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The SolidWorks files usedfor the exercises were prepared with SolidWorks 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 bookThis book uses the following typographic conventions:Bold Sans Serif For example, click theChange to opposite button.
The mouse icon and numbered sans serif bold textindicate the beginning of the exercise action. ExplanationThis style combined with the lamp icon is used forthe SolidCAM functionality explanations embeddedinto the guided exercises. The lamp icon is also usedto emphasize notes. This includes themodel name, the coordinate system position, tool options, CNC-controller, etc.
This geometry is associated with the native SolidWorks model. Technology, Toolparameters and Strategies are defined in the Operation. In short, Operation means howyou want to machine.
You have to define a number of Coordinate Systems that describethe positioning of the part on the CNC-machine. Optionally, you can define the Stock model and Target model to be used for the restmaterial calculation. The Stock model describes the initial state of the workpiece thathas to be machined. The Target model describes the one that has to be reached afterthe machining.
After every operation, SolidCAM calculates how much material wasactually removed from the CAM-Part and how much material remains unmachined restmaterial. The rest material information enables SolidCAM to automatically optimizethe tool path and avoid the air cutting.
Operations definition SolidCAM enables you to define a number of milling operations. During an operationdefinition you have to select the Geometry, choose the tool from the Part Tool Table or define a new one , define a machining strategy and a number of technologicalparameters.
At this stage, you have to define the CAM-Part name and location. Choosing a CNC-controller is a necessary step. The controllertype influences the Coordinate System definition and the Geometry definition. SolidCAM enables you to define the stock model that describesthe initial state of the workpiece to be machined. SolidCAM enables you to define the model of the part in itsfinal state after the machining. Load the SolidWorks modelLoad the Exercise1.
This model contains a number of features forming the solid body of the cover. You canenter the path or use the Browse button to define the location.
You can give any name to identify yourmachining project. By default, SolidCAM uses the name of the designmodel. The name is, by default,the name of the active SolidWorks document. In this case, the chosen SolidWorks document is loaded into SolidWorks.
When the date of the original SolidWorks model is laterthan the date of the CAM-Part creation, this means thatthe SolidWorks original model has been updated. The CAM-Part is defined, and its structure is created. The Milling Part Data dialog box is displayed. Click the arrow in the CNC-Machine area to display the list of post-processors installed onyour system.
It corresponds with the built-in controllerfunctions. You can define the Coordinate System origin position and axes orientationby selecting model faces, vertices, edges, or SolidWorks CoordinateSystems. The geometry for the machining can also be defined directlyon the solid model.
If you need to machine the partfrom different sides, use several Machine Coordinate Systems withthe Z-axis oriented normally to the machined sides.
In this exercise, it is enough todefine one Machine CoordinateSystem with the Z-axis orientedupwards. Such coordinate system enablesyou to machine the part with asingle clamping. DefineThis method enables you to define theCoordinate System by selecting points.
Youhave to define the origin and the direction ofthe X- and Y-axes. The CoordSysorigin will lie in the origin of the SolidWorks Coordinate System, and theZ-axis will be directed normally to the chosen view of the model.
By 3 Points Associative This option enables you to define the Coordinate System by selectingany 3 points. Select the model faceWith the Select Face method chosen,click on the model face as shown. The CoordSys origin is automaticallydefined in the corner of the model box.
The Z-axis of the CoordSys is normal tothe selected face. Model box SolidCAM calculates the box surrounding the model. The upper planeof the model box is parallel to the XY-plane of the defined CoordSys. The CoordSys is located in the corner of the model box. Confirm by clicking theThe CoordSys Data dialog box is displayed. The Coordinate System is defined. The default value is 1. If you use another number,the GCode file contains the G-function that prompts the machine to usethe specified number stored in the machine controller of your machine.
The Position field defines the sequential number of the CoordSys. Foreach Machine Coordinate System, several Position values are defined fordifferent positionings; each such Position value is related to the MachineCoordSys.
The Plane box defines the default work plane for the operationsu tng this CoordSys, as it ts output to the CCode program. Shift is the distance from the Machine Coordinate System to the locationof the Position in the coordinate system and the orientation of theMachine Coordinate System.
The Front and Rear tabs contain sets of facial machining levels describingthe planes parallel to the XY-plane and located along the Z-axis. The Front tab displays levels for milling from the positive Z-direction.
The Rear tab displays levels for milling from the negative Z-direction. The negative Z-direction can be used in case of milling of the part fromthe back side with the same Coordinate System in the main spindle or incase of using the back spindle. The Radial tab contains a set of machining levels describing the virtualcylinders situated around the Z-axis. This level is related to the CoordSys position andyou 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 orto a point related to the reference point. The Create planar surface at Part Lower level option enables you togenerate a transparent planar surface at the minimal Z-level of the partso that its lower level plane is visible.
This planar surface provides youthe possibility to select points that do not lie on the model entities. This dialog boxdisplays the Machine CoordSys. Confirm the CoordSys Manager dialog box with thebutton.
The Milling Part Data dialog box is displayed again. Define the Stock modelFor each Milling project, you can define the Stock model, which is the workpiece that isplaced on the machine before you start machining the CAM-Part. The Model dialog box is displayed. This dialog box enables youto choose the mode of the Stock model definition. When you choose this mode, theSTL file section becomes available. By clicking the Browse button,you can choose the STL file for the stock definition.
Choose the Box mode from the Defined by list. The appearing dialog box enables youto select a solid body for the surrounding box calculation. Optionally, offsets from the model can be defined. Click on the solid body. One of its faces is highlighted. SolidCAM automatically generates the surrounding box. By default, when you create a new CAM-Part, stock and targetmodels are defined automatically.
If you have not changed thedefault settings, the solid body is highlighted, and the targetmodel is already chosen in the Type section. Click on the solid body to clear the selection. Notice that theSolid 1 icon is also removed from the Type section. Click onthe solid body once again. The face is selected, the Solid 1 iconappears in the Type section, and the target model is defined. The defined CAM-Part is saved. At this stage, the definition of the CAM-Part is finished. There are two components in thisassembly:DesignModel.
This enables you to create auxiliary geometries i. You can also insert someadditional components into the assembly file such as stock model, CNCmachinetable, clamping and other tooling elements.
By rightclickingit, you can display the menu to manage your CAM-Parts. Double-click this subheader to review your machine configurationand parameters. CAM-Part Definitionheader. Double-click this subheader to display the CoordSys Managerdialog box that enables you to manage your Coordinate Systems.
Double-click this subheader to load the Part Settings dialog box thatenables you to edit the settings defined for the current CAM-Part. By right-clicking it, you candisplay the menu to define and manage your fixtures. The CAM-Part is closed. SolidCAM offers you the following types of 2. A workpiece is usually manufactured usingseveral machining steps and technologies. For each of these steps you can define a separateoperation. An operation can be very complex, but it always uses one tool, one major geometryand executes one machining type, e.
Profile Milling or Drilling. You can edit any single machiningoperation, change the operation sequence and generate the GCode, combining and splitting theoperation list of your CAM-Part.
The Machining Geometry has to be defined for each operation. Chain geometries are defined by selecting thefollowing entities: edges of models, 2D curves, 3D curves, circles, lines and splines. Each chain is composed of one or more entities and defines an open or closed contour. Profile OperationYou can mill on or along a contour. The profile geometry canbe open or closed.
In profile milling you can optionally usetool radius compensation to the right or to the left side of thegeometry. Pocket OperationIn pocket milling, you have to remove material from the interior ofa closed geometry. You can define anunlimited number of islands within a single pocket. Slot OperationThis operation generates a tool path along the centerline to theright or to the left of one or more profiles.
Two types of slots canbe defined: the Slot with constant depth operation machines theslot in several steps until the final depth is reached. In Slot withvariable depth, the depth profile is also defined by a 2D section. The slot can be pre-machined using rough and semi-finish cycles. The finish cut produces a tool path according to the specifiedscallop height on the floor of the slot.
With available parametersfor the right and left extension and the side step, you can milla slot wider than the tool diameter. T-Slot OperationThis operation enables you to machine slots in vertical walls witha slot mill tool.
Drilling OperationThis operation enables you to perform drills and other canneddrill cycles. SolidCAM supports the canned drill cycles providedby your particular CNC-machine such as threading, peck, ream,boring, etc. Inthis operation drilling on different levels can be carried out. The drilling levels are automatically recognized but may beedited by the user. Pocket RecognitionThis Operation recognizes automatically pocket features atthe target model and creates the necessary machining.
Contour 3D OperationThis operation enables you to utilize the power of the 3D Engravingtechnology for the 3D contour machining.
Thread Milling OperationThis operation enables you to generate a helical tool path forthe machining of internal and external threads with threadmills. You have to define several 2. In the process of definition of operations, you have to definethe machining geometry, the tool and several technologicalparameters.
The CAM-Part is loaded. The Face Milling Operation dialog box is displayed. In this operation, the upper face is machined. The FaceMilling Geometry dialog box is displayed. Therectangle chain is displayed in the Chain List section. Face Milling geometry The Define button and the related box enable you either todefine a new faces geometry with the Select Faces dialog box or choosean already defined geometry from the list.
When the model faces areselected, SolidCAM generates a number of chains surrounding theselected faces. These chains are displayed in the Chain List section. The Define button and the related box enable you eitherto define a new profile geometry with the Geometry Edit dialog box orchoose an already defined geometry from the list.
The defined chains aredisplayed in the Chain List section. In the Type section, use the default Model option for the Face Milling geometrydefinition. Click the Define button. The 3D Geometry dialog box is displayed. You can select an object by clicking on it. When anobject is selected, its icon is displayed in the list inthe bottom of the dialog box.
To unselect the object,click on it again or right-click its icon in the list ofselected elements and choose Unselect from themenu. To remove selection from all objects in thelist, click Unselect all. Click on the solid model to select it. Themodel is highlighted, and its icon appearsin the list. Confirm the 3D Geometrydialog box by clicking the button. The Face Milling Geometry dialog box isdisplayed again.
The rectangle is generated surroundingthe target model at the XY-plane. Confirm the Face Milling Geometrydialog box by clicking the button. The geometry is defined for the operation. Start the tool definitionby clicking the Select button. Currently, the Part Tool Table is empty. Define a new tool suitable for face milling. Click the Add Milling Tool button to start the tool definition. The new pane containing available tools is displayed. This dialog box enables you to add a new tool to the tool library choosing from thetools available for the current operation.
Face millThis tool type is used for machining of large flat surfaces. A tool of thistype is defined with the parameters shown in the image. Click the Select button to confirm the tool parameters and choose the tool for theoperation. Click the Facedepth button in the Milling levels area.
This button enables you to define the OperationLower level directly on the solid model. The depth is calculated automatically as thedifference between the Z-values of the Operation Upper and Lower levels.
The Pick Lower level dialog box isdisplayed. Select the model face as shown. The lower level value 0 is determined and displayed in the Pick Lower level dialog box. Confirm this dialog box with the button.
The Face depth value is displayed in the Millinglevels area. The pink background of the edit boxmeans that the parameter is associative to themodel. Associativity enables the selected level tobe synchronized with the solid model changes; SolidCAM automatically updates the CAM datawhen the model is modified. Define the technological parametersSwitch to the Technology page of the Face Milling Operation dialog box.
In theTechnology section, choose the One Pass option. The direction and locationof the pass are calculated automaticallyaccording to the face geometry, inorder to generate an optimal toolmovement with the tool covering thewhole geometry. Selecting the One pass optionautomatically opens the One passtab that enables you to define themachining parameters.
The Extension section enables you to define the tool path extensionover the face edges. The Face Milling operation data is saved, and the tool path is calculated. TheSimulation control panel is displayed. Switch to the SolidVerify page and startthe simulation with thebutton. The solid stock model defined in Exercise 1 is used in the SolidVerifysimulation mode.
During the machining simulation process, SolidCAM subtracts the tool movements using solid Boolean operations from thesolid model of the stock. The remaining machined stock is a solid modelthat can be dynamically zoomed or rotated.
It can also be compared to thetarget model in order to show the rest material. During the simulation, you can rotate , move , or zoom themodel. Use these options to see the machining area in details. The Single step mode can be used to simulate the next tool movement byclicking the button or by using the space bar on your keyboard. Close the simulation with the button. The Face Milling Operation dialog box isdisplayed.
Close this dialog box with the Exit button. The Profile Operation dialog box isdisplayed. In this operation, the external profile ismachined. Define the GeometryThe first step of definition of each operation is the Geometry selection.
At this stage,you have to define the Geometry for the Profile operation using the solid modelgeometry. Click in the Geometry page of the Profile Operation dialog box. This dialog box enables you to add and editgeometry chains. When this dialog box is displayed, you can select solid model entitiesfor the Geometry definition.
Chain Selection OptionsYou can define the geometry by selecting edges,sketch segments and points on the contour. The following options are available:CurveThis option enables you to create a chain ofexisting curves and edges by selecting themone after the other. Associativity: SolidCAM keeps the associativity to any edge or sketchentity. Any change made to the model or sketch automatically updatesthe selected geometry.
LoopThis option enables you to select a loop by picking one of the modeledges. Loop 2Loop Pick an edge shared by two model faces. Two faces towhich this edge belongs are determined, and their loopsare highlighted.
The first determined loop is consideredto be the primary and is highlighted with yellow color. The second loop is considered to be the secondary andis highlighted with blue color.
Choose one of the loops. Click on any other edgeforming the face. You are prompted to accept the chainthat is now highlighted with yellow color. Accept thechain with the Yes button. A closed geometry chain isdefined on this loop, and the secondary loop is rejected. Point to pointThis option enables you to connect specified points; the points areconnected by a straight line.
Associativity: SolidCAM does not keep the associativity to any selectedpoint. Any change made to the model or sketch does not update theselected geometry. You cannot select a point that is not located on aSolidWorks entity if you need to select such a point, adda planar surface under the model and select the pointson that surface.
Whenever the model is changed and synchronized,the geometry is updated with the model. Any change made to the model or sketch does notupdate the selected geometry. Automatic selection options SolidCAM automatically determines the chainentities and close the chain contour. The Autoselect mode offers the following options:Auto-toThe chain is selected by specifying the start curve,the direction of the chain and the element up towhich the chain is created.
SolidCAM enablesyou to choose any model edge, vertex or sketchentity to determine the chain end. The chain selection is terminated when the selectedend item is reached. End entityStart entitySelected chain If the chosen end item cannot be reached by the chain flow, the chaindefinition is terminated when the start chain segment is reached.
Thechain is automatically closed. End entityStart entitySelected chainThe confirmation message is displayed. The Auto-to option is useful if you do not want to definea closed chain, but an open chain up to a certain element. Auto-general SolidCAM highlights all the entities that are connected to the last chainentity. You have to select the entity along which you want the chain tocontinue.
You are prompted to identify thenext chain element when two entities on the same Z-level are connectedto the chain. Auto-Delta ZWhen you select this option, you are required to enter a positive andnegative Z-deviation into the Delta-Z dialog box.
Only entities in thisrange are identified as the next possible entity of the chain. In this exercise, the geometry must be defined as shown. The red arrow indicates the direction of the geometry. In SolidCAM operations, thedirection of the chain geometryis used for the tool pathcalculation. In Profile milling,the tool moves in the directionof the geometry by default. Inthis exercise, the combinationof the geometry direction andthe clockwise direction of thetool revolution enables you toperform climb milling.
Tool movementdirectionGeometrydirectionTool revolutiondirectionWhen you pick the first chain entity on the solid model, SolidCAM determines the start point of the picked entity closest to the pickedposition. The direction of the picked first chain entity is definedautomatically from the start point to the picked position. Starting pointDirectionPicked positionGeometry chainChoose the Loop option in the Chain section and click on the model edge as shown. Notice that the pickedposition must be close to thestart point of the geometry.
The red arrow indicates the direction of the selected chain. Click the secondary chain highlighted with blue color to choose it for geometrydefinition. The picked chain is now highlighted with red color, and the second chain is rejected. The confirmation message is displayed. Confirm it with the Yesbutton. The chain icon is displayed in the Chain List section. At this stage, the Geometry is defined. Confirm the Geometry selection withthe button. The Profile Operation dialog box is displayed.
Define the ToolAt this stage, you have to define the tool for the Profile milling. Switch to the Tool page of the Profile Operation dialog box and click the Select button. The Part Tool Table with the tool used in the previous operation is displayed. Click the End Mill tool to choose it for the operation. In the Tool parameter section,under Topology, set the Diameter value to Set the Spin rate used in rough milling value to TheSpin finish used in finish milling value is automatically setto When this check box is selected, thecorresponding edit box is available so that you can edit its value.
Whenthis check box is not selected, the specified Spin rate value is used forboth rough and finish machining. Select thecheck box near the Feed finish feed rate for finish milling parameter and set the value to The Feed finish check box enables you to optionally define differentvalues for Feed XY and Feed finish. Whenthis check box is not selected, the specified Feed XY value is used forboth rough and finish machining.
SolidCAM enables you to define the milling levels using the solid model data. Upper LevelThis parameter defines the Z-level at which the machining starts. Profile DepthThis parameter defines the Z-level below which the tool does not mill. This plane is not penetrated in any milling strategy. The Pick Upper level dialogbox is displayed. The Upper Level value 0 is determinedand displayed in the Pick Upper leveldialog box.
Confirm this dialog box byclicking the button. Click the Profile depth button in theMilling levels area. The Pick Lower level dialog box is displayed. Pick the bottom edge of the model asshown. The Lower level value is determinedand displayed in the Pick Lower leveldialog box. Confirm this dialog box withthe button. The Delta depth parameter defines the offset for the cutting depththat can be changed with its associativity preserved.
The Delta depthvalue is always relative to the Profile Depth defined for the operation. Set the Delta depth value to The milling levels are defined. Define the technological parametersSwitch to the Technology page of the Profile Operation dialog box. First, you need to make sure that the tool position relative to the geometry is correct.
In the Modify section, check the Tool side option. ModifyThe Tool side option enables you to determine the tool position relativeto the geometry.
Right — the tool cuts on the right side of the profile geometry. Left — the tool cuts on the left side of the profile geometry. Center — the center of the tool moves on the profile geometry nocompensation G4x can be used with this option. Left Right CenterThe Geometry button displays the Modify Geometry dialog box thatenables you to define the modification parameters of the geometryand to choose which geometry chains are active in the operation incase of multiple chain geometry.
The chain geometry of the profileis displayed on the model with the chain direction indicated anda circle representing the tool relative to the geometry. In this case, the default Left option meets therequirements of climb milling.
Click the Geometry buttonto check the tool position. Click the button in the ModifyGeometry dialog box. The ProfileOperation dialog box is displayed again. SolidCAM enables you to perform the rough and finish machining of the profile ina single Profile operation. Select the Rough check box. Definethe Step down parameter for roughing. Step downProfile roughing is performed inconstant Z-passes.
The Step downparameter defines the distancebetween each two successiveZ-levels. Step downUpperlevelProfiledepthSet the Step down to 5. With this value, SolidCAM performs two cuts at the following Z-levels: -5, ; the lastcut is performed at the Z-level defined by Profile depth. Now you need to define the wall offset that will remain after the roughing passes. OffsetsThe Wall offset and Floor offset parameters enable you to define theallowances that remain on the walls and the floor of the machined parttill the profile finish machining.
These allowances can be removed withthe finish passes in the same Profile operation or in an additional Profileoperation with another tool. Theallowance of 0. This allowance will be removed witha separate finishing cut in the end of the profile machining. Select the Finish check box to perform the finishing of theprofile.
This page enables you to define the way the tool approaches the profile and retreatsaway. Profile Lead in and Lead outThe lead-in movement is necessary to prevent vertical entering of thetool into the material.
With the lead-in strategies the tool descends to themachining level outside of the material and then horizontally penetratesthe material with the lead-in movement. The lead-out strategy enablesyou to perform the retract movements outside the material. The length of the normal canbe set in the Normal length field. Thedistance between the normal andmaterial is set in the Tangent extensionfield. The arcradius can be set in the Radius field.
Thelength of the extension can be set in theTangent extension field. The arc angle isset in the Arc angle field.
The length of the tangentcan be set in the Length field. Thedistance to the material can be set in theTangent extension field. From this position, thetool moves on a straight line to the startpoint of the profile. When you selectthis option, the Pick button is activatedso that you can select a position directlyon the solid model.
The distancebetween the point and material is set inthe Tangent extension field. When you select thisoption, you can define a geometry of the tool approach to the material.
When the Same as Lead in check box is selected, the strategy andparameters defined for Lead in are used for Lead out. Under Lead in, choose the Arc optionfrom the list, and set the Tangentextension value to 5 and the Radius valueto 2. Under Lead out, select the Same as Leadin check box. The definition of the basic technologicalparameters of profile milling is finished.
The Profile operation data is saved, and the toolpath is calculated. Simulate the operationClick the Simulate button in the Profile Operation dialogbox. The Simulation control panel is displayed. Switch tothe SolidVerify page and start the simulation with the Playbutton. When the simulation is finished, play the it step by step using thebutton.
Since all the View options ofSolidWorks are active during the simulation, you can see the tool path fromdifferent perspectives and zoom on a certain area of the model. Close the simulation with the Exitdisplayed. As the industry continues to move away from 2D drawings, the amount of information that is contained within a 3D CAD file format is increasing.
It has provided no editorial input. All opinions are mine, except where quoted or stated otherwise. Andrew Wheeler October 31, Previous Post. Next Post.
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