SolidCAM SolidWorks · 3 SolidCAM + SolidWorks = The Complete Integrated Manufacturing Solution The Leaders in Integrated CAM SolidCAM 4 2.5d Milling 10

SolidCAM + SolidWorksThe complete integrated Manufacturing Solution

The Leaders in Integrated CAM

GETTINGSTARTED

3

SolidCAM + SolidWorks = The Complete Integrated Manufacturing Solution www.solidcam.com


3



SolidCAM 4

2.5d Milling 10

FeAture reCognition 14

HigH Speed SurFACe MACHining (HSS) 16

3d Milling 18

HigH Speed MACHining (HSM) 22

Multi-Sided MACHining 26

SiM. 5-AxiS MACHining 30

turning 34

Mill-turn 38

Wire Cut 44

SySteM requireMentS 45

trAining MAteriAlS 46

4

SolidCAM + SolidWorks = The Complete Integrated Manufacturing Solution

• Don’t go for less. Go for Gold.

SolidCAM is the de-facto standard Gold-Certified integrated CAM-Engine for SolidWorks. SolidCAM provides seamless, single-window integration and full associativity to the SolidWorks design model. All machining operations are defined, calculated and verified, without leaving the SolidWorks window.

SolidCAM is widely used in the mechanical manufacturing, electronics, medical, consumer products, machine design, automotive and aerospace industries, as well as in mold and die and rapid prototyping shops.

Today successful manufacturing companies are using integrated CAD/CAM systems to get to market faster and reduce costs. With SolidCAM’s seamless single-window integration in SolidWorks, any size organization can reap the benefits of the integrated SolidWorks and SolidCAM solution. SolidWorks + SolidCAM is the Dream-Team for design and Manufacturing.

SolidCAM supports the complete set of manufacturing technologies. Following is a brief description of the main SolidCAM modules.

SolidCAM 2012 - The CuTTing edge

5

www.solidcam.com


• 2.5D Milling

SolidCAM provides both interactive and automated powerful 2.5D milling operations on SolidWorks models. SolidCAM offers one of the best pocketing algorithms in the market. Full tool path control and powerful algorithms ensure that the user can manufacture the way he needs to. Operations can be easily re-ordered, rotated, mirrored, etc. SolidCAM’s automatic feature-recognition and machining module automates the manufacturing of parts with multiple pockets, multiple drills and complex holes.

All your needs for successful production machining are provided directly inside SolidWorks with an easy and straightforward interface. SolidCAM is successfully used in production environments by thousands of manufacturing companies and job shops.

• High Speed Surface Machining (HSS)

The HSS Module is a High Speed Surface Machining module, for smooth and powerful machining of localized surface areas in the part, including undercuts. It provides easy selection of the surfaces to be machined, with no need to define the boundaries. It supports both standard and shaped tools.

76



HSS provides nine different tool path definition strategies that enable the user to work differently for each area, as needed. The linking moves between the tool paths can be controlled by the user to avoid holes and slots, without the need to modify the model surface.

Complete gouge control is available for holder, arbor and tool. Adjoining check surfaces that are to be avoided can be selected. Several retract strategies are available, under user control.

The HSS module is an important addition to the integrated SolidWorks+SolidCAM solution and is essential for each manufacturing facility as an excellent complementary module for the machining of all types of parts.

• 3D Milling

SolidCAM’s 3D Milling can be used both for prismatic parts and for 3D models. For prismatic parts SolidCAM analyzes the model and automatically recognizes pockets and profiles to be machined using Z-constant machining strategies. For 3D models, SolidCAM offers powerful 3D machining, including integrated rest material options.

• High Speed Machining (HSM)

SolidCAM HSM module is a very powerful and market-proven advanced 3D Mill and high-speed-machining module for 3D parts, aerospace parts and molds, tools and dies. The HSM module offers unique machining and linking strategies for generating advanced 3D Mill and high-speed tool paths.

76



SolidCAM’s HSM module smooths the paths of both cutting moves and retracts wherever possible to maintain a continuous machine tool motion – an essential requirement for maintaining higher feedrates and eliminating dwelling.

With SolidCAM HSM module retracts to high Z levels are kept to a minimum. Angled where possible, smoothed by arcs, retracts do not go any higher than necessary – thus minimizing aircutting and reducing machining time.

The result of the HSM module is an efficient, smooth, and optimal tool path. This translates to increased surface quality, less wear on your cutters, and a longer life for your machine tools.

With demands for ever-shorter lead and production times, lower costs and improved quality, SolidCAM’s HSM Module is a must in today’s machine shops.

• 3+2 Axis Multi-Sided Machining

With SolidCAM, programming and machining of multi-sided parts on 4- and 5-Axis machining centers is efficient and profitable. SolidCAM is an industry leader in this type of machining. SolidCAM rotates the SolidWorks model to the user-defined machining planes and automatically calculates all necessary shifts and tilts for the 3D machining coordinate systems.

SolidCAM enables flexible set-ups and reduces the need for special clamping jigs. You can define your 2.5D and 3D machining operations on any face and check them using SolidCAM’s advanced tool path verification. The output is ready-to-run programs for your 4/5-axis CNC-machine.

98



• Simultaneous 5-Axis Machining

Simultaneous 5-axis machining is becoming more and more popular due to the need for reduced machining times, better surface finish and improved life span of tools. SolidCAM utilizes all the advantages of Simultaneous 5-Axis machining and together with collision control and machine simulation, provides a solid base for your 5-axis solution.

SolidCAM provides intelligent and powerful 5-axis machining strategies, including swarfing and trimming, for machining of complex geometry parts including mold cores and cavities, aerospace parts, cutting tools, cylinder heads, turbine blades and impellers. SolidCAM provides a realistic simulation of the complete machine tool, enabling collision checking between the tool and the machine components.

• Turning and Mill-Turn

SolidCAM has a very strong capability in turning, grooving and Mill-Turn. As in milling, a rest-machining capability is built in all turning operations. SolidCAM supports all machine turning cycles. SolidCAM provides special support for the advanced machining technologies of ISCAR’s Turn-Groove tools.

98



A powerful integrated Mill-Turn capability enables the turning and milling operations to be programmed in the same environment. Access to the complete 2.5-5 axis milling is available. SolidCAM provides support for up to 5-Axis (XYZCB) Turn-Mill CNC machines including back-spindle operations.

• 2/4 Axis Wire-EDM

SolidCAM Wire EDM handles profiles and tapers with constant and variable angles, as well as 4-axis contours. SolidCAM’s intelligent algorithms prevent the falling of material pieces by automatic pocket processing. SolidCAM provides full user control of stop-points and of wire cutting conditions at any point of the profile or taper.

10


The 2_5D_Milling_1.prz example illustrates the use of SolidCAM 2.5D Milling to machine the part shown above. The machining is performed on a 3-axis CNC machine in one setup.

The following SolidCAM operations are created to perform the machining:

• Upper face machining (FM_facemill )

This Face Milling operation machines the part’s face . a 40mm end mill is used. Machining is performed in one pass : rough ,removing 0.5 mm from the stock top face.

• External contour machining (F_contour)

This operation machines the external contour of the part. A 16 mm end mill is used. Material is removed in three Step downs and an additional finish pass is made to remove the remaining 0.3mm from the wall.

• Island and pocket machining (P_F ; P_contour1 ;P_contour2)

These three operations machines the pocket and the islands in this part The first operation creates the large island in the part using a 16mm end mill. Approach from out side strategy is activated and a 0.2mm are left on the walls of the island for a finishing pass.

The second operations machines islands surface to create nubs. The same tool is used and wall finish is applied to the nubs.

The third operation machines a pocket inside the island,a 10 mm endmill is used .and a helical ramping lead in is chosen to penetrate the surface.

2.5d Milling

11

www.solidcam.com


• Round corners rest machining (P_contour2_1; F_contour_1 )

The first operation machines the corners of the pocket using a 3mm end mill. Rest material is selected to machine only material left on corners from the larger tool.

The second operation machines only material left on the corners of the profile using the same 3 mm end mill.

• Chamfer machining (F_F7)

To create a chamfer on the sharp edges left from previous operations. a profile operation is used with Ø8 mm chamfer drill

Chamfer is selected from Rest material /Chamfer combo box.

• Slot machining (TSlot_T_Slot)

This Slot Milling operation machines the side Groove . a 36mm Slot mill is used.

Finish passes is made on the groove’s floor ceiling and walls.

• Holes machining (D_D-- D_D2_1)

These Drill operations perform Center drilling and drilling of holes located on the upper surface of the part.

For more information see Exercise #3 of the SolidCAM 2.5D Milling Training Course.

12


The 2_5D_Milling_2.prz example illustrates the use of SolidCAM 2.5D Milling to machine the part shown above. The machining is performed on a 3-axis CNC machine in two setups, using two SolidCAM Coordinate systems.


• Upper faces machining (FM_facemill1)

The upper face of the part is machined in one pass using a 100 mm face mill.

• Pocket machining (D_D_Tur1-1A ;P_F2_Tur1-2A ; P_F3_Tur1-2A)

To remove material from the part a hole is drilled using a 10 mm drill (D_D_Tur1-1A ) to make penetrating the surface easier for the rough mill used later

Two pocket operations (P_F2_Tur1-2A and P_F3_tur1-2A) are used to machine the pocket in the part, working in Contour tool path and using a 10mm rough mill.

• External contour machining (F_F_Tur1-2A ; F_F1_Tur1-2A)

These operations rough the external contour of the part leaving 0.2mm on the walls. A 10mm rough mill is used .

• Slot machining ( TBX_SOW_contour3)

Using tool box cycles (spiral open slot wide)a spiral tool path is created to penetrate this slot effectively using the whole cutting length of the 10 mm rough mill.

2.5d Milling

13

www.solidcam.com


• Round corners machining ( F_F1_Tur1-3A ; F_F1_Tur1-5A)

The round corners on the external contour are machined with a 5mm rough mill to remove remaining material that couldn’t be machined with a larger tool. Rest machining strategy is selected from rest material \chamfer combo box. The second operation finishes these corners with the same tool.

• Semifinishandfinish(F_F_Tur1-4A;F_F1_Tur1-4A;F_F2_Tur1-3A;F_F3_Tur1-3A ; F_F2_Tur1-4A ; F_F5_Tur1-6A ; F_F3_Tur1-6A)

These are semi-finish and finish operations applied on the part’s external and internal surfaces using different end mills. a smaller end mill is used for finish.

• Chamfer machining (F_F7_Tur1-7A ; F_F3_Tur1-7A ; F_F8_Tur1-7A)

These profile operations are created to machine a chamfer on the parts edges using 2mm chamfer drill.

• Holes machining (D_drill ; D_drill1 ; D_drill2 ; D_drill ; D_drill1 ; D_drill2)

These Drill operations perform centre drilling and drilling of holes located on the cover part faces.

• Face and chamfer machining on the part’s lower surfaces (FM_facemill2 ; F_contour4)

Part is now rotated to a new setup and a Simple face mill operation is used to machine the part’s lower surface. Then a profile operation is used to machine chamfer on the edges of the part


14


The drill_pocket_recognition.prz example illustrates the use of SolidCAM Automatic Feature Recognition to machine the mold base part shown above. The machining is performed on a 3-axis CNC machine.


• Top face machining (FM_facemill)

This Face Milling operation performs the machining of the top face of the cover. A face mill of Ø40 is used.

• Pockets machining (PR_selected_faces)

This Pocket Recognition operation automatically recognizes all the pocket areas in the model and performs their machining. An end mill of Ø20 is used. The Open Pocket machining is used to perform the approach movement from an automatically calculated point outside of the material. The tool descends to the necessary depth outside of the material and then moves horizontally into the material. A special machining strategy is applied to the through pockets; they are deepened in order to completely machine the pocket.

FeATure reCogniTion

15

www.solidcam.com


• Center Drilling (DR_drill_r)

This Drill Recognition operation automatically recognizes all the hole features available for the machining with the current Coordinate System and performs the center drilling of all the holes in the mold base. An spot drill of Ø10 is used. The drilling depth is customized for each group of holes.

• Drilling (DR_drill_r1; DR_drill_r2; DR_drill_r3; DR_drill_r4, DR_drill_r5, DR_drill_r6)

These Drill Recognition operations perform the machining of all the hole features automatically recognized in the mold base. SolidCAM automatically recognized the Upper Level and Drill depth from the model. The through holes are extended in order to completely machine the holes.

16


The hss.prz example illustrates the use of several SolidCAM High Speed Surface Machining (HSS) strategies to machine the base part shown above.


• Engraving (HSS_Proj_faces ;HSS_Proj_faces1 HSS_Proj_faces2 ; HSS_Proj_faces3)

These operations utilize the HSS projection strategy to perform the machining of four fillet areas. A ball nose mill of Ø10 is used. The Depth Cut option is used to machine the whole the depth in several cutting passes.

• Morphing machining (HSS_MC_faces4, HSS_MC_faces6)

This operation performs the machining of two internal fillet areas using the Morph between two curves strategy. This strategy is utilized to generate the tool path evenly distributed between the fillet boundaries. The gouge checking strategy is used to avoid possible gouges between the tool and the faces of the machining area. A ball nose mill of Ø10 is used.

high Speed SurFACe MAChining (hSS)

17

www.solidcam.com


• Parallel to curve machining (HSS_ParC_faces8)

This operation performs the machining of the part bottom face. With this strategy, SolidCAM enables you to perform the machining of faces with cutting passes parallel to the selected curve. In this case, SolidCAM generates a pocket-style tool path enclosed within the boundaries of the selected face. An end mill of Ø10 is used.

• Morphing between two curves (HSS_MC_faces9)

This operation performs the machining of the external fillet and an inclined face adjacent to the fillet. The Morphing between two curves strategy is utilized to generate the tool path evenly distributed between the fillet boundaries. The tool path is generated using the Scallop of 0.004 mm in order to obtain excellent surface quality. The gouge checking strategy is used to avoid possible gouges between the tool and the faces of the machining area. A ball nose mill of Ø6 is used.

18


The 3D_Milling_1.prz example illustrates the use of SolidCAM 3D Milling for the machining of the mold core shown above.


• Roughing (3DR_target)

This operation removes the bulk of material using the Contour roughing strategy. An end mill of Ø20 is used. The machining is performed at the constant-Z levels defined, using the Step down value of 3 mm. A machining allowance of 1 mm remain unmachined for further finish operations.

• Rest material machining (3DR_target_1)

This operation performs the rest material machining of the areas that were inaccessible to the tool in the previous operation. An end mill tool of smaller diameter (Ø16) is used. The Contour roughing strategy is utilized in combination with the Rest material mode of the Working area definition in order to obtain optimal and effective tool path removing the cusps left after the previous operation. A machining allowance of 0.5 mm remains unmachined for further finish operations.

3d Milling

19

www.solidcam.com


• Steepareasfinishing(3DF_CZ_target)

This operation performs the Constant-Z finishing of the steep areas of the core. With this strategy, SolidCAM machines a number of planar sections, parallel to the XY plane, using profile machining. A ball nose mill of Ø10 is used. The machining is performed for the steep areas, with inclination angle from 30° to 90°

• Shallowareasfinishing(3DF_CS_target_1)

This operation performs the Constant Stepover finishing of the shallow areas of the core. With this 3D Milling strategy SolidCAM generates a number of tool paths, at specified constant offset (Step over) from each other, measured along the surface. The machining is performed for the shallow areas, with inclination angle from 0° to 32°. A ball nose mill of Ø10 is used.

• Partingsurfacefinishing(3DF_Lin_target)

This operation performs the Linear finishing of the parting surface of the core. In linear finishing, SolidCAM generates a line pattern on a 2D plane above the model and then projects it on the 3D Model. The Step over value determines the constant distance between adjacent lines of the linear pattern, created on the 2D plane before being projected. A ball nose mill of Ø10 is used. The defined Drive/Check surfaces enable you to perform the machining of the parting surfaces only, avoiding unnecessary contact with the already machined faces.

For more information see Exercise #1 and Exercise #10 of the SolidCAM 3D Milling Training

Course.

20


The 3D_Milling_2.prz example illustrates the use of SolidCAM 3D Milling for prismatic part machining.


• Roughing (3DR_target)

These operations remove the bulk of material using the Contour roughing strategy. An end mill of Ø10 is used. The Open Pocket machining is used to perform the approach movement from an automatically calculated point outside of the material. The tool descends to the necessary depth outside of the material and then moves horizontally into the material. A machining allowance of 0.2 mm remain unmachined on floor and wall faces for further finish operations.

• Rest material machining (3DR_target_1; 3DR_target_2)

At this stage the rest material machining is performed for the corner areas, that were inaccessible by the tool in the previous operation. The machining is performed in two operations using end mills of Ø8 and Ø5, in order to minimize the tool load. The Contour roughing strategy is utilized in combination with the Cut only in Rest material option in order to obtain optimal tool path A machining allowance of 0.2 mm remain unmachined on the floor and wall faces for further finish operations.

3d Milling

21

www.solidcam.com


• Verticalwallsfinishing(3DF_CZ_target)

This operation performs the Constant-ZWallfinishing of the vertical walls areas of the part. With this strategy, SolidCAM generates a number of profile passes along the Z-axis, with a constant Step down. An end mill of Ø4 is used.

• Horizontalfloorfinishing(3DF_CZ_target_1)

This operation performs the Constant-Z Floor finishing of the horizontal floor areas of the part. With this strategy, SolidCAM generates a number of pocket passes on the horizontal faces, parallel to the XY-plane of the current Coordinate System. An end mill of Ø4 is used.

For more information see Exercise #18 of the SolidCAM 3D Milling Training Course.

22


The hsm_1.prz example illustrates the use of several SolidCAM High Speed Machining (HSM) strategies to machine the mold cavity shown above.


• Rough machining (HSR_R_Cont_target)

This operation performs contour roughing of the cavity. An end mill of Ø20 is used with a Step down of 3 mm. A machining allowance of 0.5 mm remain unmachined for further semi-finish and finish operations.

• Rest roughing (HSR_RestR_target)

This operation performs rest roughing of the cavity. A bull nosed tool of Ø12 and corner radius of 2 mm is used with a Step down of 1.5 mm to remove the steps left after the roughing. The same machining allowance as in roughing operation is used.

• Steepfacessemi-finishing(HSM_CZ_target)

This operation performs Constant Z semi-finishing of the steep faces (from 40° to 90°). A ball nosed tool of Ø10 is used for the operation. A machining allowance of 0.25 mm remain unmachined for further finish operations. TheApplyfilletsurfacesoption is used to add virtual fillets that will smooth the tool path at the corners.

• Shallowfacessemi-finishing(HSM_Lin_target)

This operation performs Linear semi-finishing of the shallow faces (from 0° to 42°). A ball nosed tool of Ø10 is used for the operation.

high Speed MAChining (hSM)

23

www.solidcam.com


A machining allowance of 0.25 mm remain unmachined for further finish operations. The Applyfilletsurfacesoption is used.

• Corners rest machining (HSR_RM_target)

This operation uses the Rest Machining strategy for semi-finishing of the mold cavity corners. The semi-finishing of the model corners enables you to avoid tool overload in the corner areas during further finishing. A ball nosed tool of Ø6 is used for the operation. A virtual reference tool of Ø12 is used to determine the model corners where the rest machining is performed. A machining allowance of 0.25 mm remain unmachined for further finish operations.

• Steepfacesfinishing(HSM_CZ_target_1)

This operation performs Constant Z finishing of the steep faces (from 40° to 90°). A ball nosed tool of Ø8 is used for the operation. The Applyfilletsurfaces option is used.

• Shallowfacesfinishing(HSM_Lin_target_1)

This operation performs Linear finishing of the shallow faces (from 0° to 42°). A ball nosed tool of Ø8 is used for the operation. The Apply filletsurfaces option is used.

• Corners rest machining (HSR_RM_target_1)

This operation uses the Rest Machining strategy for finishing of the model corners. A ball nosed tool of Ø4 is used for the operation. A virtual reference tool of Ø10 is used to determine the model corners where the rest machining is performed.

• Chamfering (HSM_Bound_target)

This operation uses the Boundary Machining strategy for the chamfering of upper model edges. A taper tool is used for the operation. The chamfer is defined by the external offset of the drive boundary and by the Axial thickness parameter.

For more information see Exercise #16 of the SolidCAM HSM User Guide.

24


The hsm_2.prz example illustrates the use of several SolidCAM HSM strategies to machine the electronic box shown above.


• Rough machining (HSR_R_Cont_target)

This operation performs the contour roughing of the part. An end mill of Ø30 is used with a Step down of 10 mm to perform the roughing. A machining allowance of 0.5 mm remain unmachined for further semi-finish and finish operations.

• Rest roughing (HSR_RestR_target)

This operation performs the rest roughing of the part. A bull nosed tool of Ø16 and corner radius of 1 mm is used with a Step down of 5 mm to remove the steps left after the roughing. The same machining allowance as in the roughing operation is used.

• Upperfacesmachining(HSM_CZ_target)

This operation performs Constant Z finishing of the upper vertical model faces upto a certain depth. A bull nosed tool of Ø12 and corner radius of 0.5 mm is used.

high Speed MAChining (hSM)

25

www.solidcam.com


• Bottomfacesmachining(HSM_CZ_target_1)

This operation performs Constant Z finishing of the bottom vertical model faces. A bull nosed tool of Ø12 and corner radius of 0.5 mm is used.

• Flatfacesmachining(HSM_CZF_target)

This operation performs Horizontal Machining of the flat faces. A bull nosed tool of Ø12 and corner radius of 0.5 mm is used.

• Inclinedfacesmachining(HSM_CZ_target_2)

This operation performs Constant Z Machining of the inclined faces. A taper mill of 12° angle is used to perform the machining of the inclined face with large stepdown (10 mm). Using such a tool enables you to increase the productivity of the operation.

For more information see Exercise #14 of the SolidCAM HSM User Guide.

26


The multi_sided_machining_1.prz example illustrates the use of SolidCAM Multi-sided machining to machine the parts shown above, using a 5-axis CNC Machine.the part is machined in 4 setups.


• Threaded hole machining (D_D ; F_F1 , F_F1_1 ; F_F1_2 ; F_F1_3 ; THM_drill)

The first operation is a drilling operation that uses a 11 mm drill .to widen the hole a profile operation is used (F_F1) along with a 8mm end mill leaving 0.2mm on walls for finish.The third operation is created to semi-finish the hole leaving 0.05mm for finish. An 8 mm tool is used. Then another profile operation (F_F1_2) is used for finish . The fifth operation is created to machine a chamfer on the hole’s edges. A chamfer drill is 19mm chamfer drill is used and “Chamfer “is selected from Rest material\chamfer combo box. The final operation machines an internal thread using a 16mm thread mill with a pitch of 3 mm.

• Profilemachining(F_F;F_F_1;F_F_2)

First operation is a profile operation created to rough the part’s profile using a 20 mm rough mill. The second operation finishes this profile with the same tool in three step downs.

The third operation round the edges of the profile in the top face of the part using a shaped tool designed for this operation.

MulTi-Sided MAChining

27

www.solidcam.com


• Open Slot machining(F_F2 ; F_F2_1 ; F_F2_2 ; F_F2_3 ; F_F2_4)

The first operation machines the slots using an 8 mm roughing tool .the second operation works on the same location but uses a tool with greater cutting length to reach deeper levels.

The third and the fourth operations finish these slots using two tools with different cuttings lenghts.

• Hole machining(D_DB2 ; D_DB2 ; D_D1 ; D_DB4 ; D_DB4_1 ; D_DB2_2 )

These operation drills holes in the part in different setups using several tools. Two operation are created for each hole; the First to drill a centre hole using the tool cutter tip and then the hole is drilled to full depth.

•SolidCAM letters machining (S_S1 )

To machine solidCAM’s letters on the part top face a slot operation . The letters are selected as chains and machining is performed with a 0.4mm end

mill.


28


The multi_sided_machining_1.prz example illustrates the use of SolidCAM Multi-sided machining to complete the machining of the clamp part shown above, using a 5-axis CNC Machine.


• Topfacemachining(FM_profile1)

This Face Milling operation machines the top inclined face of the clamp. Machine Coordinate system #1 (Position #2) is used for the operation.

• Backfacemachining(FM_profile2)

This Face Milling operation machines the back inclined face of the clamp. Machine Coordinate system #1 (Position #3) is used for the operation.

• Frontfacemachining(FM_profile3)

This Face Milling operation machines the front inclined face of the clamp. Machine Coordinate system #1 (Position #4) is used for the operation.

• Openingsmachining(F_profile4)

This Profile operation machines two openings, located on the front inclined face of the clamp. Machine Coordinate system #1 (Position #4) is used for the operation.

MulTi-Sided MAChining

29

www.solidcam.com


• Slotmachining(P_profile5;P_profile6)

These Pocket operations machines the slot faces located on the top inclined face of the clamp, using the Contour strategy. Machine Coordinate system #1 (Position #2) is used for the operation.

• Holemachining(P_profile7;D_drill;D_drill_T4)

These operations machine the inclined counterbore hole, located on the top inclined face of the clamp. Machine Coordinate system #1 (Position #5) is used for the operation.

• Bottomfacemachining(FM_profile8)

This Face Milling operation machines the bottom inclined face of the clamp. Machine Coordinate system #2 (Position #1) is used for the operation.


30


The sim_5_axis_1.prz example illustrates the use of the SolidCAM Sim. 5 axis module for turbine blade machining.

The following Sim. 5 axis operations are used to perform the semi-finish and finish machining of the turbine blade:

• BladeSemi-finishing (5X_selected_faces ; 5X_selected_faces_1)

The first operation provides the semi-finish of the turbine blade, using a bull nosed tool of Ø16 with a corner radius of 4 mm. A combination of the Parallel Cuts strategy and Change parallel cuts to spiral option is used to perform the spiral machining of the blade.

The tool tilting is defined using the Tilted relative to cutting direction option, with lag angle of 20°. The tool contact point is defined at the front tool face. This combination of parameters enables you to perform the machining by the toroidal surface of the tool.

Gouge checking is performed to avoid the possible collisions of the tool with the planar surface of the blade base. The remaining material will be machined at a later stage, using a special tilting strategy.

SiM. 5-AxiS MAChining

31

www.solidcam.com


The second Sim. 5-axis operation provides semi-finishing of the blade area, close to the blade base. This area was not machined in the previous operation because of the gouge protection. A bull nosed tool of Ø8, with a corner radius of 2 mm, is used for the operation. Similar to the previous operation, a combination of the Parallel Cuts strategy and Change parallel cuts to

spiral option is used to perform the spiral machining of the blade.

The tool tilting is defined using the Tilted relative to cutting direction option, with a lag angle of 20°. In addition to the lag angle, a side tilting angle of 10° is defined to avoid the gouging of the planar face of the blade base.

• Bladefinishing(5X_selected_faces_2)

This operation performs the finishing of the blade. A bull nosed tool of Ø8, with a corner radius of 2.5 mm, is used for the operation.

The tool tilting is defined using the Tilted relative to cutting direction option with a lag angle of 20°. In addition to the lag angle, a side tilting angle of 10° is defined to avoid the gouging of the planar face of the blade base.

For more information see Exercise #2 of the SolidCAM Sim. 5-axis User Guide.

32


The sim_5_axis_2.prz example illustrates the use of the Sim. 5 axis operation for an aerospace part machining.

A number of Sim. 5 axis operations are defined in order to perform the finish machining of the inclined faces of the aerospace frame and their adjacent fillets. The inclined faces are forming an undercut area that cannot be machined using 3 axis milling; we have to use 5 axis milling, with the appropriate tilting strategy, to machine the inclined faces.

• Inclinedwallsfinishing (5X_selected_faces1 ; 5X_selected_faces2 ; 5X_selected_faces3 )

These operations perform the finish machining of the inclined walls.

A ball nosed tool of Ø4 is used for the operation.

The Parallel Cuts strategy is used to generate a number of cuts parallel to the XY plane of the coordinate system.

The tool tilting is defined using the Tilted relative to cutting direction option with a lag angle of 90°. These parameters enable you to perform the machining with the side face of the tool.

SiM. 5-AxiS MAChining

33

www.solidcam.com


• Fillet machining (5X_selected_faces4 ; 5X_selected_faces5 ; 5X_selected_faces6 )

These operations perform the finish machining of the fillets adjacent to the walls.

A ball nosed tool of Ø4 is used for the operation.

The Project curves strategy is used to generate a single pencil milling pass, machining the fillets.

The Tilted through curves tilting strategy is used to perform a smooth transition between different tool axis orientations.

For more information see Exercise #3 of the SolidCAM Sim. 5-axis User Guide.

34


The turning_1.prz example illustrates the use of the SolidCAM Turning for the machining of the part shown above.

The following Turning operations are used to perform the machining of the part:

• Face Turning (FT_turn_on_solid )

This operation is used to generate tool path for front face machining. An External roughing tool is used for the operation. 0.1 mm is left on the face for further operations.

• Contour Turning (TR_turn_on_solid1 )

This operation is used to generate the tool path for the external faces roughing. An External roughing tool is used for the operation. Rough is selected as a Work type for this operation; to perform machining in a number of equidistant passes.

• Drilling (DRILL )

This Drill operation is used to drill a hole in the centre of the part. A 23 mm Drill is used for this operation.

• Internal Turning (TR_turn_on_solid2 )

To rough the internal faces of the part and create chamfers on holes diameters an internal turning operations is used along with internal roughing tool . None descending motions strategy is used here to avoid collisions.

Turning

35

www.solidcam.com


.• Internal Grooving (TR_contour )

This turning operations is used to rough the part’s internal groove . An Internal grooving tool is used for the operation.Roughing type is set to smooth for a smooth finish.

• Internalfinishing(TR_contour_1;TR_contour1)

These operations are used to finish the internal surfaces of the part using internal grooving tools . None descending motions is used in the second to operations to remove material left from the first operation.

• InternalThreading(TH_profile6)

This Threading operation is used to machine an internal thread in the part with a major diameter of 28.7 mm and pitch of 16 TPI (thread per inch). An Internal threading tool is used for the operation .

For more information see Exercise #1—#11 of the SolidCAM Turning Training Course.

36


The turning_2.prz example illustrates SolidCAM functionality for Rest Material machining, during longitudinal and facial rough/finish turning operations, performed on the part shown above.

The following Turning operations are used to perform the machining of the part:

• Face turning (TR_contour )

This operation is used to rough the part’s face Using an External roughing tool. To perform machining on the face of the part Process type is selected as face .Rough Work type is selected for this operation; to rough the part in a number of equidistant passes.

• Contour turning (TR_contour1)

This turning operation is used to rough the external contour of the part. Mode is set to “external” and process type is set to “along” to create passes along the part‘s rotational axis.

• Drilling (DRILL)

This drilling operation is used to make machining the internal contour easier and quicker. A 33mm drill is used.

• Internal roughing (TR_contour2 ; TR_contour5)

These operation rough the internal contour of the part using an internal roughing tool. The first operation uses “smooth” as a rough type to create a smoother surface.

Turning

37

www.solidcam.com


• External Roughing (TR_contour14)

A normal external roughing operation is performed on the selected contour using “smooth” as a roughing type to create a smoother surface.

• External contour Finishing (TR_contour14_1 ; TR_contour13 ; TR_contour7)

The first two external turning operations finishes the contour roughed in the previous operation. The first operation finishes the entire geometry while the other is set on Rest material to remove material left unmachined.the third operation finishes different contour on the part’s perimeter .•

• Internalfinishing(TR_contour6;TR_contour8;TR_contour9)

The first operation is a rest material operation to remove material left from operation (TR_contour5) .to reach these location tool is mounted in a different orientation .similarly, the other operations are used to finish the rest of the surfaces using the same tool .

For more information see Exercise #16 of the SolidCAM Turning Training Course.

38


The mill_turn_1.prz example illustrates the use of the SolidCAM Mill-Turn module for the machining of the optical part shown above, on a 4-axis Mill-Turn CNC-Machine.

The following Turning and Milling operations are used to perform the machining of the part:

• Turning (TR_profile1;TR_profile1;DRILL;TR_profile10)

These turning operations are used to generate the tool path for the rough and finish machining of the external and internal cylindrical faces.

• FacialMilling(F_profile2_T2;D_drill3_T6;D_drill4_T6)

These operations perform the machining of the screw slot and four holes using SolidCAM capabilities for facial milling. Position #1 of Coordinate System #1 is used to perform the facial machining.

• Machiningofthesidefaces(P_profile3)

This Pocket operation is used to perform the machining of the side faces of the model. The Contour strategy is used in combination with a negative Wall

offset value in order to generate an overlapping tool path that completely machines the faces.

Position #3 of Coordinate System #1 is used for the operation. The Transform option is used to create a circular pattern of operations around the revolution axis.

Mill-Turn

39

www.solidcam.com


• Drilling on the side face (D_drill )

This Drill operation is used to perform the machining of two holes located on the side face of the model. CoordSys Position #3 is used for the operation.

• Slotmachining(F_profile5)

This Profile operation is used to perform the machining of the slot using indexial 4-axis milling.

Position #4 of Coordinate System #1 is used for the operation.

An end mill of Ø2.5 is used for the operation.

• Radial holes machining (D_drill1;P_profile6;D_drill2;P_profile7)

These Drill and Pocket operations are used to perform the machining of three counterbore holes located on the cylindrical face.

Position #5 and Position #6 of Coordinate System #1 are used for the operations.

• Pocketmachining(P_profile9)

This Pocket operation is used to perform the simultaneous 4-axis machining of the pocket, wrapped on the external face of the part. Position #2 of Coordinate System #1 is used to perform the pocket machining. An end mill of Ø2.5 is used for the operation.

The Wrap option, chosen during the machining geometry definition, enables you to define the wrapped geometry of the pocket directly on the solid model.

The Contour strategy is chosen for the pocket machining.

40


The mill_turn_2.prz example illustrates the use of the SolidCAM Mill-Turn module for the machining of the console part shown above on a 5-axis Mill-Turn CNC-Machine.


• Turning(TR_profile)

This turning operation is used to generate the tool path for the rough and finish machining of the external cylindrical faces.

• Indexialmilling(F_profile6)

This Profile operation is used to perform the machining of the cube sides using the SolidCAM indexial milling capabilities. Position #2 of Coordinate System #2 is used for the operation. The Transform option is used to create a circular pattern of operations around the revolution axis in order to machine all the cube faces.

An end mill of Ø16 is used for the operation.

• Horizontalfacesmachining(F_profile1)

This Profile operation is used to perform the indexial milling of the horizontal faces at the front part of the console. Position #4 of Coordinate System #1 is used for the operation.

Mill-Turn

41

www.solidcam.com


The Transform option is used to create a circular pattern of operations around the revolution axis in order to machine both sides of the console’s front part.

• Inclinedfacesmachining(F_profile3;F_profile4)

These Profile operations are used to perform the machining of the inclined faces using the B-axis. CoordSys positions #5 and #6 are used for these operation.

An end mill of Ø16 is used for the operations.

• Cylindricalfacemachining(F_profile2)

This Profile operation is used to perform the machining of the cylindrical face at the front part of the console. Position #4 of Coordinate System #1 is used for the operation.

An end mill of Ø16 is used for the operations.

• Pocketmachining(P_profile9)

This Pocket operation is used to perform the machining of the pocket located on the inclined faces, using the B-axis. Position #5 of Coordinate System #1 is used for the operation.


• Inclinedfacesmachining(F_profile7;F_profile8)

These Profile operations are used to perform the machining of the inclined faces on the cube, using the B-axis. CoordSys positions #7 and #8 are used for the operation.


• Hole machining (D_drill ; D_drill1 ; D_drill2 ; D_drill3 )

These Drill operations are used to perform the machining of the inclined faces on the cube, using the B-axis. CoordSys positions #4, #6, #7 and #8 are used for the operations.

42


The back_spindle.prz example illustrates the use of the SolidCAM Back Spindle functionality for the machining of the connector part shown above, on a 5-axis Mill-Turn CNC-Machine.


• Turningandfrontsidemilling(TR_profile;TR_profile_1;DRILL;F_profile1;TR_profile2)

These operations are used to perform turning and facial milling of the front faces of the connector. Position #1 of Coordinate System #1 is used for the operation. The back spindle is not used in these operations; only the main spindle is used.

• Indexial machining of the middle part (F_profile6;D_drill2;D_drill2_1;F_profile7)

These Profile and Drill operations are used to perform the machining of the pads and holes located around the cylindrical surface, in the middle part of the connector. Position #5 of Coordinate System #1 is used for the operation. The Back Spindle Connect operation is defined before these operations, enabling the combined use of both spindles (main and back) in these operations.

Mill-Turn - 2 SpindleS

43

www.solidcam.com


• Indexial machining of the back part (P_profile8;D_drill3)

These Profile and Drill operations are used to perform the machining of the pads and holes located around the conical surface, in the middle part of the connector. Position #6 of Coordinate System #1 is used for the operation. The Back Spindle MoveBack operation is defined before these operations, causing the retract of the back spindle, so that these operations are performed with the main spindle only.

• Turning and back side milling (TR_profile9;F_profile10;DRILL_1;TR_profile11;F_profile12;D_drill4; D_drill4_1)

These operations are used to perform turning and facial milling of the back faces of the connector. Position #1 of Coordinate System #1 is used for turnings operation. Position #4 of Coordinate System #1 is used for milling operations. The Back Spindle Transfer operation is defined before these operations, causing the transfer of the part from the main spindle to the back spindle. The machining is performed on the part clamped in the back spindle.

Refer to the SolidCAM Turning User Guide for more information about the Back spindle functionality.

44


The wire_cut.prz example illustrates the use of the SolidCAM Wire Cut module for the conical gear machining.

The following Wire Cut operations are used to perform the machining of the part:

• Central cut machining (F_contour)

This Profile operation is used to machine the central through cut. The Later option is used for the Auto Stop technology, generating a postponed separate sub-operation preventing the material dropping.

• Gear face machining (X_four_axis)

The 4-axis operation is used to machine the conical gear shape. The insertion point of the wire is chosen outside the cylindrical stock, simplifying the approach of the wire to the machining contour.

Refer to the Wire Cut User Guide for more information about the Wire Cut module.

Wire CuT

www.solidcam.com

45

• Microsoft® Windows 7 x32/x64 Professional and Ultimate editions,

Microsoft® Windows Vista x32/x64 Business and Ultimate editions with Service

Pack 1,

Microsoft® Windows XP Professional with Service Pack 2 or 3,

Microsoft® Windows XP Professional x64 Edition

• Intel® Core™, Intel® Core™2 Duo, Intel® Core™ Quad, Quad-core Intel® Xeon®,

AMD Phenom™, AMD Phenom™ II, AMD Athlon™ X2 Dual-Core - class processor.

• 2 GB RAM or more (4 GB or more for x64 operating system is recommended for large CAM-Parts machining)

• A OpenGL workstation graphics card (512 MB RAM recommended) and latest driver

• Mouse or other pointing device

• CD drive

• Internet Explorer version 6 if you are using the SolidCAM online help

• For viewing SolidCAM User Guides and Training Courses, Adobe Acrobat version 9 or higher is recommended.

SYSTeM reQuireMenTS

46


The following training courses are suitable both for SolidCAM frontal training and for self study.

• SolidCAM Milling Training Course: 2.5D Milling

• SolidCAM Milling Training Course: 3D Milling

• SolidCAM Turning Training Course

• SolidCAM Turn-Mill Training Course

• SolidCAM Advanced Training Course

These documents are available in the following format: PDF for on-line use + Examples

The following user guides for SolidCAM are available.

• SolidCAM Milling User Guide

• SolidCAM HSM User Guide

• SolidCAM HSS User Guide

• SolidCAM Sim. 5-axis User Guide

• SolidCAM Turning User Guide

• SolidCAM Wire Cut User Guide

The PDF versions of user guides are available for download from the Download area of SolidCAM Web site: www.solidcam.com.

On-line help, based on these user guides, is available within SolidCAM.

TrAining MATeriAlS

47

www.solidcam.com


www.solidcam.com

www.youtube.com/SolidCAMProfessor www.youtube.com/iMachining

www.facebook.com/SolidCAMwww.facebook.com/iMachining

2.5D Milling HSS (High-Speed Surface Machining) HSM (High-Speed Machining)

Wire EDM iMachining Service and Support

Indexed Multi-Sided Machining Simultaneous 5-Axis Machining Turning and Mill-Turn up to 5-Axis

SolidCAM SolidWorks · 3 SolidCAM + SolidWorks = The Complete Integrated Manufacturing Solution The Leaders in Integrated CAM SolidCAM 4 2.5d Milling 10

Documents