SolidCAM Application Tutorial

Basic Training - 3
SolidCAM + SOLIDWORKS
The Complete Integrated Manufacturing Solution
 Contents

Contents

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

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

3. 5-Axis Strategies......................................................................................................... 9

i
Introduction 1
About this course

This purpose of this tutorial is to explain the side tilt definitions, the strategy of tilted through
curve definition, different sub-tilt definitions, the gouge check definitions, the perpendicular to
curve strategy.

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. The theoretical explanations
are embedded into these exercises to give an overview of machining a port inlet.

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.

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CAM-Part Definition
2
The CAM-Part definition process for the part consists of the following stages:

CAM-Part creation

CNC-Machine definition

Coordinate System definition

Stock and Target definition

• CAM-Part creation. At this stage, you have to define the CAM-Part name and location.
SolidCAM defines the necessary system files and a folder to allocate the place to store
SolidCAM data.
• CNC-controller definition. It is necessary to choose the CNC-controller. The controller
type influences the Coordinate System definition and the Geometry definition.
• Coordinate System definition. You have to define the Coordinate System, which is the
origin for all machining operations of the CAM-Part. You can create multiple CoordSys
positions and in each machining step select which CoordSys you want to use for the
operation.
• Stock and Target definition. It is necessary to define a boundary of the stock that is used
for the CAM-Part machining. SolidCAM enables you to define the model of the part in
its final stage after the machining.
The following exercises describe the full process of the CAM-Part definition. It is recommended to
go through the stages in order to understand how the CAM-Part features are built. For this purpose,
you have to turn off the automatic CAM-Part definition.

1. Click Tools > SolidCAM > SolidCAM Settings.

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 2. CAM-Part Definition

2. In the left pane, select CAM-Part.

3.Ensure that the settings are as shown in the

image.

4. In the left pane, select Automatic CAM-Part definition. In the right pane, click the Milling tab.

5.Ensure that the settings are as shown in the

image.

6. Click OK.

7. Browse to open the SOLIDWORKS part

PORT_INLET_PART.SLDPRT.

8. Click Tools > SolidCAM > New >

Milling.

The Milling Part Data dialog box opens.

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Define the CAM-Part in the Milling Part Data dialog box.

9. In the CNC-Machine list, click table_table_exercise.

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

11. In the Place CoordSys origin to list, click Top center of model
box.

12. Select the highlighted face as shown in the image.

The coordinate system is set and looks like as shown in the image.

13. Click
The CoordSys Data window displays.

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 2. CAM-Part Definition

14. Enter the parameters as shown in the image.

15. Click to close the CoordSys Manager window.

16. Click to close the Milling Part Data dialog box.

The defined coordinate system should look like as shown in the image

The CAM part is now defined.

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8
5-Axis Strategies
3
Before you start defining 5-Axis operations, adding Machine Setup is required. Machine setup
allows to define the position of the part with respect to the machine table. It also allows you to
define fixtures and other holding elements.

1. Right click Operations > Machine Setup > Add at

start of operations tree.

The Machine Setup window displays.

2. Click Table_Pos1 [MAC 1 (1-Position)].

3. Enter a value of 250 in Z column.

This will move the part 250 mm above the machine
bed.

4. Click to see how the part mounting looks on the machine.

This is how the preview looks.

5. Close the Machine Preview window.

6.Click OK to close the Machine Setup

window.
The Machine Setup is now defined.

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 3. 5-Axis Strategies

Perpendicular to curve strategy

The Perpendicular to Curve strategy enables you to create a tool path perpendicular to a lead curve
(drive curve) on a selected drive surface. If the curve is a straight line, then the cuts are created
parallel to each other. You can use a surface edge as the lead curve, or a curve that is on the surface.
If the curve is not on the surface then it is projected onto the drive surface to create the tool path.

In the above picture you can see that the tool path cuts are taken perpendicular to the lead curve.
This is done by distributing points on the lead curve (Equal to the Step Over) and then taking the
slices on the drive surface on each of these points by creating planes normal to the lead cuve at that
point. The lead curve need not be the edge of the drive surface, it could be any curve and the cuts
will be perpendicular to that curve.

7. Right click Setup > Add Milling Operation > Sim 5-Axis Milling.

8. In the Technology list, select Perpendicular to curve.

9. Click the Geometry page.

10. Click under Drive surface.

The Select Faces dialog box displays.

11. Select the highlighted faces.

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12. Click

13. Click under Lead curve.

The Geometry Edit dialog box displays.

14. Select the curve as shown in the image.

15. Click in the Chain List section.

16. Click

17. In the Type list, click Limit cuts by one or two points.

18. Click Points.

The Limit Cuts Between 2 Points window displays.

19. Click Data.

20. Select the point as shown in the image.

21. Click

22. Define the first margin as -0.3 in the Z field.

This is needed as there is no other way to define margins while
selecting the two points option.

23. Click Data.

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 3. 5-Axis Strategies

24. Select the point as shown in the image.

25. Click

26. Click OK in the Limit cuts by one or two points window.

27. Click the Tool page > Select.

28. Select LOLLIPOP MILL.

29. Enter the parameters as shown in the below image.

30. Select BT 40 ER 32X60 as the holder.

31. Click

32. Click the Levels page.

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33. Select Plane from the Type list.

34. Ensure that Z-Axis is selected from the Direction list.

35. Select User-Defined from the Height list.

36. Enter a value of 75 mm in the Plane height field.

37. Click the Tool path parameters page.

38. Select the Sorting tab.

39. Enter the parameters as shown in the image.

40. Click the Tool axis control page.

41. Select Tilted through curve as the Tool axis direction.

42. Click

43. Expand Design Model > PORT 1 TILT > click the Show icon.

44. Click

45. Click under Tilt curve.

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 3. 5-Axis Strategies

46. Select the curve as shown in the image. Ensure that the
selection is from top to bottom, as is the direction of the
arrow.

47. Click in the Chain List section.

48. Click

49. In the Curve tilt type list, select From start to end.
This tilt type is used to force the tool axis to always follow the tilt curve from start of the curve to
the end of the curve. This is the most used tilt type option for machining ports.

50. Click the Gouge check page.

51. Select the Enable/Disable check box.

52. In the Strategy lists, select Retract tool

and Along to cut center.
The Retract tool along to cut center strategy,
helps to push the tool path to the centre of
the geometry so that it does not gouge the
geometry. This ensures that the tool sticks
to the geometry without gouging the part
surfaces.

53. Select the Drive surfaces check box.

54. Save and calculate the operation.

55. Simulate the tool path once it is calculated.

15
The calculated tool path should look as displayed in the
image.
You can see that a retract is coming through the part
and will cause a major crash on the machine. This must
be fixed.

56. Close the simulation window.

57. Click the Link page.

58. In the Last exit list, select Back to

clearance through tube center.

59. Save and calculate the operation.

The calculated tool path should look as

displayed in the image.
The tool is now retracting out through the center without
causing any gouges to the part. This retract option is
exclusively used for machining port geometries.

60. Close the Operations Manager.

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

62. In the Technology list, click Morph between two

boundary curves.

The Morph between two boundary curves option creates a morph 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. When selecting the two curves, the geometry should be
selected directly from the drive surfaces.

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 3. 5-Axis Strategies

63. Click the Geometry page.

64. In the Drive surface list, select faces.

This is the same drive surface you had selected for the earlier operation.

65. Click under Start edge curve.

66. Select the curve as shown in the image.

67. Click Yes in OK to accept? window.

68. Click

69. Click under End edge curve.

70. Select the curve as shown in the image.

71. Click Yes in OK to accept? window.

72. Click

73. In the Type list, click Limit cuts by one or two points.

74. Click Points.

75. Click Data.

76. Select the point as shown in the image.

77. Click

78. Define the first margin as -0.3 in the Z field.

17
79. Click Data.

80. Select the point as shown in the image.

81. Click

82. Click OK in the Limit cuts by one or two points window.

83. Click the Tool page > Select.

84. Select the same lollipop mill tool that was defined for the earlier operation.

85. Click the Levels page.

86. Enter a value of 75 mm in the Plane height field.

87. Click the Tool path parameters page.

88. Select the Sorting tab.

89. In the Cutting method list, select Spiral.

90. Click the Tool axis control page.

91. Select Tilted through curve as the Tool axis direction.

92. Select the Tilt curve tab and iIn the Curve tilt type list, select From start to end.

93. Click the Link page.

94. Ensure that Back to clearance through tube center is selected in Last exit list.

95. Click the Gouge check page.

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 3. 5-Axis Strategies

96. Select the Enable/Disable check box.

97. In the Strategy lists, select Retract tool and Along to cut center.

98. Select the Drive surfaces check box.

99. Save and calculate the operation.

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

100. Close the Operations Manager.

You will now machine the other port which is octagonal in shape. For that, first you must switch
on the required sketch.

101. Click

102. In the Design Model, select PORT 2 TILT > Show.

103. Click

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

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

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106. Click the Geometry page.

107. Click under Drive surface.

108.Select all the faces of the octagonal curve as shown in the

image.

109. Change the Name as Octa_Port.

110. Click

111. Click under Start edge curve.

112. Select the curve as shown in the image.

113. Click Yes in OK to accept? window.

114. Change the Name as Octo_Top.

115. Click

116. Click under End edge curve.

117. Select the curve as shown in the image.

118. Click Yes in OK to accept? window.

119. Click

120. In the Type list, click Limit cuts by one or two points.

121. Click Points.

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 3. 5-Axis Strategies

122. Click Data.

123. Select the point as shown in the image.

124. Define the margin as -0.3 in the Z field.

125. Click

126. Click Data.

127. Select the point as shown in the image.

128. Click

129. Click OK in the Limit cuts by one or two points window.

130. Click the Tool page > Select.

131. Select the same lollipop mill tool that was defined for the earlier operation.

132. Click the Tool path parameters page.

133. Select the Sorting tab.

134. In the Cutting method list, select Spiral.

135. Click the Link page.

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

137. Click
The Lead-In window displays.

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138. Unselect Use default Lead-In check box.

139. Enter the values as shown in the image.

140. Click OK.

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

142. Click
The Lead-Out window displays.

143. Unselect Use default Lead-Out check box.

144. Enter the values as shown in the image.

145. Click OK.

146. In the Last exit list, click Back to clearance through

tube center.

147. Click the Tool axis control page.

148. Select Tilted through curve as the Tool axis direction.

149. Select the Tilt curve tab and in the Curve tilt type list, select From start to end.

150. Click under Tilt curve.

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 3. 5-Axis Strategies

151. Select the curve as shown in the image.

152. Click in the Chain List section.

153. Click

154. Click the Gouge check page.

155. Select the Enable/Disable check box.

156. In the Strategy lists, select Retract tool and Along to cut center.

157. Select the Drive surfaces check box.

158. Save and calculate the operation.

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

There are no gouges but the tool path does not look very smooth. Let us fix this.

159. Close the Operations Manager.

160. Right click > Copy the operation.

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161. Right click > Paste the operation.

162. Right click > Edit the operation.

163. Click

164. Expand Design Model > Surface Bodies1 > DUMMY

SURFACE > Show.

It must look like the highlighted surface in the below image.

165. Click

166. Click the Geometry page.

167. Click under Drive surface.

You will use the cylinder. As the cylinder is hidden inside the solid model, it is difficult to select the
geometry. You must therefore, select it from the design model.

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 3. 5-Axis Strategies

168. Expand the feature manager.

169. Click DUMMY SURFACE.

You can see that it is already selected. You must ensure that the direction of the surface is proper
because you need to machine the inside of the tube.

170. Select the Show direction for selected faces check box.

171.Ensure that the arrow is indicating in the direction as

shown in the image.

172. Click

173. Click under Start edge curve.

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174. Select the curve as shown in the image.

175. Click Yes in OK to accept? window.

176. Click

177. Click under End edge curve.

178. Select the curve as shown in the image.

179. Click Yes in OK to accept? window.

180. Click

181. Click the Gouge check page.

182.Enter the parameters as shown in the

image.

183. In the Check surfaces 1 list, click Octa_

Port.

184. Click Show.

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 3. 5-Axis Strategies

The selected surfaces must look like as shown in the image.

Once the tool finds the gouges, it will move the tool away till it retracts towards the cut center so
that all the gouges disappear. This results in a gouge free tool path. With this strategy, the tool path
is effectively projected on these octo surfaces in such a way that no gouges remain.

185. Save and calculate the operation.

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

The tool path now looks much better as it has taken the circular tool path and projected it on these
octagonal surfaces.

186. Close the Operations Manager.

End of tutorial.

27
 SolidCAM Application Tutorial

Basic Training-3

iMachining 2D 2.5D Milling HSS (High-Speed Surface Machining)

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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