Powe ad Ease of Use - the w combato SolidCAM 2007
SolidCAM+SolidWorks The complete integrated machining system
Getting started
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SodCAM 2007 2.5D Milling 3D Milling HigH SPEED MACHining MUlTi-SiD MUl Ti-SiDED ED MACHin MACHining ing SiM. 5-AxiS MACHining TUrning TUrn-Mill WirE CUT TrAining TrAini ng MA MATEriAlS TEriAlS SySTEM rEqUirEMEnTS
4 10 14 18 22 26 30 34 42 44 45
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SodCAM 2007 • Don’t go or less. Go or Gold. SolidCAM is the de-facto standard Gold-Certied integrated integ rated CAM-Engine for SolidWorks. SolidWorks. SolidCAM provides seamless, single-window integration integ ration and full associativity to the SolidW SolidWorks orks design model. All machining operations are dened, calculated and veried, without leaving the SolidWorks window.
SolidCAM is widely used in the mechanical manufacturing, electronics, medical, consumer products, machine design, automotive and aerospace industries, as well well as in mold and die and rapid prototyping shops. Today successful manufacturing companies are using integrated CAD/ CAM systems to get to market faster and reduce costs. With SolidCAM’s seamless single-window integration in SolidWorks, any size organization can reap the benets of the integrated SolidWorks SolidWorks and SolidCAM solution. SolidWorks + SolidCAM is the Dream-Team for design and Manufacturing. SolidCAM supports the complete set of manufacturing technologies. technologies. Following Follo wing is a brief description of the main SolidCAM modules. modules.
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• .D Milling
SolidCAM provides both interactive and automated powerful 2.5D milling operations on SolidWorks models. SolidCAM offers one of the best pocketing algorithms in the market. Full tool path control and powerful algorithms ensure that the user can manufacture the way he needs to. Operations can be easily re-ordered, rotated, mirrored, etc. SolidCAM’s automatic featurerecognition and machining module automates the manufacturing of parts with multiple drills and complex holes. All your needs for successful production machining are provided directly inside SolidWorks with an easy and straightforward interface. SolidCAM is successfully used in production environments by thousands of manufacturing companies and job shops.
• D Milling
SolidCAM’s 3D Milling can be used both for prismatic parts and for complex 3D models. For prismatic parts SolidCAM analyzes the model and automatically recognizes pockets and proles to be machined using Zconstant machining strategies. For complex 3D models, SolidCAM offers www.cadfamily.com EMail:
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• + Axis Multi-Sided Machining
With SolidCAM, programming and machining of multi-sided parts on 4and 5-Axis machining centers is efcient and protable. SolidCAM is an industry leader in this type of machining. SolidCAM rotates the SolidWorks model to the user-dened machining planes and automatically calculates all necessary shifts and tilts for the 3D machining coordinate systems. SolidCAM enables exible set-ups and reduces the need for special clamping jigs. You can dene your 2.5D and 3D machining operations on any face and check them using SolidCAM’s advanced tool path verication. The output is ready-to-run programs for your 4/5-axis CNC-machine. •
Simultaneous -Axis Machining
Simultaneous 5-axis machining is becoming more and more popular due to the need for reduced machining times, better surface nish and improved life span of tools. SolidCAM utilizes all the advantages of Simultaneous 5 Axis machining and together with collision control and machine simulation, provides a solid base for your 5-axis solution.
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SolidCAM provides intelligent and powerful 5-axis machining strategies, including swarng and trimming, for machining of complex geometry parts including mold cores and cavities, aerospace parts, cutting tools, cylinder heads, turbine blades and impellers. SolidCAM provides a realistic simulation of the complete machine tool, enabling collision checking between the tool and the machine components. •
High Speed Machining (HSM) Module
SolidCAM HSM is a very powerful and market-proven high-speed-machining module (HSM) for molds, tools and dies and complex 3D parts. The HSM module offers unique machining and linking strategies for generating highspeed toolpaths. SolidCAM’s 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 feedrates and eliminating dwelling. With SolidCAM HSM module, 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 aircutting and reducing machining time. Any HSM 3D machining strategy can be controlled by specifying the surface slope-angle to be machined or by specifying the machining boundary. SolidCAM HSM module provides a comprehensive set of boundary creation tools, including Silhouette boundaries, Cutter Contact Area boundaries, Shallow boundaries, Theoretical Rest Area boundaries, Rest Area boundaries and User-dened boundaries. SolidCAM HSM module is a powerful solution for all users who demand advanced high speed machining capabilities. It can also be used to improve the productivity of older CNC’s with reduced air-cutting and smoothing www.cadfamily.com arcs that maintainEMail:
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The result of HSM is an efcient, smooth, and gouge-free tool path. This translates to increased surface quality, less wear on your cutters, and a longer life for your machine tools. With demands for ever-shorter lead and production times, lower costs and improved quality, High Speed Machining (HSM) is a must in today’s machine shops.
• Turning and Turn-Mill
SolidCAM has a very strong capability in turning, grooving and Turn-Mill. As in milling, a rest-machining capability is built in all turning operations. SolidCAM supports all machine turning cycles. SolidCAM provides special support for the advanced machining technologies of ISCAR’s Turn-Groove tools.
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A powerful integrated Turn-Mill capability enables the turning and milling operations to be programmed in the same environment. Access to the complete 2.5-5 axis milling is available. SolidCAM provides support for up to 5-Axis (XYZCB) Turn-Mill CNC machines including back-spindle operations.
• / Axis Wire-EDM
SolidCAM Wire EDM handles proles and tapers with constant and variable angles, as well as 4-axis contours. SolidCAM’s intelligent algorithms prevent the falling of material pieces by automatic pocket processing. SolidCAM provides full user control of stop-points and of wire cutting conditions at any point of the prole or taper.
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2.5D Milling
The _D_Milling_1.prz example illustrates the use of SolidCAM 2.5D Milling to machine the cover part shown above. The machining is performed on a 3-axis CNC machine in two setups, one for the top faces and one for bottom faces.
The following SolidCAM operations are created to perfor m the machining:
• Top ace machining (P_prole_T1) This Pocket operation performs the machining of the top face of the cover. An end mill of Ø20 is used. The machining is performed in two passes rough and nish. A machining allowance of 0.2 mm remains unmachined at the oor, after the rough pass, and is removed during the nishing pass.
• External aces machining (F_prole1_T; F_prole_T) These operations perform the prole machining of the external contour of the cover. An end mill of Ø16 is used. The Clear oset option is used at the roughing stage to perform the machining in a number of equidistant offsets from the machining geometry. The machining allowance is left unmachined during the roughing operation and removed at the nishing stage.
• Bolt seats machining (F_prole_T) This operation is used to remove the material at the bolt seat areas. An end mill of Ø8 is used for the operation.
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• Bottom ace machining (P_prole_T1) This Pocket operation performs the machining of the bottom face of the cover. This operation uses the second Coordinate system; it means that the second setup has to be performed at the CNC machine before the machining. The used tool and the machining strategy are similar to the P_prole_T1 operation.
• Internal aces roughing (P_prole_T; P_prole_T) These Pocket operations perform the rough machining of the internal faces of the cover. An end mill of Ø16 is used. The rough machining is divided into two operations to perform the machining with the optimal tool path The machining allowance is left unmachined for further nish operations.
• Internal aces rest machining (P_prole_T) This operation uses the rest material machining technique in order to machine the areas left inaccessible for the large tools used in the previous operations. An end mill of smaller diameter (Ø8) is used.
• Internal aces nishing (F_prole_T; F_prole_T) These operations perform the wall nishing of the internal pocket area of the cover part. An end mill of Ø6 is used.
• Floor aces nishing (F_prole_T; P_prole_T_1) These operations perform the oor nishing of the internal pocket area of the cover part. End mill tools of Ø6 and Ø8 are used.
• Slot machining (S_slot_T) This Slot Milling operation performs the machining of the groove at the bottom face of the cover. An end mill of Ø1.5 is used.
• Holes machining D_drill_T; D_drill_T These Drill operations perform the сenter drilling and drilling of the four holes of Ø5 located at the bottom face of the cover.
• Threaded holes machining (D_drill1_T; D_drill1_T; D_drill1_T) These Drill operations perform the сenter drilling, drilling and threading of the M2 holes located at the pads.
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2.5D Milling
The _D_Milling_.prz example illustrates the use of SolidCAM 2.5D Milling to machine the part shown above. The machining is performed on a 3-axis CNC machine in two setups, using two SolidCAM Coordinate systems.
The following SolidCAM operations are created to perfor m the machining:
• Upper aces machining (F_prole_T1; F_prole1_T1) These Prole operations remove the bulk of material performing the rough and the nish machining of upper faces. An end mill of Ø16 is used. The Clear oset option is used at the roughing stage to perform the machining in a number of equidistant offsets from the machining geometry.
• Step aces machining (F_prole_T1) This operation performs the rough and nish machining of the step faces using the Prole operation. An end mill of Ø16 is used.
• External contour machining (F_prole_T1) This operation performs the rough and nish machining of the external model faces. An end mill of Ø16 is used.
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• Connector pocket machining (P_prole_T1; F_prole1_T; F_prole_T; P_prole_T
P_prole_T;
A number of Prole and Pocket operations are used to perform the rough and nish machining of the connector pocket. End mill tools of Ø10; Ø3 and Ø4 are used. The Rest material strategy is used in the last operation to complete the machining of the connector faces.
• Machine screw head areas (F_prole_T) This operation performs the rough and nish machining of the screw head areas. An end mill tool of Ø4 is used.
• Top and Bottom ace machining (P_prole1_T1; P_prole10_T1) Two Pocket operation using the Clear strategy enable you generate the tool path for roughing and nishing of the top and bottom faces. Note that the second operation is used with the second Coordinate System, it means that the second setup has to be performed at the CNC machine before the machining.
• Internal aces roughing (P_prole11_T1; P_prole1_T1) These Pocket operations perform the roughing of the complex pocket formed by the internal faces of the part. An end mill tool of Ø10 is used.
• Internal aces roughing P_prole_T; F_prole_T)
(F_prole11_T;
F_prole1_T;
These Pocket and Prole operations perform the nish machining of the wall and oor faces if the complex pocket roughed at the previous stage. An end mill tool of Ø4 is used.
• Holes machining (D_drill_T; D_drill1_T; D_drill_T; D_drill_T; D_drill1_T; D_drill_T; These Drill operations perform center drilling and drilling of holes located on the cover part faces. For more information see Exercise # of the SolidCAM .D Milling Training Course.
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3D Milling
The D_Milling_1.prz example illustrates the use of SolidCAM 3D Milling for the machining of the mold core shown above.
The following SolidCAM operations are created to perfor m the machining:
• Roughing (DR_target_T1) This operation removes the bulk of material using the Contour roughing strategy. An end mill of Ø20 is used. The machining is performed at the constant-Z levels dened, using the Step down value of 5 mm. A machining allowance of 0.5 mm remain unmachined for further nish operations.
• Rest material machining (DR_target_T) This operation performs the rest material machining of the areas that were inaccessible to the tool in the previous operation. An end mill tool of smaller diameter (Ø16) is used. The Contour roughing strategy is utilized in combination with the Rest material mode of the Working area denition in order to obtain optimal and effective tool path removing the cusps left after the previous operation. A machining allowance of 0.5 mm remains unmachined for further nish operations.
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• Steep areas nishing (DF_CZ_target_T) This operation performs the Constant-Z nishing of the steep areas of the core. With this strategy, SolidCAM machines a number of planar sections, parallel to the XY plane, using prole machining. A ball nose mill of Ø10 is used. The machining is performed for the steep areas, with inclination angle from 30° to 90°
• Shallow areas nishing (DF_CS_target_T) This operation performs the Constant Stepover nishing of the shallow areas of the core. With this 3D Milling strategy SolidCAM generates a number of tool paths, at specied constant offset ( Step over ) from each other, measured along the surface. The machining is performed for the shallow areas, with inclination angle from 0° to 32°. A ball nose mill of Ø10 is used.
• Parting surace nishing (DF_Lin_target_T) This operation performs the Linear nishing of the parting surface of the core. In linear nishing, SolidCAM generates a line pattern on a 2D plane above the model and then projects it on the 3D Model. The Step over value determines the constant distance between adjacent lines of the linear pattern, created on the 2D plane before being projected. A ball nose mill of Ø10 is used. The dened Drive/Check surfaces enable you to perform the machining of the parting surfaces only, avoiding unnecessary contact with the already machined faces. For more information see Exercise #1 and Exercise #10 of the SolidCAM D Milling Training Course.
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3D Milling
The D_Milling_.prz example illustrates the use of SolidCAM 3D Milling for prismatic part machining.
The following SolidCAM operations are created to perfor m the machining:
• Roughing (DR_target_T1) These operations remove the bulk of material using the Contour roughing strategy. An end mill of Ø14 is used. The Open Pocket machining is used to perform the approach movement from an automatically calculated point outside of the material. The tool descends to the necessary depth outside of the material and then moves horizontally into the material. A machining allowance of 0.2 mm remain unmachined on oor and wall faces for further nish operations.
• Rest material machining (DR_target_T; DR_target_T) At this stage the rest material machining is performed for the corner areas, that were inaccessible by the tool in the previous operation. The machining is performed in two operations using end mills of Ø8 and Ø5, in order to minimize the tool load. The Contour roughing strategy is utilized in combination with the Rest material option in order to obtain optimal tool path A machining allowance of 0.2 mm remain unmachined on the oor and wall faces for further nish operations.
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• Vertical walls nishing (DF_CZ_target_T) This operation performs the Constant-Z Wall nishing of the vertical walls areas of the part. With this strategy, SolidCAM generates a number of prole passes along the Z-axis, with a constant Step down. An end mill of Ø4 is used.
• Horizontal foor nishing (DF_CZ_target_T_1) This operation performs the Constant-Z Floor nishing of the horizontal oor areas of the part. With this strategy, SolidCAM generates a number of pocket passes on the horizontal faces, parallel to the XY-plane of the current Coordinate System. An end mill of Ø4 is used. For more information see Exercise #1 of the SolidCAM D Milling Training Course.
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HigH SPEED MACHining
The hsm_1.prz example illustrates the use of several SolidCAM High Speed Machining (HSM) strategies to machine the mold cavity shown above.
The following SolidCAM operations are created to perfor m the machining:
• Rough machining (HSM_R_Cont_target_T1A) This operation performs contour roughing of the cavity. An end mill of Ø20 is used with a Step down of 3 mm. A machining allowance of 0.5 mm remain unmachined for further semi-nish and nish operations.
• Rest roughing (HSM_RestR_target_TA) This operation performs rest roughing of the cavity. A bull nosed tool of Ø12 and corner radius of 2 mm is used with a Step down of 1.5 mm to remove the steps left after the roughing. The same machining allowance as in roughing operation is used.
• Steep aces semi-nishing (HSM_CZ_target_TA) This operation performs Constant Z semi-nishing of the steep faces (from 40° to 90°). A ball nosed tool of Ø10 is used for the operation. A machining allowance of 0.25 mm remain unmachined for further nish operations. The Apply llet suraces option is used to add virtual llets that will smooth the tool path at the corners.
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• Shallow aces semi-nishing (HSM_Lin_target_TA) This operation performs Linear semi-nishing of the shallow faces (from 0° to 42°). A ball nosed tool of Ø10 is used for the operation. A machining allowance of 0.25 mm remain unmachined for further nish operations. The Apply llet suraces option is used.
• Corners rest machining (HSM_RM_target_TA) This operation uses the Rest Machining strategy for semi-nishing of the mold cavity corners. The semi-nishing of the model corners enables you to avoid tool overload in the corner areas during further nishing. A ball nosed tool of Ø6 is used for the operation. A virtual reference tool of Ø12 is used to determine the model corners where the rest machining is performed. A machining allowance of 0.25 mm remain unmachined for further nish operations.
• Steep aces nishing (HSM_CZ_target_TA) This operation performs Constant Z nishing of the steep faces (from 40° to 90°). A ball nosed tool of Ø8 is used for the operation. The Apply llet suraces option is used.
• Shallow aces nishing (HSM_Lin_target_TA) This operation performs Linear nishing of the shallow faces (from 0° to 42°). A ball nosed tool of Ø8 is used for the operation. The Apply llet suraces option is used.
• Corners rest machining (HSM_RM_target_TA) This operation uses the Rest Machining strategy for nishing of the model corners. A ball nosed tool of Ø4 is used for the operation. A virtual reference tool of Ø10 is used to determine the model corners where the rest machining is performed.
• Chamering (HSM_Bound_target_TA) This operation uses the Boundary Machining strategy for the chamfering of upper model edges. A taper tool is used for the operation. The chamfer is dened by the external offset of the drive boundary and by the Axial thickness parameter. For more information see Exercise #1 of the SolidCAM HSM User Guide.
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HigH SPEED MACHining
The hsm_.prz example illustrates the use of several SolidCAM HSM strategies to machine the electronic box shown above.
The following SolidCAM operations are created to perfor m the machining:
• Rough machining (HSM_R_Cont_target1_T1A) This operation performs the contour roughing of the part. An end mill of Ø30 is used with a Step down of 10 mm to perform the roughing. A machining allowance of 0.5 mm remain unmachined for further semi-nish and nish operations.
• Rest roughing (HSM_RestR_target1_TA) This operation performs the rest roughing of the part. A bull nosed tool of Ø16 and corner radius of 1 mm is used with a Step down of 5 mm to remove the steps left after the roughing. The same machining allowance as in the roughing operation is used.
• Upper aces machining (HSM_CZ_target_TA) This operation performs Constant Z nishing of the upper vertical model faces upto a certain depth. A bull nosed tool of Ø12 and corner radius of 0.5 mm is used.
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• Bottom aces machining (HSM_CZ_target_TA_1) This operation performs Constant Z nishing of the bottom vertical model faces. A bull nosed tool of Ø12 and corner radius of 0.5 mm is used.
• Flat aces machining (HSM_CZF_target1_TA) This operation performs Horizontal Machining of the at faces. A bull nosed tool of Ø12 and corner radius of 0.5 mm is used.
• Inclined aces machining (HSM_CZ_target1_TA) This operation performs Constant Z Machining of the inclined faces. A taper mill of 12° angle is used to perform the machining of the inclined face with large stepdown (10 mm). Using such a tool enables you to increase the productivity of the operation. For more information see Exercise #1 of the SolidCAM HSM User Guide.
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MUlTi-SiDED MACHining
The multi_sided_machining_1.prz example illustrates the use of SolidCAM Multi-sided machining to machine the manifold plate shown above, using a 5-axis CNC Machine. The initial stock for this example comes from casting.
The following SolidCAM operations are created to perfor m the machining:
• Top ace machining (P_prole_T1) This Pocket operation, using the Clear strategy, performs the machining of the top face of the cover. An end mill of Ø16 is used. The machining is performed in two passes - rough and nish. A machining allowance of 0.2 mm remain unmachined at the oor after the rough pass and removed during the nishing pass. Position #1 of the Machine Coordinate system is used for the operation.
• Front hole machining F_prole1_T1)
(D_drill_T;
D_drill_T;
D_drill_T;
These operations are used for the front hole machining using Position #2 of the Machine Coordinate system. The Drill operations perform centerdrilling and two steps drilling of the hole. The Prole operation is used for the machining of the connector faces around the hole.
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• Let hole machining (D_drill1_T; D_drill1_T; D_drill1_T; F_prole_T1) These operations are used for the left hole machining using Position #3 of the Machine Coordinate system. The sequence of the Drill and Prole operations is similar to the sequence used for the front hole machining.
• Back hole machining (D_drill_T; D_drill_T; D_drill_T; F_prole_T1) These operations are used for the left hole machining using Position #4 of the Machine Coordinate system. The sequence of the Drill and Prole operations is similar to the sequence used for the front hole machining.
• Right hole machining (D_drill_T; D_drill_T; D_drill_T; F_prole_T1) These operations are used for the left hole machining using Position #5 of the Machine Coordinate system. The sequence of the Drill and Prole operations is similar to the sequence used for the front hole machining.
• Top holes machining (P_prole_T; D_drill_T; D_drill_T; D_drill_T; D_drill_T; D_drill_T; F_prole_T) These operations are used for the machining of the holes located on the top faces of the model. Position #1 of the Machine Coordinate system is used for all the operations. For more information see Exercise #1 of the SolidCAM .D Milling Training Course.
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MUlTi-SiDED MACHining
The multi_sided_machining_1.prz example illustrates the use of SolidCAM Multi-sided machining to complete the machining of the clamp part shown above, using a 5-axis CNC Machine.
The following SolidCAM operations are created to perfor m the machining:
• Top ace machining (P_prole1_T1) This Pocket operation, using the Clear strategy, machines the top inclined face of the clamp. Machine Coordinate system #1 (Position #2) is used for the operation.
• Back ace machining (P_prole_T1) This Pocket operation, using the Clear strategy, machines the back inclined face of the clamp. Machine Coordinate system #1 (Position #3) is used for the operation.
• Front ace machining (P_prole_T1) This Pocket operation, using the Clear strategy, machines the front inclined face of the clamp. Machine Coordinate system #1 (Position #4) is used for the operation.
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• Openings machining (F_prole_T1) This Prole operation machines two openings, located on the front inclined face of the clamp. Machine Coordinate system #1 (Position #4) is used for the operation.
• Slot machining (P_prole_T; P_prole_T) These Pocket operations machines the slot faces located on the top inclined face of the clamp, using the Contour strategy. Machine Coordinate system #1 (Position #2) is used for the operation.
• Hole machining (P_prole_T; D_drill_T D_drill_T) These operations machine the inclined counterbore hole, located on the top inclined face of the clamp. Machine Coordinate system #1 (Position #5) is used for the operation.
• Bottom ace machining (P_prole_T1) This Pocket operation, using the Clear strategy, machines the bottom inclined face of the clamp. Machine Coordinate system #2 (Position #1) is used for the operation. For more information see Exercise #1 of the SolidCAM .D Milling Training Course.
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SiM. 5-AxiS MACHining
The sim__axis_1.prz example illustrates the use of the SolidCAM Sim. 5 axis module for turbine blade machining.
The following Sim. 5 axis operations are used to perform the semi-nish and nish machining of the turbine blade:
• Blade Semi-nishing (X_selected_aces_T1A_1; X_selected_aces_TA_) The rst operation provides the semi-nish of the turbine blade, using a bull nosed tool of Ø16 with a corner radius of 4 mm. A combination of the Parallel Cuts strategy and Change parallel cuts to spiral option is used to perform the spiral machining of the blade. The tool tilting is dened using the Tilted relative to cutting direction option, with lag angle of 20°. The tool contact point is dened at the front tool face. This combination of parameters enables you to perform the machining by the toroidal surface of the tool. Gouge checking is performed to avoid the possible collisions of the tool with the planar surface of the blade base. The remaining material will be machined at a later stage, using a special tilting strategy.
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The second Sim. 5-axis operation provides semi-nishing of the blade area, close to the blade base. This area was not machined in the previous operation because of the gouge protection. A bull nosed tool of Ø8, with a corner radius of 2 mm, is used for the operation. Similar to the previous operation, a combination of the Parallel Cuts strategy and Change parallel cuts to spiral option is used to perform the spiral machining of the blade. The tool tilting is dened using the Tilted relative to cutting direction option, with a lag angle of 20°. In addition to the lag angle, a side tilting angle of 10° is dened to avoid the gouging of the planar face of the blade base.
• Blade nishing (X_selected_aces_TA) This operation performs the nishing of the blade. A bull nosed tool of Ø8, with a corner radius of 2.5 mm, is used for the operation. The tool tilting is dened using the T ilted relative to cutting direction option with a lag angle of 20°. In addition to the lag angle, a side tilting angle of 10° is dened to avoid the gouging of the planar face of the blade base. For more information see Exercise # of the SolidCAM Sim. -axis User Guide.
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SiM. 5-AxiS MACHining
The sim__axis_.prz example illustrates the use of the Sim. 5 axis operation for an aerospace part machining.
A number of Sim. 5 axis operations are dened in order to perform the nish machining of the inclined faces of the aerospace frame and their adjacent llets. The inclined faces are forming an undercut area that cannot be machined using 3 axis milling; we have to use 5 axis milling, with the appropriate tilting strategy, to machine the inclined faces.
• Inclined walls nishing (X_selected_aces1_T1A; X_selected_aces_T1A; X_selected_aces_T1A) These operations perform the nish machining of the inclined walls. A ball nosed tool of Ø4 is used for the operation. The Parallel Cuts strategy is used to generate a number of cuts parallel to the XY plane of the coordinate system.
The tool tilting is dened using the Tilted relative to cutting direction option with a lag angle of 90°. These parameters enable you to perform the machining with the side face of the tool.
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• Fillet machining (X_selected_aces_T1A; X_selected_aces_T1A; X_selected_aces_T1A) These operations perform the nish machining of the llets adjacent to the walls. A ball nosed tool of Ø4 is used for the operation. The Project curves strategy is used to generate a single pencil milling pass, machining the llets. The Tilted through curves tilting strategy is used to perform a smooth transition between different tool axis orientations. For more information see Exercise # of the SolidCAM Sim. -axis User Guide.
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TUrning
The turning_1.prz example illustrates the use of the SolidCAM Turning for the machining of the part shown above.
The following Turning operations are used to perform the machining of the part:
• External Roughing (TR_prole_T1A) This operation is used to generate the tool path for the external faces roughing. An External roughing tool is used for the operation. The Long Process type is chosen for the operation to perform the machining in longitudinal direction. The Rough Work type is chosen for the operation; with this Work type the rough machining is performed in a number of equidistant passes.
• Facial Turning (TR_prole1_T1A) This operation is used to generate the tool path for the front face machining. An External roughing tool is used for the operation. The Face Process type is chosen for the operation to perform the machining in facial direction. The Rough work type is chosen for the operation; with this work type the rough machining is performed in a number of equidistant passes.
• Drilling (DRILL__TA) This Drill operation is used to perform the rough machining of the hole. A U-Drill tool of Ø28 is used for the operation.
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• External Finishing (TR_prole_TA) This Turning operation is used to perform the external faces nishing. The Prole Work type is chosen to generate the nishing pass. An External roughing tool is used for the operation.
• Internal Turning (TR_prole_TA) This Turning operation is used to perform the internal faces nishing. The Prole Work type is chosen to generate the nishing pass. An Internal roughing tool is used for the operation.
• External Grooving (GR_prole_TA) This Grooving operation is used to perform rough and nish machining of the external groove faces. An External grooving tool is used for the operation.
• Internal Grooving (GR_prole_TA) This Grooving operation is used to perform rough and nish machining of the internal groove faces. An Internal grooving tool is used for the operation.
• External Threading (TH_prole_TA) This Threading operation is used to perform the machining of the external thread with the minimal diameter of 56 mm and pitch of 1.5 mm. An External threading tool is used for the operation.
• Internal Threading (TH_prole_TA) This Threading operation is used to perform the machining of the internal thread with the maximal diameter of 33.5 mm and pitch of 1.5 mm. An Internal threading tool is used for the operation.
• Parting (GR_prole_TA) This Grooving operation is used to perform the parting (cut-off) of the machined part from the stock bar. The Cut Work type is used for the operation. An External grooving tool is used for the operation. For more information see Exercise #1—#11 of the SolidCAM Turning Training Course.
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TUrning
The turning_.prz example illustrates SolidCAM functionality for Rest Material machining, during longitudinal and facial rough/nish turning operations, performed on the wheel part shown above.
The following Turning operations are used to perform the machining of the part:
• External Roughing (TR_prole_T1A) This operation is used to generate the tool path for the external faces roughing. An External roughing tool is used for the operation. The Long Process type is chosen for the operation to perform the machining in the longitudinal direction. The Rough Work type is chosen for the operation; with this Work type the rough machining is performed in a number of equidistant passes.
• External Rest Material Roughing (TR_prole_TA) This operation utilizes the Rest Material option to perform the machining of the areas left unmachined after the previous operation. These areas were unmachined because of the orientation and geometry of the tool used in the previous operation. In this operation a tool with opposite orientation is used to machine the part, moving in the positive Z-direction.
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• External Finishing (TR_prole1_TA) This Turning operation is used to perform the external faces nishing. The Prole Work type is chosen to generate the nishing pass. An External Contour tool is used for the operation to avoid leaving unmachined areas during the external nish.
• Facial Roughing (TR_prole_TA) This operation is used to generate the tool path for the front face roughing. An External roughing tool is used for the operation. The Face Process type is chosen for the operation to perform the machining in facial direction. The Rough work type is chosen for the operation; with this work type the rough machining is performed in a number of equidistant passes.
• External Rest Material Roughing (TR_prole_TA) This operation utilizes the Rest Material option to perform the machining of the areas left unmachined after the previous operation. These areas were unmachined because of the orientation and geometry of the tool used in the previous operation. In this operation the tool with opposite orientation is used to machine the part, moving in the positive X-direction.
• External Facial Finishing (TR_prole_TA_1) This Turning operation is used to perform the front face nishing. The Prole Work type is chosen to generate the nishing pass. An External roughing tool is used for the operation.
• External Rest Material Finishing (TR_prole_TA_1) This operation utilizes the Rest Material option to perform the machining of the areas left unmachined after the previous nishing operation. These areas were unmachined because of the orientation and geometry of the tool used in the previous operation. In this operation the tool with opposite orientation is used to machine the part, moving in the positive X-direction. The Prole Work type is chosen to generate the nishing pass.
• Hole machining (DRILL__TA) This Drill operation is used to perform the machining of the hole. A U-Drill tool of Ø40 is used for the operation. For more information see Exercise #1 of the SolidCAM Turning Training Course .
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TUrn-Mill
The turn_mill_1.prz example illustrates the use of the SolidCAM Turn-Mill module for the machining of the part shown above on a CNC-Machine of the XZC type.
The following Turning and Milling operations are used to perform the machining of the part:
• External Turning (TR_prole_T1) This operation is used to generate the tool path for the rough and nish machining of the external faces. An External roughing tool is used for the operation. The Long Process type is chosen for the operation to perform the machining in longitudinal direction. The Rough Work type is chosen for the operation; with this Work type the rough machining is performed in a number of equidistant passes. The ISO_Turning_method option is chosen for the Finish in order to generate the nishing tool path with the same tool.
• Facial Milling (F_prole1_T) This Prole operation performs the rough and nish milling of the hexagon and the adjacent faces of the model. Position #1 of Coordinate System #1 is used to perform the facial machining. An end mill of Ø10 is used for the operation. The Clear oset option is used at the roughing stage to perform the machining in a number of equidistant offsets from the machining geometry.
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• External Finishing (P_prole_T) This Pocket operation is used to perform the simultaneous 4-axis machining of the pocket wrapped on the external face of the part. Position #1 of Coordinate System #2 is used to perform the pocket machining. An end mill of Ø6 is used for the operation. The Wrap option, chosen during the machining geometry denition, enables you to dene the wrapped geometry of the pocket directly on the solid model. The Contour strategy is chosen for the pocket machining. For more information see Exercise # of the SolidCAM Turn-Mill Training Course.
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TUrn-Mill
The turn_mill_.prz example illustrates the use of the SolidCAM Turn-Mill module for the machining of the optical part shown above, on a CNC-Machine of the XYZC type.
The following Turning and Milling operations are used to perform the machining of the part:
• Turning (TR_prole1_T1; TR_prole1_T1_1; DRILL__T; TR_prole10_T) These turning operations are used to generate the tool path for the rough and nish machining of the external and internal cylindrical faces.
• Facial Milling (F_prole_T; D_drill_T; D_drill_T) These operations perform the machining of the screw slot and four holes using SolidCAM capabilities for facial milling. Position #1 of Coordinate System #1 is used to perform the facial machining.
• Machining o the side aces (P_prole_T) This Pocket operation is used to perform the machining of the side faces of the model. The Contour strategy is used in combination with a negative Wall oset value in order to generate an overlapping tool path that completely machines the faces. Position #2 of Coordinate System #2 is used for the operation. The Transorm option is used to create a circular pattern of operations around www.cadfamily.com EMail:
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• Drilling on the side ace (D_drill_T) This Drill operation is used to perform the machining of two holes located on the side face of the model. Position #2 of Coordinate System #2 is used for the operation.
• Slot machining (F_prole_T) This Prole operation is used to perform the machining of the slot using indexial 4-axis milling. Position #3 of Coordinate System #2 is used for the operation. An end mill of Ø2.5 is used for the operation.
• Radial holes machining (D_drill1_T; P_prole_T; D_drill_T; P_prole_T) These Drill and Pocket operations are used to perform the machining of three counterbore holes located on the cylindrical face. Position #4 and Position #5 of Coordinate System #2 are used for the operations.
• Pocket machining (P_prole_T) This Pocket operation is used to perform the simultaneous 4-axis machining of the pocket, wrapped on the external face of the part. Position #1 of Coordinate System #2 is used to perform the pocket machining. An end mill of Ø2.5 is used for the operation. The Wrap option, chosen during the machining geometry denition, enables you to dene the wrapped geometry of the pocket directly on the solid model. The Contour strategy is chosen for the pocket machining. For more information see Exercise #1 of the SolidCAM Turn-Mill Training Course.
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TUrn-Mill
The turn_mill_.prz example illustrates the use of the SolidCAM Turn-Mill module for the machining of the console part shown above on a CNC-Machine of the XYZCB type.
The following Turning and Milling operations are used to perform the machining of the part:
• Turning (TR_prole_T1) This turning operation is used to generate the tool path for the rough and nish machining of the external cylindrical faces.
• Indexial milling (F_prole_T) This Prole operation is used to perform the machining of the cube sides using the SolidCAM indexial milling capabilities. Position #2 of Coordinate System #2 is used for the operation. The Transorm option is used to create a circular pattern of operations around the revolution axis in order to machine all the cube faces. An end mill of Ø16 is used for the operation.
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• Horizontal aces machining (F_prole1_T) This Prole operation is used to perform the indexial milling of the horizontal faces at the front part of the console. Position #2 of Coordinate System #2 is used for the operation. The Transorm option is used to create a circular pattern of operations around the revolution axis in order to machine both sides of the console’s front part.
• Inclined aces machining (F_prole_T; F_prole_T) These Prole operations are used to perform the machining of the inclined faces using the B-axis. Positions #2 and #3 of Coordinate System #3 are used for these operation. An end mill of Ø16 is used for the operations.
• Pocket machining (P_prole_T) This Pocket operation is used to perform the machining of the pocket located on the inclined faces, using the B-axis. Position #2 of Coordinate System #3 is used for the operation. An end mill of Ø6 is used for the operation.
• Inclined aces machining (F_prole_T; F_prole_T) These Prole operations are used to perform the machining of the inclined faces on the cube, using the B-axis. Positions #4 and #5 of Coordinate System #3 are used for the operation. An end mill of Ø16 is used for the operation.
• Hole machining (D_drill_T; D_drill1_T; D_drill_T; D_drill_T) These Drill operations are used to perform the machining of the inclined faces on the cube, using the B-axis. Position #2 of Coordinate System #2 and Positions #3, #4 and #5 of Coordinate System #3 are used for the operations. For more information see Exercise #1 of the SolidCAM Turn-Mill Training Course.
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TUrn-Mill - 2 SPinDlES
The back_spindle.prz example illustrates the use of the SolidCAM Back Spindle functionality for the machining of the connector part shown above, on a Turn-Mill CNC-Machine of the XYZCB type.
The following Turning and Milling operations are used to perform the machining of the part:
• Turning and ront side milling (TR_prole_T1A; DRILL__TA; F_prole1_TA; TR_prole_TA) These operations are used to perform turning and facial milling of the front faces of the connector. Position #1 of Coordinate System #1 is used for the operation. The back spindle is not used in these operations; only the main spindle is used.
• Indexial machining o the middle part (F_prole_TA; D_drill_TA; D_drill_TA; F_prole_TA) These Prole and Drill operations are used to perform the machining of the pads and holes located around the cylindrical surface, in the middle part of the connector. Position #2 of Coordinate System #2 is used for the operation. The Back Spindle Connect operation is dened before these operations, enabling the combined use of both spindles (main and back) in these operations.
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• Indexial machining o the back part (P_prole_TA; D_drill_T10A) These Prole and Drill operations are used to perform the machining of the pads and holes located around the conical surface, in the middle part of the connector. Position #2 of Coordinate System #3 is used for the operation. The Back Spindle MoveBack operation is dened before these operations, causing the retract of the back spindle, so that these operations are performed with the main spindle only.
• Turning and back side milling (TR_prole_T1B; F_prole10_T11A; DRILL__T1A; TR_prole11_ T1A; F_prole1_T1A; D_drill_T1A; D_drill_T1A) These operations are used to perform turning and facial milling of the back faces of the connector. Position #1 of Coordinate System #1 is used for the turning operation. Position #1 of Coordinate System #4 is used for the milling operation. The Back Spindle Transer operation is dened before these operations, causing the transfer of the part from the main spindle to the back spindle. The machining is performed on the part clamped in the back spindle. Refer to the SolidCAM Turning User Guide for more information about the Back spindle functionality.
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WirE CUT
The wire_cut.prz example illustrates the use of the SolidCAM Wire Cut module for the plate part machining.
The following Wire Cut operations are used to perform the machining of the part:
• Central cut machining (F_prole) This Prole operation is used to machine the central through cut. The Later option is used for the Auto Stop technology , generating a postponed separate sub-operation preventing the material dropping.
• Front cut machining (F_prole) This Prole operation is used to machine the through cut located in the front area of the part. The Later option is used for the Auto Stop technology , generating a postponed separate sub-operation preventing the material dropping.
• Cylindrical holes machining (F_prole) This Prole operation is used to machine two through cylindrical holes, located on the top face of the model.
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• Countersink machining (A_prole; F_prole) The Angle operation is used to machine the six countersink cones of 90°. The insertion points of the wire are chosen close to the hole centers, where the preparatory drilling is performed. The Angle operation tool path is generated in such a way so as to obtain the necessary diameter of the cylindrical part of the hole (8.1 mm) at the necessary depth (4.45 mm). The Prole operation performs the machining of the cylindrical part of the countersink hole. Refer to the Wire Cut User Guide for more information about the Wire Cut module.
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TrAining MATEriAlS The following training courses are suitable both for SolidCAM frontal training and for self study.
• SolidCAM Milling Training Course: .D Milling • SolidCAM Milling Training Course: D Milling • SolidCAM Turning Training Course • SolidCAM Turn-Mill Training Course These documents are available in the following format: PDF for on-line use + Examples The following user guides for SolidCAM are available.
• SolidCAM Milling User Guide • SolidCAM HSM User Guide • SolidCAM Sim. -axis User Guide • SolidCAM Turning User Guide • SolidCAM Wire Cut User Guide The PDF versions of user guides are available for download from the Download area of SolidCAM Web site: www.solidcam.com. On-line help, based on these user guides, is available within SolidCAM.
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SySTEM rEqUirEMEnTS •
Microsoft® Windows XP Professional with Service Pack 2 (recommended), Microsoft® Windows XP Professional x64 Edition, Windows 2000 with Service Pack 3 or 4
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Intel® Pentium™, Intel® Xeon™, Intel® Core™, AMD® Athlon™ - class processor
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512 MB RAM or more (1 GB or more recommended for large CAM-Parts machining)
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An OpenGL workstation graphics card (256 MB RAM recommended) and driver
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Mouse or other pointing device
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CD drive
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Internet Explorer version 6 if you are using the SolidCAM online help
•
For viewing SolidCAM User Guides and Training Courses, Adobe Acrobat version 7.0.7 or higher is recommended.
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