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The Pocket depth value 8 is determined. Set the Step down value to 4 to perform the pocketmachining in two equal steps. Define the technological parametersSwitch to the Technology page of the Pocket Operationdialog box.
In the Offsets section, set the Wall offsetand the Floor offset values to 0. These offsets remainunmachined during roughing and are removed with thefurther finishing. In the Finish area, select the Wall and Floor check boxes. These options enable you to perform finishing of the Walloffset and Floor offset that remain after the roughing. Define the machining strategy. Make sure that the defaultContour option is chosen in the Technology section.
Whenthe Contour strategy is chosen, the tool moves on offsetsparallel to the pocket contour. Switch to the Contour tab to display the Contourparameters. This page enables you to define theparameters of the Contour strategy. The Min. If the given radius is too large for a specific corner, itproduces the largest possible radius at that point. Sometimes the fillet option can leave some material. This particularly happens if the given radius is large. The tool path formsa loop in the corner, preventing anabrupt change of direction.
Althoughthis produces a sharp movement by thetool, the path itself is slightly shorterthan the smooth corner option. Thiscan help cut down on machining time. This option is not recommended for high-speed cutting. DirectionThis option enables you to choose climb or conventional milling for theroughing operation. Climb millingConventional milling Theradius of the arc is half the distance betweenthe tool path passes.
Exit materialThis option controls the tool movements between the working areas. Exit material check box notselectedWhen the tool moves from oneworking area to the next, it movesthrough the full material aroundthe island to get to the nextworking area as shown above. Connect islandsThis option enables you to keep thesame cutting direction conventional orclimb milling throughout the entire toolpath where possible.
This is particularlyimportant in high-speed cutting. Exit material check boxselectedThe tool exits the materialand travels rapidly above thematerial to the next workingarea as shown above. The leadin path is the Lead in you define. Define the strategy with which the tool is plunginginto the material during the pocket roughing. Fromthis position, the tool moves to the pocket start point calculated bythe pocket algorithm. Click the Data button to specify the positionwhere the tool plunges into the material.
The start point must be selected using the Data button. Enter theramping angle value into the Angle edit box of the Angle rampingdialog box. SolidCAM does not check the ramping movement against the pocketcontour. Check the tool path simulation to make sure that the tooldoes not gouge the pocket walls or islands. When the tool reaches the step down depth,it machines all the material at the step down depth. Click the Databutton to set the helical ramping parameters.
The difference is that the descent is performed in a linear zigzagfashion rather than in a circular one. Choose the Helical option and click the Data button. The Helical ramping dialog box is displayed. This dialog box enables you to definethe ramping position and the related parameters for each chain used in the Pocketoperation.
Helical Ramping ParametersThe Tool step down parameter defines thedistance between each two adjacent turns of thetool helical movement. The Angle parameter defines the ramping angle. The Radius parameter defines the radius of thedescending helix.
Center cuttingIf your tool has center cutting capabilities, selectthe Center cutting check box. In the Angle field,enter the descent angle that you would like thetool to follow. In the Radius field, enter theradius of the tool path helix. The working order is as follows If the tool does not have center cutting capabilities, do not select theCenter cutting check box. In the Tool step down field, enter the depth ofthe step down of the tool. Then it descends to thenext Tool step down.
ChainsThis section displays the list of all geometry chains defined for theoperation. All the chain entries are displayed under the Chains header. You can select chain entries in the list. When the Chains header is selected, SolidCAM displays the tool pathand default ramping positions for all of the chains.
The circles representthe default helical ramping movement defined for each chain. When a chain entry is selected, SolidCAM displays the tool path and thedefault ramping position for this chain. This position is automaticallydefined at the start position of the tool path segment relevant for thecurrent chain. You can change this position by picking a point on themodel or by entering the new position coordinates into the X, Y, Z dialogbox.
The schematic circle facilitates the definition of the position. When the position is picked, it is marked on the model witha red dot. The coordinates of the picked point are displayed in theX, Y, Z dialog box. The start position of the tool path is marked on themodel with a yellow dot. The circle of the tool path color represents thehelical movement of the tool plunging.
Tool path start positionRamping positionWhen the ramping position is defined, the tool descends into the materialat the specified ramping position with helical movements according tothe defined parameters. When it reaches the level of the first cutting pass,it moves to the start position of the tool path and performs machiningof the pocket. The Auto next button provides you with the selection mode that enablesyou to define the ramping positions for all of the chains one by one. Confirm the dialog box with thebutton.
The length of thenormal can be set in the Normal lengthfield. The distance between the normal andstart of the geometry is set in the Tangentextension field.
TangentExtensionNormal Length Thearc radius can be set in the Radius field. The length of the extension can be set inthe Tangent extension field.
The distanceto the material can be set in the Tangentextension field. TangentExtensionLengthWhen the Same as Lead in check box is selected, the strategy andparameters defined for Lead in are used for Lead out.
Under Lead in, choose the Arc optionfrom the list and set the Tangent extensionvalue to 3 and the Radius value to 2. The Pocket operation data is saved and the tool pathis calculated. Add a Drilling operationThis Drilling operation is used to perform thepreliminary center drilling of the four holes inthe corners of the model.
The Drilling Operation dialog box is displayed. Define the Drill geometryIn the Geometry area, click thebutton. This dialog box enables you to select the geometry for drilling directly on the solidmodel. Due to the natureof spline curves or surface boundaries, youcannot pick a center position like you couldon a circle or an arc. SolidCAM calculates thecenter position of an arc defined by threepoints positioned on the spline edges.
Thisfacilitates selecting drill centers on splinesurfaces. Four drill positions are selected. Theircoordinates are displayed in bottompart of the Drill Geometry Selectiondialog box. Click the button to confirm the geometry selection. The Drilling Operation dialogbox is displayed.
Click to start a new drilling tool definition. From theDrilling Tools section, choose the Spot drill tool for theoperation. Spot DrillThis tool type is used for center drilling and chamfering in Drillingoperations. A tool of this type is defined with the parameters shown inthe image.
Click the Select button to choose the tool for the operation. Click the Data tab. Define the spin and the feed for the operation. Define the center drilling depthSwitch to the Levels page of the Drilling Operationdialog box. Click the Drill depth button and selectthe upper face of the model. The Drill depth value 0 appears in the relevant edit box.
To perform the drilling down to the specified diameter of the tool, use the Depth typeoption. The Diameter value can vary from 0 all the way up to the drill tooldiameter. A value greater than the drill tool diameter is automaticallydecreased to the drill tool diameter. Choose the Diameter value option and set the value to 5. In this manner, the drilling is performed till the tooldiameter of 5 mm is reached at the depth of 0. The Drilling operation data is saved and the toolpath is calculated.
Simulate the operationSimulate the operation in theSolidVerify simulation mode. Add a Drilling operationAdd another Drilling operation to perform the through drilling of the holes. Define the GeometryThis operation is using the geometry that was defined inthe previous center drilling operation.
Choose the Drillgeometry from the list in the Geometry area. Each geometry defined in SolidCAM has a unique name. When the geometryis being defined, it is assigned a default name that can be changed. Usingthis name, you can choose the geometry for a specific operation. Click the Data tab in the Tool page. Define the spin and feed for the operation. Define the Drilling depthThe overall height of the model is 10 mmplus the 5 mm bottom offset defined forthe stock.
The drilling has to be performeddeeper than this depth in order to enable thetool to exit from the material and performthe through drilling. Switch to the Levels page. Define the Upper level by clicking on the top face of the model as shown. Define the Drill depth. Rotate the model and select the bottom face as shown. Since the Z- offset defined for the stock model is 5mm, set the Delta value to To perform the through drilling, choose the Fulldiameter option in the Depth type area.
With thisoption, the drilling is performed until the fulldiameter is reached at the specified drill depth. This means that the conical part of the tool exitsfrom the material. In this operation, the pecking canned cycle is used for chip breaking. With this cycle, the chip breaking is accomplished by slight retracts of the tool duringthe drilling process.
Switch to the Technology page and click the Drill cycle type button. Available drillcycles are displayed.
Click the Peck button. The cycle is chosen for the operation. Click the Data button to define the pecking parameters. The DrillOptions dialog box is displayed. Confirm the data with the OK button. The Drilling operation data is saved, and the tool path is calculated. Simulate the operationSimulate the operation in the SolidVerify simulation mode.
Since in the previous operation the drilling diameter was greater than that inthis operation, the drilling results in a chamfer on the drilled holes.
Now you have successfully finished the exercise. The cover is machined on the 3-Axis milling CNC-machine using the machining vice. The part ismachined using two positionings. At the first stage, the workpiece is positioned in the vice as shown below. At the next stage, the rest of the cover faces are machined using the second positioning. Load the SolidWorks modelLoad the Exercise3. The CAM-Part is defined. Select the CNC-machine controller.
Click the arrow in the CNC-Machine section to display the list of post-processors installedon your system. Define the Stock modelIn this exercise, you have to define the Stock model before youdefine the Coordinate System in order to use the workpiece forthe CoordSys definition. The stock Model dialog box isdisplayed. SolidCAM generates the stock box surrounding the model withthe specified allowances. In the Expand box at section, set thevalue of the Z- parameter direction to 5.
This allowance is usedfor the first clamping. Set the value of 2 for the rest of thedirections. Click on the model. The face is highlighted, and the boxsurrounding the model is displayed. Click the Add box to CAD model button. Confirm the Model dialog box with thedisplayed. The Milling Part Data dialog box is6.
The CoordSys dialog box is displayed. In the Define CoordSys options list, choose the Define option. At first, you have todefine the Coordinate System origin location and then thepoints for the X- and Y-directions. Pick the origin point in the stock box corner as shown. Click on the stock model edge as shown to define the X-axis of the Coordinate System.
Click on the stock model edge as shown to define the Y-axis of the Coordinate System. When a point is selected, the next button is automatically activated. If youmiss the selection, you can at any time select the button you want to defineand continue automatically to the next button.
The model is rotated,The CoordSys Data dialog box is displayed. Define the Part Lower level directly on the solid model.
This parameter defines thelower surface level of the part to be milled. Click the Part Lower level button. Rotate the model and select the lower facethat is milled using the first positioningas shown. The Z-coordinate of the face is displayed in the Pick Part Lowerlevel dialog box.
Confirm this dialog box by clicking thebutton. Confirm the CoordSys Manager dialog box with thedialog box is displayed again.
The Milling Part Data7. The target Model dialog box is displayed. This dialog box enables you to define a 3D model for the Target. Its face highlighted. Thedefined CAM-Part is saved. Using the first defined Coordinate System first clamping , you have to perform thefollowing operations:Upper face machiningUpper profile machiningLower profile machiningHole pads machining Then the part has to be rotated and clamped again.
With the second clamping, thefollowing operations are performed:Upper face machiningPocket machiningSlot machiningHoles machining The Face Milling operation is used for the upper facemachining. Define the Face Milling geometryClick the button in the Geometry page. The Face MillingGeometry dialog box is displayed.
Using the default Model option, click the Define button andclick on the solid model to select a face. In the Face Milling Geometry dialog box, define the 3 mm offsetto machine over the stock edges. In the Modify section, set theOffset value to 3. Confirm the Face Milling Geometry dialog box by clicking thebutton. This featurealso enables you to see a more realistic simulation in the SolidVerify simulation. Switch to the Holder page in the Choosing Tool for Operation dialog box.
This table containsa number of frequently used tool holder components. The Global holderstable can be modified by the user. Select the Use Holder check box to enable choosing a holder from the Global holderstable. The Local and Global tool holders lists become available. The SolidCAM tool holder is defined by combining two components. The first component is the tool adaptor mounted on the spindle unitof the milling machine.
The second component can consist of varioustypes of extensions and reductions like collet chucks, arbors, shanks andother components that you may have. This collet chuck is suitable for the chosen tool diameter 40 mm. Choose the defined tool for the operation by clicking the Select button. The FaceMilling Operation dialog box is displayed. Click the Face depth buttonin the Milling levels area and select the model faceas shown.
The Face depth 2 is calculated. Define the technological parametersSwitch to the Technologypage of the Face MillingOperation dialog box. Inthe Technology section,use the default Hatchoption.
Hatch Machining TechnologyThe machining is performed in a linear pattern. The Hatch page enables you to define the hatching parameters. The tool path always follows the length of the face nomatter what angle the machined surface is facing. The Delta from optimal parameter enables you to change the hatchingangle. Delta angleOptimal direction The Zigzag option enables you to create the tool path withbidirectional movements. The Extension section enables you to define theextension both along the tool path the Along section and across thetool path the Across section.
Extension acrossthe tool pass The Fillet option connects each direction witha given radius allowing for a smoother transitionbetween path directions.
Click the Data tab to define the machiningparameters. In the Hatch angle section, switch to theAutomatic optimal angle option. Switch back to the Technology tab. OverlapThis section enables you to define the tool overlapping between twosuccessive passes. This option can be defined as Percentage of the tooldiameter or as a Value. Overlap value butnot smaller than this value. When this check box is not selected,the distance between the last passand the one before it can be smallerthan that between all of the otherpasses.
When this check box is selected,the evenly spaced hatch tool pathis generated. The overlap betweentwo successive passes is not smallerthan the specified Min. Define the roughing offset that remains on the floor of the face. This offset is leftunmachined during the rough face machining and removed during the face finishing. In the Offsets section, set the Floor offset value to 0. Select the Finish check box to perform finishing of theface in this operation.
This check box enables you toremove the remaining offset with the last cutting pass. Define the Lead in and Lead outSwitch to the Link page of the Face Milling dialog box to define the way the toolapproaches the material and retreats away.
In the Lead in section, choose the Tangent option. This option enables the tool toapproach the material on a line tangent to the profile. In the Length field, set the lengthof the tangent to 5. In the Lead out section, select the Same as Lead in check box. The Simulationcontrol panel is displayed. Switch to the SolidVerify page and startthe simulation with the button.
Close this dialog box with theExit button. Add a Profile operationAt this stage, you have to define a Profile operation in order to machine the upperprofile of the cover.
The Geometry Edit dialog box is displayed. Click the Add button in the Multi-chain section. The Chains Selection dialog box is displayed. This dialog boxenables you to pick a number of chains from the model byselecting the model elements.
SolidCAM automatically createschains from the selected elements. Click on the top face of the model as shown. The face is selected, and its boundary is highlighted. Click to choose the selected chain as the geometry. The Geometry Edit dialog boxis displayed. Confirm the geometry definition with the button.
The geometry is defined for theoperation. Choose the tool holder. Switch to the Holder page and select the Use holder check box. Click the Local holders tab. When a new holder is chosen from the Globalholders table, it is copied to the local table to make a further use easier. Confirm the tool selection by clicking theSelect button. Define the Profile depthSwitch to the Levels page.
In the same manner as explained in previous steps, definethe Profile depth by clicking on the model face as shown below. Define the technological parametersSwitch to the Technology page. In theModify section, set the Tool side to Right. Click the Geometry button to check thetool position relative to the geometry.
Close the Modify Geometry dialog boxwith the button. Now you have to define the roughing and finishing parameters. SolidCAM Profileoperation enables you to perform the rough and finish machining in the single operation. Set the Step down value to3. The profile is machined in two equal Z-steps. In the Offsets section, set the Wall offset and the Flooroffset to 0.
These allowances are removed during thefinish machining. Select the Clear offset check box. Set the Offset value to 5and the Step over value to 2. Clear OffsetThis option generates several concentric profiles with a constant depththat start from the defined clear offset distance from the profile andfinish up to the geometry of the profile, thus clearing the area aroundthe profile. The Offset defines the distance from the geometry at which themilling starts. The Clear offset value should be equal to or larger thanthe Wall offset value.
The tool starts milling the profile at the distancedefined by the Clear offset and finishes at the distance defined by theWall offset; the overlap of the adjacent tool paths is defined by the Stepover parameter. The Step over parameter defines the overlap of adjacenttool paths. It determines the offset between two successive concentricprofiles.
Define the Lead in and Lead outSwitch to the Link page. In the Lead in section,choose the Tangent option. With this option, thetool approaches the material tangentially to thegeometry in the start point. Set the Length valueto The Profile operation data is saved and the tool path is calculated. SimulateClick the Simulate button in the ProfileOperation dialog box. The SolidVerify simulation mode enables you to measure distancesdirectly on solid bodies in the SolidVerify window.
This feature enableschecking the linear dimensions of the part during simulation. Click the Measure button on the toolbar. The MeasureDistance dialog box is displayed. Click on the top face of the cover and then on thehorizontal face machined in the current operation. The coordinates of the pocket points and the resultdistance are displayed in the Measure Distance dialog box. In this case, the Delta Zparameter displays the depth of the machined face relativeto the cover top face 5.
Close the simulation with theOperation dialog box is displayed. Add a Profile operationAt this stage, you have to define a Profileoperation in order to machine the lowerprofile of the cover. Define the GeometryClick the button in the Geometry page.
Click on the workpiece edge as shown to define the first entity of the chain. In the Chain section, choose the Auto-constant Z option. The closed chain isautomatically selected. Confirm it with the Yes button. Confirm the geometry with thebutton. Click the Select button in the Tool page. Choose thepreviously defined Tool 2 and click the Select button. Define the Profile depthYou have to define a new Upper level for the operation taking into account the alreadymachined faces.
Switch to the Levels page and click the Upper level button in theMilling levels area. Define the Upper level by clicking on the model face as shown. Confirm the definition of the Upper level with theIn the same manner as explained in the previoussteps, define the Profile depth by clicking onthe model vertex as shown. In the Modifysection, set the Tool side to Right. Click the Geometry button to check the tool positionrelative to the geometry. Now you have to define the parameters of profile roughing and finishing.
Set the Step down value to2. In the Offsets section, set the Wall offset value to 0. Thisallowance is removed during the finish machining. Select the Finish check box and set the Step down value to5. The 0. In the Lead insection, choose the Arc option.
The toolapproaches the material tangentially tothe geometry at the start point. Set theRadius value to In the Lead out section, select the Sameas Lead in check box.
The Profile operation data is saved, and the tool path is calculated. SimulateClick the Simulate button in the Profile Operationdialog box. The Simulation control panel isdisplayed. Switch to the SolidVerify page and start thesimulation with the button. TheProfile Operation dialog box is displayed.
Close theProfile Operation dialog box with the Exit button. Add a Profile operationAt this stage, you have to define a new Profileoperation to machine four hole pads. Define the GeometryIn the Geometry page, click the button.
TheGeometry Edit dialog box is displayed. Click on the model edge as shown. Click on the next model edges as shown below tocomplete the chain.
In the Chain List section, click thebutton to confirm the chain selection. In the same manner, define the geometry for the rest of the pads. Make sure that all theselected chains have the same direction. Confirm the geometry definition by clicking thebutton. Define the ToolDefine a new tool for the operation. Define the Milling levelsIn this operation, the machining starts atthe Z-level of the already machined faces.
The upper level has to be defined. Define the Upper level by clicking on thealready machined model face as shown. In the same manner as explained earlier,define the Profile depth by clicking on thepad face as shown.
Define the technological parametersSelect the Rough check box. Set the Step down value to 3. The profile is machined in one Z-step. Set the Offset value to 5and the Step over value to 4. Select the Finish check box and set the Step down value to3. Set theRadius value to 2. In the Lead out section,select the Same as Lead in check box. Close the Profile Operation dialog box with the Exit button. At the next stagesyou have to machine the internal faces.
Define a New Coordinate SystemThe machining of the internal model facesrequires another positioning. The part has to berotated and clamped in a vice as shown. The CoordSys Managerdialog box is displayed. Right-click the MAC 1 item in the list and choosethe Add option from the menu. The CoordSys dialog boxis displayed. In the Mac CoordSys Number field, set the value to 2. Changing of the Mac CoordSys number means that a newclamping is used. Make sure that the default SelectFace mode is chosen.
In this case,the Z-axis of the Coordinate System is normal to the selectedface. Rotate the model and click on its bottom face as shown below. Make sure that the Corner of model box option is chosen. In this case, the box surrounding the model is calculated. The upper plane of the model box is parallel to the XY-plane of thedefined CoordSys. Now you have to move the origin of the Coordinate System from the automaticallydefined position to the corner of the workpiece.
Select the Pick origin check box in the Pick sectionof the CoordSys dialog box. Click on the corner of the workpiece stockmodel as shown to choose it for the origin. Theorigin is moved to the new location. The CoordSys Data dialog box isdisplayed.
Confirm the dialog box with the OKbutton. The CoordSys Manager dialog box isdisplayed. Using them you can programoperations for different positions clamping. The Machine Coordinate System 2 isused for the machining of the back face and the internal faces. Click thebutton to confirm the CoordSys Manager dialog box.
Click the button to start the geometry definition. The Face Milling Geometry dialogbox is displayed. The model is highlighted, and its icon appearsin the list. Confirm the 3D Geometry dialog box by clicking the button. The FaceMilling Geometry dialog box is displayed again. The rectangle is generated surroundingthe Target model at the XY-plane.
Define the 3 mm offset to extend themachined surface over the stock edges. In the Modify section, set the Offset valueto 3. Click the button to confirm the Face Milling Geometry dialog box. The geometryis defined for the operation. Choose thepreviously defined tool and click the Select button. Define the Upper level by clicking on the workpiececorner as shown. Define the Face depth directly on the solid model byclicking on its bottom face as shown below.
Set the Step down to 2. Define the technological parametersSwitch to the Technology page of the Face MillingOperation dialog box. In the Technology section, choosethe Hatch option and click the Hatch tab. In the Hatch angle section, switch to the Automatic optimal angle option. This offset is being leftunmachined during the rough face machining and is removed during the face finishing. Define the Lead in and Lead outSwitch to the Link page of the Face Milling Operation dialog box to define the way thetool approaches the material and retreats away.
This option enables the tool to approach thematerial on a line tangent to the profile. In theLength field, set the length of the tangent to 5. In the Lead out section, select the Same as Leadin check box. Confirm this message with the Yes button. The operation data is saved, and the toolpath is calculated. SimulateSimulate the operation in the SolidVerifymode.
The bottom face machining is finished. Now you have to perform the pocket machining. Pocket machining overviewThe pocket is machined in several technological steps:The rough machining of the upperpart of the pocket. The machiningis performed until the Z-level ofthe pads is reached. The rough machining of the pocketwith islands pads. The machiningis performed from the upper faceof the pads till the pocket floor.
At this stage, two operations areused to perform the machiningwith two tools of big and smalldiameter. The finish machining of the outsidewall of the pocket.
The finish machining of the islandwalls. The finish machining of the islandtop face. The finish machining of the pocketfloor. Add a Pocket operationAdd a new Pocket operation to perform the rough machining of the upper part of thepocket down to the pads height. Define the Pocket depthDefine the Pocket Depth directly on thesolid model. Use the top face of the padsfor the definition. The Stepdown parameter enables you to definethe distance between each two successiveZ-levels.
Set the Step down value to 2. The pocketis machined in two Z-levels. Define the technological parametersSwitch to the Technology page of the Pocket Operation dialog box. Make sure that thedefault Contour option is chosen in the Technology section. In the Offsets section, set the Wall offset and the Flooroffset values to 0. These offsets remain unmachinedduring roughing and are removed with the further finishing.
In theRamping section, choose the Helical option. Click the Data button. Set the Radius of the descent helix to 3 and confirm the dialog boxwith the button With a circular motion tangent to the last entity of the pocket contour,the tool retreats from the profile. The radius of the arc must be specified. The Pocket operation data is saved andthe tool path is calculated. SimulatePerform the simulation of the Pocketoperation in the SolidVerify mode. During the simulation, notice the helicallead in movement.
Add a new Pocket operationAdd a new Pocket operation to machine the bottom part of the pocket including twoislands pads for the circuit board installing.
In the same manner as explained in the Step 18 of this exercise, define the geometryby clicking on the pocket bottom face as shown below. SolidCAM automatically determines the edges of the selected face and defines chainson them. The first chain is the external boundary of the pocket. All closed chains insidethe first chain of each pocket are automatically treated as pocket islands.
Overlappingchains are milled as separate pockets, not as islands. To select multiple pockets withislands, continue adding chains to the geometry. Define the Milling levelsThe machining in this operation startsat the Z-level of the top faces of thepads and ends on the bottom face of thepocket.
Define the Upper level by selecting thetop face of the pads as shown. Define the Lower level by selecting thebottom face of the pocket. Define the technological parametersMake sure that the default Contour option is chosen in the Technology section. In the Offsets section of the Technology page, set theWall offset, Island offset and Floor offset values to 0. These offsets remain unmachined during roughing and areremoved in the next finishing operations.
Wall offset — the roughing offset remaining on the wall of the pocket. Floor offset — the roughing offset remaining on the floor of the pocket. Click the Databutton.
Set the Radius of the descent helixto 3 and confirm the dialog box with the OK button. Define the Lead outIn the Lead out section, choose the Arc option. Set the Radius value to 2. The Pocket operation data is saved, and the toolpath is calculated. SimulatePerform the Pocket operation simulationin the SolidVerify mode. In order to complete the machining, you have toperform an additional Pocket operation with a tool of a smaller diameter in the areasthat were not machined in the current Pocket operation.
Add a new Pocket operationAdd a new Pocket operation. SolidCAM enables you to use the existing operations astemplates for new ones. In this case, the last created Pocket operation is used to definea new Pocket operation from the template.
All the parameters of the chosen operation are copied to the current one. Change the ToolDefine a new tool for the operation. The Part Tool Table dialog box is displayed. Since this tool is used in severaloperations, its parameters cannotbe edited. Click to define a new tool. Choose the End mill tool fromthe Tool type dialog box. A new Tool 4 is added with thedefault parameters. Choose thetool holder. In the Holder page, select the Use holdercheck box and click the Local tab.
Choosethe BT40 ER32x60 collet chuck from thelist. During the machining, when a large tool is used, the tool leaves materialin areas that it cannot enter.
Unmachined areaMachined areaGeometryThe Rest material option enables you to remove the material from theseareas without defining a new geometry. The new Rest tab appears and opens the pageautomatically. Notice that the Separate areas option ischosen by default in the Milling type box. When this option is chosen, SolidCAM performs the machining only in areas thatwere not machined with the previous tool.
Define the diameter of the end mill that was used in the previous operation. Click thePrevious tool diameter button. In the Previous wall offset field, set the value of 0.
This offset was defined in theprevious Pocket operation. Define the Ramping strategyIn the Ramping section of the Link page, choose the Helicalstrategy to define how the tool enters into the material. Click theData button. Set theZ-entry helix Radius to 3. With the defined parameters, the tool machines all the areasthat were not machined by the previous tool. The machining area is extended by 1mm to overlap the previously machined area. The Pocket operation data is saved, and the tool path is calculated.
SimulatePlay the simulation of the Pocketoperation in the SolidVerify mode. Notice that the machining is performedonly in the areas that were not machinedin the previous operation. At this stage, the rough machining of the pocket is completed, and you have to programthe finishing operations. Add a Profile operationA Profile operation is used for the finish machining ofthe pocket walls. Define the GeometryIn the Geometry page, click the button to view thegeometries defined for the current Coordinate System.
You can click entries in thelist to display the corresponding geometries on the model. Choose the Contour3 geometry from the list. Confirm the Browse Geometries dialog box by clicking thebutton. Define the Profile depthDefine the Profile depth by clicking on the bottom face of the pocket.
Define the technological parametersIn the Modify section, choose the Right option from theTool side area.
In this operation, use the Equal step down option to keepan equal distance between all Z-levels. Equal Step downThis option enables you toperform all cuts at an equalZ-level distance one from theother. SolidCAM automaticallycalculates the actual step downto keep an equal distancebetween all passes.
When the Equal step downcheck box is selected, Stepdown is replaced by Max. This value is taken intoaccount during the calculationof the actual step down so thatit is not exceeded. Actual Step downMax. Step downSelect the Equal step down check box. Select the Finish check box and set the Max. Step down value to 3. In the Depth type area, choose the Helical option. With the Helical option, the tool performs spiral movements aroundthe geometry with continuous lowering along the Z-axis.
For eachturn around the geometry, the tool moves downward along the Z-axisaccording to the step down value. When the Profile depth is reachedby the spiral movements, SolidCAM performs the last cut with theconstant-Z movement at the Profile depth. Step Down The tool approaches thematerial with the movement normal to the pocketcontour and retreats in the same way. SimulatePlay the simulation in the SolidVerify mode.
Add a Profile operationAdd a new Profile operation to machine the walls of the islands. Select the edge of the island as shown below. Such direction enables you to performthe climb milling of the profile.
The chain is automaticallycompleted. Confirm it by clicking the Yes button. The first chain is defined. Select the edge of the other island as shown below. Make sure that the chain direction is clockwise.
The same buttons are available on the Material DB tab enabling you to manage material definitions in the database. Define the machining of the outside contour In this step, the machining of the outside contour is defined. For this example, the geometry is defined as an open pocket with island. The Geometry, Tool and Levels are defined and the Offsets are specified; the iMachining Technology Wizard automatically produces the optimal Cutting conditions.
The roughing operation is then copied and the iFinish Technology type is used to define the finishing. The following videos demonstrate how different types of geometries are defined in iMachining.
Closed pocket geometries in iMachining This video focuses on several examples of closed pocket geometries and the tool path techniques that iMachining uses when cutting those geometries. Open pocket geometries in iMachining This video focuses on a few examples of open pocket geometries and the tool path techniques that iMachining uses when cutting those geometries.
Semi-open pocket geometries in iMachining This video focuses on several examples of semi-open pocket geometries and the tool path techniques that iMachining uses when cutting those geometries.
For this operation, the machining geometry is defined as an open pocket with island. Mark the outer chain 1-Chain as open to enable the tool to approach from the outside.
This parameter Angle affects the Cutting conditions and Step down values generated by the iMachining Technology Wizard. Click the Upper level button and pick on the top face of the Stock model to define at what Z-level to start the machining. In addition to the picked depths, define a Delta depth to perform machining deeper than the part bottom edge. Set the value to Switch to the Technology Wizard page of the iMachining Operation dialog box. This Wizard automatically calculates the Cutting conditions for the iMachining technology, taking into account the tool data and Milling levels defined for the operation.
Step down When the Automatic option is chosen, the Step down is calculated by the Wizard in accordance with the Pocket depth defined for the operation. When the User-defined option is chosen, the Step down can be defined by specifying a value or by setting the number of steps required to achieve the Pocket depth. Rows are created for each Step down value that is not the same.
Output cutting data This section displays two sets of data related to the current Cutting condition the Spindle speed and Feed rate of the tool, the Step over range, the material cutting speed, Chip Thickness CT , and the Cutting Angle range.
Machining level The Machining level slider enables you to select from calculated sets of Cutting conditions. Moving the slider up in machining levels provide a convenient and intuitive way to control the Material Removal Rate MRR. Increasing the position of the slider increases MRR and machining aggressiveness. For this operation, use the Cutting conditions generated by the Wizard based on the default position of the Machining level slider 3. Run the operation simulation using the default Host CAD mode to view the wireframe tool path.
The simulated tool path is performed as follows: the entire contour is machined with a morphing spiral. Define the finish machining of the outside contour. When the copied operation automatically opens, choose iFinish for the Technology type.
The copied Geometry, Tool and Levels definitions are used for finishing. The default Cutting conditions generated by the Wizard are also used. Run the operation simulation using the default Host CAD mode. The finishing tool path is performed in a single cutting pass. Define the machining of the center pocket In this step, the machining of the center pocket is defined.
For this example, the geometry is defined as a closed pocket. Add a new iMachining 2D operation. Use the default iRough Technology type to define the rough machining of the center pocket feature. Select the lower contour of the pocket for the Geometry definition. Pick the top face of the Stock model for the Upper level definition and the lower face of the pocket for the Pocket depth definition.
Specify the roughing offsets. The default Cutting conditions generated by the Technology Wizard are used. The Link page displays the Ramping angle at which the Helical Entry into the pocket will be performed.
This value is automatically calculated based on the aggressiveness of the Machining level slider. An override check box is provided in the instance you want to manually enter a preferred value.
Simulate the operation using the default Host CAD mode. The tool performs the Helical Entry into the pocket followed by a morphing spiral to the outer walls. Define the finish machining of the center pocket. Specify the finishing offsets.
The pocket corners are cleared first and then a final pass is taken along the walls. Define the machining of the pocket ledge In this step, the machining of the pocket ledge is defined. For this example, the geometry is defined as a semi-open pocket. Use the default iRough Technology type to define the rough machining of the pocket ledge feature.
Select the lower contour of the pocket ledge and then mark the front edge as open using Mark open edges. Pick the top face of the Stock model for the Upper level definition and the lower face of the pocket ledge for the Pocket depth definition.
The tool approaches from the open edge and then performs the roughing tool path, first removing material from the middle of the ledge and then clearing its corners. After the corners are cleared, the tool finishes the walls of the pocket ledge in a single cutting pass.
Verify the tool path and generate GCode In this step, the iMachining tool path is verified. A GCode file is also generated and the iMachining technology is shown managing the Feed rates with each cutting move. To verify the iMachining tool path for all operations at once, right-click the Operations header in the SolidCAM Manager and choose the Simulate command. This exercise is based on another SolidCAM Professor video series that uses the iMachining technology to define the machining of the part shown above.
During the definition process, the most common need-to-know topics about iMachining are covered in detail. Adding a new Machine and Material to the iDatabase After the part file is loaded on your computer, the following video demonstrates adding a new Machine and Material to the iMachining Database as well as defining the important parameters that are required by the iMachining technology. Finally, the machining of the outside contour is defined using the iRough and iFinish Technology types in iMachining.
Using the iMachining Technology Wizard In the following video, the iMachining Technology Wizard is discussed in detail and some of the different settings are used to control the Cutting conditions calculations. Using the iRest Technology type prior to finishing With iMachining, it is possible to use iFinish directly after iRough. In the following video however, there are narrow areas and corners inside the pocket where the roughing tool cannot fit. In such cases, the iRest Technology type is then used to remove the rest material prior to finishing.
The importance of the iRest Data is also explained in detail. The Tool definition and its effects on iMachining In the following video, the Tool definition and its important parameters related to iMachining are covered in detail. Also shown is how the Wizard calculates the depths and what the importance of ACPs are when machining. There are standard 2. Two chains are defined, with the first being the stock boundary and the second being the profile around the part. The stock chain is marked as open, which specifies the tool should start machining from that chain.
A Delta depth is specified for both operations, so the tool machines deeper than the part bottom edge. Five chains are defined, which represent the five through pockets. Two boundaries are picked off the edges the make up the chamfers. Since all ten pockets have the same depth, they can all be machined in one operation. The tool enters the remaining pockets using helical ramping and the defined entry geometry. Customized linking is used to allow short repositions and smooth transitions when starting each cut.
Two chains are defined, with the first being the stock boundary and the second being the bottom of the floor radius. The floor radius is not machined at this time. This excess material was used for clamping in the first setup.
In this case, the default allowance can be used since the desired wall was finished during the top side machining. Two chains are defined, with the first being the outside boundary of the face and the second being an offset edge created in SolidWorks.
The chain is defined as the bottom edge of the radius. For additional documentation and many more Professor videos, visit us on the web at www. With its Morphing spiral tool paths, controlled tool load at each point along the tool path, moating of islands to enable continuous spiral cuts, even with multiple islands, and automatic thin wall avoidance, iMachining brings efficiency to a new level for CAM users.
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Your internet browser will automatically launch and connect to v www. Start by opening SolidWorks. The following steps have to be implemented in order to reach the final CAM-Part: 1. On the iMachining page, disable the Dashboard option.
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