datum at the front left corner of the block of foam in X and Y with the tool tip Z0 point set to the top.

When the machine is set as instructed by your machine tool supplier, you can download the Mayka™ NC file you have made either using the Makya File>Transmit function, or your own NC transfer software.


8.3 Basics to getting started with a BMP image

8.3.1 Open a BMP file

Open the Visage.bmp file from the examples.

The following window appears:

Leave the System as Cartesian.

Change the Grid length to 30 mm. Maka™ recalculates automatically the width proportionaly to the length if the Keep aspect ratio function is checked on.

Maka™ displays distance between points (0.056 mm) which is taken into consideration. In fact, the real precision of the grid depends on the resolution of the image.

Set height of the white to 0.0 mm , set height of the black to –3.0 mm and the Control of grey to 1.000.

Click on OK to validate.

The grid of points is displayed:


Visage file converted into a grid of 3D points.

8.3.2 Cutting the grid

Select the sweeping method in the object list and double click to access the parameters.

Tool Definition parameters. Enter the values shown for a 1.0mm hemispherical tool. Or conical ball tool with 0.5mm radius.


Cutting parameters. Enter the values shown.

Check the Machine parameters and then you can click Calculate now. The dialog will close and the toolpath will be calculated.


Tool path of the Visage file.

8.3.3 Export the tool path

When the calculation is over, Select the File - Export to save a tool path, you have to give it a name, indicate the folder in which you want to save it and the format of the machine tool which will machine this object.

This is the file which will be transmitted to the machine tool.


8.4 Basics to getting started with 4 axis

8.4.1 Machine configuration

Set the machine type to a 4 axis system.

8.4.2 Open a Model or Scene

The following window appears. Make sure your part is on the centreline in the rotary axis:

8.4.3 Configure the method

Set the cylindrical zone.


Define a suitable tool

Set the cutting parameters for Roughing then Finishing as you require and calculate the toolpaths.


Check the machine parameters and click the Calculate now button.

Use Animation or Simulation to check the tool path.


8.4.4 Export your NC toolpaths


8.5 Cutting techniques 8.5.1 Multi-plane cutting

Some models cannot be easily machined in 3 or 4 axis systems without generating a lot of separate surfaces and boundary curves. The best solution is Mayka's multiplane cutting.

The principle is to position multiple working zones at different angles around the job and cut these. Multiple planes can be used in 3 and 4 axis modes to simplify your cutting tasks.


8.5.2 Internal cylindrical cutting

Mayka allows you to use internal cutting heads for cylindrical work

8.5.3 Choosing Contours (Optionin Model)


When you open a compound contour as show below you may wish to pocket just the centre circle and contour the outside of the square.

If you just use the pocketing process then you would get a result like this.

8.5.3.1 Seperating the contours

Following the basic steps you can make a copy of the contours you want.

• Click the Contour Selection tool

• Click the contour you want

• Click Copy in new object tool

A copy of the contour is added to the object list.


Here we repeated the process and renamed the contours we wanted as circle and square.

8.5.3.2 Cutting the contours

Using separate methods for pocketing the circle and then contouring the square you can easily achieve what you want.



8.5.4 Grouping NC FILES

Mayka allows you to select NC files in the Obect list and Group them together. This is ideal if you have several roughing cuts followed by a finishing cut, all using the same tool. It you have a toolchanger then various tools can be used if you have loaded them in the machine correctly.

8.5.4.1 Selecting the objects

Select the files of the same type in decending order from the top of the list down. (If the files are not in the order you want, then drag them in the list so they are in the correct sequence.)

8.5.4.2 Grouping the objects

Select the menu Transform > Group and the files will be grouped together for you to save as a new NC file for your machine.

Note:-We renamed (right click on the name to do this) the files in the list, the software does not rename the files automatically.


8.5.5 2 sided cutting using inversion

Cutting with inversion allows you to manufacture two sides of a part with a 3-axis machine.

Here we look at the basic steps to do this:

Placing the attachments.

Configure a method in 3 axes.

Define a block.

Prepare the block.

Set the invert parameters.

Choose file menu to open the file Retournement.mvscn. A plane with attachment is displayed.

8.5.5.1 Placing the attachments

To be able to turn a part over and cut both sides it is necessary to place attachments so the part will be supported and will not fall.

Before placing the attachments, it is necessary to make sure the part is correctly positioned. Select the object mustang.stl in the object list and click the align to origin.

Choose centre for X and Y, maximum for Z.

Now you are ready to place the attachments.

Set the view to top and the display to wireframe.

From the model menu select "define attachment".

Using the mouse click and drag an attachment.


Repeat this operation to obtain the same position shown below.

If you hold down the CTRL key you will keep the function active and can draw several attachments successively without selecting the menu. Release the CTRL key before drawing the last attachment.

If you now change to shaded mode and view from a different position you will be able to select each attachment in the object list, then use the mouse to adjust their positions.

You can change the dimensions numerically of each attachment by double clicking their name in the object list. Or you can use the control points on each attachment.


It is necessary to place the attachments so they just intersect with the model.

Once all the attachments are correctly positioned, select them all in the object list and select the model. Now group then all together using the transformation menu and choose group.

8.5.5.2 Create the block

Select the new model with grouped attachments in the object list.

Choose "Define block" from the model menu.


Now it is necessary to physically prepare the block for the two-sided cutting of the mustang.

8.5.5.3 Prepare the block

Select the block in the object list.

Click the cutting icon.

The following dialogue will appear. You will be able to choose the diameter of the tool that you are going to use to prepare the block. If you require you can choose one or all of the following options; surfacing the top of the block, contouring the edges or drilling location holes. In our example, we have assumed you have a square block, so we have only chose to drill the location holes. You can see the tool path on the illustration below.

These drilled location holes will need to be drilled in the block and in the fixture when the block is inverted to the other side.


8.5.5.4 Configuration of the cutting method

• Select the new model with grouped attachments in the object list.

• Click on the icon to create a method.

• In the zone dimensions select a border of 10mm and click set. Select a 6mm spherical tool. In the cutting parameters select roughing with 1mm clearance and an increment of 3mm. The depth pass will depend on the material and the machine you are using.

Your method should look similar to this.


It is important that the attachments exceed the size of the method. If this is not the case, delete the method, ungroup the objects and enlarge the attachments, the repeat the steps again.

Reduce the depth of the method so that is just below the widest point on the models partition line. (It does not save anytime if you cut lower than the partition line).

In the same manner, create a finishing method (without clearance and with a smaller increment). In configuring this method, choose the limit of cutting to be model only, this will save cutting time.

You can then start the cutting calculations by having the model selected in the list of object and click the cutting button. Save the tool paths for your machine and make the part.

8.5.5.5 Invert the model

• To invert the object and to be able to manufacture on the other side, it is necessary to select the object containing the grouped plane and attachments in the object list.

• In the transformation menu, select invert.

• The dialog is displayed with the options to invert in X or in Y. In this example select the in X. Select the block and the model.


• The objects are inverted. Now it is necessary to create two more cutting methods (roughing then finishing). Then calculate the tool paths and save them.

All that remains is to drill the location holes in your fixture board and insert some pins the same size as the holes, turn the part over and locate it on the pins. Fix the part down with your clamps etc., and then manufacture the other side. To remove the finished part you will have to manually cut through the attachments.

E&OE

The PicaSoft Team


Documents

User Manual Mayka v7 Model - PicaSoft · User Manual Mayka Model V7.0 – page 1 User Manual Mayka v7 Model (showing optional Plus 2D) Innovative tools to compliment the Creative