SolidCAM Application Tutorial

Basic Training - 2
SolidCAM + SOLIDWORKS
The Complete Integrated Manufacturing Solution
 Contents

Contents

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

2. CAM-Part Definition.................................................................................................... 3

3. Morph between two boundary curves....................................................................... 9

4. Parallel to Curve(s).................................................................................................... 27

5. Morph between two adjacent surfaces................................................................... 33

i
Introduction 1
About this course

This tutorial illustrates the strategies of morph between two curves, strategy of morph between two
surfaces, strategy of parallel to curve and to understand different side tilt definitions.

Prerequisites
Students attending this course are expected to have basic knowledge of the SolidCAM software.

Course design
This course is designed around a task-based approach to training. The guided exercises will teach
you the necessary commands and options to complete a machining task.

Using this book

This tutorial is intended to be used in a classroom environment under the guidance of an
experienced instructor. It is also intended to be a self-study tutorial.
This book is made with SOLIDWORKS 2021 and SolidCAM2022 SP1.

2
CAM-Part Definition
2
1. Click Tools > SolidCAM > SolidCAM Settings.

2. Click Machine Simulation.

3. Ensure that the settings are as shown in the image.

4. Browse to open the SOLIDWORKS part Impeller.

SLDASM.

5. Click Tools > SolidCAM > New >

Milling.

The New Milling Part window displays.

6. Click to save the default part file name and path.

The Milling Part Data window displays.

7. In the CNC-Machine list, select table_table_exercise as the machine.

8. Click CoordSys in the Define section to set the coordinate system for
this part.

4
 2. CAM-Part Definition

9.Click Select Face in the Definition options section to define the main
coordinate system.

10. In the Place CoordSys origin to section, select Top center of model box
from the list.

11. Select the face as shown in the below image.

12. The coordinate system is defined.

5
13. Click
The CoordSys Data window displays.

14.Ensure that the Levels values are set to similar values as shown in the
image.

15. Click

16. Click in The CoordSys Manager window.

17. Click Stock in the Define section.

18. In the Defined by list, click 3D Model. Select the solid body as shown in
the image.

19. Click Show to visualise the 3D representation of the selected stock.

The stock looks as displayed in the image. Close the Stock model window.

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 2. CAM-Part Definition

20. Click

21. Click Target in the Define section.

22. Select the solid body as shown in the image.

23. Click Show to visualise the 3D representation of the selected target.

The target looks as displayed in the below image.

24. Close the Target model window.

25. Click

26. Click to come out of the Milling Part Data section.

27. Right click Fixtures > Define Fixture.

28. Select the highlighted part as the fixture.

29. Click

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The stock, target and fixture are now defined for the part. Next, you must add the machine setup
before you add the machining operations.

30. Right click Operations > Machine Setup > Add

at start of operations tree.

31. Enter a value of 356.9 in the Z column.

This is the distance from the top face of the part to the bottom of the holding fixture. This distance
is required to “push” the part above the table of the machine and is essentially used in machine
simulation.

32. Click OK.

The CAM-Part is now completely defined and ready

for machining.

8
Morph between two
boundary curves 3
Morph between two boundary curves
The technology of Morph between two boundary curves creates a morphed tool path between two
leading curves. Morph means that the generated tool path gradually interpolates between the two
curves and it is evenly spread over the surface. This option is suitable to machine steep areas for
making molds, blade surfaces of impeller and turbine blades. When selecting the set of two curves,
the geometry must be selected directly from the drive surfaces.
The advantage of this technology is that the tool path is created on several surfaces by following a
pattern created by two curves and there are no lifts. The tool path is homogenous from start to end.
Care must be taken while using this strategy while machining impeller surfaces as varying surface
widths can cause the tool path to squeeze at certain areas thereby creating a rubbing effect.

1. Right click Setup > Add Milling Operation > Sim.

5-Axis Milling.

2. In the Technology list, click Morph between two boundary curves.

3. Click the Geometry page.

4. Click under Drive surface.

5. Select the faces as shown in the image.

6. Click

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 3. Morph between two boundary curves

7. Click under Start edge curve.

8. Select the curve as shown in the image.

9. Click Yes in OK to accept? window?

10. Click to close the Geometry Edit

dialog box.

11. Click under End edge curve.

12. Select the curve as shown in the image.

13. Click

14. Click to close the Geometry Edit

dialog box.

15. In the Type list, click Full, start and end at

exact surface edges.

16. Click Margins.

17. Set the values as shown in the image.

18. Click OK.

19. Click the Tool page > Select.

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20. Double click Taper Mill to add it as a tool.

21. Enter the parameters as shown in the image.

22. Click and double click the Holder icon to display the list of holders.

23. Search for BT 40 ER 32X60 and double click it to add it to the tool.

24. Click to save the tool.

25. Click the Levels page.

26. Enter the parameters as shown

in the image.

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 3. Morph between two boundary curves

27. Click the Tool path parameters page.

28. Enter a value of 0.8 in the Maximum step over field.

29. In the Step over calculation list, click Exact.

30. Click the Tool axis control page.

31. Enter a value of 70 in the Tilt

angle at side of cutting field.

32. Select the Side tilt tab.

33. In the Side tilt definition list, click

Orthogonal to cut direction at each
position.

34. Click the Link page.

35. In the First entry list, click Use Lead-In.

36. Click
The Lead-In window displays.

37. Unselect the Use default Lead-In check box.

38. In the Type list, click Vertical tang. arc.

39. Click OK.

13
40. In the Last exit list, click Use Lead-Out.

41. Click
The Lead-Out window displays.

42. Unselect the Use default Lead-Out check box.

43. In the Type list, click Vertical tang. arc.

44. Click OK.

45. Click the Links tab.

46. Enter a value of 500 in the Small move as size in % of step over field.

47. Click the Gouge check page.

48. Select the Enable/Disable check box.

49. Ensure that Tilt tool and Use side tilt angle are chosen in the Strategy section.

50. Select the Drive surfaces check box.

51. Unselect the Check surfaces check box.

52. Click Gouge 2 tab.

53. Select the Enable/Disable check box.

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 3. Morph between two boundary curves

54. Ensure that Retract tool and Along tool axis are chosen in the Strategy section.

55. Unselect the Drive surfaces check box.

56. Select the Check surfaces check box.

57. Click under Check surfaces 2 and select Surfaces.

58. Select the surfaces as shown in the image.

59. Click

60. Save and calculate the operation.

The calculated tool path should look as displayed in the image.

61. Exit the Operations Manager.

62. Right click > Copy the operation.

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63. Right click > Paste the operation.

64. Right click > Edit the operation.

65. Click the Tool axis control page.

66. Enter a value of 80 in the Tilt angle at side of cutting field.

67. In the Side tilt definition list, click Follow surface ISO Lines direction.

68. Save and calculate the operation.

The calculated tool path should look as displayed in the image.

69. Double click the Operations Manager window to minimize it.

16
 3. Morph between two boundary curves

To find out the ISO directions of this tool path, do the following:

70. Click Tools > Sketch Tools > Face

Curves.

71. Select the face as shown in

the image.

72. Unselect the pink lines

check box and enter a value of
15 in blue lines check box as
shown in the image.

73. Click

74. If you get the error window as shown in this image, just
click OK to ignore it.

75. Double click the Operations Manager window to expand

it.

76. Save and calculate the operation.

17
77. Simulate the operation once the tool path is calculated.

78. Visualise the tool path using the Single step mode icon.
Observe that the tool follows the axis of the ISO parameters. This is because of the selected side
tilt definition i.e. follow surface ISO lines direction.

79. Close the Simulation window.

80. Exit the Operations Manager.

81. Right click > Copy the operation.

82. Right click > Paste the operation.

83. Right click > Edit the operation.

84. Click the Tool axis control page.

85. In the Side tilt definition list, click Orthogonal to cut direction at each contour.

86. In the Approximate list, click Smooth.

87. Save and calculate the operation.

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 3. Morph between two boundary curves

88. Run the simulation using Single step mode.

The tool maintains orthogonal position to each contour. This is because of the chosen side tilt
definition i.e. orthogonal to cut direction at each contour.

89. Exit the Operations Manager.

90. Right click the operation > Add Milling Operation > Sim. 5-Axis Milling.

91. In the Technology list, click Morph between two boundary curves.

92. Click the Geometry page.

93. Click under Drive surface.

94.Select the faces as shown in the

image.

95. Click

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96. Click under Start edge curve.

97. Select the curve as shown in the image.

98. Click

99. Click

100. Click under End edge curve.

101. Select the curve as shown in the image.

102. Click

103. Click

104. In the Type list, click Full, start and end at

exact surface edges.

105. Click Margins.

106. Enter the parameters as shown in the image.

107. Click OK.

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 3. Morph between two boundary curves

108. Click the Tool page > Select.

109. Select the same TAPER MILL tool that was used for earlier operations.

110. Click the Levels page.

111.Enter the parameters as shown in the

image.

112. Click the Tool axis control page.

113. In the Tool axis direction list, click

Tilted relative to cutting direction.

114. Enter a value of 80 in the Tilt angle at side of cutting field.

115. In the Side tilt definition list, click Follow surface ISO lines direction.

116. Click Gouge check.

117. Select the Enable/Disable check box.

118. Ensure that Tilt tool and Automatic are selected in Strategy.

119. Select the Drive surfaces check box.

120. Unselect the Check surfaces check box.

121. Select Gouge check 2 tab.

122. Select the Enable/Disable check box.

123. Ensure that Retract tool and Along tool axis are selected in Strategy.

21
124. Unselect the Drive surfaces check box.

125. Select the Check surfaces check box.

126. Select under Check surfaces 2 and select

Surfaces.

127. Select the faces as shown in the image.

128. Click

129. Save and calculate the operation.

The calculated tool path should look as displayed in the image.
You can see that the tool path does
not look smooth as there are gouges,
and incorrect retracts etc. You must fix
these issues.

130. Click the Geometry page.

131. Click Margins.

132. Enter the values as shown in the image.

133. Click OK.

134. Save and calculate the operation.

22
 3. Morph between two boundary curves

You can see that the simulated tool path looks the same as there is not much change in the quality
of the tool path.

The tool path is created fine till the point where a fillet comes up. To understand and evaluate it
better, you must create a sketch.

135. Minimize the Operations Manager.

136. Click Insert > Reference Geometry >

Plane.

137. Select the three points as shown in

the image.

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138. Click

139. Click the Sketch icon.

140. Make a sketch as shown in the image:

The lines in the sketch must be created
nearly normal to the edge and the
fillet as marked with the arrows. These
lines represent the normal direction
of the surfaces. You can see that the
normal angle changes according to
the curvature of the surface. Since you
had kept the tool axis control at 80
degrees, the tool will always maintain
80 degrees to the lines that you just
created, which will result in a bad tool
path. Thus, you need to use a different tilt axis control.

141. Click to discard the changes to the sketch.

142. Click

143. Click Design Model > Impeller_Part > Surface Bodies(13) > Tilt Curve - Morph 2 Crv >
Show.

144. Click

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 3. Morph between two boundary curves

145. Maximize the Operations Manager.

146. Click the Tool axis control page.

147. In the Tool axis direction list, click Tilted through curve.

148. Select the Tilt curve tab.

149. In the Curve tilt type list, click Closest point.

150. Click under Tilt curve.

151. Select the curve as shown in the image.

152. Click

153. Click

154. Save and calculate the operation.

155. Simulate the calculated tool path.

The tool path should look as displayed in the image.
If you run the machine simulation, you will see
that the final 5-6 passes are gouging the part. You
need to fix this. Close the simulation window.

25
156. Click the Tool axis control page.

157. Click the Tilt curve tab.

158. In the Side tilt fanning distance field, enter a value

of 25.

159. Save and calculate the operation.

160. Simulate the operation.

If you run the machine simulation, you can see that there are no gouges now. The Side Tilt Fanning
distance evenly distributes the changes in the tilt angles over a larger distance (25mm in this tutorial)
thereby smoothing the tilt. Therefore, gouges are now avoided and you get a much better tilting
motion.

161. Close the Operations Manager.

In the next chapter, you will look at the Parallel to curves strategy.

26
Parallel to Curve(s)
4
Parallel to Curve(s) strategy
The Parallel to Curves strategy creates tool path segments parallel to a leading curve. The
neighbouring tool path segments are parallel to each other. An important point here is that the
cuts are not simply copied next to each other; every new cut is an offset of the previous cut. When
selecting the curve geometry, select the curves directly from the part. When using a single drive
surface, you can only select one curve from which to create a parallel tool path. When using multiple
drive surfaces, you can then select multiple curves to use. Each curve is only used for the drive
surface nearest to that curve. This strategy is very useful in machining impeller blades as it provides
uniform spacing of cuts.

1. Right click the operation > Add Milling Operation > Sim 5-Axis Milling.

2. Go to the Feature manager design tree and hide Tilt Curve-Morph 2 Crv.

3. In the Technology list, click Parallel to curves.

4. Click the Geometry page.

5. Click under Drive surface.

6. Select the faces as shown in the image.

7. Click

8. Click under Edge curve.

28
 4. Parallel to Curve(s)

9. Select the curve as shown in the image.

10. Click

11. Click

12. In the Type list, select Full, start and end at exact
surface edges.

13. Click Margins.

14. Set the values as shown in the image.

15. Click OK.

16. Click the Tool page > Select.

17. Select the same TAPER MILL tool that was used for earlier operations.

18. Click the Levels page.

19. Set the values as shown in the image.

20. Click the Tool path parameters page.

21. Select the Sorting tab.

22. In the Cutting method list, click One way.

23. Click Tool axis control.

24. Select Tilted relative to cutting direction as Tool axis direction.

25. Set a value of 80 in Tilt angle at side of cutting field.

29
26. Select the Side tilt tab.

27. Select Orthogonal to cut direction at each position as the Side tilt definition.

28. Click Link.

29. In the First entry and Last exit lists, click Use Lead-In and Use lead-Out.

30. Click next to Use Lead-In.

The Lead-In window displays.

31. Clear the Use default Lead-In check box.

32. Enter the parameters as shown in the image.

33. Click OK.

34. Click next to Use Lead-Out.

The Lead-Out window displays.

35. Clear the Use default Lead-Out check box.

36. Enter the parameters as shown in the image.

37. Click OK.

30
 4. Parallel to Curve(s)

38. Click the Links tab.

39. In the Large list of the Links between slices section, click Use Lead-In/Out.

40. Click

41. The Lead-In / Lead-Out window displays.

42. Make the changes as shown in the image.

43. Click OK.

44. Click Gouge check.

45. Select the Enable/Disable check box.

46. Ensure that Tilt tool and Automatic are

selected in Strategy.

47. Select the Drive surfaces check box.

48. Unselect the Check surfaces check box.

49. Select Gouge check 2 tab.

50. Select the Enable/Disable check box.

51. Ensure that Retract tool and Along tool axis are selected in Strategy.

52. Unselect the Drive surfaces check box.

53. Select the Check surfaces check box.

54. Select under Check surfaces 2.

31
55. Select the faces as shown in the image.

56. Save and calculate the operation.

57. Simulate once the tool path is calculated.

The Simulation window displays.

The tool path should look as displayed in the

image.
The parallel to curve strategy gives a uniform
spacing between passes on the entire set of
surfaces unlike the morph between curves which
cause passes to converge thereby creating a
rubbing action.

58.Close the simulation window and the

Operations Manager.

32
Morph between two
adjacent surfaces 5
Morph between two adjacent surfaces
The Morph between two adjacent surfaces feature creates a morph tool path on the drive surface.
The drive surface is enclosed by two check surfaces. Morph means that the generated tool path is
approximated between the check surfaces and evenly spread over the drive surface. This is great for
impeller machining with twisted turbine blades. The main advantage is the possibility to compensate
the tool to the drive surface and check surface in the left and right corner of the workpiece. All
you need is the tool radius which is the distance (Margin) between the tool center and the surfaces.

1. Right click the operation > Add Milling Operation > Sim 5-Axis Milling.

2. In the Technology list, click Morph between two adjacent surfaces.

3. Click Geometry.

4. Click under Drive surface.

5. Select the faces as shown in the image.

6. Click

7. Click under Start edge surfaces.

34
 5. Morph between two adjacent surfaces

8. Select the surface as shown in the image.

9. Click

10. Click under End edge surfaces.

11.Select the surface as shown in the

image.

12. Click

13. In the Type list, click Full, start and end

at exact surface edges.

14. Click Margins.

15. Enter the parameters as shown in the image.

16. Click OK.

17. Click Tool > Select.

18.Select the TAPER MILL tool that is used for the earlier
operations.

35
19. Click Levels.

20.Enter the parameters as shown in the

image.

21. Click Link.

22. Click the Links tab.

23. Enter a value of 800 in Small move as size in % of step over.

24. Click Gouge check.

25. Select the Enable/Disable check box.

26. Ensure that Retract tool and Along tool axis are selected in Strategy.

27. Select the Drive surfaces check box.

28. Unselect the Check surfaces check box.

29. Click Misc. parameters.

30. Select the Tool Center based Calculation check box.

31. Save and calculate the operation.

32. Simulate the tool path.

36
 5. Morph between two adjacent surfaces

The tool path should look as displayed in the image.

You can see that the tool path
looks really bad right now. You
can see that apart from the area to
be machined, some other areas are
also getting machined. You must
fix these issues.

33. Close the simulation window.

34. Click Geometry.

35. Click the Advanced button.

The Advanced Options of Surface Paths Pattern window displays.

36. Select the Generate tool path front side check box.

37. Click OK.

38. Save and calculate the operation.

39. Simulate the tool path.

The tool path should look as displayed in the image.
A lot of unwanted areas can still be seen
in the tool path.

37
40. Close the simulation window.

41. Click Geometry.

42. Click Margins.

43. Enter the parameters as shown in the image.

44. Click OK.

45. Save and calculate the operation.

46. Simulate the tool path.

The tool path should look as displayed in the image.

You can see that the tool path looks much
better now. You can improve it by making a
few more changes.

47. Click Tool axis control.

48. In the Tool axis direction list, click

Tilted through curve.

49. In the Curve tilt type list, click Closest

point.

50. Go to the Feature Manager Design Tree and switch on Tilt Curve-Morph 2 Srf.

38
 5. Morph between two adjacent surfaces

51. Click under Tilt curve.

52. Select the curve as shown in the image.

53. Click

54. Click

55. Save and calculate the operation.

If this error occurs this is because the tilted through curve

strategy does not allow gouge check using the tilt tool as the tilt
is being generated by the curve and cannot be changed by the
gouge check strategy.

56. Click OK.

57. Click Gouge check.

58. Unselect the Enable/Disable check box.

59. Save and calculate the opertion.

60. Simulate the tool path.

39
The tool path should look as displayed in the image.

You can see that the tool path is much better now with this strategy.

End of the tutorial.

40
 SolidCAM Application Tutorial

Basic Training-2

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iMachining 3D Indexial Multi-Sided Machining HSM (High-Speed Machining)

Sim. 5-Axis Machining Turning & Advanced Mill-Turn Solid Probe

iMachining Successes

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