SolidCAM 2016 Turning and Mill-Turn Training Course

SolidCAM Training Course: Turning & Mill-Turn iMachining 2D & 3D | 2.5D Milling | HSS | HSM | Indexial Multi-Sided | Simultaneous 5-Axis | Turning & Mill-Turn | Solid Probe

SolidCAM + SOLIDWORKS The Complete Integrated Manufacturing Solution

SolidCAM 2016 Turning & Mill-Turn Training Course

©1995-2016 SolidCAM All Rights Reserved.

Contents

Contents

1. Introduction 1.1 About this Course.....................................................................................................3 1.2 Turning Module Overview......................................................................................5 1.3 Mill-Turn Module Overview...................................................................................8 1.4 Basic Concepts...........................................................................................................9 1.5 Process Overview......................................................................................................9

2. CAM-Part Definition Exercise #1: CAM-Part Definition in Turning.................................................. 14 Exercise #2: CAM-Part Definition in Mill-Turn............................................... 27

3. Machine Preview 3.1 Understanding the Toolbar buttons.................................................................... 44

4. Turning Operations 4.1 Basic Turning.......................................................................................................... 48 Exercise #3: Turning Operations on Turning CNC-Machine........................ 51 Exercise #4: Button Lock Machining............................................................... 102 Exercise #5: Guided Ejector Bushing Machining........................................... 104 Exercise #6: Guide Pillar Machining................................................................ 106 Exercise #7: Bearing Bush Machining.............................................................. 108 4.2 Advanced Turning: Rest Material...................................................................... 110 Exercise #8: Wheel Machining.......................................................................... 111

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4.3 Advanced Turning: Partial machining............................................................... 123 Exercise #9: Long Shaft Machining.................................................................. 124 4.4 Turning on Mill-Turn CNC Machines.............................................................. 135 Exercise #10: Turning Operation on Mill-Turn CNC-Machine.................. 138

5. Milling on Mill-Turn CNC-Machines Exercise #11: Facial Milling................................................................................ 167 5.1 Using MCO on Mill-Turn CNC-machines....................................................... 181 Exercise #12: Machining with Back Spindle.................................................... 183 Exercise #13: Control of Machine Devices.................................................... 194

6. Advanced Mill Turn Advanced Mill-Turn: Exercise #1..................................................................... 202 Advanced Mill-Turn: Exercise #2..................................................................... 306 Advanced Mill-Turn: Exercise #3..................................................................... 314

7. Channel Synchronization 7.1 Understanding the Buttons on the Ribbon...................................................... 321 7.2 Applying color to Synchronization label and submachines........................... 325 7.3 General Rules of Channel Synchronization..................................................... 327 7.4 Working with the operation of Channel Synchronization............................. 328

Document number: SCMTTCENG1600SP1

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Introduction

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1. Introduction

1.1 About this Course The goal of this course is to teach you how to use SolidCAM to machine various parts using Turning and Mill-Turn CNC-machines. This tutorial covers the basic concepts of Turning and Mill-Turn machining and is a supplement to the system documentation and online help. 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. The SolidCAM 2.5D Milling Training Course is recommended but not necessary to be studied before this course for better understanding of Milling with 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 SolidCAM Mill-Turn 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. Exercises The Training Materials archive supplied together with this book contains copies of the various files that are used throughout this course. The Exercises folder contains the files that are required for doing guided and laboratory exercises. The Built Parts folder inside the Exercises contains completed manufacturing projects for each exercise. Copy the Exercises folder to your hard drive. The SolidWorks files used for the exercises were prepared with SolidWorks 2016. The Machine files folder contains a number of pre-processors (CNC-controller configuration file) used through the exercises of this book. Copy the content of this folder into your ..\SolidCAM2016\Gpptool folder.

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The CNC-machine folder contains the CNC-machines definition files used for Machine Simulation. Copy the contents of the CNC-machine folder into the machine definition folder on your hard drive (the default location is C:\Users\Public\Documents\SolidCAM\ SolidCAM2016\Tables\MachSim\xml). Windows® 7 The screenshots in this book were made using SolidCAM 2016 integrated with SolidWorks 2016 running on Windows® 7. If you are running on a different version of Windows, you may notice differences in the appearance of the menus and windows. These differences do not affect the performance 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 the Change to opposite button. The mouse icon and numbered sans serif bold

10. Define CoordSys Position text indicate the beginning of the exercise

action. The action explanation is as follows.

Explanation

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This style combined with the lamp icon is used for the SolidCAM functionality explanations embedded into the guided exercises. The lamp icon is also used to emphasize notes.

1. Introduction

1.2 Turning Module Overview The SolidCAM Turning module enables you to prepare the tool path for the following operations: Face Turning SolidCAM enables you to perform turning of facial profiles. The principal working direction is the X-axis direction.

Turning SolidCAM enables you to prepare the tool path for all types of external and internal turning operations: long external, long internal, face front, and face back.

Drilling SolidCAM enables you to perform all drilling cycles to machine the holes coincident with the revolution axis of the part.

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Threading SolidCAM enables you to prepare the tool path for all types of external and internal threading.

Grooving SolidCAM enables you to prepare the tool path for all types of external and internal grooving and parting.

Angled Grooving SolidCAM enables you to perform inclined grooves. The geometry defined for this operation must be inclined relative to the Z-axis of the CAM-Part Coordinate System..

Cutoff SolidCAM enables you to perform cutoff machining. This operation is used to cut the part or to perform a groove whose width is exactly the same as the tool width. The cutting can be performed using CNC-machine cycles; chamfers and fillets can also be generated.

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1. Introduction

Trochoidal Turning SolidCAM enables you to turn complex profiles using the Trochoidal cutting strategy. The cutting passes are rounded in the beginning and in the end to result in smooth optimized tool path that enables you to use high cutting speed and reduce tool wear. Balanced Rough SolidCAM enables you to work with two tools performing roughing cuts at the same time. The Master submachine and Slave submachine should have the same Table. Manual Turning SolidCAM enables you to perform turning according to your own geometry regardless of a stock model, target model, or envelope.

Sim. tilted turning SolidCAM enables you to perform machining of curveshaped tool paths using tilting capabilities of tools with round insert. The tool tilting is defined by specifying lines that indicate the tool vector change.

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1.3 Mill-Turn Module Overview The Mill-Turn module is intended for programming of 3-, 4- and 5-axis multi-task machines that combine several capabilities into one machine and especially for programming of 5-axis milling CNC-machines with turning capabilities (e.g. DMU FD-series of DMG, Okuma, Mazak, Nakamura, Index, Chiron). This functionality provides you with a number of significant advantages: • The Mill-Turn module provides you with full functionality of the Coordinate System definition, identical to that of SolidCAM Milling. • You can use the same coordinate system for milling as well as for turning without additional definition. • You can define a Stock model to be used in SolidCAM Milling as well as in SolidCAM Turning operations. • The Mill-Turn module enables you to perform all types of Milling and Turning operations using the same post-processor. • The Mill-Turn module enables multi-turret and multispindle programming, with turret synchronization and full machine simulation. • Using the Mill-Turn module, you do not need to learn new rules; you just work in regular milling environment and can add turning operations as needed.

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1. Introduction

1.4 Basic Concepts Every manufacturing project in SolidCAM contains the following data: CAM-Part

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

By selecting Edges, Curves, Surfaces or Solids, define what and where you are going to machine. This geometry is associated with the native SolidWorks model. Operation

An Operation is a single machining step in SolidCAM. Technology, Tool parameters and Strategies are defined in the operation. In short, operation means how you want to machine.

1.5 Process Overview Three major stages of the SolidCAM Manufacturing Project creation process are: CAM-Part definition

This stage includes the definition of the global parameters of the Manufacturing Project (CAM-Part). You have to define Coordinate Systems that describe the positioning of the part on the CNC-machine. Optionally, you can define the Stock model that will be used for milling operations and the Target model that has to be obtained after the machining. Machine Setup definition

When the part is to contain Turning operations, the clamping fixture has to be defined in order to supply SolidCAM with the information about fixing the part on the CNC-machine and the part position relative to the machine. Operations definition

SolidCAM enables you to define turning and milling operations. During the operation definition, 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 technological parameters.

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CAM-Part Definition

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The CAM-Part definition process consists of the following stages: CAM-Part creation

CNC-Machine definition

Coordinate System definition

Setup

Stock model definition

Target model definition

• CAM-Part creation. According to default settings, the CAM-Part name and location are defined automatically. However, you can define them manually, if you choose the manual option. At this stage, SolidCAM defines the necessary system files and a folder to allocate the place to store SolidCAM data. • CNC-Machine 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. • Setup. You have to define the clamping fixture, the initial stock position on main or back spindle and the position of the part zero with reference to the main or back spindle. • Stock model definition. It is necessary to define a boundary of the stock that is used for the CAM-Part machining. • Target model definition. 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 complete 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.

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2. CAM-Part Definition

Before you start, select SolidCAM Settings command from the SolidCAM main menu.

In the left pane, select CAM-Part > Automatic CAM-Part definition. In the right pane, click the Turning tab and clear the following check boxes: Create machine setup, Definition of Stock, and Definition of Target.

Click OK to confirm your choice. These settings can be turned back on at any time.

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Exercise #1: CAM-Part Definition in Turning This exercise illustrates the process of the CAM-Part definition in SolidCAM. In this exercise, you have to create the CAM-Part for the model displayed on the illustration and define the Coordinate System, the Machine Setup, the Stock and Target model, which are necessary for the part machining. The CAM-Part will be used in the exercises further on.

1.

Load the SolidWorks model

Load the Exercise1.sldprt model located in the Exercises folder. This model contains a number of features forming the solid body and several sketches used for the CAM-Part definition. 2.

Start SolidCAM

To activate SolidCAM, select SolidCAM in the Tools menu of SolidWorks and choose Turning from the New submenu or click the Turning button on the SolidCAM New toolbar.

The CAM-Part is saved in the default location defined in the CAM Settings. To learn more about saving projects, refer to the SolidCAM Turning Online Help. During this process, the structure of the CAM-Part is created.

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2. CAM-Part Definition The structure of the CAM-Part

The CAM-Part includes Turning.prt a number of data files represented on the illustration Turning that displays the data included Turning.SLDASM in the CAM-Part named Turning. CAM.SLDPRT The Turning.prt file is DesignModel.SLDPRT located in the SolidCAM User directory. The Turning subdirectory contains all the data generated for the CAM-Part. SolidCAM copies the original SolidWorks model to the Turning subdirectory and creates a SolidWorks assembly that has the same name as the CAM-Part ( Turning.sldasm). There are two components in this assembly: • DesignModel.sldprt – a copy of the SolidWorks model file. • CAM.sldprt – a file that contains SolidCAM Coordinate System data and geometry data. The SolidCAM CAM-Part uses the assembly environment of SolidWorks. This enables you to create auxiliary geometries (e.g. sketches) without making changes in the original design model. You can also insert some additional components into the assembly file such as stock model, CNC-machine table, clamping and other tooling elements. The New Turning Part dialog box is displayed. Click The Turning Part Data dialog box is displayed.

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3.

Choose CNC-Machine

Define the CNC-machine controller. Click the arrow in the CNC-Machine area to display the list of post-processors installed on your system. In this exercise, choose the T_4X_Haas_ST30_HaasCNC CNC-Machine from the list.

4.

Define the Coordinate System

Click Define in the CoordSys area of the Turning Part Data dialog box to define the Machine Coordinate System.

The Machine Coordinate System defines the origin for all machining operations on the CAM-Part. It corresponds with the built-in controller functions. It can be used for various clamping positions in various operations on the CAM-Part. Usually Turning CNC-machines have only one machine Coordinate System; its Z-axis is the rotation axis of the spindle. The Machine Coordinate System enables you to perform all turning operations.

Z-axis

The CoordSys dialog box enables you to define the location of the Coordinate System and the orientation of the axes.

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2. CAM-Part Definition

You can define the position of the Coordinate System origin and the axes orientation by selecting model faces, vertices, edges or SolidWorks Coordinate Systems. The geometry for the machining can also be defined directly on the solid model. SolidCAM offers the following methods of CoordSys definition: • Select Face

This method enables you to define a new CoordSys by selecting a face. The face can be planar or cylindrical/conical. For planar faces, SolidCAM defines CoordSys with the Z-axis normal to the face. For cylindrical or conical faces, the Z-axis of the CoordSys is coincident with the axis of revolution of the specified cylindrical/conical surface. • Define

This method enables you to define the CoordSys by picking points. You have to define the origin and the directions of the X- and Y-axes. • Select Coordinate System

This method enables you to choose the SolidWorks Coordinate System defined in the design model file as the CoordSys. The CoordSys origin and the orientation of the axes is the same as in the original SolidWorks Coordinate System. • By 3 points (associative)

This method enables you to define the CoordSys Origin and axes by selecting any three points. Choose the High precision option. High precision

When the High precision check box is selected, the Coordinate System is defined using the faceted model, which results in more precise definition, but may take more time to generate. When this check box is not selected, the Coordinate System is defined using CAD tools without facetting

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Choose the Center of revolution face option. With this option, the origin is placed automatically on the axis of revolution face. With the Select Face mode chosen, click on the model face as shown. The Z-axis of the CoordSys is coincident with the axis of revolution. Note that the CoordSys origin is automatically defined on the model back face and the Z-axis is directed backwards. Click Change to opposite.

This button enables you to change the Z-axis direction to the opposite along the revolution axis.

Now the CoordSys origin is located on the front face of the model, and the Z-axis is directed forward along the revolution axis. Confirm the selection by clicking Finish. The Coordinate System is defined. The Turning Part Data dialog box is displayed again.

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2. CAM-Part Definition Coordinate Systems for Turning

This Machine CoordSys is used for the turning operations. The turning tool movements are located in the ZX-plane.

CoordSys origin X Z

All the machining geometries are defined in the ZX-plane of the defined Coordinate System. Machining Geometry

X Z 5.

Define the Stock model

For each Turning project, it is necessary to define the boundaries of the stock material (Stock) used for the CAM-Part. Click the Stock button. The Stock dialog box is displayed. This dialog box enables you to define the Stock model of the CAM-Part to be machined.

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The following methods of Stock definition are available: • Cylinder

This option enables you to define the Stock boundary as a cylinder surrounding the selected solid model. You can define the cylindrical stock by specifying Offsets of the cylinder faces from the selected solid body or coordinates of its boundaries relative to the CAM-Part Coordinate System. The Add to CAD model button enables you to add a 3D sketch of the cylinder stock to the CAM component of the part assembly. • Box

This option enables you to define the Stock boundary as a box surrounding the selected solid model. When you click on the solid body, SolidCAM generates a 3D box around it. This box defines the geometry of the Stock. • Revolved boundary around Z

This option enables you to define the Stock boundary as a wireframe geometry chain using one of the model sketches. When the chain is selected, perpendiculars are dropped from its end points to the axis of rotation to define the material boundary. The Revolved boundary around Z option enables you to define only one chain, either opened or closed. When more than one chain is defined, the error message is displayed. Selected chain

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2. CAM-Part Definition • 3D Model

This method enables you to define the Stock boundary by selecting the 3D Model of the stock. SolidCAM automatically generates a sketch that contains the envelope of the selected solid body. The Stock boundary is defined automatically on this sketch. Envelope

Consider the revolution body surrounding the specified solid bodies. The section of this revolution body by the ZX-plane of the Coordinate System is the envelope. The envelope line is the profile of the part that has to be turned in order to obtain the model geometry.

Solid body

Surrounding revolution body

Envelope profile

Choose the Cylinder mode from the Defined by list and click on the solid body to select it.

In the Mode section, choose Relative to model. In the Offsets dialog section, define the following offsets: • Set +Z to 2 and -Z to 25 to define the front and back offsets from the model • Set the External offset to 2 • Set the Internal diameter offset to 0 21

SolidCAM defines a cylinder. Left (-Z)

Right (+Z)

External

Internal diameter

The Mode section enables you to define the offsets Relative to model or define the Stock boundaries in the Absolute coordinates. When the Internal diameter value is different from 0, SolidCAM defines a tube. Click 6.

to confirm the Stock selection. Define the Target model

Now you have to define the Target model.

The Target model is the final shape of the CAM-Part after the machining. It is used for gouge checking in the SolidVerify simulation. During the Target model definition, SolidCAM creates an Envelope sketch in the CAM component of the CAM-Part assembly. This sketch contains the geometry automatically generated by the Envelope function of SolidCAM. This function creates the envelope line of the specified solid bodies. Consider the revolution body surrounding the solid body. The section of this revolution body by the ZX-plane of the Turning Machine CoordSys is the envelope. This envelope is a profile of the part that has to be turned in order to create the model geometry.

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2. CAM-Part Definition

Solid body

Surrounding revolution body

Envelope profile

Section

The Envelope function takes into account all external model faces as well as the internal faces. The geometry created by the Envelope function can be used for the Geometry definition in SolidCAM operations. The Mirrored Envelope option generates the envelope sketch mirrored about the Z-axis in the ZX-plane. This option is applicable for machines with lower turret. In addition to the Envelope, SolidCAM enables you to generate a sketch containing a Section of the Target model by the ZX-plane. The Section sketch is created in the CAM component of the SolidCAM Part Assembly. In the Turning Part Data dialog box, click the Target button. The Target dialog box is displayed. This dialog box enables you to define a 3D Model for the Target. Click on the solid body. The wireframe model is displayed.

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Set the Facet tolerance to 0.01. This parameter defines the accuracy of the triangulation of the stock model, target model and fixtures. The triangulated models are used later in the tool path simulation. The tighter is the tolerance, the better is the performance of the simulation. . Confirm the dialog box with In the process of the Target model definition, SolidCAM creates the Envelope sketch in the CAM component of the CAM-Part assembly. The Envelope sketch is used later for the machining geometry definition.

7.

Save the CAM-Part data

Click in the Turning Part Data dialog box. The defined CAM-Part is saved. The dialog box is closed, and the SolidCAM Manager tree is displayed.

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2. CAM-Part Definition SolidCAM Manager

The SolidCAM Manager tree is the main interface feature of SolidCAM that displays complete information about the CAMPart.

The SolidCAM Manager tree contains the following elements:

• CAM-Part header

This header displays the name of the current CAM-Part. By right-clicking on it, you can display the menu to manage your CAM-Parts. The Machine subheader is located under the CAM-Part header. Double-click this subheader to display the Machine ID Editor dialog box that enables you to preview the machine parameters. The CoordSys Manager subheader is located under the CAM-Part header. Double-click this subheader to display the CoordSys Manager dialog box that enables you to manage your Coordinate Systems.

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The Stock subheader is located under the CAM-Part header. Double-click this subheader to load the Stock dialog box that enables you to edit the definition of the Stock model. The Target subheader is located under the CAM-Part header. Double-click this subheader to load the Target dialog box that enables you to edit the definition of the Target model. The Updated Stock subheader is located under the CAM-Part header. Right click this subheader to save the updated stock in the STL format. The Settings subheader is also located under the CAM-Part header. Double-click this subheader to load the Part Settings dialog box that enables you to edit the settings defined for the current CAM-Part. • Tool header

This header displays the name of the current Tool Library. Double-click this header to display the Part Tool Table, which is the list of tools available to use in the current CAM-Part. • Machining Process header

This header displays the name of the current Machining Process table. • Geometries header

This header displays all SolidCAM geometries that are not used in the operations. • Fixtures header

This header displays all SolidCAM fixtures that are not used with the current CAM-Part. • Operations header

This header displays all SolidCAM operations defined for the current CAM-Part. At this stage, the definition of the CAM-Part is finished. The definition of Turning operations is covered in the following exercises where this CAM-Part is used. 8.

Close the CAM-Part

Right-click the CAM-Part header in SolidCAM Manager and choose Close from the menu. The CAM-Part is closed. 26

2. CAM-Part Definition

Exercise #2: CAM-Part Definition in Mill-Turn This exercise illustrates the process of the CAM-Part definition in Mill-Turn module of SolidCAM. In this exercise, you have to create the CAM-Part for the model displayed on the illustration and define the Coordinate System, the Stock model and the Target model, which are necessary for the part machining. The CAM-Part will be used in the exercises further on. Before you start, select the SolidCAM Settings command from the SolidCAM menu. In the left pane, select Automatic CAM-Part definition. In the right pane, click the Mill-Turn tab and clear the following check boxes: Definition of Stock, and Definition of Target.

Then you have to turn off the default templates loading for Milling operations.

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In the left pane, select Defaults > Template. In the right pane, under 2.5D Milling, clear all check boxes next to the templates names.

Click OK to confirm your choice. These settings can be turned back on at any time. 1.

Load the SolidWorks model

Load the Exercise2.sldprt model located in the Exercises folder.

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2. CAM-Part Definition 2.

Start Mill-Turn project

Click the SolidCAM item in the Tool menu of SolidWorks and choose Mill-Turn from the New submenu or click the Mill-Turn button on the SolidCAM New toolbar.

The CAM-Part is defined, and its structure is created. The New Mill-Turn Part dialog box is displayed. Click The Mill-Turn Part Data dialog box is displayed.

3.

Choose the CNC-controller

Click the arrow in the CNC-Machine area to display the list of post-processors installed on your system. Choose the 00282_MT_4.5X_HT_NTX2000_FANUC31i CNCcontroller from the list.

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4.

Define the Coordinate System

Definition of the Machine Coordinate System is a mandatory step in the process of CAM-Part definition. This step can be performed automatically if the corresponding option is chosen in SolidCAM settings. The Machine Coordinate System defines the origin for all machining operations on the CAM-Part. It corresponds with the built-in controller functions and can be used for various clamping positions in a variety of operations on the CAM-Part. The Machine Coordinate System #1 (Position #1) can be used for turning operations as well as for all types of milling operations. In the Turning mode, SolidCAM uses the Turning Coordinate System created by rotating of the Machine Coordinate System #1 (Position #1) around the Z-axis.

Geometry

Coordinate System

The axes orientation for the Turning Coordinate System are defined in the CoordSys item of the submachine in the Machine ID file of the chosen CNC-controller. At the stage of operation definition, you will need to make sure that you choose an appropriate submachine to generate the correct GCode. Click the Coordsys button in the Coordinate System area of the Mill-Turn Part Data dialog box to define the Machine Coordinate System.

The CoordSys dialog box enables you to define the Coordinate System location and the orientation of the axes. You can define the position of the Coordinate System origin and the axes orientation by selecting model faces, vertices, edges or SolidWorks Coordinate Systems.

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2. CAM-Part Definition

SolidCAM enables you to define the CoordSys using the following methods: • Select face

This method enables you to define a new CoordSys by selecting a face. The face can be planar or cylindrical/conical. For planar faces, SolidCAM defines CoordSys with the Z-axis normal to the face. For cylindrical or conical faces, the Z-axis of the CoordSys is coincident with the axis of revolution of the specified cylindrical/conical surface. When the High precision check box is selected, the Coordinate System is defined using the faceted model, which results in more precise definition but may take more time to generate. When this check box is not selected, the Coordinate System is defined using CAD tools without facetting. • Define

This method enables you to define the CoordSys by picking points. You have to define the origin and the directions of the X- and Y-axes. • Select Coordinate System

This method enables you to choose the SolidWorks Coordinate System defined in the design model file as the CoordSys. The CoordSys origin and the orientation of the axes is the same as in the original SolidWorks Coordinate System. • Normal to current view

This option enables you to define the Coordinate System with the Z-axis normal to the model view you are facing on your screen. The CoordSys origin will lie in the origin of the SolidWorks Coordinate System, and the Z-axis will be directed normally to the chosen view of the model. • By 3 points (associative)

This option enables you to define the CoordSys Origin and axes by selecting any three points.

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5.

Select the model face

Make sure that the Center of revolution face option is chosen for Place CoordSys origin to.

With this option, the origin is placed automatically on the axis of revolution face. With the Select Face mode chosen, select the High precision check box and click on the model face as shown. The CoordSys origin is located on the front face of the model, and the Z-axis is directed forward along the revolution axis.

Click

to confirm the selection.

Click the Coordsys button in the Coordinate System area of the Mill-Turn Part dialog box.

Data

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2. CAM-Part Definition

Click the Edit button in the Coordsys Manager. The CoordSys Data dialog box is displayed.

6.

Define the CoordSys data

The CoordSys Data dialog box enables you to define the Coordinate System values and machining levels such as Tool start level, Clearance level, Part upper level, etc. CoordSys Data dialog box

The MAC Number defines the number of the CoordSys in the CNCmachine. The default value is 1. If you use another number, the GCode file contains the G-function that prompts the machine to use the specified number stored in the controller of your machine.

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The Position field defines the sequential number of the Coordinate System. For each Machine Coordinate System, several Position values can be defined for different positions; each such Position value is related to the Machine Coordinate System. • X shows the X-value of the CoordSys. • Y shows the Y-value of the CoordSys. • Z shows the Z-value of the CoordSys. The Create planar surface at Part Lower level option enables you to generate a transparent planar surface at the minimal Z-level of the part so that its lower level plane is visible. This planar surface provides you the possibility to select points that do not lie on the model entities. It is suppressed by default and not visible until you unsuppress it in the FeatureManager Design tree. The Levels section is divided into three parts: Planar, Radial and Rear. The Levels: Planar section displays levels for milling from the positive Z-direction. The Levels: Radial section contains a set of machining levels describing the virtual cylinders situated around the Z-axis. Tool Z-level Tool Start Level Clearance level Part Upper Level CoordSys

X

Z Y

Part Lower Level

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2. CAM-Part Definition

The Levels: Rear section displays levels for milling from the negative Z-direction.

CoordSys X

Part Lower Level

Z Y

Part Upper Level Clearance level Tool Start Level Tool Z-level

These tabs contain the following parameters: • The Tool Z-level is the height to which the tool moves before the rotation of the 4/5 axes to avoid collision between the tool and the workpiece. This level is related to the CoordSys position and you have to check if it is not over the limit switch of the machine. It is highly recommended to send the tool to the reference point or to a point related to the reference point. • The Tool start level defines the Z-level at which the tool starts working. • The Clearance level is the Z-level to which the tool moves rapidly from one operation to another (in case the tool does not change). • The Part upper level defines the height of the upper surface of the part to be machined. • The Part lower level defines the lower surface level of the part to be machined.

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• The Tool Z-level is the height to which the tool moves before the rotation of the 4/5 axes to avoid collision between the tool and the workpiece. This level is related to the CoordSys position and you have to check if it is not over the limit switch of the machine. It is highly recommended to send the tool to the reference point or to a point related to the reference point.

Tool Start level Rapid Movements area Clearance level

Feed Movements area

Part Upper level Part Lower level

The Translation Data option enables you to set the Shift and Rotation values. Shift is the distance from the Machine Coordinate System to the location of the Position in the coordinate system and the orientation of the Machine Coordinate System. Rotation is the angle of rotation around the main axes X, Y and Z. In the Mill-Turn module, facial and radial milling is performed using the same Coordinate System. But since the part levels used for facial milling are measured along the Z-axis, whereas those used for radial milling are measured around the Z-axis, the CoordSys data must be defined separately. The Plane box defines the default work plane for the operations using this CoordSys, as it is output to the GCode program. In the SolidCAM CAM module, you must always work on the XY-plane. Some CNC-machines, however, have different axes definitions and require a GCode output with rotated XY-planes. Confirm the CoordSys Data dialog box with

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2. CAM-Part Definition

The CoordSys Manager dialog box is displayed in the PropertyManager area of SolidWorks. This dialog box displays one Machine Coordinate System. Confirm the CoordSys Manager dialog box by clicking

.

The Mill-Turn Part Data dialog box is displayed. 7.

Define the Stock model

Define the boundaries of the stock material used for the CAM-Part. Click the Stock button. The Stock dialog box is displayed. This dialog box enables you to define the Stock model of the CAM-Part to be machined. The following methods of Stock definition are available: • Cylinder

The Stock boundary is defined as a cylinder surrounding the selected solid model. When you click on the solid body, SolidCAM generates a cylinder around it. This cylinder defines the geometry of the Stock. You can define the cylindrical stock by specifying offsets of the cylinder faces from the selected solid body or coordinates of its boundaries relative to the CAM-Part Coordinate System. • Box

The Stock boundary is defined as a box surrounding the selected solid model. When you click on the solid body, SolidCAM generates a 3D box around it. This box defines the geometry of the Stock. You can define the box stock by specifying offsets of the box faces from the selected solid body or coordinates of its boundaries relative to the CAM-Part Coordinate System.

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• Revolved boundary around Z

The Stock boundary is defined as a wireframe geometry chain using one of the model sketches in the ZX-plane. When the chain is selected, perpendiculars are dropped from its end points to the axis of rotation to create the 2D geometry that will be revolved around the Z-axis to define material boundary. • Extruded boundary

The Stock boundary is defined as a closed wireframe geometry chain using one of the model sketches in the XY-plane. This chain is extruded by the Z-axis to define the material boundary. • 3D Model

The Stock boundary is defined by selecting a 3D model. • STL

The Stock model is defined based on a STL file that exists in your system. When you choose this mode and click the Browse button in the STL file section, the Browse dialog box is displayed. This dialog box enables you to choose the STL file for the stock definition. When the Generate envelope check box is selected, SolidCAM generates a sketch containing the envelope of the selected solid body. The Stock boundary is defined in this sketch.

Solid body

38

Surrounding revolution body

Envelope profile

2. CAM-Part Definition

Choose the Cylinder mode from the Defined by list and click on the solid body to select it. SolidCAM defines a cylinder.

In the Offsets section, define the following offsets: • Set +Z to 2 and -Z to 1 to define the front and back offsets from the model. • Set the External offset to 1. • Set the Internal diameter offset to 0. When the Internal diameter value is different from 0, SolidCAM defines a tube. The defined offsets are added to the cylindrical stock.

39

In the Facet tolerance section, set the value to 0.1. This parameter defines the accuracy of triangulation of the Stock model. The triangulated model is used later in the tool path simulation. The tighter is the tolerance, the better is the performance of the simulation. Click to confirm the Stock dialog box. The Stock envelope sketch is added to the CAM component of the CAM-Part assembly and is displayed on the solid model.

8.

Define the Target model

Now you have to define the Target model. The Target model is the final shape of the CAM-Part after the machining. It is used for gouge checking in the SolidVerify simulation. The Target options are similar to those used for Turning CAM-Part definition. Click the Target button. The Target dialog box is displayed. Click on the solid body. The model is highlighted.

40

2. CAM-Part Definition

Make sure the Envelope option is selected in the Generate Envelope/Section area. Confirm the Model dialog box with . The envelope sketch is added to the CAM component of the CAM-Part assembly and is displayed on the solid model. This sketch will be used later for the turning geometry definition.

9.

Save the CAM-Part

In the Mill-Turn Part Data dialog box, click . The dialog box is closed and the SolidCAM Manager tree is displayed. The defined CAM-Part is saved. At this stage, the definition of the CAM-Part is finished. The definition of Milling and Turning operations is covered in the coming exercises using this CAM-Part. 10.

Close the CAM-Part

Right-click the CAM-Part header in the SolidCAM Manager tree and choose Close from the menu. The CAM-Part is closed.

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42

Machine Preview

3

The Machine Preview window allows you to visualize the schematic position of the machine devices without entering the Machine Simulation mode. This window is displayed in the following ways: • When you click the Preview (

) button in the Machine ID Editor.

• When you click the Machine Preview ( dialog boxes.

) button in the Setup and MCO

• When you click the Mounting button in the Tool Table window.

3.1 Understanding the Toolbar buttons The toolbar enables you to control the machine parameters in the graphic area. The toolbar buttons may vary depending on the type of the dialog box where you click the Machine Preview button.

Machine Preview from Machine ID Editor

Machine Preview from MCO

Machine Preview from Setup

Machine Preview from Tool Table

44

3. Machine Preview

The table below mentions all the buttons available in the machine preview windows:

The Show/Hide STLs Machine button enables you to toggle between showing and hiding the machine scheme represented by STL files.

Update Machine button

Update Stock

button

Update Fixtures

Update Tools

button

button

These buttons allow you to change the tool direction along the chosen axis. The Flip button enables you to turn the tool around its axis.

The Focus Tool button enables you to set the current view focused on the tool. The Show/Hide CoordSys button enables you to toggle between showing and hiding Coordinate Systems of machine devices and tools.

The Show/Hide Text button enables you to toggle between showing and hiding the names of the machine devices. The Show/Hide All Tools button enables you to toggle between showing and hiding the tools mounted on turrets.

45

These buttons enable you to manage the machine views related to the orientation of the selected CoordSys position. Axes

This section enables you to browse and edit positions of each particular machine axis. You can type the value in the edit box or change it gradually by scrolling the mouse wheel. If a position value causes collision with another devices, the edit box and the colliding device are highlighted red. The following additional buttons enable you to use data related to the machine axis: The Home Reference Axes button enables you to set axes to Home Reference values.

The Set All Axes to Zero button enables you to set all axes values to 0 regardless of their original value. The Return to Initial Axes Value button enables you to reset all axes values to the original value defined in VMID. The Paste Axes Values button enables you to paste current position values into specified edit boxes. The Add Axes Values button enables you to add a new row to the Movement list in an MCO operation and paste current position values into specified edit boxes. When you are defining a turning operation, the original MAC position is displayed in machine preview. For example, if you are using MAC1 (1-Position) for turning operation, it will be displayed in machine preview. If the additional angle is changed in tool orientation, it also updates the coordinate position. When you are defining a milling operation, the original MAC position is displayed in the machine preview. For example, if you are using MAC2 (1-Position) for milling operation, it will be displayed in machine preview.

46

Turning Operations

4

4.1 Basic Turning SolidCAM enables you to perform the following types of Turning operations.

Turning Operation types

Face Turning

Cutoff

Turning

Trochoidal Turning

Drilling

Balanced Rough

Threading

Manual Turning

Grooving

Sim. tilted turning

Angled Grooving

Face Turning Operation This operation enables you to perform turning of facial profiles. The principal working direction is the X-axis direction.

Turning Operation This operation enables you to turn a longitudinal or facial profile. The resulting tool path can either use the turning cycles of the CNC-machine, if they exist, or it can generate all the tool movements. If the tool movements are generated by the program, then minimum tool movements length is generated taking into account the material boundary in the beginning of the particular operation. The profile geometry is adjusted automatically by the program, if needed because of the tool shape, to avoid gouging of the material.

48

4. Turning Operations

Drilling Operation This operation enables you to perform a drilling action along the rotation axis. There is no geometry definition for this type of operation since it is enough to define the drill start and end positions.

Threading Operation This operation enables you to perform threading. The threading can be either longitudinal (internal or external) or facial. This operation can be used only if the CNC-machine has a thread cycle. SolidCAM outputs the tool path for the threading exactly with the same length as the defined geometry without any checking for material collision.

Grooving Operation This operation enables you to perform a groove either on a longitudinal geometry (internal or external) or a facial geometry. The resulting tool path can either use a single machine cycle, generate all the tool movements (G0, G1) or generate several machine cycles.

Angled Grooving Operation This operation enables you to perform inclined grooves. The geometry defined for this operation must be inclined relative to the Z-axis of the CAM-Part Coordinate System. The Tool angle parameter enables you to adjust the angle of the tool cutting the material.

49

Cutoff Operation This operation enables you to perform cutoff machining. This operation is used to cut the part or to perform a groove whose width is exactly the same as the tool width. The cutting can be performed using CNC-machine cycles; chamfers and fillets can also be generated.

Balanced Rough Operation This operation enables you to work with two tools performing roughing cuts at the same time. The Master submachine and Slave submachine should include the same Table.

Manual Turning Operation This operation enables you to perform turning according to your own geometry regardless of a stock model, target model, or envelope. The Reverse cutting path option enables you to machine undercuts effectively.

Sim. tilted turning This operation enables you to perform machining of curveshaped tool paths using tilting capabilities of tools with round insert. The tool tilting is defined by specifying lines that indicate the tool vector change. This operation is useful for machining of undercut areas in a single machining step.

For more detailed explanation on the Turning operations, refer to the SolidCAM Turning Online Help.

50

4. Turning Operations

Exercise #3: Turning Operations on Turning CNC-Machine In this exercise, you have to define the machine setup and clamping fixture and to perform a number of Turning operations to conclude the machining of the CAM-Part. The exercise uses the CAM-Part created in Exercise #1. First, you have to define the machine setup and clamping fixture that holds the machined workpiece on the CNC-machine table.

1.

Load the CAM-Part

Click Tools > SolidCAM > Open, or click the Open button on the SolidCAM toolbar.

In the browser window, choose Exercise1.prz to load the CAM-Part that has been prepared earlier. The CAM-Part is loaded.

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2.

Define the machine setup

Right-click the Operations header in SolidCAM Manager and choose the Machine Setup ( ) command. The Machine setup dialog box is displayed. This dialog box enables you to define the relations between fixtures, submachines, and the Machine Coordinate System.

Machine Setup

The Machine Setup definition is an optional step in definition of CAM-Parts that contain Turning operations. Using the Setup feature, you can define the fixtures and their location relative to the Coordinate Systems associated with certain submachines. This unified representation of all setup data allows you to get a more realistic picture during simulation and check possible collisions between the cutting tools and fixtures. At this stage, you have to define a fixture that helps to prevent a possible collision of tools during machining. The Fixture column enables you to choose or define a fixture to be used with the specified submachine. To define the fixture, double-click the cell, click the arrow and choose . The Model dialog box is displayed. This dialog box enables you to define the fixture geometry. Make sure that the Chuck (Standard) option is chosen in the Defined by section. This option enables you to define a standard three-step chuck by specifying the clamping method, chuck position and dimensions. Clamping method

This section enables you to define how the clamping device will be attached to the workpiece. Selecting the Mirrored check box moves the fixture on the back spindle.

52

4. Turning Operations Chuck position

The chuck positioning is defined with the Clamping diameter (CD) and Axial position ( Z ) parameters relative to the stock end face: The Clamping diameter (CD) and Axial position ( Z ) parameters can be defined by picking on the model. When the model is picked, SolidCAM measures the X- and Z- distances from the CoordSys origin to the picked positions and displays the values in the corresponding edit boxes. The default Chuck position is defined on the edge of the stock envelope created during the Stock model definition. The Clamping diameter is 94, and the Axial position is -92. Now you need to define the dimensions of the chuck. Chuck sizes library

SolidCAM enables you to define and store fixtures as libraries for reuse in fixture definition. Click the Take from library button to open the Fixture library dialog box. This dialog box enables you to create and manage the fixture library. Jaws parameters

•

The Jaw width (JW) parameter defines the overall width of a single jaw.

Step Width Jaw Height Step Height Jaw Width

•

The Jaw height (JH) parameter defines the overall height of a single jaw.

•

The Step width (SW) parameter defines the width of the lower step.

•

The Step height (SH) parameter defines the height of the lower step.

53

Associativity is not maintained for chucks defined by parameters. Set the values in the Jaws parameters section as follows: • Set the Jaw width (JW) value to 50. • Set the Jaw height (JH) value to 50. • Set the Step width (SW) value to 20. • Set the Step height (SH) value to 20. The clamping fixture is defined.

For the options of 3D options, Rotation, Visualisation, and Envelope, refer to the SolidCAM Turning Online Help. to confirm the Model dialog box. Click The Machine setup dialog box is displayed again. Now you have to define the model position relative to the submachine coordinate system. Double-click the cell in the Z column. Set the value to 132. Click the Preview icon

to see the changes.

The model is located now in 132 mm above the table allowing better visualization during the machine simulation mode. button enables you The Machine Preview to display the machine preview dialog box to quickly visualize the schematic position of the machine devices without entering the machine simulation mode.

54

4. Turning Operations

Click the Machine Preview button. The Machine Preview window opens.

For more information on Machine Preview, refer to the Machine Preview chapter. Confirm the Setup definition with OK. The Setup subheader is added to the SolidCAM Manager tree under the Operations header.

3.

Add a Turning Operation

Right-click the Operations header in the SolidCAM Manager tree and choose Turning from the Add Turning Operation submenu.

You can also select the Turning command from the Turning menu on the SolidCAM Operations ribbon.The Turning Operation dialog box is displayed. 55

4.

Define the Geometry

Make sure the Wireframe option is selected the Geometry section.

Turning geometry can be defined by selecting wireframe elements or by picking solid model entities such as faces, edges and vertices. The following geometry definition options are available: • Wireframe

This option enables you to define the turning geometry by wireframe geometry selection. • Solid

This option enables you to define the turning geometry by selecting model entities such as faces, edges, vertices, origin and sketch points. When model entities are picked, SolidCAM automatically defines the geometry on the envelope/section segment corresponding to the selected model elements. You have to define the machining geometry for the external roughing operation using the Envelope sketch. The sketch was automatically generated in the Target model definition process described in Exercise #1. Click the New icon ( ). The Geometry Edit dialog box is displayed in the SolidWorks PropertyManager area. This dialog box enables you to define and edit geometry chains. SolidCAM enables you to choose the mode of the geometry selection in the Chain section of the Geometry Edit dialog box. Chain options

You can define the geometry by selecting edges, sketch segments and points on the contour. The following options are available: • Curve

You can create a chain of existing curves and edges by selecting them one after the other. Associativity:

SolidCAM keeps the associativity to any edge or sketch entity. Any change made to the model or sketch automatically updates the selected geometry.

56

4. Turning Operations

The Curve option offers the following options: Up to Entity: The

chain is selected by specifying the start curve, the direction of the chain and the element up to which the chain is created. SolidCAM enables you to choose any model edge, vertex or sketch entity to determine the chain end.

When the end item is chosen, SolidCAM determines the chain according to the chosen selection mode (Tangent propagation, Constant Z Propogation). The chain selection is terminated when the selected end item is reached. If the chosen end item cannot be reached by the chain flow, the chain definition is terminated when the start chain segment is reached. The chain is automatically closed. Tangent propogation: A tangent entity following the current one and not located at the same Z-level is chosen.

You are required to enter a positive and negative Z-deviation into the Delta Z Tolerance edit box. Only entities within this range are identified as the next possible entity of the chain. Constant Z propogation:

• Point to point

This option enables you to connect specified points; the points are connected by a straight line. Associativity:

SolidCAM does not keep the associativity to any selected point. SolidCAM saves the X-, Y- and Z-coordinates of the selected points. Any change made to the model or sketch does not update the selected geometry. • Arc by points

This option enables you to create a chain segment on an arc up to a specific point on the arc. Associativity:

SolidCAM does not keep the associativity to any selected arcs by points. SolidCAM saves the X-, Y- and Z-coordinates of the selected points. Any change made to the model or sketch does not update the selected geometry. 57

Make sure that the default Curve mode is chosen. Unselect the check boxes of Up to Entity, Tangent propagation and Constant Z Propagation. Select the sketch segments as shown. The order of the geometry selection is important, since it defines the direction of machining. Operations in SolidCAM use the direction of the chain geometry to calculate the tool path. The arrow at the start point of the chain indicates the direction of the chain. In the Chain section of the Geometry Edit dialog box, choose the Point to point option. This option enables you to connect the specified points with a straight line. Click on the sketch point as shown. The linear geometry segment is defined.

Pick the rest of the sketch entities as shown in the image. The geometry chain is defined for the external roughing operation. Confirm the chain definition with the Accept chain button.

58

4. Turning Operations Add Selected Element

This button enables you to add the entity highlighted with the direction arrow to the current chain. Change Direction

This button enables you to toggle between available chain entities following the current segment. Undo step

This button enables you to undo the last selection of a chain element. Reverse

This button enables you to reverse the direction of the selected chain.. Reject chain

This button cancels the single chain selection. The chain icon is displayed in the Chain List section. Close the Geometry Edit dialog box with and return to the Turning Operation dialog box. In the Edit Geometry section, click the Modify Geometry button. The Modify Geometry dialog box is displayed. It enables you to modify geometries defined for SolidCAM operations: extend/trim and assign offsets, and also choose the geometry chains to be used in the operation (in case of multiple chain geometry).

59

The Start Extension/trimming and End Extension/trimming sections enable you

to define the length of the extension/ trimming applied to the start/end of the geometry chain.

The Distance option enables you to define the extension/trimming distance: when a positive value is defined, the chain is extended from the start/end point with straight lines of the specified length; when a negative value is defined, the chain is trimmed from the start/end point up to the specified distance measured along the geometry chains. End Extension

Start Extension

Clear the Auto extend Start to Stock section, and set 3 as the Distance value to extend the geometry outside the material. In the End Extension/trimming section, set the Distance value to 5. Click the Apply to all button to confirm the chain selection. Close the Modify Geometry dialog box with Turning Operation dialog box is displayed again.

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. The

4. Turning Operations 5.

Define the Tool

After the geometry definition, you have to define the tool for the operation. Switch to the Tool page of the Turning Operation dialog box and click the Select button. The Part Tool Table is displayed.

The Part Tool Table is a tool library that contains all the tools available for use with a specific CAM-Part. The Part Tool Table is stored within the CAM-Part. Click the Add Turning Tool

icon to start the definition of a new tool.

Available composite and solid tools are displayed in the right pane of the dialog box.

From the Composite Tools section, choose the Ext. Turning tool. Click the Insert tab and enter the tool parameters as shown in the image:

61

Click the Shank tab and enter the tool parameters as shown in the image:

Click

the Holder 8_251_11_004 as the

check holder.

box.

Select

Click the Mounting button. The Mounting dialog box is displayed. Using the Flip Tool shown.

and axes rotation buttons, set the tool in the position as

The Z-, Z+, X-, X+ buttons enable you to set the tool direction parallel to the corresponding axis of the station. The Flip

button enables you to turn the tool around its axis.

The Focus Tool button enables you to set the current view focused on the tool.

62

4. Turning Operations

The Show/Hide CoordSys button enables you to toggle between showing and hiding Coordinate Systems of machine devices and tools. button enables you to toggle between The Show/Hide Text showing and hiding the names of the machine devices. The Show/Hide All Tools button enables you to toggle between showing and hiding the tools mounted on turrets. The Show/Hide STLs Machine button enables you to toggle between showing and hiding the machine scheme represented by STL files. buttons enable you to manage the The machine views related to the orientation of the selected CoordSys position. The Additional angle parameter enables you to add a certain angle value to the chosen orientation if the tool must be mounted. The Tool tip position option enables you to define the tool tip position relative to the station Coordinate System for Machine Simulation. When your tool holder supports multiple tools, Position in Multitool holder option provides the possibility to rotate the turret around the Spindle axis in angle increments defined by the Min. Angle Step Around Spindle Axis parameter in the Machine ID file (*.vmid). Click the Mounting button again to close the dialog box. Switch to the Tool Data tab. This page enables you to define the general technological parameters. These parameters are associated with the current tool and applied to every operation where this tool is used.

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Spin normal

This field defines the Spin value for Normal turning. Spin finish

This field defines the Spin value for Finish turning. Generally, the Spin value can be calculated using the following formula for metric system: Spin=(1000*V)/(π*D), where V is the cutting speed and D is the diameter. And for inch system: Spin=(12*V)/(pi*D), where V is the cutting speed and D is the diameter. In this exercise, it is recommended to use the cutting speed of 210 m/min. The diameter used for spin calculation is 90 mm (maximal diameter of the part). According to the formula above, Spin≈750. Choose V (m/min) as Spin units. Define the Spin parameters. Set the Spin normal and Spin finish values to 750. icon to choose the tool for the operation. At this stage, the Click the Select tool is defined in the Part Tool Table. 6.

Define the technological parameters

Switch to the Technology page of the Turning Operation dialog box. Make sure option is chosen in the Mode area. that the default Long external This option enables you to execute external longitudinal turning (the principal working direction is the Z-axis direction). In the Work type area, use the default Rough option. Work type

This option enables you to choose the method of the machining: • Rough

The tool path movements are parallel to the Z-axis (longitudinal turning) or to the X-axis (facial turning). Semi-finish and finish passes are performed, if chosen, at the end of the rough stage.

64

4. Turning Operations • Copy

The finish pass is performed, if chosen, at the end of the copy stage.

• Finish only

This option is used for the final turning of the CAM-Part. When this option is chosen, only the semifinish or finish pass is executed. In the Rough tab, choose Smooth from the Rough type drop-down list. Set the Step down value to 2.

In the Rough offset section, choose the ZX-ABS option. Set the Distance X value to 0.4 and the Distance Z value to 0.1.

Rough offset

This drop-down list has three options: • Distance

This option defines the constant offset distance from the geometry. You are prompted to enter the Distance value. • ZX

SolidCAM enables you to define different offsets in the X and Z directions. You are prompted to enter both Distance X and Distance Z.

dz

dx

65

• ZX-ABS

This option is similar to the ZX option, except that the program chooses the sign of each vector component (dx, dz) so that the offset geometry does not intersect with the profile geometry.

In the Semi-finish/finish tab, select the No option in the Semi-finish and Finish sections. The finishing operation will be performed later. 7.

Calculate the tool path

At this stage, all of the operation parameters are defined. icon in the Turning Operation dialog box to save Click the Save & Calculate the operation data and calculate the tool path. The preview of the tool path is displayed on the solid model. 8.

Simulate the tool path

Use the simulation to check and view the generated tool path after you have defined and calculated your machining operations. If you have made mistakes in the definition of operations or used unsuitable turning strategies, the simulation helps you avoid problems that you would otherwise experience during the actual production running. icon in the Turning Operation dialog box. The Simulation Click the Simulate control panel is displayed. Switch to the Turning page. This simulation mode enables you to display the 2D simulation of the turning tool path. In the Show section, choose the Both option. This option displays both the tool path and the material.

66

4. Turning Operations

Click the Play

button. The simulation is displayed.

When the simulation is finished, switch to the SolidVerify page of the Simulation control panel. This simulation mode enables you to view the tool path on the 3D Model. Rotate the model to the isometric view with the Click the Play

button.

button to start the simulation.

SolidVerify simulation mode

This mode enables the simulation of machining on the solid model. The solid stock model defined as Stock is used in this mode. The Fixture is displayed. During the machining simulation, SolidCAM subtracts the tool movements from the solid model of the stock using solid Boolean operations. The remaining machined stock is a solid model that can be dynamically zoomed or rotated. 67

When the simulation is finished, click the Exit button. The Turning Operation dialog box is displayed. Click the Exit icon to close the dialog box.

9.

Add a Face Turning operation

Right-click the Turning operation defined in the previous steps and choose Face from the Add Turning Operation submenu to add a new facing operation. The Face Turning Operation dialog box is displayed. 10.

Define the Geometry

Define the geometry as shown on the illustration to machine the end face. Click (New) in the Geometry page. The Geometry Edit dialog box is displayed.

Click on the sketch segment as shown.

In this operation, the geometry must be directed to the rotation axis of the model.

68

4. Turning Operations

Note the direction of the geometry. When you pick the first chain entity on the solid model, SolidCAM determines the start point of the picked entity closest to the picked position. The direction of the picked first chain entity is defined automatically from the start point to the picked position. Picked position Geometry chain

Direction Start point

Accept the chain and get back to the Face Turning Operation dialog box. Click the Modify Geometry button. In the Start Extension/ trimming section, set 4 as the Distance value to extend the geometry outside the material. In the End extension/ trimming section, set the Distance value to 20. Confirm the geometry modification with the 11.

button.

Define the Tool

Use the tool defined in the previous turning operation. Click the Select button in the Tool page to choose the tool from the Part Tool Table. The Part Tool Table is displayed. Choose the Ext. turning tool used in the first operation and click the Select icon. The tool is chosen for the operation. Click the Data tab in the Tool page of the Turning Operation dialog box to customize the tool parameters such as Spin and Feed for the operation. The Spin value can be calculated using the following formula: Spin=(1000*V)/(π*D),

where V is the cutting speed and D is the

diameter. In this exercise, it is recommended to use the cutting speed of 200 m/min.

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The diameter used for spin calculation is 58 mm (maximal diameter of the end face). According to the formula above, Spin≈1100. Set the Spin normal and the Spin finish to 1100. Set the Feed normal to 0.2.

The tool is defined for the operation. 12.

Define the technological parameters

Switch to the Technology page of the Face Turning Operation dialog box. option is chosen in the Mode area. This option Make sure that the Front enables you to machine the front end face. SolidCAM enables you to perform roughing and finishing in a single operation. Make sure that the Rough option is selected. In the Rough type section, select the Smooth option. In the Offset section, set Offset Z value to 0.1. Select the Finish option to execute a finishing pass in the direction of the geometry.

13.

Save and Calculate

At this stage, all the operation parameters are defined. Click in the Face Turning Operation dialog box to save the operation data and calculate the tool path. 70

4. Turning Operations 14.

Simulate

Click in the Face Turning Operation dialog box. The Simulation control panel is displayed. Simulate the tool path in the Turning mode.

When the simulation is finished, switch to the SolidVerify mode and simulate the tool path again. Close the Simulation control panel with the Exit button. The Face Turning Operation dialog box is displayed. Close it with the Exit button.

In the following operation, you have to perform rough machining of the internal faces using a Drilling operation. The U-Drill tool is used to machine the internal hole without center drilling and to increase the machining speed by avoiding the pecking. Using the U-Drill, you can also avoid the preliminary drilling and operate the tool with the largest diameter.

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15.

Add a Drilling operation

Right-click the Face Turning operation and choose Drilling from the Add Turning submenu to add a new Drilling operation. The Drilling Operation dialog box is displayed.

Operation

16.

Define the Tool

Click the Select button in the Tool page to start the tool definition. The Part Tool Table is displayed. Click to start the definition of a new tool. Select the DRILL tool for this operation. Set the following parameters of the U-Drill tool that will be used for the operation: • Set the D parameter to 28 • Set the A parameter to 180 • Set the AD parameter to 35 • Set the TL parameter to 120

•

Set the OHL parameter to 90

• •

Set the SL parameter to 90 Set the CL parameter to 72

Switch to the Tool Data page to define the Spin and Feed parameters of drilling. The Cutting speed recommended for the drilling operation is 80 m/min. According to the following formula, Spin=(1000*V)/(π*D), diameter (28 mm),

where V is the cutting speed and D is the

Spin≈900.

Set the Spin rate and Spin finish values to 900. Set the Feed XY value to 0.08 mm/tooth. Click the Holder check box. Select BT 40 ER 32x60 as the holder. Confirm the tool definition with the Select icon. The Drilling Operation dialog box is displayed.

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4. Turning Operations 17.

Define the Drill start position

The geometry for drilling is defined by two points: start and end positions. Switch to the Technology page of the Drilling Operation dialog box. Click the Drill start button in the Positions section. The Pick Start point dialog box is displayed. Click on the front face of the part as shown.

The coordinates of the selected point are displayed in the Pick Start point dialog box. Confirm this dialog box with the button. The Drilling Operation dialog box is displayed again. 18.

Define the Drill end position

Define the end position of the drilling. Click the Drill end button in the Positions section. The Pick End point dialog box is displayed. Click on the back face of the part.

The coordinates of the selected point are displayed in the Pick End point dialog box. Confirm the dialog box with the button. The Drilling Operation dialog box is displayed again. In the Depth type section, select the Full diameter option.

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19.

Save and Calculate

At this stage, all the parameters of the operation are defined. in the Drilling Operation dialog box to save the operation data and Click calculate the tool path. 20.

Click

Simulate

in the Drilling Operation dialog box. Simulate the tool path in the

Turning mode.

Simulate the tool path in the SolidVerify mode.

Close the Simulation control panel with the Exit box with .

button. Close the Drilling

Operation dialog

21.

Add an External Finishing operation

Right-click the last defined Drilling operation in SolidCAM Manager and choose Turning from the Add Turning Operation submenu. The Turning Operation dialog box is displayed. 22.

Copy data from the existing operation

SolidCAM enables you to use an already existing operation as a template for the current operation. All the operation data is copied from the template to the current operation. This feature enables you to save the programming time. In the Operation name section, choose the first operation (TR_ contour11) as a template. The data is copied. In the current operation, use the same geometry that you used for the external roughing.

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4. Turning Operations 23.

Define the Tool

Click the Select button in the Tool page. The Part Tool Table is displayed with the data of the earlier tool copied from the template operation. Now you have to define a new tool in the Part Tool Table and choose it for the operation. Click to start the definition of the new tool. From the Composite Tools section, choose the Ext. Turning tool. In the Insert tab, enter the parameters as shown in the image:

In the Shank tab, enter the parameters as shown in the image:

Click the Holder check box and select 8_251_11_004 as the holder. Click Mounting and set the tool in the vertical position as shown. icon to Click the Select confirm the tool definition and choose it for the operation.

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Now you have to define the Spin and Feed values. Click the Data tab in the Tool page of the Turning Operation dialog box. Generally, the Spin value can be calculated using the following formula: Spin=(1000*V)/(π*D), where V is the cutting speed and D is the diameter. In this case, the differences of diameters through the tool path do not enable you to use the common Spin value. The V ( Velocity) option is used. This option enables you to define the cutting speed. The number of revolutions per minute is calculated automatically according to the actual diameter. Using this option, you can maintain the constant cutting speed along the tool path. In the areas of the smallest diameter, the number of revolutions is greater and vice versa.

Under Spin, choose the V(m/min) option in the Spin rate and Spin finish sections. Set the cutting speed value of 240 for the Spin rate and the Spin finish. Set the Reference diameter value to 100. Set the Min. Spin (rpm) value to 100. Set the Max. Spin (rpm) value to 3000. With this value, SolidCAM limits the number of revolutions per minute. The gear drop down list provides you the list of gear units as defined in the VMID file. When V(m/min) option is used in either Spin rate or Spin finish sections, the Auto Gear-switching section is enabled. This allows you to override the gear units and define the min. and max. rpm in order to maintain a constant surface speed. The Reference diameter parameter allows you to define the value used for calculating the minimum rpm. The Min. and Max. spin parameters allow you to define the min and max spin values of the current gear unit. Selecting the Stay in gear limits check box, uses the Min. and Max. spin values according to the defined machine gear unit. If you select the Auto Gear-switching check box, the gear drop down list is not available for use. 76

4. Turning Operations 24.

Define the technological parameters

Switch to the Technology page of the Turning Operation dialog box. Under the General tab, in the Work type area of the Technology page, choose the Finish only option. This option is used for the finish turning of the CAM-Part. When this option is chosen, only the semi-finish or finish pass is executed. In the Semi-finish/finish tab, choose the ISO-Turning method option in Finish area. This option enables you to perform the finishing pass in the direction of the geometry. 25.

Save and Calculate

Click in the Turning Operation dialog box to save the operation data and calculate the tool path. 26.

Click

Simulate

in the Turning Operation dialog box. Simulate the tool path in the

Turning mode.

Simulate the tool path in the SolidVerify mode.

Close the Simulation control panel with the Exit . Operation dialog box with

button. Close the Turning

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27.

Add an Internal Turning operation

Right-click the last defined Turning operation in SolidCAM Manager and choose Turning from the Add Turning Operation submenu. The Turning Operation dialog box is displayed. 28.

Define the Geometry

The following geometry has to be defined in order to perform the internal turning. Click

in the Geometry page. The Geometry Edit dialog box is displayed.

Select the chamfer segment as shown.

Note the direction of the geometry. The geometry defined for this operation must be directed in the negative direction of the Z-axis.

In the Chain section of the Geometry Edit dialog box, switch to the Point to point mode. Click on the end point of the geometry as shown. The geometry chain is selected. In the Modify Geometry section, set Distance to 3 in Start Extension/trimming. Confirm your selection by with . The Turning Operation dialog box is displayed. 29.

Define the Tool

Click the Select button in the Tool page to start the definition of a new tool for the operation. The Part Tool Table is displayed. Click

78

to define a new tool.

4. Turning Operations

From the Composite Tools section, choose the Int. Turning type to define the tool for the internal finish. In the Insert tab, enter the parameters as shown in the image:

In the Shank tab, enter the parameters as shown in the image:

Click the Holder check box and select S20R SCLCR-09_LT as the holder. Click Mounting and set the tool in the vertical position as shown. icon to confirm the tool Click the Select definition and choose it for the operation. Click the Data tab in the Tool page of the Turning Operation dialog box to define the Spin data for the operation. The Cutting speed recommended for the Turning operation is 180 m/min. According to the following formula, Spin=(1000*V)/(π*D), diameter (31.5 mm),

where V is the cutting speed and D is the

Spin≈1800.

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Set the Spin normal and Spin finish to 1800. 30.

Define the technological parameters

Switch to the Technology page. Make sure the Long internal option is chosen in the Mode area. This option enables you to perform the internal radial turning. In the Work type area, choose the Finish only option. This option is used for finish turning of the CAM-Part. When this option is chosen, only a semi-finish or a finish pass is executed. Choose the ISO-Turning method option for Finish in the Semi-finish/finish tab. At this stage, all relevant technological parameters are defined. 31.

Save and Calculate

Click in the Turning Operation dialog box to save the operation data and calculate the tool path. 32.

Simulate

Click in the Turning Operation dialog box. The Simulation control panel is displayed. Simulate the tool path in the Turning mode.

Simulate the tool path in the SolidVerify mode.

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4. Turning Operations

Close the Simulation control panel with the Exit . Operation dialog box with 33.

button. Close the Turning

Add an External Grooving operation

Right-click the last defined Turning operation in SolidCAM Manager and choose Grooving from the Add Turning Operation submenu. The Grooving Operation dialog box is displayed 34.

Define the Geometry

The following geometry has to be defined in order to perform the machining of the external groove. Click in the Geometry page. The Geometry Edit dialog box is displayed. Choose the Curve option in the Chain section and select the sketch segments as shown. Ensure that the Up to Entity, Tangent propagation and Constant Z Propagation checkboxes are unselected.

Confirm the chain definition with the Accept Chain button. In the Modify Geometry dialog box, set the Distance values to 1 in the Start Extension/trimming and End Extension/ trimming areas. Close the Modify Geometry dialog box with the 35.

button.

Define the Tool

Click the Select button in the Tool page. The Part Tool Table is displayed. Click to start a new tool definition. From Composite Tools, add an Ext. Grooving tool for the operation.

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In the Insert tab, enter the parameters as shown in the image:

In the Shank tab, enter the parameters as shown in the image:

Click Mounting and set the tool as shown in the image:

icon to confirm the tool definition and choose it for the Click the Select operation. Click the Data tab in the Tool page of the Grooving Operation dialog box. These parameters allow you to define the Feed values. Set the Feed normal to 0.18 and the Feed finish to 0.12.

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4. Turning Operations

Set the Safety angle value to 0.Safety angle This parameter defines the angle between the material and the cutting edge of the tool. It prevents the cutting edge of the tool from coinciding with the material.

Modified geometry Geometry

​

36.

Safety angle

Define the technological parameters

Switch to the Technology page. Make sure that the Long external option is chosen in the Mode area. This option enables you to perform the External grooving tool path. S olidCAM enables you to combine roughing and finishing in one operation. Make sure that the Rough option is chosen in the Work type area. Click the Rough tab to define the rough grooving parameters. In the Rough offset area, choose the Distance option. This option enables you to define a constant offset distance from the geometry. Set the Distance value to 0.2. In the Step over area, set the Value to 2.8. Step over

T his field defines the sideways distance b etween each two successive groove-cut steps. This distance must be smaller than the tool width. Switch now to Semi-finish/Finish tab. Make sure that the Turn-Groove method option is chosen in the Finish area.

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Turn-Groove method

The finishing pass is executed. The tool movements are generated in such way that only the bottom of the tool cuts the material. This can cause the tool to move against the direction of the geometry, while the movement of the tool on the geometry is not continuous. From the Finish on box, select the Entire geometry option. This option performs finishing on the entire profile geometry. Switch to the Groove parameters tab and set the Finish value to 0 in the Delta compensation area. Delta compensation

For good surface finishing and better cutting conditions, the tool should be allowed to bend slightly during the side cutting. This is important so that only the corner radius of the tool will touch the m aterial. This field defines the distance the tool retreats before going sideways. • Rough

E nter the distance the tool should retreat before moving sideways in the roughing operation. • Finish

E nter the distance the tool should retreat before moving sideways in the finishing operation.

37.

Save and Calculate

Click in the Grooving Operation dialog box to save the operation data and calculate the tool path. 38.

Simulate

C lick in the Grooving Operation dialog box. Simulate the tool path in the Turning mode. S imulate the tool path in the SolidVerify mode. Close the Simulation control panel. Close the Grooving Operation dialog box. 84

4. Turning Operations 39.

Add an Internal Grooving operation

R ight-click the last defined Grooving operation in SolidCAM Manager and choose Grooving from the Add Turning Operation submenu. The Grooving Operation dialog box is displayed. 40.

Define the Geometry

The following geometry has to be defined in order to perform machining of the internal groove. Click

in the Geometry page.

The Geometry Edit dialog box is displayed.

W ith the Curve option chosen, select the s ketch segments as shown. Ensure that the Up to Entity, Tangent propagation and C onstant Z Propagation check boxes are unselected.

C onfirm the chain definition with the Accept chain button. T he Grooving Operation dialog box is displayed. Click the Modify Geometry button. Set the Distance values in the Start Extension and the End Extension areas to 1. Close the Modify Geometry dialog box with . 41.

Define the Tool

In the Tool page, click the Select button. The Part Tool Table is displayed. Click to start the definition of a new tool. From the Composite Tools section, choose the Int.Grooving tool type.

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In the Insert tab, enter the parameters as shown in the image:

In the Shank tab, enter the parameters as shown in the image:

Click the Holder check box and select C5 ADI 25 as the holder. Click Mounting and set the tool as shown in the image:

icon to confirm the tool definition and choose it for the Click the Select operation. Click the Tool Data tab to define the feeds and safety angle.

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4. Turning Operations

• •

42.

Set Feed normal to 0.15 and Feed finish to 0.1 Set the Safety angle to 0

Define the technological parameters

Switch to the Technology page. Make sure that the Long internal option is chosen in the Mode area. This option enables you to perform the internal radial grooving.

Make sure that the Rough option is chosen in the Work type area. Click the Rough tab to define roughing parameters. Make sure that the ZX-ABS option is chosen in the Rough offset area. • Set the Distance X to 0.2 • Set the Distance Z to 0.05 • In the Step over area, set the Value to 2.8 At this stage, the technological parameters of the operation are defined. 43.

Save and Calculate

Click in the Grooving Operation dialog box to save the operation data and calculate the tool path.

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44.

Simulate

Click in the Grooving Operation dialog box. Simulate the tool path in the Turning mode. Simulate the tool path in the SolidVerify mode. Click the Half view button to see the section of the machined part as shown. Close the Simulation control panel. Close the Grooving Operation dialog box. 45.

Add an Angled Grooving operation

Right-click the last defined Grooving operation in SolidCAM Manager and choose Angled Grooving from the Add Turning Operation submenu. The Angled Grooving Operation dialog box is displayed. 46.

Define the Geometry

The following geometry has to be defined in order to perform the machining of the angled groove. Click in the Geometry page. The Geometry Edit dialog box is displayed. With the Curve option chosen, select the sketch segments as shown. Ensure that the Up to Entity, Tangent propagation and Constant Z Propagation check boxes are unselected.

Close the Geometry Edit dialog box with the

88

button.

4. Turning Operations 47.

Define the Tool

In the Tool page, click the Select button. The Part Tool Table is displayed. Click to start the definition of a new tool. From the Composite Tools section, choose the Ext.Grooving tool type. In the Insert tab, enter the parameters as shown in the image:

In the Shank tab, enter the parameters as shown in the image:

Click the Holder check box and select OD GROOVING1 as the holder. Click Mounting and set the tool as shown in the image:

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Click the Select icon to confirm the tool definition and choose it for the operation. Click the Tool Data tab to define the feeds and safety angle. 48.

Define the technological parameters

Switch to the Technology page. Make sure that the Long external option is chosen in the Mode area. This option enables you to perform the angled grooving. Make sure that the Rough option is chosen in the area and click the Rough tab to define the roughing parameters. Make sure that Single is chosen in the Step down section. This option allows you to machine the groove in a single step down. Set Step over value to 0.2. Switch to Semi-finish/Finish tab. Choose the ISOTurning method in the Finish section. Work type

49.

Save and Calculate

Click in the Angled Grooving Operation dialog box to save the operation data and calculate the tool path. 50.

Simulate

Click in the Angled Grooving Operation dialog box. Simulate the tool path in the Turning mode. Simulate the tool path in the SolidVerify mode.

Close the Simulation control panel. Close the Angled Grooving Operation dialog box. In the next stage, you have to perform machining of the external thread using a Threading operation. The minimal diameter of the thread is 56 mm, and the pitch is 1.5 mm. 90

4. Turning Operations 51.

Add a Threading operation

Right-click the last defined Angled Grooving operation in SolidCAM Manager and choose Threading from the Add Turning Operation submenu. The Threading Operation dialog box is displayed. 52.

Define the Geometry

The following geometry has to be defined to machine the external thread. Click

in the Geometry page.

The Geometry Edit dialog box is displayed.

With the Curve option chosen, select the sketch segment as shown. Ensure that the Up to Entity, Tangent propagation and Constant Z Propagation check boxes are unselected. Confirm the selected geometry with the button. Notice the direction of the geometry. The geometry for this operation must be directed in the negative direction of the Z-axis. In the Modify Geometry dialog box, set the Distance to 2 in Start Extension/ trimming and End Extension/trimming. This extension enables the tool to approach the geometry from outside. Confirm the modification with 53.

button.

Define the Tool

In the Tool page, click the Select button. The Part Tool Table is displayed. Define a new tool for the external threading. Click section.

and choose the Ext.Threading tool from the Composite Tools

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In the Insert tab, enter the parameters as shown in the image:

In the Insert tab, enter the parameters as shown in the image:

Click the Holder check box and select 8_251_11_004 as the holder. Click Mounting and set the tool as shown in the image:

icon to confirm the tool definition and choose it for the Click the Select operation. Click the Tool Data tab.

92

4. Turning Operations

The cutting speed chosen for the operation is 110 m/min. The Spin value can be calculated with the following formula: Spin=(1000*V)/(π*D),

diameter.

where V is the cutting speed and D is the

Spin=(1000*110)/(π*58)≈600 rev/min.

Set the Spin normal and Spin finish to 600. button to confirm the tool selection. The Threading Click the Select Operation dialog box is displayed. 54.

Define the technological parameters

Switch to the Technology page. Make sure that the Long external option is chosen in the Mode area. This option enables you to perform the radial external threading Make sure that the Multiple option is chosen in the Work type area. SolidCAM enables you to choose between two main Work type options: • Single – the threading is performed in a single pass (G33). • Multiple – the threading is performed in several passes according to the machine cycle. In the Pitch unit area, set the Value to 1.5. In the Minor Diameter area, set the Value to 56.

Minor diameter

This option is available with Long external mode. It defines the minimum diameter of the thread at the first point of the geometry. The thread depth is the difference between the diameter of the first geometry point of the thread and the minimum diameter value.

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Choose Yes under External finish. This option enables you to perform the finishing pass on the tips of the threads. Choose Yes under Thread finish. The finishing pass is performed on the thread. 55.

Save and Calculate

Click in the Threading Operation dialog box to save the operation data and calculate the tool path. 56.

Simulate

Click in the Threading Operation dialog box. Simulate the tool path in the Turning mode. Simulate the tool path in the SolidVerify mode.

Close the Simulation control panel. Close the Threading Operation dialog box. At this stage, you have to perform machining of the internal thread using the Threading operation. The maximal diameter of the thread is 33.5 mm and the pitch is 1.5 mm. 57.

Add a Threading operation

Right-click the last defined Threading operation in SolidCAM Manager and choose Threading from the Add Turning Operation submenu. 58.

Define the Geometry

The following geometry has to be defined to machine the internal thread. Click in the Geometry page. The Geometry Edit dialog box is displayed.

94

4. Turning Operations

Select the sketch segment as shown. Notice the direction of the geometry. The geometry for this operation must be directed in the negative direction of the Z-axis.

button. Confirm the selected geometry with the Accept chain In the Modify Geometry dialog box, set the Distance values to 2 in the Start Extension/ trimming and End Extension/ trimming. This extension enables the tool to approach (and retreat from) the geometry from outside. Close the Modify Geometry dialog box with the 59.

button.

Define the Tool

In the Tool page, click the Select button to define a new tool in the Part Tool and choose it for the operation.

Table

In the Part Tool Table, click . In the Composite Tools section, choose the Int.Threading tool type. In the Insert tab, enter the parameters as shown in the image:

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In the Shank tab, enter the parameters as shown in the image:

Click the Holder check box. Select SIL 0013 M16B_UT as the holder. Click Mounting and set the tool as shown in the image:

Switch to the Tool Data tab. Set the spin and feed data. The cutting speed chosen for the operation is 80 m/min. The spin can be calculated with the following formula: Spin=(1000*V)/(π*D), where V is the cutting speed and D is the maximal diameter of the thread. Spin=(1000*80)/(π*33.5)≈750 rev/min.

Set the Spin normal and Spin finish to 750. Click the Select button

96

to choose the tool for the operation.

4. Turning Operations 60.

Define the technological parameters

Switch to the Technology page. Make sure that the Long internal option is chosen in the Mode area. This option enables you perform the internal radial threading. Make sure that the Multiple option is chosen in the Work type area. Set the Step down to 0.1. • In the Pitch unit area, set the Value to 1.5 • In the Major Diameter area, set the Value to 33.5 Major Diameter

This option is available with the Long internal mode. It defines the maximum diameter of the thread at the first point of the geometry. The thread depth is the difference between the maximal diameter value and the diameter of the first geometry point of the thread. Choose Yes under External finish. This option enables you to perform the finish pass on the tips of the threads. Choose Yes under Thread finish. The finish pass is performed on the thread. At this stage, all the technological parameters of the Threading operation are defined. 61.

Save and Calculate

Click in the Threading Operation dialog box to save the operation data and calculate the tool path. 62.

Click box.

Simulate

in the Threading Operation dialog

Simulate the tool path in the Turning mode. Simulate the tool path in the SolidVerify mode. Use the Half view button to see the section of the machined part as shown. Close the Simulation control panel. Close the Threading Operation dialog box.

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At this stage, you have to perform parting (cutting off) of the machined part using a Cutoff operation. 63.

Add a Cutoff Operation

Right-click the last defined Threading operation and choose Cutoff from the Add Turning Operation submenu. 64.

Define the Geometry

The following geometry has to be defined to perform the parting (cutting off). In the Geometry page, click to start the geometry definition. The Geometry Edit dialog box is displayed. Select the sketch segment as shown.

Note the direction of the geometry. In this operation, the geometry directed to the model rotation axis should be used. In the Modify Geometry dialog box, set the Distance Extension/trimming and End Extension/trimming. 65.

values to 2 in Start

Define the Tool

Click the Select button in the Tool page to start the definition of a new tool. The Part Tool Table is displayed. Click

to define a new tool.

Choose the Ext. Grooving tool from the Composite Tools section.

98

4. Turning Operations

Click the Insert tab and enter the parameters as shown in the image:

Click the Shank tab and enter the parameters as shown in the image:

Click the Holder check box and select 8_251_11_004 as the holder. Click Mounting and set the tool as shown in the image:

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Click Select

button to choose the defined tool for the operation.

Click the Data tab in the Tool page of the Cutoff Operation dialog box. Define the spin and feed data. In this case, the differences of diameters through the tool path do not enable you to use the common spin value. The V (m/min) option is used. This option enables you to define the cutting speed. The number of revolutions per minute is calculated automatically according to the actual diameter. You can maintain the constant cutting speed along the tool path. In the areas of the smallest diameter, the number of revolutions is greater and vice versa. Switch to the V (m/min) option in the Spin section. Set the cutting speed value of 100 for Spin normal. Set the Feed normal value to 0.08. 66.

Define the technological parameters

Switch to the Technology page. This page enables you to define the parting (cutting off) technological parameters. Make sure the Long external option is chosen in the Mode area. Choose the option in the Tool side section. In the Corner section, choose the Chamfer option. In the Location area, choose the Right option. The chamfer is machined as shown. Left

The Location options enable you to define the tool position relative to the defined geometry: • Left

The tool cuts to the left of the geometry.

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Left

Both

Right

4. Turning Operations • Right

The tool cuts to the right of the geometry. • Both

The tool center is located on the geometry. In the Chamfer parameters section, select Distance X and Distance Z values to 1.

the Distance option and set the

At this stage, the definition of the technological parameters of the parting operation is finished. 67.

Save and Calculate

Click in the Cutoff Operation dialog box to save the operation data and calculate the tool path. 68.

Simulate

Click

in the Cutoff Operation dialog box. Simulate the tool path in the Turning mode. Simulate the tool path in the SolidVerify mode.

At this stage, the exercise is finished.

101

Exercise #4: Button Lock Machining Define the CAM-Part and operations for the machining of the button lock shown below on a Turning CNC-machine. This exercise reinforces the following skills: • • • •

Turning CAM-Part definition External rough turning External finishing Parting (cutting off)

The SolidWorks model of the Button Lock (Exercise4.sldprt) is located in the Exercises folder. The following steps have to be implemented in order to reach the final CAM-Part: 1.

Define the CAM-Part

At this stage, you have to define the CAM-Part, the CNC-controller, the Machine Coordinate System, the Stock model, the Clamp and the Target model. The OKUMALL CNC-controller has to be chosen for this exercise. 2.

External roughing

Define a Turning operation to perform the rough machining of the part.

102

4. Turning Operations 3.

External finish

Perform the finishing of the front faces of the part as shown.

4.

Back side finish

Perform the finishing of the back faces of the part.

5.

Parting

Define a Cutoff operation for cutting off the part and machining of the chamfer.

103

Exercise #5: Guided Ejector Bushing Machining Define the CAM-Part and operations for the machining of the guided ejector bushing shown below on Turning CNC-machine. This exercise reinforces the following skills: • • • • • •

Turning CAM-Part definition External turning with a groove tool Facial turning Drilling Internal turning Parting (cutting off)

The SolidWorks model of the Guided Ejector Bushing (Exercise5.sldprt) is located in the Exercises folder. The following steps have to be implemented in order to reach the final CAM-Part: 1.

Define the CAM-Part

At this stage, you have to define the CAM-Part, the CNC-controller, the Machine Coordinate System, the Target model, the Clamp and the Target model. The OKUMALL CNC-controller has to be chosen for this exercise. 2.

External turning

Define the Turning operation to perform the machining of the external radial faces. Use the grooving tool to machine the grooves located radially.

3.

Facial turning

Perform the facial turning of the front face as shown. Note that it is not necessary to machine the whole face because of the next Drilling operation.

104

4. Turning Operations

Grooves machining Define a Grooving operation to machine three grooves.

4.

Drilling

Drill the preliminary hole that will be finally turned at the next stage. Use a flat drill tool (see Exercise #3).

5.

Internal finish

Perform the internal finish of the center hole including chamfers.

6.

Parting

Define a Cutoff operation for cutting off the part and machining of the chamfer.

105

Exercise #6: Guide Pillar Machining Define the CAM-Part and operations for the machining of the guide pillar shown below on the Turning CNC-machine. This exercise reinforces the following skills: • • • • • •

Turning CAM-Part definition External rough turning External finish turning Facial turning Grooving Parting (cutting off)

The SolidWorks model of the Guide Pillar (Exercise6.sldprt) is located in the Exercises folder. The following steps have to be implemented in order to reach the final CAM-Part: 1.

Define the CAM-Part

At this stage you have to define the CAM-Part, the CNC-controller, the Machine Coordinate System, the Stock model, the Clamp and the Target model. The OKUMALL CNC-controller has to be chosen for this exercise. 2.

External rough turning

Define a Turning operation to perform the rough machining of the external radial faces.

3.

Facial turning

Perform the facial turning of the front face as shown. External finish turning Define a Turning operation to machine the external model faces except for grooves that will be machined in one of the next stages.

106

4. Turning Operations 4.

External finish turning

Define a Turning operation to machine the external model faces except for grooves that will be machined in one of the next stages.

5.

Grooves machining

Define a Grooving operation to machine four grooves.

6.

Parting

Define a Cutoff operation for cutting off the part and machining of the chamfer.

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Exercise #7: Bearing Bush Machining Define the CAM-Part and operations for the machining of the bearing bush on the Turning CNC-machine. This exercise reinforces the following skills: • • • • • •

Turning CAM-Part definition External turning Internal turning Facial turning Drilling Parting (cutting off)

The SolidWorks model of the Bearing Bush (Exercise7.sldprt) is located in the Exercises folder. The following steps have to be implemented in order to reach the final CAM-Part: 1.

Define the CAM-Part

At this stage you have to define the CAM-Part, the CNC-controller, the Machine Coordinate System, the Material boundary, the Clamp and the Target model. The OKUMALL CNC-controller has to be chosen for this exercise.

2.

Facial turning

Perform the facial turning of the front face as shown.

3.

External faces turning

Define a Turning operation to perform the machining of the external cylindrical faces.

108

4. Turning Operations 4.

Center drilling

Define a Drilling operation to perform the preliminary center drilling of the center hole.

5.

Drilling

Define two Drilling operations to machine the center hole segments as shown.

6.

Internal turning

Define a Turning operation to machine the internal model faces.

7.

Back side grooving

Define a Grooving operation to machine the back faces as shown.

8.

Parting

Define a Cutoff operation for cutting off the part and machining of the chamfer.

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4.2 Advanced Turning: Rest Material SolidCAM automatically recognizes the rest material areas left unmachined after the previous operations. Consider the longitudinal turning of the geometry presented on the illustration with an external roughing tool.

Geometry

According to its geometry, the tool cannot reach some areas of the part in the process of machining. Geometry

In SolidCAM, these unmachined areas are called Rest Material areas.

Rest Material Geometry

SolidCAM offers you a number of methods to determine and machine Rest Material areas. The following exercise illustrates SolidCAM functionality of the Rest Material turning.

110

4. Turning Operations

Exercise #8: Wheel Machining The following exercise illustrates SolidCAM functionality of Rest Material machining during longitudinal and facial rough/finish turning operations performed on the Wheel part. 1.

Load the model

Load the Exercise8.sldprt model located in the Exercises folder.

2.

Define the CAM-Part

Since the CAM-Part definition process was explained earlier, the details of the CAM-Part definition process are omitted.

20

2

Define the Coordinate System in the pierce point of the revolution axis and the front face of the model. Choose the OKUMALL CNC-controller. Define the material boundary sketch on the Plane 1 as shown. Make sure that the end points of the sketched line are coincident to the model front and back sides. Select the sketched line for the definition of the Stock. 111

Create a new sketch for the clamp on the same plane. Sketch the clamp geometry as shown. Define the SolidCAM Clamp geometry using this sketch. Define the Target model by selecting the solid body. When defining the Target model in the Model dialog box, set the Facet tolerance

value to 0.01 to get better performance during the simulation. SolidCAM automatically generates the Envelope geometry that will be used later in the definition of operations. Confirm the CAM-Part definition. 3.

Perform the external roughing

Define a new Turning operation to perform the rough machining of the external model faces. Define the geometry for the operation using the Envelope sketch as shown below.

5

112

2

4. Turning Operations

Define an External roughing tool for the operation. Set the tool tip angle (a°) value to 55°. Choose the defined tool for the operation.

Define the parameters of External roughing. Select Rough from the Work type area in the General tab. Switch to the Rough tab to define roughing parameters: In the Step down section, select the Adaptive step down option. Make sure that the default ZX-ABS option is chosen in the Rough offset area. • Set the Distance X value to 0.3 • Set the Distance Z value to 0.1 The defined offset remains unmachined till the next finishing operation.

Switch to the Semi-finish/finish tab. Make sure that the No option is selected under Finish and Semi-finish. The finish machining will be performed later in a separate operation. Save the operation data and calculate the tool path. Simulate the tool path.

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Some areas of the current geometry are unreachable for the tool. These areas are left unmachined. The next operation uses the Rest material option to perform the additional machining only in the unmachined area. 4.

Perform the rest material roughing

In the previous external roughing operation, the tool with the Left orientation was moving in the negative Z-direction. In the Rest material roughing operation, the tool moves in the positive direction of the Z-axis. The Right orientation of the tool must be chosen.

Add a new Turning operation to perform the rough machining of the Rest

material area.

SolidCAM enables you to use an already existing operation as a template for the current operation. All the data is copied from the template to the current operation. This feature enables you to save the programming time. In the Operation name section, choose the first operation (TR_contour) as a template. The data is copied. This operation contains the same geometry and technological parameters as the previous Turning operation. Define a new External roughing tool for the operation. Use the default geometric parameters of the tool. Change the Cutting edge direction from Left to Right. Choose the Mounting as shown. The tool orientation enables you to use this tool for cutting in the positive Z-direction. Choose the defined tool for the operation.

114

4. Turning Operations

Save the operation data and calculate the tool path. Simulate the tool path.

During the tool path calculation, SolidCAM automatically determines the Rest material area suitable for machining with the defined tool and technological parameters. The machining is performed in this Rest material area only. At this stage, the rough machining of the external faces is completed. At the next stage, you have to perform the finish machining. 5.

Perform the external finishing

Perform the finishing of the external faces that were rough machined in the previous steps. Add a new Turning operation. Define the geometry for the operation as shown.

2

2

Define a new tool of the Ext.Contour type for the operation. • Set the height of the tool tip (C) to 22 • Set the height of the tool (D) to 60 • Set the lengths of the two cutting edges of the tool tip (D1, D2) to 10 • Set the tool tip angle (a°) to 30 • Set the tool nose radius (Ra) to 0.8

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Confirm the tool definition and choose the tool for the operation. In the Technology page, choose the Finish only option under Work type. This option enables you to perform the finishing of the external faces. Switch to the Semi-finish/finish tab. Make sure that the ISO-Turning method is chosen for Finish. With this option, the finishing tool path is performed in the direction of the geometry. Note that the default Rest material only option is chosen in the Finish on section. This option enables you to perform finishing only in Rest material areas. In this case, the Rest material area is the allowance left unmachined in the previous operations. Save the operation data and calculate the tool path. Simulate the tool path.

At this stage, the external faces turning is complete.

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4. Turning Operations 6.

Perform the facial roughing

Perform the facial rough turning of the end faces of the wheel. Add a new Turning operation and define the geometry as shown. Use the Envelope sketch automatically generated by SolidCAM during the Target model definition. Envelope

3

22

Define the tool for the operation. Add a new tool of the Ext.Rough type to the Edit the following tool parameters: • Set the height of the tool (D) to 80 • Edit the position of the left side of the turret with reference to the tool tip point (E). Set the value to -15 • Set the tool tip angle (a°) to 35° • Set the lengths of the cutting edges of the tool (D1, D2) to 6 The tool Cutting edge direction is automatically set to Right, and it cannot be changed. This option enables you to use the tool for the facial turning directed from outside to the revolution axis. Part Tool Table.

Confirm the tool data and choose the tool for the current operation. In the Technology page, choose the Face front option in the Mode area. With this option, SolidCAM performs the facial turning of the front faces.

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Choose the Rough option in the Work type. The finish machining is performed later in a separate operation.

Save the operation data and calculate the tool path. Simulate the tool path. There is an area of the geometry that is not reachable for the tool during the machining. This area will be machined in a separate operation using the Rest material strategy.

7.

Perform the facial Rest material machining

At this stage, you have to perform an additional roughing operation that removes the bulk of material in the area left unmachined after the previous operation. In this operation, the Rest material is removed with a left-oriented tool in a number of cuts in the positive X-direction (from the revolution axis to the outside). Add a new Turning operation. In the same manner as explained in Step #4, use the previous operation as a template for the current one.

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4. Turning Operations

In this operation, you need to use the tool with the same geometric parameters as the one used for the previous operation, except for its orientation. Right-click the Tool #4 in the list and choose the Copy Tool command. A new tool identical to the previous one is added. Choose Left for Cutting edge direction. Confirm the tool definition and choose the tool for the operation. Save the operation data and calculate the tool path. Simulate the tool path.

During the tool path calculation, the Rest material area suitable for the machining with the defined tool and technological parameters is determined automatically. The machining is performed in this Rest material area only. At this stage, the rough machining of the front faces is completed. At the next stage, you have to perform the finish machining. 8.

Perform the facial finishing

Define a new Turning operation. Use the Turning operation defined in Step #6 as a template to copy all the data into the current operation. Use the same tool and the same geometry as in the template operation. Click the Data tab parameters area.

in the Tool page and set the Safety angle to 5 in the Safety

In the Work type list of the Technology page, choose the Finish only option. This type enables you to perform the finish machining along the geometry. Make sure that the ISO-Turning method option is chosen in the Finish area of the Semi-finish/finish tab.

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The Rest material only option is automatically chosen in the Finish on box. With this option, SolidCAM performs the machining only in the Rest material areas. Set the Start extension and End extension values to 1. These values enable you to overlap the rest material area. Save the operation data and calculate the tool path. Simulate the tool path.

In the same manner, define a new Turning operation based on the operation defined in Step #7. This operation performs the facial finish machining in the Rest material area. Use an External roughing tool with the lengths of cutting edges (D1, D2) of 9 mm. In the Finish section, choose the ISO-Turning method option. The Rest material only option is automatically chosen in the Finish on box. With this option, SolidCAM performs the machining only in the Rest material areas. Set the Start extension and End extension values to 1. These values enable you to overlap the rest material area. Save the operation data and calculate the tool path. Simulate the tool path.

At this stage, the facial machining of the front faces is finished.

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4. Turning Operations 9.

Hole machining

At the first stage, sketch a line as shown below to define the start and the end points for drilling. Envelope

3

1

Define a new Drilling operation to machine the hole. In the same manner as explained in Steps #15-21 of Exercise #3, define a new U-drill tool for the operation. Use the tool of Ø40.

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Define the Drill start and the Drill end at the end points of the line. Save the operation data and calculate the tool path. Simulate the tool path.

At this stage, the exercise is finished.

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4. Turning Operations

4.3 Advanced Turning: Partial machining This functionality supports rough, semi-finish and finish machining of long turning parts. In long turning parts the machining of the whole geometry all at once might cause problems due to the deformation of the workpiece under the cutting tool. Partial machining provides the capability to machine the geometry by dividing it into several segments. Segment #5

Segment #4

Segment #3

Segment #2

Segment #1

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Exercise #9: Long Shaft Machining The following exercise illustrates SolidCAM functionality of Partial machining in turning operations performed on the Long Shaft part.

1.

Load the part file

Load the Exercise9.prz file located in the Exercises folder. This file contains the pre-machined part with two Turning operations in which the machining of the front face and the first step is performed. 2.

Machine the first segment of the geometry

Add a new Turning operation in SolidCAM Manager. Define the full machining geometry as shown.

This geometry will be machined in several segments in a number of Turning operations. In the Part Tool Table, choose the Ext.rough tool (Tool #2) used in the previous operation. In the Geometry page, select the Partial machining check box. Click the Data button that becomes available. The Partial Machining dialog box is displayed, and the geometry chain is highlighted on the model.

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4. Turning Operations

This dialog box enables you to define the geometry segment that will be machined in the operation and related parameters such as its initial and final points, distance and approach/retreat data.

First point/Second point

The First point and Second point sections enable you to define the profile segment that will be machined in the operation and the parameters of the tool approach/retreat movements. The generated partial cutting pass is performed between the first and second points; the cutting pass direction is determined according to the Profile direction option state.

Second point

First point

SolidCAM automatically generates the approach and retreat passes at the First point and Second point according to the machining direction. In the illustration above, the approach movement is performed at the First point and the retreat movement is performed at the Second point.

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The approach/retreat pass consists of an arc tangential to the partial machining geometry at the First/Second point, and a line connected to the arc. The line direction is automatically chosen according to the Tool type, Tool tip angle and Safety angle parameters. By default, the Distance along axis parameter located in the First point and Second point sections displays the minimal/ maximal Z-coordinate of the geometry. Since the first segment to be machined starts at the beginning of the geometry, do not change the default value of this parameter for the First point. Pick the final point of the segment to be machined by clicking approximately in the middle of the edge as shown.

The Distance along axis value for this point is calculated automatically (-135.61) and displayed in the X,Y,Z dialog box. Round it down manually to -135. When the point has been picked, SolidCAM calculates the Distance along axis and Diameter values for the picked point and displays them in the X,Y,Z dialog box. The Distance along axis parameter displays the distance from the CoordSys to the First/Second point along the Z-axis. When the Pick option was used, the value is calculated automatically. It can also be used as an alternative to the Pick option to define the First/ Second point locations. Even if the Pick option was already used, you can edit the value received from the model and thus change the First/Second point locations.

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4. Turning Operations

The Diameter parameter displays the value of the part diameter at the specified location and is calculated automatically according to the geometry and the Distance along axis value. When there are several Diameter values for a single Distance along axis value, SolidCAM chooses the maximal Diameter value determined. Diameter

Diameter Second point

First point

X CoordSys Z Distance along axis Distance along axis

Now you need to define the approach and retreat parameters. Approach/Retreat parameters

The Radius parameter defines the radius of the approach/ retreat arc tangential to the profile at the First/second point. The Line length parameter defines the length of the straight line tangential to the arc. The direction of the approach/ retreat lines, connected to the approach and retreat arcs, is chosen according to the Tool type. Retreat line length

Retreat radius

Second point

Approach radius

Approach line length

First point

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For External Rough tools, the approach line is determined as follows:

Approach line direction

Second point

First point

When the approach/retreat lines are located inside the Material boundary of the pre-machined stock, SolidCAM automatically extends them till the Material boundary.

Approach line length

Second point

Make sure that the Radius value for both First point and Second point is 0.5. It must be equal to the tool nose radius (Ra). Select the Modify point to avoid collision check box for both First point and Second point.

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First point

4. Turning Operations Modify point to avoid collision

When this check box is selected, automatic modification of the defined First and Second points is performed according to the geometry. The point modification enables you to avoid possible collisions during the approach and retreat movements. When the First point is not modified, the approach is performed as follows:

Second point

First point

The possible collision during the approach movement can be avoided by the automatic point modification.

Second point

First point

Note the Modify contour to avoid collision check box at the bottom of the Partial Machining dialog box.

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Modify contour to avoid collision

This check box enables Non-modified contour you to perform the modification of the partial machining geometry. When this check box is selected, the geometry modification is performed according to the tool shape. The modification Modified contour enables you to avoid possible collisions between the tool and the geometry during the machining. During the geometry modification, the machining geometry is changed in areas where the possible collisions are detected. The geometry is changed taking into account the tool shape. The Modify contour to avoid collision check box affects only the finish and semi-finish tool path when the Profile option is chosen for the Work type. When the Rough option is chosen, the geometry modification is automatically performed, irrespective of the state of the Modify contour to avoid collision check box. Click the Show button to check the machining geometry and the updated partial geometry between the First point and the Second point with the tangential arcs and connected lines.

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4. Turning Operations

Confirm the Partial Machining check box by clicking the OK button. Click the Save & Calculate icon in the Turning Operation dialog box. Simulate the tool path in the Turning mode. 3.

Machine the second segment of the geometry

Click the Save & Copy icon in the Turning Operation dialog box. An additional Turning operation is added in SolidCAM Manager. This operation is a copy of the previous one and contains the same geometry and tool data. Define the Partial machining parameters to machine the next geometry segment. Switch to the Geometry page. Check the Partial Machining check box and click on the Data button. The Partial Machining dialog box is displayed. Define the first point of the segment in such way that there will be an overlap between the surface machined in the previous operation and the one to be machined. In the previous operation, the length of the machined segment was 135 mm, i.e. the Distance along axis value for the Second point was -135. Set the Distance along axis value for the First point to -134 to perform the 1 mm overlap in the machined surface. Click the Pick button in the Second point section. Pick the point as shown.

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The Distance along axis value for the Second point is calculated: -250.

Confirm the Partial Machining dialog box. Click the Save & Calculate icon in the Turning Operation dialog box. Simulate the tool path in the Turning mode.

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4. Turning Operations 4.

Machine the third segment of the geometry

In the same manner as explained in the previous step, add a new Turning operation by saving and copying the last one. Open the Partial Machining dialog box and set the Distance along axis value for the First point to -249. To define the Second point, click on the Pick button and select the point on the model as shown.

The Distance along axis value for the Second point is calculated: -350. Confirm the Partial Machining dialog box. Click the Save & Calculate icon in the Turning Operation dialog box. Simulate the tool path in the Turning mode.

5.

Machine the rest of the geometry

In the same manner as explained in the previous steps, machine the rest of the geometry in two segments.

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Simulate all of the Partial machining operations in the Turning mode.

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4. Turning Operations

4.4 Turning on Mill-Turn CNC Machines SolidCAM supports all types of Mill-Turn CNC-machines. The Mill-Turn CAM-Part is not strictly associated with the only type of machine on which it is intended to be manufactured. In the Mill-Turn module, the flexibility of CAM-Part definition in terms of CNC-machine usage enables you to easily change the type of machines for parts. The type of the chosen CNC-machine though applies certain restrictions on the technology: for example, if your programming is intended for a 3-axis CNC-machine that supports the XZC coordinates, the tool path is not supposed to contain movements along the Y-axis (except for the movements that can be translated into the available axes of the machine). Such functionality enables you to create a required machining technology and then to adapt it for usage on a certain CNC-machine. All types of Mill-Turn CNC-machines enable you to perform turning operations.

X Z The following types of milling operations are supported according the CNC-machine type: 3-Axis Mill-Turn machine

Z X

C

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This type of machine enables you to perform facial, indexial and simultaneous milling operations using the XZC axes. C

X Z

4-Axis Mill-Turn machine

Y Z X

C

This type of machine enables you to perform facial, indexial and simultaneous milling operations using the XYZC axes. C

Y

X Z

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4. Turning Operations

5-Axis Mill-Turn machine X B Z Y

C

This type of machine enables you to perform facial, indexial and simultaneous milling operations using the XYZCB axes.

B C

Y

X Z

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Exercise #10: Turning Operation on Mill-Turn CNC-Machine In this exercise, you have to define the machine setup and clamping fixture. Then you have to perform two Turning operations to machine the external faces of the model and prepare it for the next Milling operations. The exercise uses the CAM-Part created in Exercise #2. In the process of operation definition, you have to define the machining geometry, the tool and the technological parameters. 1.

Load the CAM-Part

Open the Exercise2.prz CAM-Part prepared earlier.

2.

Define the machine setup

Right-click the Operations header in SolidCAM Manager and choose Machine Setup (

) > Add at start of operation tree. The Machine setup dialog box is displayed. This machine setup shows two Tables, Main_SP and Back_SP, associated with the Machine Channels.

The Fixture column enables you to choose or define a fixture to be used on a particular table. Select the Main Spindle Main_SP. To define the fixture, doubleclick the Fixture cell in the Main_SP row, click the arrow and choose . 138

4. Turning Operations

The Model dialog box is displayed. This dialog box enables you to define the fixture geometry. In the Name section, change the fixture name to Main. Make sure that the Chuck (Standard) option is chosen in the Defined by section. In the Clamping method section, use the default clamping option. The default Chuck position is defined on the edge of the stock envelope created during the Stock model definition. • Set the Clamping diameter to 52 • Set the Axial position to -85 Set the values in the Jaws parameters section as follows: • Set the Jaw width (JW) value to 50 • Set the Jaw height (JH) value to 70 • Set the Step width (SW) value to 15 • Set the Step height (SH) value to 20 The clamping fixture is defined.

to confirm the Model dialog box. Click The Machine setup dialog box is displayed again. Now you have to define the model position relative to the machine coordinate system. Double-click the cell in the Z column. Set the value to 110. Confirm the Setup definition with OK. The Setup subheader is added to the SolidCAM Manager tree under the Operations header. 3.

Add a Face turning operation

Right-click Setup in SolidCAM Manager and choose Face from the Add Turning Operation submenu. The Face Turning Operation dialog box is displayed. 139

4.

Define the submachine

To generate the correct GCode for Turning operations, you need to choose an appropriate submachine. A submachine is a combination of a turret and a table on the CNC-machine that will be used to perform this operation. Choose the Up_main option that corresponds to the Upper Turret–Main Spindle submachine from the Output according to list on the Geometry page of the Face Turning Operation dialog box.

The structure and properties of this submachine are available in the Machine ID file of the chosen machine. 5.

Define the Geometry

Make sure that the Wireframe option is chosen on the Geometry page of the Face Turning Operation dialog box. The turning geometry has to be located in the ZX-plane and can be defined by selecting wireframe elements or solid model entities such as faces, edges and vertices. The following geometry definition options are available: • Wireframe

This option enables you to define the turning geometry by wireframe geometry selection.

140

4. Turning Operations • Solid

This option enables you to define the turning geometry by selecting model entities such as faces, edges, vertices, origin and sketch points. When model entities are picked, SolidCAM automatically defines the geometry on the envelope/section segment corresponding to the selected model elements. You have to define the machining geometry for the turning operation using the Envelope sketch that was automatically generated during the Target model definition described in Exercise #2. Click the New button. The Geometry Edit dialog box is displayed in the SolidWorks PropertyManager area. This dialog box enables you to define and edit geometry chains. The default Curve option enables you to create a chain by selecting model edges or wireframe sketch elements one after the other. In this operation, the geometry must be directed opposite to the X-axis direction. Click on the entity of the Envelope sketch as shown. The selected entity is highlighted.

button to finish the chain definition and confirm Click the Accept chain the Geometry Edit dialog box with the button. In this exercise, the geometry has to be extended in order to enable the tool approach and retreat outside of the machining geometry. On the Geometry page of the Face Turning Operation dialog box, click the Modify Geometry button.

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The Modify Geometry dialog box is displayed. Make sure that the Auto extend Start to Stock option is selected. Select the Auto extend End to Stock option direction from the available and choose the Z+ options.

Close the Modify Geometry dialog box with the button. 6.

Define the Tool

Now you have to define the tool for the turning operation. Click the Select button on the Tool page of the Face Turning Operation dialog box.

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4. Turning Operations

The Part Tool Table is displayed.

Click . The Part Tool Table provides you with a choice of tools available for the current operation. For this operation, a composite tool is used. Composite tool

Composite tool is a cutting tool where the cutting edge consists of a separate piece of material, either brazed, welded or clamped on to a separate body. For a more detailed explanation of the composite tools parameters, refer to the SolidCAM Turning Online Help. Choose the Ext. Turning tool from the Composite Tools section. For Insert, the default parameters will be used. In the Shank page, define the following parameters: • Set the Insert Lead Angle to A (90 deg)

•

Set the Total Length (L) value to 125 mm

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Select the tool holder. Switch to the Holder page. The Global tab displays the Global holders table. Choose the HSK A63WH-ASHR 25 holder from the Turning holders under the Global tab. The Global holders table is supplied within SolidCAM. This table contains a number of frequently used tool holder components. The Global holders table can be modified by the user. Using the buttons in the Flip section, set the correct position of the tool holder. Click the Mounting button and adjust the Tool tip position in the Mounting dialog box.

Click the Mounting button again to close the dialog box. button to choose the defined tool for the current Turning Click the Select operation. The Face Turning Operation dialog box is displayed. 7.

Define the machining levels

Switch to the Levels page of the Face Turning Operation dialog box. This page enables you to specify the machining levels for the operation. Use the default Safety distance value (2). Safety distance

This parameter defines the distance from the workpiece, until which the tool movements are performed in the Rapid mode. Upon reaching the Safety distance, the tool switches to the working feed and performs machining of the part. In this manner, the tool path passes are extended to ensure that the tool does not drop into 144

4. Turning Operations

the material in the Rapid mode in the beginning of machining and between one step down to another.

Safety distance

Safety distance

When the Custom safety distance check box is selected, SolidCAM enables you to define the distance at which the tool is positioned relative to the material in the beginning and in the end of the operation. The Distance X and Distance Z parameters enable you to define different distance values in the X- and Z-directions.

Distance X

Distance Z

8.

Define the technological parameters

Switch to the Technology page of the Face Turning Operation dialog box. option is chosen in the Mode area. This option Make sure that the Front enables you to perform face turning (the principal working direction is the X-axis direction).

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9.

Calculate the operation

Click in the Face Turning Operation dialog box. The operation data is saved, and the tool path is calculated. 10.

Simulate the operation in the Host CAD mode

Click

in the Face Turning Operation dialog box.

The Simulation control panel is displayed.

Host CAD simulation mode

This mode enables you to display the tool path directly on the model in the SolidWorks window. Since all the View options of SolidWorks are available during the simulation, you can see the tool path from different perspectives and zoom in on a certain area of the model.

Rotate the model to the side view by clicking the icon of the CAM Views button on the Simulation control panel. toolbar and click the Play The tool path is simulated in the SolidWorks window. Note that the lead in and lead out movements and work feed movements are displayed with different colors.

146

4. Turning Operations 11.

Simulate the operation in the Turning mode

Switch to the Turning page on the Simulation control panel.

Turning simulation mode

This mode enables you to display the section view simulation of the turning tool path. Click the Play simulated.

button. The tool path is

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12.

Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. SolidVerify simulation mode

This mode displays the simulation of machining on the solid model. The 3D Stock model is used in this mode with the clamping fixture displayed. During the machining simulation, SolidCAM subtracts the tool movements from the solid model of the stock using solid Boolean operations. The remaining machined stock is a solid model that can be dynamically zoomed or rotated. The stock model is displayed in the simulation window. Rotate the model with the mouse and click the Play button. The simulation is performed.

During the SolidVerify simulation, you can use the View buttons to place the simulation model properly on the screen. The Isometric View button displays the isometric view of the simulation model. The Top View button displays the top view of the simulation model. The Front View button displays the front view of the simulation model. The Move button moves the simulation model to any point on the screen. This operation is also available by click-anddrag of the middle mouse button.

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4. Turning Operations

The Rotate button rotates the simulation model. This operation is also available by applying the combination of the Ctrl button and click-and-drag of the middle mouse button. The Zoom button zooms in and out the image on the screen. This operation is also available by applying the combination of the Shift button and click-and-drag of the middle mouse button.

13.

Close the simulation

Click the Exit button on the Simulation control panel. The Face Turning Operation dialog box is displayed. 14.

Close the Face Turning Operation dialog box

In the Face Turning Operation dialog box, click The dialog box is closed.

.

The following operations will be performed with the tools mounted on the lower turret. This turret is a rotary turret having ten tool positions (stations). The CAM-Part stays on the main spindle. 15.

Add an operation

Click the Turning operation in SolidCAM Manager and choose Turning from the SolidCAM Turning ribbon.

The Turning Operation dialog box is displayed. 16.

Define the Geometry

In the Output according to list, choose the Lw_main submachine. This submachine allows you to use the lower turret with the main spindle. Make sure that the Wireframe option is chosen in the Geometry section and click . The Geometry Edit dialog box is displayed. The default Curve option enables you to create a chain by selecting model edges or wireframe sketch elements one after the other. In this operation, the geometry must be directed opposite to the Z-axis direction. 149

Click on the entity of the Envelope sketch as shown. The selected entity is highlighted.

In the Geometry Edit dialog box, choose the Up to Entity option and select the last chain entity as shown.

The complete selected chain is highlighted. button to finish the chain definition and confirm the Click the Accept chain Geometry Edit dialog box with the button.

In this exercise, the geometry has to be extended in order to enable the tool approach and retreat outside of the machining geometry. On the Geometry page of the Turning Operation dialog box, click the Modify Geometry button. The Modify Geometry dialog box is displayed.

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4. Turning Operations

In the Start Extension/trimming section, set the Distance value to 0. In the End Extension/trimming section, set the Distance value to 10. Click the Auto extend End to Stock check box and select the X+ option.

Close the Modify Geometry dialog box with the button. 17.

Define the Tool

Now you have to define a new tool mounted on the lower turret. Click the Select button on the Tool page of the Turning Operation dialog box. The Part Tool Table is displayed. Click

. Choose the Ext. Turning tool from the

Composite Tools section.

Use the default tool parameters for the insert. For the shank, set the Insert Lead Angle to A (90deg). Click the Select button to choose the tool for operation. For this tool, a new STL holder will be used. To export the STL holder, click Save and Exit . In SolidCAM Part ribbon, choose the Tool Library Options submenu and select Tool STL Holders option. The STL Holders Table dialog box is displayed. This dialog box enables you to mange the library of STL holders. The holders are presented in the categories according to certain criteria. The default STL holders library contains two categories: Milling and Turning.

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Right-click the Turning entity and choose the Add STL Holder option.

The Browse dialog box is displayed. Find the T00225_sc_Main.stl file stored in the Exercises folder and click Open. The holder is successfully imported to your library. Click the Save icon to close the STL Holders Table dialog box. Open the last Turning operation. In the Tool page, click Select and switch to the Holder tab. In the Global holders table, select the T00225_sc_Main holder. Click

to choose the tool for operation.

18.

Define the technological parameters

Switch to the Technology page of the Turning Operation dialog box. In the General tab, make sure that the Rough option is chosen in the Work type area. Rough Work type

The tool path movements are parallel to the Z-axis (longitudinal turning) or to the X-axis (facial turning). Semi-finishing and finishing passes are performed, if chosen, at the end of the rough stage.

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4. Turning Operations

Make sure that the Long external option is chosen in the Mode area. This option enables you to perform longitudinal turning (the principal working direction is the Z-axis direction). To define the parameters of the Rough machining, switch to the Rough tab on the Technology page of the Turning Operation dialog box. Select the Smooth option in the Rough type section. Define the Step down for roughing. This parameter enables you to define the distance between each two successive roughing passes. Select the Equal steps options and use the default value of 1. Define the offset from the geometry that Step down will remain after the roughing stage of the operation. In the Rough offset section, choose the ZX-ABS option. This option enables you to define different offsets from the geometry in the X- and Z-axis directions. The program chooses the sign of the delta-X and delta-Z vector components in such a way that the offset geometry does not intersect with the profile geometry. Use the default Distance X value Distance Z of 0.6 and Distance Z value of 0.2. Switch to the Strategies tab. Distance X Select the Non-descending motions option to leave the groove unmachined.

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19.

Calculate the operation

Click in the Turning Operation dialog box. The operation data is saved, and the tool path is calculated. 20.

Click

Simulate the operation in the Host CAD mode

in the Turning Operation dialog box.

The Simulation control panel is displayed. Play the simulation in the Host CAD mode. 21.

Simulate the operation in the Turning mode

Switch to the Turning page on the Simulation control panel. Play the simulation in the Turning mode.

22.

Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. Play the simulation in the SolidVerify mode.

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4. Turning Operations 23.

Close the simulation

Click the Exit button on the Simulation control panel. The Turning Operation dialog box is displayed. 24.

Close the Turning Operation dialog box

In the Turning Operation dialog box, click The dialog box is closed. 25.

.

Add an External Grooving operation

Right-click the last defined Turning operation in SolidCAM Manager and choose Grooving from the Add Turning Operation submenu. The Grooving Operation dialog box is displayed. 26.

Define the Geometry

The following geometry has to be defined in order to perform the machining of the external groove.

Make sure that the Wireframe option is chosen in the Geometry section and click . The Geometry Edit dialog box is displayed. Using the Up to Entity option, select the first and the last chain entities. button. Confirm the chain definition with the Accept Chain In the Modify Geometry dialog box, select both Auto select Start to Stock and Auto extend End to Stock options. Close the Modify Geometry dialog box with the Choose the Lw_main submachine. 27.

button.

Define the Tool

Click the Select button in the Tool page. The Part Tool Table is displayed. Click

to start a new tool definition. 155

From Composite Tools, add an Ext. Grooving tool for the operation. Use the default parameters for both the Insert and the Shank. Use the same T00225_sc_Main tool holder as in the previous operation. The tool parameters are defined. Click the Select 28.

button.

Define the technological parameters

Switch to the Technology page. Make sure that the Long external option is chosen in the Mode area. This option enables you to perform the External grooving tool path. SolidCAM enables you to combine roughing and semi-finishing in one operation. Make sure that the Rough option is chosen in the Work type area. Click the Rough tab to define the rough grooving parameters. In the Step down area, choose the Single option. This option enables you to perform machining in a single step down. In the Step over area, set the Value to 3. Switch to Semi-finish/Finish tab. In the Semi-finish section, choose the Down only option. In the Semi-finish offset, choose the ZX-ABS option. In the Finish section, choose the No option. External finishing of the part surface will be completed in a separate operation. 29.

Calculate the operation

Click in the Grooving Operation dialog box to save the operation data and calculate the tool path.

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4. Turning Operations 30.

Simulate

Click in the Grooving Operation dialog box. Simulate the tool path in the Turning mode. Simulate the tool path in the SolidVerify mode.

Close the Simulation control panel. Close the Grooving Operation dialog box. At this stage, the exercise is finished. The definition of Milling operations is covered in the following chapter.

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Milling on Mill-Turn CNC-Machines

5

The Mill-Turn module enables you to use all types of milling operations to generate the tool path for the driven tools. Milling Operations

ToolBox Cycles

Sim. 5-Axis Milling

Profile

Engraving

Multiaxis Roughing

Contour 3D

Pocket Recognition

SWARF Machining

Pocket

Chamfer Recognition

Multiaxis Drilling

Drilling

Drill Recognition

Contour 5-Axis Machining

Thread Milling

HSS

Slot

3D HSR

Rotary Machining 4 axis

T-Slot

3D HSM

Port Machining

Face Milling

Translated Surface

3 to 5 axis Conversion

Multiblade Machining 2D iMachining 3D iMachining

Face Milling Operation This operation enables you to machine large flat surfaces with face mill tools.

Profile Operation You can mill on or along a contour. The profile geometry can be open or closed. In profile milling you can optionally use tool radius compensation to the right or to the left side of the geometry. SolidCAM offers two types of profiling: • Milling a single profile to the specified constant or variable depth in one step or in several userdefined down steps. • Concentric profiles to the specified constant or variable depth; this type of profiling generates several concentric profiles that start from the defined clear offset distance from the profile, and finish on the profile geometry, thus clearing the area around the profile to a constant depth.

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Contour 3D Operation This operation enables you to utilize the power of the 3D Engraving technology for the 3D contour machining. In this operation, SolidCAM enables you to prevent the gouging between the tool and the 3D contour.

Pocket Operation In pocket milling, you remove material from the interior of a closed geometry. SolidCAM offers two types of pocketing: • Pocket without islands. When a profile geometry consists of one or more profiles and none of them are enclosed or intersect with one another, each is milled as a separate pocket without islands. • Pocket with islands. When a profile geometry consists of several profiles, any profile that is enclosed or intersects with another profile is treated as an island. You can define an unlimited number of islands within a single pocket.

Drilling Operation This operation enables you to perform 2D and 3D drills and other canned drill cycles. SolidCAM supports the canned drill cycles provided by your particular CNC-machine such as threading, peck, ream, boring, etc. If your CNC-machine has no canned drill cycles of its own, they can be defined using the General Pre- and Postprocessor program (GPPTool). With 3D drills, SolidCAM takes into account the solid model geometry. The program uses the holes prepared in this operation for the descent during 3D Model roughing.

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Thread Milling Operation This operation enables you to generate a helical tool path for the machining of internal and external threads with thread mills.

Slot Operation This operation generates a tool path along the centerline to the right or to the left of one or more profiles. Two types of slots can be defined: the Slot with constant depth operation machines the slot in several steps until the final depth is reached. In Slot with variable 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 specified scallop height on the floor of the slot. With available parameters for the right and left extension and the side step, you can mill a slot wider than the tool diameter. T-Slot Operation This operation enables you to machine slots in vertical walls with a slot mill tool.

Translated Surface Operation A translated surface is generated by moving a section along a profile geometry. Limit geometries can be projected on the translated surface. You can machine the resulting translated surface inside, outside or along the limit geometry.

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ToolBox Cycles ToolBox sub-operations are a set of 2.5D Milling operations, and each one of these operations is intended for a specific machining case. For example, a number of operations cover different strategies of the counterbore machining. Each operation provides you with a specific machining strategy optimal for a particular machining case.

Engraving Operations You can mill text or any other profile on a 2D or 3D geometry. The profile is projected on the surface, engraving the contour at a specified depth.

Pocket Recognition Operation This operation enables you to recognize the pocket features on the solid model and perform the machining of these features.

Chamfer Recognition Operation This operation recognizes automatically chamfer features at the target model and creates the necessary machining.

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Drill Recognition Operation This operation performs powerful drill feature recognition and automatic Drill geometry creation using the AFRM module functionality. This operation enables you to handle separate sets of Milling levels for each drill position. The initial values of the Milling levels sets are automatically recognized from the model; they can be edited by the user. HSS Operation SolidCAM HSS module is a high speed surface machining module for smooth and powerful machining of localized surface areas in the part, including undercuts. It provides easy selection of the surfaces to be machined, with no need to define the boundaries. It supports both standard and shaped tools. 3D HSR/ 3D HSM Operation SolidCAM HSR/HSM module smooths the paths of both cutting moves and retracts wherever possible to maintain a continuous machine tool motion – an essential requirement for maintaining higher feed rates and eliminating dwelling. The retracts to high Z-levels are kept to a minimum. Angled where possible, smoothed by arcs, retracts do not go any higher than necessary, thus minimizing air cutting and reducing machining time. The result of HSM is an efficient, smooth, and gouge-free tool path. Sim. 5 Axis Operation This operation enables you to perform simultaneous 5-axis machining. 5-axis machining strategies enable the use of SolidCAM for machining of complex geometry parts such as mold cores and cavities, aerospace parts, cutting tools, cylinder heads, turbine blades and impellers. SolidCAM enables collision checking between the tool and the machine components.

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Multiaxis Roughing Operation This operation creates a multiaxis tool path used to rough out pocket shaped geometries. You can specify the inputs for floor, wall and ceiling surfaces which are used by SolidCAM to create the roughing tool path. SWARF Machining Operation SWARF (Side Wall Axial Relief Feed) machining is one of 5-Axis Simultaneous milling operations. The purpose of the operation is to produce the target surface with only one cut, while the whole flute length of the tool is used.

Multiaxis Drilling Operation This operation enables you to machine a series of drills that have different orientations.

Contour 5-Axis Machining Operation This machining strategy tilts the tool along a chained 3D profile drive curve, while aligning the tool axis according to defined tilt lines, making it ideal for generating 5-axis tool path for deburring and trimming.

3 to 5 axis Conversion In some machining cases, there is a need to perform machining of 3D parts using the 5-axis capabilities. For example, 3D machining of deep cavities requires the use of tools of great length, which can cause tool breakage; the same cavities can be machined using a tool of smaller length while tilting this tool to follow the same tool path.

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Rotary Machining 4 axis This operation is designed to generate rotary tool path to mill parts on a 4-axis machine. It can be used to mill cylindrical parts like bottle molds and core, electrodes, and wood work. The tool paths are directly calculated on 3D geometry and not wrapped around. Port Machining Operation This operation is an easy-to-use method for machining ports with tapered lollipop tools, and has collision checks for the entire tool. It provides both roughing and finishing tool paths to make ports from castings or billet.

Multiblade Machining Operation This operation easily handles impellers and bladed disks, with multiple strategies to efficiently rough and finish each part of these complex shapes. Multibladed parts are used in many industries and this operation is specifically designed to generate the necessary tool paths for the different multiblade configurations.

2D iMachining / 3D iMachining SolidCAM iMachining is an advanced technology of high speed machining that generates optimized tool paths, efficient cutting and high material removal rates, while reducing machining time and tool wear. The iMachining Technology Wizard enables you to define the optimum cutting conditions for sustainable high speed machining. Using the cutting conditions produced by the Wizard, the iMachining Tool Path Generator calculates all the tool paths necessary to efficiently produce the target geometry from the given stock geometry.

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Exercise #11: Facial Milling This exercise illustrates the capabilities of facial milling. The CAM-Part prepared in the previous exercises is used. During the facial milling, the front pocket and the adjacent chamfer faces are machined using the Pocket and Profile operations. 1.

Load the CAM-Part

Load the Exercise10.prz CAM-Part prepared in the previous exercises. 2.

Add an operation

Right-click the first Face Turning operation in the SolidCAM Manager tree and choose Pocket from the Add Milling Operation submenu. The Pocket Operation dialog box is displayed. 3.

Define the Geometry

Make sure that MAC 1 (1-Position) is chosen for the Coordinate System and selected Submachine is Up_main. Click

on the Geometry page.

The Geometry section enables you to choose the appropriate Coordinate System for the operation and define the machining geometry. The Machine CoordSys #1 is chosen by default for the operation. This Coordinate System enables you to perform the facial milling operation. The tool axis is parallel to the Z-axis of the Machine CoordSys #1. 167

The Geometry has to be located in the plane parallel to the XYplane of the Machine CoordSys #1. The Geometry Edit dialog box is displayed. In the Multi-chain section, click the Add button. The Chains Selection dialog box is displayed in the SolidWorks PropertyManager area.

This dialog box enables you to define several chains by selecting the model elements. The chains are created automatically from the selected elements. Click on the floor of the front pocket as shown.

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The surface is selected. Click the

button to confirm your selection.

The chain is generated, and the chain icon is displayed in the Geometry Edit dialog box. Confirm the chain definition by clicking the defined for the operation. 4.

button. The geometry is

Define the Tool

Click the Select button on the Tool page. The Part Tool Table is displayed. It shows all the tools that can be used in the CAM-Part machining. Currently, the Part Tool Table displays the tool used in the Turning operation. Define a new Milling tool. Click the button in the Part Tool Table. From the Milling tools section, select the End mill tool. 5.

Edit the Tool parameters

By default, SolidCAM offers you a Ø6 End mill tool. Edit the tool definition as follows: • Set the Diameter to 8 • Set the Arbor diameter to 10 • Set the Total length to 80 • Set the Outside holder length to 49 • Set the Shoulder length to 45 • Set the Cutting length to 43

Shoulder Length

Cutting Length

Outside Holder Length

Total Length

Diameter

Now you need to define the tool holder. In the Part Tool Table, switch to the Holder page. Expand the HSK A 63 header and choose the HSK A63 ER 16x80 tool holder from the list.

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Click 6.

in the Part Tool Table to confirm the tool definition. Define the Machining depth

Switch to the Levels page and click the Pocket depth button. The Pick Lower level dialog box is displayed. SolidCAM enables you to define the Lower level directly on the model. The Pocket depth is calculated automatically relative to the Upper level. Click on the pocket floor as shown. The picked value (-40) is displayed in the Pick Lower level dialog box. Confirm your selection by clicking . The Pocket Operation dialog box is displayed. The Pocket depth value is calculated automatically as the difference between the Upper level and the Lower level values.

The Lower level parameter is associative to the solid model. Associativity enables SolidCAM to be synchronized with the solid model changes; SolidCAM automatically updates the CAM data when the model is modified. The Profile depth parameter is indirectly associative. The associativity is established for the Lower level. When the Upper level or the Lower level is synchronized, the Depth is updated. The background of the parameter box defined associatively to the solid model changes to the color chosen in SolidCAM setting > Defaults > Colors for associative fields (by default, green). Set the Step down value to 5.

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5. Milling on Mill-Turn CNC-Machines 7.

Define the Technological parameters

Switch to the Technology page of the Pocket Operation dialog box. Use the Contour option with the default parameters. Offsets

The Wall offset and Floor offset parameters enable you to define the allowances that remain on the walls and the floor of the machined part till the profile finish machining. These allowances can be removed with the finish passes in the same Profile operation or in an additional Profile operation with another tool.

Step down

Wall offset

Profile depth

Floor offset

8.

Define the Lead in and the Lead out

Switch to the Link page of the Profile Operation dialog box. In the Ramping section, choose the Vertical option. With this option, the tool enters material vertically at a user-defined position. From this position, the tool moves to the pocket start point, calculated by the pocket algorithm. Click the Points button to define the initial tool position. The Ramping points dialog box is displayed. Click the Set default button to define an appropriate ramping point. Click Then you have to define a lead out strategy.

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This page enables you to define the way the tool retreats from the pocket wall. The lead out strategy enables you to perform the retract movements outside the material. The following options are available: • None

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

• Normal

The tool leads in to and out from the profile from a point normal to the profile. The length of the normal can be set in the Value field.

Normal Length Tangent Extension

Radius

• Arc

The tool leads in to and out from the profile with a tangential arc. The arc radius can be set in the Value field.

Tangent Extension

• Tangent

The tool leads in/out on a line tangent to the profile. The length of the tangent can be set in the Value field.

Length Tangent Extension

• Point

The tool leads in/out from a picked position. From this position, the tool moves on a straight line to the start point of the profile. When you select this option, the Pick 172

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5. Milling on Mill-Turn CNC-Machines

button is activated so that you can select a position directly on the solid model. • User-defined

The tool’s leads in/out trajectory is specified by a user-defined wireframe chain similar to the geometry definition. When the Same as lead in check box is selected, the strategy and parameters defined for Lead in are used for Lead out. Under Lead out, choose the Arc option from Arc angle to 45. Choose the Center option. 9.

the list, set the Radius value to 2,

Define the technological parameters of facial milling

Switch to the Motion control page and select the 4th Axis check box. This check box enables you to define the technological parameters of facial milling on MillTurn CNC-machines. 4th axis type

When the Diameter option is chosen, you receive the GCode output for the part machining in standard linear coordinates (X, Y, Z).

Y

Machining Geometry

X Machine CoordSys #1 Z

The Face option enables you to perform milling using the rotary axis by translating the linear movements in the XY-plane into the rotary XC-movements.

C X Machine CoordSys #1 Machining Geometry

Z

Note that the technology offered by SolidCAM is universal: there is no limitations in terms of machines on which the part can be milled. But if you use the GCode output in the XYZ coordinates (the Diameter 173

this GCode is limited to machines with possibility of movements along three linear axes (X, Y, Z). Therefore, to enable the possibility of milling the part on 3-axis Mill-Turn CNC-machines that support only the XZC coordinates where the movements along the Y-axis is impossible, you need to choose the Face option. Choose the Face option. Coordinate type

This option enables you to determine whether the GCode will consist of blocks in polar/Cartesian coordinates: • Polar

When this option is chosen, the tool path is calculated in polar coordinates. • Cartesian

The tool path lines and arcs are calculated in Cartesian coordinates; the CoordSys position is zero for linear coordinates. The milling is processed using the rotary axis by translating the linear movements into the rotary-linear movements according to the plane. In the Coordinate type section, choose the Polar option to obtain the tool path in polar coordinates. Plane

This option offers you the choice of plane in which the translated rotary-linear movements are performed. Make sure XC is chosen for Plane to perform all movements in these coordinates. Define the Tolerance.

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5. Milling on Mill-Turn CNC-Machines Tolerance

The tool path lines and arcs are split into many blocks that do not exactly generate the required tool path. The tolerance value in the Approximate arcs by lines within tolerance option defines the maximum allowed error; the smaller is the value of this field, the greater is the number of GCode blocks generated. Set the Tolerance value to 0.01. The definition of the basic technological parameters of the profile milling is finished. 10.

Click 11.

Click

Calculate the Tool path

. The operation data is saved, and the tool path is calculated. Simulate the operation

in the Pocket Operation dialog box.

The Simulation control panel is displayed. Switch to the SolidVerify page and start the simulation with the button.

When the simulation is finished, click the Stop on next button on the Simulation control panel. The Stop on Next dialog box is displayed. This dialog box enables you to define specific points where the simulation process is stopped. 175

Select the Z Change check box. This option stops the simulation at every change of the Z-coordinate of the tool. Play the simulation again. Every time the simulation stops on Z Change, click the button to continue. The Z Change option enables you to see the tool path simulation in detail. Exit the simulation. 12.

Close the operation dialog box

Click the

button. The Pocket Operation dialog box is closed.

Define a profile operation to perform machining of the pocket chamfer. 13.

Add a Profile operation

Right-click the Pocket operation in the SolidCAM Manager tree and choose Profile from the Add Milling Operation submenu. The Profile Operation dialog box is displayed. 14.

Define the Geometry

Make sure that MAC 1 (1-Position) is chosen for the Coordinate System and selected Submachine is Up_main. Click

on the Geometry page.

The Geometry Edit dialog box is displayed. Using the Tangent Propagation option, select the geometry as shown.

Confirm the chain definition by clicking the defined for the operation. 15.

Define the Tool

Click the Select button on the Tool page. 176

button. The geometry is

5. Milling on Mill-Turn CNC-Machines

The Part Tool Table is displayed. Click

.

Define a new Chamfer mill with default parameters. Choose the same tool holder HSK A63 ER 16x80 as in the previous operation.

Click 16.

to confirm the tool definition. Define the Machining depth

Switch to the Levels page and click the Profile depth button. The Pick Lower level dialog box is displayed. Click on the model vertex as shown. The picked value (-2) is displayed in the Pick Lower level dialog box. Confirm your selection by clicking . The Profile Operation dialog box is displayed. The Profile depth value is calculated automatically as the difference between the Upper level and the Lower level values. 17.

Define the Technological parameters

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

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Tool side

The Tool side option enables you to determine the tool position relative to the geometry. Right –the tool cuts on the right side of the 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 (No compensation G4x can be used with this option).

Right

Center

Left

The Geometry button displays the Modify Geometry dialog box that enables you to define the modification parameters of the geometry and to choose which geometry chains are active in the operation (in case of multiple chain geometry). The chain geometry of the profile is displayed on the model with the chain direction indicated and a circle representing the tool relative to the geometry. In the Modify section, click the Geometry button to check the tool location relative to the selected geometry. The Modify Geometry dialog box is displayed. The tool side offered by default is suitable: the tool is located inside the defined geometry.

Confirm the Modify Geometry dialog box with the 178

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5. Milling on Mill-Turn CNC-Machines

Make sure that the default Finish option is selected. This option enables you to perform the chamfer machining in one cutting pass.

In the Rest material/Chamfer section, choose the Chamfer option. The Chamfer page is automatically displayed. Set the Cutting diameter value to 2. 18.

Define the Lead in and the Lead out

Switch to the Link page of the Profile Operation dialog box. In the Ramping section, select the Feed option. With this option, the tool moves rapidly to the Upper level minus the Safety distance. Then the tool descends to the approach plane with the given Z Feed rate. Under Lead in, choose the Normal option from the list and set the Normal length value to 1. Select the Same as Lead in check box under Lead out.

19.

Click

Calculate the Tool path

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

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20.

Simulate the operation

Simulate the operation in the SolidVerify mode.

At this stage, the exercise is completed.

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5.1 Using MCO on Mill-Turn CNC-machines SolidCAM supports the use of the back spindle in the Mill-Turn module. This functionality enables you to use the back spindle of your CNC-machine for Turning and Milling machining with the part clamped in the main or back spindle. The part is transferred between the spindles, thus enabling you to complete the part machining from both sides in a single setup. Each milling or turning operation can be performed with the part clamped in the main or back spindle. Operation sequence #1: General use There are two optional stages in this operation sequence: 1. SolidCAM Operations with Main spindle. At this stage, only the main spindle is used for milling and turning operations; this is the standard way of working in SolidCAM when the back spindle does not exist.

2. SolidCAM Operations with Back spindle. At this stage, the operations are performed with the back spindle only.

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Operation sequence #2: Optimized tool use SolidCAM enables you to define a combined sequence of operations that uses intermittently the main and back spindles. Each operation in the sequence is related either to the main or to the back spindle. The Machine Control Operation enables you to define the transfer of the machined part between the main and back spindles. In this sequence, the combined operations with the main and back spindle use enable you to avoid unnecessary tool change (in cases when the same tool can work with the main and back spindles). In the beginning or end of all operations, the finished part is ejected from the back spindle and the partly machined part is transferred from the main spindle to the back spindle.

Machining with the main and back spindle

Transferring the part to the back spindle

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Exercise #12: Machining with Back Spindle This exercise covers the process of Machine Control Operation definition in order to transfer a part from the main spindle to the back spindle. 1.

Load the CAM-Part

Load the Exercise11.prz CAM-Part prepared in the previous exercise. 2.

Add a Machine Control Operation (MCO)

At this stage, you have to transfer the part from the main spindle to the back spindle, after completion of the finishing turning operation performed on the front of the CAM-Part. Right-click the Operations header in SolidCAM Manager and choose Add Machine Control Operation

from the menu.

The Machine Control Operation dialog box is displayed

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Machine Control Operation

This operation enables you to manage and use the devices of the CNC-machine. • Action on

This section contains a list of available CNC-machine devices. Choose the device to be managed and drag-and-drop it into the Process section. • Process

In this section the various machine devices are added for performing actions such as movements, opening/closing the chuck jaws, tool change, etc. • Properties

This section contains a list of parameters of devices to be modified. Using this operation, the part will be moved from the main spindle to the back spindle. The procedure is as follows: the jaws of the back spindle chuck open, the back spindle approaches the part, its jaws take the part and close, the jaws of the main spindle chuck open to release the part, the back spindle is returned to the working position. In the Operation name field, type in a new name: Part Transfer. The name of the MCO will appear later in the SolidCAM Manager tree. Click the Start definition entry. Under Properties, select MAC-1 Position #1 for CoordSys. The CAM-Part is located in the main spindle, and you have to choose the Lw_main for the Submachine. First, the Back Spindle should approach the part at a safety distance with the rapid speed. To start the action definition, drag and drop the BACK_SP item from the Action on pane to the Process pane. You can also double-click an item to add it to the Process pane. Select the Movement item located under the BACK_SP item and define the movement properties in the right pane as follows:

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• In the Mode cell, choose MA–Machine Coordinate mode ( ) • In the A (Z) cell, type in -1390. • In the C1 (-Rz) cell, type in 60. • In the Feed cell, choose RAPID. At the same time, the clamp should be open. Select the Clamp item located under the BACK_SP item and define the properties: • In the Value cell, choose OPEN. • In the New Line cell, choose Yes.

You can use the option of dynamic preview to display the changes made with the Machine Control Operation. Choose the Movement item under BACK_SP and double click the MCO dialog box title. The dialog box is minimized, the Back Spindle movement is shown in the graphic area.

Then the Back Spindle should reach the part with the defined Feed and close the the clamp on the part. Add one more BACK_SP item to the Action on list and define the following parameters for Movement: • In the A (Z) cell, type in -1445. • In the Feed cell, type in 200.

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For the Clamp item, define the following properties: • In the Value cell, choose CLOSE ON STOCK. • In the New Line cell, choose Yes. Next, the clamp of the main spindle should be opened. Add the MAIN_SP item and select the Clamp item with following properties: • In the Value cell, choose OPEN. Now the Back Spindle can return to the Home Reference position with the rapid speed. Add the BACK_SP item and select the Part Move item with the following parameters: • In the Mode cell, choose MA–Machine Coordinate mode ( ) • In the A (Z) cell, choose Home Ref.’ • In the Feed cell, choose RAPID. For the Clamp item, define the following properties: • In the Value cell, choose CLOSE ON STOCK. to save the operation. Click Operation dialog box. Click

to close the Machine Control

The Part Transfer operation appears in SolidCAM Manager.

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Now when the part has moved to the Back Spindle, the rest of the operations can be defined. The operations performed by the Lower turret tools are set on the Lw_back submachine; the operations performed by the Upper turret tools are set on Up_back submachine. 3.

Perform face turning with the back spindle

Right click the Part Transfer operation and add a Face turning operation from the Add Turning Operation submenu to machine the back face.

In the Output according to section, select Lw_back submachine. Choose the Machine Coordinate System #2 Position #1. Define the geometry as shown.

Add a new Ext. Turning composite tool. For Insert, the default parameters will be used. In the Shank page, define the following parameters:

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• Set the Insert Lead Angle to A (90 deg) • Set the Tool Length as 100 mm. Use the VDI_40_4025_20_LD tool holder by selecting in from the Tool STL Holders list. button. The tool parameters are defined. Click the In the Technology page, select the Back mode. Save, calculate and simulate the operation in the SolidVerify mode.

4.

Perform longitudinal turning with the back spindle

Add a new Turning operation to machine the external back surface. In the Output according to section, select Lw_back submachine. Choose the Machine Coordinate System #2 Position #1. Define the geometry as shown.

Add a new Ext. Turning composite tool.

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For Insert, the default parameters will be used. In the Shank page, define the following parameters: • Set the Insert Lead Angle to L (95 deg). Use the same VDI_40_4025_20_LD tool holder as in the previous operation. The tool parameters are defined. Click the

button.

In the Technology page, select the Long external mode. In the Work type section, use the deafult Rough option. In the Rough tab, select Smooth as the Rough type. In the Semi-finish/finish tab, select No in the Semi-finish and Finish sections. Save, calculate and simulate the operation in the SolidVerify mode.

5.

Perform turning with the back spindle

Add a new Turning operation to machine the back surface. In the Output according to section, select Lw_back submachine. Choose the Machine Coordinate System #2 Position #1. Define the geometry as shown.

Select the same Ext. Turning composite tool used for the previous operation. In the Technology page, select the Long external mode. In the Work type section, use the deafult Rough option. In the Rough tab, select Smooth as the Rough type. In the Semi-finish/finish tab, select No in the Semi-finish and ISO -Turning method in Finish sections. 189

Save, calculate and simulate the operation in the SolidVerify mode.

6.

Perform grooving with the back spindle

Add a new Grooving operation to machine the back groove. In the Output according to section, select Lw_back submachine. Choose the Machine Coordinate System #2 Position #1. Define the geometry as shown.

Add a new Ext. Grooving composite tool with default parameters. Use the same holder as in the previous operation. In the Technology page, select the Long external mode. In the Work type section, use the deafult Rough option. In the Rough tab, set the Step down type to Single. Set the Step over value to 3. In the Semi-finish/Finish tab, select the Down only option in the Semi-finish section. In the Finish section, choose No. The finishing machining will be performed in the next operation.

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5. Milling on Mill-Turn CNC-Machines

Save, calculate and simulate the operation in the SolidVerify mode.

7.

Perform finish turning with the back spindle

Add a new Turning operation to machine the back face. In the Output according to section, select Lw_back submachine. Choose the Machine Coordinate System #2 Position #1. Use the same geometry as in Step #4. Add a new Ext. Grooving composite tool with default parameters: Use the same holder as in the previous operation. In the Technology page, select the mode. In the Work type section, use the Finish only option. In the Semi-finish/finish tab, use the defualt finishing options. Save, calculate and simulate the operation in the SolidVerify mode. Long external

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8.

Perform pocket machining with the back spindle

Add a new Pocket operation to machine the second pocket on the back side. In the Output according to section, select Up_back submachine. Add a new coordinate system Machine Coordinate System #2 Position #2 Choose the Machine Coordinate System #2 Position #2. Define the geometry as shown.

Use the same Ø8 End Mill as in the Pocket operation defined for the front side. Define the Pocket depth by clicking on the floor of the pocket. Set the Step down value to 5. In the Technology page, select the Contour strategy with the same parameters as in Step #7 on page page 171. In the Link page define the Vertical ramping and Arc Lead out. The Lead out parameters are the same as in Step #8 on page page 171. Save, calculate and simulate the operation in the SolidVerify mode. 9.

Perform chamfer machining with the back spindle

Double-click the Profile operation defined for the main spindle. Click the Save to create a copy of the operation.

& Copy button

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Paste the copied operation after the just defined pocket operation. Double click the copied operation. This operation should be edited to complete chamfering on the back spindle. Paste the copied operation after the just defined pocket operation. Double click the copied operation. This operation should be edited to complete chamfering on the back spindle. In the Output according to section, select Up_back submachine. Choose the Machine Coordinate System #2 Position #2. Use the same geometry as in the previous Pocket operation. In the Technology page, check the tool side. Save and calculate the operation. Simulate the operation in the SolidVerify mode.

10.

Close the CAM-Part

Right-click the CAM-Part header in SolidCAM Manager and choose Close from the menu. The CAM-Part is closed. At this stage, the exercise is finished.

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Exercise #13: Control of Machine Devices This exercise covers the process of Machine Control Operations definition for adjustment of various machine devices and preparing correct visualization in Machine Simulation. 11.

Load the CAM-Part

Load the Exercise12.prz CAM-Part prepared in the previous exercise. 12.

View Machine Devices

The CNC-machine used with the CAM-Part consists of various machine devices. Double-click the Machine header in the SolidCAM Manager to open the Machine ID Editor dialog box and see the full list of the machine devices.

Close the Machine ID Editor dialog box.

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5. Milling on Mill-Turn CNC-Machines 13.

Add an MCO to move Lower Turret to save position

Before the start of machining the CAM-Part, the lower turret should move to safe position. Right-click Setup in SolidCAM Manager and choose Add Machine Control Operation from the menu. In the Operation name field, type in a new name: lt safe_2. Click the Start definition entry. Under Properties, select MAC-1 Position #1 for CoordSys. Choose the Lw_main for the Submachine. Add the LW_TR entry to the Process pane. Double-click the entry to expand the options. Select the Movement option and define the following properties: • • • •

In the Mode cell, select In the X2 (-X) cell, type in 0 In the Feed cell,select RAPID Click the No. cell below cell 1

• •

In the Mode cell, select In the Z2 (-Z) cell, type in -680

Click the Save and Exit button to save the operation. The MCO operation appears in SolidCAM Manager tree after the first turning operation. Drag and drop it to be the first operation in the tree.

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Before performing turning operations with the lower turret, the upper turret should retract to the safe position. 14.

Add an MCO to retract the Upper Turret

Right-click the profile operation in SolidCAM Manager and choose Add Machine Control Operation from the menu. In the Operation name field, type in a new name: ut safe. Click the Start definition entry. Under Properties, select MAC-1 Position #1 for CoordSys. Choose the Up_main for the Submachine. Add the UP_TR entry to the Process pane. Define the following properties for Movement: • • • •

In the Mode cell, select In the X1 (X) cell, select Home Ref In the Feed cell,select RAPID Click the No. cell below cell 1

• • • • • •

In the Mode cell, select In the X1 (X) cell, select type in 0 In the Y1 (Y) cell, select Home Ref In the Z1 (Z) cell, select Home Ref Click the No. cell below cell 2 In the B (Ry) cell, select type in 0

Click the Save and Exit

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button to save the operation.

5. Milling on Mill-Turn CNC-Machines

Before the part transfer operation, you have to ensure that the lower turret is in the safe position. Then you will be able to perform the part transfer. Add an MCO before the part transfer operation. 15.

Add an MCO to retract the Lower Turret

Right-click the grooving operation in SolidCAM Manager and choose Add Machine Control Operation from the menu. In the Operation name field, type in a new name: lt safe. Click the Start definition entry. Under Properties, select MAC-1 Position #1 for CoordSys. Choose the Lw_main for the Submachine. Add the LW_TR entry to the Process pane. Define the following properties for Movement: • • • •

In the Mode cell, select In the X2 (-X) cell, type in 0 In the Feed cell,select RAPID Click the No. cell below cell 1

• •

In the Mode cell, select In the Z2 (-Z) cell, type in -680

When the turning operations on the back spindle are completed, the lower turret should be again retracted to a safe position. 16.

Add an MCO to retract the Lower Turret

Right-click the turning operation in SolidCAM Manager and choose Add Machine Control Operation from the menu. In the Operation name field, type in a new name: lt safe_1. Click the Start definition entry. Under Properties, select MAC-1 Position #1 for CoordSys. Choose the Lw_main for the Submachine.

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Add the LW_TR entry to the Process pane. Define the following properties for Movement: • • • •

In the Mode cell, select In the X2 (-X) cell, type in 0 In the Feed cell,select RAPID Click the No. cell below cell 1

• •

In the Mode cell, select In the Z2 (-Z) cell, type in -680

Click the Save and Exit

button to save the operation.

After completion of the milling operations with the upper turret, the turret should returned to the safe position. 17.

Add an MCO to retract the Upper Turret

Double-click the Upper safe MCO operation in SolidCAM Manager. Click the Save and Copy button to create a new machine control operation. In the Operation name field, type in a new name: ut safe_1. Click the Start definition entry. Under Properties, select MAC-1 Position #1 for CoordSys. Choose the Up_main for the Submachine. Add the UP_TR entry to the Process pane. Define the following properties for Movement:

198

• • • •

In the Mode cell, select In the X1 (X) cell, select Home Ref In the Feed cell,select RAPID Click the No. cell below cell 1

• •

In the Mode cell, select In the X1 (X) cell, select type in 0

5. Milling on Mill-Turn CNC-Machines

• • • •

In the Y1 (Y) cell, select Home Ref In the Z1 (Z) cell, select Home Ref Click the No. cell below cell 2 In the B (Ry) cell, select type in 0

Click the Save and Exit

button to save the operation.

Now the SolidCAM Manager tree contains all the operations that should be distributed between two machine Channels using the Channel Synchronization process. At this stage, the exercise is finished.

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200

Advanced Mill Turn

6

Advanced Mill-Turn: Exercise #1 This exercise illustrates the entire capabilities of the mill turn process for machines with two spindles, B axis head, and lower turret. 1.

Load the SolidWorks Part

Browse to open the SolidWorks part AMT_Exercise1.SLDPRT. 2.

Define SolidCAM Settings

Click Tools > SolidCAM > SolidCAM Settings. In the left pane, click CAM -Part. Ensure you keep the settings as shown in the image.

Click Automatic CAM -Part definition. Ensure you keep the settings as shown in the image. Click OK.

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6. Advanced Mill Turn

Click Tools > SolidCAM > New > Mill- Turn.

The Mill - Turn Part Data window displays. 3.

Define the CAM Part

In the CNC -Machine list, click IntIV200ST. Click the CoordSys button in the Coordinate System section. The CoordSys window displays. In the Place Coordsys origin to list, click Center of revolution face. Select the face as shown in the image. Click Click the CoordSys button in the Coordinate System section. Right click MAC 1 1-Position > Edit. The CoordSys Data window displays. Set the values as shown in the image. Click Right click MAC 1 1-Position > Add. In the Place Coordsys origin to list, click CoordSys # 1. Select the same face that was used for position 1. Ensure that the direction of axes is as shown in the image.

Click

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Set the values as shown in the image. Click Right click MAC 1 2-Position > Add. In the Place Coordsys origin to list, click CoordSys # 1. Select the same face that was used for position 1. Ensure that the direction of axes is as shown in the image.

Click Set the values as shown in the image. Click Right click MAC 1 2-Position > Add. In the Place Coordsys origin to list, click CoordSys # 1. Select the same face that was used for position 1. Ensure that the direction of axes is as shown in the image.

Click

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6. Advanced Mill Turn

Set the values as shown in the image. Click Click to close the CoordSys Manager window. The Mill - Turn Part Data window displays.

4.

Define the Stock and Target

Click the Stock button in the Stock section. In the Defined by list, click Cylinder. Select the face as shown in the image. Set the Offsets and other values as follows: • Set the Right (+Z): to 2 • Set the Left (-Z): to 400 This value is required as you will define a cutoff operation and the machining of the next part will start on the same bar. • Set External: to 2 • Set Internal diameter: to 0 • Set the Facet tolerance to 0.01 • Select the Generate envelope check box. Click Click the Target button in the Target section. Select the model as shown in the image. • Set the Facet tolerance to 0.01 • Select the Envelope check box in the Generate Envelope/Section area. Click

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5.

Define the iMachining Data

Click Edit iMachining Database in the iMachining Data section. The iDatabase window displays. Click the New icon to define the machine. Enter the machine name as IntIV200ST. Click Save. Enter the machine parameters as shown in the image. Click the Material DB tab. Click the New icon to define the material. Enter the material name as Alloy Steels_140BHN77HRB. Click Save.

Enter the material parameters as shown in the image. Click Save & Exit. In the Mill - Turn Part Data section, select the Machine and Material Database according to the machine and material you just defined. Set the Machining Level as 3. Click

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6. Advanced Mill Turn 6.

Define the Machine Setup

In the CAM tree, right click Operations > Machine Setup. Click the three dots icon in the Fixture column in front of the MAIN_SP. The Model window displays. In the Defined by list, click Chuck (Standard). Set the Chuck position values as follows: • Set the Clamping diameter (CD): to 89 • Set the Axial position (Z): to -120 Set the Jaws parameters values as follows: • Set the Jaw width (JW): to 70 • Set the Jaw height (JH): to 50 • Set the Step width (SW): to 20 • Set the Step height (SH): to 20 Set the 3D options values as follows: • Set the Thickness: to 20 • Set the Number of jaws: to 3 Click The defined fixture must look as shown in the image.

Click the three dots icon in the Fixture column in front of the BACK_SP. In the Defined by list, click Chuck (Standard). Set the Chuck position values as follows: • Set the Clamping diameter (CD): to 70 • Set the Axial position (Z): to -100 Set the same Jaws parameters values and 3D options values you set while defining the first fixture.

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The defined fixture must look as shown in the image. Click In the Z column, set the values as: • 187 for MAIN_SP • 45 for BACK_SP Click OK. 7.

Add a Machine Control Operation (MCO)

The first operation you have to add is an MCO to keep the lower turret in safe position as the first operations you will define are on upper turret main spindle. Right click Setup and choose Add Machine Control Operation from the menu.

The Machine Control Operation dialog box is displayed.

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6. Advanced Mill Turn

In the Operation name field, type in a new name: LT safe1. Click the Start definition entry. Under Properties, select MAC-1 Position #1 for CoordSys. Choose the Lw_main for the Submachine. To start the action definition, double click the LW_TR item in the Action on pane. Select the Movement item located under the LW_TR item and define the movement properties in the right pane as follows: • In the Mode cell, choose MA–Machine Coordinate mode ( ) • In the X2 (-X) cell, choose Home Ref • In the Z2 (Z) cell, choose Home Ref • In the Feed cell, choose RAPID Click

to save the operation. Click box.

Operation dialog

to close the Machine Control

Now when the lower turret has moved to the safe position, the rest of the operations can be defined. 8.

Face Roughing with main spindle

Right-click the defined MCO operation in SolidCAM Manager and choose Face from the Add Turning Operation submenu. The Face Turning Operation dialog box is displayed.

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9.

Define the submachine

Choose the Up_main option that corresponds to the Upper Turret–Main Spindle submachine from the Output according to list on the Geometry page of the Face Turning Operation dialog box. 10.

Define the Geometry

Make sure that the Wireframe option is chosen on the Geometry page of the Face Turning Operation dialog box. Click the New button. The Geometry Edit dialog box is displayed. Select the contour as shown in the image. Click the Accept chain button to finish the chain definition and confirm the Geometry Edit dialog box with the button. On the Geometry page of the Face Turning Operation dialog box, click the Modify Geometry button. In the Modify Geometry window, ensure that the Auto extend Start to Stock and Auto extend End to Stock option are selected. Close the Modify Geometry dialog box with the button. 11.

Define the Tool

Now you have to define the tool for the face turning operation. Click the Select button on the Tool page of the Face Turning Operation dialog box. Click the Add Turning Tool Composite Tools section. For Insert, use the parameters as defined in the image.

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button. Choose the Ext. Turning tool from the

6. Advanced Mill Turn

In the Shank page, define the following parameters: • Set the Insert Clamping to C • Set the Insert Shape to C (80 deg) • Set the Insert Lead Angle to L (95 deg) • Set the Cutting Direction to L • Set the Shank Height to 25 • Set the Shank Width (A) to 25 • Set the Shank Length (L) to N (160.00 mm) Click the Select button to choose the tool for operation. For this tool, a new STL holder will be used. To export the STL holder, click button. the Exit In SolidCAM Part ribbon, choose the Tool Library Options submenu and select Tool STL Holders option. The STL Holders Table dialog box is displayed. Right-click the Turning entity and choose the Add STL Holder option. The Browse dialog box is displayed. Find the DCLNL 2525 M12 CAPTO C6.stl file stored in the Exercises folder and click Open. The holder is successfully imported to your library. Click OK to close the STL Holders Table dialog box. Open the Face Turning operation. In the Tool page, click Select and switch to the Holder tab. In the Global holders table, select the DCLNL 2525 M12 CAPTO C6 holder. Click the Mounting button. Ensure that the tool is mounted in the way as shown in the image.

Click the Mounting button again to close the dialog box. Click the Select

button to choose the defined tool for the current operation.

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12.

Define the machining levels

Switch to the Levels page of the Face Turning Operation dialog box. This page enables you to specify the machining levels for the operation. Use the default Safety distance value (2). 13.

Define the technological parameters

Switch to the Technology page of the Face Turning Operation dialog box. option is chosen in the Mode area. Make sure that the Front Select the Stock option in the Working area section. Choose the Direction as One way. Select the Rough check box and choose the option of Stairs in the Rough type section. Set the Equal step over value to 1. In the Offset section, set the values as shown in the image.

14.

Calculate the operation

Click in the Face Turning Operation dialog box. The operation data is saved, and the tool path is calculated. 15.

Simulate the operation in the Host CAD mode

Click

in the Face Turning Operation dialog box.

The Simulation control panel is displayed. Click the Play Simulation control panel. The tool path is simulated in the SolidWorks window. 16.

Simulate the operation in the Turning mode

Switch to the Turning page on the Simulation control panel.

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button on the

6. Advanced Mill Turn

Click the Play

17.

button. The tool path is simulated.

Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

18.

Close the simulation

Click the Exit button on the Simulation control panel. The Face Turning Operation dialog box is displayed. 19.

Close the Face Turning Operation dialog box

In the Face Turning Operation dialog box, click The dialog box is closed.

.

The next operation is for the face finishing of the part.

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20.

Face Finishing with main spindle

Right-click the previous defined face turning operation in SolidCAM Manager and click Copy. Right-click the previous defined face turning operation in SolidCAM Manager and click Paste. Right-click the pasted operation and click Edit. 21.

Define the Tool

Click the Select button on the Tool page of the Face Turning Operation dialog box. Click the Add Turning Tool button. Choose the Ext. Turning tool from the Composite Tools section. For Insert, use the parameters as defined in the image. In the Shank page, define the following parameters: • Set the Insert Clamping to C

•

Set the Insert Shape to C (80 deg)

•

Set the Insert Lead Angle to L (95 deg) • Set the Cutting Direction to L • Set the Shank Height to 25 • Set the Shank Width (A) to 25 • Set the Shank Length (L) to N (160.00 mm) Switch to the Holder tab. In the Global holders table, select the HSK A63WH-ASHR-25-45 holder from the Turning list. Click the Mounting button.

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6. Advanced Mill Turn

Ensure that the tool is mounted in the way as shown in the image.

Click the Mounting button again to close the dialog box. Click the Select 22.

button to choose the defined tool for the current operation.

Calculate the operation

Click in the Face Turning Operation dialog box. The operation data is saved, and the tool path is calculated. 23.

Simulate the operation in the Host CAD mode

Click

in the Face Turning Operation dialog box.

The Simulation control panel Simulation control panel.

is displayed. Click the Play

button on the

The tool path is simulated in the SolidWorks window. 24.

Simulate the operation in the Turning mode

Switch to the Turning page on the Simulation control panel. Click the Play

button. The tool path is simulated.

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25.

Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

26.

Close the simulation

Click the Exit button on the Simulation control panel. The Face Turning Operation dialog box is displayed. 27.

Close the Face Turning Operation dialog box

In the Face Turning Operation dialog box, click The dialog box is closed.

.

The next operation is by using Balanced Rough for machining. In this operation, both the tools are used to perform roughing cuts simultaneously. 28.

Add a Balanced Rough operation

Right-click the previous defined face turning operation in SolidCAM Manager and choose Balanced Rough from the Add Turning Operation submenu. The Balanced Rough operation dialog box is displayed. 29.

Define the Master and Slave submachine

On the Geometry page of the Balanced Roughing operation dialog box, choose the Up_main option that corresponds to the Upper Turret–Main Spindle submachine from the Master Output according to list. Choose Lw_main option that corresponds to the Lower Turret–Main Spindle submachine from the Slave Output according to list.

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6. Advanced Mill Turn 30.

Define the Geometry

Make sure that the Wireframe option is chosen on the Geometry page of the Balanced Rough operation dialog box. Click the New button. The Geometry Edit dialog box is displayed. Select the contour as shown in the image.

button to finish the chain definition and confirm Click the Accept chain the Geometry Edit dialog box with the button. On the Geometry page click the Modify Geometry button. In the Modify Geometry window, ensure that the Auto extend Start to Stock and Auto extend End to Stock option are selected. Close the Modify Geometry dialog box with the button. 31.

Define the Tool

Click the Select button on the Tool page of the Balanced Rough operation dialog box. Click the Add Turning Tool button. Choose the Ext. Turning tool from the Composite Tools section. For Insert, use the parameters as defined in the image.

217

In the Shank page, define the following parameters: • Set the Insert Clamping to C • Set the Insert Shape to C (80 deg) • Set the Insert Lead Angle to L (95 deg) • Set the Cutting Direction to L • Set the Shank Height to 25 • Set the Shank Width (A) to 25 • Set the Shank Length (L) to N (160.00 mm) Switch to the Holder tab. In the Local holders table, select the DCLNL 2525 M12 CAPTO C6 holder. Click the Mounting button. Ensure that the tool is mounted in the way as shown in the image.

Click the Mounting button again to close the dialog box. Click the Select 32.

button to choose the defined tool for the current operation.

Define the Slave Tool

As you are defining a balanced rough operation in which a master and slave submachine is used, you must also define a slave tool. It is mandatory to keep the corner radius of both (master and slave) tools same even if the inserts used are different. Click the Select button on the Slave Tool page of the Balanced Rough operation dialog box. Click the Add Turning Tool Composite Tools section.

218

button. Choose the Ext. Turning tool from the

6. Advanced Mill Turn

For Insert, use the parameters as defined in the image. In the Shank page, define the following parameters: • Set the Insert Clamping to D

•

Set the Insert Shape to C (80 deg)

•

Set the Insert Lead Angle to L (95 deg) • Set the Cutting Direction to L • Set the Shank Height to 25 • Set the Shank Width (A) to 25 • Set the Shank Length (L) to K (125.00 mm) Switch to the Holder tab. Select the HSK A 63 ER16X100 holder. Click the Mounting button. Ensure that the tool is mounted in the way as shown in the image.

Click the Mounting button again to close the dialog box. Click the Select 33.

button to choose the defined tool for the current operation.

Define the technological parameters

Switch to the Technology page of the Balanced Rough operation dialog box. option is chosen in the Mode area. Make sure that the Long external Select the Rough option in the Work type section. Select the Trailing option in the Balanced mode section. Set the Distance value to 2. Click the Rough tab.

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Enter the values shown in the image.

as

Click the Strategies tab. Select the option of Nondescending motions.

34.

Calculate the operation

Click in the Balanced rough operation dialog box. The operation data is saved, and the tool path is calculated. 35.

Click

Simulate the operation in the Host CAD mode

in the Balanced Rough operation dialog box.

The Simulation control panel is displayed. Click the Play Simulation control panel. The tool path is simulated in the SolidWorks window. 36.

Simulate the operation in the Turning mode

Switch to the Turning page on the Simulation control panel. Click the Play

220

button. The tool path is simulated.

button on the

6. Advanced Mill Turn 37.

Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

38.

Close the simulation

Click the Exit button on the Simulation control panel. The Balanced rough operation dialog box is displayed. 39.

Close the Balanced Rough operation dialog box

In the Balanced rough operation dialog box, click The dialog box is closed.

.

The next operation is again defining an MCO as the lower turret is not required for the outer diameter finishing and grooving operations defined on the Upper Turret Main Spindle. 40.

Add a Machine Control Operation (MCO)

Right click the previous defined balanced rough operation and choose Add Machine Control Operation from the menu. The Machine Control Operation dialog box is displayed.

221

In the Operation name field, type in a new name: LT safe2. Click the Start definition entry. Under Properties, select MAC-1 Position #1 for CoordSys. Choose the Lw_main for the Submachine. To start the action definition, double click the LW_TR item in the Action on pane. Select the Movement item located under the LW_TR item and define the movement properties in the right pane as follows: • In the Mode cell, choose MA–Machine Coordinate mode ( ) • In the X2 (-X) cell, choose Home Ref • In the Z2 (Z) cell, choose Home Ref • In the Feed cell, choose RAPID Select the Tool change item located under the LW_TR item and define the tool change properties in the right pane as follows: • For Tool Change, in the Value cell, choose the Next Tool on Turret • For Tool Change Position, in the Value cell, choose As in Current Position Click

to save the operation. Click box.

Operation dialog

to close the Machine Control

Now when the lower turret has moved to the safe position, the finishing and grooving operations for outside diameter can be defined. 41.

External Diameter Finishing with main spindle

Right-click the defined MCO operation in SolidCAM Manager and choose Turning from the Add Turning Operation submenu. The Turning Operation dialog box is displayed.

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6. Advanced Mill Turn 42.

Define the Geometry

On the Geometry page choose the Up_main option from the Output according list. Make sure that the Wireframe option is chosen on the Geometry page of the Turning Operation dialog box.

to

Click the New button. The Geometry Edit dialog box is displayed. Select the contour as shown in the image.

button to finish the chain definition and confirm Click the Accept chain the Geometry Edit dialog box with the button. On the Geometry page click the Modify Geometry button. In the Modify Geometry window, ensure that the Auto extend Start to Stock option is selected. Close the Modify Geometry dialog box with the button. 43.

Define the Tool

Click the Select button on the Tool page of the Turning Operation dialog box. Click the Add Turning Tool button. Choose the Ext. Turning tool from the Composite Tools section. For Insert, use the parameters as defined in the image.

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In the Shank page, define the following parameters: • Set the Insert Clamping to C • Set the Insert Shape to C (80 deg) • Set the Insert Lead Angle to L (95 deg) • Set the Cutting Direction to L • Set the Shank Height to 25 • Set the Shank Width (A) to 25 • Set the Shank Length (L) to N (160.00 mm) Switch to the Holder tab. In the Local holders table, select the HSK A63WHASHR-25-45 holder. Click the Mounting button. Ensure that the tool is mounted in the way as shown in the image.

Click the Mounting button again to close the dialog box. Click the Select 44.

button to choose the defined tool for the current operation.

Define the technological parameters

Switch to the Technology page of the Turning Operation dialog box. option is chosen in the Mode area. Make sure that the Long external Select the Rough option in the Work type section. Click the Rough tab.

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6. Advanced Mill Turn

Enter the parameters as shown in the image:

Click the Semi-finish/ tab.

finish

Enter the parameters as shown in the image. Click the Strategies tab. Select the option of Nondescending motions.

45.

Calculate the operation

Click in the Turning Operation dialog box. The operation data is saved, and the tool path is calculated. 46.

Click

Simulate the operation in the Host CAD mode

in the Turning Operation dialog box.

The Simulation control panel is displayed. Click the Play Simulation control panel. The tool path is simulated in the SolidWorks window.

button on the

225

47.

Simulate the operation in the Turning mode

Switch to the Turning page on the Simulation control panel. Click the Play

48.

button. The tool path is simulated.

Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

49.

Close the simulation

Click the Exit button on the Simulation control panel. The Turning Operation dialog box is displayed. 50.

Close the Turning Operation dialog box

In the Turning Operation dialog box, click The dialog box is closed.

.

The next operation is defining a grooving operation on the Upper Turret Main Spindle.

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6. Advanced Mill Turn 51.

External Grooving with upper turret main spindle

Right-click the defined finish operation for outer diameter in SolidCAM Manager and choose Grooving from the Add Turning Operation submenu. The Grooving Operation dialog box is displayed. 52.

Define the Geometry

On the Geometry page choose the Up_main option from the Output according list. Make sure that the Wireframe option is chosen on the Geometry page of the Turning Operation dialog box.

to

Click the New button. The Geometry Edit dialog box is displayed. Select the contour as shown in the image. Click the Accept chain

button to finish the chain definition and confirm

button. On the Geometry page click the Geometry Edit dialog box with the the Modify Geometry button. In the Modify Geometry window, ensure that the Auto extend Start to Stock and Auto extend End to Stock option are selected. Close the Modify Geometry dialog box with the button. 53.

Define the Tool

Click the Select button on the Tool page of the Grooving Operation dialog box. Click the Add Turning Tool Composite Tools section.

button. Choose the Ext. Grooving tool from the

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For Insert, use the parameters as defined in the image: In the Shank page, define the following parameters: • Set the Shank type to Straight • Set the Cutting Direction to L Switch to the Holder tab. In the Local holders table, select the HSK A63WHASHR-25-45 holder. Click the Mounting button. Ensure that the tool is mounted in the way as shown in the image.

Click the Mounting button again to close the dialog box. Click the Select 54.

button to choose the defined tool for the current operation.

Define the technological parameters

Switch to the Technology page of the Grooving Operation dialog box. option is chosen in the Mode area. Make sure that the Long external Select the Rough option in the Work type section. Click the Rough tab. Enter the parameters as shown in the image:

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6. Advanced Mill Turn

Click the Semi-finish/finish tab. In the Semi-finish list, choose No. In the Finish list, choose ISO-Turning method. In the Finish on list, choose Entire geometry. Select the Compensation check box. Click the Groove parameters tab. In the Plunging conditions section, set the Spin (100%) and Feed (100%) values as 100. 55.

Calculate the operation

Click in the Grooving Operation dialog box. The operation data is saved, and the tool path is calculated. 56.

Click

Simulate the operation in the Host CAD mode

in the Grooving Operation dialog box.

The Simulation control panel Simulation control panel.

is displayed. Click the Play

button on the

The tool path is simulated in the SolidWorks window. 57.

Simulate the operation in the Turning mode

Switch to the Turning page on the Simulation control panel. Click the Play

button. The tool path is simulated.

229

58.

Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

59.

Close the simulation

Click the Exit button on the Simulation control panel. The Grooving Operation dialog box is displayed. 60.

Close the Grooving Operation dialog box

In the Grooving Operation dialog box, click The dialog box is closed.

.

The next operation is defining a grooving operation on the Lower Turret Main Spindle. 61.

Internal Grooving with lower turret main spindle

Right-click the defined grooving operation for outer diameter in SolidCAM and choose Grooving from the Add Turning Operation submenu.

Manager

The Grooving Operation dialog box is displayed. 62.

Define the Geometry

On the Geometry page choose the Lw_main option from the Output according to list. Make sure that the Wireframe option is chosen on the Geometry page of the Turning Operation dialog box. Click the New button. The Geometry Edit dialog box is displayed.

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6. Advanced Mill Turn

Select the contour as shown in the image.

button to finish the chain definition and confirm Click the Accept chain the Geometry Edit dialog box with the button. On the Geometry page click the Modify Geometry button. In the Modify Geometry window, ensure that the Auto extend Start to Stock option is selected. Close the Modify Geometry dialog box with the button. 63.

Define the Tool

Click the Select button on the Tool page of the Grooving Operation dialog box. Click the Add Turning Tool button. Choose the Ext. Grooving tool from the Composite Tools section. For Insert, use the parameters as defined in the image: In the Shank page, define the following parameters: • Set the Shank type to Straight • Set the Cutting Direction to L Switch to the Holder tab. In the Local holders table, select the HSK A63WHASHR-25-45 holder. Click the Mounting button.

231

Ensure that the tool is mounted in the way as shown in the image.

Click the Mounting button again to close the dialog box. Click the Select 64.

button to choose the defined tool for the current operation.

Define the technological parameters

Switch to the Technology page of the Grooving Operation dialog box. Make sure that the Long external option is chosen in the Mode area. Select the Rough option in the Work type section. Click the Rough tab. Enter the parameters as shown in the image:

Click the Semi-finish/finish tab. In the Semi-finish list, choose No. In the Finish list, choose ISO-Turning method. In the Finish on list, choose Rest material only. Select the Compensation check box.

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6. Advanced Mill Turn

Click the Groove parameters tab. In the Plunging conditions section, set the Spin (100%) and Feed (100%) values as 100. 65.

Calculate the operation

Click in the Grooving Operation dialog box. The operation data is saved, and the tool path is calculated. 66.

Click

Simulate the operation in the Host CAD mode

in the Grooving Operation dialog box.

The Simulation control panel Simulation control panel.

is displayed. Click the Play

button on the

The tool path is simulated in the SolidWorks window. 67.

Simulate the operation in the Turning mode

Switch to the Turning page on the Simulation control panel. Click the Play

button. The tool path is simulated.

233

68.

Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

69.

Close the simulation

Click the Exit button on the Simulation control panel. The Grooving Operation dialog box is displayed. 70.

Close the Grooving Operation dialog box

In the Grooving Operation dialog box, click The dialog box is closed.

.

The next operation is again defining an MCO as the lower turret is not required for the outer diameter grooving operation defined on the Upper Turret Main Spindle. 71.

Add a Machine Control Operation (MCO)

Right click the previous defined grooving operation and choose Add Machine Control Operation from the menu. The Machine Control Operation dialog box is displayed. In the Operation name field, type in a new name: LT safe3. Click the Start definition entry. Under Properties, select MAC-1 Position #1 for CoordSys. Choose the Lw_main for the Submachine. To start the action definition, double click the LW_TR item in the Action on pane. Select the Movement item located under the LW_TR item and define the movement properties in the right pane as follows: • In the Mode cell, choose MA–Machine Coordinate mode ( ) • In the X2 (-X) cell, choose Home Ref

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6. Advanced Mill Turn

• In the Z2 (Z) cell, choose Home Ref • In the Feed cell, choose RAPID Select the Tool change item located under the LW_TR item and define the tool change properties in the right pane as follows: • For Tool Change, in the Value cell, choose the Next Tool on Turret • For Tool Change Position, in the Value cell, choose As in Current Position Click

to save the operation. Click box.

Operation dialog

to close the Machine Control

Now when the lower turret has moved to the safe position, the grooving operation for outside diameter can be defined. 72.

External Grooving with upper turret main spindle

Right-click the defined MCO operation in SolidCAM Manager and choose Grooving from the Add Turning Operation submenu. The Grooving Operation dialog box is displayed. 73.

Define the Geometry

On the Geometry page choose the Up_main option from the Output according to list. Make sure that the Wireframe option is chosen on the Geometry page of the Turning Operation dialog box. Click the New button. The Geometry Edit dialog box is displayed.

235

Select the contour as shown in the image.

button to finish the chain definition and confirm Click the Accept chain the Geometry Edit dialog box with the button. On the Geometry page click the Modify Geometry button. In the Modify Geometry window, ensure that the Auto extend Start to Stock and Auto extend End to Stock option are selected. Close the Modify Geometry dialog box with the button. 74.

Define the Tool

Click the Select button on the Tool page of the Grooving Operation dialog box. Click the Add Turning Tool button. Choose the Ext. Grooving tool from the Composite Tools section. For Insert, use the parameters as defined in the image: In the Shank page, define the following parameters: • Set the Shank type to Straight • Set the Cutting Direction to L Switch to the Holder tab. In the Local holders table, select the HSK A63WH-ASHR-25-45 holder. Click the Mounting button.

236

6. Advanced Mill Turn

Ensure that the tool is mounted in the way as shown in the image.

Click the Mounting button again to close the dialog box. Click the Select 75.

button to choose the defined tool for the current operation.

Define the technological parameters

Switch to the Technology page of the Grooving Operation dialog box. option is chosen in the Mode area. Make sure that the Long external Select the Rough option in the Work type section. Click the Rough tab. Enter the parameters as shown in the image:

Click the Semi-finish/finish tab. In the Semi-finish list, choose No. In the Finish list, choose ISO-Turning method. In the Finish on list, choose Entire geometry. Select the Compensation check box. Click the Groove parameters tab. In the Plunging conditions section, set the Spin (100%) and Feed (100%) values as 100. 237

76.

Calculate the operation

Click in the Grooving Operation dialog box. The operation data is saved, and the tool path is calculated. 77.

Click

Simulate the operation in the Host CAD mode

in the Grooving Operation dialog box.

The Simulation control panel Simulation control panel.

is displayed. Click the Play

button on the

The tool path is simulated in the SolidWorks window. 78.

Simulate the operation in the Turning mode

Switch to the Turning page on the Simulation control panel. Click the Play

79.

button. The tool path is simulated.

Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

238

6. Advanced Mill Turn 80.

Close the simulation

Click the Exit button on the Simulation control panel. The Grooving Operation dialog box is displayed. 81.

Close the Grooving Operation dialog box

In the Grooving Operation dialog box, click The dialog box is closed.

.

The next operation is defining an MCO to move the upper turret in the safe position as the next operations will be defined using lower turret main spindle. 82.

Add a Machine Control Operation to retract the upper turret

Right click the previous defined grooving operation and choose Add Machine the menu. The Machine Control Operation dialog box is displayed. In the Operation name field, type in a new name: B home1. Click the Start definition entry. Under Properties, select MAC-1 Position #1 for CoordSys. Choose the Up_main for the Submachine. To start the action definition, double click the UP_TR item in the Action on pane. Select the Movement item located under the UP_TR item and define the movement properties in the right pane as follows: • In the Mode cell, choose MA–Machine Coordinate mode ( ) • In the X1 (X) cell, choose Home Ref • In the Y1 (Y) cell, choose Home Ref • In the Z1 (Z) cell, choose Home Ref • In the B (Ry) cell, choose Home Ref • In the Feed cell, choose RAPID Control Operation from

Click

to save the operation. Click box.

Operation dialog

to close the Machine Control

239

Now when the upper turret has moved to the safe position, the pocket, drilling, and turning operations for outside diameter can be defined. 83.

Shaped Grooved Roughing with lower turret main spindle

Right-click the defined MCO operation in SolidCAM Manager and choose Turning from the Add Turning Operation submenu. The Turning Operation dialog box is displayed. 84.

Define the Geometry

On the Geometry page choose the Lw_main option from the Output according to list. Make sure that the Wireframe option is chosen on the Geometry page of the Turning Operation dialog box. Click the New button. The Geometry Edit dialog box is displayed. Select the contour as shown in the image.

button to finish the chain definition and confirm Click the Accept chain the Geometry Edit dialog box with the button. On the Geometry page click the Modify Geometry button. In the Modify Geometry window, ensure that the Auto extend Start to Stock and Auto extend End to Stock option are selected. Close the Modify Geometry dialog box with the button.

240

6. Advanced Mill Turn 85.

Define the Tool

Click the Select button on the Tool page of the Turning Operation dialog box. Click the Add Turning Tool button. Choose the Ext. Turning tool from the Composite Tools section. For Insert, use the parameters as defined in the image: In the Shank page, define the following parameters: • Set the Insert Clamping to C • Set the Insert Shape to V (35 deg)

•

Set the Insert Lead Angle to V 72.5 deg)

• Set the Cutting Direction to N • Set the Shank Height to 25 • Set the Shank Width (A) to 25 • Set the Shank Length (L) to K (125.00 mm Click the Mounting button. Ensure that the tool is mounted in the way as shown in the image.

Click the Mounting button again to close the dialog box. Click the Select 86.

button to choose the defined tool for the current operation.

Define the technological parameters

Switch to the Technology page of the Turning Operation dialog box. option is chosen in the Mode area. Make sure that the Long external Select the Rough option in the Work type section.

241

Click the Rough tab. Enter the parameters as shown in the image:

Click the Semi-finish/finish tab. In the Semi-finish list, choose No. In the Finish list, choose ISO-Turning method. In the Finish on list, choose Entire geometry. Click the Strategies tab. Select the Descending motions option. 87.

Calculate the operation

Click in the Turning Operation dialog box. The operation data is saved, and the tool path is calculated. 88.

Click

Simulate the operation in the Host CAD mode

in the Turning Operation dialog box.

The Simulation control panel is displayed. Click the Play Simulation control panel. The tool path is simulated in the SolidWorks window.

242

button on the

6. Advanced Mill Turn 89.

Simulate the operation in the Turning mode

Switch to the Turning page on the Simulation control panel. Click the Play

90.

button. The tool path is simulated.

Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

91.

Close the simulation

Click the Exit button on the Simulation control panel. The Turning Operation dialog box is displayed. 92.

Close the Turning Operation dialog box

In the Turning Operation dialog box, click The dialog box is closed.

.

The next operation is defining a drilling operation on lower turret main spindle to machine the internal diameter of the part.

243

93.

Internal Drilling with lower turret main spindle

Right-click the defined turning operation in SolidCAM Manager and choose Drilling from the Add Turning Operation submenu. The Drilling Operation dialog box is displayed. 94.

Define the Coordsys

On the Coordsys page choose the Lw_main option from the Output according list.

to

95.

Define the Tool

Click the Select button on the Tool page of the Drilling Operation dialog box. Click the Add Milling Tool button. Choose the DRILL tool from the Drilling Tools section. Enter the parameters as shown in the image.

Switch to the Holder page. Choose integrex lt holder. Click the Mounting button. Ensure that the tool is mounted in the way as shown in the image. Click the Mounting button again to close the dialog box. button Click the Select to choose the defined tool for the current operation.

244

6. Advanced Mill Turn 96.

Define the technological parameters

Switch to the Technology page of the Drilling Operation dialog box. Select the Drill end button. Select the point as shown in the image. Click Select the option of Full diameter in the Depth type section. Select the Use cycle check box.

97.

Calculate the operation

Click in the Drilling Operation dialog box. The operation data is saved, and the tool path is calculated. 98.

Click

Simulate the operation in the Host CAD mode

in the Drilling Operation dialog box.

The Simulation control panel Simulation control panel.

is displayed. Click the Play

button on the

The tool path is simulated in the SolidWorks window. 99.

Simulate the operation in the Turning mode

Switch to the Turning page on the Simulation control panel. Click the Play

button. The tool path is simulated.

245

100. Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

101. Close the simulation

Click the Exit button on the Simulation control panel. The Drilling Operation dialog box is displayed. 102. Close the Drilling Operation dialog box

In the Drilling Operation dialog box, click The dialog box is closed.

.

The next operation you will define is a drilling operation on lower turret main spindle to machine the internal diameter of the part. 103. Internal Diameter Roughing with lower turret main spindle

Right-click the defined turning operation in SolidCAM Manager and choose Turning from the Add Turning Operation submenu. The Turning Operation dialog box is displayed. 104. Define the Coordsys

On the Geometry page choose the Lw_main option from the Output according to list. Make sure that the Wireframe option is chosen on the Geometry page of the Turning Operation dialog box. Click the New button. The Geometry Edit dialog box is displayed.

246

6. Advanced Mill Turn

Select the contour as shown in the image.

button to finish the chain definition and confirm Click the Accept chain the Geometry Edit dialog box with the button. On the Geometry page click the Modify Geometry button. In the Modify Geometry window, ensure that the Auto extend Start to Stock option is selected. Close the Modify Geometry dialog box with the button. 105. Define the Tool

Click the Select button on the Tool page of the Turning Operation dialog box. Click the Add Turning Tool button. Choose the Int. Turning tool from the Composite Tools section. For Insert, use the parameters as defined in the image:

247

In the Shank page, use the parameters as defined in the image:

Click the Mounting button. Ensure that the tool is mounted in the way as shown in the image. Click the Mounting button again to close the dialog box. button Click the Select to choose the defined tool for the current operation.

106. Define the technological parameters

Switch to the Technology page of the Turning Operation dialog box. option is chosen in the Mode area. Make sure that the Long internal Select the Rough option in the Work type section. Click the Rough tab.

248

6. Advanced Mill Turn

Enter the parameters as shown in the image:

Click the Semi-finish/finish tab. In the Semi-finish list, choose No. In the Finish list, choose ISO-Turning method. In the Finish on list, choose Entire geometry. Click the Strategies tab. Select the Non-descending motions option. 107. Calculate the operation

Click in the Turning Operation dialog box. The operation data is saved, and the tool path is calculated. 108. Simulate the operation in the Host CAD mode

Click

in the Turning Operation dialog box.

The Simulation control panel is displayed. Click the Play Simulation control panel. The tool path is simulated in the SolidWorks window.

button on the

249

109.

Simulate the operation in the Turning mode

Switch to the Turning page on the Simulation control panel. Click the Play

button. The tool path is simulated.

110. Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

111. Close the simulation

Click the Exit button on the Simulation control panel. The Turning Operation dialog box is displayed. 112. Close the Turning Operation dialog box

In the Turning Operation dialog box, click The dialog box is closed.

.

The next operation you will define is an MCO to move the lower turret in the safe position. You will define the next operations on upper turret main spindle using MAC1 2-Position.

250

6. Advanced Mill Turn 113. Add a Machine Control Operation to retract the lower turret

Right click the previous defined turning operation and choose Add Machine Control Operation from the menu. The Machine Control Operation dialog box is displayed. In the Operation name field, type in a new name: LThome. Click the Start definition entry. Under Properties, select MAC-1 Position #1 for CoordSys. Choose the Lw_main for the Submachine. To start the action definition, double click the LW_TR item in the Action on pane. Select the Movement item located under the LW_TR item and define the movement properties in the right pane as follows: • In the Mode cell, choose MA–Machine Coordinate mode ( ) • In the X2 (-X) cell, choose Home Ref • In the Z2 (Z) cell, choose Home Ref • In the Feed cell, choose RAPID Select the Tool change item located under the LW_TR item and define the tool change properties in the right pane as follows: • For Tool Change, in the Value cell, choose the Next Tool on Turret • For Tool Change Position, in the Value cell, choose As in Current Position Click

to save the operation. Click box.

Operation dialog

to close the Machine Control

Now when the lower turret has moved to the safe position, the profile operations for machining the outside diameter can be defined. 114. Profile Roughing with upper turret main spindle

Right-click the defined MCO in SolidCAM Manager and choose Profile from the Add Milling Operation submenu. The Profile Operation dialog box is displayed.

251

115. Define the Geometry

On the Geometry page choose MAC 1 (2-Position) from the CoordSys list. Choose the UP_main option from the Output according to list. Make sure that the General option is chosen on the Geometry selection section of the Profile Operation dialog box. Click the New button. The Geometry Edit dialog box is displayed. Select the contour as shown in the image.

button to finish the chain definition and confirm Click the Accept chain the Geometry Edit dialog box with the button. 116. Define the Tool

Click the Select button on the Tool page of the Profile Operation dialog box. Click the Add Milling Tool button. Choose the END MILL tool from the Milling Tools section. Use the parameters as defined in the image: Switch to the Holder page. Select HSK A 63 ER16X100 as the holder.

252

6. Advanced Mill Turn

Click the Mounting button. Ensure that the tool is mounted in the way as shown in the image.

Click the Mounting button again to close the dialog box. Click the Select

button to choose the defined tool for the current operation.

117. Define the level parameters

Switch to the Levels page of the Profile Operation dialog box. option is chosen in the Depth area. Make sure that the Constant Set the Clearance level value to 100. Set the Safety distance value to 5. Set the Profile depth value to 18. Select the Upper level button in the Milling levels section. Select the point as shown in the image. Click

253

118. Define the technological parameters

Switch to the Technology page of the Profile Operation dialog box. • Choose Left in the Tool side: list • Choose Helical in the Depth type list • Choose None in the Rest material/Chamfer list • Set the Wall offset to 0.5 • Select the Rough check box. 119. Define the link parameters

Switch to the Link page of the Profile Operation dialog box. • Use the parameters as shown in the image.

120. Define the misc. parameters

Switch to the Misc. parameters page of the Profile Operation dialog box. Set the Tolerance value to 0.1. Select the Material boundary connected to current fixture check box. 121. Calculate the operation

Click in the Profile Operation dialog box. The operation data is saved, and the tool path is calculated. 122. Simulate the operation in the Host CAD mode

Click

in the Profile Operation dialog box.

The Simulation control panel Simulation control panel.

is displayed. Click the Play

The tool path is simulated in the SolidWorks window.

254

button on the

6. Advanced Mill Turn 123. Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

124. Close the simulation

Click the Exit button on the Simulation control panel. The Profile Operation dialog box is displayed. 125. Close the Profile Operation dialog box

In the Profile Operation dialog box, click The dialog box is closed.

.

126. Profile Finishing with upper turret main spindle

Right-click the defined profile operation in SolidCAM Manager and choose Profile from the Add Milling Operation submenu. The Profile Operation dialog box is displayed. 127. Define the Geometry

On the Geometry page choose MAC 1 (2-Position) from the CoordSys list. Choose the UP_main option from the Output according to list. Make sure that the General option is chosen on the Geometry selection section of the Profile Operation dialog box. Click the New button. The Geometry Edit dialog box is displayed.

255

Select the contour as shown in the image.

button to finish the chain definition and confirm Click the Accept chain the Geometry Edit dialog box with the button. 128. Define the Tool

Click the Select button on the Tool page of the Profile Operation dialog box. Click the Add Milling Tool button. Choose the END MILL tool from the Milling Tools section. Use the parameters as defined in the image: Switch to the Holder page. Select HSK A 63 as the ER16X100 holder.

Click the Mounting button.

256

6. Advanced Mill Turn

Ensure that the tool is mounted in the way as shown in the image. Click the Mounting button again to close the dialog box. Click the Select button to choose the defined tool for the current operation.

129. Define the level parameters

Switch to the Levels page of the Profile Operation dialog box. option is chosen in the Depth area. Make sure that the Constant Set the Clearance level value to 100. Set the Safety distance value to 5. Set the Profile depth value to 18. Select the Upper level button in the Milling levels section. Select the point as shown in the image. Click

130. Define the technological parameters

Switch to the Technology page of the Profile Operation dialog box. • Choose Left in the Tool side: list • Choose Constant in the Depth type list • Choose None in the Rest material/Chamfer list. • Select the Finish check box. • Set the Number of passes value to 1. • Set the Step down value to 18.

257

131. Define the link parameters

Switch to the Link page of the Profile Operation dialog box. • Use the parameters as shown in the image.

132. Define the misc. parameters

Switch to the Misc. parameters page of the Profile Operation dialog box. Set the Tolerance value to 0.1. Select the Material boundary connected to current fixture check box. 133. Calculate the operation

Click in the Profile Operation dialog box. The operation data is saved, and the tool path is calculated. 134. Simulate the operation in the Host CAD mode

Click

in the Profile Operation dialog box.

The Simulation control panel is displayed. Click the Play Simulation control panel. The tool path is simulated in the SolidWorks window.

258

button on the

6. Advanced Mill Turn 135. Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

136. Close the simulation

Click the Exit button on the Simulation control panel. The Profile Operation dialog box is displayed. 137. Close the Profile Operation dialog box

In the Profile Operation dialog box, click The dialog box is closed.

.

138. Open Pocket Roughing and finishing with iMachining

Right-click the defined profile operation in SolidCAM Manager and choose 2D the Add Milling Operation submenu.

iMachining from

The iMachining Operation dialog box is displayed. 139. Define the Geometry

In the Technology list, choose iRough + iFinish from the list. On the Geometry page choose MAC 1 (3-Position) from the CoordSys list. Choose the UP_main option from the Output according to list. In the Material boundary section, select the option of In Geometry. In the Modify finishing geometry fillet section, select the option of Percentage. Click the New

button under CoordSys.

259

Select the contour as shown in the image.

Click the Accept chain button to finish the chain definition. In the Geometry Edit window, click the Upper button in the Levels sections. Select the point as shown in the image. Click The upper level value must be 28.284. Click the Depth button in the Levels section.

Select the face highlighted in blue color. Click The lower level value must be 3.284.

Click

260

and confirm the Geometry Edit dialog box with the

button.

6. Advanced Mill Turn 140. Define the Tool

Select the same END MILL tool that you had defined for the profile operation for roughing the outer diameter using upper turret main spindle. 141. Define the levels parameters

Switch to the Levels page of the iMachining Operation dialog box. Set the Clearance level value to 67.5. Set the Safety distance value to 2. 142. Define the technological parameters

Switch to the Technology page of the iMachining Operation dialog box. • Set the Wall / island offset value to 0.3 Switch to the Channels tab. Ensure that in the Island moating section, the option of Off is selected. 143. Define the link and motion control parameters

Switch to the Link page of the iMachining Operation dialog box. • Select the Center cutting check box • Set the Z clearance value to 0.08 Switch to the Motion control page of the iMachining Operation dialog box. • Select the Approximate arcs by lines within tolerance check box and set the value to 0.01 144. Calculate the operation

Click in the iMachining Operation dialog box. The operation data is saved, and the tool path is calculated. 145. Simulate the operation in the Host CAD mode

Click

in the iMachining Operation dialog box.

The Simulation control panel is displayed. Click the Play Simulation control panel. The tool path is simulated in the SolidWorks window.

button on the

261

146. Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

147. Close the simulation

Click the Exit button on the Simulation control panel. The iMachining Operation dialog box is displayed. 148. Close the iMachining Operation dialog box

In the iMachining Operation dialog box, click The dialog box is closed.

.

149. Drilling on Diameter with upper turret main spindle

Right-click the defined iMachining operation in SolidCAM Manager and choose Drilling from the Add Milling Operation submenu. The Drilling Operation dialog box is displayed. 150. Define the Geometry

In the Technology list, choose 2D drill from the list. On the Geometry page choose MAC 1 (4-Position) from the CoordSys list. Choose the UP_main option from the Output according to list. Click the New

262

button under Coordsys.

6. Advanced Mill Turn

Select the face highlighted by the black arrow. Click to confirm the geometry.

icon. Click the Transformation In the Open Transformations window, click 4 Axis. In the Rotate List enter the parameters as shown in the image. Click Insert. Click OK. This will add the same geometry to all the 10 holes that need to be machined.

151. Define the Tool

Click the Select button on the Tool page of the Drilling Operation dialog box. Click the Add Milling Tool button. Choose the DRILL tool from the Drilling Tools section. Use the parameters as defined in the image: Switch to the Holder page. Select HSK A 63 as the ER16X100 holder.

263

Click the Mounting button. Ensure that the tool is mounted in the way as shown in the image.

Click the Mounting button again to close the dialog box. Click the Select

button to choose the defined tool for the current operation.

152. Define the levels parameters

Switch to the Levels page of the Drilling Operation dialog box. Set the Clearance level value to 100. Set the Safety distance value to 5. Select the option of Cutter tip in the section of Depth type. Select the Upper level button in the Milling levels section. Select the point as shown in the image. Click

264

6. Advanced Mill Turn

Select the Drill depth button in the Milling levels section. Select the point as shown in the image. Click

153. Define the technological parameters

Switch to the Technology page of the Drilling Operation dialog box. Select the option of Shortest distance. Select the Use cycle check box. 154. Calculate the operation

Click in the Drilling Operation dialog box. The operation data is saved, and the tool path is calculated. 155. Simulate the operation in the Host CAD mode

Click

in the Drilling Operation dialog box.

The Simulation control panel Simulation control panel.

is displayed. Click the Play

button on the

The tool path is simulated in the SolidWorks window.

265

156. Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

157. Close the simulation

Click the Exit button on the Simulation control panel. The Drilling Operation dialog box is displayed. 158. Close the Drilling Operation dialog box

In the Drilling Operation dialog box, click The dialog box is closed.

.

159. Internal Drilling with upper turret main spindle

Right-click the defined drilling operation in SolidCAM Manager and choose Drilling from the Add Milling Operation submenu. The Drilling Operation dialog box is displayed. 160. Define the Geometry

In the Technology list, choose 2D drill from the list. On the Geometry page choose MAC 1 (4-Position) from the CoordSys list. Choose the UP_main option from the Output according to list. In the list choose the geometry defined for the previous drilling operation. Use the transformation method explained in the previous exercise. 266

6. Advanced Mill Turn 161. Define the Tool

Click the Select button on the Tool page of the Drilling Operation dialog box. Click the Add Milling Tool button. Choose the CHAMFER MILL tool from the Milling Tools section. Use the parameters as defined in the image: Switch to the Holder page. Select HSK A 63 as the ER16X100 holder.

Click the Mounting button. Ensure that the tool is mounted in the way as shown in the image.

Click the Mounting button again to close the dialog box. Click the Select

button to choose the defined tool for the current operation.

162. Define the levels parameters

Switch to the Levels page of the Drilling Operation dialog box. Set the Clearance level value to 100. Set the Safety distance value to 5. Select the option of Cutter tip in the section of Depth type.

267

Select the Upper level button in the Milling levels section. Select the point as shown in the image. Click

Select the Drill depth button in the Milling levels section. Select the point as shown in the image. Click

163. Define the technological parameters

Switch to the Technology page of the Drilling Operation dialog box. Select the option of Shortest distance. Select the Use cycle check box. 164. Calculate the operation

Click in the Drilling Operation dialog box. The operation data is saved, and the tool path is calculated.

268

6. Advanced Mill Turn 165. Simulate the operation in the Host CAD mode

Click

in the Drilling Operation dialog box.

The Simulation control panel Simulation control panel.

is displayed. Click the Play

button on the

The tool path is simulated in the SolidWorks window. 166. Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

167. Close the simulation

Click the Exit button on the Simulation control panel. The Drilling Operation dialog box is displayed. 168. Close the Drilling Operation dialog box

In the Drilling Operation dialog box, click The dialog box is closed.

.

169. Chamfer generation using Profile machining

Right-click the defined drilling operation in SolidCAM Manager and choose Profile from the Add Milling Operation submenu. The Profile Operation dialog box is displayed. 170. Define the Geometry

On the Geometry page choose MAC 1 (2-Position) from the CoordSys list. Choose the UP_main option from the Output according to list. Select the option of General in the Geometry selection section.

269

Use the transformation method to apply the same geometry to both the holes. Click the New button under Coordsys. Select the contour highlighted in the image. Click to confirm the geometry.

171. Define the Tool

Click the Select button on the Tool page of the Profile Operation dialog box. Click the Add Milling Tool button. Choose the CHAMFER MILL tool from the Milling Tools section. Use the parameters as defined in the image: Switch to the Holder page. Select HSK A 63 as the ER16X100 holder.

Click the Mounting button.

270

6. Advanced Mill Turn

Ensure that the tool is mounted in the way as shown in the image.

Click the Mounting button again to close the dialog box. Click the Select

button to choose the defined tool for the current operation.

172. Define the levels parameters

Switch to the Levels page of the Profile Operation dialog box. Set the Clearance level value to 100. Set the Safety distance value to 5. button in the Depth section. Select the Constant Select the Upper level button in the Milling levels section. Select the point as shown in the image. Click

Click Profile depth.

271

Select the point as shown in the image. Click

173. Define the technological parameters

Switch to the Technology page of the Profile Operation dialog box. Choose Left in the Tool side list. Select the Compensation on finish passes check box. Choose Constant in the Depth type list. Select the option of One way in Depth cutting type section. Choose Chamfer in the Rest material\Chamfer list. Select the Finish check box. Set the Number of passes value to 1. Set the Extension/Overlap value to 0.5. 174. Define the link parameters

Switch to the Link page of the Profile Operation. Set the parameters as shown in the image.

272

6. Advanced Mill Turn 175. Calculate the operation

Click in the Profile Operation dialog box. The operation data is saved, and the tool path is calculated. 176. Simulate the operation in the Host CAD mode

Click

in the Profile Operation dialog box.

The Simulation control panel Simulation control panel.

is displayed. Click the Play

button on the

The tool path is simulated in the SolidWorks window. 177. Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

178. Close the simulation

Click the Exit button on the Simulation control panel. The Profile Operation dialog box is displayed. 179. Close the Profile Operation dialog box

In the Profile Operation dialog box, click The dialog box is closed.

.

273

The next operation is to define an MCO to move the upper turret to safe position. 180. Add an MCO to retract the Upper Turret Right click the previous defined profile operation and choose Add Machine Control Operation from the menu. The Machine Control Operation dialog box is displayed. In the Operation name field, type in a new name: B home2. Click the Start definition entry. Under Properties, select MAC-1 Position #1 for CoordSys. Choose the Up_main for the Submachine. To start the action definition, double click the UP_TR item in the Action on pane. Select the Movement item located under the UP_TR item and define the movement properties in the right pane as follows: • In the Mode cell, choose MA–Machine Coordinate mode ( ) • In the X1 (X) cell, choose Home Ref • In the Y1 (Y) cell, choose Home Ref • In the Z1 (Z) cell, choose Home Ref • In the B (Ry) cell, choose Home Ref • In the Feed (Unit/Min) cell, choose RAPID Click

to save the operation. Click box.

Operation dialog

to close the Machine Control

The next operation is to define an MCO to move the lower turret to safe position. 181. Add an MCO to retract the Lower Turret

Right click the previous defined MCO and choose Add Machine Control the menu. The Machine Control Operation dialog box is displayed.

Operation from

274

6. Advanced Mill Turn

In the Operation name field, type in a new name: LT safe5. Click the Start definition entry. Under Properties, select MAC-1 Position #1 for CoordSys. Choose the Lw_main for the Submachine. To start the action definition, double click the LW_TR item in the Action on pane. Select the Movement item located under the LW_TR item and define the movement properties in the right pane as follows: • In the Mode cell, choose MA–Machine Coordinate mode ( ) • In the X2 (-X) cell, choose Home Ref • In the Z2 (Z) cell, choose Home Ref • In the Feed cell, choose RAPID Select the Tool change item located under the LW_TR item and define the tool change properties in the right pane as follows: • For Tool Change, in the Value cell, write 6. • For Tool Change Position, in the Value cell, choose As in Current Position. You added this LW_TR operation to ensure that the lower turret is in home position. Now will add another operation to move lower turret to the safe position so that is does not collide with the back spindle. Click the LW_TR item once more in the Action on pane. Select the Movement item located under the LW_TR item and define the movement properties in the right pane as follows: • In the Mode cell, choose MA–Machine Coordinate mode ( ) • In the Z2 (Z) cell, set a value of -454 • In the Feed cell, choose RAPID Click

to save the operation. Click box.

Operation dialog

to close the Machine Control

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Now when the lower turret has moved to the safe position, you must add another MCO for performing the bar feed operation. The bar feed operation will ensure that you can start machining on the front of another part with main spindle while the back machining is continued of the part done so far using back spindle. 182. Add an MCO to control the Bar Feeder

Right click the previous defined MCO and choose Add Machine Control the menu. The Machine Control Operation dialog box is displayed. In the Operation name field, type in a new name: BAR FEED. Click the Start definition entry. Under Properties, select MAC-1 Position #1 for CoordSys. Choose the Up_main for the Submachine. To start the action definition, double click the MAIN_SP item in the Action on pane. Select the Rotation item located under the MAIN_SP item and define the rotation properties in the right pane as follows: • For Direction Rotation, in the Value cell, choose OFF • For Spin (RPM), in the Value cell, choose 0 Select the Working Mode item and define the properties in the right pane as follows: • For Working Mode in the Value cell, choose MILLING • In the New Line cell, choose Yes Double click the BACK_SP item in the Action on pane. Select the Rotation item located under the BACK_SP item and define the Rotation properties in the right pane as follows: • For Direction Rotation, in the Value cell, choose OFF • For Spin (RPM), in the Value cell, choose 0 Select the Clamp item and define the properties in the right pane as follows: • For Clamp in the Value cell, choose OPEN • In the New Line cell, choose Yes Select the Movement item and define the movement properties in the right pane as follows: • In the Mode cell, choose MA–Machine Coordinate mode ( ) • In the Z(B) (Z) cell, set a value of -990 • In the Feed (Unit/Min) cell, choose RAPID In the second row define the movement properties as follows: • In the Mode cell, choose MA–Machine Coordinate mode ( ) • In the C1 (-Rz) cell, set a value of 45 • In the Feed (Unit/Min) cell, set a value of 200 Operation from

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6. Advanced Mill Turn

Select the Working Mode item and define the movement properties in the right pane as follows: • For Working Mode in the Value cell, choose MILLING • In the New Line cell, choose Yes Double click the BACK_SP item in the Action on pane. Select the Clamp item and define the properties in the right pane as follows: • For Clamp in the Value cell, choose CLOSE ON STOCK • In the New Line cell, choose Yes Double click the MAIN_SP item in the Action on pane. Select the Clamp item and define the properties in the right pane as follows: • For Clamp in the Value cell, choose OPEN • In the New Line cell, choose Yes Double click the BACK_SP item in the Action on pane. Select the Part Move item and define the properties in the right pane as follows: • In the Mode cell, choose MA–Machine Coordinate mode ( ) • In the Z(B) (Z) cell, set a value of -787 • In the Feed (Unit/Min) cell, choose RAPID Double click the MAIN_SP item in the Action on pane. Select the Working Mode item and define the properties in the right pane as follows: • For Working Mode in the Value cell, choose TURNING • In the New Line cell, choose Yes Select the Clamp item and define the properties in the right pane as follows: • For Clamp in the Value cell, choose CLOSE ON STOCK • In the New Line cell, choose Yes Select the Spindles Synchronization item and define the properties in the right pane as follows: • For Spindles synchronization in the Value cell, choose ON • In the New Line cell, choose Yes Select the Rotation item and define the rotation properties in the right pane as follows: • For Direction Rotation, in the Value cell, choose CW • For Spin (RPM), in the Value cell, choose 300

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Click

to save the operation. Click box.

Operation dialog

to close the Machine Control

Now when the MCO to control the bar feeder is defined, you must add the Cutoff operation. 183. Add a Cutoff Operation

Right click the previous defined MCO and choose Cutoff from the Add Turning

Operation submenu. The Cutoff Operation dialog

box is displayed.

184. Define the Geometry

On the Geometry page choose MAC 1 (1-Position) from the CoordSys list. Choose the UP_main option from the Output according to list. Make sure that the Wireframe option is chosen. Click the New button under Coordsys. Select the contour highlighted in the image. Click to confirm the geometry.

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6. Advanced Mill Turn

On the Geometry page click the Modify Geometry button. In the Modify Geometry window, ensure that the Auto extend Start to Stock and Auto extend End to Stock option are selected. Close the Modify Geometry dialog box with the button. 185. Define the Tool

Click the Select button on the Tool page of the Cutoff Operation dialog box. Click the Add Turning Tool button. Choose the Ext. Grooving tool from the Composite Tools section. For Insert, use the parameters as defined in the image: In the Shank page, define the following parameters: • Set the Shank type to Straight

•

Set the Cutting Direction to R Switch to the Holder tab. In the Global holders table, select the

HSK A63WH-TBK-32R _ CGHN 32-5DG holder from the Turning

list.

Click the Mounting button. Ensure that the tool is mounted in the way as shown in the image.

Click the Mounting button again to close the dialog box. Click the Select

button to choose the defined tool for the current operation.

186. Define the technological parameters

Switch to the Technology page of the Cutoff Operation dialog box. Select the Long external

button in the Mode section.

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Choose Left in the Tool side list. Choose Single in the Step down list. Set the Offset Z value to 2. Choose None in the Corner list. 187. Calculate the operation

Click in the Cutoff Operation dialog box. The operation data is saved, and the tool path is calculated. 188. Simulate the operation in the Host CAD mode

Click

in the Cutoff Operation dialog box.

The Simulation control panel is displayed. Click the Play Simulation control panel. The tool path is simulated in the SolidWorks window. 189.

button on the

Simulate the operation in the Turning mode

Switch to the Turning page on the Simulation control panel. Click the Play

button. The tool path is simulated.

190. Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

280

6. Advanced Mill Turn 191. Close the simulation

Click the Exit button on the Simulation control panel. The Cutoff Operation dialog box is displayed. 192. Close the Cutoff Operation dialog box

In the Cutoff Operation dialog box, click The dialog box is closed.

.

The next operation you will define is the part transfer operation. You have to transfer the part from the main spindle to the back spindle, as you have completed the turning and milling operations for the front of the CAM-Part. Now, on the back spindle, the operations will be performed on the back of the CAM-Part. 193. Add an MCO for part transfer

Right click the previous defined cutoff operation and choose Add Machine Control Operation from the menu. The Machine Control Operation dialog box is displayed. In the Operation name field, type in a new name: Transfer. Click the Start definition entry. Under Properties, select MAC-1 Position #1 for CoordSys. Choose the Up_back for the Submachine. To start the action definition, double click the MAIN_SP item in the Action on pane. Select the Rotation item located under the MAIN_SP item and define the rotation properties in the right pane as follows: • For Direction Rotation, in the Value cell, choose OFF • For Spin (RPM), in the Value cell, choose 0 Double click the BACK_SP item in the Action on pane. Select the Rotation item located under the BACK_SP item and define the rotation properties in the right pane as follows: • For Direction Rotation, in the Value cell, choose OFF • For Spin (RPM), in the Value cell, choose 0 Select the Clamp item and define the properties in the right pane as follows: • For Clamp in the Value cell, choose CLOSE ON STOCK • In the New Line cell, choose Yes Select the Part Move item and define the properties in the right pane as follows: • In the Mode cell, choose MA–Machine Coordinate mode ( ) • In the Z (B) (Z) cell, choose Home Ref • In the Feed (Unit/Min) cell, choose RAPID

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Click

to save the operation. Click box.

Operation dialog

to close the Machine Control

194. Face Roughing with back spindle

Right click the previous defined MCO and choose Face from the Add Turning Operation submenu. The Face Turning Operation dialog box is displayed. 195. Define the Geometry

On the Geometry page choose MAC 2 (1-Position) from the CoordSys list. Choose the Lw_back option from the Output according to list. Make sure that the Wireframe option is chosen. Click the New button under Coordsys. Select the contour highlighted in the image. Click the Accept chain button to finish the chain definition and confirm the Geometry Edit dialog box with the button. On the Geometry page click the Modify Geometry button. In the Modify Geometry window, ensure that the Auto extend Start to Stock and Auto extend End to Stock option are selected.

Close the Modify Geometry dialog box with the

282

button.

6. Advanced Mill Turn 196. Define the Tool

Click the Select button on the Tool page of the Face Turning Operation dialog box. Click the Add Turning Tool Composite Tools section.

button. Choose the Ext. Turning tool from the

For Insert, use the parameters as defined in the image:

In the Shank page, use the parameters as defined in the image: Click the Mounting button.

Ensure that the tool is mounted in the way as shown in the image.

Click the Mounting button again to close the dialog box. Click the Select

button to choose the defined tool for the current operation.

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197. Define the technological parameters

Switch to the Technology page of the Face Turning Operation dialog box. button in the Mode section. Select the Back Choose Z-ABS in the Offset list. In the Retreat distance section, set the Value to 0.2. Select the Finish and Compensation check boxes. 198. Calculate the operation

Click in the Face Turning Operation dialog box. The operation data is saved, and the tool path is calculated. 199. Simulate the operation in the Host CAD mode

Click

in the Face Turning Operation dialog box.

The Simulation control panel is displayed. Click the Play Simulation control panel. The tool path is simulated in the SolidWorks window. 200.

Simulate the operation in the Turning mode

Switch to the Turning page on the Simulation control panel. Click the Play

284

button. The tool path is simulated.

button on the

6. Advanced Mill Turn 201. Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

202. Close the simulation

Click the Exit button on the Simulation control panel. The Face Turning Operation dialog box is displayed. 203. Close the Face Turning Operation dialog box

In the Face Turning Operation dialog box, click The dialog box is closed.

.

204. External diameter roughing with back spindle

Right click the previous defined face turning operation and choose Turning from the Add Turning Operation submenu. The Turning Operation dialog box is displayed. 205. Define the Geometry

On the Geometry page choose MAC 2 (1-Position) from the CoordSys list. Choose the Lw_back option from the Output according to list. Make sure that the Wireframe option is chosen. Click the New

button under Coordsys.

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Select the contour highlighted in the image. Click the Accept chain button to finish the chain definition and confirm the Geometry Edit dialog box with the button.

206. Define the Tool

Click the Select button on the Tool page of the Turning Operation dialog box. Click the Add Turning Tool button. Choose the Ext. Turning tool from the Composite Tools section. For Insert, use the parameters as defined in the image:

In the Shank page, use the parameters as defined in the image:

Click the Mounting button.

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6. Advanced Mill Turn

Ensure that the tool is mounted in the way as shown in the image.

Click the Mounting button again to close the dialog box. Click the Select

button to choose the defined tool for the current operation.

207. Define the technological parameters

Switch to the Technology page of the Turning Operation dialog box. Select the Long external button in the Mode section. Choose Rough in the Work type list. Click the Rough tab. Enter the parameters as defined in the image.

Click the Semi-finish/finish tab. Choose No in the Semi-finish list. Choose ISO Turning method in the Finish list. Choose Entire geometry in the Finish on list. Select the Compensation check box.

287

Click the Strategies tab. Select the Non-descending motions option. 208. Calculate the operation

Click in the Turning Operation dialog box. The operation data is saved, and the tool path is calculated. 209. Simulate the operation in the Host CAD mode

Click

in the Turning Operation dialog box.

The Simulation control panel is displayed. Click the Play Simulation control panel. The tool path is simulated in the SolidWorks window. 210.

Simulate the operation in the Turning mode

Switch to the Turning page on the Simulation control panel. Click the Play

button. The tool path is simulated.

211. Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

288

button on the

6. Advanced Mill Turn 212. Close the simulation

Click the Exit button on the Simulation control panel. The Turning Operation dialog box is displayed. 213. Close the Turning Operation dialog box

In the Turning Operation dialog box, click The dialog box is closed.

.

214. External grooving with back spindle

Right click the previous defined face turning operation and choose Grooving from the Add Turning Operation submenu. The Grooving Operation dialog box is displayed. 215. Define the Geometry

On the Geometry page choose MAC 2 (1-Position) from the CoordSys list. Choose the Lw_back. Make sure that the Wireframe option is chosen. Click the New button under Coordsys. Select the contour highlighted in the image. Click the Accept chain button to finish the chain definition and confirm the Geometry Edit dialog box with the button. On the Geometry page click the Modify Geometry button. In the Modify Geometry window, ensure that the Auto extend Start to Stock option is selected.

Close the Modify Geometry dialog box with the

button.

216. Define the Tool

Click the Select button on the Tool page of the Grooving Operation dialog box. Click the Add Turning Tool Composite Tools section.

button. Choose the Ext. Turning tool from the

289

For Insert, use the parameters as defined in the image:

In the Shank page, use the parameters as defined in the image: Click the Mounting button.

Ensure that the tool is mounted in the way as shown in the image.

Click the Mounting button again to close the dialog box. Click the Select

290

button to choose the defined tool for the current operation.

6. Advanced Mill Turn 217. Define the technological parameters

Switch to the Technology page of the Grooving Operation dialog box. Select the Long external button in the Mode section. Choose Rough in the Work type list. Click the Rough tab. Enter the parameters as defined in the image. Click the Semi-finish/ finish tab. Choose No in the Semifinish list. Choose ISO Turning method in the Finish list. Choose Entire geometry in the Finish on list. Select the Compensation check box. Groove Click the parameters tab. In the Spin and Feed fields, enter a value of 100.

218. Calculate the operation

Click in the Grooving Operation dialog box. The operation data is saved, and the tool path is calculated. 219. Simulate the operation in the Host CAD mode

Click

in the Grooving Operation dialog box.

The Simulation control panel Simulation control panel.

is displayed. Click the Play

button on the

The tool path is simulated in the SolidWorks window.

291

220.

Simulate the operation in the Turning mode

Switch to the Turning page on the Simulation control panel. Click the Play

button. The tool path is simulated.

221. Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

222. Close the simulation

Click the Exit button on the Simulation control panel. The Grooving Operation dialog box is displayed. 223. Close the Grooving Operation dialog box

In the Grooving Operation dialog box, click The dialog box is closed.

292

.

6. Advanced Mill Turn 224. External grooving with back spindle

Right click > Copy the previous defined grooving operation. Right click > Paste the operation. Right click > Edit the pasted operation. 225. Define the Geometry

On the Geometry page click the New button under Coordsys. Select the contour highlighted in the image. Click the Accept chain button to finish the chain definition and confirm the Geometry Edit dialog box with the button.

226. Calculate the operation

Click in the Grooving Operation dialog box. The operation data is saved, and the tool path is calculated. 227. Simulate the operation in the Host CAD mode

Click

in the Grooving Operation dialog box.

The Simulation control panel is displayed. Click the Play Simulation control panel. The tool path is simulated in the SolidWorks window. 228.

button on the

Simulate the operation in the Turning mode

Switch to the Turning page on the Simulation control panel.

293

Click the Play

button. The tool path is simulated.

229. Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

230. Close the simulation

Click the Exit button on the Simulation control panel. The Grooving Operation dialog box is displayed. 231. Close the Grooving Operation dialog box

In the Grooving Operation dialog box, click The dialog box is closed.

294

.

6. Advanced Mill Turn 232. Pocket Roughing using Wrapping Method

Right click the previous defined grooving operation and choose Pocket from the Add Milling Operation submenu. The Pocket Operation dialog box is displayed. 233. Define the Geometry

On the Geometry page choose MAC 2 (1-Position) from the CoordSys list. Choose the Up_back. Click the New button under Coordsys. Select the contour highlighted in the image. Click the Accept chain button to finish the chain definition and confirm the Geometry Edit dialog box with the button.

234. Define the Tool

Click the Select button on the Tool page of the Pocket Operation dialog box. Click the Add Milling Tool button. Choose the BULL NOSE MILL tool from the Milling Tools section. Enter the parameters as shown in the image. Switch to the Holder page. Select HSK A 63 as the ER16X100 holder.

295

Click the Mounting button. Ensure that the tool is mounted in the way as shown in the image.

Click the Mounting button again to close the dialog box. Click the Select

button to choose the defined tool for the current operation.

235. Define the levels parameters

Click the Levels page of the Pocket Operation dialog box. Enter the parameters as shown in the image.

236. Define the technological parameters

Click the Technology page of the Pocket Operation dialog box. Enter the parameters as shown in the image. Click the Contour tab.

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6. Advanced Mill Turn

Select the option of Inside in the Start from section. Choose Fillet in the Corner list. Set the Corner radius value to 1.049. Set the Min. corner radius value to 0.1049. Select the option of Climb in the Direction section. Choose Linear in the Adjacent passes connection list. 237. Define the link parameters

Click the Link page of the Pocket Operation dialog box. Enter the parameters as shown in the image.

238. Define the motion control and miscellaneous parameters

Click the Motion control page of the Pocket Operation dialog box. Choose Polar in the Coordinate type list. Select the option of First Angles Pair in the 5th Axis section. Click the Misc. parameters page of the Pocket Operation dialog box. Set the Tolerance value to 0.1. Select the Material boundary connected to current fixture check box. 239. Calculate the operation

Click in the Pocket Operation dialog box. The operation data is saved, and the tool path is calculated.

297

240. Simulate the operation in the Host CAD mode

Click

in the Pocket Operation dialog box.

The Simulation control panel is displayed. Click the Play Simulation control panel. The tool path is simulated in the SolidWorks window.

button on the

241. Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

242. Close the simulation

Click the Exit button on the Simulation control panel. The Pocket Operation dialog box is displayed. 243. Close the Pocket Operation dialog box

In the Pocket Operation dialog box, click The dialog box is closed.

.

244. Internal Drilling with lower turret back spindle

Right click the previous defined pocket operation and choose Drilling from the Add Turning Operation submenu. The Drilling Operation dialog box is displayed. 245. Define the CoordSys parameters

Choose MAC 2 (1-Position) from the CoordSys list. Choose the Lw_back.

298

6. Advanced Mill Turn 246. Define the Tool

Click the Select button on the Tool page of the Drilling Operation dialog box. Click the Add Milling Tool button. Choose the DRILL tool from the Drilling Tools section. Enter the parameters as shown in the image. Switch to the Holder page. Select integrex lt holder as the holder.

Click the Mounting button. Ensure that the tool is mounted in the way as shown in the image. Click the Mounting button again to close the dialog box. Click the Select button to choose the defined tool for the current operation.

247. Define the technological parameters

Click the Technology page of the Drilling Operation dialog box. Select the Cutter tip option in the Depth type section.

299

248. Calculate the operation

Click in the Drilling Operation dialog box. The operation data is saved, and the tool path is calculated. 249. Simulate the operation in the Host CAD mode

Click

in the Drilling Operation dialog box.

The Simulation control panel Simulation control panel.

is displayed. Click the Play

button on the

The tool path is simulated in the SolidWorks window. 250. Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

251. Close the simulation

Click the Exit button on the Simulation control panel. The Drilling Operation dialog box is displayed. 252. Close the Drilling Operation dialog box

In the Drilling Operation dialog box, click The dialog box is closed.

300

.

6. Advanced Mill Turn 253. Internal diameter roughing with lower turret back spindle

Right click the previous defined drilling operation and choose Turning from the Add Turning Operation submenu. The Turning Operation dialog box is displayed. 254. Define the Geometry

On the Geometry page choose MAC 2 (1-Position) from the CoordSys list. Choose the Lw_back. Make sure that the Wireframe option is chosen. Click the New button under Coordsys. Select the contour highlighted in the image. Click the Accept chain button to finish the chain definition and confirm the Geometry Edit dialog box with the button. On the Geometry page click the Modify Geometry button. In the Modify Geometry window, ensure that the Auto extend Start to Stock option is selected. Close the Modify Geometry dialog box with the

button.

255. Define the Tool

Click the Select button on the Tool page of the Turning Operation dialog box. Click the Add Turning Tool button. Choose the Int. Turning tool from the Composite Tools section. Enter the Insert parameters as shown in the image.

301

Enter the Shank parameters as shown in the image. Switch to the Holder page. Select integrex lt holder BB as the holder. Click the Mounting button.

Ensure that the tool is mounted in the way as shown in the image. Click the Mounting button again to close the dialog box. Click the Select button to choose the defined tool for the current operation.

256. Define the technological parameters

Click the Technology page of the Turning Operation dialog box. Select the Long internal option in the Mode section. Choose Rough in the Work type section. Click the Rough tab. Enter the parameters as shown in the image.

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6. Advanced Mill Turn

Click the Semi-finish/finish tab. Choose No in the Semi-finish list. Choose ISO Turning method in the Finish list. Choose Entire geometry in the Finish on list. Click the Strategies tab. Choose the option of Descending motions. 257. Calculate the operation

Click in the Turning Operation dialog box. The operation data is saved, and the tool path is calculated. 258. Simulate the operation in the Host CAD mode

Click

in the Turning Operation dialog box.

The Simulation control panel is displayed. Click the Play Simulation control panel. The tool path is simulated in the SolidWorks window. 259.

button on the

Simulate the operation in the Turning mode

Switch to the Turning page on the Simulation control panel. Click the Play

button. The tool path is simulated.

303

260. Simulate the operation in the SolidVerify mode

Switch to the SolidVerify page on the Simulation control panel. The stock model is displayed in the simulation window. Click the Play button. The simulation is performed.

261. Close the simulation

Click the Exit button on the Simulation control panel. The Turning Operation dialog box is displayed. 262. Close the Turning Operation dialog box

In the Turning Operation dialog box, click The dialog box is closed.

.

You have completed machining of the part. Now the last operation you will add is of stock release. 263. Add an MCO for stock release

Right click the previous defined turning operation and choose Add Machine Control Operation from the menu. The Machine Control Operation dialog box is displayed. In the Operation name field, type in a new name: Stock release. Click the Start definition entry. Under Properties, select MAC-1 Position #1 for CoordSys. Choose the Up_back for the Submachine. To start the action definition, double click the BACK_SP item in the Action on pane. Select the Clamp item located under the BACK_SP item and define the properties in the right pane as follows: • For Clamp, in the Value cell, choose RELEASE STOCK • In the New Line cell, choose Yes 304

6. Advanced Mill Turn

Click

to save the operation. Click box.

Operation dialog

to close the Machine Control

At this stage, the exercise is finished. In the next exercise, you will see how this CAM Part is used for channel synchronization.

305

Advanced Mill-Turn: Exercise #2 Define the CAM-Part and operations for the machining of the advanced mill turn part as shown below on a Mill-Turn CNC-machine. This exercise gives you further practice in entire capabilities of the mill turn process and channel synchronization. The SolidWorks model of this exercise (AMT_Exercise2. is located in the Exercises folder.

SLDPRT)

The following steps have to be implemented in order to reach the final CAM-Part: 264. Define the CAM-Part

At this stage, you have to define the CAM-Part, the CNC-controller, the Machine Coordinate System, the Stock model, the Clamp and the Target model. The 00282_MT_4.5X_HT_NTX2000_FANUC31i CNC-controller has to be chosen for this exercise. The following sequence of operations should be followed while defining the operations: On Upper Turret Main Spindle 265. Face turning

Define a Turning operation to perform the rough machining of the part.

266. Balanced Rough

Define a Balanced Rough operation to perform the roughing using two tools simultaneously. 267. Machine Control Operation

Define an MCO to move the upper turret in safe position. 306

6. Advanced Mill Turn

On Lower Turret Main Spindle 268. Machine Control Operation

Define an MCO to move the lower turret in safe position. 269. Turning operation

Define a Turning operation for outer profile finishing of the CAM-part.

270. Profile operation

Define a milling operation for outer profile roughing of the CAM-part.

271. Profile operation

Define a milling operation for outer profile finishing of the CAM-part.

272. Machine Control Operation

Define an MCO to move the lower turret in safe position.

307

On Upper Turret Main Spindle 273. Drilling operation

Define a Drilling operation for central hole drilling.

274. Profile operation

Define a diameter 5 counter bore rough milling operation..

275. Profile operation

Define a diameter 8 counter bore rough milling operation.

276. Profile operation

Define a diameter 5 counter bore finishing operation.

277. Profile operation

Define a diameter 8 counter bore finishing operation.

308

6. Advanced Mill Turn 278. Machine Control Operation

Define an MCO to move the upper turret in safe position. 279. Profile operation

Define an external chamfer milling operation.

280. Drilling operation

Define an angular drilling operation to machine the holes on the CAM-Part.

281. Machine Control Operation

Define an MCO to move the upper turret in safe position. On Lower Turret Main Spindle 282. Machine Control Operation

Define an MCO to move the lower turret in safe position. On Upper Turret Main Spindle 283. Machine Control Operation

Define an MCO for part transfer.

309

On Lower Turret Back Spindle 284. Face turning

Define a Turning operation for face roughing with back spindle.

On Lower Turret Main Spindle 285. Machine Control Operation

Define an MCO to move the lower turret to the safe position. On Lower Turret Back Spindle 286. Turning operation

Define a Turning operation for rough machining with back spindle.

On Upper Turret Back Spindle 287. Profile operation

Define a groove rough milling operation using wrap function.

310

6. Advanced Mill Turn 288. Profile operation

Define a groove finish milling operation using wrap function.

289. Pocket operation

Define a slot rough milling operation using wrap function.

290. Pocket operation

Define a slot finish milling operation using wrap function.

291. Face milling operation

Define a flat rough milling operation using wrap function on the CAM-part.

311

292. Drilling operation

Define a drilling on diameter operation on the CAM-Part.

293. Drilling operation

Define a simple drilling operation on flat area of the CAM-Part.

294. Drilling operation

Define a chamfer drilling operation on the CAM-Part.

295. Drilling operation

Define a thread cutting operation using tapping function on the CAM-Part.

312

6. Advanced Mill Turn 296. Drilling operation

Define a simple drilling operation using back spindle.

297. Machine Control Operation

Define an MCO to move the upper turret to the safe position. 298. Machine Control Operation

Define an MCO for stock release.

At this stage the exercise is finished.

313

Advanced Mill-Turn: Exercise #3 Define the CAM-Part and operations for the machining of the advanced mill turn part as shown below on a Mill-Turn CNC-machine. This exercise gives you further practice in entire capabilities of the mill turn process and channel synchronization. The SolidWorks model of this exercise (AMT_ Exercise3.SLDPRT) is located in the Exercises

folder.

The following steps have to be implemented in order to reach the final CAM-Part: 299. Define the CAM-Part

At this stage, you have to define the CAM-Part, the CNC-controller, the Machine Coordinate System, the Stock model, the Clamp and the Target model. The IntIV200ST CNC-controller has to be chosen for this exercise. The following sequence of operations should be followed while defining the operations: On Upper Turret Main Spindle 300. Turning operation

Define a Turning operation to perform the rough machining of the part.

301. Balanced Rough

Define a Balanced Rough operation to perform the roughing using two tools simultaneously.

314

6. Advanced Mill Turn 302. Machine Control Operation

Define an MCO to move the lower turret in the safe position. 303. Turning operation

Define a Turning operation for outer profile finishing of the CAM-Part.

304. Pocket operation

Define a Pocket operation using wrap option.

305. Pocket operation

Define a Pocket operation for floor finishing using wrap option.

306. SWARF operation

Define a SWARF operation for wall finishing of the CAM-Part.

315

307. SWARF operation

Define another SWARF operation for wall finishing of the CAM-Part.

308. Profile operation

Define a Profile operation for flat roughing of the CAM-Part.

309. Profile operation

Define another Profile operation for spiral groove machining on the CAMPart.

310. Profile operation

Define a Profile operation for engraving the word SolidCAM on the CAM-Part.

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6. Advanced Mill Turn 311. Machine Control Operation

Define an MCO to move the lower turret in the safe position. 312. Machine Control Operation

Define an MCO to move the upper turret in the safe position. 313. Machine Control Operation

Define an MCO for part transfer. On Lower Turret Back Spindle 314. Cutoff operation

Define a Cutoff operation on the CAMPart.

315. Turning operation

Define a Turning operation for back side roughing of the CAM-Part.

On Upper Turret Main Spindle 316. Machine Control Operation

Define an to move lower turret into the home position. 317. Machine Control Operation

Define an MCO for stock release. At this stage the exercise is finished. 317

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Channel Synchronization

7

SolidCAM’s Channel Synchronization operation enables you to synchronize operations in multi-channels machines and organize the order of operations. Using the operation of channel synchronization, you can finish machining a part in the following ways: • In lesser time by simultaneously machining two sides of a part. For example, front of a part on main spindle and back of the same part on back spindle utilizing either upper turret or lower turret or both. The advantage is you do not have to keep the spindle idle, waiting for the primary operation to finish and the secondary one to start. • Simultaneously performing machining processes on both the spindles. • In Milling operations, where there is only one spindle, the channel synchronization operation can be used to synchronize the tool in such a way that without going back to the home position, the tool can finish machining operation on one part and immediatelty start the other operation on the second part. 1.

Open the Channel synchronization dialog box

Right click Setup > Channel synchronization.

The Channel Synchronization window opens.

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7. Channel Synchronization

7.1 Understanding the Buttons on the Ribbon The buttons available on the Channel synchronization window, enable you to manage the synchronization. Synchronize selected operations start to start

The Synchronize selected operations start to start button enables you to start the selected operations together by adding labels before the operations selected in the timeframe. The selected operations must be defined in different turrets. Synchronize selected operations start to end

The Synchronize selected operations start to end button enables you to add labels between the operations selected in the timeframe. The selected operations must be defined in different turrets. Synchronize selected operations end to end

The Synchronize selected operations end to end button enables you to add labels at the end of the operations selected in the timeframe. The selected operations must be defined in different turrets. Synchronize all operations as in the CAM Manager order

The Synchronize all operations as in the CAM Manager order button enables you to perform synchronization of the operations one after another as they appear in the SolidCAM Manager tree. Add new Workpiece

The Add new Workpiece button enables you to move the operations in the Channel Synchronization window to split the CAM-Tree in order to separate the Machining processes.

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Delete synchronization label

The Delete synchronization label button enables you to delete the synchronization label applied to the selected operations. Delete all synchronization labels

The Delete all synchronization labels button enables you to delete synchronization labels from all the operations. Delete all

The Delete all button enables you to delete all the labels and all the synchronization relations applied to all the operations. Operation duration

The Operation duration button displays the Operation duration dialog box that enables you to manually change the duration of a certain operation. Reset operation duration

The Rest operation duration button enables you to reset the operation duration to its initial values. Timeframe view

The Timeframe view button enables you to switch the timeframe to the state where all the operation boxes are of the uniform size regardless of the real time that they take. In the Timeframe view you can only preview the operations. No labels and synchronization options can be added in this view.

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7. Channel Synchronization Operations clash view

The Operations clash view button enables you to detect the impossible combinations of operations intended to be machined at the same time using the same spindle. The problematic timeframe segments are highlighted with the red color. Color operations by Turret

The Color operations by Turret button enables you to see all the operations that are defined for the turret by highlighting them with the color defined for the turret. Color operations by Table

The Color operations by Table button enables you to see all the operations that are defined for a table by highlighting them with the color defined for the table. Color operations by Workpiece

The Color operations by Workpiece button enables you to see all the operations that are defined for a workpiece by highlighting them with the color defined for the workpiece. Undo and Redo

The Undo button enables you to erase the last change made in the synchronization window. button enables you to bring the deleted change The Redo back in the synchronization window.

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Understanding the Timeframe Buttons The timeframe buttons available on the Channel synchronization window, enable you to perform the timeframe scaling. Show All

The Show All button displays all the operations in the single timeframe screen. The operations are scaled in/out in such way that the longest chain of operations fills the whole timeframe. Zoom to selection

The Zoom to selection button enables you to zoom to selected operation boxes. This option is relevant only when one or several operations are selected. Zoom In/Zoom Out

The Zoom In/Zoom Out out the timeframe.

buttons enable you to zoom in/

Actual size

The Actual size initial scale.

button returns the operation boxes to their

The Channel Synchronization window also displays the total machining time bar of the operations and the machining time of the selected operations. The Channel Synchronization window stores its size, position and column widths inside the CAM-part. You can resize the Channel Synchronization window and columns to your liking, and close the window. It will remember the size, position and column widths (that you set) next time you open it.

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7. Channel Synchronization

7.2 Applying color to Synchronization label and submachines The following exercise explains how you can define color for operations by turret ID, table ID, or workpiece ID. 2.

Open the SolidCAM Settings window

Click Tools > SolidCAM > SolidCAM Settings. In the SolidCAM Settings window, click Channel synchronization.

3.

Define the Synchronization label color

Click the button infront of Synchronization label. The Color window displays. Click on the color you want to give to the synchronization label and click OK. The color you defined here, is applied to the labels that you later define in the Channel Synchronization window.

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4.

Define the Manually defined time color

Click the button in front of Manually defined time. Define the color in the same way as you defined it for Synchronization label. The color you define here, will be applied when you manually define the calculation time of an operation in the Channel Synchronization window. 5.

Define the color for various submachines

In the CAM tree, double click the Machine button. The MACHINE ID EDITOR window displays. Click the Working Style tab. Click Channel Synchronization in the left pane. In the right pane, you can see the RGB values of the selected color displayed in the columns. Click in the column next to Up_TR. Click the ... icon. The Color window displays. Define the color in the same way as you defined it for Synchronization label. Click the Save button and close the MACHINE ID EDITOR window. The color you define here, will be applied when you select the Color operations by Turret button in the Channel Synchronization window. You can define the color for lower turret, main spindle, back spindle, and workpieces in the same manner. The color you define here, will be applied when you select the Color operations by Table or Color operations by Workpiece buttons in the Channel Synchronization window respectively.

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7. Channel Synchronization

7.3 General Rules of Channel Synchronization The following rules apply to the channel synchronization operation: •

•

When you right click Setup and select Channel Synchronization from the submenu, the synchronization order you see is according to the operations defined in the CAM Tree. The order of the operations defined in the CAM Tree cannot be changed in the synchronization window for the same turret. If you want to change the order, you must change the sequence in the CAM Tree. To start sequencing the operations on the back spindle, right click the first operation defined on the lower turret and click Add new Workpiece.

The Add new Workpiece operation can be defined on the operation of your choice to start the machining from there. However, it is a general practice to add it on the first operation defined on the lower turret. You can split the CAM Tree order to create separate Workpieces (Machining processes) for continuous machining process on CNC machine (loop machining). •

•

•

•

In the Channel Synchronization window, Setup should always be the first operation. Setup is loading new Stock, according to the Setup table. When you open the Channel Synchronization window, and if the Setup operation is not seen as the first operation, then you must drag and place is at the top of the operations as the defined stock must be visible in the first operation. The operation of stock release cannot be moved below the part transfer operation. However, it can be moved after the last operation on back spindle in the Channel Synchronization window. Stock release is a machine control operation with Release Stock command which deletes the stock from the active table. The operation of stock transfer is a machine control operation with two or more tables involved. As a result of this operation, the stock changes the holding Table. You can achieve this by Manual Part Transfer or Close on Stock command. The MCOs cannot be synchronized if same axis is used in both the channels. If you try to synchronize such an operation, an error message is displayed stating same axis is used in both the channels. 327

•

Each operation in the Channel Synchronization window is connected to one table in the following manner: • In non MCO operations it is connected to the Table used in operation Submchine. • In MCO operations without Stock Management it is connected to the current table. • In the setup and stock release operations, it is connected table that is used for these specific operations. • In the part transfer operation, it is related to the table that was connected to the stock before the part transfer operation.

•

To move the operation and change its place in the Channel Synchronization window, drag the operation and drop it on the lable where you want to place it. For example, in the below image, the highlighted operation in black color is dragged and placed on the lable to change its place.

7.4 Working with the operation of Channel Synchronization 6.

Labels and drive units

Label is a defined pause you can apply between two operations if a collision is detected. The labels give you information about all the channels are involved in the operation. The first label in the synchronization widow is always numbered 1. The last label is always the largest and takes into account all the channels involved. For example, if you are working on a three channel machine, you can apply some labels to two channels, but the last label will be applied to all three channels. The labels above and below the Balanced Rough operation are automatically added and cannot be deleted. For example, when you right click on the label that is above or below the Balanced Rough operation, the option of deleting the lable is not available to select.

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7. Channel Synchronization

When two operation are synchronized using the same drive unit, you can define which channel has control over it. If you want to change the control from upper turret to lower turret, right click the Drive Unit icon and select Make Drive Unit control to ‘LW_TR’ Channel to transfer the control from upper turret to lower turret.

In the image below, the control is transferred to the lower turret and now selecting the drive unit icon gives you the option of transferring the control to the upper turret.

In the Balanced Rough operation, the drive unit control cannot be changed as while defining the operation, master and slave submachines are defined. You can change the controls by editing the balanced rough operation in the CAM-Tree. You can use the same Drive Unit by more than one channel at the same time only if it is a Shared Drive Unit. You need to keep in mind the following things while using a shared drive unit: • In Milling operations, the Drive Unit must have same RPM and rotation direction. • In Turning operations, the Turning Station, connected to Drive Unit must have same RPM, rotation direction, and same Spin Type.

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7.

Removing the clash in operations

When two operations cannot be synchronized, or are arranged in such a manner that they clash with each other, they are highlighted in red color. Click on the red box to see with which operation the current operation is clashing. Select both the operations and add a label as per your requirement i.e. whether you want to synchronize the operations start to start, start to end or end to end. In the below image, two operations that are clashing (highlighted using dark blue color) are selected, and on the ribbon available on the Channel Synchronization window, the buttons of Synchronize selected operations start to start, Synchronize selected operations start to end, and Synchronize selected operations end to end are highlighted.

8.

Axes sharing and control

In the Channel Synchronization window, you can see a number of axes displayed in front of each operation. The axes represented with black color, are used in the current operation. The axes represented by grey color, and italics are not used in the current operation. However, you can see them in front of the operation because all these axes are available on that channel.

You can use the same axis on two channels at the same time, only if they are shared axis. The switching and moving of axis between channels can be done only at the label level.

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7. Channel Synchronization

Swap axis option is available on an axis which is not used in the operation and is synchronized end to end with another operation. Click on Swap Axis With option to swap the current axis with the axis available in the Swap Axis With list.

The exercises described above explain the general rules and features of the Channel Synchronization operation. You can synchronize the operations in the way you consider is best to utilize the machines for maximum output and minimum machining time. Channel Synchronization on Single Channel Machines On Milling machines, where there is only one spindle, SolidCAM’s Channel Synchronization operation can be used in the following ways: • •

Manage the prder of operations in the machine. Reduce cycle time by optimizing tool change. You can synchronize the tool in such a way that without going back to the home position, the tool can finish machining operation on one part and immediatelty start the other operation on the second part.

The example below is of a milling part, on which Channel Synchronization is defined.

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9.

Open the CAM-Part

Browse to open the 2_5D_Milling_1.PRT file from the Exercises folder. The 00350_M3X_HAAS-VF6 CNC controller has to be chosen for this exercise. The required Milling operations to machine this part have been defined on the Left Vise using MAC 1 (1- Position) and Right Vise using MAC 2 (1- Position). 10.

Right click Setup > Channel Synchronization.

The Channel Synchronization window displays. 11.

Click the Simulate button.

Click Machine Simulation in the Simulation window. You can see that tools have been synchronized in such a way that after completing operations on one part, they immediately start machining the second part without returning to the home position.

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7. Channel Synchronization 12.

Click the Exit button to close the machine sumulation.

At this stage the exercise is finished.

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SolidCAM Training Course:

Turning & Mill Turn

2D iMachining

2.5D Milling

HSS (High-Speed Surface Machining

3D iMachining

Indexed Multi-Sided Machining

)HSM (High-Speed Machining

Axis Machining-5 Simultaneous

Turning & Advanced Mill-Turn

Solid Probe

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