SolidCAM2008 R12 Milling Training Course 2 5D Milling

8/12/2019 SolidCAM2008 R12 Milling Training Course 2 5D Milling

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SolidCAMSolidCAM2008 R12

Power and Ease of Use - the winning combination

1995-2008 SolidCAM

All Rights Reserved.WWW.SOLIDCAM.COM

SolidCAM2008 R12

Milling Training

Course

2.5D Milling


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SolidCAM2008 R12

Milling Training Course

2.5D Milling

1995-2008 SolidCAM

All Rights Reserved.


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Content

5

Contents

1. Introduction

1.1 About this course............................................................................................................................9

1.2 Basic Concepts ..............................................................................................................................11

1.3 Process Overview .........................................................................................................................11

2. CAM-Part Definition

Exercise #1: CAM-Part Denition ...........................................................................................15

3. SolidCAM 2.5D Operations

Exercise #2: Guide Machining ..................................................................................................36

Exercise #3: Cover Machining ..................................................................................................81

Exercise #4: Bracket Machining .............................................................................................165

Exercise #5: Support Machining ............................................................................................167

Exercise #6: Clamp Machining ...............................................................................................174

Exercise #7: Electronic Box Machining ................................................................................182

Exercise #8: Basic Part Machining .........................................................................................185

Exercise #9: Support Frame Machining ................................................................................189

4. Advanced 2.5D Milling

Exercise #10: Pocket Recognition ..........................................................................................199

Exercise #11: Mounting Box Machining ...............................................................................207

Exercise #12: Drill Recognition ..............................................................................................209

Exercise #13: Electronic Box Machining ..............................................................................228


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5. Indexial 4-Axis Milling

Exercise #14: Frame Machining .............................................................................................235

Exercise #15: Mounting Machining .......................................................................................254

Exercise #16: Mounting Base Machining ..............................................................................259

6. Indexial 5-Axis Milling

Exercise #17: Hydraulic Block Machining ............................................................................267

Exercise #18: Manifold Plate Machining ...............................................................................278

Exercise #19: Joint Machining ................................................................................................282

Exercise #20: Clamp Machining .............................................................................................287

Document number: SCMTCENG08002


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1. Introductio

About this course1.1

The goal of this course is to teach you how to use SolidCAM to machine various parts using 2.5D

Milling technologies. This course covers the basic concepts of SolidCAM 2.5D machining an

is a supplement to the system documentation and online help. Once you have developed a goo

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

Course design

This course is designed around a task-based approach to training. With the guided exercises yo

will learn the commands and options necessary to complete a machining task. The theoretic

explanations are embedded into these exercises to give an overview of the SolidCAM 2.5D Millin

capabilities.

Using this training book

This training book is intended to be used both in a classroom environment under the guidance o

an experienced instructor and as self-study material. It contains a number of laboratory exercise

to enable you to apply and practice the material covered by the guided exercises. The laborator

exercises 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 throughouthis course. The Exercises folder contains the les that are required for guided and laboratorexercises. The Built Partsfolder inside the Exercisescontains the nal manufacturing projects foeach exercise. Copy the complete Exercises folder on your computer. The SolidWorks les used fothe exercises were prepared with SolidWorks2008.

WindowsXP

The screenshots in this book were made using SolidCAM2008 R12integrated with SolidWorks200

running on WindowsXP. If you are running on a different version of Windows, you may notic

differences in the appearance of the menus and windows. These differences do not affect thperformance 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 on

the Change to oppositebutton.

10. Define CoordSys Position

The mouse icon and numbered sans serif bold text

indicate the beginning of the exercise action.

ExplanationThis style combined with the lamp icon is used for

the SolidCAM functionality explanations embedded

into the guided exercises. The lamp icon is also used

to emphasize notes.


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1. Introductio

Basic Concepts1.2

Every manufacturing project in SolidCAM contains the following data:

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

Geometry By selecting Edges, Curves, Surfaces or Solids, dene whatand whereyoare going to machine. This geometry is associated with the native SolidWorks model.

Operation An Operation is a single machining step in SolidCAM. Technology, Tooparameters and Strategies are dened in the Operation. In short, Operation means how

you want to machine.

Process Overview1.3

The major stages of the SolidCAM manufacturing project creation process are the following:

CAM-Part definition

This stage includes the denition of the global parameters of the ManufacturinProject (CAM-Part). You have to dene a number of Coordinate Systems that describ

the positioning of the part on the CNC-machine.

Optionally, you can dene the Stock model and the Target model to be used for threst material calculation. The Stock model describes the initial state of the workpiec

that has to be machined. The Target model describes the one that has to be reache

after the machining. After every operation, SolidCAM calculates how much materia

was actually removed from the CAM-Part and how much material remains unmachine

(rest material). The rest material information enables SolidCAM to automaticalloptimize the tool path and avoid the air cutting.

Operations definition

SolidCAM enables you to dene a number of milling operations. During an operatiodenition you have to select the Geometry, choose the tool from the Part Tool tabl(or dene a new one), dene a machining strategy and a number of technologicaparameters.


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CAM-Part

Definition 2


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The CAM-Part denition process includes the following stages:

CAM-Part creation. At this stage, you have to dene the CAM-Part name and location.SolidCAM denes 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. The controllertype inuences the Coordinate System denition and the Geometry denition.

Coordinate System definition. You have to dene the Coordinate System the origin forall machining operations of the CAM-Part.

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

Target model definition. SolidCAM enables you to dene the model of the part in its nalstate 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 Definitio

Exercise #1: CAM-Part Definition

This exercise illustrates the CAM-Part denition process in SolidCAM. In this exercise, you have tcreate the CAM-Part for the guide model displayed below and dene the Coordinate System, th

Stock model and the Target model that are necessary for the part machining. The CAM-Part will b

used in the exercises further on.

When you start to program a CAM-Part, you have to decide wha

workpiece you are going to use. This decision determines th

number and the type of operations that are used to reach the npart 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 holes

emphasized below.

At the next stage, you have to decide on what type

of 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

of this type, all the required faces of the guide part

can be machined using a single positioning.


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Load the SolidWorks model1.

Load the Exercise1.sldprtmodel located in the Exercisesfolder.

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

Start SolidCAM2.

To activate SolidCAM, click on the SolidCAM

eld in the main menu of SolidWorks and chooseMilling from the New submenu. SolidCAM is

started and the New Milling Part dialog box is

displayed.


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New Milling Part dialog box

When you create a new CAM-Part, you have to enter a name for th

CAM-Part and for the model that contains the CAM-Part geometry.

Directory

Specify the location of the CAM-Part. The default directory is th

SolidCAM user directory (dened in the SolidCAM Settings). You caenter the path or use the Browsebutton to dene the location.

The Use Model file directory option enables you to automaticall

create CAM-Parts in the same folder where the original CAD mod

is located.

CAM-Part name

Enter a name for the CAM-Part. You can give any name to identifyour 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 denition. The name i

by default, the name of the active SolidWorks document. With thBrowsebutton you can choose any other SolidWorks document t

dene the CAM-Part. In this case, the chosen SolidWorks documenis loaded into SolidWorks.

Every time the CAM-Part is opened, SolidCAM

automatically checks the correspondence of the dates o

the CAM-Part and the original SolidWorks design mode

When the date of the original SolidWorks model is late

than the date of the CAM-Part creation, this means tha

the SolidWorks original model has been updated. Yocan then replace the SolidWorks design model on whic

the CAM-Part is based with the updated SolidWork

design model.


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Confirm the CAM-Part creation3.

When the Directory, CAM-Part nameand Model namehave

been dened, click on the OKbutton to conrm the CAM-Part creation. The CAM-Part is dened and its structure iscreated. The Milling Part Datadialog box is displayed.

The structure of the CAM-Part

The CAM-Part includes a number of data les represented on the

illustration that displays the data included in the CAM-Part namedMilling.

The Milling.prtle is located in the SolidCAM Userdirectory. 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 Millin

subdirectory and creates a SolidWorks assembly that has the sam

name as the CAM-Part (Milling.sldasm). There are two componentin this assembly:

DesignModel.sldprt a copy of the SolidWorks model le.

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

The SolidCAM CAM-Part uses the assembly environment o

SolidWorks. This enables you to create auxiliary geometries (e.gsketches) 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 toolin

elements.

Choose the CNC-Controller4.

Select the CNC-machine controller. Click on the arrow in the CNC-Controllerarea t

display the list of post-processors installed on your system.

In this exercise, use a 3-Axis CNC-machine with the

Awea1000-FanucCNC-controller. Choose the Awea1000-

FanucCNC-controller from the list.

Start the Coordinate System definition5.

Click on the Define button in the Coordinate System area

to dene the Machine Coordinate System.

To complete the CAM-Part denition, you need to dene the MachinCoordinate System.

The Machine Coordinate System denes the origin for all machininoperations of the CAM-Part. It corresponds with the built-i

controller functions.


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You can dene the Coordinate System origin position and axesorientation by selecting model faces, vertices, edges or the SolidWorks

coordinate system. The geometry for the machining can also be

dened directly on the solid model.

The Z-direction of the Machine

Coordinate System is parallel tothe revolution axis of the tool.

In SolidCAM, the tool approaches

from the positive direction of the

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

For 3-Axis CNC milling machines, each Machine Coordinate

System means separate clamping. If you need to machine the part

from different sides, use several Machine Coordinate Systems withthe Z-axis oriented normally to the machined sides.

X

ZY

Machine CoordinateSystem

X

Z

Y

XZ

Y

Coordinatesystem

Coordinatesystem

X

ZY

Coordinatesystem


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In this exercise, it is enough to deneone Machine Coordinate System with

the Z-axis oriented upwards.

Such coordinate system enables you

to machine the part with a single

clamping.

The CoordSys dialog box enables you to dene the CoordinateSystem location and the orientation of the axes.

You can dene the Coordinate System origin position and

axes orientation by selecting the model faces, vertices, edges orSolidWorks Coordinate Systems.

SolidCAM enables you to dene the CoordSysusing the following methods:

Select Face

This method enables you to dene a new

CoordSys by selecting a face. The face canbe planar or cylindrical/conical. For planar

faces, SolidCAM denes CoordSys with theZ-axis normal to the face. For cylindrical or

conical faces, the Z-axis of the CoordSys is

coincident with the axis of revolution of the

specied cylindrical/conical surface.

Define

This method enables you to dene theCoordinate System by selecting points. Youhave to dene the origin and the direction ofthe X- and the Z-axes.

XZ

YCoordinasystem


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Select Coordinate System

This method enables you to choose the SolidWorks Coordinate System

dened in the design model le as the CoordSys. The CoordSysorigin and axes orientation are the same as in the original SolidWorks

Coordinate System.

Normal to current view

This option enables you to dene the Coordinate System with theZ-axis normal to the model view you are facing on your screen. The

CoordSys origin will lie in the origin of the SolidWorks Coordinate

System, and the Z-axis will be directed normally to the chosen view

of the model.

Select the model face6.

With the Select Face method chosen, click on the

model face as shown.

The CoordSys origin is automatically dened in thecorner of the model box. The Z-axis of the CoordSys

is normal to the selected face.

Model box

SolidCAM calculates the box

surrounding the model. The

upper plane of the model box is

parallel to the XY-plane of the

dened CoordSys.

The CoordSys is located in the

corner of the model box with

the following coordinates: (XMIN

,

YMIN

, ZMAX

).

Conrm by clicking on the button. The Coordinate System is dened.

The CoordSys Datadialog box is displayed.

Coordinate system

X

Z

Y


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CoordSys Data7.

This dialog box enables you to dene the Machining levels such as Tool start leveClearance level, Part upper level,etc.

CoordSys Data dialog box

ThePosition eld denes the sequential number of the CoordSyFor each Machine Coordinate System, several Position values ar

dened for different positionings; each such Positionvalue is relateto the Machine CoordSys.

Xshows the X value of the CoordSys.

Yshows the Y value of the CoordSys.

Zshows the Z value of the CoordSys.

The Machine CoordSys number denes the number of the CoordSy

in the CNC-machine. The default value is 1. If you use anothenumber, the GCode le contains the G-function that prompts thmachine to use the specied number stored in the machine controlleof your machine.

The Tool start level denes the Z-level at which the tool startworking.


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The Clearance level is the Z-level to which the tool moves rapidly

from one operation to another (in case the tool does not change).

The Part upper leveldenes the height of the upper surface of thepart to be milled.

ThePart lower level

denes the lower surface level of the part to bemilled.

The Tool Z-levelparameter denes the height to which the tool movesbefore the rotation of the 4/5 axes to avoid collision between the tool

and the workpiece. This level is related to the CoordSys position and

you have to check if it is not over the limit switch of the machine. It

is highly recommended to send the tool to the reference point or to

a point related to the reference point.

The Create planar surface at Part Lower leveloption enables you to

generate a transparent planar surface at the minimal Z-level of the

part so that its lower level plane is visible. This planar surface provides

you the possibility to select points that do not lie on the model entities.

It is suppressed by default and not visible until you unsuppress it in

the FeatureManagerDesign tree.

Conrm the CoordSys Data dialog box with the OKbutton.

The CoordSys Manager dialog box is displayed in the

PropertyManager area of SolidWorks. This dialog box displays

the Machine CoordSys.

Conrm the CoordSys Manager dialog boxwith the button.The Milling Part Datadialog box is displayed again.

Rapid Movements area

Feed Movements areaPartUpper level

Part

Lower level

ToolStart level

Clearancelevel


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Define the Stock model8.

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

Click on the Stock button in the Stock & Target model areaof

the Milling Part Data dialog box.

The Stock model dialog box is displayed. This dialog

box enables you to choose the mode of the Stock model

denition.

Stock model definition modes

2D Boundary this mode enables you to dene the 2D stocgeometry by selecting a chain of geometrical elements (lines, arc

splines, edges, etc.).

3D Model this mode enables you to dene the stock model via 3D

model selection.

Box (Auto) in this mode SolidCAM automatically determines thbox surrounding the model.

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

is displayed.


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This dialog box enables you to select a solid body for the

surrounding box calculation. Optionally, offsets from the

model can be dened. 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.

Click on the button. The Stock model dialog box is

displayed again. Conrm the Stock model denition by

clicking on the button. The Milling Part Data dialog box is

displayed.

Define the Target model9.

SolidCAM enables you to dene the Target model, which is the nal shape ofthe CAM-Part after the machining. SolidCAM uses the Target model for gouge

checking in the SolidVerify simulation.

Click on the Targetbutton in the Stock & Target model area

of the Milling Part Datadialog box. The Target model dialog

box is displayed.


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This dialog box enables you to dene a 3D model for the Target. Click on the Defin3D Model button.

The 3D Geometry dialog box is displayed.


Conrm the selection with the button.

TheTarget model dialog box is displayed again. Conrm it

with the button.

The Milling Part Data dialog box is displayed.

Set the Facet tolerance to 0.01. This parameter denes

the accuracy of triangulation of the stock model, targetmodel and xtures. The triangulated models are used later

when performing the tool path simulation. The more

precise the tolerance is, the better is the performance of

the simulation.

Save the CAM-Part data10.

Conrm the Milling Part Data dialog box by clicking on

the button.

The Milling Part Datadialog box is closed, and the SolidCAM

Manageris displayed. The dened CAM-Part is saved.

At this stage, the denition of the CAM-Part is nished.The denition of Milling operations is covered in thefollowing exercises using this CAM-Part.


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SolidCAM Manager

TheSolidCAM Manager tree is the main interface feature of SolidCAM

that displays complete information about the CAM-Part.

The SolidCAM Managertree contains the following elements:

CAM-Part header

This header displays the name of the current CAM-Part. By right-clicking on it, you can display the menu to manage your CAM-Parts.

The CoordSys Manager subheader is located under the CAM-Part

header. Double-click on this subheader to display the CoordSys

Manager dialog box that enables you to manage your Coordinate

Systems.

SolidCAMManager

CAM-Part header

Operations

Tool header

Machining Processheader

Geometries header

Operations header }


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The Stock and Target subheaders are located under the CAM-Pa

header. Double-click on these subheaders to load the Stock mode

Target model dialog boxesthat enable you to change the denition othe Stock/Target models.

The Settings subheader is also located under the CAM-Part heade

Double-click on this subheader to load the Part Settings dialog bothat enables you to edit the settings dened for the current CAMPart.

Tool header

This header displays the name of the current Tool Library. Double

click on this header to display the Part Tool Table, which is the list o

tools available to use in the current CAM-Part.

Machining Process header

This header displays the name of the current Machining Proces

table.

Geometries header

This header displays all SolidCAM geometries that are not used in th

operations.

Operations header

This header displays all SolidCAM operations dened for the currenCAM-Part.

Close the CAM-Part11.

Right-click on the CAM-Part header in the

SolidCAM Manager tree and choose Close fromthe menu.

The CAM-Part is closed.


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SolidCAM 2.5D

Operations 3


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SolidCAM offers you the following types of 2.5D Milling operations:

In SolidCAM, an operation is a single machining step. A workpiece is usually manufactured using

several machining steps and technologies. For each of these steps you can dene a separate operation.An operation can be very complex, but it always uses one tool, one major geometry and executesone machining type, e.g. Prole Milling or Drilling. You can edit any single machining operation,change the operation sequence and generate the GCode, combining and splitting the operation list

of your CAM-Part.

The Machining Geometry has to be dened for each operation. The Geometry prompts SolidCAMwhat and where you want to machine.

A Geometry for Prole, Pocket, Contour 3D, Slot and T-Slot operations consists of anumber of chains. Chain geometries are dened by selecting the following entities: edgesof models, 2D curves, 3D curves, circles, lines and splines. Each chain is composed of

one or more entities and denes an open or closed contour.

A Geometry for Face Milling operations can be dened by selecting solid models, facesor chains of model elements.

A Geometry for Drilling operations consists of one or more points (drilling centers) thatcan be dened by a number of methods directly on the solid model.

A Geometry for Drill Recognition and Pocket Recognition operations is determinedautomatically by SolidCAM Automatic Feature Recognition functionality.

2.5D Milling Operations

Slot

T-Slot

Pocket Drilling

Drill RecognitionPocket Recognition

Face Milling Thread Milling

Contour 3D

Profile


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3. SolidCAM 2.5D Operation

Face Milling Operation

This operation enables you to machine large at surfaces with facemill tools.

Profile Operation

You can mill on or along a contour. The prole geometry canbe open or closed. In prole milling you can optionally use

tool radius compensation to the right or to the left side of the

geometry. SolidCAM offers two types of proling:

Milling a single prole to the specied constant orvariable depth in one step or in several user-deneddown steps.

Concentric proles to the specied constant or variable depth; this type of prolingenerates several concentric proles that start from the dened clear offset distance from

the prole, and nish on the prole geometry, thus clearing the area around the prole t

a constant depth.

Pocket Operation

In pocket milling, you have to remove material from the interior of

a closed geometry. SolidCAM offers two types of pocketing:

When a prole geometry consists of one or moreproles and none of them are enclosed or intersect with

one another, each is milled as a separate pocket withoutislands.

When a prole geometry consists of several proles, anyprole that is enclosed or intersects with another prole istreated as an island. You can dene an unlimited numberof islands within a single pocket.


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Contour 3D Operation

This operation enables you to utilize the power of the 3D Engraving

technology for the 3D contour machining. In this operation,

SolidCAM enables you to prevent the gouging between the tool and

the 3D contour.

Thread Milling Operation

This operation enables you to generate a helical tool path for

the machining of internal and external threads with thread

mills.


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Exercise #2: Guide Machining

In this exercise, you use the CAM-Part dened in the Exercise #1.You have to dene several 2.5D operations in order to machine

the guide faces represented on the picture.

In the process of denition of operations, you have to denethe machining geometry, the tool and several technological

parameters.

Open the CAM-Part1.

Click SolidCAM,Open.

In the browser window, choose Exercise1 the CAM-Partprepared in the previous exercise.

The CAM-Part is loaded.


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Add an operation2.

Right-click on the Operations header inSolidCAM Manager and choose Profile

from the Add Operationsubmenu.

The Profile Operation dialog box isdisplayed.

In this operation, the lower steps are

machined.

Define the Geometry3.

The rst step of denition of each operation is the Geometry selection. At this stagyou have to dene the Geometry for the Prole operation using the solid modegeometry.

Click on the Definebutton

in the Geometry page of

the Profile Operation dialog

box.


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The Geometry Edit dialog boxis displayed in the SolidWorksPropertyManager area. This dialog box enables you to add

and edit geometry chains.

When this dialog box is displayed, you can select solid model

entities for the Geometry denition.

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

The arrow at the start point

of the selected entity indicates

the direction of the Geometry.

In SolidCAM operations, the

direction of the chain geometry is

used for the tool path calculation.

In the Prole Milling, the tool

moves in the direction of the

geometry by default. In this

exercise, the combination of

the geometry direction and the

clockwise direction of the tool

revolution enables you to perform

climb milling.

Tool revolutiondirection

Tool movementdirection

Geometrydirection


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Click on the Accept chain button in the Chain listarea

to conrm the chain.

The chain icon is displayed.

Dene the second chain. Rotate themodel and select the model edge as

shown.

The direction of the selected chain

is the same as that of the rstchain. This means that conventionalmilling will be performed. In order

to switch to climb milling, reverse

the chain direction.

Click on the Reverse button.

The chain direction is reversed.

Click on the Accept chain

button to conrm the chain.

The second chain icon is displayed in the Chain list area.

Undo step

This button enables you to undo the last selection of a chai

element.

Reject chain

This button cancels the single chain selection.

At this stage, the Geometry is dened. Conrm the Geometry selection with thebutton. The Profile Operation dialog boxis displayed.


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Define the Tool4.

At this stage, you have to dene the tool for the Prole Milling.

Switch to the Tool page of theProfile Operation dialog box and click on the Select

button.

The Part Tool Table dialog box is displayed.


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The Part Tool Table contains all tools available for use to machin

a specic CAM-Part. The Part Tool Tableis stored within the CAMPart.

The Part Tool Table dialog box enables you to manage the tool

contained in the Part Tool Table.

Currently, the Part Tool Table is empty. Dene a new tool suitable for Prole milling.

Click on the Add button to start the tool denition.

The Tool typedialog box is displayed.

This dialog box enables you to add a new tool to the tool library.


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Tool types

SolidCAM offers you the following default tool types suitable for the

Prole operation:

End Mill/Bull nose mill/Ball nose mill

These tool types are used for the denition of rough/nish mills. The

tool shapes and basic parameters are shown below:

OutsideHolderLength

Cutting

Length

Arbor Diameter

Diameter

TotalLength

ShoulderLength

OutsideHolderLengthCutting

Length

Corner Radius

Arbor Diameter

Diameter

TotalLength

ShoulderLength

Outside

HolderLengthCutting

Length

Corner Radius

Arbor Diameter

Diameter

TotalLength

ShoulderLength


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Face mill

This tool type is used for machining of large at surfaces. A tool othis type is dened with the parameters shown in the image.

Taper Mill

This tool is used for milling internal/external walls with a consta

draft angle. In 2.5D milling operations, only the bottom diameter

taken into account in the tool path calculation.

OutsideHolderLength

CuttingLength

Arbor Diameter

Diameter

Tip Diameter

Total Length

ShoulderLength

Angle

OutsideHolderLength

CuttingLength

Angle

Diameter

TipDiameter

CornerRadius

ArborDiameter

TotalLength Shoulder

Length

ConeLength


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In this Prole operation, an end mill of 10will be used.

Click on the End mill tool to choose it for the operation. The Tool typedialog box is

closed automatically, and thePart Tool Tableis displayed again.

Set the Diametervalue to 10.

In the Lengtharea, dene the following parameters:

Set the Total lengthto 80;

Set the Outside holderlength to 72;

Set theShoulder length to 60;

Set the Cutting lengthto 50.

Click on the Selectbutton to conrm the tool parameters and choose the tool for theoperation.

Outside HolderLength

CuttingLength

Diameter

ShoulderLength

Total Length


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Define the Feed and Spin parameters5.

Click on the Data button in the Tool area of the Profile

Operation dialog box.

The Operation Tool Datadialog box is displayed.

Set the Spin Rate (used in roughmilling) and the Spin Finish (used innish milling) parameters to 6000.

Set the Feed XY (feed rate for XY

movements) to 1500and the Feed Z(feed rate for Z movements) to 250.Set the Feed Finish (feed rate fornish milling) to 1800.

Click on the OKbutton to conrmthe dened tool data. The ProfileOperation dialog boxis displayed.

Define the Profile depth6.

SolidCAM enables you to dene the depth using the solid model data. Switch to thLevelspage of the Profile Operation dialog box.

Upper level

This parameter denes the Z-level at which the machining starts.

Depth

This parameter denesthe Z-level below

which the tool does

not mill. This plane isnot penetrated in any

milling strategy.

In this exercise, the Upper level is 0because the Coordinate System is dened on thmodel top face.

XZ

Y

CoordinateSystem

Upperlevel

Depth


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Click on theProfile depth button in the Milling levelsarea.

The Pick Lower level dialog box is displayed.

SolidCAM enables you to dene the lower machining leveldirectly on

the solid model. The Profile depthvalueis calculated automatically as

the difference between the Upper level and Lower levelvalues.

The Lower level parameter is associative to the solid model.

Associativity enables the synchronization in case of solid model

change: the CAM data is updated automatically when the model is

modied. The Profile depthparameter is indirectly associative. Theassociativity is established for the Lower level. When 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 levelvalue (-10) is displayed in the Pick Lower level dialog box. Conrm th

Pick Lower leveldialog box with the button. The

Profile depth value of

10displayed in the Profile Operation dialog box. The pink background of the Profil

depthedit box means that the parameter is associative with the solid model.

Define the technological parameters7.

Switch to the Technology page of the Profile Operation dialog box.


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Modify

The Tool side option enables you to determine the tool position

relative to the geometry.

Right the tool cuts on the right side of the prole geometry.

Left the tool cuts on the left side of the prole geometry.

Middle the center of the tool moves on the prole geometry(no compensation G4x can be used with this option).

TheGeometry button displays the Modify Geometrydialog box that

enables you to dene the modicationparameters of the geometryand to choose which geometry chains are active in the operation (incase of multiple chain geometry). The chain geometry of the proleis displayed on the model with the chain direction indicated and a

circle representing the tool relative to the geometry.

In this case, the default Leftoption meets the requirements of the climb milling. Click

on the Geometry button to check the tool position.

Click on the button in the Modify Geometry

dialog box.

The Profile Operation dialog box is displayedagain.

SolidCAM enables you to perform the rough and nish machining of the prole in asingle Prole operation.

Dene the parameters of the Prole roughing. Select the Roughcheck box. Dene theStep downparameter for roughing.

Left Right Middle


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Step down

Prole roughing is performed in constant Z-passes. The Step dowparameter denes the distance between each two successive Z-level

Set the Stepdownto 3. With this value, SolidCAM performs three cuts at the followinZ-levels: -3, -6,-9; the last cut is performed at the Z-level dened by Profile depth: -10

The distance between the Z-levels of the last cut and the preceding cut is smaller tha

that between the previous cuts, because the machining depth value is not divisibl

exactly by the Step downvalue.

In this operation, use the Equal step downoption to keep an equal distance betwee

all Z-levels.

Equal step down

This option enables you to

perform all cuts at an equal

Z-level distance one from the

other. SolidCAM automatically

calculates the actual step down to

keep an equal distance between

all passes.

When the Equal step downcheck box is selected, Stepdown

is replaced by Max. Step down.

This value is taken into account

during the calculation of the

actual step down so that it is not

exceeded.

Max.Step down

Actual Step down

Step Down

Upper level

Profile Depth


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With the Max. Step downvalue set to 3, the actual step

down is automatically calculated as the largest possible

value within the bounds of 3 so that the machining depth

can be divided exactly into equal Z-levels. Four roughing

passes will be performed at the followings Z-levels: -2.5, -5,

-7.5, -10with the Step down of 2.5 mm.

Now you need to dene the wall and oor offsets that will remain after the roughingpasses.

Offsets

The Wall offsetand Floor offset parameters enable you to dene theallowances that remain on the walls and the oor of the machinedpart till the prole nish machining. These allowances can be removed

with the nish passes in the same Prole operation or in an additionalProle operation with another tool.

In the Offsetssection, set the Wall offsetand Floor offset

values to 0.2. The allowance of 0.2 mm is left on the walls

and the oor of the steps during the prole roughing. Thisallowance is removed with a separate nishing cut in the

end of the prole machining.

Select the Finish check box to perform the nishing ofthe prole. Set the Step downfor the prole nishing to10 mm.

Step downWall offset

Profile depth

Floor offset


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8. Define the Lead in and the Lead out

Switch to the Link page of the Profile Operation dialog box.

This page enables you to dene the way the tool approaches the prol

and retreats away. The lead in movement is necessary to prevent vertic

entering of the tool into the material. With the lead in strategies th

tool descends to the machining level outside of the material and the

horizontally penetrates the material with the lead in movement. The lea

out strategy enables you to perform the retract movements outside th

material.

The following options are available:

None

The tool leads in to and out from the milling level exactly adjacent tthe start point of the prole.

Normal

The tool leads in to and out fromthe prole from a point normalto the prole. The length of thenormal can be set in the Value

eld.

Approac

value


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Arc

The tool leads in to and out from

the prole with a tangential arc. Thearc radius can be set in the Value

eld.

Tangent

The tool leads in/out on a line

tangent to the prole. The length ofthe tangent can be set in the Value

eld.

Point

The tool leads in/out from a user-dened position. From this position,the tool moves on a straight line to the start point of the prole.

When you select this option, the Pickbutton is activated so that you

can select a position directly on the solid model.

When the Same as lead in check box is selected, the strategy and

parameters dened for Lead inare used for Lead out.

Under Lead in, choose the Tangent option from the list

and set the Valueto 6.

Under Lead out, select theSame as Lead incheck box.

The denition of the basic technological parameters ofprole milling is nished.

Calculate the Tool path9.

Click on the Save & Calculatebutton. The Prole operation data is saved and the toolpath is calculated.

Approach

value

Approachvalue

Normal


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Simulate the operation10.

Click on the Simulatebutton 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 dened in Exercise #1 is used in the SolidVerif

simulation mode. During the machining simulation process, SolidCAM

subtracts the tool movements (using solid Boolean operations) from thsolid model of the stock. The remaining machined stock is a solid mod

that can be dynamically zoomed or rotated. It can also be compared to th

target model in order to show the rest material.

When the simulation is nished, play the it step by step using the button.

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


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The Host CADsimulation mode enables you to display the tool path directly

on the model in the SolidWorks window. Since all the View options of

SolidWorks are active during the simulation, you can see the tool path from

different perspectives and zoom on a certain area of the model.

Close the simulation with the Exit button. TheProfile

Operation dialog box is displayed.

Close the Profile Operation dialog boxwith theExitbutton.

The SolidCAM Manager tree is displayed. The Proleoperation entry is displayed under the Operationsheader

in SolidCAM Manager.

Add a Profile operation11.

Dene a new Prole operation to machine the faces of the guide steps as shown.

Right-click on the Prole operation entryin SolidCAM Managerand choose Profile

from the Add Operationsubmenu. A new

operation is added after the rst Proleoperation.

The Profile Operation dialog box is

displayed.


Click on the Define button in theGeometry page 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 chain

enables you to perform climb milling.

Click on the Accept chain button

in the Chain list section to conrmthe chain. The chain icon is displayed.

Dene the second chain. Rotate themodel and select the model edge as

shown.

The direction of the selected chain is

the same as that of the rst chain.

Click on the Reverse button. The

chain direction is reversed to perform

climb milling for this side too.

Click on the Accept chain button

to conrm the chain.

The second chain icon is displayed in the Chain list section. At this stage, the geometr

is dened. Conrm the geometry selection with the button. The Profile Operatio

dialog box is displayed.

Define the Tool13.

In this operation, use the same tool that was dened in the previous operation. Thtool data is saved in the Part Tool Table.

Switch to theTool page and click on the Selectbutton.



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Double-click on the tool #1, the end mill tool of10dened in the previous operation.The tool is chosen for the current operation.

Click on the Databutton in the Toolarea.

The Operation Tool Datadialog box is displayed.

Set the Spin Rateand Spin Finishto 6000.

Set the following feed data:

Set theFeed XY

to800

; Set the Feed Zto 200;

Set the Feed Finish to1000.

Conrm the tool data denitionwith the OK button. The Profile

Operation dialog box is displayed.

Define the Profile depth14.

Dene the depth of the prole milling. As in the previous Prole operation, the Proledepth is dened by picking an entity on the solid model.


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Switch to the Levelspage and click on

theProfile depth button in the Milling

levelsarea.

The Pick Lower level dialog box is

displayed.

Click on the model face as shown.

The Lower levelvalue (-3) is displayedin the Pick Lower level dialog box.

Conrm the lower level selection with

the button. The Profile depth

value 3 is displayed in the Profile


Note the Clearance level and the Safety distance

parameters.

Clearance levelis the Z-level to which the tool retreats when movin

from cut to cut.

Safety distance is the distance to the Upper level at which the too

starts moving at the Z feed rate you have dened. Movements from

the Clearance level to this height are performed in the rapid mode.These parameters are dened during the Coordinate System denitioand are default for each operation that is using this Coordinate System

However, these parameters can be customized for each operation.


Switch to the Technologypage of the Profile


In this case, the default Left option set for

Tool side meets the requirements of the

climb milling. Click on the Geometry button

to check the tool position.

Close the Modify Geometry dialog box with

the button and return to the Profile



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Now you have to dene the parameters of the prole roughing and nishing.

Select the Rough check box. Set the Step down to1.5mm. With this value, SolidCAM performs two cuts at

the following Z-levels: -1.5; -3.

In theOffsets

section, set theWall offset

and theFloor

offset to 0.2 mm. These offsets are removed with a separate

nish cut in the end of the prole machining.

Select the Finish check box to perform the nishing ofthe prole. The nish pass removes the 0.2mm allowanceleft after the roughing. Set the Step downfor the prolenishing to 3 mm.

Define the Lead in and the Lead out16.

Switch to the Linkpage of the Profile Operation dialog box. In

the same manner as explained in theStep #8of this exercise,

choose the Tangent option from the Lead in list and set the

Valueto 6.

Under Lead out, select theSame as Lead incheck box.

The denition of the basic technological parameters of theprole milling is nished.

Calculate the Tool path17.

Click on the Save & Calculatebutton. The Prole operation data is saved and the toolpath is calculated.


Click on the Simulate button in the ProfileOperation dialog box. The Simulation control

panel is displayed.

Switch to the SolidVerify page and start the

simulation with the Play button.


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

displayed.

Close the Profile Operation dialog boxwith theExitbutton.

Counterbore holes machining

At this stage, you have to machine two counterbore holes located o

the top face of the guide.

The machining is performed in

three stages. At the rst stage, centerdrilling is performed to pre-machine

the holes. Then a drilling operation is

used to machine the through holes.

After the drilling, the counterbore is

milled.


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61/29061


3 Points on circumference

Usually, all curves and arcs of imported models are converte

into splines by the exporting CAD system. Due to the natur

of spline curves or surface boundaries, you cannot pick

center position like you could on a circle or an arc. SolidCAM

calculates the center position of an arc dened by three poinpositioned on the spline edges. This facilitates selecting dri

centers on spline surfaces.

Multi-positions

You can select the model face. SolidCAM automaticallrecognizes all arcs/circles located on the selected face an

selects the center points as drill positions.

All circle/arc centers

SolidCAM searches the solid model for arcs and circles an

adds all center points as drill positions to the geometry.

Choose the All circle/arc centers

option and click on the corresponding

button.

Two drill positions are selected. Their

coordinates are displayed in the XY

Drill Geometry Selectiondialog box.

Click on the button to conrm the geometry selection. The Drilling Operatio



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Define the Tool21.

Switch to the Tool page of the Drilling Operation dialog

box and click on the Select button.


Click on the Addbutton to start a new drilling tool denition. The Tool typedialog boxis displayed. Choose the Center drilltool for the operation.

Center drill

This tool type is used for center drilling in Drilling operations. A tool

of this type is dened with the parameters shown in the image.

OutsideHolderLength

Tip Diameter TipLength

Total

Length

ShoulderAngle

CuttingLength

Angle

ArborDiameter


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Dene the tool parameters as follows:

Set the Tip Diameterto 6;

Set the Tip Angle to 90.

Click on the Selectbutton to choose the tool for the operation.

The Drilling Operation dialog box is displayed. Click on the

Databutton in the Tool area.

The Operation Tool Datadialog box is displayed. Dene

the spin and the feed for the operation.

Set the Spin Rate to 1200;

Set the Feed Zto 200.

Click on the OKbutton to conrm the parameters denition. TheDrilling Operatiodialog boxis displayed.


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Define the center drilling depth22.

Switch to the Levelspage and set the Drill depthto 3.

Calculate the tool path23.

Click on the Save & Calculate button. The Drilling

operation data is saved and the tool path is calculated.


Click on the Simulatebutton in the Drilling

Operation dialog box. The Simulation control

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 is displayed.

Close the Drilling Operation dialog boxwith

theExitbutton.

Add a Drilling operation25.

Right-click on the last Drilling operation and choose Drillingfrom the Add Operation

submenu.

The Drilling Operation dialog box is displayed.


This operation is using the geometry that was dened inthe center drilling operation. Choose the Drill geometryfrom the list in the Geometryarea.

Each geometry dened in SolidCAM has a unique name. When the geometryis being dened, it is assigned a default name that can be changed. Using thisname, you can choose the geometry for the specic operation.


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Define the Tool27.

Dene a new drilling tool of 5.5 for this operation.

Switch to the Toolpage and click on the Select button in the Tool area.

The Part Tool Table dialog box is displayed. Click on the Addbutton. The Tool typ

dialog box is displayed. Choose the Drilltool.

Set the Diameterto 5.5.

In the Lengthsection, set the following parameters:

Set the Totalto 70;

Set the Outside holderto 60;

Set the Shoulderlengthto 50;

Set the Cuttingto 40.

Click on theSelect

button to choose the tool for the operation.

The Drilling Operation dialog box is displayed. Click on theDatabutton in the Toolarea.


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The Operation Tool Datadialog box

is displayed. Dene the spin and thefeed for the operation.

Set the Spin Rate to 3000;

Set the Feed Zto 360.

Click on the OKbutton to conrm

the settings. TheDrilling Operation

dialog boxis displayed.

Define the drilling depth28.

The overall height of the guide is 30 mm. The drilling

has to be performed deeper than this value in order to

enable the tool to exit from the material to performthe through drilling.

Switch to theLevels page and click on the Upper level

button. Select the top face of the model as shown.

Conrm the Pick Upper level dialog box byclicking on the button. The value (0) isdisplayed in the Milling levels area, and the

pink background of the edit box means that

this value is associative with the solid model.

Click on the Drill depth button. Rotate the

model and select the bottom face as shown.

Conrm the Pick Lower level dialog box.

The value of 30enables you to perform thethrough drilling.

Dene the Delta depth.

The Delta depthparameter denes the offset for the cutting depththat can be changed with its associativity preserved. The Delta depth

value is always relative to the Depthdened for the operation.

Height


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Set the Delta depthvalue to -1.

To perform the through drilling, use the Depth typeoption.

Depth type

This option enables you to deepen the drilled hole in order to obtaia given diameter at the specied drill depth.

Cutter tip

The drill tip reaches the dened drill depth.

Full diameter

The drill reaches the dened drill depth with the full diameter.

Diameter value

The drill reaches the dened drill depth with the drill cone diametespecied in the edit box.

The Diametervalue can vary from 0all the way up to the drill too

diameter. A value greater than the drill tool diameter is automaticall

decreased to the drill tool diameter.

In the Depth typearea, choose the Full diameteroption.

With this option, the drilling is performed until the full

diameter is reached at the specied drill depth. This meansthat the cone part of the tool exits from the material.

Drill

depth

Cutter tip Full diameter Diameter value

Drilldepth

Drill

depth

Diametervalue


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Define the Drilling type29.

SolidCAM enables you to use a number of drill canned cyclessupported by your CNC-

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 during the

drilling process.

Switch to the Technologypage and click on the Drill cycle type

button. The Drill Cycledialog box is displayed.

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

operation.

Click on the Databutton to dene the pecking parameters.The Drill Options dialog box is displayed. Set the Step down

to1.5in orderto dene the depth of each pecking movement.

Conrm the data with the OK button.


Click on the Save & Calculatebutton.

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


Click on the Simulate button in the Drilling

Operation dialog box. The Simulation control

panel is displayed.

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

Close the simulation with the button. The

Drilling Operation dialog box is displayed.

Close the Drilling Operation dialog boxwith the

Exitbutton.

Now you have to machine the counterbores.


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Add a Pocket operation32.

The Pocket operation is used for the counterbore machining. Right-click on the la

dened Drilling operation and choose Pocket from the Add Operationsubmenu.

The Pocket Operation dialog box is displayed.


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33. Define the Geometry

The geometry for a Pocket operation is represented

by a number of closed chains. In this exercise, you

have to dene two chains using the solid modeledges as shown.

Click on the Definebutton in the Geometry page to

start the geometry denition.

The Geometry Edit dialog boxis displayed.

In the Multi-chain section, click on the Addbutton.

The Chains Selection dialog box is displayed. This dialog boxenables you to dene the chain geometry by selecting the facesof the solid model. When a face is selected, SolidCAM collects

all solid model edges of the face and builds the chains.

Click on the face as shown.

The face is selected. SolidCAM highlights all face edges.

Conrm the face selection with the button. The

Geometry Edit dialog box is displayed. Three chainscollected from the selected face are listed in the Chain List

area.

Select the Chain #1 in the list. This chain represents the

external boundary of the selected face, which is not relevant

for the current operation and has to be deleted. Right-click

on the chain in the list. The menu is displayed.


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72/29072

Conrm the message with the Yes button. The chain is removed. The remainingchains are used for the geometry denition. Conrm the Geometry Editdialog box

with the button. The Pocket Operationdialog box is displayed.

Define the Tool34.

Dene a new milling tool for the operation. Switch to the Tool page and click on theSelectbutton.


Click on the Add button to add a new tool to the Part Tool Table. The Tool typedialogbox is displayed. Choose the End milltool for the operation.

Set the Diameterof the tool to 8.


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Click on the Selectbutton to choose the tool for the operation. The Pocket Operatio


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

displayed. Dene the spin and the feed for the operation.

Set theSpin Rate

and theSpin

Finishto 6000.

Set the following feed data:

Set the Feed XYto 1500;

Set the Feed Zto 250;

Set the Feed Finish to1700.

Conrm the dialog box with the OKbutton.

The Pocket Operation dialog box is displayed.

Define the Pocket depth35.

Dene the Pocket depth directly on the solid model.Switch to the Levelspage and click on the Pocket depth

button. The Pick Lower level dialog box is displayed in

the SolidWorks PropertyManagerarea.

Click on the bottom face of the counterbore as shown.

Conrm the selection with thebutton. The depth value (3.58) determined.


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Define the Step down36.

In this case, the material is machined in one step, so theStep downvalue is equal to 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. Switch to the Technology page of the Pocket Operation dialog box.

The Offsets area enables you to dene the offsets that

remain on the pocket after the rough machining. These

offsets are removed during the nishing. Set the Wall offset

and the Floor offset to 0.2.

Make sure that the default Contour pocket machining

strategy is chosen in the Technology list.

When the Contour strategy is chosen, the tool moves on offsets

parallel to the pocket contour.

You can dene the Overlap of the adjacent toolpasses as aPercentage of the tool diameter or

as a Value.

Overlap


75/29075


In the Finisharea, select the Wall and Floor check boxes.

These options enable you to perform nishing of theWall offset and the Floor offset that remain after the

roughing.

Define the Ramping strategy38.

Switch to the Linkpage of the Pocket Operation dialog

box. Dene the strategy with which the tool is plunginginto the material during the pocket roughing.

The following Ramping strategies are available for rough machining o

pockets:

None

The tool enters the material vertically at the pocket start point chose

automatically by the SolidCAM pocket algorithm.

Vertical

The tool enters the material vertically at a user-dened position. Fromthis position, the tool moves to the pocket start point calculated b

the pocket algorithm. Use the Pick button to specify the positio

where the tool plunges into the material.

Angle

The tool moves to the pocket start point at a specied ramp anglThe start point must be selected using the Pick button. Enter th

ramping angle value into the Anglebox.SolidCAM does not check the ramping movement against the pocke

contour. Check the tool path simulation to make sure that the too

does not gouge the pocket walls or islands.


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Helical

The tool descends from the safety distance above the Upper levelto

the material in a circular motion until the step down is reached using

the user-dened radius. When the tool reaches the step down depth,it machines all the material at the step down depth. Click on the Data

button to set the helical ramping parameters.

Linear

The Linear ramping follows the same rules as the Helical ramping.

The difference is that the descent is performed in a linear zigzag

fashion rather than in a circular one.

In this exercise, the Vertical strategy is used

to perform the plunging in the center of thedrilled hole.

Choose the Verticaloption from the list.

In this exercise, the model contains the sketchwith the center points of the holes. This sketch

was created by the SolidWorks Hole Wizard

during the counterbore holes modelling.

Switch to the SolidWorks FeatureManager Design tree.

In the SolidWorks FeatureManager Design tree, click on the icon near the

DesignModel component of the CAM-Part assembly to expand it and see all features

of the model.

Expand the last feature named CBORE for M5 Hex Head Bolt1by clicking on the

icon.

This feature is based on two sketches: one of them contains the geometry of the hole

section and the other the center points of the holes. These sketches are hidden by

default.


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Right-click on Sketch3under the counterbore feature

and click on the Show button in the upper menu.

The sketch is displayed.

In the Ramping area of the Pocket Operation dialog

box, 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 dene the entrancepoint for each chain used in the Pocket operation.

The schematic tool facilitates the selection.

Select the center point as shown.

In the Approach point dialog box, click on the Next Profile button to dene thentrance point for the next chain. Select the center point as shown.

Conrm your selection with the Finish button.


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Define the Lead in strategy39.

The Lead inoption is used for dening the horizontal approach of the tool to thegeometry in the nish machining of the part walls.

The following Lead instrategies are available for pocket machining:

None

The tool leads in to the milling level exactly

adjacent to the start point of the geometry.

Normal

The tool approaches at the last point of

the prole with a movement normal to the

pocket contour.

Arc

The tool approaches the prole with a

circular motion, tangent to the last entity ofthe pocket contour.

Tangent

The tool approaches the pocket wall in a

movement tangent to the last prole entity.

Lead in

value

Lead in

value

Lead in

value

Normal


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Choose the Noneoption for Lead in.

Define the Lead out strategy40.

Now you have to dene the movement of the tool when it

retreats from the pocket contour after the nishing cut.In the Lead out area, choose the Arc option, set the value to 1

and click on theDatabutton.

The Arc Lead out datadialog box is displayed.

Arc angle

This parameter denes the angle of the retreat arc segment. The defauangle value is 90; SolidCAM generates a retreat path of quarter arc.

Lead out from

With theArc Lead outoption, the tool moves by the retreat arc to tharc end point and then moves normally at the specied distance. Thfollowing options are available:

Distance

The tool nishes the lead out movement at the specied distancfrom the arc end point.

Center

The tool nishes the lead out movement at the retreat arc center.

Angle Angle Distance

Lead out from DistanceLead out from Center


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Click on the OK button to conrm the Arc Lead out datadialog box.


Click on the Save & Calculatebutton.

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


Click on the Simulatebutton 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 out movements.

Close the simulation with the

button. ThePocket Operation dialog

box is displayed.

Close the Pocket Operation dialog

boxwith theExitbutton.

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

machined using two positionings.

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


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83/29083


Load the SolidWorks model1.

Load the Exercise3.sldprtmodel that is located in theExercisesfolder.

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

Start SolidCAM2.

To activate SolidCAM, click on the

SolidCAM eld in the main menu ofSolidWorks and choose Milling from

the New submenu. SolidCAM is started

and the New Milling Part dialog box is

displayed.


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Confirm the CAM-Part creation3.

Conrm the default Directory, CAM-Part Nameand Model nameby clicking on the OKbutton in the New Milling Partdialog box. The CAM-Part is dened.

Choose the CNC-controller4.

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

Select the CNC-machine controller. Click on the arrow in the CNC-Controllerarea to

display the list of post-processors installed on your system.

In this exercise, you use a 3-Axis CNC-machine with the

Awea1000-FanucCNC-controller. Choose the Awea1000-

Fanuc CNC-controller from the list.

Define the Stock model5.

In this exercise, you have to dene the Stock model before youdene the Coordinate System in order to use the workpiecefor the CoordSys denition.

Set the Facet toleranceto 0.01.

Click on the Stock button in the Stock & Target modelarea

to start the denition process. The Stock model dialog box is

displayed.


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When the Coordinate System is not dened, SolidCAM enables you to usonly the Box (Auto)method of the Stock model denition.

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

displayed.

SolidCAM generates the stock box surrounding the modelwith the specied allowances. In the Expand box at section,set the value of the Z-parameter direction to 5. This allowance

is used for the rst clamping. Set the value of 2for the rest ofthe directions.

Click on the model. The model is highlighted and the box

surrounding the model is displayed.

Click on the Add box to CAD modelbutton. The stock model box is added into thCAM component of the CAM-Part assembly as a 3D Sketchfeature.

Conrm the Stock model denition with the button. Conrm the Stock mode

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

Define the Coordinate System6.

Click on the Define button in the Coordinate System area to

start the Coordinate System denition.


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Conrm the CoordSys Datadialog boxwith the OK button.

The icon of the dened Coordinate System is displayed in the CoordSys Manage

dialog box.

Conrm the CoordSys Manager dialog boxwith the button. The Milling Part Dat

dialog box is displayed again.

Define the Target model7.

Click on the Target button in theStock & Targetarea of the Milling Part Datadialo

box.

The Target model dialog box is displayed.

This dialog box enables you to dene a 3D model for theTarget. Click on the Define 3D Model button.

The 3D Geometry dialog box is displayed.


Conrm the selection with the button.

TheTarget model dialog box is displayed again. Conrm it with the button.

The Milling Part Data dialog box is displayed.


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Save the CAM-Part data8.

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

The Milling Part Data dialog box is closed, and SolidCAM Manager is displayed. The

dened CAM-Part is saved.

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

At the next stage, you have to dene several operations to machine the cover part.Using the rst dened Coordinate System (rst clamping), you have to perform thefollowing 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, th

following operations are performed:

Upper face machining

Pocket machining

Slot machining

Holes machining


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Add a Face Milling operation9.

In SolidCAM Manager, right-click on the Operationsheader and choose Face from

the Add Operation submenu. The Face Millingoperation is used for the upper face

machining.

The Face Milling Operationdialog box is displayed.


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Define the Face Milling geometry10.

Click on the Definebutton in the Geometrypage. The Face Milling Geometry dialo

box is displayed.

The Base Geometry section enables you to dene the face millingeometry using the following methods:

Model

This option generates a rectangle located at the XY-plane ansurrounding the Target model and selects it for the Face Millin

geometry. The rectangle chain is displayed in the Chain Lis

section.Face Milling geometry


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Faces

This option enables you to dene the Face Milling geometry byface selection. The Definebutton and the related combo-box

enable you either to dene a new faces geometry with the SelectFaces dialog box or to choose an already dened geometry

from the list. When the model faces are selected, SolidCAMgenerates a number of chains surrounding the selected faces.

These chains are displayed in the Chain List section.

Profile

This option enables you to dene the Face Milling geometry bya prole. The Define button and the related combo-box enableyou either to dene a new prole geometry with the GeometryEdit dialog box or to choose an already dened geometry fromthe list. The dened chains are displayed in the Chain List

section.

Face Milling geometry

Selected faces

Face Milling geometry


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In the Base Geometry section, use the default Model option for the Face Millin

geometry denition. Click on the Define button. The 3D Geometry dialog box displayed.

This dialog box enables you to dene the 3D Model geometry bselecting the following types of model elements:

Solid only solid objects are selected;

Surfaces only surfaces only areselected;

Both both surfaces and solids will beselected.

The CAD selection button enables you

to select the 3D geometry with theSolidWorks tools.

You can select an object by clicking on

it. When an object is selected, its icon isdisplayed in the list in the bottom of the

dialog box. To unselect the object, clickon it again or right-click on its icon in

the list of selected elements and chooseUnselect

from the menu. To removeselection from all objects in the list, clickUnselect all.

Click on the solid model to select it. The model is highlighted, and its icon appears i

the list. Conrm the 3D Geometry dialog box by clicking on the button. The FacMilling Geometrydialog box is displayed again.


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The rectangle is generated surrounding the Target model at the XY-plane.

Dene the 3 mm offset to machine over the stock edges. Inthe Modifysection, set the Offsetvalue to 3.

Conrm the Face Milling Geometry dialog box by clicking

on the button.

The geometry is dened for the operation.

Define the Tool11.

Switch to the Tool page of the Face Milling Operationdialog box. Start the tool denitionby clicking on the Select button. The Part Tool Table dialog boxis displayed.


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In this operation, a face mill of 40will be used.

Click on the Add button to add a new tool. Choose the Face mill tool from the Too

type dialog box. Dene the following parameters:

Set the Shoulder lengthto 15;

Set the Cutting lengthto 10.

SolidCAM enables you to dene a variety of tool holders to help you check and prevenall possible collisions between the tool holding system and the workpiece. This featur

also enables you to see a more realistic simulation in theSolidVerify

simulation.Switch to the Holderpage in the Part Tool Tabledialog box.


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The Global holders table is supplied within SolidCAM. This table

contains a number of frequently used tool holder components. The

Global holders table can be modied by the user.

Select the Use holdercheck box and click on the Global holders table button to choose

a holder from the Global Holders table.

The Tool Holders dialog boxis displayed.

The SolidCAM tool holder is dened by combining two components.The rst component is the tool adaptor mounted on the spindle unitof the milling machine. The second component can consist of various

types of extensions and reductions like collet chucks, arbors, shanksand other components that you may have.

SolidCAM enables you to dene the Tool adaptor in the MAC lewith the following string: mac_holder = BT40.

Tool adaptor

Extensions and reductions


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In the Tool Holders dialog box, choose

the BT40 ER3260 collet chuck. This

collet chuck is suitable for the chosen

tool diameter (40mm).

Click on the OK button to conrm thetool holder denition. The Part Tool Table

dialog box is displayed again.

Choose the dened tool for the operationby clicking on the Select button. The Face

Milling Operationdialog box is displayed.

Define the Face depth12.

Switch to the Levelspage of the Face Milling Operation

dialog box. Click on the Face depth button in the

Milling levels area. This button enables you to dene the

Operation Lower level directly on the solid model. The

depth is calculated automatically as the difference between

the Z-values of the Operation Upper and Lower levels.

The Pick Lower leveldialog box is displayed.

Select the model face as shown.

The Lower level value (-2) is determinedand displayed in the Pick Lower level

dialog box. Conrm this dialog box with

the button. The Pocket depth (2) iscalculated.

The Face depth value is displayed in the Milling levels

area. The pink background of the edit box means that

the parameter is associative to the model. In this case, the

Lower level parameter is associative to the solid model.

Associativity enables the selected level to be synchronized

with the solid model changes; SolidCAM automaticallyupdates the CAM data when the model is modied. ThePocket depth parameter is indirectly associative. When

either the Upper level or the Lower level is synchronized,

the Depthis updated.


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Hatch angle

When the Automatic optional angle option is chosen, SolidCAM

automatically calculates the

SolidCAM2008 R12 Milling Training Course 2 5D Milling

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