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Inthis operation drilling on different levels can be carried out. The drilling levels are automatically recognized but may beedited by the user. Pocket RecognitionThis Operation recognizes automatically pocket features atthe target model and creates the necessary machining.
Contour 3D OperationThis operation enables you to utilize the power of the 3D Engravingtechnology for the 3D contour machining. Thread Milling OperationThis operation enables you to generate a helical tool path forthe machining of internal and external threads with threadmills.
You have to define several 2. In the process of definition of operations, you have to definethe machining geometry, the tool and several technologicalparameters. The CAM-Part is loaded. The Face Milling Operation dialog box is displayed. In this operation, the upper face is machined.
The FaceMilling Geometry dialog box is displayed. Therectangle chain is displayed in the Chain List section. Face Milling geometry The Define button and the related box enable you either todefine a new faces geometry with the Select Faces dialog box or choosean already defined geometry from the list.
When the model faces areselected, SolidCAM generates a number of chains surrounding theselected faces. These chains are displayed in the Chain List section. The Define button and the related box enable you eitherto define a new profile geometry with the Geometry Edit dialog box orchoose an already defined geometry from the list.
The defined chains aredisplayed in the Chain List section. In the Type section, use the default Model option for the Face Milling geometrydefinition. Click the Define button. The 3D Geometry dialog box is displayed. You can select an object by clicking on it.
When anobject is selected, its icon is displayed in the list inthe bottom of the dialog box. To unselect the object,click on it again or right-click its icon in the list ofselected elements and choose Unselect from themenu. To remove selection from all objects in thelist, click Unselect all. Click on the solid model to select it. Themodel is highlighted, and its icon appearsin the list.
Confirm the 3D Geometrydialog box by clicking the button. The Face Milling Geometry dialog box isdisplayed again. The rectangle is generated surroundingthe target model at the XY-plane. Confirm the Face Milling Geometrydialog box by clicking the button.
The geometry is defined for the operation. Start the tool definitionby clicking the Select button. Currently, the Part Tool Table is empty.
Define a new tool suitable for face milling. Click the Add Milling Tool button to start the tool definition. The new pane containing available tools is displayed. This dialog box enables you to add a new tool to the tool library choosing from thetools available for the current operation. Face millThis tool type is used for machining of large flat surfaces. A tool of thistype is defined with the parameters shown in the image.
Click the Select button to confirm the tool parameters and choose the tool for theoperation. Click the Facedepth button in the Milling levels area. This button enables you to define the OperationLower level directly on the solid model.
The depth is calculated automatically as thedifference between the Z-values of the Operation Upper and Lower levels. The Pick Lower level dialog box isdisplayed.
Select the model face as shown. The lower level value 0 is determined and displayed in the Pick Lower level dialog box. Confirm this dialog box with the button. The Face depth value is displayed in the Millinglevels area.
The pink background of the edit boxmeans that the parameter is associative to themodel. Associativity enables the selected level tobe synchronized with the solid model changes; SolidCAM automatically updates the CAM datawhen the model is modified.
Define the technological parametersSwitch to the Technology page of the Face Milling Operation dialog box. In theTechnology section, choose the One Pass option. The direction and locationof the pass are calculated automaticallyaccording to the face geometry, inorder to generate an optimal toolmovement with the tool covering thewhole geometry.
Selecting the One pass optionautomatically opens the One passtab that enables you to define themachining parameters. The Extension section enables you to define the tool path extensionover the face edges. The Face Milling operation data is saved, and the tool path is calculated. TheSimulation control panel is displayed. Switch to the SolidVerify page and startthe simulation with thebutton.
The solid stock model defined in Exercise 1 is used in the SolidVerifysimulation mode. During the machining simulation process, SolidCAM subtracts the tool movements using solid Boolean operations from thesolid model of the stock. The remaining machined stock is a solid modelthat can be dynamically zoomed or rotated. It can also be compared to thetarget model in order to show the rest material. During the simulation, you can rotate , move , or zoom themodel.
Use these options to see the machining area in details. The Single step mode can be used to simulate the next tool movement byclicking the button or by using the space bar on your keyboard. Close the simulation with the button. The Face Milling Operation dialog box isdisplayed. Close this dialog box with the Exit button. The Profile Operation dialog box isdisplayed. In this operation, the external profile ismachined.
Define the GeometryThe first step of definition of each operation is the Geometry selection. At this stage,you have to define the Geometry for the Profile operation using the solid modelgeometry. Click in the Geometry page of the Profile Operation dialog box. This dialog box enables you to add and editgeometry chains.
When this dialog box is displayed, you can select solid model entitiesfor the Geometry definition. Chain Selection OptionsYou can define the geometry by selecting edges,sketch segments and points on the contour. The following options are available:CurveThis option enables you to create a chain ofexisting curves and edges by selecting themone after the other.
Associativity: SolidCAM keeps the associativity to any edge or sketchentity. Any change made to the model or sketch automatically updatesthe selected geometry. LoopThis option enables you to select a loop by picking one of the modeledges.
Loop 2Loop Pick an edge shared by two model faces. Two faces towhich this edge belongs are determined, and their loopsare highlighted. The first determined loop is consideredto be the primary and is highlighted with yellow color. The second loop is considered to be the secondary andis highlighted with blue color.
Choose one of the loops. Click on any other edgeforming the face. You are prompted to accept the chainthat is now highlighted with yellow color. Accept thechain with the Yes button. A closed geometry chain isdefined on this loop, and the secondary loop is rejected.
Point to pointThis option enables you to connect specified points; the points areconnected by a straight line. Associativity: SolidCAM does not keep the associativity to any selectedpoint.
Any change made to the model or sketch does not update theselected geometry. You cannot select a point that is not located on aSolidWorks entity if you need to select such a point, adda planar surface under the model and select the pointson that surface.
Whenever the model is changed and synchronized,the geometry is updated with the model. Any change made to the model or sketch does notupdate the selected geometry.
Automatic selection options SolidCAM automatically determines the chainentities and close the chain contour. The Autoselect mode offers the following options:Auto-toThe chain is selected by specifying the start curve,the direction of the chain and the element up towhich the chain is created. SolidCAM enablesyou to choose any model edge, vertex or sketchentity to determine the chain end.
The chain selection is terminated when the selectedend item is reached. End entityStart entitySelected chain If the chosen end item cannot be reached by the chain flow, the chaindefinition is terminated when the start chain segment is reached.
Thechain is automatically closed. End entityStart entitySelected chainThe confirmation message is displayed. The Auto-to option is useful if you do not want to definea closed chain, but an open chain up to a certain element. Auto-general SolidCAM highlights all the entities that are connected to the last chainentity. You have to select the entity along which you want the chain tocontinue.
You are prompted to identify thenext chain element when two entities on the same Z-level are connectedto the chain. Auto-Delta ZWhen you select this option, you are required to enter a positive andnegative Z-deviation into the Delta-Z dialog box.
Only entities in thisrange are identified as the next possible entity of the chain. In this exercise, the geometry must be defined as shown. The red arrow indicates the direction of the geometry. In SolidCAM operations, thedirection of the chain geometryis used for the tool pathcalculation.
In Profile milling,the tool moves in the directionof the geometry by default. Inthis exercise, the combinationof the geometry direction andthe clockwise direction of thetool revolution enables you toperform climb milling. Tool movementdirectionGeometrydirectionTool revolutiondirectionWhen you pick the first chain entity on the solid model, SolidCAM determines the start point of the picked entity closest to the pickedposition. The direction of the picked first chain entity is definedautomatically from the start point to the picked position.
Starting pointDirectionPicked positionGeometry chainChoose the Loop option in the Chain section and click on the model edge as shown. Notice that the pickedposition must be close to thestart point of the geometry. The red arrow indicates the direction of the selected chain. Click the secondary chain highlighted with blue color to choose it for geometrydefinition. The picked chain is now highlighted with red color, and the second chain is rejected. The confirmation message is displayed.
Confirm it with the Yesbutton. The chain icon is displayed in the Chain List section. At this stage, the Geometry is defined. Confirm the Geometry selection withthe button. The Profile Operation dialog box is displayed. Define the ToolAt this stage, you have to define the tool for the Profile milling.
Switch to the Tool page of the Profile Operation dialog box and click the Select button. The Part Tool Table with the tool used in the previous operation is displayed. Click the End Mill tool to choose it for the operation. In the Tool parameter section,under Topology, set the Diameter value to Set the Spin rate used in rough milling value to TheSpin finish used in finish milling value is automatically setto When this check box is selected, thecorresponding edit box is available so that you can edit its value.
Whenthis check box is not selected, the specified Spin rate value is used forboth rough and finish machining. Select thecheck box near the Feed finish feed rate for finish milling parameter and set the value to The Feed finish check box enables you to optionally define differentvalues for Feed XY and Feed finish. Whenthis check box is not selected, the specified Feed XY value is used forboth rough and finish machining.
SolidCAM enables you to define the milling levels using the solid model data. Upper LevelThis parameter defines the Z-level at which the machining starts. Profile DepthThis parameter defines the Z-level below which the tool does not mill. This plane is not penetrated in any milling strategy.
The Pick Upper level dialogbox is displayed. The Upper Level value 0 is determinedand displayed in the Pick Upper leveldialog box. Confirm this dialog box byclicking the button. Click the Profile depth button in theMilling levels area. The Pick Lower level dialog box is displayed. Pick the bottom edge of the model asshown. The Lower level value is determinedand displayed in the Pick Lower leveldialog box. Confirm this dialog box withthe button. The Delta depth parameter defines the offset for the cutting depththat can be changed with its associativity preserved.
The Delta depthvalue is always relative to the Profile Depth defined for the operation. Set the Delta depth value to The milling levels are defined. Define the technological parametersSwitch to the Technology page of the Profile Operation dialog box. First, you need to make sure that the tool position relative to the geometry is correct. In the Modify section, check the Tool side option.
ModifyThe Tool side option enables you to determine the tool position relativeto the geometry. Right — the tool cuts on the right side of the profile geometry. Left — the tool cuts on the left side of the profile geometry. Center — the center of the tool moves on the profile geometry nocompensation G4x can be used with this option.
Left Right CenterThe Geometry button displays the Modify Geometry dialog box thatenables you to define the modification parameters of the geometryand to choose which geometry chains are active in the operation incase of multiple chain geometry.
The chain geometry of the profileis displayed on the model with the chain direction indicated anda circle representing the tool relative to the geometry. In this case, the default Left option meets therequirements of climb milling. Click the Geometry buttonto check the tool position. Click the button in the ModifyGeometry dialog box. The ProfileOperation dialog box is displayed again. SolidCAM enables you to perform the rough and finish machining of the profile ina single Profile operation.
Select the Rough check box. Definethe Step down parameter for roughing. Step downProfile roughing is performed inconstant Z-passes. The Step downparameter defines the distancebetween each two successiveZ-levels.
Step downUpperlevelProfiledepthSet the Step down to 5. With this value, SolidCAM performs two cuts at the following Z-levels: -5, ; the lastcut is performed at the Z-level defined by Profile depth. Now you need to define the wall offset that will remain after the roughing passes. OffsetsThe Wall offset and Floor offset parameters enable you to define theallowances that remain on the walls and the floor of the machined parttill the profile finish machining.
These allowances can be removed withthe finish passes in the same Profile operation or in an additional Profileoperation with another tool. Theallowance of 0. This allowance will be removed witha separate finishing cut in the end of the profile machining. Select the Finish check box to perform the finishing of theprofile. This page enables you to define the way the tool approaches the profile and retreatsaway. Profile Lead in and Lead outThe lead-in movement is necessary to prevent vertical entering of thetool into the material.
With the lead-in strategies the tool descends to themachining level outside of the material and then horizontally penetratesthe material with the lead-in movement. The lead-out strategy enablesyou to perform the retract movements outside the material. The length of the normal canbe set in the Normal length field. Thedistance between the normal andmaterial is set in the Tangent extensionfield. The arcradius can be set in the Radius field. Thelength of the extension can be set in theTangent extension field.
The arc angle isset in the Arc angle field. The length of the tangentcan be set in the Length field. Thedistance to the material can be set in theTangent extension field. From this position, thetool moves on a straight line to the startpoint of the profile. When you selectthis option, the Pick button is activatedso that you can select a position directlyon the solid model. The distancebetween the point and material is set inthe Tangent extension field.
When you select thisoption, you can define a geometry of the tool approach to the material. When the Same as Lead in check box is selected, the strategy andparameters defined for Lead in are used for Lead out.
Under Lead in, choose the Arc optionfrom the list, and set the Tangentextension value to 5 and the Radius valueto 2. Under Lead out, select the Same as Leadin check box. The definition of the basic technologicalparameters of profile milling is finished. The Profile operation data is saved, and the toolpath is calculated. Simulate the operationClick the Simulate button in the Profile Operation dialogbox.
The Simulation control panel is displayed. Switch tothe SolidVerify page and start the simulation with the Playbutton. When the simulation is finished, play the it step by step using thebutton. Since all the View options ofSolidWorks are active during the simulation, you can see the tool path fromdifferent perspectives and zoom on a certain area of the model.
Close the simulation with the Exitdisplayed. The Profile Operation dialog box is Add a Pocket operationThe Pocket operation is used for the internalpocket machining. Right-click the last definedProfile operation and choose Pocket from theAdd Milling Operation submenu. The Pocket Operation dialog box is displayed. Define the GeometryThe geometry for a Pocket operation is generally represented by closed chains. In thisexercise, you have to define a chain using the solid model edges.
Click the button in the Geometrypage to start the geometry definition. The Geometry Edit dialog box isdisplayed. Using the Loop option, define thechain as shown. Confirm the geometry definition byclicking the button. Define the ToolSwitch to the Tool page and click the Select button. The Part Tool Table is displayed. Click the to start the tool definition. The Tool type table is displayed. In the Topology page, set the Diametervalue to 8. Define the Milling levelsSwitch to the Levels page of the PocketOperation dialog box and define upperand lower levels of machining directly onthe solid model.
Define the Upper level as shown. TheUpper level value 0 is determined. Define the Pocket depth by clicking onthe pocket bottom face as shown. The Pocket depth value 8 is determined. Set the Step down value to 4 to perform the pocketmachining in two equal steps. Define the technological parametersSwitch to the Technology page of the Pocket Operationdialog box. In the Offsets section, set the Wall offsetand the Floor offset values to 0.
These offsets remainunmachined during roughing and are removed with thefurther finishing. In the Finish area, select the Wall and Floor check boxes. These options enable you to perform finishing of the Walloffset and Floor offset that remain after the roughing. Define the machining strategy. Make sure that the defaultContour option is chosen in the Technology section.
Whenthe Contour strategy is chosen, the tool moves on offsetsparallel to the pocket contour. Switch to the Contour tab to display the Contourparameters. This page enables you to define theparameters of the Contour strategy. The Min. If the given radius is too large for a specific corner, itproduces the largest possible radius at that point. Sometimes the fillet option can leave some material.
This particularly happens if the given radius is large. The tool path formsa loop in the corner, preventing anabrupt change of direction. Althoughthis produces a sharp movement by thetool, the path itself is slightly shorterthan the smooth corner option. Thiscan help cut down on machining time. This option is not recommended for high-speed cutting. DirectionThis option enables you to choose climb or conventional milling for theroughing operation.
Climb millingConventional milling Theradius of the arc is half the distance betweenthe tool path passes. Exit materialThis option controls the tool movements between the working areas. Exit material check box notselectedWhen the tool moves from oneworking area to the next, it movesthrough the full material aroundthe island to get to the nextworking area as shown above. Connect islandsThis option enables you to keep thesame cutting direction conventional orclimb milling throughout the entire toolpath where possible.
This is particularlyimportant in high-speed cutting. Exit material check boxselectedThe tool exits the materialand travels rapidly above thematerial to the next workingarea as shown above. The leadin path is the Lead in you define.
Define the strategy with which the tool is plunginginto the material during the pocket roughing. Fromthis position, the tool moves to the pocket start point calculated bythe pocket algorithm.
Click the Data button to specify the positionwhere the tool plunges into the material. The start point must be selected using the Data button.
Enter theramping angle value into the Angle edit box of the Angle rampingdialog box. SolidCAM does not check the ramping movement against the pocketcontour. Check the tool path simulation to make sure that the tooldoes not gouge the pocket walls or islands. When the tool reaches the step down depth,it machines all the material at the step down depth. Click the Databutton to set the helical ramping parameters. The difference is that the descent is performed in a linear zigzagfashion rather than in a circular one.
Choose the Helical option and click the Data button. The Helical ramping dialog box is displayed. This dialog box enables you to definethe ramping position and the related parameters for each chain used in the Pocketoperation. Helical Ramping ParametersThe Tool step down parameter defines thedistance between each two adjacent turns of thetool helical movement.
The Angle parameter defines the ramping angle. The Radius parameter defines the radius of thedescending helix. Center cuttingIf your tool has center cutting capabilities, selectthe Center cutting check box. In the Angle field,enter the descent angle that you would like thetool to follow. In the Radius field, enter theradius of the tool path helix. The working order is as follows If the tool does not have center cutting capabilities, do not select theCenter cutting check box.
In the Tool step down field, enter the depth ofthe step down of the tool. Then it descends to thenext Tool step down. ChainsThis section displays the list of all geometry chains defined for theoperation. All the chain entries are displayed under the Chains header. You can select chain entries in the list. When the Chains header is selected, SolidCAM displays the tool pathand default ramping positions for all of the chains. The circles representthe default helical ramping movement defined for each chain.
When a chain entry is selected, SolidCAM displays the tool path and thedefault ramping position for this chain. This position is automaticallydefined at the start position of the tool path segment relevant for thecurrent chain. You can change this position by picking a point on themodel or by entering the new position coordinates into the X, Y, Z dialogbox.
The schematic circle facilitates the definition of the position. When the position is picked, it is marked on the model witha red dot. The coordinates of the picked point are displayed in theX, Y, Z dialog box.
The start position of the tool path is marked on themodel with a yellow dot. The circle of the tool path color represents thehelical movement of the tool plunging.
Tool path start positionRamping positionWhen the ramping position is defined, the tool descends into the materialat the specified ramping position with helical movements according tothe defined parameters. When it reaches the level of the first cutting pass,it moves to the start position of the tool path and performs machiningof the pocket. The Auto next button provides you with the selection mode that enablesyou to define the ramping positions for all of the chains one by one. Confirm the dialog box with thebutton.
The length of thenormal can be set in the Normal lengthfield. The distance between the normal andstart of the geometry is set in the Tangentextension field. TangentExtensionNormal Length Thearc radius can be set in the Radius field. The length of the extension can be set inthe Tangent extension field.
The distanceto the material can be set in the Tangentextension field. TangentExtensionLengthWhen the Same as Lead in check box is selected, the strategy andparameters defined for Lead in are used for Lead out. Under Lead in, choose the Arc optionfrom the list and set the Tangent extensionvalue to 3 and the Radius value to 2. The Pocket operation data is saved and the tool pathis calculated. Add a Drilling operationThis Drilling operation is used to perform thepreliminary center drilling of the four holes inthe corners of the model.
The Drilling Operation dialog box is displayed. Define the Drill geometryIn the Geometry area, click thebutton. This dialog box enables you to select the geometry for drilling directly on the solidmodel.
Due to the natureof spline curves or surface boundaries, youcannot pick a center position like you couldon a circle or an arc. SolidCAM calculates thecenter position of an arc defined by threepoints positioned on the spline edges. Thisfacilitates selecting drill centers on splinesurfaces. Four drill positions are selected. Theircoordinates are displayed in bottompart of the Drill Geometry Selectiondialog box. Click the button to confirm the geometry selection. The Drilling Operation dialogbox is displayed.
Click to start a new drilling tool definition. From theDrilling Tools section, choose the Spot drill tool for theoperation. Spot DrillThis tool type is used for center drilling and chamfering in Drillingoperations.
A tool of this type is defined with the parameters shown inthe image. Click the Select button to choose the tool for the operation. Click the Data tab. Define the spin and the feed for the operation.
Define the center drilling depthSwitch to the Levels page of the Drilling Operationdialog box. Click the Drill depth button and selectthe upper face of the model.
The Drill depth value 0 appears in the relevant edit box. To perform the drilling down to the specified diameter of the tool, use the Depth typeoption. The Diameter value can vary from 0 all the way up to the drill tooldiameter.
A value greater than the drill tool diameter is automaticallydecreased to the drill tool diameter. Choose the Diameter value option and set the value to 5.
In this manner, the drilling is performed till the tooldiameter of 5 mm is reached at the depth of 0. The Drilling operation data is saved and the toolpath is calculated. Simulate the operationSimulate the operation in theSolidVerify simulation mode. Add a Drilling operationAdd another Drilling operation to perform the through drilling of the holes. Define the GeometryThis operation is using the geometry that was defined inthe previous center drilling operation.
Choose the Drillgeometry from the list in the Geometry area. Each geometry defined in SolidCAM has a unique name. When the geometryis being defined, it is assigned a default name that can be changed.
Usingthis name, you can choose the geometry for a specific operation. Click the Data tab in the Tool page. Define the spin and feed for the operation. Define the Drilling depthThe overall height of the model is 10 mmplus the 5 mm bottom offset defined forthe stock.
The drilling has to be performeddeeper than this depth in order to enable thetool to exit from the material and performthe through drilling. Switch to the Levels page. Define the Upper level by clicking on the top face of the model as shown.
Define the Drill depth. Rotate the model and select the bottom face as shown. Since the Z- offset defined for the stock model is 5mm, set the Delta value to To perform the through drilling, choose the Fulldiameter option in the Depth type area.
With thisoption, the drilling is performed until the fulldiameter is reached at the specified drill depth. This means that the conical part of the tool exitsfrom the material. In this operation, the pecking canned cycle is used for chip breaking. With this cycle, the chip breaking is accomplished by slight retracts of the tool duringthe drilling process. Switch to the Technology page and click the Drill cycle type button.
Available drillcycles are displayed. Click the Peck button. The cycle is chosen for the operation. Click the Data button to define the pecking parameters. The DrillOptions dialog box is displayed. Confirm the data with the OK button.
The Drilling operation data is saved, and the tool path is calculated. Simulate the operationSimulate the operation in the SolidVerify simulation mode. Since in the previous operation the drilling diameter was greater than that inthis operation, the drilling results in a chamfer on the drilled holes.
Now you have successfully finished the exercise. The cover is machined on the 3-Axis milling CNC-machine using the machining vice. The part ismachined using two positionings. At the first stage, the workpiece is positioned in the vice as shown below.
At the next stage, the rest of the cover faces are machined using the second positioning. Load the SolidWorks modelLoad the Exercise3. The CAM-Part is defined. Select the CNC-machine controller.
Click the arrow in the CNC-Machine section to display the list of post-processors installedon your system. Define the Stock modelIn this exercise, you have to define the Stock model before youdefine the Coordinate System in order to use the workpiece forthe CoordSys definition.
The stock Model dialog box isdisplayed. SolidCAM generates the stock box surrounding the model withthe specified allowances. In the Expand box at section, set thevalue of the Z- parameter direction to 5. This allowance is usedfor the first clamping. Set the value of 2 for the rest of thedirections. Click on the model. The face is highlighted, and the boxsurrounding the model is displayed.
Click the Add box to CAD model button. Confirm the Model dialog box with thedisplayed. The Milling Part Data dialog box is6.
The CoordSys dialog box is displayed. In the Define CoordSys options list, choose the Define option. At first, you have todefine the Coordinate System origin location and then thepoints for the X- and Y-directions. Pick the origin point in the stock box corner as shown. Click on the stock model edge as shown to define the X-axis of the Coordinate System. Click on the stock model edge as shown to define the Y-axis of the Coordinate System. When a point is selected, the next button is automatically activated.
If youmiss the selection, you can at any time select the button you want to defineand continue automatically to the next button. The model is rotated,The CoordSys Data dialog box is displayed.
Define the Part Lower level directly on the solid model. This parameter defines thelower surface level of the part to be milled. Click the Part Lower level button. Rotate the model and select the lower facethat is milled using the first positioningas shown. The Z-coordinate of the face is displayed in the Pick Part Lowerlevel dialog box. Confirm this dialog box by clicking thebutton. Confirm the CoordSys Manager dialog box with thedialog box is displayed again.
The Milling Part Data7. The target Model dialog box is displayed. This dialog box enables you to define a 3D model for the Target. Its face highlighted. Thedefined CAM-Part is saved. Using the first defined Coordinate System first clamping , you have to perform thefollowing operations:Upper face machiningUpper profile machiningLower profile machiningHole pads machining Then the part has to be rotated and clamped again.
With the second clamping, thefollowing operations are performed:Upper face machiningPocket machiningSlot machiningHoles machining The Face Milling operation is used for the upper facemachining. Define the Face Milling geometryClick the button in the Geometry page. The Face MillingGeometry dialog box is displayed. Using the default Model option, click the Define button andclick on the solid model to select a face.
In the Face Milling Geometry dialog box, define the 3 mm offsetto machine over the stock edges. In the Modify section, set theOffset value to 3. Confirm the Face Milling Geometry dialog box by clicking thebutton. This featurealso enables you to see a more realistic simulation in the SolidVerify simulation. Switch to the Holder page in the Choosing Tool for Operation dialog box. This table containsa number of frequently used tool holder components.
The Global holderstable can be modified by the user. Select the Use Holder check box to enable choosing a holder from the Global holderstable. The Local and Global tool holders lists become available. The SolidCAM tool holder is defined by combining two components.
The first component is the tool adaptor mounted on the spindle unitof the milling machine. The second component can consist of varioustypes of extensions and reductions like collet chucks, arbors, shanks andother components that you may have.
This collet chuck is suitable for the chosen tool diameter 40 mm. Choose the defined tool for the operation by clicking the Select button. The FaceMilling Operation dialog box is displayed.
Click the Face depth buttonin the Milling levels area and select the model faceas shown. The Face depth 2 is calculated. Define the technological parametersSwitch to the Technologypage of the Face MillingOperation dialog box. Inthe Technology section,use the default Hatchoption. Hatch Machining TechnologyThe machining is performed in a linear pattern.
The Hatch page enables you to define the hatching parameters. The tool path always follows the length of the face nomatter what angle the machined surface is facing. The Delta from optimal parameter enables you to change the hatchingangle. Delta angleOptimal direction The Zigzag option enables you to create the tool path withbidirectional movements. The Extension section enables you to define theextension both along the tool path the Along section and across thetool path the Across section.
Extension acrossthe tool pass The Fillet option connects each direction witha given radius allowing for a smoother transitionbetween path directions. Click the Data tab to define the machiningparameters. In the Hatch angle section, switch to theAutomatic optimal angle option. Switch back to the Technology tab. OverlapThis section enables you to define the tool overlapping between twosuccessive passes. This option can be defined as Percentage of the tooldiameter or as a Value.
Overlap value butnot smaller than this value. When this check box is not selected,the distance between the last passand the one before it can be smallerthan that between all of the otherpasses. When this check box is selected,the evenly spaced hatch tool pathis generated. The overlap betweentwo successive passes is not smallerthan the specified Min. Define the roughing offset that remains on the floor of the face.
This offset is leftunmachined during the rough face machining and removed during the face finishing. In the Offsets section, set the Floor offset value to 0. Select the Finish check box to perform finishing of theface in this operation. This check box enables you toremove the remaining offset with the last cutting pass. Define the Lead in and Lead outSwitch to the Link page of the Face Milling dialog box to define the way the toolapproaches the material and retreats away.
In the Lead in section, choose the Tangent option. This option enables the tool toapproach the material on a line tangent to the profile. In the Length field, set the lengthof the tangent to 5.
In the Lead out section, select the Same as Lead in check box. The Simulationcontrol panel is displayed. Switch to the SolidVerify page and startthe simulation with the button. Close this dialog box with theExit button. Add a Profile operationAt this stage, you have to define a Profile operation in order to machine the upperprofile of the cover. The Geometry Edit dialog box is displayed. Click the Add button in the Multi-chain section.
The Chains Selection dialog box is displayed. This dialog boxenables you to pick a number of chains from the model byselecting the model elements. SolidCAM automatically createschains from the selected elements. Click on the top face of the model as shown. The face is selected, and its boundary is highlighted. Click to choose the selected chain as the geometry. The Geometry Edit dialog boxis displayed. Confirm the geometry definition with the button.
The geometry is defined for theoperation. Choose the tool holder. Switch to the Holder page and select the Use holder check box. Click the Local holders tab. When a new holder is chosen from the Globalholders table, it is copied to the local table to make a further use easier. Confirm the tool selection by clicking theSelect button. Define the Profile depthSwitch to the Levels page.
In the same manner as explained in previous steps, definethe Profile depth by clicking on the model face as shown below. Define the technological parametersSwitch to the Technology page. In theModify section, set the Tool side to Right. Click the Geometry button to check thetool position relative to the geometry. Close the Modify Geometry dialog boxwith the button.
Now you have to define the roughing and finishing parameters. SolidCAM Profileoperation enables you to perform the rough and finish machining in the single operation. Set the Step down value to3. The profile is machined in two equal Z-steps. In the Offsets section, set the Wall offset and the Flooroffset to 0.
These allowances are removed during thefinish machining. Select the Clear offset check box. Set the Offset value to 5and the Step over value to 2. Clear OffsetThis option generates several concentric profiles with a constant depththat start from the defined clear offset distance from the profile andfinish up to the geometry of the profile, thus clearing the area aroundthe profile.
The Offset defines the distance from the geometry at which themilling starts. The Clear offset value should be equal to or larger thanthe Wall offset value. The tool starts milling the profile at the distancedefined by the Clear offset and finishes at the distance defined by theWall offset; the overlap of the adjacent tool paths is defined by the Stepover parameter. The Step over parameter defines the overlap of adjacenttool paths. It determines the offset between two successive concentricprofiles.
Define the Lead in and Lead outSwitch to the Link page. Prior to creating the Project, the CAM Settings are customized to prepare for the upcoming tutorial videos. Click the play button below Complete the part programming The part programming is completed in just four operations, which begin on the following page. As shown in the illustration below, the workflow in SolidCAM is displayed in each of the Operation dialog boxes. The Geometry is defined first, followed by creating and choosing a Tool, picking the Milling levels, defining the type of Technology to use, and finally choosing the Lead in and Lead out tool Link movements.
Each operation is saved and the calculated tool path is quickly shown in Simulation. The target geometry is selected, which automatically creates a chain used for the machining boundary. The tool is set to machine the 0. The geometry is selected as a chain that runs along the outside contour of the Target model. After the full profile depth is reached, the tool will remove the 0.
Like the previous Profile operation, a single edge is picked during the geometry selection. The chain is closed automatically. The tool is set to perform a Helical entry into the pocket and a Contour strategy is used for cutting. After the roughing, the tool will take a finish pass on both the Wall and Floor to remove the excess offset material. SolidCAM finds the centers of all circle entities and defines their positions for the drill geometry. A drilling tool is defined and choosing a holder is also shown.
The Levels are picked directly off the model, like in the previous operations. The standard drilling method of G81 is defined for the Drill cycle type. The word fast meaning significantly faster than traditional machining at its best and the word safe meaning without the risk of breaking tools or subjecting the machine to excessive wear, all while maximizing tool life.
To achieve these goals, the iMachining technology uses advanced, patented algorithms to generate smooth tangent tool paths, coupled with matching conditions, that together keep the mechanical and thermal load on the tool constant, while cutting thin chips at high cutting speeds and deeper than standard cuts up to 4 times diameter. As a result, iMachining manages to cut irregularly shaped areas with a single continuous spiral.
To machine narrow passages, separating channels and tight corners, iMachining uses proprietary constant load one-way tool paths. The finish tool path is executed in several consecutive steps with intelligent tool movements, all of which would be programming intensive and difficult to achieve using traditional machining methods.
Because of its highly systematic approach to finishing and dedication to eliminate over engagement, the iMachining technology is able to further maximize tool life. The iMachining Technology Wizard, which is responsible for these calculations, provides the user with the means of selecting the level of machining aggressiveness most suitable to the specific machine and setup conditions and to their production requirements quantity, schedule and tooling costs.
Another critical task performed by the Technology Wizard is dynamically adjusting the feed to compensate for the dynamically varying cutting angle — a by-product of the morphing spiral, thus achieving a constant load on the tool, which again maximizes tool life.
Before you begin the upcoming exercises, additional changes should be made to the default SolidCAM Settings. When enabled, this option features the Dashboard page in the iMachining Operation dialog box.
The Dashboard displays the most commonly used parameters on one page. It was designed only for iMachining 2D operations and is primarily for experienced users. Click OK to confirm your changes. This exercise is based on a SolidCAM Professor video series, which provides a step- by-step guide on the definition process of the iMachining technology to machine the part shown above. The videos demonstrating the steps are duplicated and accompanied by a written walkthrough.
The roughing and finishing of the outside contour, center pocket and pocket ledge are defined. In addition, the machine and work material parameters are defined for iMachining. Click the play button below to watch the video.
Following the video is also a written walkthrough to complete this step. When using the iMachining technology, you also have to define the machine and work material parameters. SolidCAM enables you to add new and edit existing machine and material files in the iMachining Database. Clicking the Edit iMachining Database button displays the iDatabase dialog box, the interface for managing machines and work materials contained in the iMachining Database.
The same buttons are available on the Material DB tab enabling you to manage material definitions in the database.
Define the machining of the outside contour In this step, the machining of the outside contour is defined. For this example, the geometry is defined as an open pocket with island.
The Geometry, Tool and Levels are defined and the Offsets are specified; the iMachining Technology Wizard automatically produces the optimal Cutting conditions.
The roughing operation is then copied and the iFinish Technology type is used to define the finishing. The following videos demonstrate how different types of geometries are defined in iMachining. Closed pocket geometries in iMachining This video focuses on several examples of closed pocket geometries and the tool path techniques that iMachining uses when cutting those geometries.
Open pocket geometries in iMachining This video focuses on a few examples of open pocket geometries and the tool path techniques that iMachining uses when cutting those geometries. Semi-open pocket geometries in iMachining This video focuses on several examples of semi-open pocket geometries and the tool path techniques that iMachining uses when cutting those geometries.
For this operation, the machining geometry is defined as an open pocket with island. Mark the outer chain 1-Chain as open to enable the tool to approach from the outside. This parameter Angle affects the Cutting conditions and Step down values generated by the iMachining Technology Wizard.
Click the Upper level button and pick on the top face of the Stock model to define at what Z-level to start the machining. In addition to the picked depths, define a Delta depth to perform machining deeper than the part bottom edge. Set the value to Switch to the Technology Wizard page of the iMachining Operation dialog box. This Wizard automatically calculates the Cutting conditions for the iMachining technology, taking into account the tool data and Milling levels defined for the operation.
Step down When the Automatic option is chosen, the Step down is calculated by the Wizard in accordance with the Pocket depth defined for the operation. When the User-defined option is chosen, the Step down can be defined by specifying a value or by setting the number of steps required to achieve the Pocket depth. Rows are created for each Step down value that is not the same. Output cutting data This section displays two sets of data related to the current Cutting condition the Spindle speed and Feed rate of the tool, the Step over range, the material cutting speed, Chip Thickness CT , and the Cutting Angle range.
Machining level The Machining level slider enables you to select from calculated sets of Cutting conditions. Moving the slider up in machining levels provide a convenient and intuitive way to control the Material Removal Rate MRR. Increasing the position of the slider increases MRR and machining aggressiveness. For this operation, use the Cutting conditions generated by the Wizard based on the default position of the Machining level slider 3.
Run the operation simulation using the default Host CAD mode to view the wireframe tool path. The simulated tool path is performed as follows: the entire contour is machined with a morphing spiral. Define the finish machining of the outside contour. When the copied operation automatically opens, choose iFinish for the Technology type. The copied Geometry, Tool and Levels definitions are used for finishing.
The default Cutting conditions generated by the Wizard are also used. Run the operation simulation using the default Host CAD mode. The finishing tool path is performed in a single cutting pass. Define the machining of the center pocket In this step, the machining of the center pocket is defined. For this example, the geometry is defined as a closed pocket.
Add a new iMachining 2D operation. Use the default iRough Technology type to define the rough machining of the center pocket feature. Select the lower contour of the pocket for the Geometry definition. Pick the top face of the Stock model for the Upper level definition and the lower face of the pocket for the Pocket depth definition.
Specify the roughing offsets. The default Cutting conditions generated by the Technology Wizard are used. The Link page displays the Ramping angle at which the Helical Entry into the pocket will be performed. This value is automatically calculated based on the aggressiveness of the Machining level slider. An override check box is provided in the instance you want to manually enter a preferred value.
Simulate the operation using the default Host CAD mode. The tool performs the Helical Entry into the pocket followed by a morphing spiral to the outer walls.
Define the finish machining of the center pocket. Specify the finishing offsets. The pocket corners are cleared first and then a final pass is taken along the walls.
Define the machining of the pocket ledge In this step, the machining of the pocket ledge is defined. For this example, the geometry is defined as a semi-open pocket. Use the default iRough Technology type to define the rough machining of the pocket ledge feature. Select the lower contour of the pocket ledge and then mark the front edge as open using Mark open edges.
Pick the top face of the Stock model for the Upper level definition and the lower face of the pocket ledge for the Pocket depth definition. The tool approaches from the open edge and then performs the roughing tool path, first removing material from the middle of the ledge and then clearing its corners. After the corners are cleared, the tool finishes the walls of the pocket ledge in a single cutting pass.
Verify the tool path and generate GCode In this step, the iMachining tool path is verified. A GCode file is also generated and the iMachining technology is shown managing the Feed rates with each cutting move. To verify the iMachining tool path for all operations at once, right-click the Operations header in the SolidCAM Manager and choose the Simulate command.
This exercise is based on another SolidCAM Professor video series that uses the iMachining technology to define the machining of the part shown above. During the definition process, the most common need-to-know topics about iMachining are covered in detail. Adding a new Machine and Material to the iDatabase After the part file is loaded on your computer, the following video demonstrates adding a new Machine and Material to the iMachining Database as well as defining the important parameters that are required by the iMachining technology.
Finally, the machining of the outside contour is defined using the iRough and iFinish Technology types in iMachining. Using the iMachining Technology Wizard In the following video, the iMachining Technology Wizard is discussed in detail and some of the different settings are used to control the Cutting conditions calculations.
Using the iRest Technology type prior to finishing With iMachining, it is possible to use iFinish directly after iRough. In the following video however, there are narrow areas and corners inside the pocket where the roughing tool cannot fit. In such cases, the iRest Technology type is then used to remove the rest material prior to finishing.
The importance of the iRest Data is also explained in detail. The Tool definition and its effects on iMachining In the following video, the Tool definition and its important parameters related to iMachining are covered in detail. Also shown is how the Wizard calculates the depths and what the importance of ACPs are when machining. There are standard 2. Two chains are defined, with the first being the stock boundary and the second being the profile around the part. The stock chain is marked as open, which specifies the tool should start machining from that chain.
A Delta depth is specified for both operations, so the tool machines deeper than the part bottom edge. Five chains are defined, which represent the five through pockets. Two boundaries are picked off the edges the make up the chamfers.
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