SolidCAM 2016 Port Machining
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Description
SolidCAM Application Tutorial: Port Machining SolidCAM + SOLIDWORKS The Complete Integrated Manufacturing Solution
Contents
1. Introduction................................................................................................................. 1 2. CAM-Part Definition.................................................................................................... 5 3. Stock and Target Definition...................................................................................... 13 4. iMachining Operation................................................................................................ 17 5. Roughing Operations................................................................................................ 23 6. Finishing Operations................................................................................................ 41
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Introduction
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About this course The goal of this course is to teach you how to use SolidCAM’s Port Machining to machine a simple and complex port. This tutorial covers the basic concepts of Port Machining. Once you have developed a good foundation in basic skills, you can refer to the online help for information on the less frequently used options. Prerequisites Students attending this course are expected to have basic knowledge of the SolidCAM software. Course design This course is designed around a task-based approach to training. The guided exercises will teach you the necessary commands and options to complete a machining task. The theoretical explanations are embedded into these exercises to give an overview of the Port Machining capabilities. Using this book This tutorial is intended to be used in a classroom environment under the guidance of an experienced instructor. It is also intended to be a self-study tutorial.
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1. Introduction
Port Machining The Port Machining operation is an easy to use method for machining ports with tapered lollipop tool, and has collision checks for the entire tool (shank, arbor, and holder). You can choose to cut the top only, the bottom only, and specify how much stock to leave on the entire port. It uses 3-Axis machining as far into the port as possible, and then switches to 5-Axis motion. Smooth transitions are created where the tool paths meet at the middle of the port. It provides both roughing and finishing tool paths to make ports from castings or billet.
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CAM-Part Definition
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The CAM-Part definition process for the part consists of the following stages: CAM-Part creation
CNC-Machine definition
Coordinate System definition
Stock and Target definition
• CAM-Part creation. At this stage, you have to define the CAM-Part name and location. SolidCAM defines the necessary system files and a folder to allocate the place to store SolidCAM data. • CNC-controller definition. It is necessary to choose the CNC-controller. The controller type influences the Coordinate System definition and the Geometry definition. • Coordinate System definition. You have to define the Coordinate System, which is the origin for all machining operations of the CAM-Part. You can create multiple CoordSys positions and in each machining step select which CoordSys you want to use for the operation. • Stock and Target definition. It is necessary to define a boundary of the stock that is used for the CAM-Part machining. SolidCAM enables you to define the model of the part in its final stage after the machining. The following exercises describe the full process of the CAM-Part definition. It is recommended to go through the stages in order to understand how the CAM-Part features are built. For this purpose, you have to turn off the automatic CAM-Part definition. 1. Browse to open PORT.SLDPRT. 2. Click Tools Settings.
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the SolidWorks part
> SolidCAM > SolidCAM
2. CAM-Part Definition 3. In
the left pane, select CAM-Part.
4. Ensure
image:
that the settings are as shown in the
This enables you to start directly adding operations in a new part.
5. In the left pane, select Automatic CAM-Part definition. In the right pane, click the Milling tab. 6. Ensure
that all check boxes are cleared.
7. Click OK.
8. Click Tools Milling. 9. Define
> SolidCAM > New >
the CAM-Part in the Milling Part Data dialog box:
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10. In
the CNC-Machine list, click table_table_exercise.
11. Click Define button in the Coordinate System tab to set the coordinate system for this part.
12. In the Place CoordSys origin to model box.
13. Select
list, click Top center of
the face as shown in the image.
14. Click
The CoordSys Data window displays.
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2. CAM-Part Definition 15. Enter
the parameters as shown in the image.
16. Click OK. 17. Click 1-Position
18. In
> Add.
the Place CoordSys origin to list, click CoordSys # 1.
19. Select
the face as shown in the image.
20. Click
The CoordSys Data window displays.
21. Enter
the parameters as shown in the image.
22. Click 23. Click
in the CoordSys Manager window.
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24. Click Edit iMachining Database
in the iMachining Data section.
The iDatabase window displays.
25. Click
the New
icon to define a new machine.
26. Enter HERMLE_PORT as iMachining DB File window.
the machine name in the New
27. Click Save. 28. Enter
the parameters as shown in the
29. Click
the Material DB tab.
30. Click
the New
image.
31. Enter AL-6061-T6 DB File window. 32. Click Save.
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icon.
as the material name in the New iMachining
2. CAM-Part Definition 33. Enter
the MPa value of 460 as shown in the image.
34. Click Save & Exit. 35. In
the iMachining Data section select the machine and material you just defined.
36. Click
in the Milling Part Data window.
The CAM part is now defined.
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Stock and Target Definition
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To define the stock you have to follow the steps mentioned in this chapter. 1. Click
the Feature Manager Design Tree
2. Click Design Model
3. The
image:
> Solid Bodies(3) > Stock > Show.
selected stock should look as shown in the
4. Click
the SolidCAM Manager
5. Right
click Stock > Define.
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icon.
icon.
3. Stock and Target Definition 6. In
the Defined by list, click 3D Model.
7. Select
the solids as shown in the image.
8. Enter
the Facet tolerance value as 0.1 so that your system does not create a big faceting file. 9. Click
10. Click Target
11. Select
> Define.
the solid as shown in the image.
12. Click
The stock and the target are now defined.
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iMachining Operation
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1. Right
click Operations > Machine Setup.
The Machine Setup window displays.
2. Enter a value of 225 as shown in the Z column. This will raise the part above the machining level. 3. Click OK.
4. Click
the Feature Manager Design Tree
5. Click Design Model
6. Click
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> STOCK > Hide.
the SolidCAM Manager
7. Right click Setup iMachining.
icon.
icon.
> Add Milling Operation > 2D
4. iMachining Operation
You can also add the 2D iMachining operation,by clicking the SolidCAM Operations tab > iMachining > 2DMachining. Or, by clicking the SolidCAM tab > 2D iMachining.
2.5D
8. In
the Technology list, click iRough.
9. Click Geometry. 10. In
the CoordSys list, click MAC 1 (2-Position).
11. Click
the New
12. Select
image.
icon under CoordSys.
the two contours as shown in the
13. Click Yes
the times.
in the OK to accept? window both
14. Click 15. Click Tool
16. Click
> Select.
the Add Milling Tool
icon.
17. Select END MILL.
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18. Enter
the parameters as shown in the
19. Select
the Holder check box.
image.
20. Select HSK A 63 ER 32x80. 21. Click
the iData tab.
22. In the Topology / Helical Angle click 35 (Standard).
list,
23. Click 24. Click Levels. 25. Click Upper Level. 26. Select
the face as shown in the image.
27. Click
28. Click Pocket depth. 29. Select 30. Click
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the point on the face as shown in the image.
4. iMachining Operation 31. Click Technology. 32. Set 33. In
the Wall / island offset as 0.1.
the Finish section, select the Floor check box.
34. Click Link. 35. Slide
the Max. arc size slide bar to around 6.19764. Ensure that the Advanced check box is selected.
36. Click
the Save & Calculate
37. Click
the Exit
icon.
icon.
The tool path should look as displayed in the image.
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Roughing Operations
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Before you start the roughing operation, you must make a few changes to close the holes as shown in the image.
1. Right
click > Edit part.
2. Click Insert
3. Enter
> Surface > Offset.
a value of 0 in the Offset Parameters field to make a copy of this surface.
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5. Roughing operations 4. Select
the five faces as shown in the video.
5. Click
6. Click
the Feature Manager Design Tree
7. Click Solid Bodies(3)
8. Click Insert
icon.
> PART >Hide.
> Surface > Untrim.
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9. Select
the two faces as shown in the image.
10. Select
section.
the Internal edges option in the Options
11. Click
12. Click Insert
> Surface > Untrim.
13. Select
the face as shown in the image.
14. Select
the All edges option in the Options section.
15. Click
You will now split this surface into two so that you get two single tubes for machining.
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5. Roughing operations 16. Click Insert
17. Click
> Curve > Split Line.
the Feature Manager Design Tree
18. Click Design Model 19. Click
icon.
> Plane4.
once in the section highlighted in green color.
20. Select
the four faces as shown in the video.
21. Select
the Intersection option in the Type of Split
section.
22. Click 23. Click Sketch 24. Click
> 3D Sketch.
the Line
icon.
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25. Select 26. Click
the two points as shown in the image.
the esc (escape) key on your keyboard.
27. Click
to come out of the sketch.
28. Click Insert
> Surface > Fill. Ensure that in the Feature Manager Design Tree, Surface-Fill3, 3DSketch3 is switched on.
29. Select
the three edges as shown in the video.
30. Click
This will ensure that you have three distinct tubes available for machining. 31. Click
to finish editing the part.
32. Click
the SolidCAM Manager
33. Right
click the previous operation > Add Milling Operation > Port Machining.
34. In
icon.
the Technology list, click Roughing.
35. Click Geometry. 36. Click
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the New
icon under Machining surfaces.
5. Roughing operations 37. Select
the faces as shown in the video.
38. Click 39. Set
the Offset value as 0.5.
40. Click Tool
> Select.
41. Click
the Add Milling Tool
42. Enter
the parameters as shown in
43. Select
the Holder check box.
the image.
icon.
44. Select HSK A 63 ER 32x80 as the holder. 45. Click 46. Click Levels. 47. Click
the Parallel to X option to get a cylinder parallel to the X axis.
48. Click the three Through point.
points button,
next to
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49. Select
the point as shown in the image.
50. Click
51. Enter the Retract distance value in the Levels section as shown in the image.
52. Click Tool path parameters. 53. Enter
the values as shown in the image.
54. Click
the Sorting tab.
55. In
the Output type list, click Top.
56. In
the Machine to list, click Maximum from top.
57. Click Tool axis control. 58. Unselect
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the Minimize tilting check box.
5. Roughing operations 59. Click Gouge check. 60. Select
the Check surfaces check box.
61. Ensure
62. Click
that in the Feature Manager Design Tree, PART is switched on.
the New
63. Select
icon under Check surfaces.
the faces as shown in the image.
64. Click 65. Click Clearance data.
66. Enter
the parameters as shown in the
67. Click
the Save & Calculate
68. Click
the Simulate
image.
69. Click the Play window.
icon.
icon.
icon in the Simulation
The tool path should look as shown in the image.
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70. Click
the Save, Parallel Calculate & Copy
icon.
71. Click Geometry. 72. Click
the New
73. Select
icon under Machining surfaces.
the faces as shown in the image.
74. Click 75. Click Gouge check. 76. Select
77. Click
the Check surfaces check box.
the New
78. Select
icon under Check surfaces.
the faces as shown in the image.
79. Click 80. Click Clearance data.
81. Enter
image.
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the parameters as shown in the
5. Roughing operations
82. Click
the Save & Calculate
83. Click
the Simulate
84. Click
the Play
icon.
icon.
icon in the Simulation window.
The tool path should look as show in the image.
Click the Exit
icon.
85. Click
the Exit
icon to come out of the Operations Manager.
86. Right
click > Copy the operation.
87. Right
click > Paste the operation.
88. Right
click > Edit the operation.
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89. Click Geometry. 90. Click
the New
91. Select
icon under Machining surfaces.
the faces as shown in the video.
92. Click 93. Click Tool path parameters. 94. Click
the Sorting tab.
95. In
the Output type list, click Bottom.
96. In
the Machine to list, click Maximum from bottom.
97. Click
the Feature Manager Design Tree
98. Click Solid Bodies(3)
icon.
> PART >Show.
99. Click Tool axis control. 100. Unselect
the Minimize tilting check box.
101. Click Gouge check.
102. Select
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the New
icon under Check surfaces.
5. Roughing operations 103. Select
the highlighted surface.
104. Click
105. Click Clearance data. 106. Enter
the parameters as shown in the
107. Click
the Save & Calculate
108. Click
the Simulate
109. Click
the Play
image.
icon.
icon.
icon in the Simulation window.
The tool path should look as show in the image.
110. Right 111. In
click the operation > Add Milling Operation > 3D HSR.
the Technology list, click Contour roughing.
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112. Click CoordSys 113. Go
to the Feature Manager Design Tree and switch on the PART.
114. Click 2-Position 115. In
box.
the face as shown in the image.
the Modify by pick section, select the Pick XY origin check
118. Select
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> Add.
the Place CoordSys origin to list, click Top center of model box.
116. Select
117. In
on Geometry page.
the point as shown in the image.
5. Roughing operations 119. In the Modify by flip section, click the Flip around Z button twice. 120. Click
The CoordSys Data window displays. 121. Enter
the parameters as shown in the image.
122. Click 123. Click
to close the CoordSys Manager window.
124. Click Tool
125. Click
> Select.
the Add Milling Tool
126. Select BULL NOSE MILL
icon.
as the tool.
127. Enter
the parameters as shown in the
128. Select
the Holder check box.
image.
129. Select HSK A 63 ER 32x80. 130. Click
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131. Click Constraint boundaries. 132. Select 133. In
the Created manually option.
the list, click User-defined boundary.
134. Click
the New
135. Select
icon under Boundary name.
the boundary as shown in the image.
136. Click Yes
in OK to accept? window.
137. Click
138. Click Passes. 139. Enter
image.
the parameters as shown in the
140. Click Z-Top.
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5. Roughing operations 141. Select
the point as shown in the image.
142. Click 143. Click 144. In
the Adaptive step down tab.
the Adapt Step down by list, click None.
145. Click Link. 146. Click
the Ramping tab.
147. Enter
the parameters as shown in the
148. Click
the Retracts tab.
image.
149. Select the Minimal vertical retract option.
150. Click
the Save & Calculate
151. Click
the Simulate
152. Click
the Play
icon.
icon.
icon in the Simulation window.
The tool path should look as show in the image.
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153. Click
the Exit
icon to close the Simulation window.
154. Click
the Exit
icon to come out of the Operations Manager.
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Finishing Operations
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1. Right 2. In
click the operation > Add Milling Operation > Port Machining.
the Technology list, click Spiral Finishing.
3. Click Geometry. 4. In
the list, click faces.
The selected faces should look as shown in the image. You have earlier used this geometry in the roughing operation. The name in your file may differ than what is mentioned in the tutorial. Therefore, from the list, select the faces as shown in the image. 5. Click Tool 6. Select
list.
> Select.
the LOLLIPOP MILL tool from the
7. Click Levels. 8. Click
the Parallel to X option to get a cylinder parallel to the X axis.
9. Click 10. Select 11. Click
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the point as shown in the image.
6. Finishing Operations 12. Enter
the value in the Levels section as shown in the image.
13. Click Tool path parameters. 14. Click
the Sorting tab.
15. In
the Output type list, click Top.
16. In
the Machine to list, click Maximum from top.
17. Click Gouge check. 18. In
the Check surfaces list, click faces1.
The selected face should be as shown in the image. The name in your file may differ than what is mentioned in the tutorial. Therefore, from the list, select the faces as shown in the image. 19. Click Clearance data. 20. Enter
the parameters as shown in the
21. Click
the Save & Calculate
22. Click
the Simulate
23. Click
the Play
image.
icon.
icon.
icon in the Simulation window.
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The tool path should look as show in the image.
24. Click
the Exit
icon.
25. Click
the Exit
icon.
26. Right
click > Copy the operation.
27. Right
click > Paste the operation.
28. Right
click > Edit the operation.
29. In
the Technology list, click Plunge Finishing.
30. Click Geometry. 31. In
the list, click faces2.
The selected faces should look as shown in the image. You have earlier used this geometry in the roughing operation. The name in your file may differ than what is mentioned in the tutorial. Therefore, from the list, select the faces as shown in the image.
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6. Finishing Operations 32. Click Tool path parameters. 33. Click
the Sorting tab.
34. Enter
the parameters as shown in the
image.
35. Click Tool axis control. 36. Unselect
the Minimize tilting check box.
37. Click Gouge check.
38. Click
the New
39. Select
icon under Check surfaces.
the highlighted faces.
40. Click
41. Click Clearance data. 42. Enter
the parameters as shown in the
43. Click
the Save & Calculate
44. Click
the Simulate
45. Click
the Play
image.
icon.
icon.
icon in the Simulation window. 45
The tool path should look as show in the image. 46. Click
the Exit
icon.
47. Click
the Exit
icon.
48. Right
click the operation > Copy.
49. Right
click the operation > Paste.
50. Right
click the operation > Edit.
51. In
the Technology list, click Spiral Finishing.
52. Click Geometry. 53. In
the list, click faces4.
The selected faces should look as shown in the image. You have earlier used this geometry in the roughing operation. The name in your file may differ than what is mentioned in the tutorial. Therefore, from the list, select the faces as shown in the image.
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6. Finishing Operations 54. Change
the Offset value to 0.
55. Click Tool 56. Select
> Select.
the LOLLIPOP MILL tool from the list.
57. Click Tool path parameters. 58. Set
the Maximum step over limit as 1.
59. Click
the Sorting tab.
60. In
the Output type list, click Bottom.
61. In
the Machine to list, click Maximum from bottom.
62. Click Gouge check. 63. In
the Check surfaces list, click faces5.
The selected face must look as shown in the image. The name in your file may differ than what is mentioned in the tutorial. Therefore, from the list, select the faces as shown in the image.
64. Click Clearance data. 65. Enter
image.
the parameters as shown in the
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66. Click
the Save & Calculate
67. Click
the Simulate
68. Click
the Play
icon.
icon.
icon in the Simulation window.
The tool path should look as show in the image. 69. Click
the Exit
icon.
70. Click
the Exit
icon.
71. Right
click the operation > Add Milling Operation > 3D HSM.
72. In
the Technology list, click Helical machining.
73. In
the CoordSys list, click MAC 1 (3-Position) as the user coordinate system.
74. Click Tool 75. Select
> Select.
the LOLLIPOP MILL tool from the list.
76. Click Constraint boundaries. 77. Select 78. In
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the Created manually option.
the list, click User-defined boundary.
6. Finishing Operations 79. In
the Boundary name list, click contour.
The selected boundary must look as shown in the image. The name in your file may differ than what is mentioned in the tutorial. Therefore, from the list, select the contour as shown in the image.
80. Click Passes. 81. Enter
image.
the parameters as shown in the
82. Click Z-Top. 83. Select
the point as shown in the image.
84. Click
85. Select
the Adaptive step down tab.
86. Enter
the parameters as shown in the
image.
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87. Click Link. 88. Click
the Retracts tab.
89. Click
the Minimal vertical retract option.
90. Click
the Save & Calculate
91. Click
the Simulate
92. Click
the Play
icon.
icon.
icon in the Simulation window.
The tool path should look as show in the image. 93. Click
the Exit
icon.
94. Click
the Exit
icon.
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SolidCAM Application Tutorial:
Port Machining
iMachining 2D
2.5D Milling
HSS (High-Speed Surface Machining)
iMachining 3D
Indexed Multi-Sided Machining
HSM (High-Speed Machining)
Simultaneous 5-Axis Machining
Turning & Advanced Mill-Turn
Solid Probe
www.youtube.com/SolidCAMProfessor www.youtube.com/SolidCAMiMachining
www.solidcam.com
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