SolidCAM2007 R11 Turn Mill Training Course

SolidCAMSolidCAM 2007 R11

Power and Ease of Use - the winning combination

SolidCAM 2007 R11

Turn-Mill Training Course

©1995-2007 SolidCAM

All Rights Reserved.WWW.SOLIDCAM.COM

SolidCAM 2007 R11

Turn-Mill Training Course

©1995-2007 SolidCAM

All Rights Reserved.

Contents

5

Contents

1. Introduction

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

1.2 Turn-Mill Operations Overview ................................................................................................11

1.3 CNC Machines ..............................................................................................................................12

1.4 Basic Concepts ..............................................................................................................................16

1.5 Process overview ..........................................................................................................................16

2. CAM-Part Definition

Exercise #1: CAM-Part Definition ...........................................................................................19

3. Turning with Turn-Mill CNC-Machines

Exercise #2: Turning ..................................................................................................................42

4. Milling with Turn-Mill CNC-Machines

4.1 Facial Milling on XZC Machines ...............................................................................................61

Exercise #3: Facial Milling .........................................................................................................62

4.2 Indexial 4-Axis Milling on XZC machines ...............................................................................76

Exercise #4: Indexial 4-Axis Milling ........................................................................................77

4.3 Simultaneous 4-Axis milling on XZC machines ......................................................................93

Exercise #5: Simultaneous 4-Axis Milling ...............................................................................94

Exercise #6: Bracket Machining .............................................................................................101

Exercise #7: Slotted Nut Machining ......................................................................................103

Exercise #8: Stopper Machining .............................................................................................105

Exercise #9: Bushing Machining ............................................................................................107

Exercise #10: Shaft Machining................................................................................................108

SolidCAM 2007 R11 Turn-Mill Training Course

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Document number: SCMTTCENG07001

4.3 Milling on Turn-Mill CNC-machines of the XYZC type ....................................................109

Exercise #11: Milling on XYZC Machines ...........................................................................110

Exercise #12: Optical Part Machining ...................................................................................134

Exercise #13: Joint Part Machining ........................................................................................136

Exercise #14: Connector Part Machining .............................................................................137

4.4 Milling on Turn-Mill CNC-Machines of the XYZCB type .................................................139

Exercise #15: Milling on XYZCB Machines ........................................................................140

Exercise #16: Console Machining ..........................................................................................156

5. Projections Mode

Exercise #17: CAM-Part Definition and Machining in the Projections mode ................161

Exercise #18: Pin Machining ...................................................................................................187

Exercise #19: Pulley Machining ..............................................................................................189

Introduction 1


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9

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 Turn-Mill CNC-Machines. This tutorial covers the basic concepts of SolidCAM and Turn-Mill 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.

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 Turn-Mill 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. It contains a number of laboratory exercises to give you the opportunity to apply and practice the material covered by the guided exercises. The laboratory exercises do not contain step-by-step instructions.

About the CD

The CD 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 SolidWorks2007.

The MAC-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 ..\SolidCAM2007R11\GPPTOOL folder.

Windows® XP

The screenshots in this book were made using SolidCAM2007 R11 integrated with SolidWorks2007 running on Windows® XP. 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.


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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 on the Change to opposite button.

10. Define CoordSys Position The mouse icon and numbered sans serif bold text indicates the beginning of the exercise action. The action explanation is as follows.

ExplanationThis 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.

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1. Introduction

1.2 Turn-Mill Operations Overview

The Turn-Mill module enables you to prepare the tool path for turning and milling operations for Turn-Mill CNC centers. SolidCAM provides all turning operations as well as milling operations for driven tools on the face or on the perimeter of the stock. The following types of machining are available in the Turn-Mill module:

Turning SolidCAM enables you to create the tool path for all turning operations: turning, facial and radial, drilling, threading and grooving.

Facial Milling

SolidCAM enables you to perform all milling operations on the front faces of the model. In this type of machining, the tool axis is always parallel to the revolution axis of the part.

Indexial 4-Axis Milling

SolidCAM enables you to perform all the milling operations on the side faces of the model. The rotation axis of the CNC machine is used to set the part to the necessary position. The milling is performed only by the 3-Axis movement.

Simul-taneous 4-Axis Milling

SolidCAM enables you to perform all milling operations on the radial faces of the model. The rotation axis of the CNC machine is used simultaneously with 3-Axis movements.


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1.3 CNC Machines

SolidCAM supports the following CNC-machine types:

• 3-Axis Turn-Mill machine; Turning + Milling with C-axis (XZC type).

• 4-Axis Turn-Mill machine; Turning + Milling with C and Y-axes (XYZC type).

• 5-Axis Turn-Mill machine; Turning + Milling with C, Y and B-axes (XYZCB type).

Use the following parameters in the MAC-file to define these machines:

mac_axes = XZC; for Turning with C-axis.

mac_axes = XYZC; for Turning with Y and C-axis.

mac_axes = XYZCB; for Turning with Y, C and B-axis.

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1. Introduction

1.3.1 3-Axis Turn-Mill machine (XZC type)

This type of machine enables you to perform the following operations:

1. Turning

2. Facial and Radial milling with C-axis, interpolation C and X.

X

Z

C

X

Z

X

C

Z


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1.3.2 4-Axis Turn-Mill machine (XYZC type)


1. Turning

2. Facial and Radial milling with the C-axis, interpolation C and X

3. Facial and Radial milling with X-, Y-, Z- movements and rotation around the Z axis (C-axis)

X

Z

Y

C

X

Z

X

C

Z

Y

X

C

Z

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1. Introduction

1.3.3 5-Axis Turn-Mill machine (XYZCB type)


1. Turning

2. Facial and Radial milling with the C-axis, interpolation C and X

3. Facial and Side milling with X-, Y-, Z- movements, rotation around the Z axis (C-axis) and Y axis (B-axis)

X

Z

Y

B

C

X

Z

X

C

Z

X

CB

Z

Y


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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

Two major stages of the creation process of the SolidCAM Manufacturing Project are the following:

CAM-Part definition

This stage includes the definition of the global parameters of the Manufacturing Project (CAM-Part). You have to define a number of Coordinate Systems that describe the positioning of the part on the CNC Machine. It is necessary to define the Material boundary (the Stock model) that describes the initial state of the workpiece that has to be machined. Optionally, you can also define the Target model that has to be obtained after the machining. The clamp has to be defined in order to supply SolidCAM with the information about fixing the part on the CNC Machine.

Operations definition

SolidCAM enables you to define a number of 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 define a number of technological parameters.

CAM-PartDefinition 2


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Following are the stages of the CAM-Part definition process:

• CAM-Part creation. At this stage, you have to define the CAM-Part name and location. SolidCAM defines necessary system files and a folder to allocate the place to store SolidCAM data.

• CNC-Controller definition. To choose the CNC-controller is a necessary step. The controller type will influence the Coordinate System definition and the Geometry definition.

• Coordinate System definition. You have to define the Coordinate System – 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.

• Material boundary definition. It is necessary to define a boundary of the stock that is used for the CAM-Part machining.

• Clamp definition. The clamping device (chuck) has to be defined in order to prevent a possible collision with tools during the machining.

• Target Model definition. SolidCAM enables you to define the model of the part in its final shape after the machining.

CAM-Part creation

Coordinate System definition

Material Boundary definition

CNC-controller definition

Clamp definition

Target Model definition

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Exercise #1: CAM-Part Definition

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 below and define the Coordinate System, the Clamp, the Material boundary and the Target model necessary for the part machining. The CAM-Part is used for the exercises further on.

1. Load the SolidWorks model

Load the Exercise1.sldprt model that is located in the /Exercises folder.

This model contains a number of features forming the solid body and a few sketches that are used for the CAM-Part definition.

2. Start SolidCAM

To activate SolidCAM, click on the SolidCAM field in the main menu of SolidWorks and choose Turn-Mill from the New submenu. SolidCAM is started and the New Turn-Mill part dialog box is displayed.

Turn-Mill Part data dialog box

When you create a new CAM-Part, enter a name for the CAM-Part and for the model that contains the CAM-Part geometry.


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Directory

Specify the location of the CAM-Part. The default directory is the SolidCAM user directory (defined in the SolidCAM Settings). You can enter the path or use the Browse button to define the location.

The Use Model file directory option enables you to automatically create CAM-Parts in the same folder where the original CAD model is located.

CAM-Part name

Enter a name for the CAM-Part. You can give any name to identify your machining project. By default SolidCAM uses the name of the design model.

Model name

This field shows the name and the location of the SolidWorks design model that you are using for the CAM-Part definition. The name is, by default, the name of the active SolidWorks document. With the Browse button you can choose any other SolidWorks document to define the CAM-Part. In this case, the chosen SolidWorks document is loaded into SolidWorks.

Every time the CAM-Part is opened, SolidCAM automatically checks the correspondence of the dates of the CAM-Part and the original SolidWorks design model. When the date of the original SolidWorks model is later than the date of the CAM-Part creation, this means that the SolidWorks original model has been updated. You can then replace the SolidWorks design model on which the CAM-Part is based with the updated SolidWorks design model.

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3. Confirm the CAM-Part creation

After the Directory, the CAM-Part name and the Model name are defined, click on the OK button to confirm the CAM-Part creation. The CAM-Part is defined and its structure is created. The Turn-Mill Part data dialog box is displayed.

The structure of the CAM-Part

The CAM-Part includes the data files represented on the illustration that displays the data included in the CAM-Part named Cavity.

The file Cavity.prt is located in the SolidCAM User directory. The Cavity subdirectory contains all the data generated for the CAM-Part.

SolidCAM copies the original SolidWorks model to the subdirectory Cavity and creates a SolidWorks assembly that has the same name as the CAM-Part (Cavity.sldasm). There are two components in this assembly:

DesignModel.sldprt - the copy of the SolidWorks model file.

CAM.sldprt - the 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.

Cavity.prt

Cavity.SLDASM

CAM.SLDPRT

DesignModel.SLDPRT

Cavity


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4. Choose the CNC-Controller

Choose the CNC-Machine Controller. Click on the arrow next to the controller field to display the list of post-processors installed on your system.

In this exercise, you use a CNC Machine of the XZC type (see 1.3.1). Choose the XZC CNC-controller from the list.

5. Multi-sided CoordSys

Make sure that the Multi-Sided CoordSys check box is selected. This check box enables you to choose the work style for SolidCAM.

When the check box is selected (Multi-sided mode), SolidCAM enables you to define the CAM-Part directly on the solid model. You can define the Coordinate System origin position and axes orientation by choosing model faces, vertices, edges or SolidWorks coordinate systems. The geometry for the machining can also be defined directly on the solid model.

When the check box is not selected (Projections mode), SolidCAM enables you to create the CAM-Part on planar views defined by 2D sketches on the XY plane. In most cases, this mode is used when importing a DXF or IGES file and when you do not want to create a solid model.

In this exercise, you use the Multi-sided mode in order to highlight SolidCAM capabilities to work directly on solid models.

Geometry

Coordinate System

MachineCoordinate System

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6. Start the Coordinate System definition

Click on the CoordSys button to define the Machine Coordinate System.

The Machine Coordinate System defines the origin for all machining operations of the CAM-Part. It corresponds with the built-in controller functions. It can be used for various clamping positions in a variety of operations on a CAM-Part.

Usually, Turn-Mill CNC machines have only one machine coordinate system, and its Z-axis is the rotation axis of the spindle. The Machine Coordinate System enables you to perform turning and milling operations.

To complete the CAM-Part menu, you need to define the Machine Coordinate System.

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

Z


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SolidCAM offers three methods of CoordSys definition:

Select face

This method enables you to define a new CoordSys by selecting a face. The face can be either planar or cylindrical/conical. For planar faces, SolidCAM defines a 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 the revolution of the specified cylindrical/conical surface.

Define

This method enables you to define a CoordSys by picking the origin and direction of the Z- and X-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 axes orientation are the same as in the original SolidWorks coordinate system.

7. Select the model face

With the Select Face mode activated, click on the model face as shown.

The Z-axis of the CoordSys is coincident with the axis of the revolution. Note that the CoordSys origin is automatically defined on the model back face and the Z-axis is directed backwards.

Click on the Change to opposite button. This button enables you to reverse the Z-axis direction along the revolution axis.

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Now the CoordSys origin is located on the front face of the model and the Z-axis is directed forward along the revolution axis.

Click on the Finish button to confirm the selection.

The CoordSys data dialog box is displayed.

8. Define the CoordSys data

The CoordSys data dialog box

This dialog box enables you to define the Machining levels such as Tool start level, Clearance level, Part upper level, etc.

Position defines the sequential number of the position. For each Machine Coordinate System, several Positions can be defined for different positionings; each such Position is relative to the Machine CoordSys.

• X shows the X-value of the CoordSys.

• Y shows the Y-value of the CoordSys.

• Z shows the Z-value of the CoordSys.


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Machine CoordSys number defines the number of the CoordSys in the CNC-Machine. The default value is 1. If you use another number, the G-Code file contains the G-function that tells the machine to use the specified number stored in the controller of your machine.

Tool start level defines the Z-level at which the tool starts.

Clearance level is the Z-level to which the tool rapids when moving from one operation to another, in case the tool does not change.

Part upper level defines the height of the upper surface of the part to be turned.

Part lower level defines the lower surface level of the part to be turned.

The Tool Z level is the height that the tool moves to 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.

Confirm the CoordSys data dialog box with the OK button.

The CoordSys Manager dialog box is displayed in the PropertyManager area of SolidWorks. This dialog box displays two Machine Coordinate Systems.

Rapid Movements area

Feed Movements areaPart

Upper level

PartLower level

Tool Start level

Clearance level

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Coordinate Systems for 3-Axis Turn-Mill machine (XZC type)

SolidCAM enables you to define the Machine CoordSys #1 with the Z-axis directed along the revolution axis.

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

The Machine CoordSys #1 is used also for facial milling, where the axis of the milling tool is parallel to the Z-axis of the Machine Coordinate System. The XC interpolation is used.

SolidCAM automatically creates the Machine CoordSys #2. This Coordinate System is used for radial milling (indexial and simultaneous 4-axis milling).

The origin point of the Machine CoordSys #2 is the same as the origin point of the Machine CoordSys #1. The axes direction of the Machine CoordSys #2 is the following:

• The X-axis of Machine CoordSys #2 is collinear with the Z-axis of Machine CoordSys #1.

• The Z-axis of Machine CoordSys #2 is collinear with the X-axis of Machine CoordSys #1.

Confirm the CoordSys Manager dialog box with the button. The Turn-Mill Part data dialog box is displayed.

Z

Machine CoordSys #1

X

Z

C

X

Machine CoordSys #2

Z

X

C

Machine CoordSys #1


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9. Define the Material boundary

For each Turn-Mill project, it is necessary to define the boundaries of the stock material used for the CAM-Part (Material boundary).

Click on the Material Boundary button.

The Material Boundary dialog box is displayed. This dialog box enables you to choose the methods of the Material boundary definition.

Methods of Material boundary definition

• Value

This method enables you to define a cylinder or tube material boundary by values.

• 2D Boundary

This method enables you to define the Material boundary by 2D profile.

• 3D Model

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

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Envelope

Consider the revolution body surrounding the specified solid bodies. The section of this revolution body by the ZX plane of the Machine CoordSys #1 is the envelope. The envelope line is a profile of the part that has to be turned in order to obtain the model geometry.

• Cylinder

This method enables you to define the Material boundary as a cylinder (or tube) surrounding the selected Solid model. SolidCAM generates a sketch containing the envelope of the cylinder (or tube) surrounding the selected solid body. The Material boundary is automatically defined on this sketch.

Choose the Cylinder mode and click on the Define button.

The Boundary (Cylinder) dialog box is displayed in the SolidWorks PropertyManager area.

10. Select the solid body

Click on the solid body in order to select it.

Solid body Surrounding revolution

body

Envelopeprofile


30

11. Specify the Cylinder parameters

Define the following offsets in the Boundary (Cylinder) dialog box:

Set Z+ to 0 and Z- to 30 in order to define front and back offsets from the model.

Set the External offset to 2.

Set Internal diameter to 0. SolidCAM defines a cylinder.

When the Internal diameter value is different from 0, SolidCAM defines a tube.

Click on the button to confirm the Material boundary definition.

Click on the button to confirm the Material boundary dialog box.

12. Prepare the Clamp Geometry

Clamp

It is necessary to define a clamp for each Turn-Mill project. The clamp in SolidCAM is a revolution body generated by revolution of a closed contour (the section of the clamp) about the Z-axis of the Machine CoordSys #1.

In this exercise, you are required to create a sketch containing the clamp geometry that is used.

Prepare the SolidWorks sketch containing the clamp geometry. This sketch is used at the next stage for the Clamp geometry definition.

Clamp section profile

31


Switch to the FeatureManager design tree by clicking on the button.

Create a new sketch on the base plane coincident to the XZ plane of the Machine CoordSys #1.

In the FeatureManager design tree, right-click on the Plane1 (this plane is coincident to the XZ plane of the Machine CoordSys #1) item and choose Insert Sketch from the menu.

The empty sketch is created.

Sketch the geometry for a clamp as shown.20

2010

10

2

25


32

Confirm the sketch creation in the SolidWorks confirmation corner.

Return to the Turn-Mill Part data dialog box to choose the prepared geometry as the Clamp.

13. Define the Chain

Click on the Main spindle button in the Clamp area of the Turn-Mill Part data dialog box.

The Clamp Geometry dialog box is displayed. This dialog box enables you to define and edit the Clamp geometry.

Click on the Define chain button to start the chain definition.

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The Chain Options dialog box is displayed.

The chain selection options in SolidCAM enable you to select the contour of the clamp.

Click on the chain entity as shown. The chain entity is highlighted.

In the Auto Select area, choose the General Chain option. The chain is completed automatically.

The clamp should either intersect or have a common edge with the material boundary.

The confirmation dialog box is displayed:

Confirm the chain selection by clicking on the Yes button.

Confirm the Clamp Geometry dialog box with the button.

The Turn-Mill Part data dialog box is displayed again.

Hide the sketch containing the clamp geometry. Right-click on the sketch name in the FeatureManager design tree and choose the Hide command from the menu.


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14. Define the Target model

SolidCAM enables you to define the Target model, which is the final shape of the CAM-Part after the machining.

The Target model is used in SolidCAM 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.

The Envelope sketch contains the envelope of the target model.

Envelope

During the Target model definition, SolidCAM creates a new sketch in the CAM component of the SolidCAM Part Assembly. This sketch is called an Envelope. It contains the geometry that is 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 specified solid bodies. 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.

Solid body

Section

Surrounding revolution

body

Envelopeprofile

35


The Envelope takes into account all the 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.

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.

Make sure that the Envelope option is chosen in the Target section.

Now you have to define the Target model. Click on the Target model button.

The Target model dialog box is displayed. This dialog box enables you to define a 3D Model for the Target. Click on the Define 3D Model button.

The 3D Geometry dialog box is displayed.

Click on the solid body.

The model is highlighted.

Confirm the selection with the button.

The Target model dialog box is displayed again. Confirm it with the button.


3�

During the Target model definition, SolidCAM created the Envelope sketch in the CAM component of the CAM-Part assembly. The Envelope sketch contains an envelope of the target model. The Envelope sketch will be used later for the turning geometry definition.

15. Set the Facet tolerance

In the Turn-Mill Part data dialog box, set the Facet tolerance to 0.01.

Setting a more precise tolerance such as 0.01 enables you to perform a smoother simulation of the tool path.

16. Save the CAM-Part

In the Turn-Mill Part data dialog box, click on the Save & Exit button. 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.

37


SolidCAM Manager

The SolidCAM Manager is the main interface feature of SolidCAM. It displays complete information about the CAM-Part.

The SolidCAM Manager tree contains the following elements:

• CAM-Part header

This header displays the name of the current SolidCAM CAM-Part. By right-clicking on it, you can open the menu to manage your CAM-Part.

The CoordSys Manager and Target subheaders are located under the CAM-Part header. Double-click on these subheaders to load the appropriate dialog boxes.

The CoordSys Manager enables you to define a new CoordSys or edit the definition of an existing one.

The Target model dialog box enables you to edit the definition of the Target model.

SolidCAMManager

CAM-Part Header

Tool Header

Machining ProcessesHeader

Geometries Header

Operations Header

Operations


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• Tool header

This header displays the name of the current Tool Table. Right-click on the Tool header to open the menu that enables you to manage the Tool Tables.

• Machining Process header

This header displays the name of the current Machining Process Table. Right-click on the Machining Process header to open the menu that enables you to manage the MP Tables.

• Geometries header

This header displays all the SolidCAM geometries that were not used in the Operations. You can get the list of these geometries by clicking on the „+“ icon near the Geometries header. You can open the Geometries menu by right-clicking on the Geometries header. You can also display the relevant menu by right-clicking on each Geometry name.

• Operations header

This header displays the list of all SolidCAM Operations defined on the current CAM-Part. The Operations menu is available by right-clicking on the Operations header. You can also display the relevant menu by right-clicking on each Operation name.

17. Close the CAM-Part

Right-click on the CAM-Part header in the SolidCAM Manager and choose Close from the menu.

The CAM-Part is closed.

Turning with Turn-MillCNC-Machines 3


40

SolidCAM enables you to perform all types of turning operations.

The turning geometry has to be located in the XZ plane of Machine CoordSys #1 and can be defined directly on the solid model.

The turning operations are common for all types of Turn-Mill CNC Machines.

Z X

TurningGeometry

Operations

Threading Operation

Grooving Operation

Turning Operation

Drilling Operation

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Turning Operation

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

Grooving Operation

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

Drilling Operation

This operation enables you to perform drilling at 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 a thread. The thread could be either longitudinal (internal or external) or facial. This operation can be used at present only if the CNC machine has a thread cycle. SolidCAM will output the tool path for the thread exactly with the same length as the defined geometry without doing any checks for material collision.

For more detailed explanation on the turning operations please refer to the SolidCAM Turning User’s Guide.


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Exercise #2: Turning

This exercise uses the CAM-Part created in Exercise #1. In this exercise, you define the Turning Operation to machine the outside faces of the model and prepare it for the next milling operations. During the Operation definition process you have to define the machining geometry, the tool and the technological parameters.

1. Open the CAM-Part

Click on SolidCAM in the SolidWorks main menu and choose the Open item.

In the browser window, choose Exercise1 – the CAM-Part prepared in the previous exercise.

The CAM-Part is loaded.

2. Add an Operation

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

The Turning Operation dialog box is displayed.

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3. Define the Geometry

You have to define the machining geometry for the turning operation using the Envelope sketch that was automatically generated during the Target model definition process described in Exercise #1.

Click on the Define button in the Geometry name field of the Turning Operation dialog box.

The Geometry Edit dialog box is displayed in the SolidWorks PropertyManager area. It enables you to add and edit geometry chains.

The Geometry Edit dialog box also enables you to set options for the Geometry selection.

The default option is Curve. This option enables you to create a chain of existing curves and edges by selecting them one after the other.


44

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

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.

Use the Reverse button to reverse the direction of the chain, during or after the chain selection, if necessary.

Click on the next sketch entity as shown.

In the Geometry Edit dialog box, select the Auto-To Point Mode check box.

Choose the Auto-General option.

Auto-To Point Mode

The chain is selected by specifying the start curve, the direction of the chain and the vertex up to which the chain is created. This command is useful if you prefer not to define a closed chain, but an open chain up to a certain point.

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Auto-General

SolidCAM highlights all entities that are connected to the last chain entity. You have to select the entity along which you want the chain to continue.

With the Auto-To Point Mode / Auto-General option you have to define the end point of the chain. Click on the vertex as shown.

The complete chain is selected and highlighted.

In the Extension field, set both Start length and End length to 2.

The Extension option enables you to extend the selected geometry tangentially.

Start length

The extension value from the start of the geometry.

End length

The extension value from the end of the geometry.


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In this exercise, the geometry has to be extended in order to enable the tool to enter and exit outside the machining geometry.

Click on the Accept Chain button to finish the chain definition.

Confirm the Geometry Edit dialog box with the button.

4. Define the Tool

In this step, you have to define the tool for the turning operation.

Click on the Select button in the Tool area of the Turning Operation dialog box.

The Part Tool Table dialog box is displayed.

The Part Tool Table is the tool table that contains all the tools available for use within a specific CAM-Part. The Part Tool Table is stored within the CAM-Part.

The Part Tool Table dialog box enables you to manage the tools contained in the Part Tool Table.

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Click on the Add Turn button in order to start the turning tool definition. A new turning tool is defined with the SolidCAM default parameters and added to the Part Tool Table.

The selected tool is an External roughing tool.

Click on the Select button to choose the defined tool for the current Turning Operation.

For a more detailed explanation of the turning tools parameters, please refer to the SolidCAM Turning User’s Guide.

The Tool dialog box is displayed. This dialog box displays the parameters of the chosen tool.

Confirm this dialog box with the OK button.



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5. Define the technological parameters

In this exercise, use the default technological parameters. The operation parameters are explained below:

Process type: Long

This option enables you to execute longitudinal turning (principal working direction is the Z-axis direction).

Mode: External

This option enables you to execute external longitudinal turning (above the geometry and parallel to the Z-axis).

Compensation: No

The radius of the tool nose is not taken into account when calculating the tool movements. No tool nose radius compensation (G41/G42) is used in the G-Code.

Work type: Rough

The tool movements are performed parallel to the Z-axis with the specified down step.

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Modify Geometry: Falling down movement

When this option is activated, the tool machines the whole part penetrating the “closed” areas where the approach from the outside is impossible. In this case SolidCAM takes into account the tool geometry thus preventing gouges.

Down step: Constant

The Rough machining is performed with the specified constant down step.

Semi-Finish: No

A semi-finish pass is a single pass that is executed before the finish pass, at an offset from the geometry. In this exercise there is no Semi-Finish.

Finish: ISO_Turning_Method

The finish pass is a single pass that is executed at the end of the operation. The finish pass is executed; the tool moves in the direction of the geometry.

Safety Distance: 2

This field has the following two functions:

• It affects the start and end position of the tool and defines the safety distance from the material at which the tool box is positioned at the start and end of the Operation.

• It defines the length with which the tool paths are extended outside the material at the end of every tool path. The tool paths are extended only when needed in order to make sure that the tool does not drop in the Rapid mode into the material between one down step to the other.

Profile direction: Default

These options enable you to perform the tool movements in the direction defined by the machining geometry.


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Use cycle: No

This field enables you to decide whether the turning cycles of the CNC machine are used (Yes) or the tool path movements are generated by SolidCAM (No).

Semi-finish / Finish on

With this option, SolidCAM enables you to recognize and machine the rest material areas left unmachined after the previous operations. In this exercise, this option is not used.

6. Calculate the Operation

Click on the Save & Calculate button in the Turning Operation dialog box. The operation data is saved and the tool path is calculated.

7. Simulate the Operation

Click on the Simulate button in the Turning Operation dialog box.

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The Simulation control panel is displayed.

SolidCAM enables you to simulate the calculated turning tool path using the following simulation modes:

Host CAD

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.

Turning

This mode enables you to see the simulation of the turning tool paths on the section view.

3D

This mode enables you to display the tool path on the 3D Model.

The target model must be defined when you use this simulation mode.

SolidVerify

This mode enables machining verification on the solid stock model. The solid stock model defined by material boundaries is used in this mode. During the machining simulation process, SolidCAM subtracts the tool movements (using solid Boolean operations) from the solid model of the stock. The remaining machined stock is a solid model that can be dynamically zoomed or rotated.

Rest Material

This mode enables you to display the model with the rest material before and after each Operation. It also displays the existing gouge areas so that they can be prevented in real machining.

The target model must be defined when you use this simulation mode.


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8. Host CAD Simulation

Click on the Play button on the Simulation control panel.

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.

9. Turning Simulation

Switch to the Turning page on the Simulation control panel.

Click on the Play button. The tool path is simulated.

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In the Show area of the Simulation control panel, switch to the Both mode. This mode enables SolidCAM to display both the material and the tool path during the simulation.

Simulate the tool path again.

10. SolidVerify simulation

Switch to the SolidVerify page on the Simulation control panel.

The stock model is displayed in the simulation window.


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Click on the Play button. The simulation is performed.

11. Rest Material simulation

Switch to the Rest Material page on the Simulation control panel.

Choose the Before Operation option on the Simulation control panel. This option displays the CAM-Part in its initial state before the Operation. The Stock model is displayed.

SolidCAM displays the Target model and the rest material that has to be removed.

Choose the After Operation option on the Simulation control panel. This option displays the CAM-Part in its state after the Operation.

SolidCAM displays the Target model and the rest material that has to be removed during the next milling operations.

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12. Close the simulation

Click on the Exit button on the Simulation control panel.


13. Close the Turning Operation dialog box

In the Turning Operation dialog box click on the Exit button.

The dialog box is closed.





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Milling with Turn-MillCNC-Machines 4


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

Profile Operation

You can mill on or along a contour. The profile geometry can be either open or closed. In profile milling, you can optionally use tool radius compensation to the right or the left side of the geometry. SolidCAM offers two types of profiling:

• Milling a single profile to a specified constant or variable depth in one step or in several user-defined down steps.

• Concentric profiles to a 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 finishes on the profile geometry, thus clearing the area around the profile to a constant depth.

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 is enclosed or intersects with 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.

Operations

Profile Operation

Slot Operation

Pocket Operation

Drill Operation

3D Milling Operation

3D Engraving Operation

Translated Surface Operation

3D Drill Operation

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Slot Operation

This operation generates a tool path along the center line, to the right or to the left of one or more profiles. Two types of slots can be defined:

• In Slot with constant depth, SolidCAM machines the slot in several down steps until it reaches the final depth.

• In Slot with variable depth, the depth profile is defined by a 2D section.

A slot can be machined in 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 the parameters for a right and left extension and side step, you can mill a slot wider than the tool diameter.

Drill Operation

This operation enables you to perform 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 Post-processor program (GPPTool).

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.

3D Milling Operation

You can perform 3-axis gouge-free machining on solid and surface models. This operation offers a wide range of roughing, semi-finishing and finishing strategies for free-form models. It can be used to manufacture molds, dies, electrodes, prototypes and other 3D Models.


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3D Drill Operation

This operation enables you to perform drills and other canned drill cycles, while taking into account the solid model geometry. SolidCAM uses the holes prepared in this operation for the descent during 3D Model roughing.

3D Engraving Operation

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

For a more detailed explanation on the milling operations, please refer to the SolidCAM Milling User’s Guide.

It is necessary to choose the CoordSys and the Geometry for each Milling Operation. The combination of the Coordinate System and the Geometry enables you to define the machining area.

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4.1 Facial Milling on XZC Machines

SolidCAM enables you to perform facial milling on Turn-Mill CNC-machines of the XZC type. In facial milling, the tool axis is parallel to the revolution axis of the part. Machine CoordSys #1 is used for this operation. The Geometry is defined directly on the solid model.

According to the limitations of this type of CNC-machine, SolidCAM transforms all linear movements in the XY plane to XC coordinates.

Z

X

Machine CoordSys #1

Machining Geometry


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Exercise #3: Facial Milling

This exercise illustrates the capabilities of facial milling. The CAM-Part prepared in Exercises #1 and #2 is used. During the facial milling operation, the hexagon and the adjacent faces of the model are machined with the Profile Operation.

1. Load the CAM-Part

Load the CAM-Part Exercise1 prepared in the previous exercises.

2. Add an Operation

Right-click on the last Turning Operation subheader in the SolidCAM Manager and choose Profile from the Add Milling submenu.

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The Profile Operation dialog box is displayed.


The Geometry area 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.

The Geometry has to be located in the plane parallel to the XY plane of the Machine CoordSys #1.

Z

X

Machine CoordSys #1

Machining Geometry


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Click on the Define button in the Geometry area.

The Geometry Edit dialog box is displayed.

In the Multi-Chain section, click on the Add button.

The Chains Selection dialog box is displayed in the SolidWorks PropertyManager area.

The Chains selection dialog box enables you to choose a number of chains from a model by selecting the model elements. The chains are created automatically from the selected elements.

Click on the front face of the model hexagon as shown.

The face is selected.

Click on 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 with the button.

The Geometry is defined for the operation.

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4. Define the Tool

Click on the Select button in the Tool area.


The Part Tool table displays all the tools that can be used in the CAM-Part machining. Currently, the Part Tool Table contains only one tool used for the turning operation provided in the previous exercise. For this operation, you have to define a new milling tool.

In the Part Tool Table dialog box, switch to the Edit page and click on the Add Mill button. A new milling tool is defined.


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5. Edit the Tool parameters

By default, SolidCAM offers you an end mill tool Ø6. Edit the tool definition by setting the following parameters:

Set the Diameter to 10.

Set the parameters in the Length area:

• Set the Total to 60;

• Set the Outside Holder to 40;

• Set the Cutting to 35.

Click on the Select button to confirm the tool definition.

The Tool dialog box is displayed.

Click on the OK button to confirm the tool selection.

The tool is defined.

Total Length

CuttingLength

Outside HolderLength

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6. Set the Machining depth

Click on the Profile depth button in the Milling levels area.

The Pick Lower level dialog box is displayed.

SolidCAM enables you to define the Lower level directly on the model. The Profile depth is calculated automatically relative to the Upper level.

Click on the model face as shown.

The picked value (-10) is displayed in the Pick Lower level dialog box. Confirm your selection by clicking on the button. The Profile Operation dialog box is displayed.

The Profile depth 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 either 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 pink.


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7. Set the Tool side

Tool Side

The Tool side parameter enables you to decide on 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.

Middle – the center of the tool moves on the profile geometry (No compensation G4x can be used with this option).

The Show Tool button displays the chain geometry of the profile, its direction and the circle that represents the tool relative to the geometry. The display uses the current settings in the Profile direction and Tool side fields.

Click on the Show Tool button to check the tool location relative to the selected geometry.

As you see, the tool side offered by the default is not suitable. The Tool is located inside the defined geometry. The Tool side has to be changed.

Close the Show Geometry dialog box with the button.

Set the Tool Side to Right.

Left Right Middle

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Check the tool location relative to the geometry again with the Show Tool button in order to make sure that the tool is located properly.

8. Define the Rough and Finish parameters

SolidCAM enables you to perform the rough and finish machining of the profile within a single Profile Operation.

Now you have to define the parameters of the profile roughing.

Select the Rough check box.

SolidCAM enables you to set the following offsets in order to define the allowances for rough and finish machining:

Wall offset

This parameter defines the allowance for the profile finish machining. This allowance can be removed either in the same Profile Operation or in an additional Profile Operation with another tool.

Clear offset

This parameter generates several concentric profiles with a constant depth that starts at the defined clear offset distance from the profile and finishes at the geometry of the profile, thus clearing the area around the profile.

• The Offset value defines the distance from the geometry at which the milling starts. The Clear offset value should be equal or greater than the Wall offset value. The tool starts milling the profile at the distance defined by Clear offset and finishes at the distance defined by Wall offset; the overlap of the adjacent tool paths is defined by Step over.


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• The Step over value defines the overlap of adjacent tool paths. It determines the offset between two successive concentric profiles.

• The ZigZag option enables you to create the tool path for the Clear offset removal containing both climb and conventional movements.

• The One Way option enables you to create the tool path for the Clear offset removal containing only climb movements.

Wall offset

Step over

Geometry

Clear offset

Clear offsettool path

Profilegeometry

Clear offsettool path

Profilegeometry

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Define the Wall offset. Set the value to 0.2.

This setting means that the allowance of 0.2 mm is left during the profile roughing, and it is removed with a separate finish cut at the end of the profile machining.

SolidCAM enables you to define the Step down parameter for Roughing. With this parameter, SolidCAM performs a number of cuts defined by the Step down in order to reach the final machining depth (Profile depth).

Set the Step down to 3. With this value, SolidCAM performs three cuts on the depth defined by the Step down: -3; -6; -9. The last cut is performed on the depth defined by the Profile depth: -10.

Select the Finish check box. The finishing of the Profile will be performed. The Step down for the profile finishing is 5 mm.

9. Define the Lead in and the Lead out

SolidCAM enables you to define the way the tool approaches the profile and retreats from it.

The following options are available:

None

The tool approaches to and retreats from the milling level exactly adjacent to the start point of the profile.

Normal

The tool approaches to and retreats from the profile from a point normal to the profile. The length of the normal can be set in the Value box.

Approachvalue


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Arc

The tool approaches to and retreats from the profile on a tangential arc. The arc radius can be set in the Value box.

Tangent

The tool approaches to and retreats from a profile on a line tangent to the profile. The length of the tangent can be set in the Value box.

Point

The tool approaches and retreats from a user-defined position. From this position the tool moves in a straight line to the start point of the profile. When you choose this option, the Pick button is activated, and you can select a position directly on the solid model.

Set the Tangent option for the Lead in and the Lead out.

Set the Value to 5 for both parameters.

The definition of the basic technological parameters of the profile milling is finished. Now you have to define a number of parameters and options relative to the machining on the Turn-Mill machine of the XZC type.

Approachvalue

Normal

Approachvalue

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10. Define the 4th Axis parameters

Click on the 4th Axis button.

The 4th Axis dialog box is displayed.

This dialog box enables you to define the technological parameters of the facial milling on Turn-Mill CNC machines.

4th Axis type: Face

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

Coordinate type

This field enables you to determine whether the G-code for simultaneous 4th axis milling consists of split blocks or blocks in Cartesian or Polar coordinates. It contains three options:


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• Split

In this option, the tool path is split into many blocks according to the specified error. The blocks consist of rotary and linear movements according to the plane.

• Polar

This option appears only if the polar_4x = Yes is defined in the Mac file. The tool path lines and arcs are calculated in polar coordinates. The CoordSys position is zero for linear and rotary coordinates.

• Cartesian

This option appears only if the cartez_4x = Yes is defined in the Mac file. 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 movement into the rotary-linear movement according to the plane.

Tolerance

The tool path lines and arcs are split into many blocks that do not exactly generate the required tool path. The Tolerance field defines the maximum allowed error; the smaller is the value of this field, the greater is the number of G-code blocks generated.

Set the Coordinate type to Cartesian. Confirm the dialog box with the OK button.

11. Calculate the Tool path

Click on the Save & Calculate button. The operation data is saved and the tool path is calculated.


Click on the Simulate button in the Profile Operation dialog box.

The Simulation control panel is displayed.

Switch to the SolidVerify page and start the simulation with the button.

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When the simulation is finished, click on 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.

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 on the button to continue.

The Z-change option enables you to see the tool path simulation in detail.

Exit the simulation.

13. Close the Operation dialog box

Click on the Exit button.

The Profile Operation dialog box is closed.





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4.2 Indexial 4-Axis Milling on XZC machines

SolidCAM enables you to perform indexial 4-axis milling operations on Turn-Mill CNC-machines of the XZC type. In these operations, the C-axis is used for positioning of the part. The positioned part is then milled using XZ-movements.

Note that this type of Turn-Mill Machines has no possibility of Y-axis movement. This applies the following restriction on the use of indexial 4-axis milling: the axis of the tool must always intersect with the revolution axis of the part.

For example, the XZC machine can be used for the following operations:

• Face milling

The tool must be larger than the machining area (see the picture).

• Slot (key grooves) machining

Indexial 4-axis milling on XZC machines can be used for the machining of slots (key grooves) with the symmetry plane intersecting the part revolution axis.

• Hole machining

Indexial 4-axis milling on XZC-machines can be used for the machining of the holes when the hole axis intersects with the revolution axis of the part.

Z

X

C

Positioning Machining

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Exercise #4: Indexial 4-Axis Milling

This exercise covers the SolidCAM functionality for indexial 4-axis milling using Turn-Mill CNC machines of XZC type. The exercise uses a predefined CAM-Part with defined turning operations.

The CAM-Part after the turning The complete CAM-Part after the milling

The milling is performed by Profile and Drill Operations to machine each dodecahedron face and drill two holes on it. The circular pattern of these two operations is used to machine the other faces and holes.

1. Open the CAM-Part

Open the CAM-Part Exercise4.prt.

2. Simulate the CAM-Part

This CAM-Part contains a number of turning operations for the external and internal faces.

Right-click on the Operations header in the SolidCAM Manager and choose Simulate from the menu.

This command enables you to simulate the complete CAM-Part.

The Simulate command is also available for each operation separately by right-clicking on the specific operation icon in the SolidCAM Manager.


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Play the SolidVerify simulation.

Close the Simulation control panel and return to the SolidCAM Manager.

3. Define the CoordSys Position

SolidCAM enables you to define a number of CoordSys Positions for indexial 4-axis milling directly on the solid model. These positions correspond to the Machine Coordinate System #2. The geometry for the machining has to be located in the plane parallel to the XY plane of such CoordSys Position.

In the SolidCAM Manager tree, double-click on the CoordSys Manager header.

The CoordSys Manager dialog box is displayed in the SolidWorks PropertyManager area.

In the CoordSys Manager dialog box, right-click on the Machine Coordinate System #2 (Mac 2) and choose the Add command from the menu.

CoordSys

Machiningplane

Geometry

Z

XY

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The CoordSys dialog box is displayed.

4. Select the face


Note that you have to select the face containing the line sketch that is used in the next steps for the milling geometry definition.

The origin of the CoordSys Position #2 is defined at the origin of the Machine Coordinate System #2.

Click on the Finish button to confirm the CoordSys dialog box. Confirm the CoordSys data dialog box with the OK button.

The defined CoordSys Position #2 is displayed in the CoordSys Manager dialog box.

Close this dialog box with the button.


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5. Add a Profile Operation

Right-click on the last turning Operation icon in the SolidCAM Manager and choose Profile from the Add Milling submenu.


6. Choose the Coordinate System

Choose the Position #2 of the Machine Coordinate System #2 (Mac 2 - Position 2) in the CoordSys box of the Geometry area.

This CoordSys Position is used for the profile milling of the dodecahedron face.


Click on the Define button in the Geometry area. The Geometry Edit dialog box is displayed.

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Select the predefined sketch line as shown.

Make sure that the selected geometry chain direction is from the model front face backwards. You can change the direction using the Reverse button.

Click on the Accept Chain button to confirm the chain selection.

Close the Geometry Edit dialog box with the button.

The geometry is defined.

8. Define the Tool

Click on the Select button in the Tool area to choose a milling tool for the operation.


The Part Tool Table contains the tool #4 (End Mill Ø16) suitable for this operation.

Select the tool in the table and click on the Select button.


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The Tool dialog box is displayed with the parameters of the selected tool.


9. Define the Machining depth

Click on the Upper level button in the Milling levels area. This button enables you to define the plane where the machining will start directly on the solid model.

Click on the model face that contains the profile geometry as shown.

The value (25) of the Upper level is displayed in the Pick Upper level dialog box. Confirm your selection with the button.

Click on the Profile depth button in the Milling levels area. This option enables you to define the machining depth directly on the solid model.

Click on the same model face. The value of the Lower level is displayed. Confirm your selection with the button.

The Profile depth is calculated automatically according to the Upper and Lower levels values. The 0 value of the Profile depth means that the machining is performed in a single Z-step.

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10. Define the Tool side

Define the tool position relative to the selected geometry. Choose the Middle option in the Tool side box.

When the Middle option is chosen, the center of the tool moves on the profile geometry.

Click on the Show Tool button.

As you can see, the tool completely covers the face to be milled.

Click on the button to return to the Profile Operation dialog box.


Choose the Tangent option for the Lead in and the Lead out.

Set the Lead in value to 10. The tool enters the material tangentially to the Geometry from outside the material.

Set the Lead out value to 1. This tangential lead out movement enables the tool to completely machine the geometry.

12. Calculate the Operation

Click on the Save & Calculate button to save the Operation data and calculate the tool path.


Click on the Simulate button and choose the SolidVerify mode for the simulation.

Play the simulation.


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During the SolidVerify simulation, you can use the View operation 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-and-drag of the middle mouse button.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.

Close the simulation and exit from the Profile Operation dialog box.

The SolidCAM Manager is displayed.

14. Add a Drill Operation

Right-click on the just defined Profile Operation in the SolidCAM Manager and choose Drill from the Add Milling submenu.

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The Drill Operation dialog box is displayed.

15. Choose the Coordinate System

In the Geometry area, choose the same CoordSys position (Machine CoordSys #2, Position #2) that was used in the previous operation.

16. Define the Drill geometry

In the Geometry area, click on the Define button to start the geometry definition.

The XY Drill Geometry selection dialog box is displayed.

This dialog box enables you to select the drill positions.

Select/Unselect drill centers

You can switch between the Select/Unselect mode to define or remove drill positions from the geometry. The Undo/Redo button deletes or restores the last selection. All selected points are shown in the list at the bottom of the dialog box. To remove a point from the list, right-click on the point name in the list and choose the Delete option from the menu or choose the Delete All option to remove all points.


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Selecting modes (Select drill centers by)

You can add drill positions to the current geometry. The Selection field contains three options.

• Pick position

You can define the Drill positions one by one using the CAD point selection options. You can also type the coordinates (X,Y,Z) into the Edit bar and confirm each drill point by clicking on the Enter button of the Edit bar.

• 3 Points on circumference

Usually, all curves and arcs of imported models are converted into splines by the exporting CAD system. Due to the nature of spline curves or surface boundaries, you cannot pick a center position like you could on a circle or an arc. SolidCAM calculates the center position of an arc defined by three points positioned on the spline edges. This facilitates selecting drill centers on spline surfaces.

• Multi-positions

You can select circular edges of the solid model. The drill position is automatically defined in the circular edge center.

• All circle/arc centers

SolidCAM searches the solid model for arcs and circles parallel to the XY plane of the current Coordinate System and add all center points as drill positions to the geometry.

CAD selection

SolidCAM enables you to select the drill geometry with the host CAD tools.

For more information about the Drill Geometry Selection dialog box functionality, please refer to the SolidCAM Milling User’s Guide.

Choose the All circle/arc centers option in the Select centers by field. Click on the All circle/arc centers button to search for all the circular edges parallel to the XY plane of the CoordSys Position.

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Two circular edges are recognized and their center points are selected.

Click on the button to confirm the geometry definition.

17. Define the Tool

Click on the Select button in the Tool information area.


The Part Tool Table contains a tool suitable for this operation.

Select tool #5 in the Part Tool Table and click on the Select button.


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This dialog box displays the parameters of the chosen tool and enables you to change them.

Click on the OK button to confirm the tool choice.


18. Define the Drill depth

Click on the Upper level button to define the upper machining level directly on the solid model.

Click on the face as shown.

In the Pick Upper level dialog box, click on the button to confirm the selection.

Set the Drill depth value to 15.

19. Define the drilling cycle

Click on the Drill cycle type button.

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The Drill cycle dialog box is displayed.

SolidCAM enables you to use several types of Drill canned cycles supported by the post-processor of the current CNC-controller.

Examples:

Drilling. The drill travels in one single motion to the specified depth and retracts.

Peck. The drill travels in steps to the specified depth. At each depth step the tool rapidly retracts to the safety distance. Then the tool rapidly returns to the point where it must continue drilling. This sequence is repeated until it reaches the final depth.

Tapping. The tap travels in one single motion to the specified depth and then retracts reversing its spin direction.

Choose the Peck option.

In the Drill cycle area, click on the Data button to specify the pecking parameters.

The Drill Options dialog box is displayed.

This dialog box enables you to define the parameters of the chosen drill canned cycle.


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Delay

Enter the amount of time (in seconds) you want the tool to pause at the end of each step in the hole.

Step down

Enter the depth that you want the tool to travel at each step.

Set the Step down to 2 and click on the OK button to confirm the dialog box.

20. Save and Calculate the Operation

Click on the Save & Calculate button to save the Operation data and calculate the drilling tool path.


Click on the Simulate button. The Simulation control panel is displayed.

Simulate the tool path using the SolidVerify mode.

Close the Simulation control panel. Close the Drill Operation dialog box.

22. Define the Operations pattern

At this stage, the operations definition is finished. Now you have to define a circular pattern of the operations around the revolution axis of the CAM-Part in order to machine all of the dodecahedron faces.

In the SolidCAM Manager tree, select the last two operations (Profile Operation and Drill Operation) with the Ctrl button pressed.

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Right-click on one of these operations and choose the 4th Axis option from the Transform submenu.

The Rotate List dialog box is displayed.

This dialog box enables you to define a circular pattern of the operations around the revolution axis of the CNC-Machine (C-axis).

Set the Angle value to 30. This value defines the rotation angle for each pattern instance.

Enter 11 for the number of instances.

Click on the Add button. A specific value of the rotation angle is calculated for each instance of the pattern.

Select the Include Original check box. This enables you to include the original operations into the pattern.

Confirm the dialog box with the OK button.


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Note that the Profile and Drill operations icons are marked with the icon. This icon means that the operations were transformed using the C-axis.

23. Simulate the Operations

Right-click on the selected Profile and Drill Operations and choose Simulate from the menu.

Simulate the tool path in the SolidVerify mode.

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4.3 Simultaneous 4-Axis milling on XZC machines

SolidCAM enables you to perform simultaneous 4-axis milling on Turn-Mill CNC-machines of the XZC type. Machine Coordinate System #2 Position #1 is used for the geometry definition for simultaneous 4-axis milling.

Note that according to the limitations of this CNC-machine type, the tool axis always intersects with the part revolution axis.

XZ

Machine CoordSys #2

ZC


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Exercise #5: Simultaneous 4-Axis Milling

This exercise illustrates the SolidCAM capabilities for simultaneous 4-axis milling using Turn-Mill CNC-machines of the XZC type. This exercise uses the pre-machined CAM-Part defined in the previous exercises.

The wrapped elliptical pocket is machined in this exercise.

1. Load the CAM-Part

Load the CAM-Part Exercise1 prepared in Exercises #1-3.

2. Add an Operation

Right-click on the last operation header in the SolidCAM Manager and choose Pocket from the Add Milling submenu.

The Pocket Operation dialog box is displayed.

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In the Geometry area, choose the CoordSys (Mac 2, Position 1) suitable for the simultaneous 4-axis machining.

Click on the Define button to start the geometry definition.


Select the model edge as shown.

The confirmation message is displayed.

Click on the Yes button. The Geometry Edit dialog box is displayed.

Select the Wrap check box.


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When the Wrap option is not chosen, SolidCAM projects the selected Geometry on the XY plane of the Coordinate System. This projection is used for the tool path calculation.

When the Wrap option is chosen, SolidCAM unfolds the Geometry on the XY plane and uses it for the Tool path calculation.

Click on the button to confirm the Geometry selection.

The Pocket Operation dialog box is displayed.

4. Define the Tool

In the Tool area of the Pocket Operation dialog box, click on the Select button to add a new tool to the Part Tool Table and choose it for the operation.

XY plane

Model Edge

Unfolding

XY plane

Model Edge

Projection

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The Part Tool Table is displayed.

Switch to the Edit page and click on the Add Mill button to define a new milling tool.

A new milling tool is added to the Part Tool Table. By default, this is a Ø6 end mill.

Click on the Select button to choose the tool for the operation.


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5. Define the Pocket depth

Click on the Pocket depth button in the Milling levels area. SolidCAM prompts you to pick the Lower Level directly on the solid model. The Pocket depth is automatically calculated according to the Upper and Lower levels.

Click on the bottom face of the wrapped pocket as shown below.

Confirm the lower machining level selection with the button in the Pick Lower level dialog box.

The Pocket depth is automatically calculated.

Set the Step down to 3.

6. Define the Pocket type

SolidCAM enables you to choose a number of strategies for the pocket machining:

• Contour machines the pocket in a round pattern.

• Hatch mills the pocket in a linear pattern.

• Hatch+Finish mills the pocket in a linear pattern and cleans up the profile on each cutting depth.

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• Clear machines an area that is half a tool diameter larger than the pocket geometry in a hatch-style linear pattern. This enables you to clean the upper face of a workpiece.

• Plunging pattern – the tool moves up and down in a drilling motion, travelling inside the pocket.

By default, SolidCAM offers you the Contour strategy.

With the Contour strategy, the tool moves at parallel offsets to the pocket contour.

7. Define the 4th axis options

Click on the 4th Axis button.


Geometry Tool Path


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When the Machine Coordinate System #2 is chosen for the operation and the wrapped geometry on the model is defined, SolidCAM automatically defines the 4th axis option for the operation.

Wrap

The full range of angles of the perimeter is supported when you draw a layout of the cylindrical material. The geometry is wrapped around the outside diameter by dividing each corresponding linear movement by the radius to generate the rotary axis rotation. The rotary axis rotation is therefore not limited to 360 degrees.

SolidCAM automatically determines the Diameter of the cylindrical surface on which the geometry is wrapped.

Click on the OK button to confirm the parameters.

8. Save & Calculate



Click on the Simulate button and simulate the CAM-Part using the SolidVerify simulation mode.

Play the simulation with the button.

Close the Simulation control panel.

Close the Pocket Operation dialog box with the Exit button.


Right-click on the CAM-Part header in the SolidCAM Manager and choose the Close item from the menu.

At this stage, the exercise is finished.

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Exercise #6: Bracket Machining

Define the CAM-Part and operations for the machining of the bracket presented on the illustration on Turn-Mill CNC-machine of the XZC type.

This exercise reinforces the following skills:

• CAM-Part definition;

• Turning;

• Facial milling;

• Indexial 4-axis machining.

The SolidWorks model of the Bracket (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 Material boundary, the Clamp and the Target model.

The XZC CNC-controller has to be chosen for this exercise.

2. Turning of the cylindrical faces

Define the turning operation to obtain the following revolution body.


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3. Drill three holes on the front face

Use two Drilling Operations to machine three holes on the front face of the model.

4. Machine side faces of the bracket

Define the Profile Operation to machine the side faces of the bracket using the facial milling feature.

5. Machine Holes on the cylindrical face

Define a Drill Operation to machine holes radially located on the cylindrical model face. Use the indexial 4-axis feature and define a circular pattern of the operations to machine all the holes.

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Exercise #7: Slotted Nut Machining

Define the CAM-Part and operations for the machining of the slotted nut presented on the illustration on Turn-Mill CNC-machine of the XZC type.



• Turning;

• Indexial 4-axis machining.

The SolidWorks model of the Slotted Nut (Exercise7.sldprt) is located in the ../Exercises folder.



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.


2. External turning



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3. Internal turning

Machine the internal faces of the model.

4. Machine the side faces

Machine the side faces of the Slotted Nut.

5. Machine the slots

Machine the slots located on the sides of the nut.

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Exercise #8: Stopper Machining

Define the CAM-Part and operations for the machining of the stopper presented on the illustration on Turn-Mill CNC-machine of the XZC type.



• Turning;

• Facial milling;

• Simultaneous 4-axis machining.

The SolidWorks model of the Stopper (Exercise8.sldprt) is located in the ../Exercises folder.



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.


2. External turning


2. Facial milling of the pentahedron

Machine the pentahedron using the facial milling feature.


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3. Pocket machining

Machine the pocket wrapped on the cylindrical surface of the stopper using the simultaneous 4-axis milling.

4. Helical Slot machining

Machine the helical slot wrapped on the cylindrical surface of the stopper using the simultaneous 4-axis milling.

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Exercise #9: Bushing Machining

Define the CAM-Part and operations for the machining of the bushing presented on the illustration on Turn-Mill CNC-machine of the XZC type.



• Turning;

• Facial milling.

The SolidWorks model of the Bushing (Exercise9.sldprt) is located in the ../Exercises folder.





2. External turning


3. Machining of the inner faces

Define a number of Turning Drill operations to obtain the following model faces.

4. Facial Drilling

Machine the circular pattern of drills using the facial milling feature.


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Exercise #10: Shaft Machining

Define the CAM-Part and operations for the machining of the shaft presented on the illustration on Turn-Mill CNC-machine of the XZC type.



• Turning;

• Facial milling;

• Radial milling.

The SolidWorks model of the Shaft (Exercise10.sldprt) is located in the ../Exercises folder.





2. External turning

Define a turning operation to obtain the following revolution body.

3. Facial Milling

Machine the highlighted model faces using the facial milling option.

4. Drilling

Machine three holes using the facial and radial milling option.

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4.3 Milling on Turn-Mill CNC-machines of the XYZC type

SolidCAM enables you to perform machining on the Turn-Mill CNC-machines of the XYZC type. This type of CNC-machines provides you with all functionalities of CNC-machines of the XZC type. In addition it provides the capability for Y-axis movements during facial and radial (indexial and simultaneous) milling (see topic 1.3.2).

X

C

Z

Y


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Exercise #11: Milling on XYZC Machines

This exercise covers the process of CAM-Part definition and Milling on Turn-Mill CNC-Machines of the XYZC type. The following model of support is used.

Since the CAM-Part definition process was explained in detail in Exercise #1, the details of this CAM-Part definition process are omitted.



This model contains a number of features forming the solid body and a few sketches that are used in the CAM-Part definition.

2. Start a new SolidCAM Turn-Mill part

Click on SolidCAM in the main menu of SolidWorks and choose Turn-Mill from the New submenu. SolidCAM is started and the New Turn-Mill Part dialog box is displayed. Confirm this dialog box with the OK button.

The Turn-Mill Part data dialog box is displayed.

3. Define the CNC-controller

In this exercise, the CNC-Machine of the XYZC type is used. Choose the XYZC CNC-controller from the list.

4. Define the Coordinate System

In the CoordSys area, make sure that the Multi-sided check box is selected. This option enables you to define the Coordinate System origin and the orientation of axes directly on the solid model.

Click on the CoordSys button to start the Coordinate System definition.

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Click on the cylindrical face of the model as shown.

The Z-axis of the Machine Coordinate System is collinear to the revolution axis of the part.

Click on the Change to opposite button in the CoordSys dialog box. The Machine Coordinate System is defined on the front face of the model.

Click on the Finish button to confirm the definition.

The CoordSys data dialog box is displayed. Close it with the OK button.



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Coordinate Systems for 4-axis Turn-Mill machine (XYZC type)

SolidCAM enables you to define Machine Coordinate System #1 with the Z-axis directed along the revolution axis.

This Machine Coordinate System is used for the turning operations; the turning tool movements are located in the ZX plane.

The Machine Coordinate System #1 is used also for facial milling, where the axis of the milling tool is parallel to the Z-axis of the Machine Coordinate System.

SolidCAM automatically creates the Machine CoordSys #2. This Coordinate System is used for radial milling (indexial and simultaneous 4-axis milling).

Z

XYMachine CoordSys #1

Machine CoordSys #1

Z

XY

C

Machine CoordSys #2

X

C

Z

Y

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The direction of the axes in the Machine CoordSys #2 is the following:

• The X-axis of the Machine CoordSys #2 is collinear with the Z-axis of the Machine CoordSys #1.

• The Z-axis of the Machine CoordSys #2 is collinear with the X-axis of the Machine CoordSys #1.

Confirm the CoordSys Manager dialog box with the button.



Click on the Material Boundary button. The Material Boundary dialog box is displayed in the SolidWorks PropertyManager area.

Choose the Cylinder option.

The Cylinder option enables you to define the Material boundary as a cylinder (or tube) surrounding the selected solid model. SolidCAM generates a sketch containing the envelope of the cylinder (or tube) surrounding the selected solid body. The Material boundary is automatically defined on this sketch.

Click on the Define button.

The Boundary (Cylinder) dialog box is displayed.

Click on the solid body in order to select it.

Specify the following parameters in the dialog box:

• Set the Right (+Z) value to 0. The front face of the stock material is coincident with the front face of the model.

• Set the Left (-Z) value to 20. This offset enables you to have stock at the back side of the model for the clamping.

• Set the External to 0. The external diameter of the stock is the same as the external diameter of the model.

• Set the Internal diameter to 40. The stock used in this exercise is a tube with this internal diameter.


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Confirm the parameters with the button.

The Material Boundary dialog box is displayed.

Close the Material boundary dialog box with the button.


6. Define the Clamp Geometry

As explained in Exercise #1, define a new sketch in the plane coincident to the XY plane of the Machine CoordSys #1 (Plane2).

Sketch the Clamp geometry as shown.

Confirm the sketch. This sketch is used in the next step for the Clamp geometry definition.

20Material boundary

Ø40

1520

2010

10

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7. Define the Clamp

In the Clamp area of the Turn-Mill Part data dialog box, click on the Main Spindle button.

The Clamp Geometry dialog box is displayed.

Click on the Define chain button.


In the same manner as explained in Exercise #1, select the chain geometry of the clamp.

Confirm the Clamp Geometry dialog box with the button.


After the Clamp is defined, you can hide the clamp sketch.


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In the Turn-Mill Part data dialog box, click on the Target model button.

The Target model dialog box is displayed.

Click on the Define 3D Model button to start the Target model definition.

Click on the solid body. It is highlighted.


The Target model dialog box is displayed. Confirm it with the button.


9. Save the CAM-Part

Click on the Save & Exit button in the Turn-Mill Part data dialog box.

The CAM-Part is saved and the SolidCAM Manager tree is displayed.

At this stage the CAM-Part definition is finished. Now you have to define a number of technological operations in order to machine the part.

10. Define a Profile Operation

Define a new Profile Operation to machine the step presented on the illustration using the facial milling capabilities of XYZC machines.


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The facial milling is used for this Operation. Make sure that the Machine CoordSys #1 Position #1 is chosen for the operation.

Click on the Define button in the Geometry area to start the tool definition.



Click on the Accept Chain button in the Geometry Edit dialog box to confirm the chain selection.

Close the dialog box with the button.

The geometry for the operation is defined.

12. Define the Tool

Click on the Select button in the Tool area.


Switch to the Edit page.

Click on the Add Mill button to define a new milling tool.

A new tool is defined.


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Under User tool type, choose End Mill. Set the Diameter to 10.

Click on the Select button to choose the defined tool for the operation.

The Tool dialog box is displayed. Note that the From Face option is chosen in the Direction section.

Direction

The direction of machining is determined by the choice of Coordinate System position. The Coordinate System chosen for the current operation (Mac CoordSys #1 Position 1) requires the tool to be oriented relative to the part in such way that facial milling is performed, therefore Direction is automatically set to From Face. Whenever another CoordSys position is chosen to perform the outside-diameter machining, Direction is automatically set to From OD.

From OD

Turret

From Face

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Confirm the Tool dialog box with the OK button.

Click on the Data button in the Tool area. The Operation Tool Data dialog box is displayed.

This dialog box enables you to define the tool spin and feed for the operation.

Spin

This parameter defines the spinning speed of the tool. It defines two spin values:

• Spin Rate – normal spin rate used in rough milling;

• Spin Finish – finish spin rate used in finish milling.

The spin value can be defined in two types of units: S and V.

S is the default and it signifies Revolutions per Minute. V signifies Material cutting speed in Meters per Minute in the Metric system or in Feet per Minute in the Inch system; it is calculated according to the following formula:

V = (S * PI * Tool Diameter) / 1000

Feed

This parameter defines the feed rate of the tool. It defines three feed values:

• Feed XY – the feed rate in the XY plane.

• Feed Z – feed-rate in the Z direction.

• Feed Finish – Feed-rate used for finish milling.

The feed value can be defined in two types of units: F and Fz.


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F is the default and signifies Units per minute. Fz signifies Units per tooth and is calculated according to the following formula:

Fz = F/(Number of Teeth * S)

Define the parameters in the following way:

• Set the Spin Rate parameter to 1500.

• Set the Spin Finish parameter to 2000.

Confirm the dialog box with the OK button.

The Profile Operation dialog box is displayed again.

13. Define the Milling levels

Click on the Profile depth button in the Milling levels area to define the machining depth directly on the solid model.


Confirm the Pick Lower level dialog box with the button.

14. Specify the technological parameters

In the Tool side area, click on the Show tool button to check the tool location relative to the profile.

If the tool is located at the wrong side, change the Tool side to Left.

For more information on the Tool side definition, please refer to the Step 7 of the Exercise #3.

Select the Rough check box in order to perform the Rough machining of the Profile. Set the Wall offset to 0.2.

The offset of 0.2 mm is left on the profile during machining. This offset is removed in a separate cut at the end of the profile machining.

In the Clear offset area, set Offset to 10. Set Step over to 5.

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The profile is machined with two equidistant profiles located at the offset of 5 mm.

For more information on the Offsets definition, please refer to Step 8 of Exercise #3.

Set the Step down to 5. The material is removed with several Z-cuts.

The finish section is activated. The finish machining of the profile will be performed. Set the Step down for the finishing to 5.

Choose the Tangent option for the Lead in and Lead out. This option enables the tool to approach the material from outside tangentially to the profile.

Set the Lead in value to 3.

Set the Lead out value to 1.

In this case, you do not have to use the 4th axis options to translate XY-movements into XC-movements. The XY-movements are supported by this CNC machine type.

At this stage, the definition of the technological parameters is finished. Click on the Save & Calculate button to save the operation data and generate the tool path.


In the same manner as explained earlier, simulate the operation using the SolidVerify simulation mode.

When the simulation is finished, close the Profile Operation dialog box with the Exit button.


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16. Add a new CoordSys position

In order to machine the top face of the part and the pocket, you have to define an additional Coordinate System Position related to the Machine CoordSys #2. The Z-axis of this CoordSys Position has to be normal to the top face.

With the (+) icon, expand the CAM-Part item in the SolidCAM Manager tree.

Double-click on the CoordSys Manager header.

The CoordSys Manager dialog box is displayed.

Right-click on Mac 2 in the dialog box and choose Add from the menu.


Note that the Mac CoordSys number is 2 and the Position number is 2. Now SolidCAM can define CoordSys Position #2 related to Machine Coordinate System #2.

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Click on the face as shown.

The CoordSys Position origin is defined in the same location as the Machine CoordSys #1. The Z-axis of the Position is normal to the selected face.

Click on the Finish button to confirm the CoordSys Position definition.


The Part upper level and Part lower level values are determined automatically according to the solid model.

Set the Part upper level value to 35 in order to take into account the full cylinder of the stock.

Confirm the CoordSys data dialog box with the OK button. The CoordSys Manager dialog box is displayed again. Close it with the button.

PartUpper Level

PartLower Level

MachineCoordSys #2

28

35


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17. Define a new Pocket Operation

Define a new Pocket Operation to machine the model face using CoordSys Position #2.


In the Geometry area, choose the Machine CoordSys #2, Position #2.

Define the pocket chain directly on the solid model.

19. Define the Tool

In the Part Tool Table, define a new Ø10 end mill.

In the previous operation, you used an end mill with the same parameters, i.e. the Part Tool Table already contains a Ø10 end mill. In this operation, you are required to define a new tool with the same diameter, because in this operation you are working with another Coordinate System position that requires different direction of machining (From OD). Therefore, you cannot use the Ø10 end mill defined in the previous operation.

For a detailed explanation of machining direction, see Step #12.


Click on the Pocket depth button in the Milling levels area.

Define the Lower level directly on the solid model as shown.

Set the Step down to 3.5.

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21. Define the Pocket strategy

In the Pocket type area, choose the Clear option.

The Clear strategy machines an area that is half a tool diameter larger than the pocket geometry in a hatch-style linear pattern. This enables you to clean the upper face of a workpiece.

22. Define the Offset

In the Offsets area, set the Floor offset value to 0.2. SolidCAM leaves 0.2 mm roughing offset on the floor of the pocket.

In the Finish area, choose the Floor option to perform the finish cut that removes the remaining offset.

23. Define the Lead in

In the Lead in area, choose the Vertical option.

With the Vertical option, the tool enters the material vertically at a user-defined position. From this position the tool moves to the start point of the pocket, that is calculated by the pocket algorithm.

Specify the position where the tool plunges into the material.

Click on the Pick button.


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SolidCAM displays the calculated tool path pattern.

Rotate the model to the Top view using the button.

Select the point on the model edge as shown.

Click on the Finish button in the Approach point dialog box in order to confirm the selection.

This enables you to perform the lead in movements to the material from outside.

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24. Save and Calculate

Click on the Save & Calculate button to save the operation data and calculate the tool path.

25. Simulate

Simulate the tool path with the SolidVerify mode.

When the simulation is finished, close the Pocket Operation dialog box.

26. Add a Pocket Operation

Define a new Pocket Operation to machine the through pocket located on the face machined in the previous operation.


Choose Machine CoordSys #2 Position #2 for the operation (the same Coordinate System used for the previous operation).

Define the Geometry for the Pocket Operation as shown. In the Geometry Edit dialog box, use the Auto-Constant Z button to complete the chain.


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28. Define the Tool

In the Part Tool Table, choose the same tool of Ø10 that was used in the previous operation.


Define the Upper level on the face machined in the previous operation as shown.

Set the Pocket depth to 15 in order to enable the tool to machine the pocket through the material.

Set the Step down to 5.

30. Define the Offset

In the Offsets area, set the Wall offset to 0.2.

In the Finish area, choose the Wall option.

With the specified Wall offset value, a roughing offset of 0.2 mm is left on the wall of the pocket. This offset is removed at the end of pocket machining by the separate cut.

31. Define the Lead in

In the Lead in area, choose the Helical option from the list.

This option enables the tool to plunge into the material along a helix at the automatically calculated point.

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Click on the Data button to define the Helical Lead in parameters.

The Helical dialog box is displayed.

The tool chosen for the operation has center cutting capabilities, therefore select the Center cutting check box.

Set the Angle value to 5.

Set the Radius value to 1.

Confirm the Helical dialog box with the OK button.


Click on the Save & Calculate button in order to save the Operation data and calculate the tool path.

33. Simulate

Simulate the tool path with the SolidVerify mode.

When the simulation is finished, close the Pocket Operation dialog box.

34. Define a Drill Operation

Define a new Drill Operation in order to machine four holes Ø4 located on the top face of the model.


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Choose Machine CoordSys #2 Position #2 for the operation (this Position was used for the previous operation).

In the Geometry area, click on the Define button to start the geometry definition.

The Drill Geometry Selection dialog box is displayed.

In the Select centers by area, choose the Multi-positions option and click on the top face of the model as shown.

SolidCAM selects all drill centers on the selected face.

The coordinates of the selected hole centers are displayed in the Drill Geometry Selection dialog box.

Confirm the geometry selection with the button.

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36. Define the Tool

Click on the Select button in the Tool information area.


Switch to the Edit page.

Click on the Add Mill button to define a new milling tool. A new tool is defined.

Set the Diameter to 4.

Click on the Select button to choose the defined tool for the operation.


Confirm the dialog box with the OK button. The Drill Operation dialog box is displayed.


132


Define the Upper level on the top face of the model as shown.

In the same manner, define the Drill depth by picking the entity on the solid model. Use the drill cone vertex to define the Drill depth.

38. Define the Drill Cycle

Click on the Drill Cycle type button to choose the drill cycle.

The Drill Cycle dialog box is displayed.

Choose the Peck option.

In the Peck mode, the tool drills in steps to the specified depth. At each depth step, the tool rapidly retracts to the safety distance. Then the tool rapidly returns to the point where it must continue drilling. This sequence is repeated until the tool reaches the final depth.

133


Click on the Data button in the Drill cycle area to define the pecking parameters.

The Drill Options dialog box is displayed.

This dialog box enables you to define the parameters of the chosen canned drill cycle.

Delay

In the Delay field, enter the amount of time (in seconds) you want the tool to pause at the end of each step in the hole.

Step down

In the Step down field, enter the depth that you want the tool to travel at each step.

Set the Step down to 2 and click on the OK button to confirm the dialog box.



40. Simulate

Simulate the tool path in the SolidVerify mode.

When the simulation is finished, close the Drill Operation dialog box.

At this stage, the exercise is finished.


134

Exercise #12: Optical Part Machining

Define the CAM-Part and operations for the machining of the optical part presented on the illustration on a Turn-Mill CNC-machine of the XYZC type.



• Turning;

• Facial milling on XYZC machines;

• Indexial and Simultaneous 4-axis machining on XYZC machines.

The SolidWorks model of the Optical Part (Exercise12.sldprt) is located in the ../Exercises folder.



At this stage, you have to define the CAM-Part, the CNC-controller, the Coordinate System, the Material boundary, the Clamp and the Target model.

The XYZC CNC-controller has to be chosen for this exercise.

2. External turning

Machine the external turning faces using the automatically generated envelope.

3. Internal turning

Turn internal model faces using the feature of internal turning. Use the preliminary drilling to remove a bulk of the material.

135


4. Facial milling

Machine the screw slot and four holes using the SolidCAM capabilities for facial milling.

5. Machining of the side faces

Machine the side faces of the model. Use the SolidCAM Transform option to create a circular pattern of operations around the revolution axis.

6. Drilling on the side face

Machine two holes located on the side face of the model.

7. Slot machining

Machine the slot using indexial 4-axis milling.

8. Radial holes machining

Machine three counterbore holes located on the cylindrical face.

9. Pocket machining

Machine the pocket using simultaneous 4-axis milling.


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Exercise #13: Joint Part Machining

Define the CAM-Part and operations for the machining of the joint part presented on the illustration on a Turn-Mill CNC-machine of the XYZC type.



• Turning;

• Indexial 4-axis machining on XYZC machines.

The SolidWorks model of the Joint (Exercise13.sldprt) is located in the ../Exercises folder.

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


At this stage, you have to define the CAM-Part, the CNC-controller, the Coordinate System, the Material boundary, the Clamp and the Target model.


2. External turning


3. Drilling

Machine the hole located on the spherical surface.

4. Side slots machining

Machine the two slots using the capabilities of SolidCAM for radial milling.

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Exercise #14: Connector Part Machining

Define the CAM-Part and operations for the machining of the Connector part presented on the illustration on a Turn-Mill CNC-machine of the XYZC type.



• Turning;

• Facial milling;

• Indexial 4-axis machining on XYZC machines.

The SolidWorks model of the Connector part (Exercise14.sldprt) is located in the ../Exercises folder.



Define the CAM-Part, the CNC-controller, the Coordinate System, the Material boundary, the Clamp and the Target model.


2. External turning



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3. Facial milling

Machine the highlighted faces using the capabilities of SolidCAM for facial milling.

4. Slot machining

Machine the highlighted model faces.

5. Drilling

Drill all the holes.

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4.4 Milling on Turn-Mill CNC-Machines of the XYZCB type

SolidCAM enables you to perform machining using Turn-Mill CNC-machines of the XYZCB type. This type of CNC-machine provides you with all the functionalities of CNC machines of the XZC and XYZC types. In addition, it provides the capability for indexial B-axis rotation around the Y-axis (see topic 1.3.3).

X

C

B

Z

Y


140

Exercise #15: Milling on XYZCB Machines

This exercise covers the process of CAM-Part definition and Milling on Turn-Mill CNC Machines of the XYZCB type. The following model of a flange is used.

Since the CAM-Part definition process was explained in detail in previous exercises, some details of the CAM-Part definition process are omitted in this exercise.



This model contains a number of features forming the solid body and a few sketches that are used for the CAM-Part definition.


Click on SolidCAM in the main menu of SolidWorks and choose Turn-Mill from the New submenu. SolidCAM is started and the New Turn-Mill part dialog box is displayed. Confirm this dialog box with the OK button.


3. Define the CNC-controller

In this exercise, a CNC-Machine of XYZCB type is used (see topic 1.3.3). Choose the XYZCB CNC-controller from the list.

4. Define the Coordinate System

Make sure that the Multi-sided CoordSys option is activated in order to define the Coordinate System origin and axis orientation directly on the solid model.

Click on the CoordSys button to start the Coordinate System definition.

141



Click on the cylindrical face of the model as shown.

The Z-axis of the Machine CoordSys is collinear to the revolution axis of the part.

Click on the Change to opposite button in the CoordSys dialog box.

The Machine Coordinate System is defined on the model front face.

Click on the Finish button to confirm the Machine Coordinate System definition.


Close it with the OK button.



142

Coordinate Systems for 5-axis Turn-Mill machine (XYZCB type)

SolidCAM enables you to define Machine CoordSys #1 with the Z-axis directed along the revolution axis.

This Machine Coordinate System is used for the turning operations; the turning tool movements are located in the ZX plane.

Machine CoordSys #1 is used also for facial milling, where the axis of the milling tool is parallel to the Z-axis of the Machine Coordinate System.

SolidCAM automatically creates the Machine CoordSys #2. This CoordSys is used for radial milling (indexial and simultaneous 4-axis milling).

Z

XY

Machine CoordSys #1

C

Machine CoordSys #1

Z

XY

Machine CoordSys #2

X

C

Z

Y

143


The origin point of the Machine CoordSys #2 is the same as the origin point of Machine CoordSys #1. The directions of the axes in the Machine CoordSys #2 are the following:

• The X-axis of Machine CoordSys #2 is collinear with the Z-axis of Machine CoordSys #1.

• The Z-axis of Machine CoordSys #2 is collinear with the X-axis of Machine CoordSys #1.

SolidCAM automatically creates the Machine CoordSys #3 to be used for milling by rotating the XY plane around the Y-axis (B-axis).

The origin point of Machine CoordSys #3 is the same as the origin point of Machine CoordSys #1. The directions of the axes of the Machine CoordSys #3 are collinear with those of Machine CoordSys #1.

Confirm the CoordSys Manager dialog box with the button.



Click on the Material Boundary button in the Turn-Mill Part data dialog box.

Choose the Cylinder option in the Material Boundary dialog box.

Click on the Define button to define the cylindrical material boundary.

C

B

Machine CoordSys #3

Z

XY


144

Click on the solid body in order to choose it for the material boundary definition. In the Boundary (Cylinder) dialog box, define the following parameters:

• Set the Right (+Z) and Left (-Z) offsets to 0;

• Set the External offset to 0;

• Set the Internal diameter to 75.

The defined Material Boundary is a tube with the same diameter dimensions as the final part. Only the inclined faces and holes have to be milled.

Confirm the Boundary (Cylinder) dialog box with the button.

Confirm the Material Boundary dialog box with the button.

6. Prepare the Clamp geometry

Define a new sketch in the SolidCAM Part assembly. Choose the Plane2 (the plane parallel to the XY plane of the Machine CoordSys #1) for the sketch.

Sketch the geometry as shown.

Confirm the sketch.

5

15

157.57.5

145


7. Define the Clamp

As explained in the previous exercises, define the Clamp geometry sketched in the previous step.

When the clamp is defined, you can hide the sketch used for the geometry definition.


Select the solid body as the Target model.



Setting a low tolerance value such as 0.01 produces a smoother surface in the SolidVerify simulations such as on the screen captures in this training course.


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10. Save the CAM-Part definition

In the Turn-Mill Part data dialog box, click on the Save & Exit button to confirm the CAM-Part definition.

The SolidCAM Manager tree is displayed.

Technological Overview

The current CAM-Part requires the following technological operations:

• Facial milling – machining of two inclined faces.

• Step machining – machining of the steps around the inclined faces.

• Holes machining – machining of the pattern of holes ø3 located on the inclined faces.

All of these operations are performed using B-axis rotation, therefore additional Coordinate System positions of the Machine CoordSys #3 have to be defined in order to perform the machining.

147


11. Define additional CoordSys Positions

In the SolidCAM Manager tree, click on the (+) icon near the CAM-Part icon and double-click on the CoordSys Manager header to display the CoordSys Manager dialog box.

In the CoordSys Manager dialog box, right-click on the Machine CoordSys #3 item and choose the Add command from the menu.



The CoordSys Position #2 is defined at the origin of the Machine CoordSys #3 with the Z-axis of the Position normal to the selected face.

Confirm the CoordSys dialog box with the Finish button. Close the CoordSys data dialog box with the OK button.

In the same manner, add the CoordSys Position #3 related to Machine CoordSys #3 to machine the second inclined face.

Confirm the definition of the Coordinate System Positions and close the CoordSys

Manager dialog box with the button.


12. Define the Profile Operation

Add a new Milling Profile Operation to machine the inclined face.

Z


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In the Geometry area, choose Machine CoordSys #3 Position #2 from the list.




Confirm the edge selection with the Accept Chain button in the Geometry Edit dialog box.

Confirm the geometry definition with the button.

14. Define the Tool

Define a new milling tool for the operation – End Mill Ø16.


Click on the Profile depth button.

Define the Profile depth directly on the solid model by clicking on the face as shown.

Confirm the definition with the button.

149



In the Tool side area, click on the Show tool button to check the tool position relative to the selected geometry.

The tool has to be located inside the geometry. If it is not located correctly relative to the geometry, change the tool side.

17. Define the Modify offset parameter

The Modify offset parameter enables you to define the offset for the Machining geometry. The machining is performed at the specified offset.

Set the Modify offset value to -2.

With a negative offset value, SolidCAM performs a finish cut that overlaps the geometry.

18. Define the Roughing parameters

Select the Rough check box.

Set the Wall offset to 0. The machining is performed exactly on the Geometry defined by the Modify offset parameter.

In the Clear offset area, set the Offset value to 26 and the Step over value to 10.

MachiningGeometry

Modify offset

2

Geometry


150

Clear offset

This option generates several concentric profiles with a constant depth that starts at the defined clear offset distance from the profile and finishes at the geometry of the profile, thus clearing the area around the profile.

• Offset defines the distance from the geometry, at which the milling starts. The Clear offset value should be equal or larger than the Wall offset value. The tool starts milling the profile at the distance defined by the Clear offset and finishes at the distance defined by the Wall offset. The overlap of the adjacent tool paths is defined by the Step over.

• Step over defines the overlap of adjacent tool paths; it determines the offset between two successive concentric profiles.

Set the Step down to 5. The machining is performed with several 5 mm Z-cuts.

In this exercise, the finish is not performed because the Wall offset is 0. Clear the Finish check box.


Choose the Tangent option for both Lead in and Lead out. Set the Value to 10 for both.

Step over

Cle

ar o

ffset

151



Click on the Save & Calculate button to save the Operation parameters and calculate the tool path.


Simulate the Operation in the SolidVerify simulation mode.

Close the Profile Operation dialog box with the Exit button.


Add a new profile operation to machine the step located on the machined inclined face.


In the Geometry area, choose the Machine CoordSys #3 Position #2.

Click on the Define button. The Geometry Edit dialog box is displayed.


Confirm the edge selection with the Accept Chain button in the Geometry Edit dialog box.


24. Define the Tool

Choose the tool used in the previous operation from the Part Tool Table (End Mill Ø16).


152


Define the Milling levels directly on the solid model.

Use the inclined face for the Upper level definition.

Use the lower face of the step for the Profile depth definition.

In the Finish area, set the Step down value to 1.

With this value, the step is machined in one single cut.


In the Tool side area, click on the Show tool button to check the tool position relative to the selected geometry.

The tool has to be located inside the geometry; if it is not located correctly, change the tool side.

153



Choose the Tangent option for both Lead in and Lead out. Set the Value to 10 for both.


Click on the Save & Calculate button to save the Operation parameters and calculate the tool path.


Simulate the Operation in the SolidVerify simulation mode.


Add a new Drill Operation to machine holes Ø3 located on the inclined face.


In the Geometry area, choose Machine CoordSys #3 Position #2 for the operation.

Click on the Define button to define the Geometry. The Drill Geometry Selection dialog box is displayed.

In the Select centers by field, choose the Multi-positions option. This option enables you to choose all holes located on the selected model face.


154

Select the inclined face as shown. SolidCAM automatically determines all centers of the holes located on the selected face.

Confirm the geometry selection with the button.

32. Define the Tool

Define a new drilling tool Ø3 for the operation.


Define the Upper level and the Drill depth directly on the solid model.

Define the Upper level by clicking on the inclined face of the model as shown.

Pick the drill cone vertex to define the Drill depth.

34. Define the Drill cycle

Choose the Peck Drill cycle for the operation.

In the Drill Options dialog box, set the Step down to 2.

155



Click on the Save & Calculate button to save the operation parameters and calculate the tool path.


Simulate the operation in the SolidVerify simulation mode.

37. Define the machining of the other side

Repeat steps 12-36 for the other inclined face of the model.

Use Machine CoordSys #3 Position #3 for the operations.


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Exercise #16: Console Machining

Define the CAM-Part and operations for the machining of the console presented on the illustration on Turn-Mill CNC-machine of the XYZCB type.



• Turning;

• Indexial 4-axis machining on XYZCB machines.

The SolidWorks model of the Console (Exercise16.sldprt) is located in the ../Exercises folder.



At this stage you have to define the CAM-Part, the CNC-controller, the Coordinate System, the Material boundary, the Clamp and the Target model.

The XYZCB CNC-controller has to be chosen for this exercise.

2. External turning


3. Indexial milling

Define a number of operations for indexial milling to machine the highlighted faces.

157


4. Pocket machining

Machine the pocket located on the inclined face.

5. Inclined faces machining

Define a number of operations to machine the inclined faces.

6. Drilling

Define a number of drilling operations to machine all the holes on the model.


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Projections Mode 5


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SolidCAM enables you to define the CAM-Part either on the solid model or on 2D projections of the model (the drawing views). The geometry can be defined by a number of drawing views that can be imported from DXF or 2D IGES files. In the Projections mode, you need a lot of imagination and knowledge in multiaxial positioning in order to define the correct Coordinate Systems.

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5. Projections Mode

Exercise #17: CAM-Part Definition and Machining in the Projections mode

This exercise covers the process of CAM-Part definition and machining using the Projections mode.

A Turn-Mill CNC-Machine of the XYZC type is used. The drawing views of the Part are as follows:

Since the CAM-Part definition process was explained in details in previous exercises, some details of the CAM-Part definition process are omitted in this exercise.

1. Load the SolidWorks Model


There is no solid body in the SolidWorks document. It contains the following sketches:

Material Boundary

Side

Clamp

Turning

WrapFacial


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• Turning – this sketch contains the geometry used for the turning.

• Facial – this sketch contains the geometry used for the facial milling.

• Side – this sketch contains the geometry used for the indexial 4-axis milling.

• Wrap – this sketch contains the geometry wrapped on the cylindrical surface of the part.

• Material boundary – this sketch contains the geometry of the material boundary.

• Clamp – this sketch contains the geometry of the clamp.

The final part that you will reach after the machining is presented on the illustration.


Click on SolidCAM in the main menu of SolidWorks and choose Turn-Mill from the New submenu. SolidCAM is started and the New Turn-Mill Part dialog box is displayed.

Confirm the New Turn-Mill Part dialog box. The Turn-Mill Part data dialog box is displayed.

3. Define the CNC controller

In this exercise, use a CNC-Machine of the XYZC type (see 1.3.2). Choose the XYZC CNC-controller from the list.

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5. Projections Mode

4. Projections mode

Clear the Multi-sided check box in the CoordSys area. When this check box is not active, SolidCAM works in the Projections mode.

The Turning CoordSys and Milling CoordSys buttons are displayed.

Turning and Milling Coordinate systems

SolidCAM enables you to define the Machine Coordinate System by defining a Turning Coordinate System and a Milling Coordinate System.

The Turning CoordSys is the projection of the Machine Coordinate System on the top view of the part that is clamped on the CNC-machine. SolidCAM uses the Turning Coordinate System for the turning operations.

Z

X

Y

Machine CoordSys #1

Turning CoordSys Milling CoordSys

Z

X YX


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The Z-axis of the Turning Coordinate System is coincident with the revolution axis. The X-axis is defined normal to the Z-axis in the plane of the view.

SolidCAM enables you to define only one Turning Coordinate System in the Turn-Mill CAM-Part.

The Milling CoordSys is the second projection of the Machine Coordinate System #1. The direction of the axes is defined automatically by SolidCAM as shown below.

The Milling Coordinate System must be defined on the appropriate view containing the front face geometry.

The geometry defined with the Milling Coordinate System is rotated according to the orientation of the part on the CNC-machine.

Z

X

Z

X

Milling CoordSys

YX

Z

XY

Machine CoordSys #1

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5. Projections Mode

5. Define the Turning Coordinate System

Click on the Turning CoordSys button.

The Pick CoordSys Origin dialog box is displayed.

Select the point on the sketch as shown to define it as the Coordinate System origin.



6. Define the Milling Coordinate System

Click on the Milling CoordSys button.


Define the Coordinate System origin on the Front view as shown.

Confirm the Milling CoordSys definition with the Finish button.

The CoordSys data dialog box is displayed. Confirm it with the OK button.


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The CoordSys Manager dialog box is displayed. Confirm it with the button.


Click on the Material boundary button in the Turn-Mill Part data dialog box.

The Material Boundary dialog box is displayed.

Choose the 2D Boundary option.

The 2D Boundary option enables you to define the Material boundary via the 2D Profile definition.

The chosen profile is revolved around the Z-axis of the Machine Coordinate System in order to get the revolved body of the stock.

Z

X

Material Boundary

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5. Projections Mode


The Boundary (2D) dialog box is displayed.

Click on the Define chain button in order to start the material boundary definition.


Define the material boundary chain as shown.


Confirm the Boundary (2D) dialog box with the button.

Confirm the Material Boundary dialog box with the button.

8. Define the Clamp

In the same manner as explained in previous exercises, define the clamp as shown.


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10. Save the CAM-Part data

Click on the Save & Exit button in the Turn-Mill Part data dialog box.


11. Add a Turning Operation

In the SolidCAM Manager tree, right-click on the Operations header and choose Turning from the Add Turning submenu.



In the Geometry area, click on the Define button.


Select the geometry as shown.

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5. Projections Mode

In the Extension area of the Geometry Edit dialog box, set the Start and End lengths to 2. These parameters enable you to extend the geometry tangentially in order to provide safe lead in and lead out movements from outside the material.

Click on the Accept Chain button to finish the chain definition.


13. Define the Tool

In the Tool area, click on the Select button.

The Part Tool Table is displayed.

In this exercise you have to use a pre-defined grooving tool contained in the external Tool Table.

Click on the Import button.

The Tool table to import from to dialog box is displayed.


170

Click on the Browse button and open the Exercises folder. Choose the Grooving tool library in the Library name box.

Right-click on the grooving tool name in the Tool List and choose Copy to Table.

The tool is imported into the Part Tool Table and the confirmation message is displayed. Close it with the OK button.

Close the Tool table to import from to dialog box with the Close button.

The Choosing Tool for Operation dialog box is displayed again. Click on the Select button to choose the imported tool for the operation.

The Tool dialog box is displayed. Confirm it with the OK button.




171

5. Projections Mode

15. Simulate

Simulate the tool path in the SolidVerify simulation mode.

When the Simulation is finished, close the Simulation control panel.

Close the Turning Operation dialog box with the Exit button.

16. Add a Turning Operation

In the same manner as explained in Step #10 of this exercise, define a new Turning Operation.

17. Copy the data from the previous Operation

In the Operation name box, choose the previous Operation name.

All the data of the chosen operation is copied to the current operation.


In the Geometry area, clear the current Geometry name (profile) and click on the Define button to define a new Geometry for the operation.

In the same manner as explained in Step #11, define the Geometry as shown.

Set the End length in the Extension field to 2 in order for the currently defined Geometry to overlap with the Geometry of the previous Turning Operation.


172


This operation uses the same technology parameters as the previous Turning Operation.


20. Simulate



Close the Turning Operation dialog box with the Exit button.


In the SolidCAM Manager, right-click on the last operation and choose Profile in the Add Milling submenu.



Now you define the geometry to machine the hexagon using the facial milling capabilities of SolidCAM.

Click on the Define button in the Geometry area. The Geometry Edit dialog box is displayed.

In the Chain area of the Geometry Edit dialog box, choose the Auto-General option.

173

5. Projections Mode

Select the two lines of the hexagon as shown.

The chain is completed automatically and the confirmation message is displayed.

Click on the OK button to confirm the Geometry definition.

Close the Geometry Edit dialog box with the button.

23. Define the Tool

Define a new milling tool for the operation: an End Mill of Ø6.


In the Projections mode, the Milling levels parameters cannot be defined by picking entities directly on the model. You have to enter the appropriate values.

Set the Upper level to -11 and the Profile depth to 5.5.

25. Define the Rough parameters

According to the technological requirements, the machining of the hexagon includes rough and finish paths.

Select the Rough check box to define the roughing parameters.

Note that the default value of the Wall offset parameter is 0.5; this offset is left during the roughing and removed by the finish path.

The default Step down value is 3.

26. Define the Finish parameters

The Finish section is activated in order to perform the finish path.

Set the value of 5.5 for the Step down. The finishing is performed in a single path for all sides of the hexagon.

Line 1Line 2


174


In the same manner as explained in the previous exercises, define the Tangent strategy for the Lead in and Lead out. Set the value of 4 for both.


Click on the 4th Axis button. The 4th Axis dialog box is displayed. This dialog box enables you to define the technological parameters of the facial milling on Turn-Mill CNC-machines.

Choose the Face option in the 4th Axis type box. This option enables you to perform milling using the rotary axis by translating the linear movement in the XY-plane to the rotary movement of XC-axes.

Choose the Cartesian option in the Coordinate type box. The tool path is calculated in Cartesian coordinates relative to the Machine Coordinate System. The milling is processed using the rotary axis by translating the linear movement to rotary-linear movement, according to the plane.

Click on the OK button to confirm the parameters.



30. Simulate



Close the Profile Operation dialog box with the Exit button.

175

5. Projections Mode


In the SolidCAM Manager tree, right-click on the last operation and choose Drill in the Add Milling submenu.


32. Define the Drill Geometry

In the Geometry area, click on the Define button to start the Geometry definition.

The XY Drill Geometry Selection dialog box is displayed.

In the Select centers by section, choose the Multi-positions option. This option enables you to define the drilling geometry by selecting circles. Select the circles as shown.

Confirm the Geometry selection with the button.



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33. Define the Tool

Add a new Drill tool of Ø3 to the Part Tool Table.


In the Milling levels area, set the Upper level to -16.5 to define the start position of the machining.

Set the Drill depth to 5.

35. Define the Drill cycle

Click on the Drill Cycle type button and choose the Peck type in the Drill Cycle dialog box.

Click on the Data button to define the pecking parameters. The Drill Options dialog box is displayed.

Set the Step down value to 1.


In the same manner as explained in the Step #28, define the 4th Axis parameters.


Click on the Save & Calculate button in order to save the operation data and calculate the tool path.

38. Simulate


When the simulation is finished, close the Simulation control panel.

Close the Drill Operation dialog box with the Exit button.

177

5. Projections Mode

39. Define an additional Coordinate System

SolidCAM enables you to define a number of the CoordSys positions for indexial and simultaneous 4-axis milling. These positions are related to the Machine Coordinate System. These positions have to be defined on the appropriate views displaying the geometry for the machining.

Now you have to define an additional Coordinate System in order to perform the indexial 4-axis machining of the part.


The CoordSys Manager dialog box is displayed.

Right-click on the last item in the list and choose the Add command from the menu. The CoordSys dialog box is displayed.

Set the Mac CoordSys number to 2 in order to start the definition of Machine Coordinate system #2.

The Machine Coordinate System #2 is used for radial milling (indexial and simultaneous 4-axis milling).

Select the origin for the Coordinate System as shown.


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The directions of the axes in the Machine CoordSys #2 are the following:

• The X-axis of the Machine CoordSys #2 is collinear with the Z-axis of the Machine CoordSys #1.

• The Z-axis of the Machine CoordSys #2 is collinear with the X-axis of the Machine CoordSys #1.

Confirm the Coordinate System definition with the Finish button.


The Coordinate System is defined. Close the CoordSys Manager dialog box with the button.

40. Define a new Profile Operation

Define a new Profile Operation in order to machine the shown geometry.


In this operation, the newly defined Coordinate System is used. In the Geometry area of the Profile Operation dialog box, choose the Mac 2 Position 1.


The Geometry Edit dialog box is displayed. Select the geometry as shown.

179

5. Projections Mode

Click on the Accept Chain button in order to confirm the chain selection.

Confirm the Geometry definition with the button.


42. Define the Tool

Define a new Ø6 End Mill tool for the operation.


Set the Upper level to 4.2. The machining is started from the radius of the cylindrical surface.

Set the Profile depth value to 1.2.

44. Define the technological parameters

In the Finish area, set the Step down to 1.2. The machining is performed in a single movement.

45. Define the Lead in and Lead out

Define the Tangent strategy for Lead in and Lead out. Set the value of 4 for both.



The message is displayed to inform you that the Upper level of the operation is higher than the Upper level of the Machine Coordinate System used in the operation.

Confirm this message with the Yes button.

Click on the Exit button to close the Profile Operation dialog box.


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47. Define the copy of the operation

Create a 180° rotated copy of the defined operation in order to machine the second symmetrical step.

In the SolidCAM Manager tree, right-click on the last Profile Operation and choose 4th Axis from the Transform submenu.

The Rotate list dialog box is displayed.

Set the Angle value to 90 for the original step to be copied and click on the Add button. The angle value is displayed in the Angle list.

Set the Angle value to 270 for the symmetrical step to be machined and click on the Add button. Confirm the dialog box with the OK button.

48. Simulate



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5. Projections Mode

49. Define an additional Coordinate system position

Now you have to define an additional position for Machine Coordinate System #2 in order to perform the simultaneous 4-axis machining of the pockets wrapped on the cylindrical surface.

The Coordinate System and Geometry for the simultaneous 4-axis milling

The Coordinate System and Geometry for the simultaneous 4-axis milling can be defined in two ways:

• On the view containing the projected geometry

In this case, the geometry is projected on the appropriate revolution surface.

Z

X


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Only the range of 180 degrees is supported when you draw a top view.

• On the view containing the unfolding of the revolution surface

The full range of the angles of the perimeter is supported when you draw a layout of the cylindrical surface. The geometry is wrapped by SolidCAM around the outside diameter. The length of the full unfolded cylindrical surface is equal to π*D, where D is the diameter of the cylinder.

The rotary axis rotation is not limited to 360 degrees and therefore the unfolding length can be more than π*D.

<180°Geometry

Z

X

Z

X

D

π*D

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5. Projections Mode


In the CoordSys Manager dialog box, right-click on the Mac 2 item and choose the Add command from the menu.


The CoordSys position for the simultaneous 4-axis milling is defined on the view containing the unfolded revolution surface.

Select the origin for the Coordinate System as shown.

Confirm the origin definition with the Finish button.


Close the CoordSys Manager dialog box with the button.

50. Define a Pocket operation

Define a new Pocket operation to machine pockets wrapped on the cylindrical surface.


In this operation, use the newly defined Coordinate System position. In the Geometry section of the Pocket Operation dialog box, choose the Mac 2, Position 2.


The Geometry Edit dialog box is displayed. Select the geometry as shown.


This unfolded geometry is wrapped on the cylindrical surface.


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52. Define the Tool

Define a new tool (End Mill tool of Ø3) for the operation.


In the Upper level box, enter the radius of the cylindrical surface where the pockets are wrapped: 22.73.

Set the Pocket depth to 2.

Set the Step down to 1. The pocket is machined in equal Z-steps.


Click on the 4th Axis button in the Pocket Operation dialog box.


There are two options available in the 4th Axis dialog box to specify the technological parameters of the simultaneous 4-axis milling:

• Wrap

The geometry is wrapped around the specified diameter; each linear movement is divided by the radius to generate the rotary axis rotation. The rotary axis rotation is not limited to 360 degrees.

• Top

Only the range of 180 degrees is supported when you draw a top view from any angle. SolidCAM splits each tool movement into small movements to generate the required top view drawing within a tolerance. Every corresponding coordinate is projected on the top view and then translated to rotary axis rotation.

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5. Projections Mode

Choose the Wrap option in the 4th Axis type box.

In the Diameter box, enter the value of the diameter where the geometry is wrapped: 45.46.

Coordinate type and Tolerance

The tool path lines and arcs are split into many blocks that do not exactly generate the required tool path. The Tolerance parameter defines the maximal allowed error. The smaller the value of the tolerance, the larger the number of G-code blocks generated.

Center plane

This field defines the height of the rotation axis of the part.

Parallel to

This option enables you to determine which axis (X or Y) on the screen is the linear axis.

Parallel to X – The X axis on the screen is the linear axis.

Parallel to Y – The Y axis on the screen is the linear axis.

Confirm the 4th Axis dialog box with the OK button.



The confirmation message is displayed to inform you that the Upper level of the operation is higher then the Upper level of the Machine Coordinate System used in the operation.

Confirm this message with the Yes button. Click on the Exit button to close the dialog box.


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56. Define the operations pattern

Create the circular pattern of the pocket operations around the revolution axis. The pattern includes four instances equally distributed on the cylindrical surface.

In the SolidCAM Manager tree, right-click on the last Pocket Operation and choose 4th Axis from the Transform submenu.

The Rotate List dialog box is displayed.

Set the Angle value to 90 and define the number of the pattern instances: 4. Click on the Add button.

The angle values are displayed in the Angle list.

Confirm the Rotate List dialog box with the OK button.

57. Simulate



At this stage, the Exercise is completed.

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5. Projections Mode

Exercise #18: Pin Machining

Define the CAM-Part and operations for the machining of the pin shown below on Turn-Mill CNC-machine of the XZC type.

Define the CAM-Part using the Projections mode based on the following drawing views:



• Coordinate System and Geometry definition in the Projections mode;

• Turning;

• Facial milling;

• Simultaneous 4-axis machining on XZC machines.

The SolidWorks model of the Pin (Exercise18.sldprt) is located in the ../Exercises folder.


10


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1. Define CAM-Part

Define the CAM-Part, the CNC-controller, the Machine Coordinate System (in the Projections mode), the Material boundary and the Clamp.


2. External Turning

Machine the external turning faces using an automatically generated envelope.

3. Facial milling

Define a number of operations using SolidCAM capabilities for facial milling and drilling in order to machine the highlighted faces.

4. Pocket machining

Machine the pocket wrapped onto the cylindrical face.

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5. Projections Mode

Exercise #19: Pulley Machining

Define the CAM-Part and operations for the machining of the pulley shown below on Turn-Mill CNC-machine of the XZC type.

Define the CAM-Part using the Projections mode based on the drawing views:



• Coordinate System and Geometry definition in the Projections mode;

• Turning;

• Facial milling;

• Simultaneous 4-axis machining on XZC machines.

The SolidWorks model of the Pulley (Exercise19.sldprt) is located in the ../Exercises folder.



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Define the CAM-Part, the CNC-controller, the Machine Coordinate System (in the Projections mode), the Material boundary and the Clamp.


2. External turning


3. Facial milling

Define a number of operations using SolidCAM capabilities for facial milling and drilling in order to machine the highlighted faces.

4. Pockets machining

Machine the pockets wrapped onto the cylindrical face.

Congratulations!

You have successfully finished the SolidCAM2007 Turn-Mill Training Course.

Documents

SolidCAM2007 R11 Turn Mill Training Course