solidcam2007_r11_2_milling_training_course_2_5d_milling.pdf

8/10/2019 SolidCAM2007_R11_2_Milling_training_course_2_5D_Milling.pdf

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SolidCAMSolidCAM2007 R11.2

Power and Ease of Use - the winning combination

1995-2007 SolidCAM

All Rights Reserved.W W W. S O L I D C A M . C O M

SolidCAM2007 R11.2

Milling TrainingCourse

2.5D Milling


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SolidCAM2007 R11.2Milling Training Course

2.5D Milling

1995-2007 SolidCAM

All Rights Reserved.


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Contents

5

Contents

1. Introduction

1.1 About this course .......................................................................................................................

1.2 2.5D Milling Operations Overview ...........................................................................................

1.3 Basics Concepts .........................................................................................................................

1.4 Process Overview .......................................................................................................................

2. CAM-Part Definition

Exercise #1: CAM-Part De nition ..........................................................................................

3. SolidCAM 2.5D Operations

Exercise #2: Guide Machining ..................................................................................................3

Exercise #3: Cover Machining ..................................................................................................7

Exercise #4: Bracket Machining .............................................................................................15

Exercise #5: Support Machining ............................................................................................15Exercise #6: Clamp Machining ...............................................................................................16

Exercise #7: Electronic Box Machining ................................................................................165

Exercise #8: Basic Part Machining .........................................................................................16

4. Indexial 4-Axis Milling

Exercise #9: Frame Machining................................................................................................17

Exercise #10: Mounting Machining .......................................................................................19

Exercise #11: Mounting Base Machining ..............................................................................199


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5. Indexial 5-Axis Milling

Exercise #12: Hydraulic Block Machining ............................................................................207

Exercise #13: Manifold Plate Machining ...............................................................................220

Exercise #14: Joint Machining ................................................................................................224

Exercise #15: Clamp Machining .............................................................................................229

Document number: SCMTCENG07002


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Introduction 1


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1. Introduction

1.1 About this course

The goal of this course is to teach you how to use SolidCAM to machine various parts using 2.5DMilling technologies. This course covers the basic concepts of SolidCAM 2.5D machining anis a supplement to the system documentation and online help. Once you have developed a good

foundation in basic skills, you can refer to the online help for information on the less frequentlyused options.

Course design

This course is designed around a task-based approach to training. With the guided exercises you will learn the commands and options necessary to complete a machining task. The theoreticalexplanations are embedded into these exercises to give an overview of the SolidCAM 2.5D Millincapabilities.

Using this training book

This training book is intended to be used both in a classroom environment under the guidance ofan experienced instructor and as self-study material. It contains a number of laboratory exercisesto enable you to apply and practice the material covered by the guided exercises. The laboratoryexercises do not contain step-by-step instructions.

About the CD

The CD supplied together with this book contains copies of various les that are used throughoutthis course. The Exercises folder contains the les that are required for guided and laboratoryexercises. The Built Parts folder inside the Exercises contains the nal manufacturing projects foeach exercise. Copy the complete Exercises folder on your computer. The SolidWorks les used fothe exercises were prepared with SolidWorks2007.

Windows XP

The screenshots in this book were made using SolidCAM2007 R11.2 integrated with SolidWorks200running on Windows XP. If you are running on a different version of Windows, you may noticedifferences in the appearance of the menus and windows. These differences do not affect theperformance of the software.


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Conventions used in this book

This book uses the following typographic conventions:

Bold Sans Serif This style is used to emphasize SolidCAM options,commands or basic concepts. For example, click onthe Change to opposite button.

10. Define CoordSys Position

The mouse icon and numbered sans serif bold textindicate the beginning of the exercise action.

Explanation This style combined with the lamp icon is used forthe SolidCAM functionality explanations embeddedinto the guided exercises. The lamp icon is also usedto emphasize notes.


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1. Introduction

1.2 2.5D Milling Operations Overview

SolidCAM Milling module enables you to prepare the tool path for the following 2.5D Millinoperations:

Profile milling

You can mill on or along a contour. The pro le geometry canbe either open or closed.

Pocket milling

In pocket milling you have to remove material from the interiorof a closed geometry.


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Slot milling

This operation generates a tool path along the center line tothe right or to the left of one or more pro les.

Drilling

This operation enables you to perform drills and other canneddrill cycles.


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1. Introduction

1.3 Basics Concepts

Every Manufacturing Project in SolidCAM contains the following data:

CAM-Part The CAM-Part de nes the general data of the workpiece. This includes themodel name, the coordinate system position, tool options, CNC-controller, etc.

Geometry By selecting Edges, Curves, Surfaces or Solids, de newhat and where youare going to machine. This geometry is associated with the native SolidWorks model.

Operation An Operation is a single machining step in SolidCAM. Technology, Toolparameters and Strategies are de ned in the Operation. In short, Operation means howyou want to machine.

1.4 Process Overview

The major stages of the creation process of the SolidCAM Manufacturing Project are thefollowing:

CAM-Part definition

This stage includes the de nition of the global parameters of the ManufacturinProject (CAM-Part). You have to de ne a number of Coordinate Systems that describthe positioning of the part on the CNC-machine.

Optionally, you can de ne the Stock model and the Target model to be used for the restmaterial calculation. The Stock model describes the initial state of the workpiece thahas to be machined. The Target model describes the one that has to be reached afterthe machining. After every Operation, SolidCAM calculates how much material waactually removed from the CAM-Part and how much material remains unworked (resmaterial). The rest material information enables SolidCAM to automatically optimizthe tool path and avoid the air cutting.

Operations definition

SolidCAM enables you to de ne a number of milling operations. During an Operationde nition you have to select the Geometry, choose the tool from the Part Tool table(or de ne a new one), de ne a machining strategy and a number of technologicaparameters.


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CAM-PartDenition 2


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Following are the stages of the CAM-Part de nition process:

CAM-Part creation . At this stage you have to de ne the CAM-Part name and location.SolidCAM de nes the necessary system les and a folder to allocate the place to storeSolidCAM data.

CNC-controller definition . Choosing a CNC-controller is a necessary step. Thecontroller type in uences the Coordinate System de nition and the Geometryde nition.

Coordinate System definition . You have to de ne the Coordinate System the originfor all machining operations of the CAM-Part.

Stock model definition . SolidCAM enables you to de ne the stock model that describesthe initial state of the workpiece that has to be machined.

Target model definition . SolidCAM enables you to de ne the model of the part in itsnal state after the machining.

CAM-Part creation

Coordinate System definition

Stock model definition

CNC-controller definition

Target model definition


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2. CAM-Part Denition

Exercise #1: CAM-Part Definition

This exercise illustrates the process of the CAM-Part de nition in SolidCAM. In this exercisyou have to create the CAM-Part for the guide model displayed below and de ne the CoordinateSystem, the Stock model and the Target model that are necessary for the part machining. The CAM-

Part will be used in the exercises further on.

When you start to program a CAM-Part, you have to decide what workpiece you are going to use. This decision determines thnumber and the type of operations that are used to reach the nalpart shape.

In this exercise, the block workpiece is used. The block dimensionsare the same as the overall dimensions of the guide part.

With this stock, you have to machine only the steps and holesemphasized below.

At the next stage, you have to decide on what typeof CNC-machine you are going to use (3-, 4- or5-axis). In this exercise, a 3-axis CNC-machine ischosen for the machining. With a CNC-machine ofthis type, all necessary faces of the guide part canbe machined using a single positioning.


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1. Load the SolidWorks model

Load the Exercise1.sldprt model located in the /Exercises folder.

This model contains a number of features forming the solid body of the guide.

2. Start SolidCAM

To activate SolidCAM, click on the SolidCAM eldin the main menu of SolidWorks and choose Milling from the New submenu. SolidCAM is started and theNew Milling Part dialog box is displayed.


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The New Milling Part dialog box

When you create a new CAM-Part, you have to enter a name for theCAM-Part and for the model that contains the CAM-Part geometry.

Directory

Specify the location of the CAM-Part. The default directory is theSolidCAM user directory (de ned in theSolidCAM Settings ). You caenter the path or use the Browse button to de ne the location.

The Use Model file directory option enables you to automaticallcreate CAM-Parts in the same folder where the original CAD modeis located.

CAM-Part name

Enter a name for the CAM-Part. You can give any name to identifyyour machining project. By default, SolidCAM uses the name of thdesign model.

Model name

This eld shows the name and location of the SolidWorks desigmodel that you are using for the CAM-Part de nition. The name isby default, the name of the active SolidWorks document. With theBrowse button you can choose any other SolidWorks document tode ne the CAM-Part. In this case, the chosen SolidWorks documenis loaded into SolidWorks.

Every time the CAM-Part is opened, SolidCAMautomatically checks the correspondence of the dates ofthe CAM-Part and the original SolidWorks design model

When the date of the original SolidWorks model is latethan the date of the CAM-Part creation, this means thatthe SolidWorks original model has been updated. Youcan then replace the SolidWorks design model on whichthe CAM-Part is based with the updated SolidWorksdesign model.


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3. Confirm the CAM-Part creation

When the Directory , CAM-Part name and Model name havebeen de ned, click on the OK button to con rm the CAM-Part creation. The CAM-Part is de ned and its structure iscreated. The Milling Part Data dialog box is displayed.

The structure of the CAM-Part

The CAM-Part includes a number of data les represented on theillustration that displays the data included in the CAM-Part namedMilling .

The Milling.prt le is located in the SolidCAM User directory. TheMilling subdirectory contains all the data generated for the CAM-Part.

Milling.prt

Milling.SLDASM

CAM.SLDPRT

DesignModel.SLDPRT

Milling


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SolidCAM copies the original SolidWorks model to the Millinsubdirectory and creates a SolidWorks assembly that has the samename as the CAM-Part ( Milling.sldasm ). There are two componentin this assembly:

DesignModel.sldprt the copy of the SolidWorks model le.

CAM.sldprt the le that contains SolidCAM Coordinate System datand geometry data.

The SolidCAM CAM-Part uses the assembly environment ofSolidWorks. This enables you to create auxiliary geometries (e.sketches) without making changes in the original design model. Yocan also insert some additional components into the assembly lsuch as stock model, CNC-machine table, clamping and other toolingelements.

4. Choose the CNC-Controller

Select the CNC-machine Controller. Click on the arrow inthe CNC-Controller area to display the list of post-processorsinstalled on your system.

In this exercise, use a 3-Axis CNC-Machine with the Fanuc CNC-controller. Choosethe Fanuc CNC-controller from the list.

5. Multi-sided CoordSys

Make sure that the Multi-Sided check box is selected in theCoordinate System area. This check box enables you tochoose a future work style for SolidCAM.

When this check box is selected ( Multi-sided mode), SolidCAMenables you to de ne the CAM-Part directly on the solid model. Yocan de ne the Coordinate System origin position and axes orientatioby choosing model faces, vertices, edges or the SolidWorks coordinatsystem. The geometry for the machining can also be de ned directlon the solid model.


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When this check box is not selected ( Projections mode), SolidCAMenables you to create the CAM-Part on planar views de ned by 2Dsketches on the XY-plane. In most cases, this mode is used whenimporting a DXF or IGES le and when you do not want to createa solid model.

In this exercise, use the Multi-sided mode to highlight SolidCAM capabilities to workdirectly on solid models.

6. Start the Coordinate System definition

Click on the Define CoordSys button to de ne the MachineCoordinate System.

To complete the CAM-Part de nition, you need to de ne the MachineCoordinate System .

The Machine Coordinate System de nes the origin for all machiningoperations of the CAM-Part. It corresponds with the built-incontroller functions.

Coordinatesystem

X

Z YCoordinate

system


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The Z-direction of the MachineCoordinate System is parallel tothe revolution axis of the tool.

In SolidCAM, the tool approachesfrom the positive direction of the

Z-axis (like on a vertical CNC-machine).

For 3-Axis CNC milling machines, each Machine CoordinatSystem means separate clamping. If you need to machine the parfrom different sides, use several Machine Coordinate systems withthe Z-axis oriented normally to the machined sides.

In this exercise, it is enough tode ne one Machine Coordinatesystem with the Z-axis orientedupwards.

Such coordinate system enablesyou to machine the part with asingle clamping.

X

Z YMachine Coordinate

System

X

Z

Y

XZ

Y

Coordinatesystem

Coordinatesystem

XZ

YCoordinate

system


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The CoordSys dialog box enables you to de ne the Coordinate System location andaxis orientation.

You can de ne the Coordinate System origin position and axes orientation by choosingthe model faces, vertices, edges or SolidWorks coordinate systems.

SolidCAM enables you to choose the CoordSysde nition in the following ways:

Select Face

This method enables you to de ne a newCoordSys by selecting a face. The face can beeither planar or cylindrical/conical. For planarfaces, SolidCAM de nes CoordSys with theZ-axis normal to the face. For cylindrical orconical faces, the Z-axis of the CoordSys iscoincident with the axis of revolution of thespeci ed cylindrical/conical surface.

Define

This method enables you to de ne theCoordinate System by points. You haveto de ne the origin and the direction of

the X- and the Z-axes.Select Coordinate system

This method enables you to choose theSolidWorks Coordinate System de ned inthe design model le as the CoordSys. TheCoordSys origin and axes orientation are thesame as in the original SolidWorks coordinatesystem.

Normal to current view

This option enables you to de ne the Coordinate System with theZ-axis normal to the model view you are facing on your screen. TheCoordSys origin will lie in the origin of the SolidWorks CoordinateSystem, and the Z-axis will be directed normally to the chosen viewof the model.


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7. Select the model face

When the Select Face method is chosen,click on the model face as shown.

The Z-axis of the CoordSys is normal to the

selected face.

The CoordSys origin is automatically de nedin the corner of the model box.

Model box

SolidCAM automatically calculates thebox surrounding the model. The upperplane of the model box is parallel to theXY-plane of the de ned CoordSys.

The CoordSys is located in the cornerof the model box with the followingcoordinates: ( XMIN, YMIN, ZMAX ).

Click on the button to con rm the operation. The Coordinate System is de ned.

The CoordSys Data dialog box is displayed.

Coordinate systemX

Z

Y


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8. CoordSys Data

This dialog box enables you to de ne the Machining levels such as Tool start level ,Clearance level , Part upper level , etc.

The CoordSys Data dialog box

Below is an explanation of the elds of the CoordSys Data dialogbox.

The Position eld de nes the sequential number of the CoordSys.For each Machine Coordinate System, several Position values arede ned for different positions; each such Position value is related tothe Machine CoordSys.

X shows the X value of the CoordSys.

Y shows the Y value of the CoordSys.

Z shows the Z value of the CoordSys.

The Machine CoordSys number de nes the number of the CoordSysin the CNC-Machine. The default value is 1. If you use anothernumber, the G-Code le contains the G-function that prompts themachine to use the speci ed number stored in the machine controllerof your machine.

The Tool start level de nes the Z level at which the tool starts working.


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The Clearance level is the Z level to which the tool rapids whenmoving from one operation to another (in case the tool does notchange).

The Part upper level de nes the height of the upper surface of thepart to be milled.

The Part lower level de nes the lower surface level of the part to bmilled.

The Tool Z Level parameter de nes the height to which the tool movesbefore the rotation of the 4/5 axes to avoid collision between the tooland the workpiece. This level is related to the CoordSys position andyou have to check if it is not over the limit switch of the machine. Itis highly recommended to send the tool to the reference point or to apoint related to the reference point.

The Create planar surface at Part Lower level option enables you togenerate a transparent planar surface at the minimal Z-level of thepart so that its lower level plane is visible. This planar surface provideyou the possibility to select points that do not lie on the model entitiesIt is suppressed by default and not visible until you unsuppress it inthe FeatureManager Design tree.

Con rm the CoordSys Data dialog box with the OK button.

The CoordSys Manager dialog box is displayed in thePropertyManager area of SolidWorks. This dialog box displaysthe Machine CoordSys.

Con rm the CoordSys Manager dialog box with the button. The Milling Part Data dialog box is displayed again.

Rapid Movements area

Feed Movements areaPartUpper level

PartLower level

ToolStart level

Clearancelevel


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9. Define the Stock model

For each Milling project, you can de ne the Stock model, which is the workpiece thatis placed on the machine before you start machining the CAM-Part.

Click on the Stock button in the Stock & Target model area of

the Milling Part data dialog box.

The Stock model dialog box is displayed. This dialogbox enables you to choose the mode of the Stock modelde nition.

Stock model definition modes

2D Boundary this mode enables you to de ne the 2D stockgeometry with the chain of geometrical elements (lines, arcs,splines, edges, etc.).

3D Model this mode enables you to de ne the stock model via3D model selection.

Box (Auto) in this mode SolidCAM automatically determinesthe box surrounding the model.

Choose the Box (Auto) mode and click on the Define button. The 3D Box dialog boxis displayed.


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This dialog box enables you to select a solid body for thesurrounding box calculation. Optionally, offsets from themodel can be de ned. In this exercise, use the stock model ofthe box exactly surrounding the guide model. In such cases,set the offsets to 0.

Click on the solid body. It is highlighted.

SolidCAM automatically generates the surrounding box.

To con rm the operation, click on the button. The Stockmodel dialog box is displayed again. Con rm the Stock modelde nition with the button. The Milling Part Data dialogbox is displayed.

10. Define the Target model

SolidCAM enables you to de ne the Target model, which is the nal shape othe CAM-Part after the machining. SolidCAM uses the Target model for the gougechecking in the SolidVerify simulation.

Click on the Target button in the Stock & Target model area of the Milling Part Data dialog box. The Target model dialogbox is displayed.


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This dialog box enables you to de ne a 3D model for the Target. Click on the Define3D Model button.

The 3D Geometry dialog box is displayed.


Con rm the selection with the button.

The Target model dialog box is displayed again. Con rm it with the button.

The Milling Part Data dialog box is displayed.

Set the Facet tolerance to 0.01 . This parameter de nes theaccuracy of triangulation of the stock model, target modeland xtures. The triangulated models are used later whenperforming the tool path simulation. The more precise thetolerance is, the better is the performance of the simulation.

11. Save the CAM-Part data

In theMilling Part Data

dialog box, click on the button. The Milling Part Data dialog box is closed and the SolidCAMManager is displayed. The de ned CAM-Part is saved.

At this stage, the de nition of the CAM-Part is nished. Thede nition of Milling Operations is covered in the comingexercises using this CAM-Part.


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SolidCAM Manager

The SolidCAM Manager is the main interface feature of SolidCAM. Thcomplete information about the CAM-Part is shown in the SolidCAMManager .

The SolidCAM Manager contains the following elements:

CAM-Part header

This header displays the name of the current SolidCAM CAM-PartBy right-clicking on it, you can activate the CAM-Part menu to managyour CAM-Parts.

The CoordSys Manager icon is located under the CAM-Part headeClick on this icon to display the CoordSys Manager that enables yoto manage your Coordinate Systems.

The icons of the Stock Model and Target Model are located underthe CAM-Part header. Double-click on these icons to load the Stockmodel dialog box or the Target model dialog box that enable you tchange the de nition of the Stock or Target models.

SolidCAMManager

CAM-Part Header

Tool Header

Machining ProcessesHeader

Geometries Header

Operations Header


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Tool header

This header displays the name of the current Tool Library. Double-click on its icon to display the Part Tool Table, which is the list of thetools that are available to use in the current CAM-Part.

Machining Process header

This header displays the name of the current Machining Processtable.

Geometries header

This header displays all SolidCAM geometries that are not used in theOperations.

Operations header

This header shows you all SolidCAM Operations.

12. Close the CAM-Part

Right-click on the CAM-Part header in the SolidCAM Manager and choose Close fromthe menu.

The CAM-Part is closed.


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SolidCAM 2.5DOperations 3


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SolidCAM offers you the following 2.5D Milling Operations:

In SolidCAM, an Operation is a single machining step. A workpiece is usually manufacturedusing several machining steps and technologies. For each of these steps you can de ne a separateOperation. An Operation can be very complex, but it always uses one tool, one major geometryand executes one machining type, e.g. Pro le Milling or Drilling. You can edit any single machiningoperation, change the operation sequence and generate the GCode, combining and splitting theoperation list of your CAM-Part.

The Machining Geometry has to be de ned for each operation. The Geometry prompts SolidCAM what and where you want to machine.

A Geometry for the Pro le, Pocket and Slot operations consists of a number of chains. Chaingeometries are de ned by selecting the following entities: edges of models, 2D curves, 3D curves,circles, lines and splines. Each chain is composed of one or more entities and de nes an open orclosed contour.

A Geometry for the Drilling operation consists of one or more points (drilling centers) that can bede ned by a number of methods directly on the solid model.

Profile Operation

You can mill on or along a contour. The pro le geometry canbe either open or closed. In pro le milling you can optionallyuse tool radius compensation to the right or to the left side ofthe geometry. SolidCAM offers two types of pro ling:

Milling a single pro le to the speci ed constant or variable depth in one step or in several user-de neddown steps.

Concentric pro les to the speci ed constant or variable depth; this type of pro linggenerates several concentric pro les that start from the de ned clear offset distancefrom the pro le, and nish on the pro le geometry, thus clearing the area around thepro le to a constant depth.

2.5D Milling Operations

Drilling Operation

Slot Operation

Profile Operation

Pocket Operation


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Pocket Operation

In pocket milling, you have to remove material from the interior ofa closed geometry. SolidCAM offers two types of pocketing:

When a pro le geometry consists of one or more

pro les and none of them are enclosed or intersect withone another, each is milled as a separate pocket withoutislands.

When a pro le geometry consists of several pro les, anypro le that is enclosed or intersects with another pro le istreated as an island. You can de ne an unlimited numberof islands within a single pocket.

Slot Operation

This Operation generates a tool path along the centerline to theright or to the left of one or more pro les. Two types of slots can bede ned: The Slot Operation with constant depth machines the slotin several steps until the nal depth is reached. In Slot with variabledepth, the depth pro le is also de ned by a 2D section. The slotcan be pre-machined using rough and semi- nish cycles. The nishcut produces a tool path according to the speci ed scallop heighton the oor of the slot. With available parameters for a right andleft extension and side step, you can mill a slot wider than the tooldiameter.

Drilling Operation

This operation enables you to perform drills and other canned drillcycles. SolidCAM supports the canned drill cycles provided by yourparticular CNC-machine such as threading, peck, ream, boring, etc.If your CNC-machine has no canned drill cycles of its own, theycan be de ned using the General Pre- and Post-processor program

(GPPTool).


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Exercise #2: Guide Machining

In this exercise, you use the CAM-Part de ned in the Exercise #1 . You have to de ne several 2.5D Operations in order to machinethe guide faces represented on the picture.

In the process of de nition of Operations, you have to de nethe machining geometry, the tool and several technologicalparameters.

1. Open the CAM-Part

Click on SolidCAM in the SolidWorks main menu and choose the Open item.

In the browser window choose Exercise1 the CAM-Part prepared in the previousexercise.

The CAM-Part is loaded.


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2. Add an Operation

Right-click on the Operations header inthe SolidCAM Manager and choose Profile from the Add Operation submenu.

The Profile Operation dialog box isdisplayed.

In this operation, the lower steps aremachined.

3. Define the Geometry

The rst step of de nitionof each operation is theGeometry selection. At thisstage, you have to de ne theGeometry for the Pro leoperation using the solidmodel geometry.

Click on the Define buttonin the Geometry eld of theProfile Operation dialog box.


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The Geometry Edit dialog box is displayed in the SolidWorksPropertyManager area. This dialog box enables you to addand edit geometry chains.

When this dialog box is activated, you can select solid modelentities for the Geometry.

Click on the model edge as shown. The edge is selected.

The arrow at the startpoint of the selected entityindicates the direction ofthe Geometry. In SolidCAMOperations, the direction ofthe chain geometry is used tocalculate the tool path. In thePro le Milling, by default, thetool moves in the direction

of the geometry. In thisexercise, the combination ofthe geometry direction andclockwise direction of thetool revolution enables youto use the climb milling.

Tool revolutiondirection

Tool movementdirection

Geometrydirection


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Click on the Accept chain button in the Chain list area to con rm the chain.

The chain icon is displayed.

De ne the second chain. Rotate the model and select the model edge as shown.

The direction of the selected chain is the same as the direction of the rst chain. Thismeans that conventional milling is performed. In order to switch to climb millingreverse the chain direction.

Click on the Reverse button. The chain direction is reversed. Click on the Acceptchain button to con rm the chain.

The second chain icon is displayed in the Chain list area. At this stage, the Geometryis de ned. Con rm the Geometry selection with the button. The Profile Operationdialog box is displayed.


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Undo step

This button enables you to undo the last selection of a chainelement.

Reject Chain

This button cancels the single chain selection.

4. Define the Tool

At this stage, you have to de ne the tool for the Pro leMilling.

Click on the Select button in the Tool section of the ProfileOperation dialog box.

The Part Tool Table dialog box is displayed.

The Part Tool Table is the tool table that contains all tools that areavailable for use within a speci c CAM-Part. The Part Tool Table isstored within the CAM-Part.

The Part Tool Table dialog box enables you to manage the toolscontained in the Part Tool Table .


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At the moment, the Part Tool Table is empty. De ne a new milling tool suitable for thPro le Milling.

Tool types

SolidCAM offers you the following default tool types suitable for thePro le operation:

Tool Rough Mill/Tool End Mill

These tool types are used for the de nition of rough/ nish cutters.

The tool shape and basic parameters are shown below:

Drill

This tool type is used for the de nition of

drills, bores, reams, threading tools, etc. The tool shape and basic parameters areshown below.

Shaped Tools (Shaped Tool Drill, ShapedTool Rough, Shaped Tool End Mill)

These tool types are used for de nitionof shaped end/rough mills and drill tools.

The tool shape is de ned by a sketch. The Tool Diameter de ned in the Part Tool table describes the cutting diameterof the shaped tool that is coincident tothe machining geometry.

DiameterCornerRadius

Cuttinglength

Cuttinglength

Diameter

DiameterCuttinglength

Angle

Diameter


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Taper Mill

This tool type is supported in thecalculations of Sim. 5 Axis operation.In addition, the taper tool is fullysupported in the calculation of the 3D

Milling Rough and Finish operations.In 2.5D milling operations, such asPro le and Pocket, only the bottomdiameter is taken into account in thetool path calculation.

This tool is used for milling internal/external walls with a constant draftangle.

Lollipop Mill

The Lollipop tool is used in Simultaneous5 Axis operations. The followingparameters are used to de ne the Lollipoptool geometry:

Slot Mill

Slot mill tools can be used in a variety of applications from simple 2.5Dundercut pro les all the way up to machining cavities in Simultaneous5 Axis operations.

Shankdiameter

Cornerradius

Diameter

Taperangle

Cuttinglength

Shankdiameter

Cuttinglength

Diameter

Shank diameter

Cornerradius

Diameter

Cuttinglength


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The parametric de nition of a slot mill tool also enables you to de na cylindrical tool with a shank that has a relieved diameter.

Click on the Add button to start the tool de nition.

A new milling tool is de ned with the SolidCAM default parameters and added to thPart Tool Table .

In this Pro le Operation, use an end mill of 10 .

Set the Diameter value to 10 .

In the Length area, set the following parameters:

Set the Total length to 80 ;

Set the Outside holder length to 72 ;

Set the Cutting length to 50 .

Click on the Select button to con rm the tool parameters and choose the tool for theoperation.

Total Length

Cutting Length

Outside HolderLength


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5. Define the Feed and the Spin

De ne the Feed and Spin parameters. Click on the Data button in the Tool area.

The Operation Tool Data dialog box is displayed.

Set the Spin Rate (used in rough milling)and the Spin Finish (used in nish milling)parameters to 6000 .

Set the Feed XY (feed rate for XYmovements) to 1500 and the Feed Z (feedrate for Z movements) to 250 . Set theFeed Finish (feed rate for nish milling) to1800 .Click on the OK button to con rm thede ned tool data. The Profile Operationdialog box is displayed.

6. Define the Profile depth

De ne the depth of the pro le milling. SolidCAM enables you to de ne the depth

using the solid model data.

SolidCAM enables you to control the machining levels with the followingparameters:

The Upper level is the Z-level at which the machining starts in cuttingoperations.

XZ

Y

CoordinateSystem

Upperlevel

Depth


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The Depth sets the Z level below which the tool does not millSolidCAM does not penetrate this plane in any milling strategy.

In the current exercise, the Upper level is 0 because the Coordinate Systemis de ned at the model top face.

Click on the Profile depth button in the Milling levels area.

The Pick Lower level dialog box is displayed.

SolidCAM enables you to de ne the lower machining level directly o

the solid model. The Profile depth value is calculated automatically the difference between the Upper level and Lower level values.

The Lower level parameter is associative to the solid mode Associativity enables SolidCAM to be synchronized with the solimodel changes; SolidCAM automatically updates the CAM da

when the model is modi ed. The Profile depth parameter is indirectlassociative. The associativity is established for the Lower level . Wheeither the Upper level or the Lower level is synchronized, the Depthis updated.

XZ

Y

Coordinatesystem

Lowerlevel

Upperlevel

Depth


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Click on the model face as shown.

The Lower level value ( -10 ) is displayed in thePick Lower level dialog box. Con rm the PickLower level dialog box with the button.

The Profile depth value of 10 is displayed inthe Profile Operation dialog box. The pinkbackground of the Profile depth eld meansthat the parameter is associative with the solidmodel.

Delta depth

This parameter de nes the offset for the cutting depth that can be

changed with its associativity preserved. The Delta depth value isalways relative to the Depth de ned for the operation.

In this operation, Delta depth is equal to 0.

7. Define the Tool side

Tool side

This parameter enables you to determine the tool position relative to thegeometry.

Right The tool cuts on the right side of the pro le geometry.

Left The tool cuts on the left side of the pro le geometry.

Middle The center of the tool moves on the pro le geometry(NO compensation G4x can be used with this option).

Left Right Middle


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The Show Tool button displays the chain geometry of the pro le, thdirection of the chain and a circle representing the tool relative to thegeometry. The display uses the current settings in the Profile directionand Tool side elds.

In this case, the default Left option meetsthe requirements of the climb milling. Clickon the Show Tool button to check the toolposition.

Return to the Profile Operation dialog boxby clicking on the button in the ShowGeometry dialog box.

8. Define the Rough and Finish parameters

SolidCAM enables you to perform the rough and nish machining of the pro le in asingle Pro le Operation.

De ne the parameters of the Pro le roughing. Select the Rough check box.

De ne the Wall offset .

Wall offset

This parameter enables you to de ne the allowance for the pro lnish machining. This allowance can be removed either in the sam

Pro le Operation at the nish paths or in an additional Pro leOperation with another tool.

Set the Wall offset to 0.2 . This setting means that theallowance of 0.2 mm is left during the pro le roughing. This

allowance is removed with a separate nish cut at the end ofthe pro le machining.

SolidCAM enables you to de ne the Step down parameterfor roughing. With this parameter, SolidCAM performs anumber of cuts (de ned by the Step down ) in order to reachthe nal machining depth ( Profile depth ).


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Set the Step down to 4. With this value, SolidCAM performs two cuts on the depthde ned by the Step down : -4; -8. The last cut is performed on the depth de ned byProfile depth : -10 .

Note that the Finish check box is selected. SolidCAMperforms the nishing of the Pro le. At the nish path, the0.2 mm allowance left after the roughing is removed. Set theStep down for the Pro le nishing to 10 mm.

9. Define the Lead in and the Lead out

You can de ne the way the tool leads into andout of the pro le. The lead in movement isnecessary to prevent vertical penetration of thetool into the material. With the lead in strategies

the tool descends to the machining level outsideof the material and then horizontally penetratesthe material with the lead in movement. The leadout strategy enables you to perform the retractmovements outside the material.

The following options are available:

None

The tool leads in/out to the milling level exactly adjacent to the start

point of the pro le.

Normal

The tool leads in/out to the pro le froma point normal to the pro le. The lengthof the normal can be set in the Value

eld.

Arc

The tool leads in/out to the pro le witha tangential arc. The arc radius can be setin the Value eld.

Approachvalue

Approachvalue


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Tangent

The tool leads in/out on a line tangent tothe pro le. The length of the tangent canbe set in the Value eld.

Point The tool leads in/out from a user-de ned position. From this position,the tool moves on a straight line to the start point of the pro le

When you select this option, the Pick button is activated so that youcan select a position directly on the solid model.

When the Same as lead in check box is selected, the strategy and parameterde ned for Lead in are used for Lead out .

Under Lead in , choose the Tangent option from the list andset the Value to 6.

Under Lead out , select the Same as Lead in check box.

The de nition of the basic technological parameters of pro lemilling is nished.

10. Calculate the Tool path

Click on the Save & Calculate button. The Pro le Operation data is savedand the tool path is calculated.

Approachvalue

Norma


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11. Simulate the Operation

Click on the Simulate button in the Profile Operation dialog box. The Simulation control panel is displayed.Switch to the SolidVerify page and start the simulation

with the Play button.

The solid stock model de ned in Exercise #1 is used in the SolidVerifysimulation mode. During the machining simulation process, SolidCAMsubtracts 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.

When the simulation is nished, play the simulation step by step using thebutton.

Switch to the Host CAD simulation mode and click on the Play button.


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The Host CAD simulation mode enables you to display the tool path directlyon the model in the SolidWorks window. Since all the View options oSolidWorks 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 Exit button. The ProfileOperation dialog box is displayed.

Close the Profile Operation dialog box with the Exit button. The SolidCAM Manager is displayed. The Pro le Operationitem is displayed under the Operations header in SolidCAMManager .

12. Add a Profile Operation

De ne a new Profile Operation to machine the faces of the guide steps as shown.

Right-click on the Pro le Operation headerin the SolidCAM Manager and choose Profilefrom the Add Operation submenu. A newoperation is added after the rst Pro leOperation.

The Profile Operation dialog box isdisplayed.


Click on the Define button in the Geometryeld of the Profile Operation dialog box.


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The Geometry Edit dialog box is displayed in the SolidWorksPropertyManager area.

Click on the model edge as shown. The edge is selected.

The direction of the selected chainenables you to use the climb milling.

Click on the Accept chain buttonin the Chain list section to con rmthe chain.

The chain icon is displayed.

De ne the second chain. Rotate themodel and select the model edge asshown.

The direction of the selected chain isthe same as the direction of the rstchain. Click on the Reverse button. The chain direction is reversedto use the climb milling for this side

too.

Click on the Accept chain button to con rm the chain.

The second chain icon is displayed in the Chain list section. At this stage, the geometryis de ned. Con rm the geometry selection with the button. The Profile Operationdialog box is displayed.

14. Define the Tool

In this operation, use the same tool that was de ned inthe previous operation. The tool data is saved in the PartTool Table .

Click on the Select button in the Tool area.



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Double-click on the tool #1 , the end mill tool of 10 de ned in the previous operation The tool is chosen for the current operation.

Click on the Data button in the Tool area.

The Operation Tool Data dialog box is displayed.

Set the Spin Rate and Spin Finish to 6000 .

Set the following feed data:

Set the Feed XY to 800 ;

Set the Feed Z to 200 ;

Set the Feed Finish to 1000 .

Con rm the tool data de nition withthe OK button. The Profile Operationdialog box is displayed.

15. Define the Profile depth

De ne the depth of the pro le milling. As in the previous Pro le Operation,the Pro le depth is de ned by pickingan entity on the solid model.


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Click on the Profile depth button in theMilling levels area.

The Pick Lower level dialog box isdisplayed.

Click on the model face as shown.

The Lower level value ( -3 ) is displayed inthe Pick Lower level dialog box. Con rmthe lower level selection with thebutton. The Profile depth value 3 isdisplayed in the Profile Operation dialogbox.

Note the Clearance level and the Safety distanceparameters.

Clearance level is the Z-level to which the tool retreats when movingfrom cut to cut.

Safety distance is the distance to the Upper level at which the toolstarts moving at the Z feed rate you have de ned. Movements from

the Clearance level to this height are performed in rapid move. These parameters are de ned during the Coordinate System de nitionand are default for each operation using this Coordinate System.However, these parameters can be customized for each operation.

16. Define the Tool side

In this case, the default Left option meetsthe requirements of the climb milling.Click on the Show Tool button to checkthe tool position.

Close the Show Geometry dialog box

with the button and return to theProfile Operation dialog box.


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Now you have to de ne the parameters of the Pro le roughing.

Select the Rough check box. Set the Wall offset to 0.2 mm. This offset is removed witha separate nish cut in the end of the pro le machining.

SolidCAM enables you to de ne the Step down parameter forroughing. With this parameter, SolidCAM performs a numberof cuts (de ned by the Step down ) in order to reach the nalmachining depth ( Profile depth ).

Set the Step down to 1.5 mm. With this value, SolidCAMperforms two cuts on the depth de ned by Step down : -1.5 ; -3.

Make a note that the Finish check box is selected. SolidCAM will perform the nishing of the Pro le. At the nish path, the

0.2 mm allowance left after the roughing is removed. Set theStep down for the Pro le nishing to 3 mm.

18. Define the Lead in and the Lead out

In the same manner as in the Step #8 of this exercise, choosethe Tangent option from the Lead in list and set the Value to 6.

Under Lead out , select the Same as Lead in check box.

The de nition of the basic technological parameters of thepro le milling is nished.


Click on the Save & Calculate button. The Pro le Operation data is saved and the toolpath is calculated.


Click on the Simulate button in the ProfileOperation dialog box. The Simulation controlpanel is displayed.

Switch to the SolidVerify page and start thesimulation with the Play button.


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Close the simulation with the Exit button. The Profile Operation dialog box isdisplayed.

Close the Profile Operation dialog box with the Exit button.

Counterbore holes machining

At this stage, you have to machine two counterbore holes located onthe top face of the guide.

The machining is performed inthree stages. At the rst stage, centerdrilling is performed to pre-machinethe holes. Then a drilling operation isused to machine the through holes.

After the drilling, the counterbore ismilled.


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21. Add a Drilling operation

Right-click on the last Pro le Operation in the SolidCAM Manager and choose Drillingfrom the Add Operation submenu. The Drilling Operation is used to perform thepreliminary center drilling.

The Drill Operation dialog box is displayed.

22. Define the Drill geometry

In the Geometry area, click on the Define button.

The XY Drill Geometry Selection dialog box is displayed in theSolidWorks PropertyManager area. This dialog box enables you toselect the geometry for the drilling directly on the solid model.

SolidCAM enables you to select the drill centersusing the following options:

Pick position . You can de ne Drill positionsone by one directly on the solid model. You canalso type the coordinates (X, Y, Z) into the Editbar.


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3 Points on circumference . Usually, all curves and arcs of importedmodels are converted into splines by the exporting CAD system.Due to the nature of spline curves or surface boundaries, youcannot pick a center position like you could on a circle or an arc.SolidCAM calculates the center position of an arc de ned by threepoints positioned on the spline edges. This facilitates selecting drill

centers on spline surfaces.

Multi-positions . With this option, you can select the model face.SolidCAM automatically recognizes all arcs/circles located on theselected face and select the center points as drill positions.

All circle/arc centers . SolidCAM searches the solid model forarcs and circles and add all center points as drill positions to thegeometry.

Choose the All circle/arc centers option and click on the All circle/arc centers button.

Two drill positions are selected. Their coordinates are displayed inthe XY Drill Geometry Selection dialog box.

Click on the button to con rmthe geometry selection. The DrillingOperation dialog box is displayed.

23. Define the Tool

Click on the Select button in the Tool information area to display the Part Tool Table.


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Switch to the Edit page to start a new drilling tool de nition.

Click on the Add button. A new drilling tool is added with the default parameters.

Use the Center drill of 6 for the operation.

Edit the tool parameters:

Set the Diameter to 6;

Set the Angle to 90 .

Click on the Select button to choose the tool dimensions and the tool for theoperation.


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The Drilling Operation dialog box is displayed.

Click on the Data button in the Tool information area.

The Operation Tool Data dialog box is displayed. De nethe spin and the feed for the operation.

Set the Spin Rate to 1200 ; Set the Feed Z to 200 .

Click on the OK button to con rm the parameters de nition. The Drilling Operationdialog box is displayed.

24. Define the center drilling depth

In the Milling levels area, set the Drill depth to 3.


Click on the Save & Calculate button. The Drilling Operation data is saved and thetool path is calculated.


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Click on the Simulate button in the Drilling Operation dialog box. The Simulationcontrol panel is displayed.

Switch to the SolidVerify page and start the simulation with the button.

Close the simulation with the button. The Drilling Operation dialog box displayed.

Close the Drilling Operation dialog box with the Exit button.

27. Add a Drilling Operation

Right-click on the last Drilling Operation and choose Drilling from the Add Operationsubmenu.

The Drilling Operation dialog box is displayed.

28. Choose the Geometry

This operation is using the Geometry that was de ned inthe center drilling operation.

Choose the Drill geometry from the list in the Geometry area.


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Each geometry de ned in SolidCAM has a unique name. During thegeometry de nition, SolidCAM gives the geometry a default name that canbe changed. Using this name, you can choose the geometry for the speci coperation.

29. Define the Tool

You have to de ne a new drilling tool of 5.5 for this operation.

Click on the Select button in the Tool information area to display the Part Tool Table.

The Part Tool Table dialog box is displayed. Click on the Add button. A new drillingtool with the default parameters is added.

Set the Diameter to 5.5 .

In the Length section, set the following parameters:

Set the Total to 60 ;

Set the Outside holder to 50 ;

Set the Cutting to 40 .

Click on the Select button to choose the tool dimensions and the tool for theoperation.


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The Drilling Operation dialog box is displayed. Click on theData button in the Tool information area.

The Operation Tool Data dialog box is displayed. De ne thespin and the feed for the operation.

Set the Spin Rate to 3000 ;

Set the Feed Z to 360 .

Click on the OK button to con rm thesettings. The Drill Operation dialog box is displayed.

30. Define the Drilling depth

The overall height of the guide is 30 mm. The drilling has to be performed deeper thanthis value in order to enable the tool to exit from the material to perform the through

drilling.

In the Milling levels area, set the Drill depth to 30 . This depth value enables you tperform the through drilling.

To perform the through drilling, use theDepth type option.

Height


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Depth type

This option enables you to deepen the drilled hole in order to obtain agiven diameter at the speci ed drill depth.

Cutter tip

The drill tip reaches the de ned drill depth.

Full diameter

The drill reaches the de ned drill depth with the full diameter.

Diameter value

The drill reaches the de ned drill depth with the drill cone diameter

speci ed in the edit box. 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.

In the Depth type area, choose the Full diameter option. With this option, the drilling is performed until the fulldiameter is reached at the speci ed drill depth. This meansthat the cone part of the tool exits from the material.

Drilldepth

Cutter tip Full diameter Diameter value

Drilldepth

Drilldepth

Diametervalue


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31. Define the Drilling type

SolidCAM enables you to use a number of Drill canned cycles supported by youCNC-controller. 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.

Click on the Drill cycle type button in the Drill Operationdialog box. The Drill Cycle dialog box is displayed.

Click on the Peck button. The cycle is chosen for theoperation.

Click on the Data button to de ne the pecking parameters. The Drill Options dialog box is displayed.

Set the Step down to 1.5 in order to de ne the depth of each pecking movementCon rm the data with the OK button.


Click on the Save & Calculate button.

The Drilling Operation data is saved and the tool path is calculated.


Click on the Simulate button in the Drill Operationdialog box. The Simulation control panel isdisplayed.

Switch to theSolidVerify

page and start thesimulation with the button.

Close the simulation with the button. The DrillOperation dialog box is displayed.

Close the Drill Operation dialog box with the Exit button.

Now you have to machine the counterbores.


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34. Add a Pocket Operation

The Pocket operation is used for thecounterbore machining. Right-click on the lastde ned Drilling operation and choose Pocketfrom the Add Operation submenu. The Pocket

Operation dialog box is displayed.


The geometry for a Pocket operation is represented by a number of closed chains. Inthis exercise, you have to de ne two chains using the solid model edges as shown.

Click on the Define button in the Geometry section to start the geometry de nition.

The Geometry Edit dialog box is displayed.

In the Multi-Chain section, click on the Add button.


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The Chains Selection dialog box is displayed. This dialog boxenables you to de ne the chain geometry by selecting the facesof the solid model. When a face is selected, SolidCAM collectsall solid model edges from the face and builds the chains.

Click on the face as shown.

The face is selected. SolidCAM highlights all face edges.

Con rm the face selection with the button. The GeometryEdit dialog box is displayed. Three chains collected from theselected face are listed in the Chain List area.

Select the Chain #1 from the list. This chain represents theexternal boundary of the selected face. This chain is not relevantfor the current operation and has to be deleted. Right-click onthe chain in the list. The menu is displayed.

SolidCAM enables you to perform the following operations with chains:

Replace

This command enables you to update a chain in the current chaingeometry. The old chain is deleted, and you can de ne a new chain.

Insert

This command enables you to insert a chain between two existingchains.


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Edit

This command enables you to edit an existing chain. You can reversethe chain or undo the selection steps to change the chain.

Rename

This command enables you to rename the geometry chain.

Reverse

This command enables you to reverse the direction of the chain.

Set CW/Set CCW

These commands enable you to set a clockwise or counterclockwisedirection to the selected chains.

Delete

This command removes a chain from the current geometry.

Click Delete . The con rmation message is displayed.

Con rm the message with the Yes button. The chain is removed. The remainingchains are used in the Pocket operation. Con rm the Geometry selection with the button. The Pocket Operation dialog box is displayed.

36. Define the Tool

De ne a new milling tool for theoperation. Click on the Select button in the Tool area of thePocket Operation dialog box.

The Part Tool Table dialog box isdisplayed.


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Click on the Add button to add anew tool to the Part Tool Table. Anew tool is added. An End mill of8 is used for the operation. Setthe Diameter of the tool to 8.

Click on the Select button tochoose the tool for the operation.

The Pocket Operation dialog boxis displayed.

Click on the Data button in the Tool area. The Operation Tool Data dialog box is

displayed. De ne the spin and the feedfor the operation.

Set the Spin Rate and the Spin Finish to6000 .

Set the following feed data:

Set the Feed XY to 1500 ;

Set the Feed Z to 250 ;

Set the Feed Finish to 1700 .

Con rm the dialog box with the OK button.

The Pocket Operation dialog box is displayed.

37. Define the Pocket depth

De ne the Pocket depth directly on the solid model. Clickon the Pocket depth button in the Milling levels area. ThePick Lower level dialog box is displayed in the SolidWorksPropertyManager area.


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Click on the bottom face of the counterboreas shown.

Con rm the selection with the button. The depth value ( 3.58 ) is determined.

38. Define the Step down

Step down

SolidCAM uses the constant-Z passes for the Pocket generation. TheStep down parameter enables you to de ne the distance between eachtwo successive Z-levels.

In this case, the material is machined in one step, so theStep down value is the same as that of the Pocket depth .

Set the Step down to 3.58 .


SolidCAM enables you to perform rough and nish pocket machining in a singleoperation.

The Offsets area enables you to de ne a number of offsets that are applied to thepocket during the rough machining. These offsets are removed during the nishing.

Step Down

Upper level

Pocket Depth


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Set the Wall offset to 0.2 . This offset is applied to the walls ofthe pocket.

Set the Floor offset to 0.2 . This offset is applied to the oorof the pockets.

In the Finish area, choose the Wall+Floor option from the list. This option enables you to perform nishing of the Wall andFloor offsets that remain after the roughing.

40. Define the Pocket type

Make sure that the default Pocket type ( Contour ) is chosen forthe operation.

When the Contour strategy is chosen, the tool moves on offsetsparallel to the pocket contour.

The distance between the parallel offsets in the Contour strategy isde ned by the Overlap parameter.

Overlap


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41. Define the Ramping strategy

De ne the strategy with which the tool is plunging into thematerial during the pocket roughing.

The following Ramping strategies are available for rough machining ofpockets:

None

The tool enters the material vertically at the pocket start point chosenautomatically by the SolidCAM pocket algorithm.

Vertical

The tool enters the material vertically at auser-de ned position. From this position,the tool moves to the pocket start point,calculated by the pocket algorithm. Use thePick button to specify the position where thetool plunges into the material.

Angle

The tool moves to the pocket start point at

a speci ed ramp angle. The start point mustbe selected using the Pick button. Enter theramping angle value into the Angle 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.

Helical

Click on the Data button to set the helicalramping parameters.

Linear

The Linear ramping follows the same rulesas the Helical ramping. The difference is thatthe descent is performed in a linear zigzagfashion rather than in a circular one.


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In this exercise, the Vertical strategy is used in order to perform the plunging in thecenter of the drilled hole.

Choose the Vertical option from the list.

In this exercise, the model contains thesketch with the center points of the holes.

This sketch was created by the SolidWorksHole Wizard during the counterbore holesmodelling.

Switch to the SolidWorks FeatureManagerDesign tree as shown.

In the SolidWorks FeatureManagerDesign tree, click on the (+) icon near theDesignModel component of the CAM-Partassembly to expand it and see all featuresof the model.

Expand the last feature named CBORE forM5 Hex Head Bolt1 with the (+) icon.

This feature is based on two sketches: one of themcontains the geometry of the hole section and theother the center points of the holes. These sketchesare hidden by default.

Right-click on the Sketch3 item under the counterborefeature and choose the Show command from themenu. The sketch is displayed.

In the Ramping area of the Pocket Operation dialobox, click on the Pick button to choose the points

where the tool is plunging into the material. TheApproach point dialog box is displayed.

This dialog box enables you to de ne the entrancpoint for each chain used in the Pocket operation.

The schematic tool facilitates the selection.


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Select the center point as shown.

In the Approach point dialog box, clickon the Next Profile button to de ne theentrance point for the next chain. Selectthe center point as shown.

Con rm your selection with the Finishbutton.

42. Define the Lead in

The Lead in option is used for horizontal approach of the tool to the geometry in thenish machining of the part walls.

The following Lead in strategies are available for nish machining ofpockets:

Normal

The tool approaches at the last point ofthe pro le with a movement normal to thepocket contour.

Lead invalue


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Arc

The tool approaches the pro le with acircular motion, tangent to the last entityof the pocket contour.

Tangent

The tool approaches the pocket wall ina movement tangent to the last pro leentity.

Make sure that the default None option is chosen under Leadin .

43. Define the Lead out

Now you have to de ne the movement of the tool when it retreats from the pocketcontour after the nishing cut.

In the Lead out area, choose the Arc option, set the value to 1 and click on the Databutton.

Lead in

value

Lead invalue

Normal


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The Arc Lead out data dialog box is displayed.

Arc angle

This parameter de nes the angle of the retreat arc segment. Thedefault angle value is 90; in this case SolidCAM generates a retreatpath of quarter arc.

Lead out from

With the Arc Lead out option, the tool moves by the retreat arc to thearc end point and then moves normally at the speci ed distance. Thefollowing options are available:

Distance

The tool nishes the lead out movement at the speci eddistance from the arc end point.

Center

The tool nishes the lead out movement at the retreat arccenter.

Click on the OK button to con rm the Arc Lead out data dialog box.


Click on the Save & Calculate button.

The Pocket Operation data is saved and the tool path is calculated.

Angle Angle Distance

Lead out from DistanceLead out from Center


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Click on the Simulate button in the Pocket Operation dialog box.

The Simulation control panel is displayed.

Switch to the SolidVerify page and start the simulation with the button.

Perform the simulation in the step-by-step mode to check the lead in and lead outmovements.

Close the simulation with thebutton. The Pocket Operation dialogbox is displayed.

Close the Pocket Operation dialogbox with the Exit button.

Now you have successfully nishedthe exercise.


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Exercise #3: Cover Machining

In this exercise, a number of SolidCAM 2.5D operations are used for the cover part machining.

The cover is machined on the 3-Axis milling CNC-machine using the machining vice. The part ismachined using two positionings.

At the rst stage, the workpiece is positioned in the vice as shown below.


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The highlighted faces are machined.

At the next stage, the rest of the cover faces are machined with the second positioning.


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1. Load the SolidWorks model

Load the Exercise3.sldprt model that is located in the /Exercises folder.

This model contains a number of features forming the solid body of the guide.

2. Start SolidCAM

To activate SolidCAM, click on the SolidCAMeld in the main menu of SolidWorks and choose

Milling from the New submenu. SolidCAM isstarted and the New Milling Part dialog box isdisplayed.


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3. Confirm the CAM-Part creation

Con rm the default Directory , CAM-Part Name and Model name by clicking on the OKbutton in the New Milling Part dialog box. The CAM-Part is de ned.

4. Choose the CNC-Controller

When the CAM-Part is de ned, the Milling Part Data dialog box is displayed.

Select the CNC-machine Controller. Click on the arrow inthe CNC-Controller eld to display the list of post-processorsinstalled on your system.

In this exercise, you use a 3-Axis CNC-machine with theFanuc CNC-controller. Choose the Fanuc CNC-controller

from the list.

5. Define the Stock model

In this exercise, you have to de ne the Stock model before youde ne the Coordinate System in order to use the workpiecefor the CoordSys de nition.

Set the Facet tolerance to 0.01 .

Click on the Stock model button to start the de nition process. The Stock model dialog box is displayed.


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When the Coordinate System is not de ned, SolidCAM enables you to useonly the Box (Auto) method of the Stock model de nition.

Click on the Define button. The 3D Box dialog box is displayed.

SolidCAM generates the stock box surrounding the model with the speci ed allowances. In the Expand box at section,set the value of the Z- parameter direction to 5. This allowanceis used for the rst clamping. Set the value of 2 for the rest ofthe directions.

Click on the model. The model is highlighted and the boxsurrounding the model is displayed.

Click on the Add box to CAD model button. The stock model box is added into theCAM component of the CAM-Part assembly as a 3D Sketch feature.

Con rm the Stock model de nition with the button. Con rm the Stock model

dialog box with the button. The Milling Part Data dialog box is displayed.

6. Define the Coordinate System

Make sure that the Multi-sided CoordSys check box is selected. This check box enables you to de ne the Coordinate Systemsdirectly on the solid model.

Click on the Define button to start the Coordinate Systemde nition.


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The CoordSys dialog box is displayed.

In the Define CoordSys Options list, choose the Defineoption.

This mode enables you to de ne the Coordinate System bypicking three points on the solid model. At rst, you have tode ne 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.


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Click on the stock model edge as shownto de ne the X-axis of the CoordinateSystem.

Click on the stock model edge as shownto de ne the Y-axis of the CoordinateSystem.

When a point is selected, the next button is automatically activated. Ifyou miss the selection, you can at any time select the button you wantto de ne and continue automatically to the next button.


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Con rm the Coordinate System de nition with the button. The model is rotatedand the Coordinate System is displayed.

The CoordSys Data dialog box is displayed.

De ne the Part Lower level directly on the solid model. This parameter de nes thelower surface level of the part to be milled.

Click on the Part lower level button.

Rotate the model and select the lower facethat is milled with the rst positioning asshown. The Z-coordinate of the face( -12 ) is displayed in the Pick Part Lowerlevel dialog box.

Con rm this dialog box with thebutton.


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Con rm the CoordSys Data dialog box with the OK button.

The icon of the de ned Coordinate System is displayed in the CoordSys Managerdialog box.

Con rm the CoordSys Manager dialog box with the button. The Milling Part Data

dialog box is displayed again.

7. Define the Target model

Click on the Target button in the Stock & Target area of the Milling Part Data dialogbox.

The Target model dialog box is displayed.

This dialog box enables you to de ne a 3D model for the Target. Click on the Define 3D Model button.

The 3D Geometry dialog box is displayed.


Con rm the selection with the button.

The Target model dialog box is displayed again. Con rm it with the button.

The Milling Part Data dialog box is displayed.


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8. Save the CAM-Part data

In the Milling Part Data dialog box, click on the button.

The Milling Part Data dialog box is closed, and SolidCAM Manager is displayed. Thde ned CAM-Part is saved.

At this stage, the de nition of the CAM-Part is nished.

At the next stage, you have to de ne several operations to machine the cover partUsing the rst de ned Coordinate System ( rst clamping), you have to perform thfollowing operations:

Upper face machining

Upper profile machining

Lower profile machining

Hole pads machining


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Then the part has to be rotated and clamped again. With the second clamping, thefollowing operations are performed:

Upper face machining

Pocket machining

Slot machining

Holes machining


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9. Add a Pocket operation

In SolidCAM Manager , right-click on the Operations header and choose Pocket from thAdd Operation submenu. The Pocket operation is used for the upper face machining.

The Pocket Operation dialog box is displayed.


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10. Define the Pocket geometry

Click on the Define button in the Geometry area. The Geometry Edit dialog box isdisplayed.

Chain options

Curve

You can create a chain of existing curves and edges by selecting themone after the other.

Associativity

SolidCAM keeps the associativityto any edge or sketch entity. Anychange made to the model orsketch automatically updates theselected geometry.

Point to point

This option enables you to connect speci ed points; the points areconnected by a straight line.

Associativity

SolidCAM does not keep theassociativity to any selectedpoint. SolidCAM saves theX-, Y- and Z-coordinates ofthe selected points. Any changemade to the model or sketchdoes not update the selectedgeometry.


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You cannot select a point that is not located on a SolidWorksentity (if you need to select such a point, add a planer surfacunder the model and select the points on that surface).

The following rules apply to the virtual line selection using the Pointo Point option:

When you select a virtual line between two edges, the line behaveas a spring. Whenever the model is changed and synchronizedthe geometry is updated with the model.

When you select a sequence of several virtual lines, only the poinconnected to model edges or sketch elements are updated, but allother points stay xed at the de ned X-, Y- and Z-positions.

Arc by points

This option enables you to create a chain segment on an arc up to aspeci c point on the arc.

Associativity

SolidCAM does not keep the associativity to any selected arcs bpoints. SolidCAM saves the X-, Y- and Z-coordinates of the selectedpoints. Any change made to the model or sketch does not update the

selected geometry.

First Point

Second Point Third Point


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Auto Select options

SolidCAM automatically determines the chain entities and close the chaincontour. The Auto select mode offers the following three options:

Auto-general

SolidCAM highlights all the entities that are connected to the lastchain entity. You have to select the entity along which you want thechain to continue.

Auto-to-point

The chain is selected by specifying the start curve, the direction of thechain and the vertex up to which the chain is created. This command

is useful if you do not want to de ne a closed chain, but an openchain up to a certain point.


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Auto-Constant Z

This option identi es only the entities on the same XY-plane withthe previously selected chain entity. You are prompted to identifythe next chain element when two entities on the same Z-level areconnected to the chain. The system tolerance for this option can be

set in SolidCAM Settings .

Auto-Delta Z

When you select this option, you are required to enter a positive andnegative Z-deviation into the Delta-Z dialog box. Only entities in thirange are identi ed as the next possible entity of the chain.

Click on the workpiece edge as shown to de ne the rst entity of the chain.

Chains for Pocket Milling must be closed. The rst chain de nes the contouof the pocket. All closed chains inside the rst chain of each pocket arautomatically treated as pocket islands.


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In the Chain section, choose the Auto-Constant Z option.

The closed chain is automatically selected.

The con rmation message is displayed.

Con rm it with the Yes button.

Con rm the geometry with the button.

11. Define the Tool

Start the tool de nition by clicking on the Select button in the Tool section of thePocket Operation dialog box. The Part Tool Table dialog box is displayed.


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Click on the Add button to add a new end mill tool. Set the following toolparameters:

Set the Diameter to 20 ;

Set the Total length to 80 ;

Set the Outside holder length to 70 ;

Set the Cutting length to 50 .

SolidCAM enables you to de ne a variety of tool holders to help you check and prevenall possible collisions of the tool holding system with the workpiece. This feature alsenables you to see a more realistic simulation when using the SolidVerify simulation.

Select theHolder

check box in thePart Tool Table

dialog box.

SolidCAM enables you to use the Global holders table supplied within SolidCAM. This table contains a numberof frequently used tool holder components. The Globalholders table can be modi ed by the user.

Click on the Global holders table button tochoose a holder from the Global Holderstable.

The Tool Holders dialog box is displayed.


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The SolidCAM tool holder is de ned by combining two components. The rst component is the tool adaptor mounted in the spindle unit ofthe milling machine. The second component may consist of varioustypes of extensions and reductions like collet chucks, arbors, shanksand other components that you may have.

SolidCAM enables you to de ne the Tool adaptor in the MAC le

with the following string: mac_holder = BT40 .

In the Tool Holders dialog box, choose theER3260 Collet Chuck. This collet chuckis suitable for the chosen tool diameter( 20 ).

Click on the OK button to con rm thetool holder de nition. The Part Tool Table

dialog box is displayed aga

solidcam2007_r11_2_milling_training_course_2_5d_milling.pdf

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