SolidCAM2007_R11_2_Milling_training_course_3D_Milling.pdf

8/10/2019 SolidCAM2007_R11_2_Milling_training_course_3D_Milling.pdf

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SolidCAM2007 R11.2

Power and Ease of Use - the winning combination

1995-2008 SolidCAM

All Rights Reserved.WWW.SOLIDCAM.COM

SolidCAM2007 R11.2

Milling Training

Course

3D Milling

The Leaders in Integrated CAM


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SolidCAM2007 R11.2

Milling Training Course

3D Milling

1995-2008 SolidCAM

All Rights Reserved.


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Content

5

Contents

1. Introduction

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

1.2 SolidCAM 3D Machining overview...........................................................................................11

1.3 Process overview ..........................................................................................................................12

2. General 3D Milling

2.1 3D Milling Operation dialog box overview ..............................................................................15

2.2 3D Roughing .................................................................................................................................17

Exercise #1: Mold core roughing .............................................................................................18

Exercise #2: Mold cavity roughing ...........................................................................................47

Exercise #3: Toy mold cavity roughing ...................................................................................57

Exercise #4: Bottle-bottom mold cavity roughing .................................................................58

Exercise #5: Spoon die core roughing .....................................................................................59

2.3 3D Semi-Finishing/Finishing .....................................................................................................60Exercise #6: Cover nishing......................................................................................................63

Exercise #7: Bottle-bottom mold cavity nishing.................................................................71

Exercise #8: Electrode nishing ...............................................................................................82

Exercise #9: Mold cavity nishing ...........................................................................................94

Exercise #10: Mold core nishing ..........................................................................................111

Exercise #11: Electrode pencil milling ..................................................................................121

Exercise #12: Toy mold cavity nishing ................................................................................127Exercise #13: Spoon die core nishing .................................................................................129

Exercise #14: Spoon die cavity nishing ...............................................................................132

Exercise #15: Cavity nishing .................................................................................................134


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Document number: SC3DMTCENG07002

3. 3D Milling of Prismatic Parts

Exercise #16: Cover machining ..............................................................................................139

Exercise #17: Electronic box machining ...............................................................................155

Exercise #18: Connector cover machining ...........................................................................158

4. 3D Milling of Aerospace Parts

Exercise #19: Bracket machining ............................................................................................162

Exercise #20: Aerospace support machining .......................................................................173

5. 3D Drilling

4.1 3D Drilling Operation dialog box overview...........................................................................179

Exercise #21: 3D Drilling of the Mold core ........................................................................181

Exercise #22: 3D Drilling of the Toy mold cavity ..............................................................188

6. 3D Engraving

5.1 3D Engraving Operation dialog box overview ......................................................................191

Exercise #23: 3D Engraving of the Electrode .....................................................................193

Exercise #24: 3D Engraving of the Mold cavity .................................................................199

Exercise #25: 3D Engraving of the Stamp insert ................................................................203


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Introduction 1


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1. Introductio

1.1 About this course

The goal of this course is to teach you how to use SolidCAM to machine various parts using 3DMilling technologies. This course covers the basic concepts of SolidCAM 3D machining and 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.

Prerequisites

Students attending this course are expected to have a basic knowledge of SolidCAM softwarThe course has to be preceded by the SolidCAM 2.5D Milling Training Course, in which the basiconcepts of the SolidCAM software are discussed. Detailed explanations of basic concepts are no

included in this manual.

Course design

This course uses a task-based approach to training. With the guided exercises you will learn th

commands and options necessary to complete a machining task. The theoretical explanations arembedded into these exercises to give an overview of the SolidCAM 3D Milling capabilities.

Using this training book

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

About the CD

The CD supplied together with this manual contains copies of the various les that are usethroughout this course. The Exercisesfolder contains the les that are required for guided anlaboratory exercises. The Built Partsfolder inside the Exercisescontains the nal manufacturinprojects for each exercise. Copy the complete Exercises folder on your computer. The SolidWork

les used for the exercises were prepared with SolidWorks2007.


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WindowsXP

The screenshots in this book were made using SolidCAM2007 R11.2integrated with SolidWorks2007running on WindowsXP. If you are running on a different version of Windows, you may noticedifferences in the appearance of the menus and windows. These differences do not affect theperformance of the software.

Conventions used in this book

This book uses the following typographic conventions:

Bold Sans Serif This style is used to emphasize SolidCAM options,commands or basic concepts. For example, click onthe Change to 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 forthe SolidCAM functionality explanations embedded

into the guided exercises. The lamp icon is also usedto emphasize notes.


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1. Introductio

1.2 SolidCAM 3D Machining overview

SolidCAM provides you with powerful 3D Machining functionality that can be used both foprismatic parts and for complex 3D Models.

For prismatic parts SolidCAM analyzes the model and automatically recognizes pockets and proleto be machined using Constant Z machining strategies. For complex shape models such as molds

electrodes and prototypes, SolidCAM offers powerful 3D Machining, including integrated optionfor material machining.

SolidCAM Milling module enables you to prepare the tool path for the following 3D MillinOperations:

3D Milling Operation

This Operation enables you to calculate the tool pathfor the rough, semi-nish and nish machining of3D Models. A number of strategies can be applied toprovide you with effective and high-quality machining.

3D Engraving Operation

This Operation enables you to perform the engraving

of text or artwork on the part faces.

3D Drilling Operation

This Operation enables you to perform drills that take

into account the 3D Model geometry.

SolidCAM enables you to use holes machined with thisOperation for the Z-Entry in 3D Rough Milling.


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1.3 Process overview

The major stages of creation of the SolidCAM Manufacturing Project are the following:

CAM-Part definition

This stage includes the denition of the global parameters of the ManufacturingProject (CAM-Part). You have to dene a number of Coordinate Systems that describethe positioning of the part on the CNC-machine.

Optionally, you can dene the Stock model and the Target model to be used for therest material calculation. The Stock model describes the initial state of the workpiecethat has to be machined. The Target model has to be reached after the machining. Afterevery Operation, SolidCAM calculates the amount of material actually removed fromthe CAM-Part and the amount of material left not machined (rest material). The restmaterial information enables SolidCAM to automatically optimize the tool path andavoid air cutting.

Technology definition

SolidCAM enables you to dene a number of 3D Milling Operations. During theOperation denition, you have to select the Geometry, choose the Tool from thePart Tool Table (or dene a new one), dene a machining strategy and a series oftechnological parameters.

Generally, the 3D Milling is performed in three major stages: Roughing, Semi-Finishing

and Finishing. At the Roughing stage, the fast and efcient bulk material removal hasto be performed. The nish machining allowance remains for the further Semi-nishand Finish Operations. At the Semi-nishing/Finishing stages, this allowance has to beremoved using a number of strategies that provide excellent surface quality.


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General

3D Milling 2


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You can perform 3-axis gouge-free machining on solid and surface models. This Operation offers awide range of roughing, semi-nishing and nishing strategies for free-form models. It can be usedto manufacture molds, dies, electrodes, prototypes and other 3D Models.


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2. General 3D Millin

2.1 3D Milling Operation dialog box overview

SolidCAM 3D Milling Operationdialog box enables you to dene the parameters of the roughingsemi-nishing and nishing tool path on 3D Model faces.

Geometry section

This section enables you to dene or choose the 3D Model Geometry for thOperation.

Tool section

This section enables you to dene a new Tool for the Operation or choose an existinTool from the Part Tool Table.

Operation name section

This section displays the name of the Operation. When the Geometry and the Toohave been dened, SolidCAM generates a default name (e.g. 3DM_Model_T2) based o

the Operation type, Geometry name and Tool number.

Milling levels section

In this section, you have to specify the Z-levels for the Operation. The default inpuvalues are the CAM-Part values you have specied at the stage of the Coordinat

System denition.

Geometry section

Tool section

Rough section

Milling levels section

Working area section

Operation name section

Tolerance section

Finish section

Operation buttons

Semi Finish section


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Tolerance section

The precision tolerances dened here directly affect the surface quality of your

machined model.

SolidCAM generates the tool path in two steps:

SolidCAM generates a mathematical representation of surfaces and solids of

the 3D Model geometry according to the given Facet tolerance.

SolidCAM calculates the tool path according to the value of the Tool pathtolerancethat denes the accuracy of the tool path.

Working area section

SolidCAM enables you to limit the tool path with a specied Working area. When theWorking area denition is used, SolidCAM calculates the whole tool path and thenremoves all tool path lines lying outside the Working area.

Rough section

Rough milling removes the bulk of material surrounding the 3D Model. The material

is removed on Z-levels controlled by the Operation Upper level, Surface offset andStep downvalues.

Semi Finish section

Semi-Finish machining prepares the model for nishing. After semi-nishing, a uniformoffset remains on the material. This offset is removed in the last nishing cut.

The same machining strategies in Finish machining can be applied for Semi-nishing.The only difference is in one parameter,Surface offset, that controls the X-, Y- andZ-offset that remains on the original surface. Otherwise, all strategies are dened andused in the same way as in nishing.

Finish section

Finish machining generates the tool path directly on the surfaces and solids of your3D Model geometry. No offset can be specied and the model is machined to its naltopology and dimensions. You can apply a number of different machining strategies

to nish your models. Each strategy offers parameters to adjust the strategy to yourneeds.

Operation buttons

Operation buttons enable you to save the Operation data, perform the tool pathcalculation, simulate the already calculated tool path, generate the GCode for theOperation and close the Operation dialog box.


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2.2 3D Roughing

The target of the rough machining is the fast and efcient removal of the greater part of thmachining allowance with the large tools. SolidCAM provides you with the following functionalitieof the rough machining:

Constant Z roughing of the whole model or model areas;

Rest material machining enables you to automatically determine the areas that were nomachined in the previous stages and machine them with a smaller tool.

A number of Z-Entry strategies enabling you to choose the optimal way of the too

plunging into the material. SolidCAM enables you to use the pre-drilled holes for thZ-Entry.

The Open pocket functionality enables SolidCAM to locate open pocket areas anenables you to machine them with a specic strategy. This strategy enables you t

combine pocket and prole tool paths in order to provide the best productivity in opepocket machining.

You can use three different strategies to execute rough machining of 3D Models.

Contour and Hatch strategies perform rough cuts on constant Z-levels that ar

automatically calculated using the specied values for the Lower level, Surface offset anStep down.

Contour strategy Hatch strategy

Plungingis a totally different concept of removing

material from a given pocket, carried out with a

special tool. Instead of milling the material, the toolmoves up and down as in a drilling motion, travellingalong the specied path type.


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Exercise #1: Mold core roughing

This exercise illustrates the process of rough machining using the Contour strategy in SolidCAM.

In this exercise you have perform the rough machining of the mold core of a pet dish.

Dish Mold Core

1. Load the SolidWorks model

Load the Exercise1.sldprtmodel located in the Exercisesfolder.

This model consists of a number of features forming the solid body of the moldcore.


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The 3D MillingOperation dialog box is displayed.

4. Define the geometry

The main geometry used for the 3D Milling is a 3D Model. The Geometry section of the3D Milling Operation dialog box enables you to dene a new chain or choose an alreadydened 3D Model geometry. In this exercise, the previously dened Target model

geometry is used for the 3D Milling Operation denition.

In the Geometry section, choose the Target geometry fromthe list.

5. Define the tool

In the Toolsection, click on the Selectbutton to start the tool denition.


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The Choosing Tool For Operation dialog box is displayed. This dialog box displays thcontent of the Part Tool table in the current CAM-Part.

Click on the Addbutton to dene a new tool forthe Operation. A tool with default parameters is

added to the Part Tool Table.

In this exercise, a 20End milltool is used.

Edit the following tool parameters:

Set the User tool typeto End Mill.

Set the Diameter to 20.

Set the Total length to 120;

Set the Outside Holder length to 100;

Set the Cutting length to 85.

TotalLength

DiametCutting Length

Outside Holder

Length


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Dene the tool holder. Select the Holder checkbox. The Holder section is activated.

In the Holder section, click on the Globalholders table button to choose the tool holderfrom the global holders table supplied with the

SolidCAM software. The Tool Holdersdialog boxis displayed.

The SolidCAM tool holder is dened by combining two components.The rst component is the tool adaptor mounted in the spindle unit ofthe milling machine. The tool adaptor is dened in the CNC machinepre-processor le (MAC le). The second component can consist ofdifferent types of extensions and reductions such as collet chucks,

arbors, shanks and any other components that you may have. TheToolHoldersdialog box enables you to choose this second component.

Choose the ER32x60 collet chuck from the list and conrm the dialog box with theOKbutton. The Choosing Tool For Operation dialog box is displayed again.

Click on the Selectbutton to conrm the dialog box and choose the dened tool forthe Operation.

The tool has been chosen for the Operation. The 3D Milling Operation dialog box isdisplayed again.


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6. Define the Milling levels

At this stage you have to specify the milling levels for the Operation.

Milling levels

SolidCAM performs the cutting between the Upper level and thLower level. The Upper level is the Z-level at which the cuttinstarts. The Lower level sets the Z-level below which the tool doenot mill. The cutting path is performed between these levels. Aftethe machining of any cutting level, the tool vertically retreats tthe Clearance level with rapid feed. All the necessary horizont

movements are performed at this level with rapid feed. The tool thedescends to the next cutting level. SolidCAM enables you to specifthe Safety distance. The descent movement to the Safety distance

performed with rapid feed. From the Safety distance to the cuttinlevel, the tool descends with working feed.

Specify the Lower level for the Operation. SolidCAMenables you to dene the milling levels directly on the solid

model.

In the Milling levels section, click on the Lower levelbutton to start the denition.

Clearance Level

Upper level

Lower levelRapid movements

Feed movements

Safety

distance

Cutting

levels


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Click on the model face as shown.

The Lower level is determined and displayed in the Pick Lower level dialog box.

Conrm the Lower level denition with the button. The3D Milling Operationdialog box is displayed with the updated

value of the Lower level. The pink background of theparameters box means that the parameter value is denedassociatively to the solid model. If the model is changed, thisparameter value is updated automatically.

7. Define the facet tolerance

Set the Facet tolerancevalue to 0.01.

This tolerance value controls the maximum deviation of the

faceted model, used for the tool path calculation, from thesolid model.

The 3D Model geometry is triangulated and the resulting facets are savedin the modelname.fct le in the CAM-Parts folder. The triangulation isperformed on the 3D Model geometry when you use it for the rst time ina 3D Milling Operation. If you use the 3D geometry in another Operation,SolidCAM checks the tolerance of the existing *.fctle of this geometry.It does not perform another triangulation as long as the *.fctle has beencreated within the same facet tolerance.


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8. Choose the roughing strategy

In the Rough section of the 3D Milling Operation dialog box, choose the Contou

strategy from the list.

Contour roughing

The Contour roughing strategy enables SolidCAM to producConstant Z pockets on different Z-levels. Within the pockets, the toomoves in parallel offsets to the contour of the section of the model athe Z-level of each step down.

The major parameters of the Contourroughing strategy are Overla

and Step down.

The Overlap parameter denes the tool overlap when the tool

located on the two adjacent lines of the tool path.

The default value is 0.65 (65% of thetool diameter). With the tool diameterof 20 mm, the overlap of 0.7 (70%) is14 mm. It means that the side step (thedistance between adjacent lines of thetool path) is 6 mm for the next toolmovement.

Overlap

Overlap14 mm

Side step6 mm

2


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SolidCAM uses the Constant Z pocketing for the roughing. With theStep downparameter, you can dene the distance between each twosuccessive Z-levels.

Set the value of 0.7 for the Overlap. With this value, the

distance between the adjacent lines of the tool path (sidestep) is 6 mm.

Set the Step down to 5.

Under Clean flat, choose the Clean flat during Roughingoption.

Clean flat options

SolidCAM generates a set of Z-levels with an equal step down.Sometimes the model ledge with the specied offset lies between theZ-levels dened by Step downand is not machined. The Clean flat

options enable you to perform the machining of such ledges.

CuttinglevelsStep down

Unmachinedledges betweenZ-Levels

Model withoffset

Z-levels with theequal Step Down


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Set the Surface offset value to 1. This offset is removed in the semi-nish/nishOperations.

10. Define the technological parameters

In the Rough section of 3D Milling Operation dialogbox, click on the Data button. The Contour Parametersdialog box is displayed. This dialog box enables you toset the technological parameters of the contour roughingstrategy.

Contour parameters

Exit material

This option controls the tool movements between the cutting areas.

Exit material option not selected

When the tool moves from one

cutting area to the next one, itmoves through the full materialaround the island to get to thenext area to be cut as shown.


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Exit material option selected

The tool exits from the materialand travels rapidly above thematerial to the next cutting area as

shown. The approach path is the

approach you choose.

Connect islands

During walls and islands machining, SolidCAM uses a differencutting direction (climb or conventional) for different areas othe tool path. The Connect islandsoption enables you to prevensuch direction changes by connecting all of the areas into a singlcontour. The connected contour is machined with the same cuttin

direction (conventional or climb).

Start from

Inside

This option enables you to work in a pocket area starting fromthe middle of the pocket and cutting towards the outsid

border of the pocket.

Outside

This option enables you to work in a pocket area startinfrom the outside border of the pocket and cutting towardthe middle of the pocket.

Mixed cutting direction Constant cutting direction

Climb

Conventional

Clim


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Corner

None

The tool path is formed with sharpcorners between one tool path direction

and the next.

Fillet

Each tool path direction is connectedto the next one with a given radius,enabling a smoother transition between

tool path directions.

Smooth

The connecting points on the pathare cleaned using a smooth transition.

The tool path forms a loop in the

corner, preventing an abrupt change ofdirection.

Sharp

Using a short and simple movement

cleans the connecting points on the

path. Although this produces a sharpmovement by the tool, the path itself isslightly shorter than the smooth corneroption. This can help to reduce themachining time.

This option is not recommended for high-speedcutting.


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Direction

This option enables you to choose climb or conventional milling fothe roughing.

Arc approximation

This command enables you to create G2/G3 GCode output fromContour roughing Operations. SolidCAM checks whether successiv

points of the calculated tool path can be connected using an aror circle. If an arc or circle connection within the specied arapproximation tolerance can be made, you receive arc and circlinterpolation commandsG2and G3in the generated GCode.

Adjacent tool paths connection

This option enables you to choose the method with which the toomoves within a pocket from one tool path to the next.

Linear connection

The tool moves in a normal approach fromone tool path to the next.

Rounded connection

The tool moves in an arc path from one toolpath to the next one. The radius of the arcis half the distance between the tool paths.

Conventional MillingClimb Milling


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In the Corner section of the Contour parameters dialogbox, choose the Smooth option.

In the Adjacent tool paths connectionsection, choose theRounded option.

These parameters enable you to perform smoothertransition between tool path directions.

Dene the Arc approximation value. Generally, therecommended value of for the arc approximation is2.5 times the Facet tolerancevalue.

In this exercise, set the Arc approximationvalue to 0.025.

Conrm the Contour parameters dialog box with the OK

button.

11. Define the Working area

SolidCAM enables you to limit the tool path with a specied Working area.

In the Working area section, clickon the Define button.

The Working Area dialog box isdisplayed.


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Working area types

SolidCAM enables you to use one or a combination of the followinfour methods:

Working area geometry. This method enables you to specify

closed contour of the Working area boundary.

Angle limits. This method enables you to dene the Working areby surface inclination angle range and to apply various machininstrategies to model areas with a different inclination.

Selected faces. This method enables you to select the model facewhere the machining has to be performed. You can also specify th

faces that have to be avoided during the machining.

Rest Material. With this method, you can limit the machining to th

rest material. The rest material is what has to be machined after thprevious Operations in order to reach the Target model.

In this exercise, the Working area is dened by a closed planar

contour.

Select the Working areacheck box to dene the Working areageometry.

Click on the Definebutton to start the geometry denition. TheGeometry Edit dialog box is displayed. This dialog box enablesyou to select and manage geometry chains.

The geometry selection procedure and interfaceis covered in detail in the SolidCAM 2.5D MillingTraining coursebook.

In the Multi-chain section of the dialog box, click on the Add

button. This button enables you to choose a number of chainsfrom a model by selecting the model elements. The programautomatically creates chains from the selected elements.


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The Chains Selection dialog box is displayed.

Rotate the model as shown and click on the bottom face.

The selected face and its boundary are automatically

determined. Click on the button to build chains based onthe selected face boundary. The Geometry Editdialog box is

displayed again. Conrm it with the button.

The Working area geometry has been dened.


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Now you have to dene the tool location relative to the Working area.

Tool on Working area

This option controls the position ofthe tool relative to the boundaries ofthe Working area. Select one of theoptions from the Tool position in the

Working area list eld.

Internal

The tool machines up to theboundary of the Working area.

The center point moves at anoffset equal to the tool radius.

Working are


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12. Define the Z-Entry strategy

Dene the way the tool plunges into the material.

Click on the Z-Entrybutton to display the Z-Entry dialog

box.

Z-Entry types

None

The tool plunges into the material witha normal downward movement at thespecied Z-feed rate.

Angle

If you choose this Z-Entry type andenter the Angle value, the tool enters

the material with a ramp movement.The ramp starts from the given Safety

distance down to the model contour.If, due to the model contour, the rampcannot be created in a straight line,the Z-Entry movement follows thecontour.

Helical

The tool descends to the machininglevel with a helical motion. In the Angleeld, enter the descent angle that you

would like the tool to follow. In theRadius eld, enter the radius of thehelical tool path.

Angle


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Linear

The tool descends to the machininglevel with a linear zigzag motion. In theAngleeld, enter the descent angle that

you would like the tool to follow.

Choose the Helical option for the Z-Entryand set the Anglevalue to 5. Set the Radiusvalue to 5.

Clear theReturn to Clearance Level between Z stepscheck

box.

Conrm the dialog box with the OK button.

Return to Clearance Level between Z steps

This option enables you to control the height where the horizontalrapid movement is performed.

When this check box is selected (default), SolidCAM performs thehorizontal rapid movements on the Clearance level of the Operation(see Step #6).

Clearance Level

Rapid movementsFeed movements

Safetydistance

Cuttinglevels


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When this check box is not selected, SolidCAM performs thhorizontal rapid movements at the Safety distance from the last cuSolidCAM checks for possible collisions. In areas where the rapimovements on the Safety distance cause gouges, the horizontal rapimovements on the Clearance level are performed.

13. Open pocket machining

SolidCAM enables you to customize your machining strategy for more effectivmachining of open pocket areas.

During the preparation for

the machining, SolidCAMgenerates the modelsections located at theZ-levels determined by theStep down value. Thesesections contain both:

Closed pocket areaswhere the approachfrom outside is

impossible; Open pocket areas that are accessible from the outside.

The closed pocket areas are machined as pockets, with the tooplunging into these areas with the Z-Entry strategy (see Step #12Open Pockets can be machined with a combination of pocket anprole paths.

Open pocket

area

Closed pocke

area

Clearance Level

Rapid movements

Feed movements

Safety

distance

Cuttinglevels


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In the Rough section of the 3D Milling Operation dialog box,click on the Mode button. The Open Pocket modedialog boxis displayed.

This dialog box enables you to dene the mode of Openpocket machining.

There are three modes of open pocket machining:

Pockets: open areas at each down stepare milled as pockets.

Profiles: open areas at each down stepare milled by a number of equidistantproles starting from the outside themodel; the tool then moves in parallel

offsets to the contour of the sectionon the specied Z-Levels.

Pockets+Profile: if the open areasat each down step cannot be milledcompletely with one prole, thenthose unmilled areas are milled rst

by pocket paths and then the prole isused for nish.

Choose the Pockets + Profileoption for the Open pocket machining.

Profiles

Pockets

Pockets

Profile


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Select the Approach open pocket from outside check box. This option enables yoto perform the approach movement from the automatically calculated point outsidof the material. The tool approaches to the necessary depth outside of the materiand then plunges into the material. Such an approach enables you to decrease the tooloading when plunging into the material.

In closed areas, where outside approach is impossible, the tool plunges intthe material with a strategy dened in the Z-Entry eld of the Operatiodialog box.

Dene the Profile Lead in strategy, which is the way thetool approaches the proles during open pocket machining.Choose the Tangent option to perform the tool movementtangential to the automatically calculated tool path line. Setthe Value to 20.

Conrm the Open Pocket mode dialog box with the OKbutton.

14. Save and Calculate

Click on the Save&Calculatebutton.

The 3D Milling Operation data is saved and the tool path is calculated.

15. Simulate

Click on the Simulatebutton in the 3D Milling Operationdialog box. The Simulation control panel is displayed.

Click on the button to start the simulation. Thesimulation is displayed directly on the solid model.


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Since the simulation is performed in the SolidWorks window, all the viewfunctions of SolidWorks such as Zoom, Panor Rotateenable you to checkthe tool path.

Switch to the SolidVerifypage and start the simulation with the button.

When the simulation is nished, display the side view of the part with the button.

After the rough machining, the part faces have steps.

During nishing, these steps (cusps) cause a non-uniform tool load that result inbad surface conditions. To remove these cusps before the nishing, it is necessary to

perform an additional rest roughing Operation.

Close the Simulation control panel with the button.

Close the3D Milling Operationdialog box with the Exit button. The SolidCAM Managertree is displayed.


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16. Define a 3D Milling Operation

Right-click on the dened 3D MillingOperation in SolidCAM Manager andchoose 3D Millingfrom the Add Operation

submenu.

The 3D Milling Operation dialog box isdisplayed.

17. Choose the Operation template

SolidCAM enables you to choose an already dened Operation as a template fo

additional Operations. All the template Operation data can be copied to a newOperation.

In this exercise, the previously dened Operation is used as a template.

In the Operation name section, choose the previous 3DR_target_T1Operation fromthe list.

All data is copied from the template Operation.

18. Define a new tool for the Operation

In the Toolsection of the 3D Milling Operation dialog box, click on the Select button t

change the current tool coming from the template Operation with a new one.


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The Choosing Tool For Operation dialog box is displayed. Click on the Add buttonto add a new tool to the Part Tool Table. A new tool with the default parameters isadded.

A 16End milltool is used for the Operation.


Set the User tool typeto End Mill.






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Choose the same tool holder (ER32x60) used for the previous Operation.

Click on the Selectbutton to conrm the tool denition and choose the dened toofor the Operation.

The 3D Milling Operationdialog box is displayed.

19. Define the surface offset

Set the Surfaceoffsetvalue to 0.5.

This offset from the model is left unmachined during theOperation; it is nished in the following Operations.

20. Define the Step down

Set the Step down value to 2. With this value, SolidCAMperforms the machining between the cutting levels of theprevious Operation and removes the steps left unmachined.

21. Define the open pocket parameters

Click on the Modebutton to display the Open pocket mode

dialog box.

Choose the Profiles mode of the open pocket machining.

Open areas at each down step are milled by several equidistantproles, starting from the outside the model; then the tool

moves in parallel offsets to the contour of the section on thespecied Z-levels.

Note that the Tangentstrategy is chosen for the Profile Lead in. The lead in movemen

to the machining proles is performed tangentially.

22. Define the rest material machining

Since the bulk of material is already removed in the previous roughing Operation, thcurrent Operation has to be performed only on the rest material areas that remaiunmachined after the previous Operation.


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In the Working area section, click on theDefine button to display the WorkingArea dialog box.

Select the Cut only the Rest materialcheck box to perform cutting only in theRest material areas. SolidCAM calculatesthe Updated Stock model after theprevious Operations. The updated stockmodel is automatically compared to the

target model and the rest material areasare generated.

In this Operation, the combination of the

Working area dened by 2D geometryand the rest material area is used to limitthe tool path.

Conrm the Working Area dialog boxwith the OK button.

23. Save and Calculate



24. Simulate

Perform the Operation tool path simulation in the HostCADand SolidVerifymodes.

The machining is performed in the areas where the material remains unmachined afterthe previous Operation.

At this stage, the exercise is nished. The CAM-Part will be nished in the followingexercises.


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Exercise #2: Mold cavity roughing

This exercise illustrates the process of rough machining using the Hatch strategy.

In this exercise, you have perform the rough machining of the mold cavity for the handle.

The original model of the mold cavity contains two SolidWorks congurations: Default and Stock

The Default conguration (see the illustration) contains thecomplete cavity geometry used for the Target model denition andmachining Operations.

TheStock conguration contains the model of the part in theinitial state before the machining. This conguration is used forthe Stock model denition.

1. Load the SolidWorks model

Load the Exercise2.sldprtmodel located in the Exercisesfolder.

This model consists of features forming the solid body of the mold cavity.


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2. Define the CAM-Part

At this stage, you have to dene the CAM-Part.

Choose the Fanuc CNC-controller for

the CAM-Part.

Dene the Coordinate System in thecenter of the cylindrical face at the topface of the model.

Dene the Stock model as 3D Modelusing the Stock conguration.

Dene the Target model.

3. Add a new 3D Millling Operation

In the SolidCAM Manager, right-click on the Operations header and choose the3D Milling command from theAdd Operationsubmenu.


4. Choose the geometry

In the Geometrysection, choose the Target model geometry from the list.

5. Define the tool

In the same manner as explainedin the previous exercise, dene anEnd mill tool of 16 mm for theOperation.

Dene the following parameters:


Set the Outside Holder

length to 55;

Set the Cutting length to50.


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6. Choose the cutting strategy

In the Rough section, choose the Hatch type of the roughmachining.

The model is roughed in a linear pattern.

Hatch roughing creates a linear raster toolpath up to the model contour.

Set the value of 0.7for the Overlap. With this value, the distance between the adjacenlines of the tool path is 4.8 mm.

Set the Step down to 5.

7. Define the machining allowances

Set the Surface offset to 1to dene the machining allowance for the nishing.

8. Define the facet tolerance

Set the Facet tolerancevalue to 0.01.

9. Define the technological parameters

In the Roughsection, click on the Databutton to dene the

technological parameters of the hatching. The Hatch Datadialog box is displayed.

Hatching parameters

Exit material

This option controls the tool movementsbetween the cutting areas. See Exercise #1 fora more detailed explanation of this option.


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Hatch angle

SolidCAM enables you to choose one of the following options todene the angle of hatching:

User-defined angle

This option enables you to determine theangle of the tool path.

Automatic optimal angle

SolidCAM automatically calculates theoptimal angle of hatching to expedite the

machining. The tool path always followsthe length of the pocket no matter whatangle the pocket is facing.

You can change the angle by entering adifferent delta angle value in the Delta fromoptimal option.

Keep cutting direction

This option enables you to keep a constant cutting direction duringmilling.

Yes

A constant cutting direction is kept.

No

SolidCAM generates a shorter, optimized tool path by reversingsome tool movements. The milling direction may change between

climb and conventional milling.


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Cutting direction

Zigzag

This option enables you to create the tool pathcontaining bi-directional movements.

One way

This option enables you to create the tool pathcontaining only one-directional movements.

Corner

None

The tool path is formed with sharp cornersbetween one direction and the next.

Fillet

Each tool path direction is connected to thenext one with a given radius allowing a smoothertransition between tool path directions.

Choose the Automatic optimal angle option. The machining of each shaped instancof the cavity is performed with an optimal angle.

Conrm the Hatch Data dialog box with the OK button.


In this exercise, the machining has to be performed only in the cavity areas. Dene thWorking area to limit the tool path to these areas.

In the Working area section, click on the Define button.

The Working Areadialog box is displayed.

Zigzag

One way


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Select the Working areacheck box and click on the Define

button to start the Working area geometry denition.

The Geometry Edit dialog box is displayed.

In this exercise, the external boundariesof cavities are used for the Working

area geometry denition. Select theseboundaries as shown.

When the geometry is dened, conrmthe Geometry Edit dialog box with

the button.

Make sure that the Internal option is

chosen in the Tool on Working areasection.

The tool machines up to the boundary of the Working area.

Conrm the Working Area dialog box with the OK button.


Dene the way the tool plunges into the material.

Click on the Z-Entrybutton to display the Z-Entry dialogbox.

Choose the Angle option and set the Anglevalue to 5.

The tool will plunge into the material with the speciedangle.

Clear the Return to Clearance Level between Z-steps

check box.

Conrm the Z-Entry dialog box with the OK button.


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12. Save and calculate



13. Simulate

In the 3D Milling Operationdialog box, click onthe Simulate button to perform the tool path

simulation.

Perform the simulation using the HostCADmode.

The machining is performed inside three cavityareas.

Rotate the model to the Topview by clicking on

the button on theCAM Viewstoolbar.

SolidCAM automatically determines the optimal

hatch angle for each cutting area to minimize thenumber of the cutting direction changes.

Switch the solid model to the Wireframe view

using the button in the SolidWorks toolbarand rotate it to the Front view by clicking on

the button on the CAM Viewstoolbar.

Such model display and orientation enable you to see the angle Z-Entry movementAfter the simulation, return to the shaded view.

Close the simulation and return to the 3D Milling Operationdialog box. Click on thExitbutton to close it.


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14. Add a 3D Milling Operation

Add a 3D Milling Operation to perform an additional roughing Operation removingthe steps caused in the previous Operation (cusp removal).

In this exercise, the previously dened Operation is used as a template for the current

Operation. In the Operation name section, choose the previous Operation name(3DR_target_T1) from the list.

The previous Operation data is loaded into the current Operation. The same geometryis used. Now you have to edit the technological parameters to perform the cusp

removal.

15. Define the tool

In the same manner as explainedearlier, dene a new tool for theOperation.

Dene a 12End milltool. Edit thefollowing length parameters:



length to 55;


16. Change the cutting strategy

In the Rough section, change the Hatch type used in theprevious Operation to Contour. The cusp removal is

performed in several concentric proles.

Set the Step downvalue to 2. With this value, the machiningis performed between the previously machined cutting levels.

Set theSurface offsetvalue to 0.5. This allowance is removedin the nish Operations.


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Click on the Databutton to set the additional parameters oftheContourstrategy. The Contour parametersdialog box isdisplayed.

Set the Arc approximation tolerance value to 0.02 andconrm the dialog box with the OKbutton.


Since the bulk of material is already removed in the previousOperation, the current Operation has to be performed onlyon the rest material areas remaining unmachined after theprevious Operation.

In the Working area section, click on the Define button to

display the Working Area dialog box.

Select the Cut only the Rest materia

check box to perform cutting only in thRest Material areas.

In this Operation, the combination of thWorking area dened by geometry an

the rest material areas is used to limit thtool path.

Conrm the Working Area dialog bowith the OK button.





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19. Simulate

Perform the simulation of the Operation in the HostCADand SolidVerifymodes.

At this stage, the rough machining of the cavity part is nished. The roughed part will

be nished in the following exercises.


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Exercise #3: Toy mold cavity roughing

Dene the CAM-Part and Operations for the rough machining of thetoy mold cavity.

This exercise reinforces the following skills:

CAM-Part denition;

3D Contour roughing;

Working area denition;

Rest material roughing.

The SolidWorks model of the toy mold cavity (Exercise3.sldprt) is located in the Exercises folde

The following steps have to be implemented to reach the nal CAM-Part:

1. Define the CAM-PartAt this stage, you have to dene the CAM-Part, the CNC-controller, the MachinCoordinate System, the Stock model and the Target model.

Choose the FanucCNC-controller for this exercise.

2. Perform rough machining

Dene a 3D Milling Operation using the Contourstrategyto perform the rough machining of the cavity.

Use a 20 End millfor the Operation. Dene the relevanttechnological parameters and the Z-Entrystrategy.

Dene the Working area to avoid unnecessary toolmovements.

3. Perform rest material roughing

Dene a 3D Milling Operation to remove the rest materialleft unmachined in the previous Operation. Choose theContourstrategy for the Operation.

Use a 16End millfor the Operation. Dene the relevanttechnological parameters and the Z-Entrystrategy.

Dene smaller Step down and Surface offsetvalues thanin the previous Operation.

Use the combination of the Working area dened in the previous Operation ancutting the rest material.


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Exercise #4: Bottle-bottom mold cavity roughing

Dene the CAM-Part and Operations for the rough machining ofthe bottle-bottom mold cavity presented on the illustration.


CAM-Part denition;

3D Contour roughing;



The SolidWorks model of the cavity (Exercise4.sldprt) is located in the Exercisesfolder.

The following steps have to be implemented in order to reach the nal CAM-Part:


At this stage, you have to dene the CAM-Part, the CNC-controller, the MachineCoordinate System, the Stock model and the Target model.

The FanucCNC-controller has to be chosen for this exercise.


Dene a 3D Milling Operation using the Contourstrategyto perform the rough machining of the cavity.

Use a 12End millfor the Operation. Dene the relevanttechnological parameters and the Z-Entrystrategy.



Dene a 3D Milling Operation to remove the rest materialleft unmachined by the previous Operation. Choose the

Contourstrategy for the Operation.Use a 8End millfor the Operation. Dene the relevanttechnological parameters and the Z-Entrystrategy.


Use the combination of the Working area dened in the previous Operation andcutting in rest material.


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Exercise #5: Spoon die core roughing

Dene the CAM-Part and Operations for the rough machining ofthe spoon die core presented on the illustration.


CAM-Part denition;

3D Hatch roughing;



The SolidWorks model of the core (Exercise5.sldprt) is located in the Exercisesfolder.

The following steps have to be implemented in order to reach the nal CAM-Part:


At this stage, you have to dene the CAM-Part, the CNC-controller, the MachinCoordinate System, the Stock model and the Target model.

The FanucCNC-controller has to be chosen for this exercise.


Dene a 3D Milling Operation using the Hatchstrategy

to perform the rough machining of the core.

Use a 20 End mill for the Operation. Dene the relevanttechnological parameters and the Z-Entrystrategy.



Dene a 3D Milling Operation to remove the rest materialleft unmachined by the previous Operation. Choose the

Contourstrategy for the Operation.

Use a 16End mill for the Operation. Dene the relevanttechnological parameters and the Z-Entrystrategy.


Use the combination of the Working area dened in the previous Operation ancutting in rest material.


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2.3 3D Semi-Finishing/Finishing

Semi-Finish machining prepares the model for

nishing. After semi-nishing the model, a uniformoffset remains on the material. This offset isremoved in the last nishing cut.

Finish machining generates the tool path directlyon the surfaces and solids of your 3D Modelgeometry. No offset can be specied and the modelis machined to its nal topology and dimensions.

You can apply a number of machining strategies tonish your models, each of them offers parametersto adjust the strategy to your needs.

The same machining strategies in Finish machining

can be applied for Semi-nish. The only differenceis the denition in Semi-nish of the Surface offsetparameter that controls the X-,Y- and Z-offset

that remains on the original surface. Otherwise, allstrategies are dened and used in the same way asin Finish machining.

Linear strategy

In Linear cutting, the lines of a linear pattern with the specic

step over are generated on a 2D plane above the model. Thelinear pattern is then projected on the 3D Model.

Offset Cutting Finishing strategy

Offset cuttingis a form of 3D prole milling that can be used to mill specic areas of the model.

Pencil Milling

SolidCAM Finishingstrategies

Linear

Offset cutting

Spiral

Circular pocket

Constant Z

Constant Step over


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If you select one prole, you mustspecify the clear offset distance. Onthe right side of the prole, relativeto the chain direction, the machiningis performed until the specied clearoffset distance has been reached. In

this example, one Offset prole on theupper part of the model is machinednormal to the prole geometry.

When you dene two Offset proles, both prole geometries are connected and the toopath is projected on the 3D Model.

Spiral Finishing strategy

Different types of spiral tool path movements can be selected for this nishing strategy. The spiratool path pattern is rst generated in 2D and then is projected on the 3D Model.

Offset Geometry

Tool path

CleaOffse

Offset

Geometry

Tool path


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Circular Pocket Finishing strategy

The selected Working area is used to create a 2D pocket line patternon a plane above the model. The line pattern is then projected on the3D Model.

Constant Z Finishing strategy

This strategy is used to generate high quality nish on both steep andat areas. The machining of the steep areas is performed by machiningsections, at Z-levels dened by either step down or scallop. The atareas are automatically recognized and machined with pocket strategy.

Constant Step over strategy

The 3D Projection machining strategies (Linear, Spiral, Offset cutting,Circular pocket) generate a 2D tool path mesh, with a constant Stepover in the plane parallel to the XY-plane of the current CoordinateSystem. This 2D tool path mesh is then projected on the 3D Model toget the 3D tool path. This method provides good results for prismaticparts machining but has a disadvantage for the machining of curved

surfaces because it does not take into account the surface curvaturewhen it generates a tool path pattern.

The Constant Step over strategy gives an excellent surface nish becausethe step over is constant along all surfaces irrespective of whether theyare steep walls or shallow areas.

Pencil milling

Pencil milling uses an algorithm that determines all of the corners of apart and automatically drives the tool along these corners.


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Exercise #6: Cover finishing

This exercise illustrates the use of SolidCAM 3D Finishing for theaerospace electronic box cover machining.

The Linear strategy is used in this exercise to perform the nish of the

upper faces of the model highlighted below.

1. Load the SolidCAM Part

Load the Exercise6.prt CAM-Partlocated in the Exercises folder.

This CAM-Part contains two 3Droughing Operations. Perform theSolidVerify simulation of theseOperations.

Rough machining Rest material roughing


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2. Add a new 3D Milling Operation

In SolidCAM Manager, right-click on the lastOperation in the list and choose Add Operation, 3DMilling.

The3D Milling Operationdialog box is displayed.


In the Geometry section, choose the Target modelgeometry (Target) from the list.

4. Define the tool

Dene a new tool for the Operation. Add

a 12 Ball-nosedmill.


Set the User tool type to Ball-nosed mill.

Set the Diameter to 12;


Set the Outside Holder lengthto 50;


5. Define the Facet tolerance

In the Facet tolerance section, set the value to 0.01. Smalltolerance values result in better surface quality.

6. Choose the machining strategy

In theFinishsection, choose the Linearstrategy from the list.


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7. Define the linear finish parameters

In the Finish section, click on the Data

button. The Linear Finish dialog box isdisplayed. This dialog box enables youto adjust the technological parameters of

the Linearstrategy.

Technological parameters

Step over

In linear nishing, a line pattern is

generated on a 2D plane above themodel and then projected on the3D Model. The Step over valuedetermines the constant distance

between all lines of the linear patterncreated on the 2D plane before it isprojected.

Scallop

This parameter enables you to control the distance between the toopath lines according to the cusp height you want to achieve on th

nished model. SolidCAM adjusts the distance between the singllines of the 2D pattern (before projection on the model) to thtopology of the model to match the specied scallop height.

Maximum step over

This parameter limits the Step over when the Scallop option is used

Linear pattern

Step over

Projected

tool path


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Arc approximation

You can create the G2/G3 GCode output from Linear nishing

Operations. SolidCAM checks whether successive points of thecalculated tool path can be connected with an arc or circle. If an arcor circle connection within the specied arc approximation tolerancecan be made, you receive arc and circle interpolation commands G2

and G3in the generated GCode. This feature can drastically reducethe number of lines in GCode les. Most CNC-controllers andmachines work much faster on arcs and circles than on single toolpath points or splines. Arc approximation increases actual feed rates

on older CNC-machines and the machine works smoother.

The Tolerancevalue denes the tolerance SolidCAM uses to positiontool path points on arcs or circles.

In this exercise, set the Step overvalue to 0.2.

Direction type

This option controls the direction of the tool on each line of thelinear pattern that has been projected on the model. Different materialsand cutters require specic cutting conditions, e.g. some tools give bettersurface nish when cutting only downward; in other applications you needto use other settings to achieve optimal results.

Zigzag

The tool nishes one line of the linear pattern,then moves directly to the next line, and so on.It mills forward and backward without leavingthe material, thus constantly switching betweenclimb milling and conventional milling.

Connection radius: you can connect lines of the linear tool path witha radius. If theRadius value is 0, SolidCAM connects the linear tool

path with straight lines.

Connection with radius Connection without radius


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In this exercise, the machining isperformed in a number of tool pathsnormal to the X-axis direction. In theDefine direction angle by section, set theValueto 90.

Make sure that the default Zigzag optionis chosen for Direction type.

Conrm the dialog box with the OK

button.


The linear nishing in this exercise has to be applied to thetop faces of the model.

Work on Selected faces

SolidCAM enables you to dene the area of the 3D Model machiningby selecting two sets of model faces:

Drive faces the set of faces to bemilled. The tool path is generatedonly for machining of these faces.

Check faces the set of faces tobe avoided during the generation ofthe tool path.

Other faces of the model is not considered during the tool pathcalculation.

In the model shown above, SolidCAM generates the tool path onlyfor the shallow area. During the calculation, SolidCAM avoids thegouging of the check faces. The remaining faces do not participate in

the tool path calculation.

Drive Faces

Check Faces


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In the Working area section, click on the Define button. TheWorking Area dialog box is displayed.

In the Working Area dialog box, select theWork on selected faces check box.

In the Drive faces section, click on the Definebutton to start the drive faces denition.

The Select Faces dialog box is displayed in thePropertyManager area.

This dialog box enables you to perform faces selection.

Click on the CAD selection button to use theselection tool of SolidWorks.

Right-click on the top model face as shown andchoose the Select Tangency option from themenu.

All the tangential top faces are selected. In the

Select Faces dialog box, click on the Resumebutton to resume the selection.

Click on the button to conrm the geometry selection. The Working Areadialobox is displayed again.

Click on the OKbutton to conrm the Working area denition.


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The 3D Milling Operationdata is saved and linear nishing tool path is calculated.

10. Simulate

Perform the simulation of the Operation in the HostCADandSolidVerify modes.

At this stage, the exercise is completed.


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Exercise #7: Bottle-bottom mold cavity finishing

This exercise illustrates the use of SolidCAM 3D MillingOperation for semi-nishing and nishing of the bottle-bottom

mold cavity machining.

The Spiral nishing strategy is used in this exercise to semi-nish/nish the forming faces of the cavity highlighted below.


Load the CAM-Part pre-machined in Exercise #4 or Exercise7.prt located in thExercises folder.

This CAM-Part contains two 3D Roughing Operations. Perform the SolidVerifsimulation of these Operations.

Rough Machining Rest material roughing


In SolidCAM Manager, right-click on the last Operation in the list and choose Ad

Operation, 3D Milling.



In the Geometry section, choose the Target model geometry (Target) from the list.


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4. Define the tool

Dene a new tool for the Operation. Add a 10 Ball-nosedmill.

Modify the following tool parameters:

Set the User tool type toBall-nosed mill;



Set the Outside holder

length to 45;



In the Facet tolerance section, set the value to 0.01.

6. Define the semi-Finishing strategy

In theSemi-Finishsection, choose the Spiralstrategy from the list.

Set the Surface offset value to 0.2. This allowance isremoved in the nishing Operation.


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7. Define the spiral finish parameters

In the Semi-Finish section, click on the Data

button. The Spiral Semi-Finish dialog boxis displayed. This dialog box enables you todene the technological parameters of the

SpiralFinishing strategy.

Path type & Profile type

By combining the options in the Path typeandProfile typeelds, yocan generate ve types of tool path spirals.

Linear

The tool path is performed in a radial linearpattern dened by the Start angle and End

angle parameters in the Angle section. Theangular distance between tool path lines isdened by the Delta angleparameter.

Spiral

Profile type: Arcs

The machining is performed in a spiral tool path.

The spiral tool path is dened by thefollowing parameters:

Start Angle;

End Angle;

Start Radius;

End Radius;

Delta Radius.


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Profile type: Lines

The machining is performed by a linear spiral

tool path.

The spiral is dened by the followingparameters:

Start Radius;

End Radius;

Delta Radius.

Circular

Profile type: Arcs

The machining is performed in a number

of concentric arcs/circles dened with thefollowing parameters:

Start Angle;

End Angle;

Start Radius;

End Radius;

Delta Radius.

Profile type: Lines

The machining is performed in a number ofconcentric squares dened with the followingparameters:

Start Radius;

End Radius;

Delta Radius.

In the Path type section, choose the Spiraloption to perform the spiral tool path. Makesure that the Arcsoption is chosen in the Profile typesection.

In the Radius section, set the Deltavalue to 0.3. This parameter denes the distancebetween the turns of the spiral.


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8. Define the spiral center

At this stage, you have to dene the center point of the spiral. In this exercise, thcenter point is dened as a sketched point located on the center of the top face of thcavity. To create this point, do the following:

Select the top face of the mold cavity as shown.

In the SolidWorks menu, click Insert, Sketchto create a new sketch on the selected face.

Sketch a new point and apply the Concentricgeometric relation between the sketched pointand the circular edge of the cavity.

The sketched point is located in the center of the cavity at the top plane. Conrm th

relation denition with the button.

Close the sketch.

In the Spiral Semi-Finish dialog box, click on

the Pick center of spiral pathbutton.

The Pick Center point of tool pathdialog box

is displayed.


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Click on the sketched point as shown. Thecoordinates are displayed in the Pick Centerpoint of tool pathspiral dialog box.

Conrm the center point selection with

the button.

Conrm theSpiral Semi-Finishdialog box with the OKbutton.


At this stage, you have to dene a Working area to limit the tool path.

In theWorking areasection, click on the Definebutton. The Working Area dialog box

is displayed.

Select the Working areacheck box and choose the alreadydened Working area geometry from the list. This geometry

was previously used to limit the roughing tool path.

Click on the Show button to check the Working areageometry.

In the Show geometry dialog box, click

on the button. The Working Areadialog box is displayed again.

In the Tool on Working area section,choose the Middle option.

Conrm the Working Area dialog boxwith the OKbutton.


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In the Semi-Finish section, click on the Z-Entry buttonto dene the way the tool plunges into the material. TheZ-Entry dialog box is displayed.

Choose the Arc option from the list and set the Arc radius

value to 5. The tool plunges in a spiral movement with thespecied radius.




The 3D Milling Operation data is saved and the spiral tool path is calculated.

12. Simulate

Perform the simulation of the Operation in the HostCADand SolidVerifymodes.

At this stage the semi-nish machining of the mold cavityis completed.


Add a new 3D Milling Operation to performthe nishing of the mold cavity. The nishingis also performed with the Spiralstrategy.

In the Operation name section, choose the previous Operation (3DS_Sp_target_T3

from the list to use it as a template for the current Operation.


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All the data of the template Operation is copied to the current Operation.

Operation name

Once you select a geometry and a tool, SolidCAM automaticallyenters a default name (e.g. 3DM_Profile_T1) based on the Operationtype, geometry name and tool number.

Later you can change the Operation name, if necessary.

SolidCAM uses the following Operation type abbreviations for the

3D Milling Operations:

3DR 3D Roughing

3DS_Lin Linear 3D Semi-Finishing strategy

3DS_Offs Offset cutting 3D Semi-Finishing strategy

3DS_Sp Spiral 3D Semi-Finishing strategy;

3DS_Cir Circular Pocket 3D Semi-Finishing strategy

3DS_CZ Constant Z 3D Semi-Finishing strategy

3DS_Pen Pencil Milling 3D Semi-Finishing strategy

3DS_CS Constant Step over 3D Semi-Finishing strategy

3DF_Lin Linear 3D Finishing strategy

3DF_Offs Offset cutting 3D Finishing strategy

3DF_Sp Spiral 3D Finishing strategy

3DF_Cir Circular Pocket 3D Finishing strategy

3DF_CZ Constant Z 3D Finishing strategy

3DF_Pen Pencil Milling 3D Finishing strategy

3DF_CS Constant Step over 3D Finishing strategy

3DD 3D Drill Operation3DE 3D Engraving Operation

When you add a new Operation, you can use an existing Operation as

a template for the new Operation. All elds of the template Operationare copied and you only need to edit some changing parameters, e.g.select another geometry or surface offset.

3DM_Profile_T1

ToolGeometry

name

Operation type

abbreviation


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14. Define the tool

Dene a new tool for the Operation. Add a 6 Ball-nosed mill.


Set the User tool type to

Ball-nosed mill;




length to 45;


15. Choose the finishing strategy

In the Semi-Finish section, choose the Noneoption from the list.

In the Finishsection, choose the Spiral option from the list.

Click on theDatabutton to dene the Spiral nishing parameters. The Spiral Finis

dialog box is displayed.

Choose the Linear option in the Pathtypesection. The tool path is performedin a radial linear pattern.

Dene the angular distance between toolpath lines. Set the Deltavalue in the Angle

section to 0.2.

In the same manner as explained earlier,

dene the spiral center using the samesketched point used in the previousOperation.


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Exercise #8: Electrode finishing

This exercise illustrates the use of SolidCAM 3D Finishing for the electrode machining.

Mold cavity Electrode

The Circular pocket strategy is used in this exercise to nish the forming

surfaces highlighted on the illustration.

The Offset cuttingstrategy is used in this exercise to nish the partingsurfaces highlighted on the illustration.


Load the pre-machined CAM-Part Exercise8.prtlocated in the Exercises folder.

This CAM-Part contains two 3D roughing Operations. Perform the SolidVerifysimulation of these Operations.

Rough Machining Rest material roughing


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In SolidCAM Manager, right-click on the last Operation in the list and choose AdOperation, 3D Milling.

The 3D Milling Operation dialog box is displayed.



4. Define the tool



Set the User tool type to Ball-nosed mill.





5. Define Facet tolerance

In the Facet tolerance section, set the tolerance value to 0.01.

6. Define the Finishing strategy

In the Finish section, choose the Circular pocket strategyfrom the list.


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In this strategy uses the selected Working area to create a 2D pocket linepattern on a plane above the model. The line pattern is then projected on the3D Model. During this projection, the Z-position of the tool is calculated toavoid gouging of the material.

7. Define the Circular pocket parameters

In the Finish section, click on the Data

button. The Circular Pocket Finishdialogbox is displayed. This dialog box enablesyou to adjust the technological parameters

of theCircular pocketFinishing strategy.

Circular Pocket parameters

Cutting direction

The pocket is machined in either Conventionalor Climbdirection.

Start from

The machining can be started from Outsideor Insidethe pocket.

Working area


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Connection type

This option enables you to control the way the tool moves betweetwo adjacent tool paths.

Stairs

The tool moves in two steps between twoadjacent tool paths. If the next path is lower

than the present path, the tool rst movesaway from the surface in the XY-directionand then downwards in Z. If the next pathis higher than the present path, the tool rstmoves upwards in Z and then approachesthe surface in the XY-direction.

Smooth

Between two adjacent tool paths, the toolmoves on the surface of the model. Theline connecting two adjacent tool paths isprojected on the model. When this option

is used, the tool does not leave materialwhen it moves to the start point of the nexttool path.

Step over

In pocket nishing, SolidCAM generates the pocket line pattern o

a 2D plane above the model and then projects it on the 3D ModeThe Step overvalue determines the constant distance between thlines of the pocket created on the 2D plane before it is projected othe model.

In the Start from section, choose the Outside option to start the machining fromoutside.

In theConnection type section, choose the Smoothoption.

Set the Step overvalue to 0.2.

Click on the OKbutton to conrm the Circular pocketparameters.


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The Working area denition is necessary for the circular pocket machining. The shapeof the Working area directly effects the tool path.

In the Working area section, click on theDefinebutton to start the denition.

In the Working Area dialog box, select the Working area

check box and click on the Define button to dene thegeometry.

Select the Working area geometry at the boundary of theforming faces as shown.

Conrm the selection.

In the Working Area dialog box, choose the Middle option in the Tool on Working area

section.




The 3D Milling Operation data is saved and the circular pocket nishing tool path iscalculated.


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10. Simulate

Perform the simulation of the Operation in the HostCADandSolidVerifymodes.


Add a new3D MillingOperation to perform the machining of the parting surface.


12. Define the tool


Modify the following tool parameters:

Set the User tool type toBall-nosed mill;



Set the Outside holderlength to 45;

Set the Cutting length to40.


In the Facet tolerance section, set the tolerance value to 0.01.


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14. Define the Finishing strategy

In theFinishsection, choose the Offset cutting strategy fromthe list.

Offset cutting is a form of 3D prole milling that can be used tomill specic areas of the model. This strategy offers two possiblealternatives of prole selection:

If you select one prole, you have to specify the Clear offset

distance. The machining will be performed at the dened side ofthe prole until the specied Clear offset distance is reached.

When you dene two proles, both prole geometries areconnected and the tool path is projected on the 3D Model.

Offset

Geometry

Tool path

Offset Geometry

Tool path

Clear

Offset


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In the Finish section, click on the Data button.The Offset Finish dialog box is displayed. Thisdialog box enables you to dene the technologicalparameters of the offset cutting.

15. Define the Offset geometry

In the Offset geometry name section, click onthe Define button to dene the offset cuttinggeometry. In this exercise, two closed contoursare dened and the offset cutting is performedbetween them.

The Geometry Edit dialog box is displayed.

Select the external edges of the partingsurface as shown to dene the rstgeometry chain.

When the rst chain is completely selected,

start the denition of the second chain.

Start the selection from the opposite edgeof the same face that was used for thedenition of the start edge of the rstchain. Make sure that the directions ofboth of chains are the same.

Complete the chain and conrm the

selected geometry with the button.

The Offset Finishdialog box is displayed.


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16. Define the offset cutting parameters

Cutting area

Clear offset

This value determines the offset distance from the prole that will bemachined. This eld is available if you use an offset geometry thatconsists of only one prole. In this exercise the geometry has twoproles, therefore this eld is unavailable.

Step over

In offset cutting, SolidCAM generates the offset pattern on the XY-plane above the model and then projects it on the 3D Model. TheStep overvalue determines the constant distance between all lines ofthe offset pattern created on the plane before it is projected.

Tool side

This option enables you to dene the side of the geometry relative tothe geometry direction, where the Clear offset is applied.

This option is not relevant in this exercise, where the geometry isdened by two chains.

Set the Step overvalue to0.2.

Cutting direction

Cross Finish

Select this check box if you wantto perform a Cross finishon theoffset area. After nishing themachining in the rst specieddirection, i.e. parallel or normalto the prole geometry, the other

cutting direction is also applied.

Left side machining Right side machiningGeometry direction


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First cutting direction

If you have selected the Cross finishcheck box, both cutting direction

are applied to the offset area. Select which one you want to start withWhen no cross nish is used, only the selected option is performed

Parallel to geometry: SolidCAM generates a pattern with offset line

parallel to the offset prole geometry. This pattern is then projecteon the mode

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SolidCAM2007_R11_2_Milling_training_course_3D_Milling.pdf

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