SolidCAM + SolidWorks

The complete integrated Manufacturing Solution

MILLING TRAINING COURSE

2.5D Milling
 SolidCAM 2012
Milling Training Course
2.5D Milling

©1995-2012 SolidCAM
All Rights Reserved.
 Contents

Contents

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.1 About this course......................................................................................................................3

1.2 Basic Concepts ..........................................................................................................................5
1.3 Process Overview .....................................................................................................................5

2. CAM-Part Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Exercise #1: CAM-Part Deinition .............................................................................................. 9

3. SolidCAM 2.5D Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Exercise #2: Cover Machining .................................................................................................... 30

Exercise #3: Cover Machining .................................................................................................... 84
Exercise #4: Bracket Machining ...............................................................................................155
Exercise #5: Electronic Box Machining ..................................................................................157
Exercise #6: Clamp Machining .................................................................................................160
Exercise #7: Basic Part Machining ...........................................................................................168
Exercise #8: Cover Machining ..................................................................................................172
Exercise #9: Mounting Base Machining..................................................................................179
Exercise #10: Support Machining ............................................................................................189

4. Indexial 4-Axis Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197

Exercise #11: Frame Machining ...............................................................................................201

Exercise #12: Mounting Machining .........................................................................................220

5. Indexial 5-Axis Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227

Exercise #13 : Clamp Machining .............................................................................................231

v
6. ToolBox Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235

Exercise #14: Standard Cycles Machining ..............................................................................240

7. Automatic Feature Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . .253

Exercise #15: Pocket Recognition............................................................................................255

Exercise #16: Mounting Box Machining.................................................................................262
Exercise #17: Drill Recognition ...............................................................................................264
Exercise #18: Electronic Box Machining................................................................................288

Document number: SCMTCENG12000

vi
Introduction 1
2
 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 2.5D
Milling technologies. This course covers the basic concepts of SolidCAM 2.5D 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. With the guided exercises you
will learn the commands and options necessary to complete a machining task. The theoretical
explanations are embedded into these exercises to give an overview of the SolidCAM 2.5D Milling
capabilities.

Using this training book

This training book is intended to be used both in a classroom environment under the guidance of
an experienced instructor and as self-study material. It contains a number of laboratory exercises
to enable you 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 various iles that are used throughout
this course. The Exercises folder contains the iles that are required for guided and laboratory
exercises. The Built Parts folder inside the Exercises contains the inal manufacturing projects for
each exercise. Copy the complete Exercises folder on your computer. The SolidWorks iles used
for the exercises were prepared with SolidWorks 2012.

Windows 7
The screenshots in this book were made using SolidCAM 2012 integrated with SolidWorks 2012
running on Windows 7. If you are running on a different version of Windows, you may notice
differences in the appearance of the menus and windows. These differences do not affect the
performance of the software.

3
Conventions used in this book
This book uses the following typographic conventions:
This style is used to emphasize SolidCAM options,
Bold Sans Serif commands or basic concepts. For example, click the
Change to opposite button.

10. Define CoordSys Position The mouse icon and numbered sans serif bold text
indicate the beginning of the exercise action.

This style combined with the lamp icon is used for

Explanation the SolidCAM functionality explanations embedded
into the guided exercises. The lamp icon is also used
to emphasize notes.

4
 1. Introduction

1.2 Basic Concepts

Every manufacturing project in SolidCAM contains the following data:

• CAM-Part – The CAM-Part deines 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, deine 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 deined in the Operation. In short, Operation means how
you want to machine.

1.3 Process Overview

The major stages of the SolidCAM manufacturing project creation process are the following:

CAM-Part definition
This stage includes the deinition of the global parameters of the Manufacturing
Project (CAM-Part). You have to deine a number of Coordinate Systems that describe
the positioning of the part on the CNC-machine.
Optionally, you can deine the Stock model and Target model to be used for the rest
material calculation. The Stock model describes the initial state of the workpiece that
has to be machined. The Target model describes the one that has to be reached after
the machining. After every operation, SolidCAM calculates how much material was
actually removed from the CAM-Part and how much material remains unmachined (rest
material). The rest material information enables SolidCAM to automatically optimize
the tool path and avoid the air cutting.

Operations definition
SolidCAM enables you to deine a number of milling operations. During an operation
deinition you have to select the Geometry, choose the tool from the Part Tool Table
(or deine a new one), deine a machining strategy and a number of technological
parameters.

5
6
CAM-Part
Definition 2
The CAM-Part deinition process includes the following stages:

CAM-Part creation

CNC-controller definition

Coordinate system definition

Stock model definition

Target model defintion

• CAM-Part creation. At this stage, you have to deine the CAM-Part name and location.
SolidCAM deines the necessary system iles and a folder to allocate the place to store
SolidCAM data.
• CNC-controller definition. Choosing a CNC-controller is a necessary step. The controller
type inluences the Coordinate System deinition and the Geometry deinition.
• Coordinate system definition. You have to deine the Coordinate System – the origin
for all machining operations of the CAM-Part.
• Stock model definition. SolidCAM enables you to deine the stock model that describes
the initial state of the workpiece to be machined.
• Target model definition. SolidCAM enables you to deine the model of the part in its
inal state after the machining.

8
 2. CAM-Part Definition

Exercise #1: CAM-Part Definition

This exercise illustrates the CAM-Part deinition process

in SolidCAM. In this exercise, you have to create the CAM-
Part for the cover model displayed and deine the Coordinate
System, the Stock model and Target model that are necessary
for the part machining. The CAM-Part will be used in the
exercises further on.
When you start to program a CAM-Part, you have to decide
what workpiece you are going to use. This decision determines
the number and the type of operations that are used to reach
the inal part shape.
In this exercise, the box stock is used. The box dimensions include offsets from the actual model.

At the next stage, you have to decide on what

type of CNC-machine you are going to use
(3-, 4- or 5-axis). In this exercise, a 3-axis
CNC-machine is chosen for the machining.
With a CNC-machine of this type, all the
required faces of the cover part can be
machined using a single positioning.

9
 1. Load the SolidWorks model
Load the Exercise1.sldprt model located in the Exercises folder.
This model contains a number of features forming the solid body of the cover.

2. Start SolidCAM
To activate SolidCAM, click the SolidCAM ield in the
main menu of SolidWorks and choose Milling from the
New submenu or click New > Milling on the SolidCAM Part
toolbar.

SolidCAM is started and the New Milling Part dialog box

is displayed.

10
 2. CAM-Part Definition

New Milling Part dialog box

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

Specify the location of the CAM-Part. The default directory is the

SolidCAM user directory (deined in the SolidCAM Settings). You can
enter the path or use the Browse button to deine 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 ield shows the name and location of the SolidWorks design model
that you are using for the CAM-Part deinition. The name is, by default,
the name of the active SolidWorks document. With the Browse button
you can choose any other SolidWorks document to deine 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.

11
 3. Confirm the CAM-Part creation
When the Directory, CAM-Part Name and Model Name have
been deined, click the OK button to conirm the CAM-Part
creation. The CAM-Part is deined, and its structure is created.
The Milling Part Data dialog box is displayed.

4. Choose the CNC-Machine

Select the CNC-machine controller. Click the arrow in the CNC-
Machine area to display the list of post-processors installed on
your system.
In this exercise, use a 3-Axis CNC-machine with the AWEA1000-
Fanuc CNC-controller. Choose the AWEA1000-Fanuc CNC-
controller from the list.

5. Start the Coordinate System definition

Click the Define button in the Coordinate System area to deine
the Machine Coordinate System.

12
 2. CAM-Part Definition

To complete the CAM-Part deinition, you need to deine the

Machine Coordinate System.

The Machine Coordinate System deines the origin for all machining
operations of the CAM-Part. It corresponds with the built-in controller
functions.
You can deine the Coordinate System origin position and axes orientation
by selecting model faces, vertices, edges, or SolidWorks Coordinate
Systems. The geometry for the machining can also be deined directly
on the solid model.
Coordinate
System
Z
Y

The Z-direction of the Machine

Coordinate System is parallel to the
revolution axis of the tool. Z Y
Machine
In SolidCAM, the tool approaches from Coordinate
the positive direction of the Z-axis (like System
X
on a vertical CNC-machine).

Z
Y
X X
Y
Coordinate
Coordinate
System
System Z

13
 For 3-Axis CNC milling machines, each Machine Coordinate
System means separate clamping. If you need to machine the part
from different sides, use several Machine Coordinate Systems with
the Z-axis oriented normally to the machined sides.
In this exercise, it is enough to
Z
deine one Machine Coordinate
System with the Z-axis oriented Y X

upwards. Coordinate
System
Such coordinate system enables
you to machine the part with a
single clamping.

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

SolidCAM enables you to deine the CoordSys using the following

methods:

Select Face

This method enables you to deine a new

CoordSys by selecting a face. The face can be
planar or cylindrical/conical. For planar faces,
SolidCAM deines CoordSys with the Z-axis
normal to the face. For cylindrical or conical
faces, the Z-axis of the CoordSys is coincident
with the axis of revolution of the speciied
cylindrical/conical surface.

Define

This method enables you to deine the

Coordinate System by selecting points. You
have to deine the origin and the direction of
the X- and Y-axes.

Select Coordinate System

This method enables you to choose the SolidWorks Coordinate System

deined in the design model ile as the CoordSys. The CoordSys origin
and axes orientation are the same as those of the original SolidWorks
Coordinate System.

14
 2. CAM-Part Definition

Normal to Current View

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

This option enables you to deine the Coordinate System by selecting

any 3 points.

6. Select the model face

With the Select Face method chosen,

click on the model face as shown.
The CoordSys origin is automatically
deined in the corner of the model box.
The Z-axis of the CoordSys is normal to
the selected face.

Model box

SolidCAM calculates the box surrounding the model. The upper plane
of the model box is parallel to the XY-plane of the deined CoordSys.
The CoordSys is located in the corner of the model box.
Coordinate
System
Z
Y
X

15
 Conirm by clicking the button. The Coordinate System is deined.
The CoordSys Data dialog box is displayed.

7. CoordSys Data
This dialog box enables you to deine the Machining
levels such as Tool Start Level, Clearance Level,
Part Upper Level, etc.

CoordSys Data dialog box

The Machine CoordSys Number deines the number of the CoordSys in

the CNC-machine. The default value is 1. If you use another number,
the GCode ile contains the G-function that prompts the machine to use
the speciied number stored in the machine controller of your machine.
The Position ield deines the sequential number of the CoordSys. For
each Machine Coordinate System, several Position values are deined for
different positionings; each such Position value is related 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.
The Plane box deines the default work plane for the operations
u tng this CoordSys, as it ts output to the CCode program. In the
SolidCAM CAM module, you must always work on the XY-plane. Some
CNC-machines, however, have different axes deinitions and require a
GCode output with rotated XY-planes.
Shift is the distance from the Machine Coordinate System to the location
of the Position in the coordinate system and the orientation of the
Machine Coordinate System.

16
 2. CAM-Part Definition

Rotation is the angle of rotation around the main axes X, Y and Z.

The Front and Rear tabs contain sets of facial machining levels describing
the planes parallel to the XY-plane and located along the Z-axis.
The Front tab displays levels for milling from the positive Z-direction.
The Rear tab displays levels for milling from the negative Z-direction.
The negative Z-direction can be used in case of milling of the part from
the back side with the same Coordinate System in the main spindle or in
case of using the back spindle.
The Radial tab contains a set of machining levels describing the virtual
cylinders situated around the Z-axis.
These tabs contain the following parameters:
• The Tool Start level deines the Z-level at which the tool starts
working.
• The Clearance level is the Z-level to which the tool moves rapidly
from one operation to another (in case the tool does not change).
• The Part Upper level deines the height of the upper surface of the
part to be milled.
• The Part Lower level deines the lower surface level of the part to be
milled.

Tool start
level
Rapid movements area
Part Upper
Clearance Feed movements area level
level Part Lower
level

• The Tool Z-level parameter deines the height to which the tool moves
before the rotation of the 4/5 axes to avoid collision between the tool
and the workpiece. This level is related to the CoordSys position and
you have to check if it is not over the limit switch of the machine.
It is highly recommended to send the tool to the reference point or
to a point related to the reference point.
The Create planar surface at Part Lower level option enables you to
generate a transparent planar surface at the minimal Z-level of the part
so that its lower level plane is visible. This planar surface provides you
the possibility to select points that do not lie on the model entities. It

17
 is suppressed by default and not visible until you unsuppress it in the
FeatureManager Design tree.

Conirm 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 the Machine CoordSys.

Conirm the CoordSys Manager dialog box with the

button. The Milling Part Data dialog box is displayed again.

8. Define the Stock model

For each Milling project, you can deine the Stock model, which is the workpiece that is
placed on the machine before you start machining the CAM-Part.
Click the Stock button in the Stock & Target model section of
the Milling Part Data dialog box.

The Model dialog box is displayed. This dialog box enables you
to choose the mode of the Stock model deinition.

Stock Model Definition Modes

• Box – in this mode SolidCAM automatically determines the box

surrounding the model.
• Extruded boundary – this mode enables you to deine the 2D stock
geometry by selecting a chain of geometrical elements (lines, arcs,
splines, edges, etc.).
• 3D Model – this mode enables you to deine the stock model via 3D
model selection.

18
 2. CAM-Part Definition

• Cylinder – this mode enables you to deine the stock model as a

cylinder (or a tube) surrounding the selected solid model.
• STL file – this mode enables you to deine the stock model based on
a STL ile that exists in your system. When you choose this mode, the
STL file section becomes available. By clicking the Browse button,
you can choose the STL ile for the stock deinition.

Choose the Box mode from the Defined by list. The appearing dialog box enables you
to select a solid body for the surrounding box calculation.
Optionally, offsets from the model can be deined. In this exercise, deine the stock
model offsets as follows:
• For the X+, X-, Y+ and Y- offsets, use the default values of 2;
• For the Z+ offset, set the value to 0.25.
• For the Z- offset, set the value to 5.
Click on the solid body. One of its faces is highlighted.

SolidCAM automatically generates the surrounding box.

Conirm the Stock model deinition by clicking the button.

The Milling Part Data dialog box is displayed.

19
 9. Define the Target model
SolidCAM enables you to deine the Target model, which is
the inal shape of the CAM-Part after the machining. SolidCAM
uses the Target model for gouge checking in the SolidVerify
simulation.
Click the Target button in the Stock & Target model area of the
Milling Part Data dialog box. The Model dialog box is displayed.

By default, when you create a new CAM-Part, stock and target

models are deined automatically. If you have not changed the
default settings, the solid body is highlighted, and the target
model is already chosen in the Type section.

Click on the solid body to clear the selection. Notice that the
Solid 1 icon is also removed from the Type section. Click on
the solid body once again. The face is selected, the Solid 1 icon
appears in the Type section, and the target model is deined.
Conirm the Model dialog box with the button.
The Milling Part Data dialog box is displayed.

10. Save the CAM-Part data

Conirm the Milling Part Data dialog box by clicking
the button.
The Milling Part Data dialog box is closed, and the SolidCAM
Manager is displayed. The deined CAM-Part is saved.

At this stage, the deinition of the CAM-Part is inished. The

deinition of Milling operations is covered in the following
exercise using this CAM-Part.

20
 2. CAM-Part Definition

The Structure of the CAM-Part

The CAM-Part includes a number of data iles represented on the

illustration that displays the data included in the CAM-Part named
Milling.

Milling.prt

Milling

Milling.SLDASM

CAM.SLDPRT

DesignModel.SLDPRT

The Milling.prt ile is located in the SolidCAM User directory. The Milling
subdirectory contains all the data generated for the CAM-Part.
SolidCAM copies the original SolidWorks model to the Milling
subdirectory and creates a SolidWorks assembly that has the same name
as the CAM-Part (Milling.sldasm). There are two components in this
assembly:
DesignModel.sldprt – a copy of the SolidWorks model ile.

CAM.sldprt – a ile 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 (i.e. sketches) without
making changes in the original design model. You can also insert some
additional components into the assembly ile such as stock model, CNC-
machine table, clamping and other tooling elements.

21
 The SolidCAM Manager tree is the main interface feature of SolidCAM
that displays complete information about the CAM-Part.

SolidCAM
Manager

The SolidCAM Manager tree contains the following elements:

CAM-Part header

Tool header

Machining Process
header

Geometries header

Fixtures header

}
Operations header

Operations

• CAM-Part header

This header displays the name of the current CAM-Part. By right-

clicking it, you can display the menu to manage your CAM-Parts.
The Machine subheader is located under the CAM-Part header.
Double-click this subheader to review your machine coniguration
and parameters.
The CoordSys Manager subheader is located under the CAM-Part

22
 2. CAM-Part Definition

header. Double-click this subheader to display the CoordSys Manager

dialog box that enables you to manage your Coordinate Systems.
The Stock and Target subheaders are located under the CAM-Part
header. Double-click these subheaders to load the Stock model/
Target model dialog boxes that enable you to change the deinition of
the Stock/Target models.
The Settings subheader is also located under the CAM-Part header.
Double-click this subheader to load the Part Settings dialog box that
enables you to edit the settings deined for the current CAM-Part.
• Tool header

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

This header displays the name of the current Machining Process

table.
• Geometries header

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

This header displays available ixtures. By right-clicking it, you can

display the menu to deine and manage your ixtures.
• Operations header

This header displays all SolidCAM operations deined for the current
CAM-Part.

23
 11. Close the CAM-Part
Right-click the CAM-Part header in the SolidCAM
Manager tree and choose Close from the menu.

The CAM-Part is closed.

24
SolidCAM 2.5D
Operations 3
SolidCAM offers you the following types of 2.5D Milling operations:

2.5D Milling Operations

Face Milling Slot

Profile T-Slot

Contour 3D Translated Surface

Thread Milling ToolBox Cycles

Pocket Drilling

Pocket Recognition Drill Recognition

In SolidCAM, an operation is a single machining step. A workpiece is usually manufactured using

several machining steps and technologies. For each of these steps you can deine a separate
operation. An operation can be very complex, but it always uses one tool, one major geometry
and executes one machining type, e.g. Proile Milling or Drilling. You can edit any single machining
operation, change the operation sequence and generate the GCode, combining and splitting the
operation list of your CAM-Part.
The Machining Geometry has to be deined for each operation. The Geometry prompts SolidCAM
what and where you want to machine.
• A Geometry for Proile, Pocket, Contour 3D, Slot and T-Slot operations, and Toolbox
cycles consists of a number of chains. Chain geometries are deined by selecting the
following entities: edges of models, 2D curves, 3D curves, circles, lines and splines.
Each chain is composed of one or more entities and deines an open or closed contour.
• A Geometry for Face Milling operations can be deined by selecting solid models, faces
or chains of model elements.
• A Geometry for Drilling and Thread Milling operations consists of one or more points
(drilling centers) that can be deined by a number of methods directly on the solid
model.
• A Geometry for Drill Recognition and Pocket Recognition operations is determined
automatically by SolidCAM Automatic Feature Recognition functionality.

26
 3. SolidCAM 2.5D Operations

Face Milling Operation

This operation enables you to machine large lat surfaces with
face mill tools.

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

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

27
Slot Operation
This operation generates a tool path along the centerline to the
right or to the left of one or more proiles. Two types of slots can
be deined: the Slot with constant depth operation machines the
slot in several steps until the inal depth is reached. In Slot with
variable depth, the depth proile is also deined by a 2D section.
The slot can be pre-machined using rough and semi-inish cycles.
The inish cut produces a tool path according to the speciied
scallop height on the loor of the slot. With available parameters
for the right and left extension and the side step, you can mill
a slot wider than the tool diameter.

T-Slot Operation
This operation enables you to machine slots in vertical walls with
a slot mill tool.

Drilling 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 deined using the General Pre- and Post-
processor program (GPPTool).

28
 3. SolidCAM 2.5D Operations

Drill Recognition
This Operation carries out a highly eficient drill recognition
and geometry creation with the functionality of the AFRM-
module (Automatic Feature Recognition and Machining). In
this operation drilling on different levels can be carried out.
The drilling levels are automatically recognized but may be
edited by the user.

Pocket Recognition
This Operation recognizes automatically pocket features at
the target model and creates the necessary machining.

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

Thread Milling Operation

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

29
Exercise #2: Cover Machining

In this exercise, you use the CAM-Part deined in the Exercise

#1. You have to deine several 2.5D operations in order to
machine the model external faces, pocket and holes in the
corners.
In the process of deinition of operations, you have to deine
the machining geometry, the tool and several technological
parameters.

1. Open the CAM-Part

In the menu, choose SolidCAM > Open, or click Open on the
SolidCAM Part toolbar.

In the browser window, choose Exercise1 – the CAM-Part prepared

in the previous exercise.
The CAM-Part is loaded.

30
 3. SolidCAM 2.5D Operations

2. Add a Face Milling operation

In SolidCAM Manager, right-click the Operations header and choose Face from
the Add Milling Operation submenu.

The Face Milling Operation dialog box is displayed.

In this operation, the upper face is machined.

31
 3. Define the Face Milling geometry
Click the New button ( ) in the Geometry page. The Face
Milling Geometry dialog box is displayed.

The Type section enables you to deine the face milling geometry using
the following methods:

• Model

This option generates a rectangle located at the XY-plane and surrounding

the Target model and selects it for the Face Milling geometry. The
rectangle chain is displayed in the Chain List section.

Face Milling geometry

32
 3. SolidCAM 2.5D Operations

• Faces

This option enables you to deine the Face Milling geometry by face
selection. The Define button and the related box enable you either to
deine a new faces geometry with the Select Faces dialog box or choose
an already deined geometry from the list. When the model faces are
selected, SolidCAM generates a number of chains surrounding the
selected faces. These chains are displayed in the Chain List section.

Face Milling geometry

Selected faces

• Profile

This option enables you to deine the Face Milling geometry

by a proile. The Define button and the related box enable you either
to deine a new proile geometry with the Geometry Edit dialog box or
choose an already deined geometry from the list. The deined chains are
displayed in the Chain List section.
Face Milling geometry

33
 In the Type section, use the default Model option for the Face Milling geometry
deinition. Click the Define button. The 3D Geometry dialog box is displayed.

This dialog box enables you to deine the 3D Model

geometry by selecting the following types of model
elements:
• Solid – only solid objects are selected;
• Surfaces – only surfaces are selected;
• Both – both surfaces and solids will be selected.
The CAD selection button enables you to select the
3D geometry with SolidWorks tools.
You can select an object by clicking on it. When an
object is selected, its icon is displayed in the list in
the bottom of the dialog box. To unselect the object,
click on it again or right-click its icon in the list of
selected elements and choose Unselect from the
menu. To remove selection from all objects in the
list, click Unselect all.

Click on the solid model to select it. The

model is highlighted, and its icon appears
in the list. Conirm the 3D Geometry
dialog box by clicking the button.
The Face Milling Geometry dialog box is
displayed again.
The rectangle is generated surrounding
the target model at the XY-plane.
Conirm the Face Milling Geometry
dialog box by clicking the button.
The geometry is deined for the operation.

34
 3. SolidCAM 2.5D Operations

4. Define the Tool

Switch to the Tool page of the Face Milling Operation dialog box. Start the tool deinition
by clicking the Select button.

The Choosing Tool for Operation dialog box with a Part Tool Table is displayed.

The Part Tool Table contains all tools available for use to machine
a speciic CAM-Part. The Part Tool Table is stored within the CAM-Part.
The Choosing Tool for Operation dialog box enables you to manage the
tools contained in the Part Tool Table.

35
 Currently, the Part Tool Table is empty. Deine a new tool suitable for face milling.
Click the Add Milling Tool button ( ) to start the tool deinition.
The new pane containing available tools is displayed.

This dialog box enables you to add a new tool to the tool library choosing from the
tools available for the current operation. In this operation, a face mill of Ø100 will be
used.

Face mill

This tool type is used for machining of large lat surfaces. A tool of this
type is deined with the parameters shown in the image.
Arbor Diameter
Total Length

Shoulder
Outside
Length
Holder
Length

Cutting
Length Taper
Angle

Tip Diameter

Diameter

36
 3. SolidCAM 2.5D Operations

Choose the Face mill tool.

In the new pane, deine the following parameters:
• Set the Diameter to 100;
• Set the Arbor Diameter to 80.
Click the Select button to conirm the tool parameters and choose the tool for the
operation.

5. Define the Face depth

Switch to the Levels page of the Face Milling Operation dialog box. Click the Face
depth button in the Milling levels area. This button enables you to deine the Operation
Lower level directly on the solid model. The depth is calculated automatically as the
difference between the Z-values of the Operation Upper and Lower levels.

37
 The Pick Lower level dialog box is
displayed.

Select the model face as shown.

The lower level value (0) is determined and displayed in the Pick Lower level dialog box.
Conirm this dialog box with the button.
The Face depth value is displayed in the Milling
levels area. The pink background of the edit box
means that the parameter is associative to the
model. Associativity enables the selected level to
be synchronized with the solid model changes;
SolidCAM automatically updates the CAM data
when the model is modiied.

6. Define the technological parameters

Switch to the Technology page of the Face Milling Operation dialog box. In the
Technology section, choose the One Pass option.

38
 3. SolidCAM 2.5D Operations

One Pass machining technology

SolidCAM performs the face milling

in one pass. The direction and location
of the pass are calculated automatically
according to the face geometry, in
order to generate an optimal tool
movement with the tool covering the
whole geometry.
Selecting the One pass option
automatically opens the One pass
tab that enables you to deine the
machining parameters.

The Extension section enables you to deine the tool path extension
over the face edges. The extension can be deined either by
percentage of the tool diameter (the % of tool diameter option) or by
value (the Value option).

Extension

7. Save and Calculate

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

39
 8. Simulate
Click the Simulate button in the Face
Milling Operation dialog box. The
Simulation control panel is displayed.

Switch to the SolidVerify page and start

the simulation with the button.

The solid stock model deined in Exercise #1 is used in the SolidVerify

simulation 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. It can also be compared to the
target model in order to show the rest material.
During the simulation, you can rotate , move , or zoom the
model. Use these options to see the machining area in details.
The Single step mode can be used to simulate the next tool movement by
clicking the button or by using the space bar on your keyboard.

Close the simulation with the button. The Face Milling Operation dialog box is
displayed. Close this dialog box with the Exit button.

9. Add an operation
Right-click the Face Milling operation
entry in SolidCAM Manager and choose
Profile from the Add Milling Operation
submenu.
The Profile Operation dialog box is
displayed.
In this operation, the external proile is
machined.

40
 3. SolidCAM 2.5D Operations

10. Define the Geometry

The irst step of deinition of each operation is the Geometry selection. At this stage,
you have to deine the Geometry for the Proile operation using the solid model
geometry.
Click in the Geometry page of the Profile Operation dialog box.

The Geometry Edit dialog box is displayed in the SolidWorks

PropertyManager area. This dialog box enables you to add and edit
geometry chains.
When this dialog box is displayed, you can select solid model entities
for the Geometry deinition.

41
 Chain Selection Options

You can deine the geometry by selecting edges,

sketch segments and points on the contour.
The following options are available:
Curve

This option enables you to create a chain of

existing curves and edges by selecting them
one after the other.

Associativity: SolidCAM keeps the associativity to any edge or sketch

entity. Any change made to the model or sketch automatically updates
the selected geometry.

Curve + Close corners

This option enables you to close the gaps between successive chain
entities irrespective of the Gap minimum and Gap maximum values
(deined in the Units section of SolidCAM Settings) by virtually extending
the entities up to their intersection.

Splines and arcs are extended by lines

tangential to the arc/spline at its end point.

42
 3. SolidCAM 2.5D Operations

Associativity: When the model used for the geometry deinition is

modiied, SolidCAM enables you to synchronize the geometry with the
updated model. During the synchronization, SolidCAM determines gap
areas created using the Curve + Close Corners option and regenerates
the extension of the chain elements so as to close the gaps.

Loop

This option enables you to select a loop by picking one of the model
edges.
Loop #2

Loop #1

1. Pick an edge shared by two model faces. Two faces to

which this edge belongs are determined, and their loops
are highlighted. The irst determined loop is considered
to be the primary and is highlighted with yellow color.
The second loop is considered to be the secondary and
is highlighted with blue color.
2. Choose one of the loops. Click on any other edge
forming the face. You are prompted to accept the chain
that is now highlighted with yellow color. Accept the
chain with the Yes button. A closed geometry chain is
deined on this loop, and the secondary loop is rejected.
Associativity: SolidCAM keeps the associativity to any edge or sketch
entity. Any change made to the model or sketch automatically updates
the selected geometry.

43
 Point to point

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

Associativity: SolidCAM does not keep the associativity to any selected

point. SolidCAM saves the X-, Y- and Z-coordinates of the selected
points. Any change made to the model or sketch does not update the
selected geometry.
You cannot select a point that is not located on a
SolidWorks entity (if you need to select such a point, add
a planar surface under the model and select the points
on that surface).
The following rules apply to the virtual line selection using the Point to
point option:

• When you select a virtual line between two edges, the line
behaves as a spring. Whenever the model is changed and synchronized,
the geometry is updated with the model.
• When you select a sequence of several virtual lines, only the points
connected to model edges or sketch elements are updated, but all
other points stay ixed at the deined X-, Y- and Z-positions.

44
 3. SolidCAM 2.5D Operations

Arc by points

This option enables you to create a chain segment on an arc up to

a speciic point on the arc.

Second Third
point point

First
point

Associativity: SolidCAM does not keep the associativity to any selected

arcs by points. SolidCAM saves the X-, Y- and Z-coordinates of the
selected points. Any change made to the model or sketch does not
update the selected geometry.
Automatic selection options

SolidCAM automatically determines the chain

entities and close the chain contour. The Auto
select mode offers the following options:
Auto-to

The chain is selected by specifying the start curve,

the direction of the chain and the element up to
which the chain is created. SolidCAM enables
you to choose any model edge, vertex or sketch
entity to determine the chain end.
When the end item is chosen, SolidCAM determines the chain according
to the rules of the chosen selection mode (Auto-general, Auto-constant
Z or Auto-Delta Z). The chain selection is terminated when the selected
end item is reached.

End entity

Start entity Selected chain

45
 If the chosen end item cannot be reached by the chain low, the chain
deinition is terminated when the start chain segment is reached. The
chain is automatically closed.
End entity

Start entity Selected chain

The conirmation message is displayed.

The Auto-to option is useful if you do not want to deine

a closed chain, but an open chain up to a certain element.

Auto-general

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

46
 3. SolidCAM 2.5D Operations

Auto-constant Z

This option identiies only the entities found on the same XY-plane with
the previously selected chain entity. You are prompted to identify the
next chain element when two entities on the same Z-level are connected
to the chain. The system tolerance for this option can be set in SolidCAM
Settings.

Auto-Delta Z

When you select this option, you are required to enter a positive and
negative Z-deviation into the Delta-Z dialog box. Only entities in this
range are identiied as the next possible entity of the chain.

In this exercise, the geometry must be deined as shown.

The red arrow indicates the direction of the geometry.

47
 In SolidCAM operations, the
Tool revolution
direction of the chain geometry direction
is used for the tool path Tool movement
direction
calculation. In Proile milling,
the tool moves in the direction
of the geometry by default. In
this exercise, the combination
of the geometry direction and
the clockwise direction of the
Geometry
tool revolution enables you to direction
perform climb milling.
When you pick the irst chain entity on the solid model, SolidCAM
determines the start point of the picked entity closest to the picked
position. The direction of the picked irst chain entity is deined
automatically from the start point to the picked position.
Starting point
Direction

Picked position

Geometry chain

Choose the Loop option in the Chain section and click on the model edge as shown.

Notice that the picked

position must be close to the
start point of the geometry.

48
 3. SolidCAM 2.5D Operations

Two faces shared by the selected edge are determined, and their loops are highlighted.
The red arrow indicates the direction of the selected chain.

Click the secondary chain highlighted with blue color to choose it for geometry
deinition.
The picked chain is now highlighted with red color, and the second chain is rejected.

The conirmation message is displayed. Conirm it with the Yes

button.
The chain icon is displayed in the Chain List section.

At this stage, the Geometry is deined. Conirm the Geometry selection with
the button. The Profile Operation dialog box is displayed.

49
 11. Define the Tool
At this stage, you have to deine the tool for the Proile milling.
Switch to the Tool page of the Profile Operation dialog box and click the Select button.

The Part Tool Table with the tool used in the previous operation is displayed.

Click the Add Milling Tool button ( ) to start the tool deinition.

In this Proile operation, an End mill of Ø16 will be used.

50
 3. SolidCAM 2.5D Operations

End Mill/Bull Nose Mill/Ball Nose Mill

These tool types are used for the deinition of rough/inish mills. The
tool shapes and basic parameters are shown below:

Arbor Diameter

Total
Length Outside
holder
Shoulder
Length Cutting
Length

Diameter

Arbor Diameter

Total
Length Outside
Shoulder Holder
Length Cutting
Length

Edge Radius
Diameter
Arbor Diameter

Total
Length Outside
Shoulder Holder
Cutting
Length Length

Edge Radius
Diameter

51
 Click the End Mill tool to choose it for the operation. In the Tool parameter section,
under Topology, set the Diameter value to 16.

Click the Select button to conirm the tool parameters and choose the tool for the
operation.

12. Define the Feed and Spin parameters

Switch to the Data tab in the Tool section of the Profile
Operation dialog box.

52
 3. SolidCAM 2.5D Operations

Set the Spin rate (used in rough milling) value to 6000. The
Spin finish (used in inish milling) value is automatically set
to 6000.

The Spin finish check box enables you to optionally deine different
values for Spin rate and Spin finish. When this check box is selected, the
corresponding edit box is available so that you can edit its value. When
this check box is not selected, the speciied Spin rate value is used for
both rough and inish machining.

Set the Feed XY (feed rate for XY movements) to 1500 and

the Feed Z (feed rate for Z movements) to 250. Select the
check box near the Feed finish (feed rate for inish milling)
parameter and set the value to 1800.

The Feed finish check box enables you to optionally deine different
values for Feed XY and Feed finish. When this check box is selected, the
corresponding edit box is available so that you can edit its value. When
this check box is not selected, the speciied Feed XY value is used for
both rough and inish machining.

13. Define the Milling levels

Switch to the Levels page of the Profile Operation dialog box.
SolidCAM enables you to deine the milling levels using the solid model data.

53
 Upper Level

This parameter deines the Z-level at which the machining starts.

Profile Depth

This parameter deines the Z-level below which the tool does not mill.
This plane is not penetrated in any milling strategy.

Coord. System
Z
X

Y
Upper
Level
Profile
Depth

Click the Upper level button in the Milling

levels area. The Pick Upper level dialog
box is displayed.
Select the model face as shown.
The Upper Level value (0) is determined
and displayed in the Pick Upper level
dialog box. Conirm this dialog box by
clicking the button.
Click the Profile depth button in the
Milling levels area. The Pick Lower level dialog box is displayed.

Pick the bottom edge of the model as

shown.
The Lower level value (-10) is determined
and displayed in the Pick Lower level
dialog box. Conirm this dialog box with
the button.

54
 3. SolidCAM 2.5D Operations

Now you need to deine the Delta depth.

The Delta depth parameter deines the offset for the cutting depth
that can be changed with its associativity preserved. The Delta depth
value is always relative to the Profile Depth deined for the operation.

Set the Delta depth value to -1.

The milling levels are deined.

14. Define the technological parameters

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

First, you need to make sure that the tool position relative to the geometry is correct.
In the Modify section, check the Tool side option.

55
 Modify

The Tool side option enables you to determine the tool position relative
to the geometry.
Right – the tool cuts on the right side of the proile geometry.

Left – the tool cuts on the left side of the proile geometry.

Center – the center of the tool moves on the proile geometry (no
compensation G4x can be used with this option).

Left Right Center

The Geometry button displays the Modify Geometry dialog box that
enables you to deine the modiication parameters of the geometry
and to choose which geometry chains are active in the operation (in
case of multiple chain geometry). The chain geometry of the proile
is displayed on the model with the chain direction indicated and
a circle representing the tool relative to the geometry.

In this case, the default Left option meets the

requirements of climb milling. Click the Geometry button
to check the tool position.

Click the button in the Modify

Geometry dialog box. The Profile
Operation dialog box is displayed again.

SolidCAM enables you to perform the rough and inish machining of the proile in
a single Proile operation.

56
 3. SolidCAM 2.5D Operations

Deine the parameters of the Proile roughing. Select the Rough check box. Deine
the Step down parameter for roughing.

Step down
Step down
Proile roughing is performed in Upper
constant Z-passes. The Step down level
parameter deines the distance
between each two successive
Profile
Z-levels. depth

Set the Step down to 5. With this value, SolidCAM

performs two cuts at the following Z-levels: -5, -10; the last
cut is performed at the Z-level deined by Profile depth.
Now you need to deine the wall offset that will remain after the roughing passes.

Offsets

The Wall offset and Floor offset parameters enable you to deine the
allowances that remain on the walls and the loor of the machined part
till the proile inish machining. These allowances can be removed with
the inish passes in the same Proile operation or in an additional Proile
operation with another tool.

Step down
Wall offset
Profile depth

Floor offset

In the Offsets section, set the Wall offset value to 0.5. The
allowance of 0.5 mm will be left on the model walls during
the proile roughing. This allowance will be removed with
a separate inishing cut in the end of the proile machining.

57
 Select the Finish check box to perform the inishing of the
proile.

15. Define the Lead in and Lead out

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

This page enables you to deine the way the tool approaches the proile and retreats
away.

Profile Lead in and Lead out

The lead-in movement is necessary to prevent vertical entering of the

tool into the material. With the lead-in strategies the tool descends to the
machining level outside of the material and then horizontally penetrates
the material with the lead-in movement. The lead-out strategy enables
you to perform the retract movements outside the material.
The following options are available:
• None

The tool leads in to and out from the milling

level exactly adjacent to the start point of the
proile.

58
 3. SolidCAM 2.5D Operations

• Normal

The tool leads in to and out from the Normal

proile from a point normal to the Length

proile. The length of the normal can Tangent

be set in the Normal length ield. The Extension

distance between the normal and

material is set in the Tangent extension
ield.
• Arc
Radius
The tool leads in to and out from the
proile with a tangential arc. The arc
Tangent
radius can be set in the Radius ield. The Extension
length of the extension can be set in the
Tangent extension ield. The arc angle is
set in the Arc angle ield.
• Tangent

The tool leads in/out on a line tangent Length

to the proile. The length of the tangent Tangent

can be set in the Length ield. The Extension

distance to the material can be set in the

Tangent extension ield.

• Point

The tool leads in/out from a user-

deined position. From this position, the
tool moves on a straight line to the start
point of the proile. When you select
this option, the Pick button is activated Tangent
Extension
so that you can select a position directly
on the solid model. The distance
between the point and material is set in
the Tangent extension ield.
• User-defined

The tool leads in/out from a user-deined position. When you select this
option, you can deine a geometry of the tool approach to the material.
When the Same as Lead in check box is selected, the strategy and
parameters deined for Lead in are used for Lead out.

59
 Under Lead in, choose the Arc option
from the list, and set the Tangent
extension value to 5 and the Radius value
to 2.
Under Lead out, select the Same as Lead
in check box.

The deinition of the basic technological

parameters of proile milling is inished.

16. Calculate the Tool path

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

17. Simulate the operation

Click 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 Play
button.

When the simulation is inished, play the it step by step using the button.

Switch to the Host CAD simulation mode and click the Play button.

60
 3. SolidCAM 2.5D Operations

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

Close the simulation with the Exit button. The Profile Operation dialog box is
displayed.

18. Add a Pocket operation

The Pocket operation is used for the internal
pocket machining. Right-click the last deined
Proile operation and choose Pocket from the
Add Milling Operation submenu.

The Pocket Operation dialog box is displayed.

61
 19. Define the Geometry
The geometry for a Pocket operation is generally represented by closed chains. In this
exercise, you have to deine a chain using the solid model edges.
Click the button in the Geometry
page to start the geometry deinition.
The Geometry Edit dialog box is
displayed.
Using the Loop option, deine the
chain as shown.
Conirm the geometry deinition by
clicking the button.
The Pocket Operation dialog box is displayed.

20. Define the Tool

Switch to the Tool page and click the Select button.
The Part Tool Table is displayed.

Click the to start the tool deinition. The Tool type table is displayed.
In this Proile operation, an End mill of Ø8 will be used.

62
 3. SolidCAM 2.5D Operations

Choose the End mill tool for the operation. In the Topology page, set the Diameter
value to 8.

Click the Select button to conirm the tool parameters and choose the tool for the
operation.

21. Define the Milling levels

Switch to the Levels page of the Pocket
Operation dialog box and deine upper
and lower levels of machining directly on
the solid model.
Deine the Upper level as shown. The
Upper levelvalue (0) is determined.
Deine the Pocket depth by clicking on
the pocket bottom face as shown. The Pocket depth value (8) is determined.

Set the Step down value to 4 to perform the pocket

machining in two equal steps.

63
 22. Define the technological parameters
Switch to the Technology page of the Pocket Operation
dialog box. In the Offsets section, set the Wall offset
and the Floor offset values to 0.2. These offsets remain
unmachined during roughing and are removed with the
further inishing.
In the Finish area, select the Wall and Floor check boxes.
These options enable you to perform inishing of the Wall
offset and Floor offset that remain after the roughing.

Deine the machining strategy. Make sure that the default

Contour option is chosen in the Technology section. When
the Contour strategy is chosen, the tool moves on offsets
parallel to the pocket contour.

Switch to the Contour tab to display the Contour

parameters. This page enables you to deine the
parameters of the Contour strategy.

64
 3. SolidCAM 2.5D Operations

Contour parameters

Start from

• Inside

This option allows you to work in a pocket area starting from the
middle of the pocket and cutting towards the outside border of the
pocket.
• Outside

This option allows you to work in a pocket area starting from the
outside border of the pocket and cutting towards the middle of the
pocket.
Corner

• None

The tool path is formed with sharp

corners between one direction and the
next.

• Fillet

This option connects each direction with

a given radius allowing for a smoother
transition between path directions.
The Min. corner radius option enables
you to deine the minimal value of the
corner radius.

If the given radius is too large for a speciic corner, it

produces the largest possible radius at that point.
Sometimes the illet option can leave some material.
This particularly happens if the given radius is large.

65
 • Loop

This option ensures that the connecting

points on the path are cleaned using a
smooth transition. The tool path forms
a loop in the corner, preventing an
abrupt change of direction.

• Sharp

This option ensures that using a short

and simple movement cleans the
connecting points on the path. Although
this produces a sharp movement by the
tool, the path itself is slightly shorter
than the smooth corner option. This
can help cut down on machining time.

This option is not recommended for high-speed cutting.

Direction

This option enables you to choose climb or conventional milling for the
roughing operation.

Climb milling Conventional milling

66
 3. SolidCAM 2.5D Operations

Adjacent passes connection

This option enables you to choose the method of the tool movement
within the pocket from one tool path pass to the next one.
• Linear

The tool performs normal approach from

one tool path pass to the next one.

• Rounded

The tool performs an arc movement from

one tool path pass to the next one. The
radius of the arc is half the distance between
the tool path passes.

• Smooth

The tool performs a smooth movement from one tool path pass to
the next one.

67
 Exit material

This option controls the tool movements between the working areas.

Exit material check box not Exit material check box

selected selected

When the tool moves from one The tool exits the material
working area to the next, it moves and travels rapidly above the
through the full material around material to the next working
the island to get to the next area as shown above. The lead
working area as shown above. in path is the Lead in you deine.
Connect islands

This option enables you to keep the

same cutting direction (conventional or
climb milling) throughout the entire tool
path where possible. This is particularly
important in high-speed cutting.

23. Define the Ramping strategy

Switch to the Link page of the Pocket Operation dialog
box. Deine the strategy with which the tool is plunging
into the material during the pocket roughing.

68
 3. SolidCAM 2.5D Operations

The following Ramping strategies are available for rough machining of

pockets:

• None

The tool enters the material vertically at the pocket start point chosen
automatically by the SolidCAM pocket algorithm.
• Vertical

The tool enters the material vertically at a user-deined position. From

this position, the tool moves to the pocket start point calculated by
the pocket algorithm. Click the Data button to specify the position
where the tool plunges into the material.
• Angle

The tool moves to the pocket start point at a speciied ramp angle.
The start point must be selected using the Data button. Enter the
ramping angle value into the Angle edit box of the Angle ramping
dialog box.
SolidCAM does not check the ramping movement against the pocket
contour. Check the tool path simulation to make sure that the tool
does not gouge the pocket walls or islands.
• Helical

The tool descends from the safety distance above the Upper level to
the material in a circular motion until the step down is reached using
the user-deined radius. When the tool reaches the step down depth,
it machines all the material at the step down depth. Click the Data
button to set the helical ramping parameters.
• Linear

The Linear ramping follows the same rules as the Helical ramping.
The difference is that the descent is performed in a linear zigzag
fashion rather than in a circular one.

69
 Choose the Helical option and click the Data button.

The Helical ramping dialog box is displayed. This dialog box enables you to deine
the ramping position and the related parameters for each chain used in the Pocket
operation.

Helical Ramping Parameters

The Tool step down parameter deines the

distance between each two adjacent turns of the
tool helical movement.
The Angle parameter deines the ramping angle.
The Radius parameter deines the radius of the
descending helix.
Center cutting

If your tool has center cutting capabilities, select

the Center cutting check box. In the Angle ield,
enter the descent angle that you would like the
tool to follow. In the Radius ield, enter the
radius of the tool path helix.

70
 3. SolidCAM 2.5D Operations

The working order is as follows:

• The tool descends from the safety distance above the Upper level to
the material in a circular motion until the step down is reached using
the user-deined radius.
• When the tool reaches the step down depth, it machines all the
material at the step down depth.
• When the machining is completed at this depth, the tool goes up to
the Clearance level.
• At this stage, the tool repositions itself at the Z safety distance above
the previous step down depth and repeats the Helical Lead in to the
next working depth.
• This process repeats itself until the inal depth has been machined.
If the tool does not have center cutting capabilities, do not select the
Center cutting check box. In the Tool step down ield, enter the depth of
the step down of the tool. The result of this action is the same as with a
center cutting tool except for the following differences:
• The tool descends from the safety distance above the Upper level to
the material in a circular motion up to the Tool Step down.
• At this point, the tool clears a circular path. Then it descends to the
next Tool step down.
• This is repeated until the tool reaches the CAM-Part step down
depth.
• When the tool reaches the step down depth, it machines all the
material on that step down depth.
• When the machining is completed at this depth, the tool goes up to
the Clearance level.
• At this stage, the tool repositions itself at the Z safety distance above
the previous step down depth and repeat the Helical Lead in to the
next working depth.
• This process repeats itself until the inal depth has been machined.

71
 Chains

This section displays the list of all geometry chains deined for the
operation. 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 path
and default ramping positions for all of the chains. The circles represent
the default helical ramping movement deined for each chain.
When a chain entry is selected, SolidCAM displays the tool path and the
default ramping position for this chain. This position is automatically
deined at the start position of the tool path segment relevant for the
current chain. You can change this position by picking a point on the
model or by entering the new position coordinates into the X, Y, Z dialog
box. The schematic circle facilitates the deinition of the position.
When the position is picked, it is marked on the model with
a red dot. The coordinates of the picked point are displayed in the
X, Y, Z dialog box. The start position of the tool path is marked on the
model with a yellow dot. The circle of the tool path color represents the
helical movement of the tool plunging.

Tool path start position Ramping position

When the ramping position is deined, the tool descends into the material
at the speciied ramping position with helical movements according to
the deined parameters. When it reaches the level of the irst cutting pass,
it moves to the start position of the tool path and performs machining
of the pocket.

72
 3. SolidCAM 2.5D Operations

Ramping Position

The Set default button enables you to replace the currently deined
ramping position for the selected chain by the default ramping position
located at the tool path start position.
The Auto next button provides you with the selection mode that enables
you to deine the ramping positions for all of the chains one by one.

Conirm the dialog box with the button.

24. Define the Lead in and Lead out

The Lead in and Lead out strategies are used for deining the horizontal
approach/retreat of the tool to/from the geometry in the inish machining of the
part walls.

Pocket Lead in and Lead out

The following Lead in and Lead out strategies are available for pocket
machining:
• None

The tool leads in to and out from the milling

level exactly adjacent to the start point of
the geometry.
• Normal

The tool leads in and out at the last point

of the geometry with a movement normal
to the pocket contour. The length of the
normal can be set in the Normal length
ield. The distance between the normal and
start of the geometry is set in the Tangent
extension ield.

Tangent
Extension Normal Length

73
 • Arc

The tool leads in to and out from the

geometry with a circular motion, tangent to
the last entity of the pocket contour. The
arc radius can be set in the Radius ield.
The length of the extension can be set in
the Tangent extension ield. The arc angle is
set in the Arc angle ield.

Tangent
Extension
Radius

• Tangent

The tool leads in to and out from the

pocket wall in a movement tangent to the
last proile entity. The length of the tangent
can be set in the Length ield. The distance
to the material can be set in the Tangent
extension ield.

Tangent
Extension Length

When the Same as Lead in check box is selected, the strategy and
parameters deined for Lead in are used for Lead out.

Under Lead in, choose the Arc option

from the list and set the Tangent extension
value to 3 and the Radius value to 2.
Under Lead out, select the Same as Lead
in check box.

74
 3. SolidCAM 2.5D Operations

25. Calculate the Tool path

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

26. Simulate the operation

Simulate the operation in the SolidVerify
and Host CAD simulation modes.

27. Add a Drilling operation

This Drilling operation is used to perform the
preliminary center drilling of the four holes in
the corners of the model.
Right-click the last Proile operation in
SolidCAM Manager and choose Drilling
from the Add Milling Operation submenu.
The Drilling Operation dialog box is displayed.

75
 28. Define the Drill geometry
In the Geometry area, click the button.
The Drill Geometry Selection dialog box is displayed in the SolidWorks PropertyManager
area. This dialog box enables you to select the geometry for drilling directly on the solid
model.

SolidCAM enables you to select the drill centers

using the following options:
• Pick position
You can deine drill centers one by one
directly on the solid model.
• 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 deined by three
points positioned on the spline edges. This
facilitates selecting drill centers on spline
surfaces.
• Multi-positions
You can select the model face. SolidCAM
automatically recognizes all arcs/circles
located on the selected face and selects the
center points as drill positions.
• All circle/arc centers
SolidCAM searches the solid model for arcs
and circles and adds all center points as drill
positions to the geometry.

76
 3. SolidCAM 2.5D Operations

Choose the All circle/arc centers option and click the corresponding button.
Four drill positions are selected. Their
coordinates are displayed in bottom
part of the Drill Geometry Selection
dialog box.

Click the button to conirm the geometry selection. The Drilling Operation dialog
box is displayed.

29. Define the Tool

Switch to the Tool page of the Drilling Operation dialog
box and click the Select button.
The Part Tool Table is displayed.
Click to start a new drilling tool deinition. From the
Drilling Tools section, choose the Spot drill tool for the
operation.

Spot Drill

This tool type is used for center drilling and chamfering in Drilling
operations. A tool of this type is deined with the parameters shown in
the image.
Arbor Diameter

Diameter

Total
Outside
Length
Shoulder Holder
Length
Angle

Cutting Length

77
 A Spot drill of Ø6 is used in this operation.

Click the Select button to choose the tool for the operation.
The Drilling Operation dialog box is displayed. Click the Data tab.
Deine the spin and the feed for the operation.
• Set the Spin rate to 1200;
• Set the Feed Z to 200.

30. Define the center drilling depth

Switch to the Levels page of the Drilling Operation
dialog box. Click the Drill depth button and select
the upper face of the model. The Drill depth value
(0) appears in the relevant edit box.
To perform the drilling down to the speciied diameter of the tool, use the Depth type
option.

78
 3. SolidCAM 2.5D Operations

Depth Type

This option enables you to deepen the drilled hole in order to obtain
a given diameter at the speciied drill depth.

Drill Drill
Drill
depth depth
depth

Diameter
value

Cutter tip Full diameter Diameter value

• Cutter tip

The drill tip reaches the deined drill depth.

• Full diameter

The drill reaches the deined drill depth with the full diameter.
• Diameter value

The drill reaches the deined drill depth with the drill cone diameter
speciied in the edit box.
The Diameter value can vary from 0 all the way up to the drill tool
diameter. A value greater than the drill tool diameter is automatically
decreased 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 tool
diameter of 5 mm is reached at the depth of 0.

Drill Depth (0)

Diameter_value (5)

79
 In accordance with these parameters, Diameter_value Centering_depth
SolidCAM calculates the centering
depth using the following formula: α

Diameter_value / 2
Centering_depth =
tan(α/2)

If Diameter_value is 5 mm, and α is 90°, the centering depth is calculated as follows:

5/2
Centering_depth = = 2.5
tan(90/2)

31. Calculate the tool path

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

32. Simulate the operation

Simulate the operation in the

SolidVerify simulationmode.

33. Add a Drilling operation

Add another Drilling operation to perform the through drilling of the holes.
Right-click the last Drilling operation and choose Drilling from the Add Milling
Operation submenu. The Drilling Operation dialog box is displayed.

34. Define the Geometry

This operation is using the geometry that was deined in
the previous center drilling operation. Choose the Drill
geometry from the list in the Geometry area.

Each geometry deined in SolidCAM has a unique name. When the geometry
is being deined, it is assigned a default name that can be changed. Using
this name, you can choose the geometry for a speciic operation.

80
 3. SolidCAM 2.5D Operations

35. Define the Tool

Deine a new Drill tool of Ø4 for this operation.

Click the Select button to choose the tool for the operation.
The Drilling Operation dialog box is displayed. Click the Data tab in the Tool page.
Deine the spin and feed for the operation.
• Set the Spin rate to 3000;
• Set the Feed Z to 360.

36. Define the Drilling depth

The overall height of the model is 10 mm
plus the 5 mm bottom offset deined for
the stock. The drilling has to be performed
deeper than this depth in order to enable the
tool to exit from the material and perform
the through drilling.
Switch to the Levels page.

Height

81
 Deine the Upper level by clicking on the top face of the model as shown.
Deine the Drill depth. Rotate the model and select the bottom face as shown.

Since the Z- offset deined for the stock model is 5

mm, set the Delta value to -5.
To perform the through drilling, choose the Full
diameter option in the Depth type area. With this
option, the drilling is performed until the full
diameter is reached at the speciied drill depth.
This means that the conical part of the tool exits
from the material.

37. Define the Drilling type

SolidCAM enables you to use a number of drill canned cycles supported by your
CNC-controller. 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 during
the drilling process.
Switch to the Technology page and click the Drill cycle type button. Available drill
cycles are displayed.
Click the Peck button. The cycle is chosen for the operation.

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

82
 3. SolidCAM 2.5D Operations

Set the Step down to 1.5 in order to deine the depth of each pecking movement.
Conirm the data with the OK button.

38. Calculate the tool path

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

39. Simulate the operation

Simulate the operation in the SolidVerify simulation mode.

Since in the previous operation the drilling diameter was greater than that in
this operation, the drilling results in a chamfer on the drilled holes.

Now you have successfully inished the exercise.

83
Exercise #3: Cover Machining

In this exercise, a number of SolidCAM 2.5D operations are used for the cover part machining.

The cover is machined on the 3-Axis milling CNC-machine using the machining vice. The part is
machined using two positionings.
At the irst stage, the workpiece is positioned in the vice as shown below.

84
 3. SolidCAM 2.5D Operations

The highlighted faces are machined.

At the next stage, the rest of the cover faces are machined using the second positioning.

85
 1. Load the SolidWorks model
Load the Exercise3.sldprt model that is located in the Exercises folder.
This model contains a number of features forming the solid body of the cover.

2. Start SolidCAM
To activate SolidCAM, click the SolidCAM ield in the main
menu of SolidWorks and choose Milling from the New
submenu or click the Milling button on the SolidCAM New
toolbar.

SolidCAM is started, and the New Milling Part dialog box

is displayed.

86
 3. SolidCAM 2.5D Operations

3. Confirm the CAM-Part creation

Conirm the default Directory, CAM-Part Name and Model Name by clicking the OK
button in the New Milling Part dialog box. The CAM-Part is deined.

4. Choose the CNC-controller

When the CAM-Part is deined, the Milling Part Data dialog box
is displayed.
Select the CNC-machine controller. Click the arrow in the CNC-
Machine section to display the list of post-processors installed
on your system.
In this exercise, you use a 3-Axis CNC-machine with the AWEA1000-Fanuc CNC-
controller. Choose the AWEA1000-Fanuc CNC-controller from the list.

5. Define the Stock model

In this exercise, you have to deine the Stock model before you
deine the Coordinate System in order to use the workpiece for
the CoordSys deinition.
Click the Stock button in the Stock & Target model section
to start the deinition process. The stock Model dialog box is
displayed.

87
 When the Coordinate System is not deined, SolidCAM enables you to use
only the Box (Auto) method of the Stock model deinition.

SolidCAM generates the stock box surrounding the model with

the speciied allowances. In the Expand box at section, set the
value of the Z- parameter direction to 5. This allowance is used
for the irst clamping. Set the value of 2 for the rest of the
directions.
Click on the model. The face is highlighted, and the box
surrounding the model is displayed.

Click the Add box to CAD model button. The stock model box is added into the CAM
component of the CAM-Part assembly as a 3D Sketch feature.

Conirm the Model dialog box with the button. The Milling Part Data dialog box is
displayed.

6. Define the Coordinate System

Click the Define button in the Coordinate System area to start
the Coordinate System deinition.

88
 3. SolidCAM 2.5D Operations

The CoordSys dialog box is displayed.

In the Define CoordSys options list, choose the Define option.

This mode enables you to deine the Coordinate System by

picking three points on the solid model. At irst, you have to
deine the Coordinate System origin location and then the
points for the X- and Y-directions.
Pick the origin point in the stock box corner as shown.

89
 Click on the stock model edge as shown to deine the X-axis of the Coordinate System.

Click on the stock model edge as shown to deine the Y-axis of the Coordinate System.

When a point is selected, the next button is automatically activated. If you

miss the selection, you can at any time select the button you want to deine
and continue automatically to the next button.

90
 3. SolidCAM 2.5D Operations

Conirm the Coordinate System deinition with the button. The model is rotated,
and the Coordinate System is displayed.

The CoordSys Data dialog box is displayed.

Deine the Part Lower level directly on the solid model. This parameter deines the
lower surface level of the part to be milled.
Click the Part Lower level button.
Rotate the model and select the lower face
that is milled using the irst positioning
as shown. The Z-coordinate of the face
(-12) is displayed in the Pick Part Lower
level dialog box.

Conirm this dialog box by clicking the

button.

91
 Conirm the CoordSys Data dialog box with the OK button.
The icon of the deined Coordinate System is displayed in the CoordSys Manager
dialog box.
Conirm the CoordSys Manager dialog box with the button. The Milling Part Data
dialog box is displayed again.

7. Define the Target model

Click the Target button in the Stock & Target section of the Milling Part Data dialog box.
The target Model dialog box is displayed.
This dialog box enables you to deine a 3D model for the Target.
Click on the solid body. Its face highlighted.

Conirm the Model dialog box with the button.

The Milling Part Data dialog box is displayed.

8. Save the CAM-Part data

In the Milling Part Data dialog box, click the button.

The Milling Part Data dialog box is closed, and SolidCAM Manager is displayed. The
deined CAM-Part is saved.
At this stage, the deinition of the CAM-Part is inished.

92
 3. SolidCAM 2.5D Operations

At the next stage, you have to deine several operations to machine the cover part.
Using the irst deined Coordinate System (irst clamping), you have to perform the
following operations:

Upper face machining

Upper profile machining

Lower profile machining

Hole pads machining

93
 Then the part has to be rotated and clamped again. With the second clamping, the
following operations are performed:

Upper face machining

Pocket machining

Slot machining

Holes machining

94
 3. SolidCAM 2.5D Operations

9. Add a Face Milling operation

In SolidCAM Manager, right-click the Operations header and choose Face from the
Add Milling Operation submenu. The Face Milling operation is used for the upper face
machining.

The Face Milling Operation dialog box is displayed.

95
 10. Define the Face Milling geometry
Click the button in the Geometry page. The Face Milling
Geometry dialog box is displayed.
Using the default Model option, click the Deine button and
click on the solid model to select a face.

In the Face Milling Geometry dialog box, deine the 3 mm offset

to machine over the stock edges. In the Modify section, set the
Offset value to 3.

Conirm the Face Milling Geometry dialog box by clicking the

button. The geometry is deined for the operation.

11. Define the Tool

Deine a new Face mill of Ø40 for this operation and edit the following parameters:
• Set the Shoulder length to 15;
• Set the Cutting length to 10.

96
 3. SolidCAM 2.5D Operations

SolidCAM enables you to deine a variety of tool holders to help you check and prevent
all possible collisions between the tool holding system and the workpiece. This feature
also 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.

The Global holders table is supplied within SolidCAM. This table contains
a number of frequently used tool holder components. The Global holders
table can be modiied by the user.
Select the Use Holder check box to enable choosing a holder from the Global holders
table. The Local and Global tool holders lists become available.

The SolidCAM tool holder is deined by combining two components.

The irst component is the tool adaptor mounted on the spindle unit
of the milling machine. The second component can consist of various
types of extensions and reductions like collet chucks, arbors, shanks and
other components that you may have.
Tool adaptor

Extensions and reductions

SolidCAM enables you to deine the Tool adaptor in the *.vmid ile
under Devices > Spindle > Stations.

97
 In the Global table, choose the BT40 ER32×60 collet chuck by clicking its check box.
This collet chuck is suitable for the chosen tool diameter (40 mm).

Choose the deined tool for the operation by clicking the Select button. The Face
Milling Operation dialog box is displayed.

12. Define the Face depth

Switch to the Levels page of the Face Milling
Operation dialog box. Click the Face depth button
in the Milling levels area and select the model face
as shown.

The Face depth (2) is calculated.

98
 3. SolidCAM 2.5D Operations

13. Define the technological parameters

Switch to the Technology
page of the Face Milling
Operation dialog box. In
the Technology section,
use the default Hatch
option.

Hatch Machining Technology

The machining is performed in a linear pattern.

The Hatch page enables you to deine the hatching parameters.

99
 • Hatch angle

When the Automatic optional angle option is chosen, SolidCAM

automatically calculates the optimal angle of hatching to expedite the
machining. The tool path always follows the length of the face no
matter what angle the machined surface is facing.

The Delta from optimal parameter enables you to change the hatching
angle.

Delta angle

Optimal direction

100
 3. SolidCAM 2.5D Operations

When the User-defined angle option is chosen, you can determine

the angle of the tool path.

Angle

X
• Cutting direction

The One Way option enables you to create the tool path with only
one-directional movements.
The Zigzag option enables you to create the tool path with
bidirectional movements.

One Way Zigzag

• Extension

During face milling, the tool path is extended over the edges of the
machined face. The Extension section enables you to deine the
extension both along the tool path (the Along section) and across the
tool path (the Across section). The extension can be deined either
by percentage of the tool diameter (the % of tool diameter option) or
by value (the Value option).

Extension across
the tool pass

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101
 • Corner

When the None option is chosen, the tool path is

formed with sharp corners between one direction
and the next.

The Fillet option connects each direction with

a given radius allowing for a smoother transition
between path directions.

Click the Data tab to deine the machining

parameters.
In the Hatch angle section, switch to the
Automatic optimal angle option.

Switch back to the Technology tab.

Notice that in the Overlap section the % of tool diameter

option is chosen and the value is set to 30, and the Equal
step over check box is selected.

Overlap

This section enables you to deine the tool overlapping between two
successive passes. This option can be deined as Percentage of the tool
diameter or as a Value.

0.5D 0.2D
Overlap 0.5D Overlap 0.2D

102
 3. SolidCAM 2.5D Operations

Equal Step over

This option enables you to generate

the hatch tool path spaced evenly
with the automatically calculated
Overlap value, which is nearest to
the speciied Min. Overlap value but
not smaller than this value.
When this check box is not selected, Overlapping Overlapping
the distance between the last pass
and the one before it can be smaller
than that between all of the other
passes.
When this check box is selected,
the evenly spaced hatch tool path
is generated. The overlap between
two successive passes is not smaller
than the speciied Min. Overlap
value. Overlapping Overlapping

This option is available only for the Hatch strategy.

Deine the roughing offset that remains on the loor of the face. This offset is left
unmachined during the rough face machining and removed during the face inishing.
In the Offsets section, set the Floor offset value to 0.2.
Select the Finish check box to perform inishing of the
face in this operation. This check box enables you to
remove the remaining offset with the last cutting pass.

14. Define the Lead in and Lead out

Switch to the Link page of the Face Milling dialog box to deine the way the tool
approaches the material and retreats away.
In the Lead in section, choose the Tangent option. This option enables the tool to
approach the material on a line tangent to the proile. In the Length ield, set the length
of the tangent to 5.

103
 In the Lead out section, select the Same as Lead in check box.

15. Save and Calculate

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

16. Simulate
Click the Simulate button in the Face Milling Operation dialog box. The Simulation
control panel is displayed.
Switch to the SolidVerify page and start
the simulation with the button.

Close the simulation with the button.

The Face Milling Operation dialog box is
displayed. Close this dialog box with the
Exit button.

104
 3. SolidCAM 2.5D Operations

17. Add a Profile operation

At this stage, you have to deine a Proile operation in order to machine the upper
proile of the cover.

In SolidCAM Manager, add a new Proile operation.

18. Define the Geometry

Click the button in the Geometry page of the Profile
Operation dialog box. 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 box
enables you to pick a number of chains from the model by
selecting the model elements. SolidCAM automatically creates
chains from the selected elements.
Click on the top face of the model as shown.
The face is selected, and its boundary is highlighted.

105
 Click to choose the selected chain as the geometry. The Geometry Edit dialog box
is displayed.
Conirm the geometry deinition with the button. The geometry is deined for the
operation.

19. Define the Tool

Add a new End mill tool of Ø16 for the operation.

Choose the tool holder. Switch to the Holder page and select the Use holder check box.
Click the Local holders tab.

The Local holders table contains the tool holders that were already used
in the current CAM-Part. When a new holder is chosen from the Global
holders table, it is copied to the local table to make a further use easier.

Choose the BT40 ER32×60 Collet chuck.

Conirm the tool selection by clicking the
Select button.

106
 3. SolidCAM 2.5D Operations

20.Define the Profile depth

Switch to the Levels page. In the same manner as explained in previous steps, deine
the Profile depth by clicking on the model face as shown below.

21. Define the technological parameters

Switch to the Technology page. In the
Modify section, set the Tool side to Right.
Click the Geometry button to check the
tool position relative to the geometry.
Close the Modify Geometry dialog box
with the button.

Now you have to deine the roughing and inishing parameters. SolidCAM Proile
operation enables you to perform the rough and inish machining in the single operation.

Select the Rough check box. Set the Step down value to
3.5. The proile is machined in two equal Z-steps.

In the Offsets section, set the Wall offset and the Floor
offsetto 0.2. These allowances are removed during the
inish machining.

Select the Clear offset check box. Set the Offset value to 5
and the Step over value to 2.5.

107
 Clear Offset

This option generates several concentric proiles with a constant depth

that start from the deined clear offset distance from the proile and
inish up to the geometry of the proile, thus clearing the area around
the proile.
The Offset deines the distance from the geometry at which the
milling starts. The Clear offset value should be equal to or larger than
the Wall offset value. The tool starts milling the proile at the distance
deined by the Clear offset and inishes at the distance deined by the
Wall offset; the overlap of the adjacent tool paths is deined by the Step
over parameter. The Step over parameter deines the overlap of adjacent
tool paths. It determines the offset between two successive concentric
proiles.

Geometry

Wall offset

Clear offset
Step over

In the Finish section, set the Step down value to 7. The

0.2 mm allowances that remain after the roughing are
removed in one step.

22. Define the Lead in and Lead out

Switch to the Link page. In the Lead in section,
choose the Tangent option. With this option, the
tool approaches the material tangentially to the
geometry in the start point. Set the Length value
to 12.

108
 3. SolidCAM 2.5D Operations

In the Lead out section, select the Same as Lead in check box.

23. Save and Calculate

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

24. Simulate
Click 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.

The SolidVerify simulation mode enables you to measure distances

directly on solid bodies in the SolidVerify window. This feature enables
checking the linear dimensions of the part during simulation.

Click the Measure button on the toolbar. The Measure

Distance dialog box is displayed.

Click on the top face of the cover and then on the

horizontal face machined in the current operation.

109
 The coordinates of the pocket points and the result
distance are displayed in the Measure Distance dialog box.
SolidCAM displays the measured distance value and Delta
values for the X-, Y- and Z-axes. In this case, the Delta Z
parameter displays the depth of the machined face relative
to the cover top face (5).

Close the simulation with the button. The Profile

Operation dialog box is displayed.

Close the Profile Operation dialog box with the Exit button.

25. Add a Profile operation

At this stage, you have to deine a Proile
operation in order to machine the lower
proile of the cover.
In SolidCAM Manager, add a new Proile
operation.

26. Define the Geometry

Click the button in the Geometry page. The Geometry Edit dialog box is displayed.
Click on the workpiece edge as shown to deine the irst entity of the chain.

In the Chain section, choose the Auto-constant Z option. The closed chain is
automatically selected.

110
 3. SolidCAM 2.5D Operations

The conirmation message is displayed.

Conirm it with the Yes button.

Conirm the geometry with the button.

27. Define the Tool

In this operation, use the same tool as in the previous operation (Ø16 End mill).
Click the Select button in the Tool page. The Part Tool Table is displayed. Choose the
previously deined Tool #2 and click the Select button.

111
 28. Define the Profile depth
You have to deine a new Upper level for the operation taking into account the already
machined faces. Switch to the Levels page and click the Upper level button in the
Milling levels area.

Deine the Upper level by clicking on the model face as shown.

Conirm the deinition of the Upper level with the button.

In the same manner as explained in the previous
steps, deine the Profile depth by clicking on
the model vertex as shown.

29. Define the technological parameters

Switch to the Technology page of the Profile Operation dialog box. In the Modify
section, set the Tool side to Right. Click the Geometry button to check the tool position
relative to the geometry.

112
 3. SolidCAM 2.5D Operations

Close the Modify Geometry dialog box with the button.

Now you have to deine the parameters of proile roughing and inishing.
Select the Rough check box. Set the Step down value to
2.5. The proile is machined in two equal Z-steps.

In the Offsets section, set the Wall offset value to 0.5. This
allowance is removed during the inish machining.
Select the Finish check box and set the Step down value to
5. The 0.5 mm allowance that remains after the roughing is
removed in one step.

30. Define the Lead in and Lead out

Switch to the Link page of the Profile
Operation dialog box. In the Lead in
section, choose the Arc option. The tool
approaches the material tangentially to
the geometry at the start point. Set the
Radius value to 12.

In the Lead out section, select the Same

as Lead in check box.

31. Save and Calculate

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

32. Simulate
Click 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.

Close the simulation with the button. The

Profile Operation dialog box is displayed. Close the
Profile Operation dialog box with the Exit button.

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 33. Add a Profile operation
At this stage, you have to deine a new Proile
operation to machine four hole pads.
In SolidCAM Manager, add a new Proile operation.

34. Define the Geometry

In the Geometry page, click the button. The
Geometry Edit dialog box is displayed.

Click on the model edge as shown.

Click on the next model edges as shown below to
complete the chain.

In the Chain List section, click the button to conirm the chain selection.
In the same manner, deine the geometry for the rest of the pads. Make sure that all the
selected chains have the same direction.

Conirm the geometry deinition by clicking the button.

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 3. SolidCAM 2.5D Operations

35. Define the Tool

Deine a new tool for the operation. Use an End mill of Ø8 with the BT40 ER32×60
tool holder.

36. Define the Milling levels

In this operation, the machining starts at
the Z-level of the already machined faces.
The upper level has to be deined.
Deine the Upper level by clicking on the
already machined model face as shown.
In the same manner as explained earlier,
deine the Profile depth by clicking on the
pad face as shown.

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 37. Define the technological parameters
Select the Rough check box. Set the Step down value to 3.
The proile is machined in one Z-step.
In the Offsets section, set the Wall offset value to 0.5. This
allowance is removed during the inish machining.
Select the Clear offset check box. Set the Offset value to 5
and the Step over value to 4.5.
Select the Finish check box and set the Step down value to
3. The 0.5 mm allowance remaining after the roughing is
removed in one step.

38. Define the Lead in and Lead out

Set the Arc option for Lead in. Set the
Radius value to 2. In the Lead out section,
select the Same as Lead in check box.
The tool leads in/leads out to the proile
with a tangential arc.

39. Save and Calculate

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

40. Simulate
Click 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.

Close the simulation with the button.

The Profile Operation dialog box is
displayed.

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 3. SolidCAM 2.5D Operations

Close the Profile Operation dialog box with the Exit button.
At this point, the machining of the external cover faces is inished. At the next stages
you have to machine the internal faces.

41. Define a New Coordinate System

The machining of the internal model faces
requires another positioning. The part has to be
rotated and clamped in a vice as shown.
SolidCAM enables you to deine the second
Coordinate System.
Double-click the CoordSys Manager header in
SolidCAM Manager. The CoordSys Manager
dialog box is displayed.
Right-click the MAC 1 item in the list and choose
the Add option from the menu. The CoordSys dialog box
is displayed.
In the Mac CoordSys Number ield, set the value to 2.
Changing of the Mac CoordSys number means that a new
clamping is used.

Make sure that the default Select

Face mode is chosen.

When this mode is chosen, SolidCAM enables you to deine

a new Coordinate System by selecting a planar face. In this case,
the Z-axis of the Coordinate System is normal to the selected
face.
Rotate the model and click on its bottom face as shown below.

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 The Coordinate System origin is placed according to the Place CoordSys origin to
setting. 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 the
deined CoordSys. The CoordSys is located in the corner of the model
box with the following coordinates: (XMIN, YMIN, ZMAX).

Now you have to move the origin of the Coordinate System from the automatically
deined position to the corner of the workpiece.
Select the Pick origin check box in the Pick section
of the CoordSys dialog box.

Click on the corner of the workpiece (stock

model) as shown to choose it for the origin. The
origin is moved to the new location.

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 3. SolidCAM 2.5D Operations

Conirm the CoordSys dialog box by

clicking the button.
The CoordSys Data dialog box is
displayed.
SolidCAM automatically determines the
Part Upper level and the Part Lower level
parameters relative to the Coordinate
System location.
Conirm the dialog box with the OK
button.
The CoordSys Manager dialog box is
displayed.
Two Machine Coordinate Systems are
listed in the CoordSys Manager dialog
box. Using them you can program
operations for different positions (clamping). The Machine Coordinate System #2 is
used for the machining of the back face and the internal faces.

Click the button to conirm the CoordSys Manager dialog box.

42. Add a new Face Milling operation

Add a new Face Milling operation to perform the back face milling.

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 43. Define the Geometry
Since this operation is performed with the second
Coordinate System position, choose the Machine
Coordinate System #2.

Choose MAC 2 from the CoordSys list in the Geometry

section.
Click the button to start the geometry deinition. The Face Milling Geometry dialog
box is displayed.
In the Base Geometry section, use the default Model option for the Face Milling
geometry deinition. Click the Define button. The 3D Geometry dialog box is displayed.
Click on the solid model to select it. The model is highlighted, and its icon appears
in the list. Conirm the 3D Geometry dialog box by clicking the button. The Face
Milling Geometry dialog box is displayed again.

The rectangle is generated surrounding

the Target model at the XY-plane.
Deine the 3 mm offset to extend the
machined surface over the stock edges.
In the Modify section, set the Offset value
to 3.

Click the button to conirm the Face Milling Geometry dialog box. The geometry
is deined for the operation.

44. Define the Tool

Use the Ø40 Face mill used in previous operations.
Click the Select button in the Tool page. The Part Tool Table is displayed. Choose the
previously deined tool and click the Select button.
The Face Milling Operation dialog box is displayed.

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 3. SolidCAM 2.5D Operations

45. Define the Milling levels

In this operation, the machining starts on the top face of the workpiece (Z=0 of the
Machine Coordinate System #2) and ends on the back face of the cover part (Z=-5 of
the Machine Coordinate System #2).
Deine the Upper level by clicking on the workpiece
corner as shown.
Deine the Face depth directly on the solid model by
clicking on its bottom face as shown below.

Set the Step down to 2.5.

46. Define the technological parameters

Switch to the Technology page of the Face Milling
Operation dialog box. In the Technology section, choose
the Hatch option and click the Hatch tab.
In the Hatch angle section, switch to the Automatic optimal angle option.

Switch back to the Technology tab. Note that in the Overlap section the % of tool
diameter option is chosen, and the value is set to 30.

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 Deine the roughing offset that remains on the loor of the face. This offset is being left
unmachined during the rough face machining and is removed during the face inishing.
In the Offsets section, set the Floor offset value to 0.2.
Select the Finish check box to perform inishing of the
face in this operation. This check box enables you to
remove the remaining offset with the last cutting pass.

47. Define the Lead in and Lead out

Switch to the Link page of the Face Milling Operation dialog box to deine the way the
tool approaches the material and retreats away.
In the Lead in section, choose the Tangent option.
This option enables the tool to approach the
material on a line tangent to the proile. In the
Length ield, set the length of the tangent to 5.

In the Lead out section, select the Same as Lead

in check box.

48. Save and Calculate

Click the Save & Calculate button.
SolidCAM notiies you that the upper level chosen for the operation is above the
CoordSys Upper level.

Conirm this message with the Yes button. The operation data is saved, and the tool
path is calculated.

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 3. SolidCAM 2.5D Operations

49. Simulate
Simulate the operation in the SolidVerify
mode.

The bottom face machining is inished. Now you have to perform the pocket machining.

Pocket machining overview

The pocket is machined in several technological steps:

The rough machining of the upper
part of the pocket. The machining
is performed until the Z-level of
the pads is reached.

The rough machining of the pocket

with islands (pads). The machining
is performed from the upper face
of the pads till the pocket loor.
At this stage, two operations are
used to perform the machining
with two tools of big and small
diameter.
The inish machining of the outside
wall of the pocket.

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 The inish machining of the island
walls.

The inish machining of the island

top face.

The inish machining of the pocket

loor.

50. Add a Pocket operation

Add a new Pocket operation to perform the rough machining of the upper part of the
pocket down to the pads height.

51. Define the Geometry

Choose the Machine Coordinate System #2 and deine the geometry as shown below
using the Auto-constant Z option.

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 3. SolidCAM 2.5D Operations

52. Define the Tool

Choose the already deined Tool #2 (Ø16 End mill) from the Part Tool Table for the
pocket rough machining operation.

53. Define the Pocket depth

Deine the Pocket Depth directly on the
solid model. Use the top face of the pads
for the deinition.
SolidCAM uses the constant-Z passes
for the Pocket generation. The Step
down parameter enables you to deine
the distance between each two successive
Z-levels.
Set the Step down value to 2. The pocket
is machined in two Z-levels.

54. Define the technological parameters

Switch to the Technology page of the Pocket Operation dialog box. Make sure that the
default Contour option is chosen in the Technology section.
In the Offsets section, set the Wall offset and the Floor
offset values to 0.2. These offsets remain unmachined
during roughing and are removed with the further inishing.

55. Define the Ramping strategy

Switch to the Link page of the Pocket Operation dialog box. In the
Ramping section, choose the Helical option.

Click the Data button. The Helical ramping dialog box is displayed.
Set the Radius of the descent helix to 3 and conirm the dialog box
with the button

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 56. Define the Lead out
In the Lead out section, choose the Arc option and set the Radius value to 2.

With a circular motion tangent to the last entity of the pocket contour,
the tool retreats from the proile. The radius of the arc must be speciied.

Radius

57. Save and Calculate

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

58. Simulate
Perform the simulation of the Pocket
operation in the SolidVerify mode.
During the simulation, notice the helical
lead in movement.

59. Add a new Pocket operation

Add a new Pocket operation to machine the bottom part of the pocket including two
islands (pads for the circuit board installing).

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 3. SolidCAM 2.5D Operations

60. Define the Geometry

Choose the Machine Coordinate System #2 for the operation.
In the same manner as explained in the Step #18 of this exercise, deine the geometry
by clicking on the pocket bottom face as shown below.

SolidCAM automatically determines the edges of the selected face and deines chains
on them. The irst chain is the external boundary of the pocket. All closed chains inside
the irst chain of each pocket are automatically treated as pocket islands. Overlapping
chains are milled as separate pockets, not as islands. To select multiple pockets with
islands, continue adding chains to the geometry.

61. Define the Tool

Choose the Tool #2 (Ø16 End mill) from the Part Tool Table for the operation.

62. Define the Milling levels

The machining in this operation starts
at the Z-level of the top faces of the
pads and ends on the bottom face of the
pocket.
Deine the Upper level by selecting the
top face of the pads as shown.

Deine the Lower level by selecting the

bottom face of the pocket.
Set the Step down to 2.

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 63. Define the technological parameters
Make sure that the default Contour option is chosen in the Technology section.
In the Offsets section of the Technology page, set the
Wall offset, Island offset and Floor offset values to 0.2.
These offsets remain unmachined during roughing and are
removed in the next inishing operations.

Wall offset – the roughing offset remaining on the wall of the pocket.
Island offset – the roughing offset remaining on the pocket’s islands.
Floor offset – the roughing offset remaining on the loor of the pocket.

64. Define the Ramping strategy

In the Ramping section of the Link page, choose the Helical option. Click the Data
button. The Helical ramping dialog box is displayed. Set the Radius of the descent helix
to 3 and conirm the dialog box with the OK button.

65. Define the Lead out

In the Lead out section, choose the Arc option. Set the Radius value to 2.

66. Save and Calculate

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

67. Simulate

Perform the Pocket operation simulation

in the SolidVerify mode.

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 3. SolidCAM 2.5D Operations

Make a note that the pocket geometry is not completely machined because the tool is
too large to reach some model areas. In order to complete the machining, you have to
perform an additional Pocket operation with a tool of a smaller diameter in the areas
that were not machined in the current Pocket operation.

68. Add a new Pocket operation

Add a new Pocket operation. SolidCAM enables you to use the existing operations as
templates for new ones. In this case, the last created Pocket operation is used to deine
a new Pocket operation from the template. In the Operation name section, choose the
last deined operation name (P_contour4) from the list.
All the parameters of the chosen operation are copied to the current one.

69. Change the Tool

Deine a new tool for the operation.
Click the Select button in the Tool page. The Part Tool Table dialog box is displayed.
This dialog box displays the
parameters of the currently
active Tool #2 (Ø16 End mill).
Since this tool is used in several
operations, its parameters cannot
be edited.
Click to deine a new tool.
Choose the End mill tool from
the Tool type dialog box.
A new Tool #4 is added with the
default parameters. Choose the
tool holder.
In the Holder page, select the Use holder
check box and click the Local tab. Choose
the BT40 ER32x60 collet chuck from the
list.
In the Part Tool Table dialog box, click the
Select button to choose the deined tool
(Ø6 End mill) for the operation.

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 70. Define the Rest material parameters
In the Rest Material/Chamfer section of the Technology
page, choose the Rest option from the list.

During the machining, when a large tool is used, the tool leaves material
in areas that it cannot enter.
Unmachined area Machined area

Geometry

The Rest material option enables you to remove the material from these
areas without deining a new geometry.

The new Rest tab appears and opens the page

automatically.
Notice that the Separate areas option is
chosen by default in the Milling type box.
When this option is chosen, SolidCAM
performs the machining only in areas that
were not machined with the previous tool.

Deine the diameter of the end mill that was used in the previous operation. Click the
Previous tool diameter button. The Part Tool Table dialog box is displayed with all the
tools used in the operations of the current CAM-Part. Choose the Ø16 End mill used
in the previous operation and click the Select button.
In the Previous wall offset ield, set the value of 0.2. This offset was deined in the
previous Pocket operation.
Deine the Extension/Overlap parameter – the overlap distance that you would like to
start from and end with the previous larger end mill. Set the Extension/Overlap value
to 1.

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 3. SolidCAM 2.5D Operations

71. Define the Ramping strategy

In the Ramping section of the Link page, choose the Helical
strategy to deine how the tool enters into the material. Click the
Data button. The Helical ramping dialog box is displayed. Set the
Z-entry helix Radius to 3. Conirm the dialog box with the
button.
With the deined parameters, the tool machines all the areas
that were not machined by the previous tool. The 0.2 mm allowance
remains for further inishing. The machining area is extended by 1
mm to overlap the previously machined area.

72. Save and Calculate

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

73. Simulate
Play the simulation of the Pocket
operation in the SolidVerify mode.
Notice that the machining is performed
only in the areas that were not machined
in the previous operation.

At this stage, the rough machining of the pocket is completed, and you have to program
the inishing operations.

74. Add a Profile operation

A Proile operation is used for the inish machining of
the pocket walls.

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 75. Define the Geometry

In the Geometry page, click the button to view the

geometries deined for the current Coordinate System.
The Browse Geometries dialog box is displayed with a list
of geometries deined for this CAM-Part associated with
the current Coordinate System. You can click entries in the
list to display the corresponding geometries on the model.
Choose the Contour3 geometry from the list.

Conirm the Browse Geometries dialog box by clicking the button.

76. Define the Tool

Choose the already existing Tool #4 (Ø6 End mill) from the Part Tool Table.

77. Define the Profile depth

Deine the Profile depth by clicking on the bottom face of the pocket.

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 3. SolidCAM 2.5D Operations

78. Define the technological parameters

In the Modify section, choose the Right option from the
Tool side area.

In this operation, use the Equal step down option to keep

an equal distance between all Z-levels.

Equal Step down

Max.
This option enables you to Step down
perform all cuts at an equal
Z-level distance one from the
other. SolidCAM automatically
calculates the actual step down
to keep an equal distance
between all passes.
When the Equal step down
check box is selected, Step
down is replaced by Max. Step
down. This value is taken into
account during the calculation
of the actual step down so that Actual Step down
it is not exceeded.

Select the Equal step down check box.

Select the Finish check box and set the Max. Step down value to 3.

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 In the Depth type area, choose the Helical option.

The Helical milling option enables you to enhance the productivity of

proile machining by avoiding lead in/out movements at each Z-level
and eliminating unnecessary rapid movements.

With the Helical option, the tool performs spiral movements around
the geometry with continuous lowering along the Z-axis. For each
turn around the geometry, the tool moves downward along the Z-axis
according to the step down value. When the Proile depth is reached
by the spiral movements, SolidCAM performs the last cut with the
constant-Z movement at the Proile depth.

Step Down

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 3. SolidCAM 2.5D Operations

79. Define the Lead in and Lead out

Choose the Normal option in the Lead in section
of the Link page and set the Normal length value
to 5. In the Lead out section, select the Same
as Lead in check box. The tool approaches the
material with the movement normal to the pocket
contour and retreats in the same way.

80. Save and Calculate

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

81. Simulate
Play the simulation in the SolidVerify mode.

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 82. Add a Profile operation
Add a new Proile operation to machine the walls of the islands.

83. Define the Geometry

Choose the Machine Coordinate System #2 for the operation and click the button
in the Geometry page. The Geometry Edit dialog box is displayed.
Select the edge of the island as shown below.

Make sure that the chain direction is clockwise. Such direction enables you to perform
the climb milling of the proile.
In the Chain section, choose the Auto-constant Z option. The chain is automatically
completed.

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 3. SolidCAM 2.5D Operations

The conirmation message is displayed.

Conirm it by clicking the Yes button. The irst chain is deined.

Select the edge of the other island as shown below.

Make sure that the chain direction is clockwise. Such direction enables you to perform
the climb milling of the proile.
In the Chain section, choose the Auto-constant Z option. The chain is automatically
completed and the conirmation message is displayed. Conirm it by clicking the Yes
button.
The irst selected entity in the geometry chain deines the approach
location for the whole chain. In this case, the internal edges of the pads
are chosen in order to prevent the collision between the tool and pocket
wall during the lead in movement.

Conirm the Geometry deinition with the button.

84. Define the Tool

Choose the Tool #4 (Ø6 End mill) for the operation.

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 85. Define the Milling levels
Deine the operation Upper level directly on the solid model by clicking on the top face
of the pad as shown below.

Deine the Profile depth by clicking on the bottom face of the pocket.

86. Define the technological parameters

In the Technology page, make sure the Finish check box is selected and set the Step
down value to 4.

In the Depth Type area, set the Helical option.

87. Define the Lead in and Lead out

Choose the Arc option in the Lead in section and set the Radius value to 2. In the Lead
out section, select the Same as Lead in check box. The tool approaches the material
with an arc movement tangential to the geometry and retreats in the same way.

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 3. SolidCAM 2.5D Operations

88. Save and Calculate

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

89. Simulate
Play the simulation in the SolidVerify mode.

90. Add a Face Milling operation

Add a new Face Milling operation to machine the top faces of the pads.

91. Define the geometry

In the Geometry page, choose the Coordinate System #2 (MAC 2) and click the
button to deine the geometry for this milling operation.
Choose the Faces option in the Type section and then click the Define button.
The Select Faces dialog box is displayed.

Click on the surface of the tow pads and conirm your selection by clicking .

139
 The Face Milling Geometry dialog box is displayed again. In
order to machine the two faces separately, click the Separate
button.

Two separate chains are created.

Conirm the geometry deinition by clicking .

92. Define the tool

Choose the Tool # 3 (Ø8 End mill) for the operation.

140
 3. SolidCAM 2.5D Operations

93. Milling levels

Deine the operation Upper level directly on the
solid model by clicking on the top face of the pad.
Deine the Face depth value by clicking on the
same face.

94. Define the technological parameters

In the Technology page, choose the One Pass strategy from the list.

95. Save and Calculate

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

96. Simulate
Play the simulation in the SolidVerify mode.

At the next stage you have to machine the pocket loor.

97. Add a Pocket operation

Deine a new Pocket operation to perform the inish machining of the pocket loor.

141
 98. Define the geometry
Use the already deined geometry Contour4.

99. Define the tool

Choose the Tool #4 (Ø6 End mill) for the operation.

100. Define the Milling levels

Deine the operation Upper level directly on the bottom face of the pocket. Deine the
Pocket depthvalue by clicking on the same face to perform the machining in a single
Z-level.

101. Define the technological parameters

Make sure that the default Contour strategy is chosen in the Technology page.
In the Offsets section, set the Wall offset and Island offset values to 0.1. Such offset
prevents the contact between the tool and the already inally machined wall and island
surfaces during the loor machining.

102. Define the Lead out

Choose the Arc option from the Lead out list. Set the Radius value to 2.

103. Save and Calculate

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

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 3. SolidCAM 2.5D Operations

104. Simulate
Play the simulation in the SolidVerify mode.

105. Add a Slot operation

Add a new Slot operation to machine the slot on
the bottom face of the cover model.
In the SolidCAM Operations toolbar of the
CommandManager, choose 2.5D > Slot.

The Slot Operation dialog box is displayed.

143
 106. Define the Geometry
Choose the Machine Coordinate System #2 for the operation and deine the geometry
for the slot as shown.

Make sure that the chain direction is clockwise to perform the climb milling.

107. Define the Tool

Deine a new tool in the Part Tool Table (Ø1.5 End mill).
Edit the following tool parameters:
• Set the Total tool length to 20;
• Set the Outside holder length to
15;

• Set the Shoulder length to 12;

• Set the Cutting length to 10.
Choose the BT40 ER16x70 collet chuck
from the Global holders table for the
operation.

108. Define the technological parameters

In the Tool side area, choose the Right option to machine the slot at the right side of
the selected geometry.
In the Slot levels area, click the Depth button to deine the slot depth directly on the
solid model.

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 3. SolidCAM 2.5D Operations

Click on the bottom face of the slot and conirm

the deinition with the button.
The Slot depth (1.5 mm) is determined.
Set the Step down value to 0.5.

109. Save and Calculate

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

110. Simulate
Play the simulation in the SolidVerify
mode.

At the inal stage of the cover part, you have to perform several operations to machine
the holes located on the bottom face and pads.

111. Define a Drilling operation

Deine a new Drilling operation for the center drilling of the holes located on the
bottom face of the cover.

145
 112. Define the Geometry
In the Geometry page, choose the Machine Coordinate System #2 for the operation and
click the button to start the deinition of drill positions.
The Drill Geometry Selection dialog box is displayed.
Choose the Multi-positions option in the Select centers by
section.
Click on the bottom model face as shown below.

All the circular edges located on the selected face are collected, and the drill positions
are determined. Conirm the geometry selection with the button.

113. Define the Tool

In the Tool page, click the Select button. The Part Tool Table is displayed.
In the drilling operations
of this exercise, the
tools imported from an
external tool library are
used. The Exercise3_
Drill_Tools library
contains several drilling
tools required for this
exercise.
In the Part Tool Table,
click the Import Tool(s)
button and choose
Import to import the
tool from the previously
deined tool library.

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 3. SolidCAM 2.5D Operations

The Import from Tool Table dialog box is displayed. Click the Browse button ( ) and
choose the location of the Exercise3_Drill_Tools tool library. Set it in the Library list.

Click the Import All Tolls button ( ) located in the left bottom part of the dialog box.
The tools are imported into the Part Tool Table.
Click the OK button to exit from the tool library.
In the Part Tool Table, choose the Tool #6 (Ø6 Spot drill) for the operation.
Conirm the tool deinition by clicking the Select button.
The Drilling Operation dialog box is displayed.

114. Define the Drilling depth

In the Milling levels area, set the Drill depth to 0.

To perform center drilling, use the Depth type
option. In the Depth type section, choose the
Diameter value option and set the value to 5.5 mm.

The center drilling operation is performed until

the speciied diameter is reached at the upper level
(the top face of the model). The upper diameter
of the center drilling cone is greater than the
drilled hole diameter; this means that the 0.25 mm
chamfer is performed at the hole edge.

147
 115. Save and Calculate
Click the Save & Calculate button. The
Drilling operation data is saved and the
tool path is calculated.

116. Simulate
Play the simulation of the center drilling
in the SolidVerify mode.

117. Add a Drilling operation

In SolidCAM Toolbar, add a new Drilling operation to drill the holes center-drilled at
the previous stage.
Choose the same Drill geometry used in the previous operation.
Choose the Tool #7 (Ø5 Drill) from the Part Tool Table.

118. Define the Drilling depth

In the Levels page, deine the Upper level by clicking on the model upper face. Deine
the Drill depth by clicking on the model face as shown.
Set the Delta depth value to -1.
To perform through drilling, use the Depth type
option. In the Depth type section, choose the Full
diameter option. The drilling is performed until
the given diameter is reached at the speciied Drill
depth. This means that the conical part of the tool
exits from the material.

119. Save and Calculate

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

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 3. SolidCAM 2.5D Operations

120. Simulate
Play the simulation of the drilling in the
SolidVerify mode.

At the next stage, you have to perform a number of drilling operations (center drilling,
drilling, tapping) for eight holes located on the pads top faces.

121. Add a Drilling operation

Add a new Drilling operation to perform the center drilling of the pad holes.

122. Define the Geometry

In the same manner as explained in Step #112, deine the geometry for the drilling.
Use the Machine Coordinate System #2 for the operation.

123. Define the Tool

Choose the Tool #6 (Ø6 Spot drill) from the Part Tool Table for the operation.

149
 124. Define the Drilling depth
In the Levels page, deine the Upper level
by clicking on the top face of the pad.
Set the Drill depth value to 1.

125. Save and Calculate

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

126. Add a Drilling operation

Add a new Drilling operation to perform the drilling of the pad holes.
In the Geometry area, choose the Drill1 geometry deined in Step #122.
Choose the Tool #8 (Ø1.6 Drill) for the operation. This tool enables you to perform
preliminary drilling for the M2 tapping.

127. Define the Milling levels

In the Levels page, deine the Upper level in the same manner as explained in Step
#124.

Deine the Drill depth directly on the solid

model. Pick the lower vertex of the hole
cone as shown to deine the depth.

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 3. SolidCAM 2.5D Operations

128. Define the Drill cycle type

Click the Drill cycle type button in the Technology page.

The Drill Cycles panel is displayed.
Choose the Peck type to perform the pecking canned cycle.
Click the Data button to deine the pecking parameters.
The Drill options dialog box is displayed. Set the Step down value for pecking to 0.5.

Conirm the dialog box with the OK button.

129. Save and Calculate

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

130. Add a Drilling operation

Add a new Drilling operation to perform the tapping of the pads holes.
In the Geometry area, choose the Drill1 geometry deined in Step #122.
Choose the Tool #9 (Ø2 Tap) for the operation.

151
 Tap Tool

This tool is intended

for the machining of
Arbor Diameter
internal threads in Drilling
operations.
Total
The tool consists of two Length
parts: cylindrical and Outside
conical, and is deined Holder
Length Chamfer Cutting
by the following major
Length Length
parameters presented on
the illustration.

Tip Diameter
Diameter

When the Tap tool is used in the operation, the Tapping

is chosen automatically.
drill cycle

131. Define the Drilling depth

In the Levels page, deine the Upper level in the same manner as explained in Step
#124.

Set the Drill Depth to 4.

132. Save and Calculate

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

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 3. SolidCAM 2.5D Operations

133. Simulate
Click the Simulate button. The Simulation
control panel is displayed.
SolidCAM enables you to simulate
several operations together. Holding the
Shift key, select the last three operations
in SolidCAM Manager (center drilling,
drilling and tapping of the pad holes) and
play the simulation.

At this stage, programming of the machining operations is completed. Now you have
to generate the GCode to send it to the CNC-machine controller.

134. Generate the GCode

SolidCAM enables you to generate the GCode for several operations or for the complete
CAM-Part.
Right-click the Operations header in SolidCAM Manager and choose the Generate
command from the GCode All submenu.

Alternatively, you can choose GCode > Generate icon from the SolidCAM Operations
toolbar.

153
 The GCode is generated for
the complete CAM-Part. The
generated GCode is displayed in
the Notepad window.

At this stage, the exercise is completed.

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 3. SolidCAM 2.5D Operations

Exercise #4: Bracket Machining

Deine the CAM-Part and operations for the machining of

the bracket presented on the illustration on a Milling CNC-
machine.
This exercise reinforces the following skills:
• CAM-Part deinition;
• Face milling;
• Pocket machining;
• Proile machining;
• Drilling.
The SolidWorks model of the Bracket (Exercise4.sldprt) is located in the Exercises folder.
The following steps have to be implemented in order to reach the inal CAM-Part:

1. Define the CAM-Part

At this stage, you have to deine the CAM-Part, CNC-controller, Machine Coordinate
System, the Stock and Target models.
The AWEA1000-Fanuc CNC-controller has to be chosen for this exercise.

2. Machine the top face

Deine a Face Milling operation to machine the top
face of the bracket.

3. Machine the side faces

Perform the Proile rough and inish machining of
the bracket side faces.

155
 4. Machine the open pockets
Deine a Proile operation to perform the machining
of the open areas as shown.

5. Machine the pocket

Deine a Pocket operation to perform rough and
inish machining of the pocket located on the top face
of the bracket.

6. Pre-machine the cylindrical hole

Deine two Drilling operations to perform the center
drilling and preliminary drilling for the further pocket
operation.

7. Machine the cylindrical hole

Perform two Pocket operations to machine the faces
of the through hole.
Use the pre-drilled hole to perform the safe lead in
movement of the tool into the material.

8. Machine the holes

Perform center drilling and drilling of the holes.

9. Machine the bottom face

Deine a Face Milling operation to machine the
bottom face of the bracket.
This operation requires different clamping, so deine
and use a new Coordinate System with the Z-axis
oriented normally to the bottom face.

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 3. SolidCAM 2.5D Operations

Exercise #5: Electronic Box Machining

Deine the CAM-Part and operations for machining of the electronic box presented on the
illustration on Milling CNC-machine.
This exercise reinforces the following skills:
• CAM-Part deinition;
• Face milling;
• Pocket machining;
• Proile machining;
• Rest material machining;
• Drilling.
The SolidWorks model of the Electronic Box
(Exercise5.sldprt) is located in the Exercises folder.
The following steps have to be implemented in order to reach the inal CAM-Part:

1. Define the CAM-Part

At this stage, you have to deine the CAM-Part, CNC-controller (AWEA1000-Fanuc),
Machine Coordinate System, the Stock and Target models.

2. Machine the top face

Deine a Face Milling operation to machine the top face of the electronic box part with
the Hatch strategy.

157
 3. Machine the side faces
Deine two Proile operations to perform rough machining of the external faces.

4. Machine the pocket

Deine two Pocket operations to perform rough machining of the internal pocket faces
with a tool of large diameter.

5. Perform the pocket finish machining

Deine a number of Pocket operations to perform inish machining of the internal
pocket faces. Choose the Tool according to the minimal radius of the model illets.

During the wall inish machining, use the Rest Material strategy to remove the bulk of
material in the corners.

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 3. SolidCAM 2.5D Operations

6. Perform finish machining of the external faces

At the irst stage, perform the rest material machining of the corner faces to remove
the bulk of the material.

Deine a number of Proile operations to machine the external faces.

7. Machine the holes

Deine a number of Drilling operations to perform
the center drilling, drilling, and tapping of the
holes. Use a Pocket operation for counterboring
of the holes.

8. Machine the bottom face

Deine a Face Milling operation to machine the
bottom face of the electronic box part using the
Hatch strategy.

This operation requires different clamping, so

deine and use a new Coordinate System with the
Z-axis oriented normally to the bottom face.

159
Exercise #6: Clamp Machining

Deine the CAM-Part and operations for the machining of the clamp part presented on the
illustration on a Milling CNC-machine.

This exercise reinforces the following skills:

• CAM-Part deinition;
• Multi-sided machining using 2.5-axis CNC-machine;
• Proile machining;
• Open pocket machining;
• Drilling;
The SolidWorks model of the Clamp (Exercise6.sldprt) is located in the Exercises folder.
The following steps have to be implemented in order to obtain the inal CAM-Part:

1. Define the CAM-Part

At this stage you have to deine the CAM-Part, CNC-
controller (AWEA1000-Fanuc), Machine Coordinate
System, the Stock and Target models.
Make a note that the workpiece used for this part is the
box exactly surrounding the clamp model without an
offset.

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 3. SolidCAM 2.5D Operations

2. Holes machining
Perform a number of Drilling operations to
machine the holes.
Use the appropriate Machine Coordinate System
deined for the positioning shown below.

3. Open pocket machining

Add a Machine Coordinate System for the
positioning shown below to machine the open
pocket.

161
 Add a new Pocket operation. In this operation, the open pocket machining strategy will
be used.
Select the open pocket geometry chain as shown.

Click the button to conirm the selected chain. The Close Chain dialog box is
displayed.

Close Chain dialog box

This dialog box is displayed when you conirm an open chain deinition
in the Geometry Edit dialog box.
When you conirm this dialog box with the Yes button, the chain is
closed with a line that connects the start and the end points of the
chain. The Mark line as open edge check box enables you to mark the
connecting line as open edge to perform open pocket machining.
When you click the No button, SolidCAM returns to the geometry
deinition and enables you to close the chain manually by the model
element selection.

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 3. SolidCAM 2.5D Operations

Select the Mark line as open edge check box and

conirm the dialog box with the OK button. The
open edge is marked.
Conirm the Geometry Edit dialog box by clicking
the button.
Choose the Tool #4 (Ø6 End mill) for the operation.
Select the upper face of the model as the Upper
level and the pocket loor as the Pocket depth.

In the Technology page, only the Contour

machining strategy is available. Switch to the Open
pocket tab to deine the parameters of the open
pocket machining.
Deine the extension of the tool path beyond the
open edge.

Extension

This section enables you to deine the overlapping between the tool and
the open edges. The overlapping can be deined as percentage of the
tool diameter (the % of tool diameter option) or as a value (the Value
option).
Open edge

Extension

163
 Set the Extension value to 60% of the tool diameter. Since the diameter of the tool used
in this operation is 6 mm, the tool path is extended by 3.6 mm over the open pocket
edge.

Note that the Extension value cannot be smaller than the radius of the tool.

Select the Use profile strategy check box.

Use Profile Strategy

This option enables you to perform

the open pocket machining in a Proile
manner. The tool path at a speciic
Z-level consists of several equidistant
proiles starting from outside the model
at the distance deined by the Extension
parameter. The tool moves on offsets
parallel to the pocket geometry.
The following options enable you to
deine the tool path direction and linking:
• When the One way option is chosen,
the tool inishes one proile pass,
then rapidly moves (G0) to the
safety distance and then to the
start of the next cutting pass. The
cutting direction (either climb or
conventional) is preserved for each
cutting pass.

• When the Zigzag option is chosen,

the tool inishes one proile pass
and then moves directly to the next
pass. The machining is performed
without leaving the material, thus
constantly switching between climb
and conventional milling.

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 3. SolidCAM 2.5D Operations

Use the default One way option.

Select the Approach from outside check box.

Approach from Outside

This option enables the tool to approach from outside of the material
in the open pocket areas, if possible. Such approach enables you to
decrease the tool loading when plunging into the material. This option
enables you to perform the approach movement from the automatically
calculated point outside of the material. The tool moves to the required
depth outside of the material and then plunges into the material.

Switch to the Technology tab. In the Offsets section, set the Wall offset and the Floor
offset to 0.2. To remove these offsets with the inishing cut, select the Wall and Floor
check boxes in the Finish section.

4. Hole machining
Deine two Drilling operations to perform center
drilling and drilling of the hole located at the
bottom of the open pocket. Use the same Machine
Coordinate System (positioning) as in the previous
operation.

165
 5. Step machining
Deine a Proile operation to machine the step.
Deine the Machine Coordinate System for the
positioning shown below.

Use the Point to point option in the Geometry Edit dialog box to deine the geometry.

Point to Point Mode

This option enables you to connect the speciied points. The points are
connected by a straight line. This option is useful when it is impossible
to deine the geometry using the model edges.
In this exercise, it is impossible to deine the straight geometry for the
Proile Milling using the model edges. The Point to Point option enables
you to deine the geometry by two points located on the model vertices.

166
 3. SolidCAM 2.5D Operations

Use the Zigzag cutting type to connect the successive Z-level passes directly from the
end of a pass to the beginning of the next pass.

Depth Cutting Type

When the One Way option is chosen, the

cutting passes are oriented in the same
direction, and the connection between
them is performed through the Operation
Clearance level. At the end of each pass
the tool performs a retreat movement
to the Operation Clearance level,
a horizontal movement at rapid feed to
the start point of the next pass and then
descends to the Z-level of the next pass.
The same cutting direction (climb or
conventional) is kept along the whole tool path.
When the Zigzag option is chosen,
the tool path is performed in a zigzag
manner, with the tool path direction
changing from one pass to the next. The
passes located at two successive Z-levels
are connected directly from the end of
one pass to the beginning of the next
pass.

The Zigzag option cannot be used together with the

Clear offset technology.

167
Exercise #7: Basic Part Machining

Deine the CAM-Part and operations for the machining of

the basic part presented on the illustration on a Milling CNC-
machine.
This exercise reinforces the following skills:
• CAM-Part deinition;
• Pocket machining;
• Proile machining;
• Rest material machining;
• Face milling;
• Drilling.
The SolidWorks model of the Basic part (Exercise7.sldprt) is
located in the Exercises folder.
The following steps have to be implemented in order to reach
the inal CAM-Part:

1. Define the CAM-Part

At this stage, you have to deine the CAM-Part, CNC-controller (AWEA1000-Fanuc),
Machine Coordinate System, the Stock and Target models.

2. Upper cusp machining

Deine two Proile operations to remove the bulk of material and perform the rough
and the inish machining of the cusp.

168
 3. SolidCAM 2.5D Operations

3. Step machining
Perform the rough and inish machining of the
step faces using the Proile operation.

4. External contour machining

Deine a Proile operation to perform the rough
and inish machining of the external model faces.

5. Connector opening machining

Deine a Pocket operation to perform the rough
machining of the connector opening faces.

6. Connector pocket machining

Deine a number of Pocket and Proile operations
to perform the roughing and inishing of the
connector pocket.

169
 7. Connector opening finish machining
Use the Pocket rest material strategy to perform
the inish machining of the connector opening
faces.

8. Machine screw head areas

Deine a Proile operation to perform the rough
and inish machining of the screw head areas.

9. Top face machining

Use the Face milling Hatch strategy to perform the
rough and inish machining of the top face.

10. Bottom face machining

Use the Face milling Hatch strategy to perform the
rough and inish machining of the bottom face of
the Cover part.
Note that this operation and the following ones
use a new positioning and therefore you have to
deine a new Machine Coordinate System.

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 3. SolidCAM 2.5D Operations

11. Pocket rough machining

Use a Pocket operation to perform the rough machining of the highlighted faces.

12. Wall finish machining

Deine two Proile operations to perform the
inish machining of the wall faces of the pockets.

13. Bottom pocket machining

Perform the rough and inish machining of the
bottom pocket with the island.

14. Hole machining

Deine a number of Drilling operations to machine
holes located on the cover part faces.

171
Exercise #8: Cover Machining

Machine the hole and chamfer on the pre-machined cover

part presented on the illustration on a Milling CNC-machine.
This exercise reinforces the following skills:
• 3D contour machining.
The part ile (Exercise8.prz) is located in the Exercises folder.
This ile contains the deined CAM-Part. The model used
for the part deinition contains two conigurations: Default
(model with the hole and chamfer features) and Stock (hole
and chamfer features suppressed).

Default Stock

The following steps have to be implemented in order to reach the inal CAM-Part:

1. Open the CAM-Part

Open the Exercise8.prz ile located in the Exercises folder.

2. Add a Contour 3D operation

Add a new Contour 3D operation to
perform machining of the hole on the
upper face of the part.
The Contour 3D Operation dialog box is
displayed.

172
 3. SolidCAM 2.5D Operations

A through hole located on a convex surface can be machined in several

methods, such as Proile machining and Contour 3D machining. Proile
milling used for machining of such holes results in a great number of tool
path passes with unavoidable air cutting, because it yields a planimetric
tool path parallel to the XY-plane. Contour 3D machining enables you
to generate a curved tool path in three-dimensional space. Therefore,
in this exercise the Contour 3D operation is used for hole machining to
optimize the tool path and avoid redundant tool movements.

Profile Machining

Profile 3D Machining

3. Define the Geometry

Deine the geometry chain on the upper edge of the hole as shown.

173
 4. Define the Tool
Add a new Ø10 End mill tool for the operation.

5. Define the technological parameters

In the Modify section, click the Geometry
button to check the position of the tool
relative to the geometry.
In this case, the default Left option set for
Tool side meets the requirements of the
climb milling. Close the Modify Geometry
dialog box by clicking the button.
In the Offsets section, set the Wall offset
value to 0.2. The allowance of 0.2 mm
will be left on the hole wall during the roughing. This allowance will be removed with
a separate inishing cut in the end of the machining.
Select the Rough check box. Set the Step down to 2. The hole will be machined in three
equidistant rough passes.
Select the Finish check box. Set the Step down to 6. The inishing will be performed
in a single pass.

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 3. SolidCAM 2.5D Operations

6. Define the Lead in and Lead out

For Lead in, choose the Arc option and use the default Radius value of 2. For Lead out,
select the Same as Lead in check box.

7. Simulate the operation

Perform the simulation of the operation in the SolidVerify mode.

8. Add a Contour 3D operation

Add a new Contour 3D operation to perform chamfering of the upper face of the
cover.

9. Define the Geometry

Deine the geometry chain on the upper edge of the face as shown.

175
 10. Define the Tool
Add a new Ø10 Spot drill tool for the operation.

11. Define the Milling levels

In the Levels page, set Depth to 0.

176
 3. SolidCAM 2.5D Operations

12. Define the technological parameters

In the Modify section of the Technology page, set the Tool side to Right. Click the
Geometry button to check the tool position relative to the geometry.

Close the Modify Geometry dialog box by clicking the button.

Select the Rough check box. Set the Step down to 0.
In the Chamfer section, select the check box and switch to
the Chamfer tab.
Set the Cutting diameter value to 2.

Cutting Profile depth

Diameter (Chamfer depth)

13. Define the Lead in and Lead out

For Lead in, choose the Arc option and use the default Radius value of 2. For Lead out,
select the Same as Lead in check box.

177
 14. Simulate the operation
Perform the simulation of the operation in the SolidVerify mode.

178
 3. SolidCAM 2.5D Operations

Exercise #9: Mounting Base Machining

Deine the CAM-Part and operations for the machining of the mounting base presented on the
illustration on a Milling CNC-machine.

This exercise reinforces the following skills:

• CAM-Part deinition;
• Pocket machining;
• Drafted proile machining;
• T-slot milling;
• Drilling.
The SolidWorks model of the Mounting base (Exercise9.sldprt) is located in the Exercises folder.
The following steps have to be implemented in order to obtain the inal CAM-Part:

1. Define the CAM-Part

At this stage, you have to deine the CAM-Part, CNC-controller (Fanuc4ax), Machine
Coordinate System, the Stock and Target models.

2. Contour machining
Deine a Proile operation to machine the mounting
base external faces.

179
 3. Top face machining
Deine a Face Milling operation to machine the
top face of the mounting base.

4. Pocket machining
Deine a Pocket operation to perform rough and
inish machining of the pocket faces.

Use the lower edges of the islands for

the internal chains deinition, because
the walls are drafted.
Use a Bull nose tool of Ø8 with Corner radius of
0.2 mm for machining the pocket.

5. Profile machining for islands

Deine a Proile operation for two draft angled walls at the islands. Use the Bull nose
tool of Ø8 already deined in Step #4.

Deine the geometry as shown.

Select the Finish option in the Technology
page and set the Step down value to 0.1.

Switch to the Advanced tab and click the

Wall draft angle button.

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 3. SolidCAM 2.5D Operations

In the Wall Draft Angle dialog box, check the same

option.
Set the External wall angle to 8.
In the Cut from area select the Bottom to top
option.

Wall Draft Angle

When this check box is selected, the inclined wall machining is performed.

• External wall angle

This parameter deines the draft angle of the wall measured from the
Z-axis direction as shown.
For the inclined wall machining, each cutting pass located at a speciic
Z-level is generated according to the speciied External wall angle
value.

181
 • External corner type

This option enables you to deine how the cutting passes are
connected during the external corners machining. There are three
ways to connect between the cutting passes:
Sharp corner: the tool path is calculated to perform the machining of
a sharp corner. This option affects only the machining of geometry
sharp corners.
Geometry

Conical fillet: the tool path is calculated to perform the machining of

the corner with a conical illet; the radius of the tool path rounding
increases from one pass to the next. This option affects only the
machining of sharp geometry corners.
Geometry

Cylindrical fillet: this

option affects the machining of both of sharp
and illeted corners of the geometry. The machining of sharp corners
is performed similar to the Conical illet option. For the illeted
corners, the tool path is calculated to perform the machining of the
corner with a cylindrical illet; the radius of the tool path rounding is
the same for all the cutting passes.
Geometry

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 3. SolidCAM 2.5D Operations

6. T-Slot machining
In SolidCAM Toolbar, select 2.5D >
T-Slot.

The T-Slot Operation dialog box is displayed.

Deine two geometry chains as shown. Make sure the direction of the chains geometry
is the same as on the illustration.

183
 Add a new Slot mill tool.

Slot Mill

This type of tool can be used for all types of machining from simple
2.5D undercuts up to 5-axis simultaneous machining.
A tool of this type is deined with the parameters shown in the image.
Arbor
Diameter

Total
Length Outside
Holder

Cutting
Corner Radius Length
Diameter

Edit the tool parameters as follows:

• Set Diameter to 36;
• Set Corner radius to 0;
• Set Cutting length to 3.
Add the BT40 ER32x60 tool holder.
Conirm the tool deinition by clicking
the Select button.
In the Tool page, click the Data tab.
Select the Offsets option and the Top tool offset
number check box.

184
 3. SolidCAM 2.5D Operations

The Top Tool Offset Number deines the register number of the upper
cutting edge of the T-slot mill. This option enables SolidCAM to
automatically take into account the minor size differences between the
deined tool and the one actually used for cutting the workpiece, if there
are any.

7. Define the Milling levels

Deine the Upper level for slot machining
by clicking on the model face as shown.
Conirm the value (-4.5) in the Pick Upper
level dialog
box.
Deine the T-slot depth of the T-slot by
clicking on the model as shown.

The depth value calculated in the T-slot depth area is 6.

8. Define the technological parameters

Deine the rough parameters in the Technology page. To perform roughing of the slot,
select the Rough check box.
To perform the rough machining of the slot, you have to specify offsets on the slot
geometry. These offsets are removed with the inishing cut.

185
 The Wall offset option deines the offset that remains on the slot wall
after roughing.

Wall Offset

The Ceiling offset option deines the offset that remains on the slot
ceiling after roughing.

Ceiling
Offset

The Floor offset option deines the offset that remains on the slot loor
after roughing.

Floor
Offset

186
 3. SolidCAM 2.5D Operations

Set all of the offset to 0.2

Deine the inishing parameter.

Select the Finish check box. Notice that the Ceiling, Wall
and Floor check boxes are selected by default. These
check boxes deine the offsets (Ceiling, Wall and Floor,
respectively) to be removed with the inishing pass. Set the
Cutting depth overlap value for inishing to 2.

Cutting depth overlap

This parameter deines the overlap of each two adjacent tool paths in
both rough and inish machining of the slot.

Cutting depth
overlap Cutting depth
overlap

9. Define the Lead in and Lead out

For Lead in, select the Tangent option and set the Tangent extension to 12. For Lead
out, select the Same as Lead in check box.

10. Simulate the operation

Perform the simulation of the operation
in the SolidVerify mode.

187
 11. Holes machining
Deine several Drilling operations
to perform the machining of the
countersink holes located on the top
face of the mounting plate.

188
 3. SolidCAM 2.5D Operations

Exercise #10: Support Machining

Machine the threads on the pre-machined support

part presented on the illustration on a Milling CNC-
machine.
This exercise reinforces the following skills:
• Threading.

The part ile (Exercise10.prz) is located in the Exercises

folder. This ile contains the deined CAM-Part.
The following steps have to be implemented in order to perform the internal and external threading:

1. Open the CAM-Part

Open the Exercise10.prz ile located in the Exercises folder.

2. Add a Thread Milling Operation

Add a new Thread Milling operation to perform threading of the internal surface of
the part.
The Thread Milling Operation dialog box is displayed.

189
 3. Define the Geometry
Deine the geometry by clicking on the internal
surface of the part.
The tread milling position is selected, and its
coordinates are displayed in the Drill Geometry
Selection dialog box.

4. Define the Tool

Switch to the Tool page of the Thread Milling Operation dialog box and click the Select
button.
The Part Tool Table dialog box is displayed.
Click to start a new threading tool deinition. The Tool Type pane is displayed.
Choose the Thread Mill tool for the operation.

Thread Mill

This tool type is used for threading in Thread Milling operations. A tool
of this type is deined with the parameters shown in the image.
Arbor
Diameter

Outside
Holder Total
Length Length

Shoulder
Length

Thread
Cutting
Cutting Diameter Length

190
 3. SolidCAM 2.5D Operations

In the Pitch/Standard area under Tool

Parameters, click the arrow near Choose
standard table and select the Metric (ISO)
option from the list.
The Threading Type: Metric (ISO) dialog
box is displayed.
Select the M64 x 4.0 standard from the list
and click OK.

Use the default tool parameters.

191
 5. Define the Milling levels
Deine the operation Upper level directly on the solid model by clicking on the top of
the part.
Deine the Thread depth by clicking on the bottom face of the part.
In the Depth definition area, set the Delta value to -4.

6. Define the technological parameters

In the Technology page, make sure the default Internal type is chosen in the Thread
Data area. Set the Major thread diameter value to 64. In the Cut from section, select Top
to bottom.

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 3. SolidCAM 2.5D Operations

7. Define the Lead in

Switch to the Link page. Under Lead in/out Arc, clear the Start from the center check
box.

Start from the center

This option enables you to start threading from the center of the
geometry. When this option is cleared, the tool starts machining from
a safety distance, which allows to avoid air cutting and save machining
time.

8. Simulate the operation

Perform the simulation of the operation
in the Host CAD mode. Set the CAM-
Part in the Top view to observe that the
tool approaches the material not in the
center.
Perform the simulation of the operation
in the SolidVerify mode.

9. Add a Thread Milling Operation

Add a new Thread Milling operation to perform small internal threads.

10. Define the Geometry

Deine the geometry by clicking on the upper surface of the model containing the
holes.

193
 11. Define the Tool
Deine a new Thread mill selecting the M14x1.5 standard from the Metric (ISO) table.

12. Define the Milling levels

Deine the operation Upper level directly
on the solid model by clicking on the
small pocket surface as shown.
Deine the Thread depth by clicking on
the model bottom face.

13.Define the technological parameters

In the Technology page, make sure the default Internal type is chosen in the Thread
data area. Set the Major thread diameter value to 14. In the Cut from section, select Top
to bottom.

14. Define the Lead in

Switch to the Link page. Under Lead in/out Arc, make sure that the Start from the center
check box is selected.

15. Simulate the operation

Perform the simulation of the operation in the SolidVerify mode.

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 3. SolidCAM 2.5D Operations

16. Add a Thread Milling operation

Add a new Thread Milling operation to perform threading of the external surface of
the part.

17. Define the Geometry

Use the Drill geometry deined in the irst operation.

18. Define the Tool

Deine a new Thread mill. In the Tool parameters area, under
Pitch / Standards, select User and set 3 for the Pitch value. From the list, select the ISO
FINE standard.

• Set the Cutting diameter to

45.3333.

19. Define the Milling levels

Deine the operation Upper level directly on the
solid model by clicking on the top face of the part
as shown.
Deine the Thread depth by clicking on the model
surface as shown.

195
 20. Define the technological parameters
In the Technology page, choose the External type in the Thread data area. Set the Major
thread diameter value to 86.

In the Cut from area, choose the Top to bottom option.

21. Simulate the operation

Perform the simulation of the operation in the SolidVerify mode.

At this stage, the exercise is completed.

196
Indexial
4-Axis Milling 4
SolidCAM enables you to perform indexial 4-axis milling on vertical or horizontal CNC-machines
with a 4th axis rotary table.

The 4th axis rotation is used for the positioning of the part. When the part is positioned to the
required orientation, the 4th axis is locked and the machining is performed using 3-axis movements.

For each clamping, SolidCAM enables you to deine the Machine Coordinate System with X-axis
(for vertical machines) or Y-axis (for horizontal machines) parallel to the revolution axis of the
rotary table.

Machine
Coordinate Y
Machine
Coordinate System
X
Z System
Z
Y

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 4. Indexial 4-Axis Milling

Within one clamping (Machine Coordinate System), SolidCAM enables you to deine a number of
positions around the revolution axis. For vertical machines the X-axis of these positions is parallel
to the X-axis of the Machine Coordinate System.
Machine Coordinate System

Z
Y

Positions

Z Z
Y Y
Z Y

X X
X

For horizontal machines, the Y-axis of these positions is parallel to the Y-axis of the Machine
Coordinate System.
Machine Coordinate System

Y
X Z

Positions
Y Y
Y
X Z X Z
X Z

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For each position, SolidCAM automatically determines the Shift and the Rotation parameters
relative to the Machine Coordinate System.
Machine
Coordinate Rotation X
System
Z Y'
Z Y Z' Y
Y'
X Position
Z' X'
Shift Z X
Shift X X'
Shift Y

The Shift components (Shift X, Shift Y and Shift Z) describe the shifting of the position relative to
the Machine Coordinate System.
The Rotation components (Rotation around X, Rotation around Y and Rotation around Z) describe
the axis orientation of the position relative to the Machine Coordinate System.
Positions can be deined only around the revolution axis. For vertical machines only positions
around X-axis can be added, so the Rotation around Y and Rotation around Z values are 0. The
Rotation around X parameter can be different from 0. For horizontal machines only positions
around Y-axis can be added, so the Rotation around X and Rotation around Z values are 0. The
Rotation around Y parameter can be different from 0.

Machine Coordinate Systems and their positions are used for the geometry deinition. Before the
geometry deinition you have to choose the Coordinate System position. The geometry has to be
located in the plane parallel to the XY-plane of the chosen CoordSys.

200
 4. Indexial 4-Axis Milling

Exercise #11: Frame Machining

In this exercise, indexial 4-axis operations are used for the frame part machining.

The frame is machined from the pre-machined stock on a vertical 4-axis milling CNC-machine
using the special jig.

The jig with the clamped workpiece is placed on the rotary table of the machine. Such clamping
enables you to machine four sides of the model using the rotation of the 4th axis.

The tail used for the part clamping is removed in

a separate operation using a 3-axis CNC-machine.

201
 1. Change default settings
First, you have to cancel automatic deinition of the stock and target models, which is
set in the preferences by default.
In the SolidCAM menu, click the SolidCAM Settings
command.
The SolidCAM Settings dialog box is displayed. From the
left menu, choose Automatic CAM-Part definition. Clear the
Definition of Stock and Definition of Target check boxes.

From now on, the stock and target models will not be deined automatically for each
CAM part you create.

2. Load the SolidWorks model

Load the Exercise11.sldprt model located in the Exercises folder.
The model contains three conigurations:
• Default
The original design model without changes.

202
 4. Indexial 4-Axis Milling

• Stock
The stock model that is used for the SolidCAM stock deinition.

• Machining
The machining model with a tail that was not removed. This coniguration is
used for the SolidCAM geometries deinition.

3. Start SolidCAM
To start SolidCAM, click the SolidCAM command in the main menu of SolidWorks and
choose Milling from the New submenu. SolidCAM is started, and the New Milling Part
dialog box is displayed.

4. Confirm the CAM-Part creation

Conirm the New Milling Part dialog box by clicking the OK button. The Milling Part
Data dialog box is displayed.

5. Define the CNC-controller

Choose a CNC-machine controller. Click the arrow in the CNC-Machine section to
display the list of post-processors installed on your system.
In this exercise, use a vertical 4-axis CNC-machine with the Fanuc CNC-controller.
Choose the AWEA1000-Fanuc CNC-controller from the list.

203
 6. Define the Machine Coordinate System
Click the Define button in the Coordinate System section of
the Milling Part Data dialog box to start the Coordinate System
deinition.

The CoordSys dialog box is displayed.

SolidCAM assigns the irst Position number to the Machine
Coordinate System by default.

Make sure that the default Select Face option is chosen.

Click on the model bottom face as shown.

The Machine Coordinate System #1 is automatically deined in

the corner of the model box. Click the button.
The CoordSys Data dialog box is displayed.

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 4. Indexial 4-Axis Milling

SolidCAM automatically determines the Shift and Rotation values. For the irst
Position related to a new Machine Coordinate System, the Shift and Rotation parameters
values are always 0.
Close this dialog box with the OK button. The CoordSys Manager dialog box is
displayed.

7. Define the CoordSys positions

Now you have to deine several additional Positions around
the Machine Coordinate System #1.
In CoordSys Manager, right-click the Position #1 item and
choose the Add command from the menu.
The CoordSys dialog box is displayed again.
SolidCAM assigns the next sequential number to the
position.
Click on the model face as shown.

The origin is automatically placed in

the corner of the model. The Z-axis
is directed outwards normally to the
selected face. The X-axis direction is the
same as the direction of the X-axis of the
Machine Coordinate System (Position
#1).

Click the button to conirm the

position location. The CoordSys Data
dialog box is displayed.

205
 The Part upper level (0) and the Part lower level Machine Coordinate System
(-100) are automatically determined on the model.
Z Position #1
The Shift and Rotation parameters are deined
automatically for the Position #2. The Shift Z is -35; Y
the Shift X and Shift Y are 0. The Rotation around X
is -90; other Rotation values are 0.
Conirm the dialog box with the OK button.
Rotation X X
-90° Y
Shift Z
35 Position #2

In the same manner, deine Position #3 and Position

Z X
#4 using the model faces as shown.

Position #3 Position #4
Shift (0,100,-35) Shift (0,100,0)
Rotation (180,0,0) Rotation (90,0,0)
Conirm the CoordSys Manager dialog box with the button.

8. Define the Stock model

Click the Stock button in the Stock & Target model area. The
Model dialog box is displayed.

Select the 3D Model option in the Defined by section. This option

enables you to deine the stock model by picking solid bodies.
In the Configurations section, switch to the Stock coniguration.

206
 4. Indexial 4-Axis Milling

The model is displayed in the Stock coniguration.

Click on the model to select it for the stock model.

Close the Model dialog box with the button.

9. Define the Target model

In the Milling Part Data dialog box, click the Target button. The Model dialog box is
displayed.
In the Configuration section, choose the Machining coniguration
that describes the model after the machining.

The coniguration is changed. Click on the model as shown.

Close the Model dialog box with the button.

10. Save the CAM-Part

Click the button to save the CAM-Part data and close the Milling Part Data dialog
box.
The SolidCAM Manager dialog box is displayed.

207
 11. Define the Fixture
SolidCAM enables you to deine the Part fixtures such as clamps, vises, jig plates, etc.
This feature enables you to get a more realistic picture during the simulation and check
possible collisions between the cutting tools and ixtures.
At irst, you have to add the model of the clamping device to the CAM-Part assembly.

It is recommended to copy your clamp model iles into the CAM-Part folder
before the insertion into the CAM-Part assembly.

Click the Insert command in the

SolidWorks menu and choose the
Existing Part/Assembly option
from the Component submenu.
The Insert Component dialog
box is displayed.
Click the Browse button and
choose the Clamp.sldprt ile.
This ile contains the model of
the clamping device.

208
 4. Indexial 4-Axis Milling

Conirm the component insertion with

the button. The model is added.
Align the model as shown below using
the Mate or the SmartMates option.

In SolidCAM Manager, right-click the Fixtures header and

choose the Define Fixture command from the menu.

The Model dialog box is displayed. This dialog box enables

you to deine the ixture by selecting solid bodies of the CAM-
Part assembly components.
Click on the clamping device model as shown.

Conirm the Model dialog box with the button.

209
 To choose this new ixture for future operations, right-
click the Operations header and choose the Machine Setup
command from the menu.
The Machine setup dialog box is displayed.

Until now, no ixture has been choosen for operation,

therefore the Fixture cell in the table contains the None
ield. Double-click this ield and choose the clamping_
fixture option for the ixture that you have deined earlier.
Click OK.
The Setup sub-header is now displayed under the Operations
header.

12. Define a Pocket operation

Deine a Pocket operation to perform the rough
machining of the highlighted faces.
Choose the Coordinate System Position #1 in the
Geometry page of the Pocket Operation dialog
box.
Deine the Geometry as shown.

Deine a new End mill tool of Ø10 and

choose it for the operation. Choose the
appropriate tool holder.

210
 4. Indexial 4-Axis Milling

Deine the Pocket depth on the top face

of the pad as shown.
Set the Wall offset and the Floor offset
values to 0.2 to leave allowance for the
next inishing operation.
Use the Helical Ramping strategy. Set the
Radius value to 5.

13. Define a Pocket operation

Deine a Pocket operation to perform the rough
machining of the highlighted faces.
The Coordinate System Position #1 has to be
chosen in the Geometry page of the Pocket
Operation dialog box.

Deine the Geometry as shown.

Choose the Tool #1 (Ø10 End mill) for the operation.
Deine the Upper level for the operation
on the top face of the pad (used in the
previous operation for the Pocket depth
deinition). Deine the Pocket depth on
the bottom face as shown.

Set the Wall offset and the Floor offset

values to 0.2 to leave allowance for the
further inishing.
Use the Helical Ramping strategy. Set the
Radius value to 5.

211
 14. Define a Pocket operation
Deine a Pocket operation to perform the rough
machining of the highlighted faces.
Choose the Coordinate System Position #1 in the
Geometry page of the Pocket Operation dialog
box.
Deine the Geometry as shown.
Choose the Tool #1 (Ø10 End mill) for the
operation.
Deine the Upper level for the operation
using the bottom face of the previously
machined pocket. Pick the Pocket depth
as shown.

Set the Delta value for the Pocket Depth to -1 to

perform the through pocket machining.
Set the Wall offset value to 0.2 to leave allowance for
the further inishing.
Use the Helical Ramping strategy. Set the Radius value
to 5.

15. Define a Profile operation

Deine a Proile operation to perform the
inish machining of the highlighted faces.
Choose the Coordinate System Position #1 in
the Geometry page of the Profile Operation
dialog box.
Use the geometry deined in Step #12.
Choose the Tool #1 (Ø10 End mill) for the
operation.
Use the same milling levels that were deined in Step #12.
Choose the Arc strategy for Lead in and select the Same as Lead in check box under
Lead out.

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 4. Indexial 4-Axis Milling

16. Define a Profile operation

Deine a Proile operation to perform the inish
machining of the highlighted faces.
Choose the Coordinate System Position #1 in the
Geometry page of the Profile Operation dialog
box.
Use the geometry deined in Step #13.
Choose the Tool #1 (Ø10 End mill) for the operation.
Use the same milling levels used in Step #13. Set the
Clear offset and the Step over parameters to perform the machining of the bottom face
in several concentric proiles.
Choose the Arc strategy for Lead in and select the Same as lead in check box under
Lead out.

17. Define a Profile operation

Deine a Proile operation to perform the inish
machining of the highlighted faces.
Choose the Coordinate System Position #1 in the
Geometry page of the Profile Operation dialog
box.
Use the geometry deined in Step #14.
Choose the Tool #1 (Ø10 End mill) for the operation.
Use the same milling levels used in Step #14.
Choose the Arc strategy for Lead in and select the Same as lead in check box under
Lead out.

18. Define a Pocket operation

In the same manner as explained in Step #12,
deine a Pocket operation to perform the rough
machining of the highlighted faces.
Use the Coordinate System Position #3 for the
operation.

213
 19. Define a Pocket operation
In the same manner as explained in Step #13,
deine a Pocket operation to perform the rough
machining of the highlighted faces.
Use the Coordinate System Position #3 for the
operation.

20. Define a Profile operation

In the same manner as explained in Step #15,
deine a Proile operation to perform the inish
machining of the highlighted faces.
Use the geometry deined in Step #18.
Use the Coordinate System Position #3 for the
operation.

21. Define a Profile operation

In the same manner as explained in Step #16,
deine a Proile operation to perform the inish
machining of the highlighted faces.
Use the Coordinate System Position #3 for the
operation.
Use the geometry deined in Step #19.
Choose the Tool #1 (Ø10 End mill) for the
operation.
Set the Clear offset and the Step over values to perform the machining of the bottom
face in several concentric proiles.

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 4. Indexial 4-Axis Milling

22. Define a Pocket operation

Deine a Pocket operation to perform the rough and

inish machining of two connector openings.
Use the Coordinate System Position #4 for the
operation. Deine the geometry as shown.

Deine a new End mill tool of Ø6 for the operation. Choose the appropriate tool holder.

23. Define a Pocket operation

Deine a Pocket operation to perform the rough and
inish machining of the highlighted pocket faces.
Use the Coordinate System Position #2 for the
operation. Deine the geometry for the operation as
shown.

Choose the Tool #1 (Ø10 End mill) for the operation.

215
 In the Finish section of the Technology page, select the Wall and the Floor check
boxes to perform inishing of the walls and the loor of the pocket.

Pocket Wall Finishing

Wall inishing can be performed in a single cut at the whole depth or in

a number of cuts at each step down.
• Total depth

When this option is chosen, the wall inishing is performed in

a single cut at the whole depth.

Finish pass

• Each step down

When this option is chosen, the wall inishing is performed in several

successive cuts at each step down.

Finish passes

216
 4. Indexial 4-Axis Milling

The options of the Depth section are available only

when the wall inishing is performed in the operation
(the Wall check box is selected).

Under Depth, choose the Each step down option.

24. Perform the holes machining

Deine several Drilling operations to perform
center drilling, drilling and threading of the holes.
Using the Coordinate System Position #1, perform
the machining of the M3 holes.
Use a Ø6 spot drill (with 90° tool tip angle), a Ø2.5
drill and a Ø3 tap tool. Choose the appropriate tool
holders.
Using the Coordinate System Position #2, perform
the machining of the M6 holes.
Use the Ø6 spot drill (with 90° tool tip angle);
a Ø5 drill and a Ø6 tap tool. Choose the appropriate
tool holders.

25. Perform the chamfer machining

At this stage, you have to deine a Proile

operation for the 0.5 mm chamfer machining.
Choose the geometry deined in Step #12 for
the operation. This geometry is deined using
the Coordinate System Position #1.

217
 Deine a Chamfer drill tool of Ø6 for the operation.

Chamfer drill

This tool is used for chamfering. A tool of this type is deined with the
parameters shown in the image.
Arbor Diameter

Total
Length Outside
Shoulder
Holder
Length
Length Cutting
Length
Angle

Diameter

For the chamfer machining, set the value of

the chamfer depth in the Profile depth ield.
In this case, set the value of 0.5.
Cutting Profile depth
In the Rest material/Chamfer section, choose Diameter (Chamfer depth)
the Chamfer option from the list. A new page
under the Chamfer tab is displayed.
Deine the Cutting diameter, which is the
diameter of the tool coincident with the
geometry at the chamfer depth.

Set the Cutting diameter value to 2.

In the Link section of the Profile Operation dialog box, choose the Arc strategy for
Lead in and select the Same as Lead in check box under Lead out.
In the same manner, deine a new Proile operation to machine another chamfer of
0.5 mm using Coordinate System Position #3.

218
 4. Indexial 4-Axis Milling

26. Simulate the tool path

Simulate the CAM-Part in the SolidVerify mode.
SolidCAM displays the ixture and checks the possible gouges during the simulation.

In the SolidVerify simulation, the tool is shown going around the part (rather than
rotating the part as it actually occurs in the CNC-machine). Therefore, for all CNC-
machine types, the simulation looks the same.
At this stage, you have completed the exercise.

219
Exercise #12: Mounting Machining

Deine the CAM-Part and operations for machining of the mounting part shown below on the
4-axis vertical milling CNC-machine.

This exercise reinforces the following skills:

• CAM-Part deinition;
• Face milling;
• Pocket machining;
• Drilling.
The SolidWorks model of the Mounting part (Exercise12.sldprt) is
located in the Exercises folder.
The mounting is machined from the stock pre-machined by turning.
The following steps have to be implemented in order to obtain the inal
CAM-Part:

1. Define the CAM-Part

At this stage, you have to deine the CAM-Part, CNC-controller (Fanuc4ax), Machine
Coordinate System, the Stock and Target models.

Machine Coordinate System definition

In this exercise, the Machine Coordinate System

has to be deined in the center of the revolution
face as shown.

220
 4. Indexial 4-Axis Milling

Using the Flip options in the CoordSys

dialog box, rotate the Coordinate System
so that the X-axis is collinear with the
revolution axis and the Z-axis is directed Z
upwards as shown.
Deine an additional Machine Coordinate Y
System #2 to machine the back faces of the X

mounting part.

Deine the Stock and the Target models using the conigurations of the original
SolidWorks model.

2. Face milling
Deine a Face Milling operation with the Hatch strategy to
machine the shown face.
Use the Machine Coordinate System #1 (Position #1) for
the machining.

3. Holes machining
Deine three Drilling operations to perform center drilling,
drilling and threading of the M6 holes.

221
 4. Define the operation pattern

Now you have to deine a circular pattern of the operations around the revolution axis
(4th axis) of the CAM-Part in order to machine all the sides.
In SolidCAM Manager, select all the deined
operations holding the Shift or Ctrl keys. Right-
click one of the selected operations and choose
the Transform option from the menu.

The Operation Transformations dialog box is

displayed.

This dialog box enables you to perform various transformations, such as rotating,
translating, and mirroring of the selected operations.

222
 4. Indexial 4-Axis Milling

Operation transformations
This section offers you the choice of whether the original operation will
be transformed or its copy will be added for transformation and, in the
latter case, enables you to deine the placing of the new operation in the
SolidCAM Manager tree.
The following options are available:
• Edit operation transformations
This option enables you to perform transformation of the
selected operation.
• New operation (add at current position in operations tree)
This option enables you to add a copy of the selected operation
and apply the transformation to the copied operation,
without effect on the original operation. The transformed
copy is inserted immediately after the original operation in
the SolidCAM Manager tree. The original operation can be
suppressed by selecting the appropriate check box in the
Options section.

• New operation (add at end of operations tree)

This option also enables you to add a copy of the selected
operation and apply the transformation to the copied operation,
without effect on the original operation. The transformed copy
is inserted at the end of the operation list in the SolidCAM
Manager tree. The original operation can be suppressed by
selecting the appropriate check box in the Options section.

In the Operation transformations section, use the default Edit operation

transformations option.
In this exercise, you need to deine a circular pattern of the selected
operations around the 4th axis. Click the 4 Axis button.
The Rotate List dialog box is displayed.

223
 Select the Include original operation check box. When this
check box is selected, the original operation tool path is
included in the transforming action.
In the Angle ield, type the value of 120°. This parameter
deines the rotation angle for each pattern instance. In the
Steps ield, enter 2 for the number of instances.

Click the Insert button. The speciic value of the rotation

angle is calculated for each instance of the pattern.

Conirm the Rotate List dialog box with the OK button.

The operations to be transformed appear in the Operation Transformations dialog box.

Conirm this dialog box with the OK button.

Note that the icons of the transformed operations are marked with the icon. This
icon means that the operations were patterned using the 4th axis.

224
 4. Indexial 4-Axis Milling

5. Simulate the transformed operations

Play the simulation of the transformed operations in the SolidVerify mode.

6. Remove the clamping tail

Deine a Face Milling operation with the Hatch
strategy using the Machine Coordinate System #2
to remove the tail that was necessary for the part
clamping at the 4th axis operations.

7. Machine the back side

Machine the pocket faces on the back side of the
mounting.
Deine several Pocket operations to perform
rough and inish machining of the pockets.
Use the Machine Coordinate System #2 for the
operations.

225
226
Indexial
5-Axis Milling 5
SolidCAM enables you to perform indexial 5-axis milling using either vertical or horizontal 5-axis
CNC-machines.
The 4th and 5th axis rotation is used for positioning of a part. When the part is positioned to the
necessary orientation, the 4th and the 5th axes are locked and machining is performed with 3-axis
movements.
For each clamping, SolidCAM enables you to
deine the Machine Coordinate System.

Machine
Coordinate
System

228
 5. Indexial 5-Axis Milling

For each clamping (Machine Coordinate System), SolidCAM enables you to deine a number of
related positions around the Machine CoordSys. Take care of the machine limitations (angles or
undercuts).
Machine Coordinate System

Z
Y

Z Y
Positions

Z Z
Y Y

X X

229
For each position, SolidCAM automatically determines the Shift and Rotation parameters relative
to the Machine Coordinate System.

Shift X
Machine
Coordinate Z Y
System

Shift Z

X'

Position
Y' Z'

Shift Y

Machine Coordinate Systems and their

positions are used for the geometry Machine X'
Z Y
deinition. Before the geometry Coordinate Position
deinition you have to choose the System Y' Z'
Coordinate System position. The
geometry has to be located in the plane X
parallel to the XY-plane of the chosen Rotation:
CoordSys. X= 0
Y= -90
Z= 180

230
 5. Indexial 5-Axis Milling

Exercise #13 : Clamp Machining

Deine the CAM-Part and operations for the machining of the clamp shown below on the 5-axis
vertical milling CNC-machine.

This exercise reinforces the following skills:

• CAM-Part deinition;
• Face milling;
• Pocket machining;
• Proile machining;
• Drilling;
• Indexial 5-axis machining.
The SolidWorks model of the Clamp (Exercise13.sldprt) is located in the Exercises folder. The
model contains two SolidWorks conigurations:
• Machining

This coniguration represents the model after the machining.

• Stock

This coniguration represents the pre-machined

workpiece before machining. The dovetail is pre-
machined to perform simple clamping of the part
during the machining.

1. Define the CAM-Part

At this stage, you have to deine the CAM-Part, CNC-
controller (Fanuc5a), Machine Coordinate System and its Positions, the Stock and
Target models.

231
 Coordinate System definition

Deine Machine Coordinate Systems #1 and #2 and related positions

using the previously deined Stock model.

Machine Coordinate System

#1
Position #1

Machine Coordinate System

#1
Position #2

Machine Coordinate System

#1
Position #3

Machine Coordinate System

#1
Position #4

232
 5. Indexial 5-Axis Milling

Machine Coordinate System

#1
Position #5

Machine Coordinate System

#2
Position #1

Deine the Stock model using the Stock coniguration of the CAM-Part assembly.
Deine the Target model using the Machining coniguration of the CAM-Part assembly.

2. Top face machining

Deine a Face Milling operation with the Hatch strategy
to machine the top inclined face of the clamp. Use the
Machine Coordinate System #1 (Position #2) for the
operation.

3. Back face machining

Deine a Face Milling operation with the Hatch strategy
to machine the back inclined face of the clamp. Use
the Machine Coordinate System #1 (Position #3) for the
operation.

233
 4. Front face machining
Deine a Face Milling operation with the Hatch strategy
to machine the front inclined face of the clamp. Use
the Machine Coordinate System #1 (Position #4) for the
operation.

5. Openings machining
Deine a Proile operation to machine two openings
located on the front inclined face of the clamp. Use
the Machine Coordinate System #1 (Position #4) for the
operation.

6. Slot machining
Deine a number of operations to machine the slot
faces located on the top inclined face of the clamp. Use
the Machine Coordinate System #1 (Position #2) for the
operation.

7. Hole machining
Deine a number of operations to machine the inclined
counterbore hole located on the top inclined face of
the clamp. Use the Machine Coordinate System #1
(Position #5) for the operation.

8. Bottom face machining

Deine a Face Milling operation with the Hatch strategy
to machine the bottom inclined face of the clamp. Use
the Machine Coordinate System #2 (Position #1) for the
operation.

234
ToolBox Cycles 6
Toolbox sub-operations are a set of 2.5D Milling operations, each intended for a speciic machining
case. For example, some operations cover different strategies of the counterbore machining. Each
sub-operation provides you with a speciic machining strategy optimal for a particular machining
case.
These operations are combined in a single dialog box as sub-operations.
SolidCAM offers you the following types of ToolBox Cycles:

ToolBox Cycles

Spiral Open Slot Spine Slot Ruled Surface

Spiral Open Slot Wide Four Nubs Cycle O-Ring

Spiral Closed Slot Wide Flattened Surface

Simple Corner
on Cylinder

Additional ZigZag Slot Broaching Flattened Surface

on Corner

Simple Slot Simple Multi Bosses Simple Boss

Closed Slot One Side Open Slot Spiral Pocket

236
 6. ToolBox Cycles

Spiral Open Slot

This strategy enables you to perform the machining of open slots.
The geometry consists of two chains. The machining is performed
in a spiral manner.

Spiral Open Slot Wide

This strategy enables you to perform the machining of wide open
slots. The irst cutting pass is performed in the spiral manner along
the determined spine of the slot, and then the machining of the slot
walls is performed by a number of proiles equidistant to the slot
geometry.

Spiral Closed Slot Wide

This strategy enables you to perform the machining of wide closed
slots. The irst cutting pass is performed in the spiral manner along
the determined spine of the slot, and then the machining of the slot
walls is performed along the slot geometry.

Additional Zigzag Slot

This strategy enables you to machine long slots. The tool path starts
from the slot center approaching it in a zigzag movement and goes
toward the walls.

Simple Slot
This strategy enables you to perform the one-pass machining of the
slots with the width equal to or smaller than double diameter of the
tool.

Closed Slot
This strategy enables you perform the machining of a closed
slot with the width equal to the tool diameter. The machining is
performed in the zigzag manner; the last cut is horizontal to clean
the slot loor.

237
Spine Slot
This strategy enables you to perform the machining of a slot opened
from one side. SolidCAM automatically determines the spine of the
slot and performs the machining according to the spine’s shape. In
this sub-operation, the tool approaches the material along the spine
and then machines the walls of the slot.
Four Nubs Cycle
This strategy enables you to machine the proile of a pocket while
preserving the rest of the material ixed to the wall using small thin
bridges. Inner material will be hammered for shorter machining
time.

Broaching
This strategy enables you to perform broaching of holes.

Simple Multi Bosses

This strategy enables you to perform the machining of several
bosses starting from one face. The machining is performed in a
number of equidistant Clear Offset passes parallel to the selected
bosses geometry. The cutting passes are generated for the whole
geometry combined from the initial bosses.

One Side Open Slot

This strategy enables you to machine an one-sided slot using two
chains: a main chain and a drive chain. A spiral tool path is generated
during this sub-operation.

Ruled
This strategy enables you to perform the machining of an analytical
ruled surface deined by two open contours. The cutting passes are
evenly distributed between the deined contours.

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 6. ToolBox Cycles

O-Ring
This strategy enables you to machine O-Ring slots.

Flattened Surface on Cylinder

This strategy enables you to perform machining of the lattened
surface on a cylinder.

Flattened Surface on Corner

This strategy enables you to machine an angled plane using a deined
working area in order to prevent air cuts.

Simple Boss
This strategy enables you to perform machining of a boss located on
a model face. SolidCAM enables you to deine the closed geometry
chain for the boss and closed chain for the initial model face from
which the boss starts. The machining is performed in a number of
equidistant cutting passes parallel to the boss geometry. The passes
are cut with the outer contour of the initial face.

Spiral Pocket
This strategy enables you to perform machining of the closed pocket
areas using spiral techniques. With this strategy, the tool penetrates
into the material in the automatically calculated point inside the
pocket with a helix (with the automatically calculated radius and
angle). Then the tool performs the spiral cutting pass morphing
from the penetration point to the closed area walls.

239
Exercise #14: Standard Cycles Machining

In this exercise, you use the Standard Cycles

Plate to machine eighteen Standard Toolbox
operations.
The SolidWorks model of the Standard
Cycles Plate (Exercise14.sldprt) is located in
the Exercises folder.

1. Define the CAM-Part

At this stage, you have to deine the CAM-Part, CNC-controller (AWEA1000-Fanuc),
Machine Coordinate System, the Stock and Target models.

2. Spiral open slot machining

In the SolidCAM Operations toolbar, choose 2.5D
> Toolbox Cycles.
Alternatively, you can right-click the Operations
header in SolidCAM Manager and select Add
Milling Operation > Toolbox Cycles.

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 6. ToolBox Cycles

The ToolBox Cycles Operation dialog box is displayed.

Make sure the default Spiral Open Slot strategy is chosen in the top left corner under
Technology.

Click to deine new geometry.

Choose a pair of chains as shown.

Conirm the geometry by clicking .

Add a new End mill of Ø10.
Select the Milling levels directly on the model.
In the Technology page, under Offsets, set Wall
Offset to 0.5. Under Extension, set % of Tool
Diameter to 80. Under Finish, select the Wall Finish option.

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 3. Wide Spiral Open Slot machining
In the manner as described in the previous step, deine a new ToolBox Cycles operation.
Under Technology, select the Spiral Open Slot Wide strategy.

Deine a new geometry, selecting a pair of chains

on the wide slot edges.
Use the same tool as in the previous operation.
In the Technology page, under Offsets, set Wall
Offset to 1. Under Finish, select the Wall Finish
option.

4. Wide Spiral Closed Slot machining

Deine a new ToolBox Cycles operation.

Under Technology, select the Spiral Closed Slot Wide strategy.

Deine a new geometry, selecting the open chain as shown.

Use the same tool as in the previous operation.

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 6. ToolBox Cycles

5. Additional Zigzag slot machining

Deine a new ToolBox Cycles operation.

Under Technology, select the Additional Zigzag Slot strategy.

Deine a new geometry, selecting the closed chain as shown.

Use the same tool as in the previous operation.

6. Simple Slot machining

Deine a new ToolBox Cycles operation.

Under Technology, select the Simple Slot strategy.

Deine a new geometry, selecting a pair of chains on the slot edges.

Add a new End mill of Ø16.

7. Closed Slot machining

Deine a new ToolBox Cycles operation.

Under Technology, select the Closed Slot strategy.

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 Deine a new geometry, selecting the closed chain as show.

Use the previously deined Tool #1 of Ø10.

In the Closed Slot cycle, the tool diameter is equal to the slot width.

8. Spine Slot machining

Deine a new ToolBox Cycles operation.

Under Technology, select the Spine Slot strategy.

Deine a new geometry, selecting the open chain as shown.

Use the same tool as in the previous operation.

9. Four Nubs Cycle machining

Deine a new ToolBox Cycles operation.

Under Technology, select the Four Nubs Cycle strategy.

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 6. ToolBox Cycles

Deine a new geometry, selecting the closed chain as shown.

Deine a new End mill of Ø10 for this operation and edit the following parameters:
• Set the Shoulder length to 60;
• Set the Cutting length to 60.

10. Simple corner machining

Deine a new ToolBox Cycles operation.

Under Technology, select the Simple Corner strategy.

Deine a new geometry, selecting the open chain as shown.

Use the previously deined Tool #1 of Ø10.

11. Broaching
Deine a new ToolBox Cycles operation.

Under Technology, select the Broaching strategy.

245
 Deine a new geometry, selecting the linear chains as shown.

With this operation, only a Broaching tool is available.

Broaching Tool

The tool of this type can only be used within the Broaching sub-operation.
It is not available for deining or choosing in any other operation.
Arbor
Diameter

Total Cutting
Length Length Outside
Holder
Shoulder Length
Length

Width Depth

Corner Radius

12. Simple Multi Bosses machining

Deine a new ToolBox Cycles operation.
Under Technology, select the Simple Multi Bosses
strategy.
Deine a new geometry, selecting the closed chains
as shown.
Use the previously deined Tool #1 of Ø10.

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 6. ToolBox Cycles

13. One Side Open Slot machining

Deine a new ToolBox Cycles operation.

Under Technology, select the One Side Open Slot strategy.

Deine a new geometry, selecting a pair of open chains: the irst one is considered main,
and the second one is the drive chain.

Use the same tool as in the previous operations.

14. Ruled Surface machining

Deine a new ToolBox Cycles operation.

Under Technology, select the Ruled strategy.

Deine a new geometry, selecting a pair of open chains on the slot edges.

Use the same tool as in the previous operations.

15. O-ring machining

Deine a new ToolBox Cycles operation.

Under Technology, select the O-Ring strategy.

247
 Deine a new geometry, selecting a pair of closed chains as shown. The irst chain is
considered external and the second one – internal.

Add a new End mill of Ø4.

16. Surface Flattening on Cylinder

Deine a new ToolBox Cycles operation.

Under Technology, select the Flattened Surface on Cylinder strategy.

For this operation, deine a new Coordinate System position with the origin located at
the cylinder revolution axis.
Deine a new geometry, selecting the linear open chain as shown.

Use the previously deined Tool #1 of Ø10.

17. Surface Flattening on Corner

Deine a new ToolBox Cycles operation.

Under Technology, select the Flattened Surface on Corner strategy.

For this operation, deine a new Coordinate System position with the origin located on
the lattened surface plane.

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 6. ToolBox Cycles

Deine a new geometry, selecting a straight line chain.

In the Working area section, click the Define button to assign a triangle working area to
the selected line.

The Working area dialog box is displayed. Make sure the Start
angle and End angle are 45°.

Use the same tool as in the previous operation.

Deine the Upper level by clicking on the upper edge of the
lattened plane. Deine the Depth by clicking on the lower edge
of the lattened plane.

18. Simple Boss Machining

Deine a new ToolBox Cycles operation.

Under Technology, select the Simple Boss strategy.

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 In the Coordinate System #1, deine a new geometry using the Multi-chain option.
A pair of closed chains is selected automatically, where the irst chain is considered
external and the second one is internal.

Use the same tool as in the previous operation.

19. Spiral Pocket Machining

Deine a new ToolBox Cycles operation.

Under Technology, select the Spiral Pocket strategy.

Deine a new geometry, selecting the closed chain as shown.

Use the same tool as in the previous operation.

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 6. ToolBox Cycles

20. Simulate the operation

Right-click the Operations header and choose Simulate to play simulation for all
ToolBox operations.

251
252
Automatic Feature
Recognition 7
This chapter covers the following types of 2.5D Milling operations performed using the Automatic
Feature Recognition module (AFRM) functionality:
Pocket Recognition Operation
This operation enables you to recognize pocket features on a solid model and perform machining
of these features.

Drill Recognition Operation

This operation performs powerful drill feature recognition and automatic Drill geometry creation.
This operation enables you to handle separate sets of Milling levels for each drill position. The
initial values of the Milling levels sets are automatically recognized from the model; they can be
edited by the user.

A Geometry for Drill Recognition and Pocket Recognition operations is determined automatically
by SolidCAM AFRM functionality.

254
 7. Automatic Feature Recognition

Exercise #15: Pocket Recognition

This exercise illustrates the SolidCAM functionality of

automatic pocket recognition and machining.
This exercise reinforces the following skills:
• Automatic pocket recognition and machining.
The following steps have to be implemented in order to
reach the inal CAM-Part:

1. Open the CAM-Part

Open the Exercise15.prz ile located in the Exercises folder. This ile contains the pre-
deined CAM-Part.

2. Add a Pocket Recognition operation

Right-click the Operations header in SolidCAM Manager and choose Pocket Recognition
from the Add Milling Operation submenu.

Alternatively, you can choose the Pocket

Recognition icon from the Recognition menu on
the SolidCAM Operations toolbar.
The Pocket Recognition Operation dialog box is
displayed.

255
 3. Define the Geometry
In the Geometry page, click the button.

The Select Faces dialog box is displayed. This dialog box

enables you to deine the parameters of the pocket feature
recognition geometry.
First, you need to set the pocket recognition ilters and then
the mode of geometry selection.
Make sure that the Through Pocket check box is selected.

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 7. Automatic Feature Recognition

Through Pocket

When this check box is selected with the Selection Mode set to Solid
Body,the recognition of through pocket features is also performed.
Through Pockets

Upper loop

Only the through pocket features where

the upper loop is identical to the lower
loop are recognized. The through pocket
features that cannot be machined with
Lower loop
the current CoordSys position cannot be
selected.

In the Circular Pocket diameter filter section, make sure that the Apply filter check
box is selected.

Circular Pocket Diameter Filter

When this check box is selected with the Selection mode set to Solid
Body, circular pocket features can be selected according to their diameter.
All circular pocket features with the diameter greater than the speciied
Min. Diameter value will be selected. Using this option, you can avoid
machining of drill features that are supposed to be machined in other
operations (Drilling, Drill recognition, etc.).
The Min. Diameter parameter deines the minimum diameter of the pocket
features. You can enter the value in the edit box or pick a cylindrical surface
or a circular edge on the solid model when the cursor is placed in the
Min. Diameter edit box.

When the Circular Pocket check box is not selected, all recognized
circular pocket areas suitable for the current Coordinate System are
selected.

257
 Generally, all the through holes of this part are recognized
as circular pockets. In this operation, not all of these
holes will be machined, only four column holes located
in the corners of the top face.
Place the cursor in the Min. Diameter edit box and then
pick the edge of the column hole on the solid model.
The circular edge diameter of 42 mm is displayed in the
edit box. Edit the diameter by setting the value to 40. All
of the holes with the diameter smaller than the speciied
value will not be machined.
Deine the mode of geometry selection.

Selection Mode

This section enables you to set the mode of the geometry selection. The
following selection modes are available:
• Solid Body

This mode enables you to perform automatic recognition of pocket

features on the picked solid body. All planar faces are recognized
with the surface normal vector oriented parallel to the Z-axis of the
current CoordSys. The planar faces that cannot be machined with
the current CoordSys position (undercuts) cannot be selected (the
selection is rejected). All the through pocket areas are recognized
according to the Through pocket option.

Selected faces

Undercut face
(selection rejected)

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 7. Automatic Feature Recognition

• Face

This mode enables you to pick single planar faces. When a face is
picked, SolidCAM checks the parallel relation between the surface
normal vector of the picked face and the positive direction of the
Z-axis of the current CoordSys. If they are not parallel, the face
is not selected. The undercut faces that cannot be machined with
the current CoordSys position are also not selected. The selection is
working in the toggling mode: the irst click on a face selects it, the
next click on the selected face removes the selection.
• Through Pocket Chain

This mode enables you to select the through pockets by picking one
of the edges of the lower loop of the pocket area. When the edge is
picked, the complete geometry of the through pocket is automatically
selected. The lower loop is highlighted on the model. The selection
is working in the toggling mode: the irst click on an edge selects the
loop, the next click on an edge of the already selected loop removes
the selection.
Under Selection mode, use the default Solid Body option.
Click on the solid model. SolidCAM generates the list of elements that suit your ilter
settings.
Click the Solid1 element in the list. All the recognized model
features that take part in this geometry are highlighted. The
geometry includes all the planar faces, through pockets of
slots, and circular through pockets of column holes. Each
model element is accompanied by its Z-level value enclosed
in parentheses.

Conirm the Select Faces dialog box by clicking the

button.

259
 4. Define the Tool
Add an End mill of Ø16 for the operation. Define the tool parameters as follows:
• Set the Total length to 130;
• Set the Outside holder length to 120;
• Set the Shoulder length to 110;
• Set the Cutting length to 100.

Choose the tool for the operation.

5. Define the machining levels

Deine the Upper level by clicking on the
upper model face as shown.
The cutting depth is calculated
automatically for each recognized feature
according to the solid model.
Select the Equal step down option and set
the Step down value to 5.

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 7. Automatic Feature Recognition

6. Define the technological parameters

Switch to the Technology page. All the parameters in this page are identical to those
used in the Pocket operation.
Use the default parameters of pocket machining.
Since the recognized geometry contains open pocket areas,
the Open pocket tab is made available. Switch to the Open
pocket page and select the Approach from outside check
box. With this option, the approach to the open pocket
areas is performed from the outside of the material.

7. Define the Ramping strategy

In the Link page, choose the Helical ramping strategy and set the Radius to 5. The
chosen ramping strategy affects the close pocket areas where the horizontal approach
from outside (deined in the previous step) is impossible.

8. Calculate the tool path

Click the Save & Calculate button.

9. Simulate the operation

Simulate the operation in the SolidVerify
mode.

Now you have successfully inished the exercise.

261
Exercise #16: Mounting Box Machining

In this exercise, the SolidCAM functionality of

automatic pocket recognition and machining is used
for rough milling of the mounting box inner surfaces.
This exercise reinforces the following skills:
• CAM-Part deinition;
• Proile machining;
• Automatic pocket recognition and
machining;
• Rest material machining.
The SolidWorks model of the mounting box part (Exercise16.sldprt) is located in the Exercises
folder.
The following steps have to be implemented in order to reach the inal CAM-Part:

1. Define the CAM-Part

At this stage, you have to deine the CAM-Part, CNC-controller (AWEA1000-Fanuc),
Machine Coordinate System, the Stock and Target models.

2. External contour machining

Deine a Proile operation to perform
rough machining of the external contour
of the part. Use an End mill tool of Ø20.

3. Pocket roughing
Deine a Pocket Recognition operation to
remove the bulk of material and perform
the rough machining of the part inner
surfaces. Use the End mill tool of Ø20
used in the previous operation.

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 7. Automatic Feature Recognition

4. Pocket rest material machining

Deine a Pocket Recognition operation
to perform the rest material machining of
the part inner surfaces. Use an End mill
tool of Ø10.

263
Exercise #17: Drill Recognition

This exercise illustrates the SolidCAM functionality of

automatic drill recognition and machining.
This exercise reinforces the following skills:
• Automatic drill recognition and
machining.
The following steps have to be implemented in order
to reach the inal CAM-Part:

1. Open the CAM-Part

Open the Drilling.prz ile located in the Exercises folder. This ile contains the CAM-
Part machined in the Pocket Recognition Exercise.

2. Add a Drill Recognition operation

Add a new Drill Recognition operation to perform center drilling of holes.

3. Define the Geometry

In the Geometry page, click the button.

264
 7. Automatic Feature Recognition

SolidCAM parses the solid model and recognizes all of its

hole features.
The HR Drill Geometry Selection dialog box is displayed.
This dialog box enables you to specify the holes to be
included in the operation geometry.
In this operation, you will perform the center drilling of all
the holes that can be machined using the deined CoordSys
position, except for the column holes that were machined
in the previous operation as through pocket features.
In the Hole Type section, make sure that both the Through
and Blind check boxes are selected. In this operation, both
through and blind holes will be drilled.
The HR Drill Geometry Selection dialog box enables you to
ilter the hole features to be machined by diameter, upper
level and height.
Select the Hole Diameter check box.

Hole Diameter (d)

When this section is activated, the hole features are iltered according to
the diameter of the hole. With this ilter, only the hole features with the
Hole Diameter value within the speciied range are recognized.

The From and To values enable you to deine the Diameter range by
entering the values or by picking on the solid model. When the cursor
is placed in the From/To edit box, you can specify the diameter value by
picking a speciic cylindrical surface or a circular edge on the solid model.
When a cylindrical surface or a circular edge is picked, its diameter is
calculated and inserted into the corresponding edit box replacing the
previous value. The edit box becomes pink. When you remove the
automatically determined value, the edit box becomes white.

265
 Deine the upper limit for the diameter range. Place
the cursor in the To edit box and pick the edge of the
column hole as shown. The diameter of the hole
(42 mm) is displayed in the edit box.

Edit the diameter by setting the value to 40.

In this operation, the holes will be machined irrespective of their upper levels. Make
sure that the Hole Upper level check box is not selected.

Hole Upper level (u)

When this section is activated, the hole features are iltered according to
the Upper level. With this ilter, only the hole features with the Upper
level value within the speciied range are recognized.

The From and To values enable you to deine the Upper level range by
entering the values or by picking on the solid model. When the cursor is
placed in the From/To edit box, you can specify the Upper level value by
picking on the solid model. When a model point is picked, the Z-value of
the picked position is calculated and inserted into the corresponding edit
box replacing the previous value. The edit box becomes pink. When you
remove the automatically determined value, the edit box becomes white.

In this operation, the holes of all heights will be machined. Make sure that the Hole
height check box is not selected.

Hole Height (h)

When this section is activated, the hole features are iltered according
to the Hole height. With this ilter, only the hole features with the Hole
height value within the speciied range are recognized.

The From and To values enable you to deine the Hole height range by
entering the values or by picking on the solid model. When the cursor is
placed in the From/To edit box, you can specify the Hole height value by

266
 7. Automatic Feature Recognition

picking on the solid model. When a model point is picked, the Z-value of
the picked position is calculated and inserted into the corresponding edit
box replacing the previous value. The edit box becomes pink. When you
remove the automatically determined value, the edit box becomes white.

Click the Find Holes button. The hole features that match
the speciied ilter criteria are determined. These features
are listed in the Holes Tree section.
Click the Preview button. The hole features are highlighted
on the model.

Holes Tree

In this list, the recognized hole features are classiied by Shapes and
Groups. A Shape contains all the hole features with the same topology;
within a Shape, the Groups include all the hole features with the same
parameter values (Upper Level, Height and Diameter). For each Group,
the Upper level (u) and Height (h) are displayed in parentheses. When you
select a Shape or a Group item in the list, the hole features that belong to
this Shape or Group are highlighted on the model.

267
 Conirm the HR Drill Geometry Selection dialog box by clicking the button.

4. Define the Tool

Add a new Spot drill tool of Ø16. Define the tool parameters as follows:
• Set the Total length to 70;
• Set the Outside holder length to 60;
• Set the Shoulder length to 50.

Choose the tool for the operation.

5. Define the Levels

Click the Depth Edit button in the Levels page.

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 7. Automatic Feature Recognition

The Depth Edit dialog box is displayed. This dialog box

enables you to edit the Milling Levels parameters (Upper
Level, Drill Depth, Delta Depth) for each drill separately.

Notice the list of drill instances displayed in the Holes Tree

section.

Holes Tree

This section displays the list of all drill

instances chosen for the geometry. All the
drill instances in the list are structured into
Groups with the same Upper Level, Drill
Depth, Delta Depth and Depth Type. For
each Group in the list, the drill instances
data are displayed in parentheses. Each drill
instance in the list is accompanied by the
X- and Y-coordinates of the drilling
position. Selecting the check boxes next
to each element in the list enables you to
include the hole features, Shapes or Groups
into the geometry.
Do not confuse the Group classiication in this dialog
box with that taking place at the stage of geometry
deinition.

By default, the Depth Edit dialog box displays the parameter values recognized from
the solid model. Now you need to deine the Upper Level, Drill Depth and Depth Type
parameters for each group of drill instances separately.

269
 Select the Group1 item in the Holes Tree section. The drill instances that belong to this
group are highlighted on the model.

First, deine the upper level for drilling.

Upper Level (u)

This value can be applied to a single hole, a group or all holes.

The edit box displays the Upper Level value of the selected item (a group
or a hole). You can enter the value or pick it directly from the model
(when the cursor is placed in the edit box). SolidCAM enables you to
pick planar faces parallel to the XY-plane of the Coordinate System,
model vertices and sketch points. When a model is picked, the Z-value
of the picked position is displayed in the edit box. The edit box has pink
background, which means that the parameter is deined associatively to
the solid model. When the edit box value is typed in, it is not associative
to the model; in this case the edit box has white background.
The Apply button enables you to apply the deined Upper Level value to
the selected list item (a group or a hole). When a new Upper Level value
is applied, SolidCAM checks the Holes Tree items and reorganizes them
into groups according to the changed parameters. SolidCAM checks all
the groups to ind a group with identical Upper Level, Drill Depth, Delta
Depth and Depth Type parameters. If such group is found, SolidCAM
adds the updated drill to this group. In case of absence of a suitable
group, a new group is created; the updated drill instance is added to this
group.

Leave the Upper Level value unchanged (-24).

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 7. Automatic Feature Recognition

Deine the depth of the center drilling.

Drill Depth (d)

This value can be applied to a single hole, a group or all holes.

The edit box displays the Drill Depth value of the selected item (a group
or a hole). The edit box enables you enter the value or pick the value
directly from the model (when the cursor is placed in the edit box). You
can pick drill faces or edges. SolidCAM determines the depth of the
picked drill according to the deined Upper Level and displays the value
in the edit box. The edit box has pink background, which means that the
parameter is deined associatively to the solid model. When the edit box
value is typed in, it is not associative to the model; in this case the edit
box has white background.
The Apply button enables you to apply the deined Drill Depth value to
the selected list item (a group or a hole). When a new Drill Depth value
is applied, SolidCAM checks the Holes Tree items and reorganizes them
into groups according to the changed parameters. SolidCAM checks all
groups to ind a group with identical Upper Level, Drill Depth, Delta
Depth and Depth Type parameters. If such group is found, SolidCAM
adds the updated drill to this group. In case of absence of a suitable
group, a new group is created; the updated drill instance is added to this
group.

Set the Drill Depth value to 0 and click the Apply button.

Notice that if you do not click the Apply button

after editing values, the change does not take effect.

Deine the Depth Type.

Depth Type

This parameter can be deined for a single

hole, a group or all holes. You can deine the
diameter on the conical part of the drilling
tool that will reach the speciied drilling depth
during the machining. You can also deepen a
drilled hole in order to obtain a given diameter
at the speciied drill depth.

271
 The following options are available:
• Cutter Tip

The drill tip reaches the deined drilling depth.

• Full Diameter

The drill reaches the deined drilling depth with the full diameter.
• Diameter Value

The drill reaches the deined drilling depth with the drill cone
diameter speciied by the Diameter Value parameter.
The Apply button enables you to apply the deined Depth Type to the
selected list item (a group or a hole). When a new Depth Type is applied,
SolidCAM checks the Holes Tree items and reorganizes them into groups
according to the changed parameters. SolidCAM checks all groups to
ind a group with identical Upper Level, Drill Depth, Delta Depth and
Depth Type parameters. If such group is found, SolidCAM adds the
updated drill to this group. In case of absence of a suitable group, a new
group is created; the updated drill instance is added to this group.

Choose the Diameter Value option for Depth Type.

Place the cursor in the edit box and pick the upper
edge of one of the Group1 holes on the model.
The diameter of the hole (6.8 mm) is displayed in
the edit box.

Edit this value to add a 0.2 mm chamfer to the holes. Set the Diameter Value to 7.2 and
click the Apply button.

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 7. Automatic Feature Recognition

Select the Group2 item in the Holes Tree section.

Leave the Upper Level value unchanged (-24).

Set the Drill Depth value to 0 and click the Apply button.
Under Depth Type, choose the Diameter Value option,
place the cursor in the edit box and pick the upper edge of
the hole. The value displayed in the edit box is 8. To add
a 0.5 mm chamfer to the holes, set the Diameter Value to 9
and click the Apply button.
In the same manner, deine the levels for the rest of the
groups.
For Group3, set the Drill Depth to 0 and the Diameter Value to 4.6 to add a 0.2 mm
chamfer. Click the Apply button.

273
 For Group4, set the Drill Depth to 0 and the Diameter Value to 10. This value will not
result in a chamfer, because the diameter of the holes is greater, therefore only center
drilling will be performed. Click the Apply button.

For Group5, set the Drill Depth to 0 and the Diameter Value to 6.9 to add a 0.2 mm
chamfer. Click the Apply button.

Apply the changes and conirm the Depth Edit dialog box with the button.

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 7. Automatic Feature Recognition

6. Define the sorting of drill positions

Switch to the Technology page.

Use the Advanced Sorting option to sort the drill positions of the geometry.

Under Sorting, choose the Advanced option and click .

The Advanced Sorting dialog box is

displayed. This dialog box enables you to
deine the parameters of sorting of drill
positions for machining of linear and
circular drill patterns.

275
 Linear sorting of drill positions

The Linear tab contains sorting methods appropriate for machining of

linear drill patterns.
Linear pattern

According to linear sorting methods, the machining is performed either

by rows of drill positions with the same Y-coordinate or by columns
of drill positions with the same X-coordinate. The Tolerance parameter
enables you to deine the tolerance that is used to determine if a drill
position belongs to the current row/column or to a different row/
column.
When the machining is performed by rows, SolidCAM
determines the irst drill position for each row (the start position of the
irst row is the start position of the whole pattern). For each next drill
position, SolidCAM determines the Y-coordinate and compares it with
the Y-coordinate of the irst drill position of the current row. If the linear
deviation is within the speciied Tolerance limit, SolidCAM considers
this position to belong to the current row. If the deviation exceeds the
Tolerance value, the drill position is rejected from the current row; later
this position will be checked again for belonging to next rows.
In the similar manner, when the machining is performed by columns,
the speciied Tolerance value is used to determine whether a speciic
drill position belongs to the current column. In this case, the deviation
of X-coordinates between the irst drill position in the column and the
current drill position is compared with the Tolerance value.

Choose the option in the Linear tab of

the Advanced Sorting dialog box, and set the
Tolerance value to 5.

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 7. Automatic Feature Recognition

When this option is chosen,

SolidCAM determines the position
with the minimal X- and Y-coordinates
and accepts it as the start position of
the drill sequence. From this position,
SolidCAM continues the machining of
the drills with the same Y-coordinate;
the machining is performed in the
direction of increasing X-coordinates.
When the last position of the current Y-coordinate is machined,
SolidCAM passes to the next Y-coordinate (in the increasing order)
and continues the machining of the next row from the position with the
maximal X-coordinate to the position with the minimal X-coordinate
(decreasing order), and so on. In such manner, the machining of two
successive rows is performed in the opposite order: each odd row is
machined in the direction of increasing X-coordinates, each even row is
machined in the direction of decreasing X-coordinates.
The rows are machined in the direction of increasing Y-coordinates.

In the Advanced Sorting dialog box, click the OK button to conirm the deinition of
sorting parameters.
Click the Show Sorted
button to preview the
sorted drill positions on the
solid model.

Close the Show Geometry dialog box with the button.

277
 7. Calculate the tool path
Click the Save & Calculate button.

8. Simulate the operation

Simulate the operation in the SolidVerify mode.

9. Machine the Ø6.8 holes

Add a new Drill Recognition operation to perform
drilling of the Ø6.8 holes.
In the HR Drill Geometry Selection dialog box,
activate the Hole Diameter section. Place the
cursor in the From edit box and pick the hole edge
as shown.
The diameter value (6.8) is displayed in both From
and To edit boxes deining the range for the Hole
Diameter ilter.

278
 7. Automatic Feature Recognition

Click the Find Holes button. The

holes of the speciied diameter
are highlighted on the model.
Conirm the HR Drill Geometry
Selection dialog box by clicking
the button.

Add a new Ø6.8 Drill tool.

Click the Depth Edit button in the Levels page. The

Depth Edit dialog box is displayed. Note that the values of the
Upper Level (-24) and Drill Depth (26.29) parameters are offered
you as defaults. These values are recognized automatically on
the model.
Conirm the Depth Edit dialog box dialog box by clicking the
button.
In the Technology page, choose the Advanced sort option under Sorting and click the
button.

279
 In the Linear tab of the Advanced Sorting dialog

box, choose the option.

When this option is chosen,

SolidCAM determines the position
with the minimal X- and Y-coordinates
and accepts it as the start position
of the drill sequence. From this
position, SolidCAM continues the
machining of the drills with the
same X-coordinate; the machining
is performed in the direction of
increasing Y-coordinates.
When the last position of the current X-coordinate is machined,
SolidCAM passes to the next X-coordinate (in the increasing order) and
continues the machining of the next column from the position with the
maximal Y-coordinate to the position with the minimal Y-coordinate
(decreasing order), and so on. In such manner, the machining of two
successive columns is performed in the opposite order: each odd
column is machined in the direction of increasing Y-coordinates, each
even column is machined in the direction of decreasing Y-coordinates.
The columns are ordered in the direction of increasing X-coordinates.

280
 7. Automatic Feature Recognition

Click the Show Sorted button to preview the sorted drill positions on the solid model.

Under Drill cycle, click the Drill cycle type button and
choose the Peck type from the list. Click the Data button
to deine the pecking parameters.
In the displayed Drill Options dialog box, set the Step down
value to 2 and conirm the dialog box with the OK button.

Save and calculate the operation.

10. Machine the Ø8 holes

Add a new Drill Recognition
operation to perform drilling of the
Ø8 holes.

In the HR Drill Geometry Selection

dialog box, activate the Hole
Diameter section. Deine the range
for the Hole Diameter ilter as
explained in the previous step. The
values of 8 mm are displayed in the
Hole Diameter section.

281
 Add a new Drill tool. The diameter of the drilling tool must be smaller than the
diameter of the holes, because these holes will be reamed at the next stage.

You can deine the diameter of the tool by clicking on the entity to be
machined with this tool directly on the solid model. Place the cursor in the
Diameter edit box in the Topology page of the Part Tool Table and pick the
edge of the hole as shown.

The Diameter value (7.8) is displayed in the edit box.

In the Technology page, choose the Advanced option
under Sorting and click the button.
In the Linear tab of the Advanced Sorting dialog box,

choose the option, set the Tolerance value to 2

and click the Show sorted button.

Under Drill cycle, choose the

Peck cycle type and set the Step
down value to 2.

Save and calculate the operation.

282
 7. Automatic Feature Recognition

11. Machine the Ø4.2 holes

Add a new Drill Recognition operation to perform drilling of the Ø4.2 holes.

In the HR Drill Geometry Selection dialog box, deine the range for the Hole Diameter
ilter as explained in the previous steps. The values of 4.2 mm will be displayed in the
Hole Diameter section.

Add a new Ø4.2 Drill tool.

In the Technology page, choose the Advanced option
under Sorting and click the button.
In the Linear tab of the Advanced Sorting dialog box,

choose the option and click the Show Sorted

button.

Under Drill cycle, choose the Peck cycle type and set the Step down value to 2.
Save and calculate the operation.

283
 12. Machine the Ø13.5 holes
In the same manner as explained in the previous steps, perform drilling of the set of
Ø13.5 holes.

Use the Default drill sorting option.

13. Machine the Ø6.5 holes

In the same manner as explained in the previous steps, perform drilling of the set of
Ø6.5 holes.

Use the option of Advanced drill sorting.

284
 7. Automatic Feature Recognition

When this option is chosen,

SolidCAM determines the position
with the minimal X- and Y-coordinates
and accepts it as the start position
of the drill sequence. From this
position, SolidCAM continues the
machining of the drills with the
same Y-coordinate; the machining
is performed in the direction of
increasing X-coordinates.
When the last position of the current Y-coordinate is machined,
SolidCAM passes to the next Y-coordinate (in the increasing order) and
continues the machining of the next row from the position with the
minimal X-coordinate to the position with the maximal X-coordinate
(increasing order) and so on. In such manner, the machining of the rows
is performed in the same direction of increasing X-coordinates.
The ordering of rows is performed in the direction of increasing
Y-coordinates.

Click the Show Sorted button to preview the sorted drill positions on the solid model.

285
 14. Perform reaming of the Ø8 holes
Add a new Drill Recognition operation to perform reaming of the Ø8 holes.
Use the Drill_r2 geometry deined in Step #10.
Add a new Ø8 Reamer tool.

Reamer

This tool is used to machine precise holes in Drilling operations.

A tool of this type is deined with the parameters shown in the image.
Arbor
Diameter

Total
Outside
Length
Holder
Length
Cutting
Length

Tip Diameter Chamfer

Length
Diameter

286
 7. Automatic Feature Recognition

To deine the depth, pick the model face as shown.

The Drill Depth value (12) is displayed. Click the Apply button.
Deine the sorting of drill positions as explained in Step #10.
Click the Save & Calculate button.

15. Simulate the operations

Simulate the operations deined in Steps #9 – #14 in the SolidVerify mode.
Now you have successfully inished the exercise.

287
Exercise #18: Electronic Box Machining

In this exercise, the SolidCAM functionality of automatic

drill recognition and machining is used for rough milling of
the electronic box hole features.
This exercise reinforces the following skills:
• Automatic drill recognition and machining
The electronic box part ile (Exercise18.prz) is located in
the Exercises folder. This ile contains the deined CAM-
Part. The model used for the part deinition contains two
conigurations: Default (model with hole features) and
Stock (hole features suppressed).

Default Stock

The following steps have to be implemented in order to reach the inal CAM-Part:

1. Center drilling
Deine a Drill Recognition operation to perform center drilling of all hole features. Use
a Spot drill tool of Ø2.5.

288
 7. Automatic Feature Recognition

2. Drilling
Deine a Drill Recognition
operation to perform drilling of
the Ø1.2 holes. Use a Drill tool of
Ø1.2.

3. Drilling
Deine a Drill Recognition
operation to perform drilling of
the Ø1.8 holes. Use a Drill tool of
Ø1.8.

4. Drilling
Deine a Drill Recognition
operation to perform drilling of
the Ø2.2 holes. Use a Drill tool of
Ø2.2.

Congratulations!
You have successfully inished the 2.5D Milling part of the SolidCAM 2012 Milling Training Course.

289
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