HIGH SPEED MACHINING

The Leaders in Integrated CAM

HSM
SolidCAM HIGH SPEED MACHINING MODULE

World-Class HSM Module – fully integrated in SolidWorks

SolidCAM 2009
HSM Module
User Guide

©1995-2009 SolidCAM

WW W . S O L I D C A M . C O M All Rights Reserved.

 SolidCAM 2009
HSM Module User Guide

©1995-2009 SolidCAM

All Rights Reserved.

 Contents

Contents

1. Introduction and Basic concepts

1.1 Start HSM Operation............................................................................. 13

1.2 SolidCAM HSM Operation overview................................................. 14
1.3 Parameters and values............................................................................ 16
2. Technology

2.1 Contour roughing................................................................................... 22

2.2 Hatch roughing....................................................................................... 23
2.3 Rest roughing........................................................................................... 24
2.4 Constant Z machining........................................................................... 25
2.5 Helical machining................................................................................... 26
2.6 Horizontal machining............................................................................ 27
2.7 Linear machining.................................................................................... 28
2.8 Radial machining..................................................................................... 29
2.9 Spiral machining...................................................................................... 30
2.10 Morphed machining............................................................................. 31
2.11 Offset cutting........................................................................................ 32
2.12 Boundary machining............................................................................ 33
2.13 Rest machining...................................................................................... 34
2.14 3D Constant step over machining..................................................... 35
2.15 Pencil milling......................................................................................... 36
2.16 Parallel pencil milling........................................................................... 37
2.17 3D Corner offset.................................................................................. 38
2.18 Prismatic Part machining..................................................................... 39
2.19 Combined strategies............................................................................. 40

5
3. Geometry

3.1 Geometry definition............................................................................... 43

3.1.1 CoordSys........................................................................................ 43
3.1.2 Target geometry............................................................................ 44
3.1.3 Faceting tolerance......................................................................... 44
3.1.4 Apply fillets.................................................................................... 45
3.1.5 Fillet surfaces dialog box............................................................. 46
4. Tool

4.1 Tool selection.......................................................................................... 51

4.2 Holder Clearance.................................................................................... 53
4.3 Spin & Feed Rate definition.................................................................. 54
5. Boundaries

5.1 Introduction............................................................................................. 58
5.1.1 Drive Boundaries.......................................................................... 58
5.1.2 Constraint boundaries.................................................................. 63
5.2 Boundary Definition.............................................................................. 65
5.2.1 Boundary type................................................................................. 65
5.2.2 Boundary name............................................................................. 66
5.2.3 Tool on working area................................................................... 67
5.3 Automatically created boundaries........................................................ 70
5.3.1 Auto-created box of target geometry........................................ 70
5.3.2 Auto-created box of stock geometry......................................... 71
5.3.3 Auto-created silhouette................................................................ 72
5.3.4 Auto-created outer silhouette..................................................... 73
5.4 2D manually created boundaries.......................................................... 74
5.4.1 Boundary Box................................................................................ 74
5.4.2 Silhouette Boundary..................................................................... 76
5.4.3 User-defined boundary................................................................ 78

6
 Contents

5.4.4 Profile Geometry.......................................................................... 79

5.4.5 Combined boundary.................................................................... 80
5.4.6 Select Faces dialog box................................................................ 84
5.4.7 Select Chain dialog box................................................................ 85
5.5 3D manually created boundaries.......................................................... 86
5.5.1 Common parameters.................................................................... 86
5.5.2 Selected faces................................................................................. 89
5.5.3 Shallow Areas................................................................................ 91
5.5.4 Theoretical Rest Areas................................................................. 92
5.5.5 Tool Contact Area........................................................................ 93
5.5.6 Rest Areas...................................................................................... 96
6. Passes

6.1 Passes parameters................................................................................... 99

6.1.1 Wall offset...................................................................................... 100
6.1.2 Floor offset.................................................................................... 102
6.1.3 Tolerance........................................................................................ 103
6.1.4 Step down...................................................................................... 103
6.1.5 Step over........................................................................................ 104
6.1.6 Pass Extension.............................................................................. 105
6.1.7 Offsets............................................................................................ 106
6.1.8 Limits.............................................................................................. 107
6.1.9 Point reduction.............................................................................. 109
6.2 Smoothing parameters........................................................................... 110
6.2.1 Max. radius..................................................................................... 111
6.2.2 Profile Tolerance........................................................................... 111
6.2.3 Offset Tolerance........................................................................... 111
6.3 Adaptive step down parameters........................................................... 112
6.4 Edit Passes parameters........................................................................... 116

7
 6.5 Axial offset............................................................................................... 121
6.6 Analysis..................................................................................................... 123
6.7 Strategy parameters................................................................................ 124
6.7.1 Contour roughing......................................................................... 125
6.7.2 Hatch roughing............................................................................. 127
6.7.3 Rest roughing................................................................................. 130
6.7.4 Linear machining.......................................................................... 132
6.7.5 Helical machining......................................................................... 137
6.7.6 Radial machining........................................................................... 139
6.7.7 Spiral machining............................................................................ 143
6.7.8 Morphed machining..................................................................... 147
6.7.9 Offset cutting................................................................................ 149
6.7.10 Rest machining parameters....................................................... 150
6.7.11 3D Constant step over............................................................... 156
6.7.12 Pencil milling............................................................................... 160
6.7.13 Parallel pencil milling................................................................. 162
6.7.14 3D Corner offset........................................................................ 164
6.7.15 Prismatic Part machining parameters...................................... 166
6.7.16 Combined strategy parameters................................................. 168
6.8 Calculation Speed.................................................................................... 174
7. Links

7.1 General Parameters................................................................................ 177

7.1.1 Direction options.......................................................................... 178
7.1.2 Order passes.................................................................................. 188
7.1.3 Retract............................................................................................. 190
7.1.4 Start hint......................................................................................... 191
7.1.5 Minimize reverse linking.............................................................. 192
7.1.6 Minimize full wide cuts................................................................ 193

8
 Contents

7.1.7 Link by Z-level.............................................................................. 194

7.1.8 Link per cluster............................................................................. 195
7.1.9 Min. Profile Diameter.................................................................. 196
7.1.10 Refurbishment............................................................................. 197
7.1.11 Safety............................................................................................ 198
7.2 Ramping Parameters............................................................................... 199
7.3 Strategy Parameters................................................................................ 206
7.3.1 Stay on surface within.................................................................. 207
7.3.2 Along surface................................................................................. 208
7.3.3 Linking radius................................................................................ 211
7.3.4 Link clearance................................................................................ 212
7.3.5 Horizontal link clearance............................................................. 213
7.4 Retracts Parameters................................................................................ 214
7.4.1 Style................................................................................................. 215
7.4.2 Clearance........................................................................................ 217
7.4.3 Smoothing...................................................................................... 219
7.4.4 Curls................................................................................................ 219
7.5 Leads Parameters.................................................................................... 220
7.5.1 Fitting.............................................................................................. 221
7.5.2 Trimming........................................................................................ 223
7.5.3 Vertical leads.................................................................................. 224
7.5.4 Horizontal Leads........................................................................... 225
7.5.5 Extensions...................................................................................... 227
7.5.6 Basic approaches........................................................................... 228
7.6 Down/Up Mill parameters.................................................................... 230
7.7 Refurbishment parameters.................................................................... 234
7.7.1 Spikes.............................................................................................. 235

9
8. Miscellaneous Parameters

8.1 Message.................................................................................................... 238

8.2 Extra parameters..................................................................................... 238
8.3 Approximation of arcs.......................................................................... 239
9. Examples

Example #1: Rough Machining and Rest Roughing............................... 243

Example #2: Constant Z, Helical and Horizontal machining............... 244
Example #3: Linear machining................................................................... 245
Example #4: Radial and Spiral machining................................................ 246
Example #5: Morphed machining and Offset cutting............................ 247
Example #6: Boundary machining............................................................ 248
Example #7: Rest machining...................................................................... 249
Example #8: 3D Constant Step over machining..................................... 250
Example #9: Pencil, Parallel Pencil and 3D Corner Offset................... 251
Example #10: Mold Cavity machining...................................................... 252
Example #11: Aerospace part machining................................................. 254
Example #12: Electronic box machining.................................................. 256
Example #13: Mold insert machining....................................................... 258
Example #14: Mold cavity machining....................................................... 260
Example #15: Mold core machining......................................................... 262
Index. ..................................................................................................................... 265

Document number: SCHSMUGENG09001

10
Introduction and
Basic Concepts 1
Welcome to SolidCAM HSM!

SolidCAM HSM is a very powerful and market-proven high-speed machining

(HSM) module for molds, tools and dies and complex 3D parts. The HSM module
offers unique machining and linking strategies for generating high-speed tool paths.

SolidCAM HSM module smooths the paths of both cutting moves and retracts
wherever possible to maintain a continuous machine tool motion – an essential
requirement for maintaining higher feed rates and eliminating dwelling.

With SolidCAM HSM module, retracts to high Z-levels are kept to a minimum.
Angled where possible, smoothed by arcs, retracts do not go any higher than
necessary, thus minimizing air cutting and reducing machining time.

The result of HSM is an efficient, smooth, and gouge-free tool path. This translates
to increased surface quality, less wear on your cutters, and a longer life for your
machine tools.

With demands for ever-shorter lead and production times, lower costs and
improved quality, HSM is a must in today’s machine shops.

About this book

This book is intended for experienced SolidCAM users. If you are not familiar
with the software, start with the lessons in the Getting Started Manual and then
contact your reseller for information about SolidCAM training classes.

About the CD

The CD supplied together with this book contains the various CAM-Parts
illustrating the use of the SolidCAM HSM Module. The CAM-Parts are located
in the Examples folder and described in Chapter 9. Copy the complete Examples
folder to your hard drive. The SolidWorks files used for exercises were prepared
with SolidWorks 2009.

The examples used in this book can also be downloaded from the SolidCAM web-
site http://www.solidcam.com.

12
 1. Introduction and Basic Concepts

1.1 Start HSM Operation

This command enables you to add a SolidCAM HSM operation to your CAM-
Part. The HSM Operation dialog box is displayed.

13
1.2 SolidCAM HSM Operation overview

Operation name Template

Technology
Info
Geometry parameters
Tool parameters

Boundary parameters

Passes parameters
Link parameters

Misc. parameters

Parameter illustration

Parameters page

The definition of a SolidCAM HSM operation consists of the following stages:

Strategy choice

Geometry definition

Tool definition

Boundary definition

Passes definition

Link definition

Misc. parameters definition

14
 1. Introduction and Basic Concepts

At the first stage you have to choose one of the available machining strategies.
The machining strategy defines the technology that will be used for the machining.
For more information on the machining strategies, refer to chapter 2.

At the Geometry definition stage you have to specify the 3D model geometry that
will be machined. For more information on the Geometry definition, refer to
chapter 3.

The next stage enables you to choose from the Part Tool Table a cutting tool that
will be used for the operation. For more information on the tool definition, refer
to chapter 4.

The Boundaries definition page enables you to limit the operation machining to
the specific model areas. For some machining strategies an additional boundary
defines the drive curve of the operation tool path. For more information on the
boundary definition, refer to chapter 5.

In the Passes definition, SolidCAM enables you to specify the technological

parameters used for the tool passes calculation. For more information on the
passes definition, refer to chapter 6.

The Link parameters page enables you to define the tool link moves between
cutting passes. For more information on the link definition, refer to chapter 7.

The Miscellaneous parameters page enables you to define the non-technological

parameters related to the HSM operations. For more information on the
miscellaneous parameters definition, refer to chapter 8.

15
1.3 Parameters and values

Most of the parameters used in the SolidCAM HSM operation receive default values
according to built-in formulas that define dependencies between the parameters.
When a number of basic parameters such a tool diameter, corner radius, offsets,
etc. are defined, SolidCAM updates the values of dependent parameters.

For example, the Step down parameter for Contour roughing is defined with the
following formula:

If the tool corner radius is 0 (end mill), the Step down parameter default
is set to 1. If a ball-nosed tool is chosen, the Step down value is equal
to the tool corner radius value divided by 0.5; for bull-nosed tools the
Step down value is equal to the tool corner radius value divided by 0.3.

Yes Tool Corner No

Radius = 0

Yes Is tool No
Step down = 1
ball nosed?

Step down = Tool Step down = Tool

Corner Radius / 0.5 Corner Radius / 0.3

SolidCAM provides you with a right-click edit box menu for each parameter.

16
 1. Introduction and Basic Concepts

View Parameter Info

This command displays the Parameter Info dialog box. This dialog box shows the
internal parameter name and the related formula (if exists) or a static value.

The Unfold button displays a brief explanation of the parameter.

The button displays the flow chart of the parameter value calculating.

17
Reset

When you manually change a parameter default value, the formula assigned to the
parameter is removed.

The Reset commands enable you to reset parameters to their default formulas and
values.

• This parameter. This option resets the current parameter.

• This page. This option resets all the parameters at the current page.

• All. This option resets all the parameters of the current HSM operation.

18
Technology
2
The Technology section enables you to choose the rough or finish machining
strategy to be applied. The following strategies are available:

Roughing strategies:

• Contour roughing

• Hatch roughing

• Rest roughing

Finishing strategies:

• Constant Z machining

• Helical machining

• Horizontal machining

• Linear machining

• Radial machining

• Spiral machining

20
 2. Technology

• Morphed machining

• Offset cutting

• Boundary machining

• Rest machining

• 3D Constant step over

• Pencil milling

• Parallel pencil milling

• 3D Corner offset

• Prismatic Part machining

• Combined strategies:

• Constant Z with Horizontal machining

• Constant Z with Linear machining

• Constant Z with 3D Constant step over machining

21
2.1 Contour roughing

With the Contour roughing strategy, SolidCAM generates a pocket-style tool path
for a set of sections generated at the Z-levels defined with the specified Step down
(see topic 6.1.4).

22
 2. Technology

2.2 Hatch roughing

With the Hatch roughing strategy, SolidCAM generates linear raster passes for
a set of sections generated at the Z-levels defined with the specified Step down
(see topic 6.1.4). Hatch roughing is generally used for older machine tools or softer
materials because the tool path predominantly consists of straight line sections.

23
2.3 Rest roughing

The Rest roughing strategy determines the areas where material remains
unmachined after the previous machining operations (the "rest" of the material)
and generates a tool path for the machining of these areas. The tool path is
generated in the Contour roughing (see topic 2.1) manner. Rest roughing operation
uses a tool of smaller diameter than that used in previous roughing operations.

The following image illustrates the hatch roughing tool path performed with an
End mill of Ø20.

After the hatch roughing, a Rest roughing operation is performed with an End mill
of Ø10. The tool path is generated in the contour roughing manner.

24
 2. Technology

2.4 Constant Z machining

Similar to Contour roughing, the Constant Z tool path is generated for a set of
sections created at different Z-heights determined by the Step down (see topic
6.1.4) parameter. The generated sections are machined in a profile manner. The
Constant Z strategy is generally used for semi-finishing and finishing of steep
model areas with the inclination angle between 30 and 90 degrees. Since the
distance between passes is measured along the Z-axis of the Coordinate System,
in shallow areas (with smaller surface inclination angle) the Constant Z strategy is
less effective.

The image above illustrates the Constant Z finishing. Note that the passes are densely
spaced in steep areas. Where the model faces get shallower, the passes become
widely spaced, resulting in ineffective machining. Therefore, the machining should
be limited by the surface inclination angle to avoid the shallow areas machining.
These areas can be machined later with a different SolidCAM HSM strategy, e.g.
3D Constant step over (see topic 2.14).

25
2.5 Helical machining

With this strategy, SolidCAM generates a number of closed profile sections of

the 3D Model geometry located at different Z-levels, similar to the Constant Z
strategy. Then these sections are joined in a continuous descending ramp in order
to generate the Helical machining tool path.

The tool path generated with the Helical machining strategy is controlled by two
main parameters: Step down and Max. ramp angle (see topic 6.7.5).

26
 2. Technology

2.6 Horizontal machining

With the Horizontal machining strategy, SolidCAM recognizes all the flat areas in
the model and generates a tool path for machining these areas.

This strategy generates a pocket-style (a number of equidistant profiles) tool path

directly at the determined horizontal faces (parallel to the XY-plane of the current
Coordinate System). The distance between each two adjacent passes is determined
by the Offset (see topic 6.1.7) parameters.

27
2.7 Linear machining

Linear machining generates a tool path consisting of a set of parallel passes at

a set angle with the distance between the passes defined by the Step over (see topic
6.1.5) parameter.

With the Linear machining strategy, SolidCAM generates a linear pattern of passes,
where each pass is oriented at a direction defined with the Angle value. This
machining strategy is most effective on shallow (nearing horizontal) surfaces, or
steeper surfaces inclined along the passes direction. The Z-height of each point
along a raster pass is the same as the Z-height of the triangulated surfaces, with
adjustments made for applied offsets and tool definition.

In the image above, the passes are oriented along the X-axis. The passes are evenly
spaced on the shallow faces and on the faces inclined along the passes direction.
The passes on the side faces are widely spaced; Cross Linear machining (see topic
6.7.4) can be used to finish these areas.

28
 2. Technology

2.8 Radial machining

The Radial machining strategy enables you to generate a radial pattern of passes
rotated around a central point.

This machining strategy is most effective on areas that include shallow curved
surfaces and for model areas formed by revolution bodies, as the passes are spaced
along the XY-plane (step over), and not the Z-plane (step down). The Z-height
of each point along a radial pass is the same as the Z-height of the triangulated
surfaces, with adjustments made for applied offsets and tool definition.

29
2.9 Spiral machining

The Spiral machining strategy enables you to generate a 3D spiral tool path over
your model. This strategy is optimal for model areas formed by revolution bodies.
The tool path is generated by projecting a planar spiral (located in the XY-plane of
the current Coordinate System) on the model.

30
 2. Technology

2.10 Morphed machining

Morphed machining passes are generated across the model faces in a close-to-
parallel formation, rather like Linear machining passes (see topic 2.7); each path
repeats the shape of the previous one and takes on some characteristics of the
next one, and so the paths "morph" or gradually change shape from one side of
the patch to the other.

The shape and direction of the patch is defined by two drive boundary curves.

Drive boundary curves

31
2.11 Offset cutting

This strategy is a particular case of the Morphed machining strategy (see topic
2.10). The Offset cutting strategy enables you to generate a tool path using a single
Drive curve. The tool path is generated between the Drive curve and a virtual
offset curve, generated at the specified offset from the Drive curve.
Tool path
Drive curve

32
 2. Technology

2.12 Boundary machining

A Boundary machining strategy enables you to create the tool path by projecting the
defined Drive boundary (see topic 5.1.1) on the model geometry. The Machining
depth is defined relative to the model surfaces with the Wall offset (see topic 6.1.1)
parameter. The tool path generated with the Boundary machining strategy can
be used for engraving on model faces or for chamfer machining along the model
edges.

33
2.13 Rest machining

Rest machining determines the model areas where material remains after the
machining by a tool path, and generates a set of passes to machine these areas.

Pencil milling vertical corners can cause both the flute of the tool and the radius
to be in full contact with the material, creating adverse cutting conditions. Rest
machining picks the corners out from the top down, resulting in better machining
technique. Steep and shallow areas are both machined in a single tool path, with
different rest machining strategies.

34
 2. Technology

2.14 3D Constant step over machining

3D Constant step over machining enables you generate a 3D tool path on the
CAM-Part surfaces. The passes of the tool path are located at a constant distance
from each other, measured along the surface of the model.

This is an ideal strategy to use on

the boundaries generated by rest
machining or in any case where
you want to ensure a constant
distance between passes along
the model faces.

Closed boundary
Constant surface step over is
performed on a closed profile
of the Drive boundary (see topic
5.1.1). SolidCAM creates inward
offsets from this boundary.

35
2.15 Pencil milling

The Pencil milling strategy creates a tool path along internal corners and fillets
with small radii, removing material that was not reached in previous machining.
This strategy is used to finish corners which might otherwise have cusp marks left
from previous machining operations. This strategy is useful for machining corners
where the fillet radius is equal to or smaller than the tool radius.

36
 2. Technology

2.16 Parallel pencil milling

Parallel pencil milling is a combination of the Pencil milling strategy and the 3D
Constant step over strategy. At the first stage, SolidCAM generates a Pencil milling
tool path. Then the generated pencil milling passes are used to create 3D Constant
step over passes; the passes are generated as a number of offsets on both sides
of the pencil milling passes. In other words, the Parallel pencil milling strategy
performs 3D Constant step over machining using Pencil milling passes as drive
curves to define the shape of passes.

This strategy is particularly useful when the previous cutting tool was not able to
machine all the internal corner radii to size. The multiple passes generated by this
strategy will machine from the outside in to the corner, creating a good surface
finish.

37
2.17 3D Corner offset

The 3D Corner offset strategy is similar to the Parallel pencil milling strategy. This
strategy is also a combination of the Pencil milling strategy and the 3D Constant
step over strategy. SolidCAM generates a Pencil milling tool path and uses it for
the 3D Constant step over passes generation. These passes are generated as offsets
from the Pencil milling passes. In contrast to the Parallel pencil milling strategy, the
number of offsets is not defined by user but determined automatically in such a
way that all the model within the boundary will be machined.

38
 2. Technology

2.18 Prismatic Part machining

The Prismatic Part machining strategy is designed especially for high-speed finishing
of prismatic parts. This strategy comprises the technology of the Constant Z (see
topic 2.4) and 3D Constant step over (see topic 2.14) strategies by integrating
these two strategies into one smart functionality of prismatic part machining. The
difference from the Combined Constant Z with 3D Constant step over strategy
(see topic 2.19) is as follows: in the Combined strategy, the subsequent strategies
are performed successively one after the other. In the Prismatic Part machining
strategy, the machining is performed consistently according to the order of the
walls and flat faces along the Z-axis.

The user-defined geometry parameters are taken into account by the system for
calculation of default values for technological parameters to provide you with the
optimized machining solution. For example, the minimal and maximal Z-levels of
the defined geometry are used for calculation of the surface inclination angle, and
so on.

The tool choice also affects the automatic calculation of defaults for technological
parameters.

39
2.19 Combined strategies

SolidCAM enables you to combine two machining strategies in a single HSM

operation: Constant Z with Horizontal, Linear or 3D Constant step over machining.
Two combined machining strategies share the Geometry, Tool and Constraint
boundaries data. The technological parameters for the passes calculation and
linking are defined separately for each strategy.

40
Geometry
3
The Geometry page enables you to define the 3D model geometry for the
SolidCAM HSM operation.

42
 3. Geometry

3.1 Geometry definition

The Target Geometry section enables you to specify the appropriate Coordinate
System for the operation and to define the machining geometry.

3.1.1 CoordSys

SolidCAM enables you to define the Coordinate System for the operation by
choosing it from combo-box or by selecting it from the graphic screen by clicking
on the CoordSys button. The CoordSys Manager dialog box will be displayed.
Together with this dialog box, SolidCAM displays the location and axis orientation
of all Coordinate Systems defined in the CAM-Part.

To get more information about the Coordinate

System, right-click on the CoordSys entry in
CoordSys Manager and choose the Inquire option
from the menu.

The CoordSys Data dialog box will be displayed.

43
When the CoordSys is chosen for the operation, the model will be rotated to the
appropriate orientation.
The CoordSys selection operation must be the first step in the geometry definition
process.

3.1.2 Target geometry

After the Coordinate System is chosen, define the 3D Model geometry for the
SolidCAM HSM operation.
If you have already defined 3D Model geometries for
this CAM-Part, you can select a geometry from the
list.
The Show button displays the chosen 3D model
geometry in the SolidWorks window.
The Define button enables you to define a new 3D
Model geometry for the operation with the 3D Model
Geometry dialog box.

For more information on 3D Geometry selection,

refer to the SolidCAM Milling User Guide book.

When you choose the geometry from the list, the related Coordinate
System is chosen automatically.

3.1.3 Faceting tolerance

Before the machining, SolidCAM generates a triangular mesh for all the faces of
the 3D model geometry used for the operation. Faceting tolerance is the accuracy
to which triangles fit the surfaces. The smaller the value the more accurate the
triangulation is, but the slower the calculation.
The 3D model geometry will be triangulated and the resulting facets will be saved.
The triangulation is performed on the 3D model geometry when you use it for the
first time in a SolidCAM HSM operation. If you use the 3D geometry in another
operation, SolidCAM will check the tolerance of the existing geometry. It will not
perform another triangulation as long as the facets have been created with the
same surface tolerance.

44
 3. Geometry

3.1.4 Apply fillets

This option automatically adds fillets to the internal model corners. Therefore,
the tool does not have to dramatically change direction during the machining,
preventing damage to itself and to the model surfaces and enabling faster feed
rates and eventually better surface quality.

When the corner radius is smaller than By adding fillets, the corner radius
or equal to the tool radius, the tool path becomes greater than the tool radius
consists of two lines connected with a and the tool path lines are then
sharp corner; at this corner point the connected with an arc, resulting in a
tool sharply changes its direction. smooth tool movement without sharp
changes in direction.

Select the Apply fillets check box to automatically add fillets for the tool path
generation.

Click on the Define button to create a new fillets geometry. The Fillet surfaces
dialog box is displayed.

45
The Show button displays the chosen fillet geometry directly on the solid model.

Model without fillets Model with fillets

3.1.5 Fillet surfaces dialog box

The Fillet surfaces dialog box enables you to generate fillet

geometry for the current 3D Model geometry used for the
HSM operation.

Boundary

The Boundary type section enables you to specify the

boundary geometry for the fillet generation. The fillets will
be generated inside the specified 2D boundary.

SolidCAM enables you to choose the 2D boundary type from

the list. 2D boundaries of the following types are available:
Auto-created silhouette (see topic 5.3.3), Auto-created
outer silhouette (see topic 5.3.4), User-defined boundary
(see topic 5.4.3), and Auto-created box of target geometry
option. The latter option automatically generates a planar
box surrounding the Target geometry.

46
 3. Geometry

The Boundary name section enables you to choose a 2D boundary geometry from
the list or define a new one using the Define button. The appropriate dialog box
will be displayed.

The Show button displays the Select Chain dialog box and the chains are displayed
and highlighted in the graphic window. If needed, you can unselect some of the
automatically created chains.

Filleting Tool Data

For the calculation of fillets, SolidCAM uses a virtual

tool. The Filleting Tool data section enables you to
specify the geometry parameters of this tool.

• Tool Diameter. This field enables you to specify

the cutting diameter of the virtual tool.

• Corner radius. This field enables you to specify

the corner radius of the virtual tool.

• Taper (°/side). This field enables you to Angle

specify the taper angle of the side of
the tool. SolidCAM does not support
tool with a back taper, like a Dove tail
tool.

• Cutting length. This field enables you

to specify the length of the cutting
edge of the tool.

• Shank diameter. This field enables you

to specify the shank diameter.

• Outside holder length. This field

enables you to specify the length of the
visible part of the tool, from the tip to
the start of the tool holder.

47
General

• Tolerance. This parameter defines the tolerance

of fillet surfaces triangulation. A lower value
will give more accurate results, but will increase
the calculation time.

• Resolution. This is the "granularity" of the

calculation. Using a smaller value will give finer
detail but will increase the calculation time.

• Minimum Z. This option sets the lowest Z-level the tool can reach.

• Number of facets. This is the number of flat faces (triangles) across the
radially curved section of the fillet.

• Bitangency angle. This is the minimum angle required between the two
normals at the contact points between the tool and model faces, in order
to decide to generate the fillet.

Bitangency angle

48
Tool
4
In the Tool data section of the SolidCAM HSM operation dialog box, the following
tool parameters are displayed:

• Type

• Number

• Diameter

• Corner radius

50
 4. Tool

4.1 Tool selection

The Select button enables you to edit tool parameters or define the tool you want
to use for this operation.

• When the tool is not defined for the operation, this button displays the
View page of the Part Tool Table dialog box that enables you to choose
the tool from the Part Tool Table.

Choose the required tool from the Part Tool Table and click on
the Select button. The tool will be chosen for the operation.

51
 • When the tool is defined for the operation, this button displays the Edit
page of the Part Tool Table dialog box with the parameters of the chosen
tool. You can also add a new tool to be defined for the operation or
choose another tool from the Part Tool Table.

For more information on the tool definition, refer to the SolidCAM Milling User
Guide book.

52
 4. Tool

4.2 Holder Clearance

The Holder Clearance parameter enables you to define how close the holder can
approach the material during the machining.

Holder Clearance

53
4.3 Spin & Feed Rate definition

The Data button displays the Operation Tool Data dialog box that enables you to
define the spin and feed parameters.

Spin

This field defines the spinning speed of the tool.

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

S is the default and signifies Revolutions per Minute. V signifies Material cutting
speed in Meters/Minute in the Metric system or in Feet/Minute in the Inch system;
it is calculated according to the following formula:
V = (S * PI * Tool Diameter) / 1000

54
 4. Tool

Feed Rate

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

F is the default that signifies Units per minute.

FZ signifies Units per tooth and is calculated according to the following formula:

FZ = F/(Number of Flutes * S)

The F/FZ buttons enable you to check the parameter values.

Cutting. This field defines the feed rate of the cutting section of the tool path.

Link down. The feed rate to be set for lead in moves.

Link up. The feed rate to be set for lead out moves.

Rapid. This parameter enables you to define a feed rate for the retract sections of
the tool path, where the tool is not contacting with the material.

55
56
Boundaries
5
5.1 Introduction

SolidCAM enables you to define two types of boundaries for the SolidCAM HSM
operation tool path.

5.1.1 Drive Boundaries

Drive boundaries are used to drive the shape of the tool path for the following
SolidCAM HSM strategies: 3D Constant step over, Morphed machining and
Boundary machining.

58
 5. Boundaries

Drive boundaries for Morphed machining

SolidCAM enables you to define drive boundary curves for the Morphed machining
strategy (see topic 2.10).

You can choose an existing geometries for the first and second drive curves from
list or define a new one by clicking on the Define button. The Geometry Edit
dialog box is displayed. For more information on geometry selection, refer to the
SolidCAM Milling User Guide book.

The Show button displays the chosen drive curve geometry directly on the solid
model.

Drive boundary curves

Make sure that the
directions of both
drive curves are the
same in order to
perform the correct
machining.

59
 Cutting direction

This option enables you define the tool path direction between the
drive curves.

• Across. The morphed tool path is performed across the drive

curves; each cutting pass connects the corresponding points on
the drive curves.
Drive boundary curves

• Along. The morphed tool path is performed along the drive

curves. The tool path morphs between the shapes of the drive
curves gradually changing shape from the first drive curve to the
second.
Drive boundary curves

60
 5. Boundaries

Drive boundaries for Offset cutting

The Drive boundaries page of the HSM Operation dialog box enables you to define
the curve and the related parameters.

Curve

This section enables you to define the Drive curve used for the tool
path definition.

Clear direction

This section enables you

to specify the direction Left
Drive curve
in which a virtual offset
from the Drive curve is
created. The offset can Right
be generated in the Right,
Left or Both directions
from the Drive curve.

61
 Cutting direction

This section enables you to determine how the machining is performed.

When the Along option is chosen, the machining is performed along
the Drive curve. The tool path morphs between the shapes of the
Drive curve and the offset curve, gradually changing shape from
the first Drive curve to the offset curve. When the Across option is
chosen, the tool path is performed across the Drive curve; each cutting
pass connects the corresponding points on the Drive curve and offset
curve.

Along Across

Tool on working area

The Tool on working area section enables you to define the position of
the tool relative to the defined boundary and the related parameters.

For more information, see topic 5.2.1.

62
 5. Boundaries

5.1.2 Constraint boundaries

A constraint boundary enables you to limit the machining to specific model areas.

Machining always takes place within a boundary or a set of boundaries. The

boundaries define the limits of the tool tip motion. The area actually machined
can be extended beyond the boundary by as much as the tool shaft radius.

In the image above, the tool center is located at the edge of the boundary, therefore
the tool extends beyond the edge by tool radius. You can use the Offset (see topic
6.1.7) feature to offset the tool inside by a certain distance.

63
If there are several boundary contours then the operation will use all of them.

If one boundary is completely inside another, then it will act as an island. The area
enclosed by the outer boundary, minus the area defined the inner boundary, will
be machined.

You can extend this to define more complicated shapes by having islands within
islands.

64
 5. Boundaries

5.2 Boundary Definition

5.2.1 Boundary type

The following boundary types are available:

Created automatically

This option enables you to automatically create the boundary using the stock or
target models.

The following types of automatically created boundaries are supported in

SolidCAM:
• Auto-created box of target geometry

• Auto-created box of stock geometry

• Auto-created silhouette

• Auto-created outer silhouette

65
Created manually

This option enables you to define the constraint

boundary that limits the tool path by creating a 2D
area above the model in the XY-plane of the current
Coordinate system or by an automatically generated
3D curve mapped on the surface.

The following types of 2D boundaries are supported:

• Boundary box

• Silhouette boundary

• User-defined boundary

• Profile geometry

• Combined boundary

The following types of 3D boundaries are supported:

• Selected faces

• Shallow areas

• Theoretical rest areas

• Tool contact areas

• Rest areas

5.2.2 Boundary name

This section enables you to define a new boundary geometry or choose an already
defined one from the list.

• The Define button displays the appropriate dialog box for the geometry
definition.
• The Edit button displays the Select Chain dialog box (see topic 5.4.7)
enabling you to choose the necessary chains for the boundary. The
chosen boundaries are displayed and highlighted in the graphic window.

66
 5. Boundaries

5.2.3 Tool on working area

This option controls how the tool is positioned

relative to the boundaries. This option is relevant
only for 2D boundaries.

Internal

The tool machines inside the boundary.

Boundary

Tool

External

The tool machines outside the boundary.

Boundary

Tool

Center

The tool center is positioned on the boundary.

Boundary

Tool

67
Tangent

The Internal/External/Center methods of the boundary definition have several

limitations. In some cases, the limitation of the tool path by planar boundary
results in unmachined areas or corners rounding.

Unmachined area

Tool on working area: Internal

Unmachined
area

Tool on working area: Center

Tool path rounding

Tool on working area: External

The Tangent option enables you to avoid these problems.

When this option is chosen, SolidCAM generates the tool path boundaries by
projecting the planar working area on the 3D model. The tool path is limited in
such a way that the tool is tangent to the model faces at the boundary.

68
 5. Boundaries

This option enables you to machine the exact boundary taking the geometry into
account.
The tool is tangent
to the projection
of the working area
onto the model faces

Tool on working area: Tangent

Offset value

This value enables you to specify the offset of the tool center.

-
+
-
+

A positive offset value will enlarge the boundary; a negative value will reduce the
boundary to be machined.

69
5.3 Automatically created boundaries

5.3.1 Auto-created box of target geometry

With this option SolidCAM automatically generates a rectangular box surrounding

the target model. The tool path is limited to the area contained in this box.

Target Model

70
 5. Boundaries

5.3.2 Auto-created box of stock geometry

With this option SolidCAM automatically generates a rectangular box surrounding

the stock model. The tool path is limited to the area contained in this box.

Stock Model

Target Model

71
5.3.3 Auto-created silhouette

With this option, SolidCAM automatically generates a silhouette boundary of the

target model. A silhouette boundary is a projection of the outer and inner contours
of the target model onto the XY-plane.

Target Model

72
 5. Boundaries

5.3.4 Auto-created outer silhouette

With this option, SolidCAM automatically generates an outer silhouette boundary

of the target model. In this case, an outer silhouette boundary is a projection of
the outer contours only onto the XY-plane.

Target Model

73
5.4 2D manually created boundaries

5.4.1 Boundary Box

A Boundary Box is a rectangular box surrounding the selected model geometry.

SolidCAM enables you to limit the machining passes to the area contained in the
Boundary box.

The Select Faces dialog box enables you to choose the

necessary model faces. When the faces are chosen and
the dialog box is confirmed, the Boundary box dialog
box is displayed.

74
 5. Boundaries

This dialog box enables you to define a necessary

parameters and choose the model elements for the
bounding box calculation.

The boundary will be created on

This option enables you to select the faces for which a

bounding box is generated. Click the Select button to
display the Select Faces dialog box (see topic 5.4.6).

The Show button displays the already selected faces

geometry.

The table section displays the automatically calculated

minimum and maximum coordinates, center and length
of the bounding box.

SolidCAM enables you to change the XY-

coordinates of the minimum and maximum
coordinates of the bounding box.

When the geometry for the bounding box generation is defined, click on
the button. The boundary chains will be generated and the Select Chain dialog
box (see topic 5.4.7) will be displayed.

75
5.4.2 Silhouette Boundary

A Silhouette boundary is a projection of the face edges onto the XY-plane. In

other words, it is the shape that you see when you looking at a set of surfaces down
the tool axis.

The Select faces dialog box enables you to choose the

necessary model faces. When the faces are chosen and
the dialog box is confirmed, the Silhouette boundary
dialog box is displayed.

This dialog box enables you to define the parameters

and choose the solid model elements for the silhouette
boundary calculation.

76
 5. Boundaries

The boundary will be created on

This option enables you to choose a faces geometry to generate a silhouette

boundary. SolidCAM enables you either to choose an already existing Faces
geometry from the list or define a new one with the Select button. The Select
Faces dialog box (see topic 5.4.6) will be displayed. The Show button displays the
selected face geometry.
Min. diameter

This value defines the spanning of the boundary, the distance between
two points on either side. Boundaries that have a diameter smaller than
this are discarded.
Aperture

This value defines the fuzziness of the Silhouette. Decrease the value
to bring it into sharper focus; increase it to close up unwanted gaps
between boundaries.
Resolution

This value defines the granularity of the calculation: a small value

results in a more detailed boundary, but it is slower to calculate.

When the geometry for the silhouette boundary generation is defined, click on
the button. The boundary chains will be generated and the Select chain dialog
box (see topic 5.4.7) will be displayed.

77
5.4.3 User-defined boundary

SolidCAM enables you to define a user-defined boundary based on a Working area

geometry (closed loop of model edges as well as sketch entities).

For more information on Working area geometry, refer to the SolidCAM Milling
User Guide book.

SolidCAM automatically projects the selected geometry on the XY-plane and

defines the 2D boundary.

The Geometry Edit dialog box enables you to define the geometry.

78
 5. Boundaries

5.4.4 Profile Geometry

SolidCAM enables you to define a user-defined boundary based on a Profile

geometry. All the HSM strategies enable you to use closed profile geometries. The
Boundary machining strategy (see topic 2.12) enables you to use also open profiles
for the boundary definition; this feature is useful for single-contour text engraving
or for chamfering.

For more information on Profile geometry, refer to the SolidCAM Milling User
Guide book.

SolidCAM automatically projects the selected geometry on the XY-plane and

defines the 2D boundary.

The Geometry Edit dialog box enables you to define the geometry.

79
5.4.5 Combined boundary

This option enables you to define the boundary by performing a number of

boolean operations between working area geometries and boundaries.

The Boolean Operations dialog box is displayed.

Coordinate System

This field enables you to choose the Coordinate System where the source geometries
for the boolean operation are located. The resulting combined geometry will be
created in the chosen coordinate system.

Configurations

This field enables you to choose the SolidWorks configuration where the source
user-defined geometries for the boolean operation are located.

80
 5. Boundaries

Operation type

This field enables you to define the type of the boolean operation. The following
boolean operations are available:
Unite

This option enables you to unite Source geometries

selected geometries into a single one.
All internal segments are removed;
the resulting geometry is outer
profile.

Geometry 1 Geometry 2

Resulting geometry

Merge
Source geometries

This option enables you to merge a

number of geometries, created by
different methods, into a single one.

Geometry 1 Geometry 2

Resulting geometry

Geometry 3

81
 Subtract Source geometries

This option enables you to perform

subtraction of two geometries. The
order of the geometry selection
is important; the second selected
geometry is subtracted from the first Geometry 1 Geometry 2
selected one.
Resulting geometry

Intersect
Source geometries

This option enables you to perform

intersection of two geometries.

The Accept button performs the chosen

operation with the geometries chosen in the
Geometries section. Geometry 1 Geometry 2

Resulting geometry
Geometries

The Geometries section displays all the available

working area geometries classified by the
definition method.

This section enables you to choose the appropriate

geometries for the boolean operation. Select the check
box near the geometry name in order to choose it for the
boolean operation.

82
 5. Boundaries

When you click on the Accept button, the resulting

geometry is displayed in the list under the Combined
2D header. SolidCAM enables you to edit the name of
the created geometry. The newly created geometry is
automatically chosen for the further boolean operation.

The resulting combined geometry is always

a 2D geometry even if one or more of the
input geometries is a 3D boundary.

The right-click menu available on the list items enables you to perform the
following operations:

• Accept. This button enables you to perform the chosen boolean

operation with the selected geometries.

• Unselect All. This option unselects all the chosen geometries.

• Delete. This option enables you to delete combined geometries generated

in the current session of the Boolean Geometries dialog box.

83
5.4.6 Select Faces dialog box

This dialog box enables you to select one or several faces of the SolidWorks model.
The selected Face tags will be displayed in the dialog box.

If you have chosen wrong entities, use the Unselect

option to undo your selection. You can also right-click
on the entity name (the object will be highlighted) and
choose the Unselect option from the menu.

The Reverse/Reverse all option enables you to change

the direction of the normal vectors of the selected faces.

The CAD Selection option enables you to select faces

with the SolidWorks tools.

84
 5. Boundaries

5.4.7 Select Chain dialog box

Depending on the boundary type, SolidCAM generates a number of chains for

the selected faces. The Select Chain dialog box enables you to select the chains for
the boundary.

85
5.5 3D manually created boundaries

5.5.1 Common parameters

The boundary will be created on

• Selected faces. This option enables you to

choose a faces geometry to generate a boundary
of the defined type. SolidCAM enables you
either to choose an already existing Faces
geometry from the list or define a new one with
the Select button. The Select Faces dialog box
(see topic 5.4.6) will be displayed. The Show
button displays the selected face geometry.

• Whole model. With this option, SolidCAM

generates boundaries of the chosen type for all
the model faces.

Limits
• Z Limits

Set the machining range along the Z-axis

by definition of upper and lower limits.
Boundaries will be generated within this range.

• Angle

Set the contact angle range of your tool by setting the minimum and
maximum contact angle. Boundaries will be generated around areas
where the angle is within that range. For Shallow Area boundaries (see
topic 5.5.3), the range should typically be between 0 and 30 degrees,
but where surfaces are very close to the minimum or maximum angle,
you may get an undesirably jagged edge so you may want to alter the
range slightly. Alternatively, you can sometimes prevent formation of
jagged edges by giving the boundary a small offset.

86
 5. Boundaries

• Contact Areas Only

This option should be selected to choose only boundaries that are in

contact with the model surface.

Boundaries

• Wall offset

This value defines the distance at which the boundaries and therefore
the tool will be away from the surface, similar to the Wall offset
parameter on the Passes page (see topic 6.1.1).

For roughing and semi-finishing operations, this value must be greater

than zero. The calculations are based on a modified tool, the surface of
which is offset to be larger than the actual tool. This will leave material
on the part.

For finishing operations, the value must be set to zero. The calculations
are based on the dimensions of the defined tool with no offset.

In special circumstances, such as producing electrodes with a spark

gap, this value can be smaller than zero. The tool will remove material
at a level below the designated surface. The calculations are based on a
modified tool, offset smaller than the one used.

• Floor offset

This value defines the distance away from the surface at which the
boundaries will be in the tool axis direction.
The boundary is calculated using the Wall offset. The resulting
boundary is updated by offsetting along the tool axis by a distance
equal to the Floor offset.

• Min Diameter

This value defines the spanning of the boundary, the distance between
two points on either side. Boundaries that have a diameter smaller than
this are discarded.

87
 • Offset

The boundaries are calculated and then offset by this amount.

It may be advantageous sometimes to set a small offset value to prevent
jagged boundary edges where surface area is at angle similar to the
Contact Angle.

In Rest areas (see topic 5.5.6) with no offset, the exact boundary area
would be machined, resulting in marks or even cusps around the edge.
For Theoretical rest areas (see topic 5.5.4), the boundaries are offset
outwards along the surface by this amount after they have been made;
a good surface finish is ensured at the edges of the rest areas. Without
offsetting, the exact Theoretical rest area would be machined, probably
leaving marks or even cusps (of just under the minimum material depth
value) around the edge. The offsetting makes the boundaries smoother,
so a tool path made using them is less jagged.

• Resolution

This value defines the granularity of the calculation. A small value

results in a more detailed boundary but it will be slower to calculate.

88
 5. Boundaries

5.5.2 Selected faces

This option enables you to define the boundary by selecting drive and check faces
similar to the Working area definition for 3D Milling operations.

Under Boundary name, click on the Define button to start the boundary definition.
The Selected faces dialog box enables you to define the drive and check faces.

Name

This section enables you to define the boundary name and the tolerance that is
used for the boundary creation.

89
Drive faces

This section enables you to define Drive faces – the set of faces to be milled.
The tool path is generated only for machining of these faces. The Define button
displays the Select Faces dialog box used for the faces selection. The Offset edit
box enables you to define the offset for the Drive faces. When the offset is defined,
the machining is performed at the specified offset from the Drive faces.
Check face
Drive face
Drive faces offset

Check faces

This section enables you to define Check faces – the set of faces to be avoided
during the generation of the tool path. The Define button displays the Select
Faces dialog box used for the faces selection. The Offset edit box enables you to
define the offset for the Check faces. When the offset is defined, the machining is
performed at the specified offset from the Check faces.
Check faces offset
Check face

Drive face

90
 5. Boundaries

5.5.3 Shallow Areas

With this option, SolidCAM enables you to automatically determine shallow areas
in the model and define boundaries around them.

The tool has to be chosen for the operation

before the shallow areas boundary
definition.

The Select faces dialog box enables you to choose the

necessary model faces. When the faces are chosen and
the dialog box is confirmed, the Shallow Areas dialog
box is displayed.

This dialog box enables you to define a number of

parameters for the shallow areas boundary generation.

91
5.5.4 Theoretical Rest Areas

You can create 3D boundaries from rest areas left by an imaginary reference tool.
This gives good results when used for semi-finish and finish machining operations.
You can then use these boundaries to limit another SolidCAM HSM operation
performed with a tool of an equal or smaller size.

The Select faces dialog box enables you to choose the

necessary model faces. When the faces are chosen and
the dialog box is confirmed, the Theoretical Rest Areas
dialog box is displayed.

This dialog box enables you to define a number

of parameters for the theoretical rest material areas
generation.

Limits
Include Corner Fillets

In corner area, the angle is degenerate. Use

this option to include or exclude all corner
areas from the rest area boundaries.

92
 5. Boundaries

Min material depth

The smallest amount of material to be found in areas included in the

rest area boundary prior to rest machining. If the reference tool left
parts of the material with less than this amount, those material areas
would not be included in the rest area boundaries.
The Min material depth should be greater than the cusp height left by
the passes of the imaginary reference tool path. If the Min material
depth is smaller than the cusp height left by the passes of the imaginary
reference tool path the whole area machined by the reference tool will
be included in the rest area boundary.

Reference Tool

This section enables you to specify the tool with which the Theoretical Rest Areas
will be calculated. This tool is usually larger than the tool that will be used to cut
the rest areas. The reference tool is used to represent an imaginary tool path, and
the rest areas are created assuming that the tool path had been created.
Define the size of the tool by inserting values into the Tool Diameter and Corner
Radius fields.

5.5.5 Tool Contact Area

Tool Contact Area detection enables you to create 3D boundaries around areas
where the tool is in contact with the selected surface or surfaces.

Tool Contact Area

boundaries do not
work on vertical or
near-vertical surfaces.
The steepest angle you
should use for best
results is 80 degrees.

93
The surface has to be selected as shown below.

If a Tool Contact Area boundary is created from this selection, there will be offset
from the edges where the selected surface is adjacent to another surface. The tool
can only reach the edges where there are no other surfaces to hinder its movement.

The Select faces dialog box enables you to choose the

necessary model faces. When the faces are chosen and
the dialog box is confirmed, the Tool Contact Areas
dialog box is displayed.

This dialog box enables you to define the parameters for

the boundary calculation.

Boundaries

• Overthickness

This option is available only for Tool Contact

Area boundaries. Overthickness is an extra
offset that can be applied to the tool in
addition to the set Wall offset when you
wish to calculate with a tool slightly larger
than the one you intended to use, to create
smooth filleted edges.

94
 5. Boundaries

• Constrain

This option enables you to limit the tool motion in two ways:

• Center Point

The point of contact between the tool and the surfaces always lies
within the boundary.

• Contact Point

The edge of the tool always lies within the boundary.

95
5.5.6 Rest Areas

This option enables you to define rest material left unmachined after any machining
strategy to create 3D boundaries. You can then use these boundaries to limit the
operation tool path, made with a tool of an equal or smaller size to these specific
areas.

The Select faces dialog box enables you to choose the

necessary model faces. When the faces are chosen and
the dialog box is confirmed, the Rest Areas dialog box
is displayed.

This dialog box enables you to define the parameters for

the rest areas calculation.

Previous operations

SolidCAM enables you to choose any previous HSM

operation for the Rest areas calculation.

Min Material

This value defines the granularity of the calculation. A

small value results in a more detailed boundary but it will
be slower to calculate.

96
Passes
6
The Passes page enables you to define the technological parameters needed to
generate the tool path for the SolidCAM HSM operation.

Common Parameters

The Passes parameters for the various machining strategies vary

slightly, but most of them are the same. The following section is a
general overview of the common parameters for all the SolidCAM
HSM strategies.
• Passes parameters

• Smoothing parameters

• Adaptive step down parameters

• Edit Passes parameters

• Axial offset

98
 6. Passes

6.1 Passes parameters

The Passes tab displays the major parameters that affect the generation of tool
path passes.

• Wall offset

• Floor offset

• Tolerance

• Step down

• Step over

• Pass Extension

• Offsets

• Limits

• Point reduction

99
6.1.1 Wall offset Wall
offset
This option enables you modify the tool diameter.
The machining is performed using the modified
tool.

Positive value

The tool is moved away from the machining surface

by the defined value. The offset is left unmachined
on the surfaces. Generally, positive values are used
for roughing and semi-finishing operations to leave
an allowance for further finishing operations.

No offset

The tool with the specified diameter is used for the

tool path calculation. The machining is performed
directly on the model surfaces. Generally, zero
offset is used for finishing operations.

Negative value

The tool is moved deeper into the material penetrating Wall

the machining surface by the specified value. offset

This option is used in special circumstances, such

as producing electrodes with a spark gap. The tool
will remove material at a level below the designated
surface. The calculations are based on a modified tool
smaller than the one used.

Since the calculations for negative values

are based on a modified tool which is
smaller than the one used, the offset
must be equal to or smaller than the

100
 6. Passes

corner radius of the tool. Where the

offset is greater than the corner radius
of the tool, surfaces at angles near to 45°
are unfavorably affected as the corner of
the tool impacts on the machined surface, 1 mm
since the offset at the corners is in fact
greater than the value set (see image).
Surfaces that are horizontal or vertical are
not affected. ~1.4 mm

If a negative value (e.g. –1 mm) is applied to a tool without corner

radius, the real offset at the corners of the tool will be considerably
greater than 1 mm (–1.4 mm appx.). This is obviously incorrect. If
you want to simulate a negative offset with a slot mill, start by defining
a bull-nosed tool with the corner radius equal to the negative value
of the offset – corner radius of 1 mm is used with negative offset of
–1 mm.

If you define an end mill, the offset will be greater than the value set
on surfaces nearing 45 degrees.

101
 Using a bull-nosed tool with a positive corner radius equal to the
desired negative offset, you will achieve better and more accurate
results.

6.1.2 Floor offset

This offset is applied to the tool and has the

effect of lifting (positive value) or dropping
(negative value) the tool along the tool axis.
As a result, Floor offset has its greatest effect
on horizontal surfaces and no effect on
vertical surfaces. By default, this value is equal
to that of Wall offset (see topic 6.1.1). Floor
offset
The tool path is calculated taking into account
the tool plus Wall offset. The resulting tool
path is calculated by offsetting along the tool
axis by the distance equal to the specified
Floor offset value.

102
 6. Passes

6.1.3 Tolerance

All machining operations have a tolerance, which is the accuracy of the calculation.
The smaller is the value, the more accurate is the tool path.

Surface

Cut with high tolerance

Cut with low tolerance

The tolerance is the maximum amount that the tool can deviate from the surface.

6.1.4 Step down

The Step down parameter defines the spacing of the passes along the tool axis.
This parameter is different from Adaptive Step down (see topic 6.3), which adjusts
the passes to get the best fit to the edges of a surface. The passes are spaced at the
distance set, regardless of the XY-value of each position (unless the Adaptive step
down check box is selected).
Step down

This parameter is available for Rough machining and the Constant Z

finishing strategy.

103
6.1.5 Step over

Step over is the distance between two adjacent passes. For all the strategies, Step
over is measured in the XY-plane, but for the 3D Constant step over strategy (see
topic 2.14), Step over is measured along the surface.

Step over

This parameter is available for Linear machining, Radial machining,

Spiral machining, Morphed machining, 3D Constant step over and
Hatch roughing.

104
 6. Passes

6.1.6 Pass Extension

This option enables you to extend the tool path beyond the boundary to enable
the tool movement into the cut with machining feed rather than rapid feed.

The Linear tool path shown below is created with the zero pass extension:

The Linear tool path shown below is created with 5 mm pass extension:

The Pass Extension parameter is available for Linear machining and

Radial machining strategies.

105
6.1.7 Offsets

Each Z-level comprises a "surface profile" and a series of concentric offset profiles.
The minimum and maximum offset values define the range of the size of spaces
between the passes. SolidCAM will choose the largest value possible within that
range that does not leave unwanted upstands between the passes.

Offset

A set of Contour Roughing passes, for example, is created from a series of offset
profiles. If each profile is offset by no more than the tool radius then the whole
area will be cleared. In certain cases where the profile is very smooth it is possible
to offset the profiles by up to the tool diameter and still clear the area. Obviously,
offsetting by more than the tool diameter will leave many upstands between the
passes. Between these two extremes, the radius and the diameter, there is an ideal
offset where the area will be cleared leaving no upstands. SolidCAM uses an
advanced algorithm to find this ideal offset.

The Min. Offset value should be greater than the Offset tolerance (see topic 6.2.3)
parameter and smaller than the tool shaft radius; the Max. Offset value is calculated
automatically.

This parameter is used for Contour Roughing, Hatch roughing and

Horizontal finishing.

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 6. Passes

6.1.8 Limits

The limits are the highest and lowest Z-positions

for the tool – the range in which it can move.
• Z-Bottom limit. This parameter enables
you to define the lower Z-level of
the machining. The default value is
automatically set at the lowest point of
the model.
This limit is used to limit the passes to level ranges or to prevent the tool
from falling indefinitely if it moved off the edges of the model surface.
When the tool moves off the surface, it continues at the Z-Bottom limit
and falls no further.

• Z-Top limit. This parameter defines the upper machining level. The default
value is automatically determined at the highest point of the model.

• CoAngle. This parameter defines the contact angle alignment to be used

when making cross machining passes.

This option is available only for the Linear finishing strategy.

• Angle. SolidCAM enables you to limit the surface angles within a range
most appropriate to the strategy. The Constant Z strategy, for example,
is most effective on steeper surfaces, because the spaces between the
passes are calculated according to the Step down value, and on surfaces
where there is little Z-level change, the spaces between the passes are
greater, therefore you may get unsatisfactory results. You can limit the
work area to surface angles between, for example, 30 and 90 degrees.
The angle is measured between the two normals
at the contact points between the tool and model
faces. The angle of 0 means coincidence of surface
normal and tool axis (horizontal surface).

This option is available for the Constant Z, Linear, Radial,

Spiral, Morphed, Boundary, 3D Constant Step over, and Pencil
milling strategies.

107
 Contact Areas Only

When this check box is selected, the tool path is only created where
the tool is in contact with model faces. The examples below show the
result of Constant Z strategy with and without the Contact Areas Only
option.

When this check box is selected, the machining is limited to the actual
surfaces of your geometry.

When this check box is not selected, the outer edge of the base surface
is machined as well as the central boss.

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 6. Passes

6.1.9 Point reduction

SolidCAM enables you to optimize the tool path by reducing the number of points.

The Fit arcs option enables you to activate the fitting of arcs to the machining
passes according to the specified Tolerance value.

The Tolerance value is the chordal deviation to be used for point reduction and
arc fitting.

109
6.2 Smoothing parameters

The Smoothing option enables you

to round the tool path corners. This
option enables the tool to maintain
a higher feed rate and reduces wear
on the tool. This feature is often
used in rough machining.

Tool path without smoothing

Tool path with smoothing

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 6. Passes

6.2.1 Max. radius

A curve can be approximated as an arc. The Max. radius parameter defines the
maximum arc radius allowed.

6.2.2 Profile Tolerance

This value is the maximum distance that the smoothed outer profile will diverge
from the actual profile. Set the Profile tolerance to a low or zero value to reduce
the amount of material missed.

6.2.3 Offset Tolerance

This value is the maximum distance that the smoothed profile offset will diverge
from the inner (offset) profiles. This parameter is identical to the Profile Tolerance,
except that it refers only to the inner (offset) profiles and not to the outer profile.
The Offset Tolerance is measured between any given smoothed profile (excluding
the outermost one) and the sharp corner of an imaginary profile drawn without
smoothing, but at the same offset as the smoothed one.

Unlike the Profile Tolerance parameter, above, changing this value does not mean
you miss material.
Profile
tolerance
Original Smoothed
tool path tool path

Offset
tolerance

111
6.3 Adaptive step down parameters

• In areas where the horizontal distance between the passes is significant,

Adaptive Step down can be used to insert extra passes and reduce the
horizontal distance.

• In areas where the passes on the topmost edges of a surface would fall too
close or too far away from that edge, Adaptive Step down will add extra
passes to compensate. So the Step down value controls the maximum
Z-distance between the passes for the entire surface, while Adaptive Step
down adjusts those values for best fitting the surfaces.

Adaptive step down

passes

Adaptive step down is not chosen Adaptive step down is chosen

112
 6. Passes

If passes are applied without Adaptive Step down, some material may be left on
the top faces. In passes generated with the Adaptive Step down option, a pass is
inserted to cut the top face; the next step down will be calculated from this pass.
Minimum Step down

This parameter specifies the minimum step down value to be used,

which means that passes will be no less than this distance from each
other.

Precision

This parameter controls how accurately the system finds the appropriate
height to insert a new slice.

Profile Step in

This parameter defines the maximal XY-distance between cutting

profiles located on two successive Z-levels. When SolidCAM calculates
the cutting profile at a given Z-level, the distance to the cutting profile
on the previous Z-level is calculated. If the calculated value is greater
than the defined Profile Step in, SolidCAM inserts an additional Z-level
and calculates the cutting profile in such way that the distance between
cutting profiles located on two successive Z-levels will be smaller than
the specified Profile Step in value.
Large cusp Small cusps

Inserted
Z-level

Without Profile step in With Profile step in

113
 Scallop

The cusp that remains after the machining can be defined either by
combination of the Min. Step down and Profile step in parameters
or by combination of the Min. Step down and Scallop parameters.
Therefore, the Profile step in and Scallop parameters are mutually
exclusive.
Profile step in Cusp

Min. step down

Machined surface

Cusp

Machined surface
Scallop

When the combination of the Scallop and Min. Step down parameters
is used for the operation definition, SolidCAM performs the parameters
validation according to the criteria below.

• The Scallop value must be positive;

• The Scallop value must be smaller than that of the Min. Step
down parameter.

114
 6. Passes

If the Scallop parameter does not match the validation criteria, the Error Parameters
dialog box is displayed during the operation calculation. This dialog box specifies
the parameters defined incorrectly and prompts you to edit these parameters
definition.

115
6.4 Edit Passes parameters

If you start the machining with a formed stock instead of a rectangular or

cylindrical block of material, you could trim the passes to the formed stock faces
to avoid unnecessary air cutting. The tool path trimming is used either when you
use a casting as stock for the part machining or you use the updated stock resulting
from a number of previous operations.

For example, suppose you want to machine (using Contour roughing) the following
model:

Using the Contour roughing

strategy you get the following
tool path.

116
 6. Passes

Rather than starting from a cylindrical block of material, you start with the casting
shown below.

The resulting trimmed tool path is shown below.

117
The Edit passes page enables you to define the parameters for the trimming of
passes.

Edit using surfaces

By selecting this check box, you can limit the machining by using the Updated
Stock model or by defining an offset from the operation geometry.

Stock surfaces

This option enables you to specify the method of machining area

definition.

• When the Updated stock option is chosen, SolidCAM calculates

the Updated Stock model after all the previous operations.
SolidCAM automatically compares the updated stock model
with the operation target geometry and machines the difference
between them.

• When the Main geometry option is chosen, the machining is

performed in the area defined by an offset from the operation
geometry. The offset is defined by the Overthickness parameter.

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 6. Passes

Mach. stock name

This option enables you to choose the previously generated Updated

Stock model for the tool path calculation.

This option is available only in the following cases:

• When Stock surfaces is set to Updated stock;
• When the Manual method of the Updated Stock model
calculation is used.

Show

This button displays the difference between the updated stock model
and the target geometry used in the operation.

Overthickness

This parameter defines an extra thickness that can be temporarily

applied to the tool and can be set when editing passes. The use of
this parameter can help to create better trimmed passes. A negative
value will cause the system to select only passes that are below the
model faces by the specified amount, while a positive value will select
all passes that are within the specified distance from the model faces.

Resolution

This parameter defines the granularity of the calculation: the smaller

the value, the finer the detail, but the calculation is slower. Using a
larger resolution, you can decrease detection time, but this may lead to
very small features being missed.
The system will search along the tool path, examining appropriate
points along the tool path and recording whether that position is
above or below the surfaces. The current and previous positions are
compared and if they are different (i.e. one above and one below)
then the tolerance is used to locate the precise position of the change
between above and below. This information is used to trim the tool
path.

119
 The system will check points along a tool path where the direction
changes, but long and straight passes are supplemented by extra points.
The resolution is used to determine the distance between these points.

Tolerance

This parameter defines the maximum amount that the tool can move,
either above or below the surface. All machining operations have a
tolerance, the smaller the value, the more accurate the calculation.

Pass extension

This parameter defines the pass extension length. The trimmed passes
will be extended in each direction by this value; this enables the tool to
move into the cut at machining feed rather than rapid.

Join gaps of

Passes that lie along the same line and are separated by less than the
amount specified will be joined to create a single pass.

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 6. Passes

6.5 Axial offset

This page enables you to axially offset the tool path (one or several times). The tool
path can be generated by any of the HSM finish strategies, except for Constant Z
and Rest machining.
When the Axial offset check box is selected, you have to define the following
parameters:

• Axial offset

This parameter defines the distance between two successive tool path
passes.

• Number of offsets

This parameter enables you to define how many times the offset of the
tool path is performed. This final number of tool path passes is equal
to Number of offsets +1.
Tool path Axial offset

Number of offsets = 3

121
The tool path passes are generated in the positive Z-direction. The machining is
performed from the upper instance to the lower.

The Axial offset feature enables you to perform the semi-finish and finish
machining in a number of equidistant vertical steps. It can be used for engraving in
a number of vertical steps with the Boundary Machining strategy or for removing
the machining allowance by a finishing strategy in a number of vertical steps.

122
 6. Passes

6.6 Analysis

The Analysis page enables you to perform the tool path checking for invalid arcs
and possible gouges.

When the Checker check box is selected, the tool path checking is performed. If
an error is found, creation of passes is stopped.

The Step distance parameter is used to specify the distance along the tool path
between the points where the gouge checking is performed.

123
6.7 Strategy parameters

In addition to the common parameters relevant for all of the machining strategies,
SolidCAM provides you with options and parameters that enable you to control
specific features of various machining strategies.
• Contour roughing

• Hatch roughing

• Rest roughing

• Constant Z machining

• Horizontal machining

• Linear machining

• Radial machining

• Helical machining

• Spiral machining

• Morphed machining

• Offset cutting

• Rest machining

• 3D Constant step over machining

• Pencil milling

• 3D Corner offset machining

• Parallel pencil milling

• 3D Corner offset machining

• Prismatic part machining

• Combined strategies

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 6. Passes

6.7.1 Contour roughing

With the Contour roughing strategy, SolidCAM generates a pocket-style tool path
for a set of sections generated at the Z-levels defined with the specified Step down
(see topic 6.1.4).

125
Detect core areas

This option causes the tool to start from the outside of the model rather than take
a full width cut in the center of the component.

If your model includes both core and cavity areas, the system will automatically
switch between core roughing and cavity roughing within the same tool path.

When these passes are linked to create a Contour roughing tool path, the areas are
machined from the top downwards. Obviously, material has to be machined at one
level before moving down to the next one.

The passes for the Z-Top level machining are not usually included in
the operation tool path. Adjust the Z-Top level by adding the Step
down value to the current Z-Top level value when you want to include
the top level passes in the operation tool path.

126
 6. Passes

6.7.2 Hatch roughing

With the Hatch roughing strategy, SolidCAM generates linear raster passes for
a set of sections generated at the Z-levels defined with the specified Step down
(see topic 6.1.4). Hatch roughing is generally used for older machine tools or softer
materials because the tool path predominantly consists of straight line sections.

127
Angle

This option enables you to define the angle of the hatch passes relative to the
X-axis of the current Coordinate System.

Z
Y

X
Angle

128
 6. Passes

Offset

The Offset parameter defines the distance between the hatch passes and the outer/
inner profiles.

Offset

129
6.7.3 Rest roughing

The Rest roughing strategy determines the areas where material remains unmachined
after the previous machining operations (the "rest" of the material) and generates
a tool path for the machining of these areas. The tool path is generated in the
Contour roughing (see topic 2.1) manner. Rest roughing operation uses a tool of
smaller diameter than that used in previous roughing operations.

The following image illustrates the hatch roughing tool path performed with an
End mill of Ø20.

After the hatch roughing, a Rest roughing operation is performed with an End mill
of Ø10. The tool path is generated in the contour roughing manner.

130
 6. Passes

Previous operations page

The Previous operations page of the SolidCAM HSM Operation dialog box enables
you to choose the previous SolidCAM HSM operations for the rest material
roughing calculation.

The Previous operations list displays all the previously defined roughing HSM
operations available for the rest material calculation. Choose the necessary
operations by selecting the appropriate check boxes in the list.

• The Select all button enables you to select all the operations in the list
for the rest material roughing calculation.

• The Unselect all button enables you to unselect all the selected operations.

• The Invert select states button enables you to unselect the selected
operations and select the unselected ones.

131
6.7.4 Linear machining

Linear machining generates a tool path consisting of a set of parallel passes at

a given angle with the distance between the passes defined by the Step over
parameter (see topic 6.1.5).

With the Linear machining strategy,

SolidCAM generates a linear pattern of
passes, where each pass is oriented at a
direction defined with the Angle value.
This machining strategy is most effective
on shallow (nearly horizontal) surfaces,
or steeper surfaces inclined along the
passes direction. The Z-height of each
point along a raster pass is the same as
the Z-height of the triangulated surfaces,
with adjustments made for applied wall
offset and tool definition.

In the image, the passes are oriented along the X-axis. The passes are evenly
spaced on the shallow faces and on the faces inclined along the passes direction.
The passes on the side faces are widely spaced; Cross linear machining can be used
to finish these areas.

Angle

132
 6. Passes

The Angle parameter enables you to define the angle of the passes direction. The
value of this parameter is within the range of –180° to 180°. If Angle is set to 0°,
the direction of passes is parallel to the X-axis of the current Coordinate System.
The order of the passes and the direction of the machining is controlled by the
link settings.

The defined angle affects the step over calculation. If you are machining vertical
surfaces, Linear machining works best where the angle is perpendicular to these
surfaces.

Tangential extension

This option enables you to extend the passes tangentially to the model faces by a
length defined by the Pass extension parameter.

133
When the check box is not selected, the extension passes are generated as a
projection of the initial pattern (either linear or radial) on the solid model faces.
When the check box is selected, the extension passes are generated tangentially to
the solid model faces.
Extension

Extension

Extension

The check box The check box

is not selected is selected

Cross linear machining

SolidCAM automatically determines the areas where the Linear machining passes
are sparsely spaced and performs in these areas an additional Linear tool path in a
direction perpendicular to the direction of the initial Linear tool path. The passes
parameters used for the Cross linear machining definition are the same as those
used for the initial Linear machining.

Initial Linear machining tool path

134
 6. Passes

Cross linear machining tool path

Combined Linear and Cross linear machining tool path

135
 Cross page

The Cross page enables you to define the order of performing Linear
and Cross linear machining.

• None

Cross linear machining is not performed.

• Before

Cross linear machining is performed before the main

Linear machining.

• After

Cross linear machining is performed after the main Linear

machining.

• Only

Only Cross linear machining is performed; the main Linear

machining is not performed.

136
 6. Passes

6.7.5 Helical machining

This strategy enables you to generate a number of closed profile sections of

the 3D Model geometry located at different Z-levels, similar to the Constant Z
strategy. Then these sections are joined in a continuous descending ramp in order
to generate the Helical machining tool path.

The tool path generated with the Helical machining strategy is controlled by two
main parameters: Step down and Max. ramp angle.

137
Step down

This parameter defines the distance along the Z-axis between two successive
Z-levels, at which the geometry sections are generated. Since the Step down
is measured along the Z-axis (similar to the Constant Z strategy), the Helical
machining strategy is suitable for steep areas machining.

Max. ramp angle

This parameter defines the maximum angle (measured from horizontal) for
ramping. The descent angle of the ramping helix will be no greater than this value.

Max. ramp angle

Step down

138
 6. Passes

6.7.6 Radial machining

The Radial machining strategy enables you to generate a radial pattern of passes
rotated around a central point.

This machining strategy is most effective on areas that include shallow curved
surfaces and for model areas formed by revolution bodies, as the passes are spaced
along the XY-plane (Step over), and not the Z-plane (Step down). The Z-height
of each point along a radial pass is the same as the Z-height of the triangulated
surfaces, with adjustments made for applied offset and tool definition.

139
Step over Step over

Step over is the spacing between the

passes along the circumference of the
circle.

The passes are spaced according to the

Step over value measured along the circle
defined by the Maximum Radius value.

Center
Center point
You must specify the XY-position of
the center point of the radial pattern of
passes. The Radial passes will start or
end in this center point.

140
 6. Passes

Angle

The minimum and maximum angles enables you to define start and end of the
pattern passes. These parameters control the angle span of the operation, that is,
how much of a complete circle will be machined.
Max.
angle

Min.
angle

The angles are measured relative to the X-axis in the center point in the
counterclockwise direction.

Radii

The Min. radius and Max. radius values enable you to limit the tool path in the
radial direction.
Max. Radius

Min. Radius

The diagram above shows the effect of different minimum and maximum radii on
Radial passes.

You can define the radii by entering the values or by

clicking on the buttons and picking points on the model.
The X- and Y-coordinates of this point are displayed in
the Select a coordinate dialog box.

141
When this dialog box is confirmed, the radius value appears in the appropriate edit
box calculated as the distance from the defined center point of the radial pattern
of passes.

You can use the Min. radius value to protect the part faces from over-machining
in the central point and around it. Alternatively, you can define boundaries to limit
the machining.
Over-machining is visible in the center point:

The tool path is limited at the center point area using a boundary, or by increasing
the Min. radius value:

You can use another strategy (e.g. 3D Constant step over) to machine the central
area.

Tangential extension

This option enables you to extend the passes tangentially to the model faces by a
length defined by the Pass extension parameter (see topic 6.7.4).

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 6. Passes

6.7.7 Spiral machining

The Spiral machining strategy enables you to generate 3D spiral tool path over
your model. This strategy is optimal for model areas formed by revolution bodies.
The tool path is generated by projecting a planar spiral (located in the XY-plane of
the current Coordinate System) on the model.

143
Step over

The Step over parameter defines the distance between two adjacent spiral turns in
the XY-plane of the current Coordinate System.

Step over

144
 6. Passes

Center

You have to specify the XY-position of the center point of the spiral. The spiral
tool path is calculated from this point, even if it does not actually start from there
(minimum radius may be set to a larger value).
Center point

Radii

Define the area to be machined by the spiral by setting the minimum and maximum
Radii. If the spiral is to start from the center point, set the Minimum Radius value
to 0. When the spiral is to start further from the center, enter the distance from the
center point by setting the Minimum Radius to a higher value. Control the overall
size of your spiral with the Maximum Radius value.

Max. Radius

Min. Radius

You can define the radii by entering the values or by

clicking on the buttons and picking points on the model.
The X- and Y-coordinates of this point are displayed in
the Select a coordinate dialog box.

145
When this dialog box is confirmed, the radius value appears in the appropriate edit
box calculated as the distance from the defined center point of the spiral pattern
of passes.

Clockwise

This option enables you to define the direction of the spiral. When this check
box is selected, SolidCAM generates a spiral tool path in the clockwise direction.
When this check box is not selected, SolidCAM generates a spiral tool path in the
counterclockwise direction.

Clockwise direction Counterclockwise direction

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 6. Passes

6.7.8 Morphed machining

Morphed machining passes are generated across the model faces in a close-to-
parallel formation, rather like Linear machining passes (see topic 2.6); each path
repeats the shape of the previous one and takes on some characteristics of the
next one, and so the passes "morph" or gradually change shape from one side of
the patch to the other.

The shape and direction of the patch is defined by two drive boundary curves.

Drive boundary curves

147
Step over

This parameter defines the distance between each two adjacent passes and is
measured along the longest drive boundary curve; for the other drive boundary
curve the step over is calculated automatically. For best results, the two drive
boundaries should be as close in length as possible.

This machining strategy is most effective on areas that include shallow surfaces as
the passes are spaced along the XY-plane (Step over) and not the Z-plane (Step
down).

148
 6. Passes

6.7.9 Offset cutting

The Clear offset parameters enable you to define the offset distance used for the
virtual offset curve calculation.

SolidCAM enables you to define separate values for the Left clear offset and Right
Clear offset.
Tool path

Drive curve

Left clear offset

Right clear offset

149
6.7.10 Rest machining parameters

Rest machining determines the model areas where material remain after the
machining by a tool path, and generates a set of passes to machine these areas.

Pencil milling vertical corners

can cause both the flute of the
tool and the radius to be in full
contact with the material, creating
adverse cutting conditions. Rest
machining machines the corners
from the top down, resulting
in better machining technique.
Steep and shallow areas are both
machined in a single tool path,
with different Rest machining
strategies.

SolidCAM determines the rest material areas using a Reference tool

(the tool that is assumed to have already been used in the CAM-
Part machining) and a Target tool (the tool that is used for the Rest
machining). Both tools must be ball-nosed.

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 6. Passes

Bitangency angle

This parameter defines the minimum angle required between the two normals at
the contact points between the tool and model faces in order to perform the Rest
machining.

Bitangency angle

This value enables you to control the precision with which rest material areas are
found. Reducing the value will typically cause the system to find more areas due
to the triangle variations, however the most appropriate value will depend on the
geometry of the machined piece.

Steep threshold

This parameter enables you to specify the angle range at which SolidCAM splits
steep areas from shallow areas. The angle is measured from horizontal, so that 0°
represents a horizontal surface and 90° represents a vertical face.

Setting the value to 90° will mean that all areas in

this range will be treated as shallow and the passes
in the rest material areas will run along the corner.

151
Setting the value to 0° will mean that all areas in this
range will be treated as steep and the passes in the
rest material areas will run across the corner.

Setting the value to 45° will mean that areas where

the slope is between 0 and 45° will be treated as
shallow and the passes will run along the corner.
Areas where the slope is between 45 and 90° will
be treated as steep and the passes will run across
the corner.

Shallow strategy

This option enables you to choose the machining strategy to be used in shallow
areas (i.e. those below the Steep Threshold value). The following options are
available:

• Linear. This option enables you to perform links between passes using
straight line motions.

• Spiral. This option joins some passes using smooth curved paths. This
results in passes that are continuous, and reduces the use of linking
moves. The spiral linking move will cut across the corner, avoiding the
large volume of material that lies in the center of the rest area. Corner
areas may not be fully finished.

• Spiral on surface. This option links the passes with smooth curved paths
resulting in continuous passes and reducing the rapid moves. The spiral
linking move is projected into the rest corner up to the maximal depth
of the cut specified.

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 6. Passes

Min. depth of cut

This parameter specifies the minimum depth of material to be removed from the
areas to be machined. Areas in which the depth of material to be cut is smaller
than this will be ignored.

Min. depth of cut can also be useful in situations where a fillet radius
of the part is approximately equal to the radius of the reference tool,
i.e. places where, in theory, there is no material to be removed. If
unwanted passes are created in such areas, increasing the value of
Min. depth of cut may improve the situation.

Max. depth of cut

This parameter specifies the maximum depth of material that can be cut. Areas
in which the depth of material is greater than this value will be ignored. This
parameter is used to avoid situations where the cutter may otherwise attempt to
make deep cuts. This may result in some rest area material not being removed; by
creating further sets of Rest machining passes, using smaller reference tools, you
can clear such areas.

Areas

This option enables you to decide whether to perform

the machining in the steep areas only, in the shallow
areas only or in both of them.
• Shallow
The machining is performed only in the
shallow areas (the surface inclination is
smaller than the Steep threshold value).
• Steep
The machining is performed only in the steep areas (the surface
inclination is greater than the Steep threshold value).
• All
The machining is performed in both steep and shallow areas.

153
Stroke ordering

This option enables you to control how the passes are merged, in order to generate
better Rest machining passes. The available strategies are:
• None

Passes are not combined; uncut material might be left in corners where
several sets of passes converge.

• Planar

SolidCAM looks at the passes from the tool axis direction (from +Z)
and connects passes that have a direction change with an angle smaller
than the Max. deviation value.

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 6. Passes

• Angular
The system looks at the passes in 3D and connects passes that have a
direction change with an angle smaller than the Max. deviation value.

Max. deviation
When Rest machining passes approach a sharp change of direction,
they can be made continuous round the corner, or can be split into
separate segments. The value of Max. deviation is used to determine
whether the passes are split (if the angle of deviation of the passes
is larger than the Max. deviation value) or continuous (if the angle of
deviation of the passes is smaller than the Max. deviation value).

Reference tool page

This page enables you to define the reference tool used for the Rest machining
tool path calculation.
• The Diameter field defines
the diameter of the
reference tool.
• The Corner radius field
defines the corner radius of
the reference tool. Since the
reference tool is ball-nosed,
the corner radius is equal to
half of the reference tool
diameter.

155
6.7.11 3D Constant step over

3D Constant step over machining enables you generate 3D tool path on the CAM-
Part surfaces. The passes of the tool path are located at a constant distance from
each other, measured along the surface of the model.

This is an ideal strategy to use on

the boundaries generated by Rest
machining or in any case where
you want to ensure a constant
distance between passes along
the model faces.

Constant surface step over is Closed boundary

performed on a closed profile
of the Drive boundary (see topic
5.1.1). SolidCAM creates inward
offsets from this boundary.

156
 6. Passes

Step over

This parameter enables you to define the distance between cutting passes. In 3D
Constant step over machining, the Step over value is calculated in such a way that
all passes are equidistant along the surface.
Step over

157
The Horizontal and Vertical Step over parameters determine the distance between
passes. The two step over types relate to the direction in which the step over is
being measured. Where passes are offset horizontally, the Horizontal step over
distance is used while for passes that are offset vertically, the Vertical step over
distance is used. Where the step direction is neither vertical nor horizontal, the an
average of the two values is used.
Horizontal
Step over

Vertical
Step over

Limit Offsets number to

The Limit Offsets number to parameter enables you to limit the number of offsets
of a drive boundary profile. Select the Limit Offsets number to check box and set
the offsets number.

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 6. Passes

Adaptive variable side step

If the Adaptive variable side step check box is selected, the step over will be taken
from the horizontal plane only, that is, a 2D offset. With this option, only the
Horizontal Step over value is used, the Vertical Step over value is not relevant.

You can see from the illustration above that using this option on this model
creates only few passes on steep areas since the spacing is calculated only along the
horizontal plane; using this option is therefore not recommended for such models.

159
6.7.12 Pencil milling

The Pencil milling strategy creates a tool path along internal corners and fillets
with small radii, removing material that was not reached by previous machining.
This strategy is used to finish corners which might otherwise have cusp marks left
from previous machining operations. This strategy is useful for machining corners
where the fillet radius is the same or smaller than the tool radius.

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 6. Passes

Bitangency angle

This is the minimum angle required between the two normals at the contact points
between the tool and model faces, in order to decide to perform the pencil milling.

The default value of the

Bitangency angle parameter is
20°. Generally, with this value
SolidCAM detects all the corners
without fillets and with fillet radii
smaller than the tool radius. To
detect corners with fillets radii Bitangency angle

greater than the tool radius you

can either use the Overthickness
parameter or decrease the
Bitangency angle value. Note
that decreasing the Bitangency
angle value can result in the
occurrence of unnecessary
passes.

Overthickness

This parameter enables you to define an extra thickness that can be temporarily
applied to the tool in addition to the normal Wall offset.

You can use the Overthickness parameter to generate a tool path along fillets whose
radius is greater than the tool radius. For example, if you have a filleted corner of
radius 8 mm and you want to create a Pencil milling tool path along it with the
10 mm diameter ball-nosed tool, you can set the Overthickness value to 4 mm.
The Pencil milling tool path is calculated for a ball-nosed tool with the diameter of
18 mm (which will detect this fillet), and then projected back onto the surface to
make a tool path for the 10 mm diameter tool.

Since this is an offset value, it is specified in exactly the same manner as other
offsets, except that it is added to the defined tool size, in addition to any surface
offset, during calculations.

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6.7.13 Parallel pencil milling

Parallel pencil milling is a combination of the Pencil milling strategy and the 3D
Constant step over strategy. At the first stage, SolidCAM generates a Pencil milling
tool path. Then, the generated pencil milling passes are used to create 3D Constant
step over passes; the passes are generated as a number of offsets on both sides
of the pencil milling passes. In other words, the Parallel pencil milling strategy
performs 3D Constant step over machining using Pencil milling passes as drive
curves to define the shape of passes.

This is particularly useful when the previous cutting tool has not been able to
machine all the internal corner radii to size. The multiple passes generated by this
strategy will machine from the outside in to the corner, creating a good surface
finish.

The order of passes machining is determined by the Order parameters

(see topic 7.1.2).

In this combined strategy, you define the Pencil milling parameters and the 3D
Constant step over parameters in two separate pages.

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 6. Passes

Pencil milling parameters

The Pencil passes page enables you to define the parameters of the Pencil milling
passes (see topic 6.7.12).

3D Constant step over parameters

The Passes page defines the parameters of the 3D Constant step over passes (see
topic 6.7.11).

163
6.7.14 3D Corner offset

The 3D Corner offset strategy is similar to the Parallel pencil milling strategy. This
strategy is also is a combination of Pencil milling strategy and 3D Constant step
over strategy. SolidCAM generates a Pencil milling tool path and uses it for the
3D Constant step over passes generation. These passes are generated as offsets
from the Pencil milling passes. In contrast to the Parallel pencil milling strategy, the
number of offsets is not defined by user, but determined automatically in such a
way that all the model inside a boundary will be machined.

The order of passes machining is determined by Order parameters

(see topic 7.1.2).

In this combined strategy you define the Pencil milling parameters and the 3D
Constant step over parametersin two separate pages.

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 6. Passes

Pencil milling parameters

The Pencil passes page enables you to define the parameters of the Pencil milling
passes (see topic 6.7.12).

3D Constant step over parameters

The Passes page defines the parameters of the 3D Constant step over passes (see
topic 6.7.11).

165
6.7.15 Prismatic Part machining parameters

The Prismatic Part machining strategy is designed especially for high-speed finishing
of prismatic parts. This strategy comprises the technology of the Constant Z and
3D Constant step over strategies by integrating these two strategies into one smart
functionality of prismatic part machining. The difference from the Combined
Constant Z with 3D Constant step over strategy is as follows: in the Combined
strategy, the subsequent strategies are performed successively one after the other.
In the Prismatic Part machining strategy, the machining is performed consistently
according to the order of the walls and flat faces along the Z-axis.

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 6. Passes

Step down

This parameter defines the height of the passes spacing along the tool axis in the
Constant Z finishing.

Step over

This parameter defines the distance between the adjacent tool passes measured
along the surface.

Offset type

This option enables you to define an offset between adjacent Constant Z passes.
When the Upper option is chosen, the upper Constant Z pass is offset and trimmed
to the lower Constant Z pass. When the Lower option is chosen, the lower Constant
Z pass is offset and trimmed to the upper Constant Z pass. When the Both option
is chosen, both passes are offset together.

167
6.7.16 Combined strategy parameters

Constant Z combined with Horizontal strategy

The Constant Z passes page defines the parameters of the Constant Z machining
strategy.

The Horizontal passes page defines the parameters of the Horizontal machining
strategy.

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 6. Passes

The following parameters defined on the Constant Z Passes page are automatically
assigned the same values on the Horizontal passes page:
• Wall offset (see topic 6.1.1);
• Floor offset (see topic 6.1.2);
• Tolerance (see topic 6.1.3);
• Limits (see topic 6.1.8);
• Smoothing parameters (see topic 6.2);
• Adaptive step down parameters (see topic 6.3);
• Edit passes parameters (see topic 6.4).

When these parameters are edited on the Constant Z passes page, their values
are updated automatically on the Horizontal passes page. But when edited on
the Horizontal passes pages, the values in the Constant Z passes page remain
unchanged.
Two Link pages located under the Constant Z passes and Horizontal passes pages
define the links relevant for each of these strategies.
On the Link page for Horizontal passes, there is the Machining order tab that
enables you to define the order in which the Constant Z and Horizontal machining
will be performed. The default option is Constant Z first.
When the tool has finished performing the passes of the first machining strategy,
it goes up to the Clearance level, then descends back to the machining surface to
continue with the next strategy.

169
Constant Z combined with Linear strategy

The Constant Z passes page defines the parameters of the Constant Z machining
strategy.

The Linear passes page defines the parameters of the Linear machining strategy.

170
 6. Passes

The following parameters defined on the Constant Z Passes page are automatically
assigned the same values on the Linear passes page:
• Wall offset (see topic 6.1.1);
• Floor offset (see topic 6.1.2);
• Tolerance (see topic 6.1.3);
• Limits (see topic 6.1.8);
• Smoothing parameters (see topic 6.2);
• Adaptive step down parameters (see topic 6.3);
• Edit passes parameters (see topic 6.4).

When these parameters are edited on the Constant Z passes page, their values are
updated automatically on the Linear passes page. But when edited on the Linear
passes page, the values in the Constant Z passes page remain unchanged.

Two Link pages located under the Constant Z passes and Linear passes pages
define the links relevant for each of these strategies.
On the Link page for Linear passes, there is the Machining order tab that enables
you to define the order in which the Constant Z and Linear machining will be
performed. The default option is Constant Z first.
When the tool has finished performing the passes of the first machining strategy,
it goes up to the Clearance level, then descends back to the machining surface to
continue with the next strategy.

171
Constant Z combined with 3D Constant Step over strategy

The Constant Z passes page defines the parameters of the Constant Z machining
strategy.

The Constant Step over passes page defines the parameters of the 3D Constant
Step over machining strategy.

172
 6. Passes

The following parameters defined on the Constant Z Passes page are automatically
assigned the same values on the Constant Step over passes page:
• Wall offset (see topic 6.1.1);
• Floor offset (see topic 6.1.2);
• Tolerance (see topic 6.1.3);
• Limits (see topic 6.1.8);
• Smoothing parameters (see topic 6.2);
• Adaptive step down parameters (see topic 6.3);
• Edit passes parameters (see topic 6.4).

When these parameters are edited on the Constant Z passes page, their values are
updated automatically on the Constant Step over page. But when edited on the
Linear passes page, the values in the Constant Z passes page remain unchanged.

Two Link pages located under the Constant Z passes and Constant Step over
passes pages define the links relevant for each of these strategies.

On the Link page for Constant Step over passes, there is the Machining order tab
that enables you to define the order in which the Constant Z and Constant Step
over machining will be performed. The default option is Constant Z first.

When the tool has finished performing the passes of the first machining strategy,
it goes up to the Clearance level, then descends back to the machining surface to
continue with the next strategy.

173
6.8 Calculation Speed

The tool path for three tool basic tool types (end mill, ball-nosed mill and bull-
nosed ill) is calculated with completely different machining algorithms. This means
that the calculation speed may be different for the same operation and geometry
with a different tool type. For example, using a bull-nosed tool with a smaller
corner radius will result in a longer calculation time.

The calculation speed depend also on the tolerance. When you set a tolerance
for a tool path, this defines the worst tolerance; the actual tolerance may, in some
circumstances, be significantly tighter. This is particularly true for the Contour
roughing and Constant Z machining operations when a bull-nosed tool with a small
corner radius is used; the results are often more accurate than required and the
calculation is slower.

When a positive Wall offset is defined, the machining algorithm is executed for
a tool with larger corner and shaft radii than the original one. When a small Wall
offset is applied to an end mill, the tool used for the machining algorithm is bull-
nosed with a small corner radius. This tool with applied Wall offset has different
algorithmic characteristics, as mentioned above, and the calculation time may
change.

The only other instance in which the tool type may change when applying a Wall
offset is when a negative Wall offset equal to or exceeding the corner radius is
applied to a bull-nosed tool. Then an end mill is used in the machining algorithm,
and a result may be produced much more quickly. However, there are instances
where applying a negative Wall offset which is significantly greater than the corner
radius does not produce satisfactory results, see note on Negative Wall offset.

174
Links
7
The Link page in the HSM Operation dialog box enables you to define the way how
the generated passes are linked together into a tool path.

In the image the link movements

are in green, the rapid movements
are in red and the machining
passes are in blue.

Following are the linking

parameters that can be defined
by the user:
• General parameters
• Ramping parameters
• Strategy parameters
• Retracts parameters
• Leads parameters
• Down/Up Mill parameters
• Refurbishment parameters
• Link Shaft Profile parameters

176
 7. Links

7.1 General Parameters

The General page enables you to set the general parameters of the tool path linking.

• Direction
• Order passes
• Retract
• Start Hint
• Minimize reverse linking
• Minimize full wide cuts
• Link by Z level
• Link per cluster
• Min. Profile Diameter
• Refurbishment
• Safety

177
7.1.1 Direction options

This parameters group enables you to define the direction of the machining.
Machining pass
One Way Linking pass

With this option, machining is performed

in one direction, but there is no guarantee
that this will be consistently climb or
conventional milling. It is up to you
to check the tool path and respond
by selecting the Reverse check box, if
needed, for the desired milling style.

A one way hatch path has many retractions; after the machining pass the tool has
to perform air movement to the start point of the next pass (shown in red).

• One way cutting with Radial

Machining strategy. The radial
arrows indicate the direction of the
passes themselves while the circular
arrow indicates the ordering of the
passes.

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 7. Links

• One way cutting with Spiral machining strategy.

The spiral pass is limited by a boundary. The
circular arrow indicates the direction of the
passes themselves while the radial arrow
indicates the ordering of the passes. Passes are
machined in the clockwise direction, moving
outwards.

• One way cutting with 3D Constant

Step over strategy. The passes are
limited by a boundary, with another
boundary inside it. The passes are
ordered in a one way direction
to perform climb milling. The
inner circular arrow indicates the
direction for the passes adjacent to
the inner boundaries.

The outer circular arrow

indicates the direction for outer
boundaries. In this example, most
machining passes are performed
in the counterclockwise direction,
working from the farthest offsets
outwards to the outer boundary,
then rapidly moving to machine
the farthest offset of the inner
boundary and working inwards
towards the inner boundary.

179
Reverse

The Reverse option results in the direction of passes being reversed.

The example below shows one-way radial passes with the reversed direction; the
passes will be climb milled.

The example below shows a reversed one way spiral passes.

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 7. Links

Bi-directional

With this option, each pass is machined in the opposite direction to the previous
pass. A short linking motion (shown in green) connects the two ends - this is often
called zigzag machining.
Machining pass
Linking pass

Both Climb milling and Conventional milling methods are used in the bi-directional
tool path.

Bi-directional milling

181
Bi-directional Radial machining:

Bi-directional Spiral machining:

Bi-directional 3D Constant Step over machining:

182
 7. Links

Down Mill/Up Mill

These options enables you to perform the machining downwards or upwards. Flat
pieces are machined in the direction defined by the Reverse parameter.

This option is available for strategies where the Z-level varies along
a pass. This option is not available for the Constant Z and Horizontal
strategies.

The Down/Up Mill page (see topic 7.6) enables you to define the parameters of the
down and up milling.

• Down Mill direction

• Up Mill direction

183
The image below shows the direction of the Radial Machining passes when the
Down/Up Mill options are used.

Down mill

Up mill

Climb/Conventional Milling

These options enables you to set the tool path direction in such a manner that the
climb/conventional milling will be performed.

Climb milling Conventional milling

These options are available for the Contour Roughing, Constant Z and
Horizontal strategies.

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 7. Links

Prefer climb milling

This option is available for the Pencil Milling strategy.

If this option is selected, the Pencil Milling passes will usually be climb milled. A
decision is made as to whether the material is mainly on the left or the right of the
tool as it goes along a pass. The direction is then chosen so that most material is
on the right.

When this option is not selected, the milling direction for all the passes is reversed,
so that they will probably be conventionally milled.

185
Direction for Hatch Roughing

Raster Passes

This section enables you to define the direction for the hatch (raster)
passes.
SolidCAM enables you to choose One way or Bi-directional direction
for the raster passes.
The Reverse order option enables you to reverse the order of the
hatch passes machining.

Initial order Reversed order

Profile Passes

This section enables you to define the direction for profile passes.
SolidCAM enables you to choose the Climb or Conventional direction
of the Profile passes.

186
 7. Links

Direction for Rest Machining

Steep regions

This section enables you to define the direction of the steep areas
machining.
SolidCAM enables you to choose the following options.
• Climb milling

• Conventional milling

• Bi-directional

187
7.1.2 Order passes

Some passes allow you to specify the direction of the pass ordering. When no
options are selected, the passes will be linked in an efficient way and so limit the
rapid travel between passes. Where several separate areas are machined, each area
will be machined to completion, before the machining of the next area is started.

The passes will be linked in the most efficient way. Below is shown a set of Linear
passes, linked in the default order (starting from the top left-hand corner) to
minimize the rapid travel between the passes.

Reverse order

This option enables you to reverse

the order of the tool path relative to
the default order.

Simple ordering

Passes will be linked in the order of

their creation. Parts of a specific pass
divided by a boundary will be linked
together with a rapid movement.
This option enables you to maintain
the order of the passes, but increases
the number of air movements.

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 7. Links

Order 3D Constant Step over passes

From first pass

When this option is turned off, the passes are machined from the
smallest of the outside boundary offsets to the outer boundary and
then from the largest offset of the internal boundary to the inside.

When this option is turned on, the machining is performed in the

reverse order. The machining starts from the internal boundary outside.
After that the machining is performed from the outer boundary inside.

If you reverse the order or the direction, conventional milling will be

performed. If you reverse both, climb milling will be performed again.

189
 Islands at same time

If the original boundaries have islands, SolidCAM will normally

machine inwards from the outer boundary, then outwards from the
island boundary.

With this option turned on, SolidCAM performs machining while

swapping between the outer and the island boundary offsets, ensuring
that each is never more than one pass ahead of the other.

Simple ordering

Passes will be linked in the order of their creation. Parts of a specific

pass divided by a boundary will be linked together with a rapid
movement. This option enables you to maintain the order of the
passes, but increases the number of air movements.

7.1.3 Retract

The image below shows a set of linked one way Hatch roughing passes along a flat
horizontal surface.

The tool path starts from the Start Hint

point that is set at the Safety distance level.
The rapid movements (shown in red) are
performed at the Clearance level and above
it. The tool moves along the green lines
towards, away from, or along the surface,
without cutting (link movements). The
blue lines show the tool path when cutting
is performed. The tool path finished in the
end point located at the Safety distance
level.

The Retract section enables you to define a

number of parameters of the start and end of
the tool path.

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 7. Links

Start from home point/Return to home point

These options enable SolidCAM to start/finish the operation tool path in the
specified home point. The XYZ boxes defines the location of this point.

Clearance level

This field defines the plane where the rapid movements of the operation (between
passes) will be performed. The default Clearance level value generally equals to a
value approximately 5% above the upper point of the model.

Safety distance

This field defines the distance to the Upper level at which the tool will start moving
at the Z feed rate you have entered for the tool. Movements from the Clearance
level to this height are performed in rapid mode.

7.1.4 Start hint

Enter the XY-coordinates of the starting position of the tool; the tool will move
to this position at the beginning of the tool path. The default value for the Start
hint is the center of your model. On larger models, where there is a great distance
from the center of the model and your current work area, you may want to change
these values. If there is more than one set of passes to be linked, the linking will
start with the passes closest to the start hint point.

191
7.1.5 Minimize reverse linking

This option will reduce the amount of reverse linking on the tool path. It will also
ensure that the tool cutting direction is maintained when linking passes.

If this option is chosen, the linking moves within a Z-level will be adjusted to
maintain climb or conventional milling.

If this option is not chosen, linking moves may conventionally mill even though
climb milling is maintained for the passes and vice versa.

This option is only available if the Detect Core areas option (see topic
6.7.1) of the Contour Roughing strategy is enabled.

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 7. Links

7.1.6 Minimize full wide cuts

This option will reduce full width cuts wherever possible. This is useful because
full width cuts (those which have equal width to the tool diameter) are not
recommended in most machining situations.

This option is only available if the Detect Core areas option (see topic
6.7.1) of the Contour Roughing strategy is enabled.

193
7.1.7 Link by Z-level

The Link by Z-level option enables you to perform all the passes at a specific
Z-level before moving to the next one. This will frequently result in occurrence of
air movements between different areas of the same Z-level.

1 2 1 5
3 4 2 6
5 6 3 7
7 8 4 8

Check box is selected Check box is not selected

By default the option is not chosen. It means that the passes are linked in such a
manner that each area is machined completely before moving to the next one.

This option is available for the Contour Roughing, Constant Z and

Horizontal strategies.

194
 7. Links

7.1.8 Link per cluster

When you link machining passes that are made up of several different clusters of
passes, in corners, for example, the Link per cluster option allows each corner to
be machined before the tool moves to another corner. If you do not select this
option, the machine may need to make a number of rapid feed rate moves to
connect the clusters of passes.

This option is available for the Contour Roughing, Hatch Roughing,

Rest Roughing and Horizontal strategies.

195
7.1.9 Min. Profile Diameter

The diameter of a profile is its "span", which is the largest distance between
two points of the profile. Any profile that is smaller than this value will not be
machined to avoid difficulties in ramping the tool into this space. The default
Min. profile diameter value is slightly smaller than that of the flat part of the end
mill tool (and zero for ball-nosed tools).

For example, if the set of surfaces has a hole about the size of the tool you want to
use, you will get a column of profiles that appear to "fall" through the hole down
to the lowest Z-level. If you do not want these profiles, you can use the Min. profile
diameter parameter.

This option is available for the Contour Roughing, Constant Z and

Horizontal strategies.

196
 7. Links

7.1.10 Refurbishment

Min. pass length

The Min. pass length parameter enables you to define the minimal
length of the pass that will be linked. Passes with length smaller than
this parameter will not be linked. This option enables you to avoid
the machining of extremely short passes and increases the machining
performance.

This option is available for the Constant Z Machining.

197
7.1.11 Safety

Max. stock thickness

The Max. stock thickness parameter enables you to control the order
of Constant Z machining of several cutting areas.

When the distance between cutting areas is smaller than the specified
Max. stock thickness value, the machining is ordered by cutting levels.
In this case SolidCAM machines all of these cutting areas at the specific
cutting level, and then moves down to the next level.

When the distance between cutting areas is greater than the specified
Max. stock thickness value, the machining is ordered by cutting areas.
In this case SolidCAM machines a specific cutting area at all of the
cutting levels, and then moves to the next cutting area.

This option is available for the Constant Z Machining.

198
 7. Links

7.2 Ramping Parameters

The Ramping page enables you to control the ramping aspects of the tool path.

Ramping is used when the tool moves from one machining level down to the next
one; the tool moves downwards into the material at an angle.

Ramp height offset

Angle

This page is available for the Contour Roughing, Hatch

Roughing, Rest Roughing and Horizontal strategies.

199
Max. ramp angle

The Ramp angle is calculated automatically and depends on the model geometry
and the tool type. The Max. ramp angle parameter enables you to limit this angle.

The dimensions and type of tool you are using and the power of your machine
tool will determine an appropriate ramp angle. The angle used on a profile will
often be shallower than this, as the ramp always steps forward by at least the shaft
radius of the tool.

If a profile is very small, then the angle used might have to be larger
than you specify. In this case you can avoid the machining of short
profiles with the Min. profile diameter (see topic 7.1.9) parameter
located in the General page.

Relative and absolute ramp height

SolidCAM enables you to define also the relative or absolute start position for the
ramp motion with the Ramp height offset/Ramp height parameter measured from
the Coordinate System origin.

200
 7. Links

• Relative height

With this option, the start position of the ramp motion for the upper
Constant Step over pass is defined relative to the first point of the pass
using the Ramp height offset parameter.
Ramp height offset

• Absolute height

With this option, the start position of the ramp motion is defined with
the absolute Ramp height value measured from the Coordinate System
origin.

Ramp height

CoordSys

These options are available only for the 3D Constant Step over
machining, when Helix and Profile ramping strategies are used.

201
Ramp height offset

This parameter defines the height used in the ramping motion to the first upper
profile. It ensures that the tool has fully slowed down from rapid speeds before
touching the material so that it enters the material at a ramping angle.

SolidCAM enables you to perform the ramp movement either with a profile, or
with a helix (spiral).

Profile ramping

The tool performs the downward movements to the specific Z-level around the
contour of the profile.

Min. profile diameter to ramp on

SolidCAM enables you to avoid ramp movements along small profiles,

as a very tight tool motion would counterbalance any advantages gained
by ramping for the smoothness of transition; by setting a minimum
profile diameter ("span") you will be able to ensure that small profiles
will not be ramped down to.

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 7. Links

Helix ramping

The tool performs the downward movements to the specific Z-level in a corkscrew
fashion, ensuring a smooth movement. Helix ramping also puts less load on the
tool than profile ramping.

Helix diameter

This is the diameter of the ramping helix. In cases where the profile
is too small for a helix ramp of this diameter, Profile ramping will be
used.

Plunge ramping

The tool performs the downward movements to the specific Z-level in a vertical
movement.

203
Use approach points

This section enables you to define the ramping by approach points in pre-drilled
holes. The centers of the holes are defined as approach points.

No tool path for a specific

area is generated, if the
approach point is defined
outside of the area.

Approach
points

204
 7. Links

To define the approach points, click on the Define button.

The Ramping Geometry Selection dialog box is displayed.
This dialog box enables you to define the approach points
by picking on the solid model.

The content of this dialog box is similar to

that of the Drill Geometry Selection dialog box
used for drilling geometry definition (for more
information, refer to SolidCAM Milling User
Guide).

Limit depth

This check box controls the maximum depth

at which the cutting in the current area will be
performed. When this check box is selected,
the Z-coordinate of the lowest approach point
defines the maximum depth at which the cutting
will be performed; the tool will not descend
lower than the Z-level of this point.
Approach point

Depth limit

205
7.3 Strategy Parameters

The Strategy page enables you to define the following parameters related to the
linking strategy.
• Stay on surface within

• Along surface

• Linking radius

• Link clearance

• Horizontal link clearance

• Trim to ramp advance

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 7. Links

7.3.1 Stay on surface within

The Stay on surface within parameter enables you

to control the way how the tool moves from the
end point of a pass to the start point of the next
one. When the distance between these points is
greater than the specified parameter value, the
tool movement is performed at the Clearance
plane, using rapid feed.

When the distance between the points is smaller than the parameter value, the tool
moves with cutting feed directly on the model face.

This option enables you to decrease the

number of air-movements between the passes
of the tool path.

To control the manner of the link movement

between passes, when the tool moves on
surface, use the Along surface option (see
topic 7.3.2).

207
7.3.2 Along surface

Links between passes when the tool moves on the surface can be:
• Straight line

When this option is active, a direct

connection is made on the surface in
a straight line.
• Spline

When this option is active, a spline

connection is made along the
surface. The movement is smooth;
there are no sharp corners so there
is little change of speed of the tool
throughout the length of the link.

These options are available for the Linear Machining, Spiral

Machining, Radial Machining, Boundary Machining and Pencil
Milling strategies.

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 7. Links

Ramp when possible with angle

The Ramp when possible with angle option

enables you to perform the connection along the
surface at the specified angle.
Ramp angle

Use Tangential Ramp

This option enables you to perform the angled link movements in

a smooth S-curve. With this option the transition between passes is
performed smoothly without sharp corners.
Ramp angle

209
 Trim to ramp advance

This option enables you generate a helical

style finish when linking Constant Z passes.

When this check box is selected, the Constant Z pass above which
a ramp linking movement is performed is trimmed by the length of
the ramping move. In such a way a helical style tool path is generated,
avoiding the unnecessary cutting moves at the already machined areas
and maintaining a constant tool load.
Constant Z passes Ramp movements

When this check box is not selected, the whole Constant Z passes are
linked with the ramp movements.
Constant Z passes Ramp movements

The Ramp when possible with angle option only has effect
on passes that consist of closed loops at different Z-heights,
such as Constant Z and 3D Constant Step over passes.

210
 7. Links

7.3.3 Linking radius

Using this parameter, SolidCAM enables you to generate S-shaped curves linking
the adjacent closed passes of the contour machining. The value defines the radius
of the link arc. If you set the Linking Radius to 0 or turn off Smoothing then a
simpler, straight-lined route will link each loop.
Linking radius

When the radius is set to zero, straight line link movements are performed.

These options are available for Contour roughing and Horizontal

Machining.

211
7.3.4 Link clearance

With this parameter, SolidCAM enables you to maintain a horizontal clearance

from the bounding profile when moving horizontally from one location to another.
The value defines the minimal distance from the bounding profile.

These options are available for the Contour roughing, Hatch roughing,
Rest roughing and Horizontal Machining.

212
 7. Links

7.3.5 Horizontal link clearance

When the Detect Core areas (see topic 6.7.1) option is used, the Horizontal link
clearance parameter defines the distance outside of the material to perform
plunging.

These options are available for the Contour roughing and Rest
roughing.

213
7.4 Retracts Parameters

This page enables you to control retract movements between passes of the tool
path.
• Style

• Clearance

• Smoothing

• Curls

214
 7. Links

7.4.1 Style

The Style options enables you to define the way how the retract movements are
performed between passes.

Shortest route

The tool performs a direct movement from one pass to another. SolidCAM
generates a curved retract movement trajectory. The minimum height of the
retract movement is controlled by the Clear surface by parameter, and the curve's
profile is controlled by the Smoothing and Curls parameters.

This style is chosen by default, as it creates the shortest retract movements.

However, some machine tools are unable to rapid effectively along a curved path;
in these cases you can choose one of the other two retract styles.

215
Minimal vertical retract

The tool moves vertically to the minimum Z-level where the safe rapid movement
can be performed, moves along this plane in a straight line and drops down
vertically to the start point of the ramp movement to the next pass. The minimum
height of the retract is controlled by the Clear surface by parameter.

Full vertical retract

The tool moves vertically up to the clearance plane, rapidly moves at this level in
a straight line, and drops down vertically to the start point of the ramp movement
to the next pass.

216
 7. Links

7.4.2 Clearance

The Clearance parameters apply both to the lead in and the lead out components
of retract motions.

Clear surface within

This option affects the tool path when the Shortest route style is chosen. It
specifies the distance the tool moves away from the surface with the cutting feed
rate, before the rapid movement starts.

The distance is measured from the end of the lead out arc to the point where the
tool is guaranteed to be clear of the surface.

Clear surface by

This is the minimum distance by which the tool will be clear of the surface during
its rapid linking motion. All points of the tool – on both the tip and the side have
to avoid the surface by this distance.

For Minimal vertical retract motions, the tool lifts up to a height that ensures
clearance.

Clear surface by

217
For Shortest route motions, the tool is lifted up above the surface to ensure the
clearance, then it performs rapid motion maintaining the Clear surface within
distance.
Clear surface by

This clearance is applied in addition to any wall offset that you have
already specified for the tool. In particular, with a negative wall offset,
the clearance is above the reduced surface and not the real surface –
so you should set this value higher to prevent the tool from gouging
the surface.

218
 7. Links

7.4.3 Smoothing

Radius Radius

SolidCAM enables to round sharp

corners of the retract motions
when the Shortest route option is
used by adding a vertical curve of a
defined radius. This makes the tool
movement smoother and enables
higher feed rates.

7.4.4 Curls

SolidCAM enables you to add arcs in the end if the

lead-out movements and in the beginning of the lead
in movements. The Curl over radius and Curl down
radius define the radii of these arcs.

Curl down radius

Curl over radius Rapid movement
Lead in movement
Lead out movement

Cutting pass

The Curls options affect the tool path when the linking style is
Shortest route.

219
7.5 Leads Parameters

The parameters located on this page enable you to control the lead in and lead out
motions.
• Fitting

• Trimming

• Vertical leads

• Horizontal leads

• Extensions

• Basic approaches

The Stay on surface within parameter located on the Strategy page

enables you to define the maximum distance between passes to stay
on the surface and when to perform a retract movement.

The style of the retract movement can be defined on the Retracts

page.

220
 7. Links

7.5.1 Fitting

You define here how the lead in and lead out arcs of the retract movements fit to
the machining pass.
Lead in/Lead out arc

Tool pass

Machine the whole pass

With this option the complete pass is machined. The arc can be applied at the end
of the pass, without trimming of the pass.

221
The arc can be inserted only if it can be done safely without gouging the part faces.
When the arc is conflicting with the model geometry, a straight vertical lead in/out
movement is performed.

Minimize trimming

This option enables you to perform the arc retract movement with minimal
possible trimming of the cutting tool pass. The retract pass is as close to the
surface as possible, maintaining a minimum distance from the surface to fit the arc
of the defined radius.

Fully trim pass

In cases where it is crucial to prevent over-machining, this is a good and cautious

strategy modification. The pass is trimmed back so the entire arc fits into it, but no
nearer than a full machine pass link would be.

Minimize trimming

Fully trim pass

222
 7. Links

7.5.2 Trimming

When a lead arc is added to a horizontal machining pass, the length of pass
trimmed off will be at most the radius of the arc. However, when adding an arc
to a steep finishing pass, the length of pass trimmed (trimming distance) will be
much greater.

Trimming
distance

Such trimming of the passes can result in the occurrence of large unmachined
areas. To avoid this, SolidCAM enables you to limit the trimming distance with the
Max. Trimming Distance parameter. If the trimming distance exceeds this value,
then no arc is used; the whole pass is machined, and a straight vertical motion is
added.

This option affects the path when the Lead fitting is Minimize trimming
or Fully trim pass.

223
7.5.3 Vertical leads

The Vertical leads parameters enable you to define the radius of the arcs located
in a vertical plane used to enter and leave the machining pass.
Rapid movement

Lead in radius

Lead out radius

Cutting pass

224
 7. Links

7.5.4 Horizontal Leads

SolidCAM enables you to perform Horizontal

lead in/out movements to provide you with
smooth entering/exiting from the material.

Using horizontal leads the tool path can be set up

so that the tool approaches and leaves machining
passes tangentially using helical moves. Note that
if the requested radius (Lead in or Lead out) is
too large, then the horizontal lead is omitted, and
only vertical leads are used.

Lead in/out radius

These parameters enable you to define the radius of the arcs, located in a horizontal
plane, used to enter and leave the machining pass.

Lead in
radius

Lead out
radius

225
Max. ramp angle

SolidCAM enables you to perform ramp down movements during the arc lead
in. The Max. Ramp angle parameter enables you to limit the maximum angle
(measured from the horizontal plane) for ramping.

Ramp height offset

The ramp height offset is an extra height used in the ramping motion down from a
top profile. It ensures that the tool has fully slowed down from rapid speeds before
touching the material, and that it enters the material smoothly at the ramping angle.

Ramp height
Ramp offset
angle

The Max. ramp angle and Ramp height offset parameters are available
for the Contour roughing, Hatch roughing, Rest roughing and Constant
Z strategies.

226
 7. Links

Lead out angle

SolidCAM enables you to perform inclined upwards movements during the arc
lead out. The Lead out angle parameter enables you to define the angle of inclined
lead out movement. The angle is measured from horizontal plane.

Lead out
angle

The Lead out angle parameter is available for the Contour roughing,
Hatch roughing, Rest roughing and Constant Z strategies.

7.5.5 Extensions

Ramp in extension

The ramp in height offset is an extra height used in the ramping motion
down from a top profile. It ensures that the tool has fully slowed down
from rapid speeds before touching the material so that it enters the
material smoothly at the ramping angle.

Ramp out extension

The ramp out height offset is an extra height used in the ramping
motion. It ensures that the tool speeds up to rapid speeds gradually.

227
7.5.6 Basic approaches

The Basic horizontal approaches check box enables

you to perform a separate lead in/lead out movement
for each Z-level pass in Constant Z machining. This
functionality is useful for smooth entrance into the
material from outside in semi-finish machining of
steep model areas.

When this check box is not selected, the tool enters the material according to
the defined approach/retreat parameters, and the Z-level passes are machined
successively one after the other without exits from the material.

When this check box is selected, the tool exits from the material after machining
of each Z-level pass and enters again on the next Z-level pass.

Basic horizontal approaches Basic horizontal approaches

check box is not selected check box is selected

• The Lead in angle parameter defines the angle between the tool approach
line and the line tangent to the Z-level pass in the start point of the
machining.

• The Lead out angle parameter defines the angle between the tool retreat
line and the line tangent to the Z-level pass in the end point of the
machining.

228
 7. Links

• The Linear extension parameter defines the length of the tool horizontal
approach line.

Lead out Lead in

angle angle

Linear extension

229
7.6 Down/Up Mill parameters

This page enables you to define the parameters of the Down/Up milling.

This page is available for all strategies but Contour roughing, Hatch
roughing, Rest roughing, Horizontal Machining and Constant Z
machining.

Unless Down/Up milling options are chosen on the General page, the
parameters on this page are disabled.

230
 7. Links

Pass overlap

When a pass is broken in order to perform down and up movements, each segment
can be extended, from the point where pass segments are connected, so that they
overlap. This ensures a smoother finish.

No Pass overlap

Pass overlap Passes connect point

Since both pass segments are extended by the Pass overlap value, the
actual length of overlap is twice the defined value.

231
Shallow angle

Model areas with the inclination angles less than the Shallow angle value are
considered as shallow. Such areas can be machined in either direction, as obviously
up or down milling is irrelevant, and in these areas the tool path will be less broken
up.

The image below illustrates the case when the inclination angles of the model
faces are greater than the defined Shallow angle value.

In the illustration below the Shallow angle value has been increased resulting in no
break up of the tool path.

232
 7. Links

Merge %

SolidCAM enables you to machine some segments of the tool path upwards where
downward movement is preferred, and vice versa, to avoid too much fragmentation.

The Merge % parameter defines the limit length of the opposite segments as
a relative percentage of the whole pass. When the percentage of the segments
length where the direction of the machining to be changed is less than the defined
value, the direction will not be changed.

Maintain milling direction

This option affects the ordering of Linear, Radial, Spiral and 3D Constant Step over
passes. It ensures that all segments will either be climb milled or conventionally
milled, if selected.

When the Maintain milling direction check box is not selected, passes will be either
climb or conventional passes, depending on the relative position of the tool at the
time.

233
7.7 Refurbishment parameters

This page enables you to define a number of parameters of the tool path
refurbishment.

Min. pass length

The Min. pass length parameter enables you to define the minimal length of the
pass that will be linked. Passes with length less than this parameter will not be
linked.

This option enables you to avoid the machining of extremely short passes and
increases the machining performance.

234
 7. Links

7.7.1 Spikes

Sometimes at the end of a pass, where

one surface is adjacent to another at a very
steep angle, there is a sharp jump. This Spike
can happen where the tool touches a steep
wall and is lifted to the top, or where it
"falls off" a high ledge and drops to the
bottom. SolidCAM enables you to remove
these spikes.

Remove Spikes

This option enables you to remove sharp

jumps (spikes) from the tool path.

Spikes
removed

Max. acceptable angle

Spikes or jumps with an angle greater than this value are removed from
the tool path. The angle is measured from the horizontal plane.

235
Remove first/last spikes only

When this option is active, only spikes at the beginning and end of passes are
removed. There will be no spike removal on a looped pass if this option is active,
as there is no pass end.
Non-spike allowance

You can trim off any small horizontal areas left at the top or bottom
of the spike. The value here is the maximum length of horizontal pass
that will be removed from the tool path.

Horizontal passes Horizontal passes

at the top of spikes trimmed

236
Miscellaneous
Parameters 8
This page displays the non-technological parameters related to the HSM operation.

8.1 Message

This field enables you to type a message that will appear in the generated GCode
file.
G43G0 X-49.464 Y-38.768 Z12. S1000 M3
(Upper Face Milling)
(--------------------------)
(P-POCK-T2 - POCKET)
(--------------------------)
G0 X-49.464 Y-38.768
Z10.

8.2 Extra parameters

This field is activated only when special operation

options have been implemented in the post-
processor you are using for this CAM-Part.

Click on the Parameters list button. The

Operation Options dialog box is displayed with
the additional parameters defined in the post-
processor.

238
 8. Miscellaneous Parameters

8.3 Approximation of arcs

This option enables you to control the process of arcs approximation at the
operation level.

The Approximate arcs by lines check box that enables you to control the existence
of arcs in the GCode output for the current operation.

When this check box is selected, SolidCAM approximates all tool path arcs by
lines. The precision of the approximation depends on the arc_max_chord and
arc_max_angle parameters located in the MAC file; the resulting GCode does
not contain arcs.

When this check box is not selected, the resulting GCode might contain arcs.

239
240
Examples
9
The CD supplied together with this book contains the various CAM-Parts
illustrating the use of the SolidCAM HSM Module.

Examples #1 — #9 illustrate the usage of specific HSM strategies.

Examples #10 — #15 illustrate the use of several HSM machining strategies to
completely finish a part.

Copy the complete Examples folder to your hard drive. The SolidWorks files used
for exercises were prepared with SolidWorks 2009.

The examples used in this book can also be downloaded from the SolidCAM web-
site http://www.solidcam.com.

242
 9. Examples

Example #1: Rough Machining and Rest Roughing

This example illustrates the use of SolidCAM HSM roughing strategies for the
mold core machining.

• HSM_R_Cont_target_T1

This operation performs Contour roughing of the core model. The

Detect core areas option is used to perform the approach into the
material from outside.

• HSM_RestR_target_T2

This operation performs Rest roughing of the core model in the areas
where material is left after the previous Contour roughing operation.

• HSM_R_Lin_target_T1

This operation performs Hatch roughing of the core model; this

strategy can be used as an alternative to contour roughing for older
machine tools or softer materials.

243
Example #2: Constant Z, Helical and Horizontal machining

This example illustrates the use of Constant Z, Helical and Horizontal strategies for
the machining of a mold core part.

• HSM_CZ_target_T1

This operation performs Constant Z machining of the part with

constant Step down. The Max. Stock thickness parameter enables you
to perform the separate machining of the forming faces and the boss
faces.

• HSM_CZ_target_T1_1

This operation is a variation of the previous operation with the

Adaptive Step down option set.

• HSM_Helical_target_T1

This operation performs Helical machining of the core faces.

• HSM_CZF_target_T2

This operation performs Horizontal machining of the flat faces of the

part.

244
 9. Examples

Example #3: Linear machining

This example illustrates the use of the Linear strategy for the machining of a mold
core part.

• HSM_Lin_target_T1

This operation performs Linear machining of the forming faces of the

mold core. This operation illustrates the use of Cross Linear finishing
in order to completely machine the model faces where the Linear
passes are sparsely spaced.

245
Example #4: Radial and Spiral machining

This example illustrates the use of Radial and Spiral machining strategies for the
machining of a bottle-bottom mold insert.

• HSM_Rad_target_T1

This operation performs Radial machining of the forming faces of the

insert. The user-defined boundary is used to limit the tool path.

• HSM_Sp_target_T1

This operation performs Spiral machining of the forming faces of

the insert. The user-defined boundary is used to limit the tool path.
The Simple ordering option is used to perform optimal ordering and
linking of the tool path.

246
 9. Examples

Example #5: Morphed machining and Offset cutting

This example illustrates the use of Morphed machining and Offset cutting strategies
for the machining of a cavity part.

• HSM_Morph_target_T1

This operation performs Morphed machining of the model faces.

• HSM_OffsetCut_target_T1

This operation illustrates the Offset Cutting strategy use for the parting
surface machining.

247
Example #6: Boundary machining

This example illustrates the use of the Boundary machining strategy for the
machining of the cylindrical part shown below.

• HSM_Bound_target_T1

This operation illustrates the use of the Boundary machining strategy

for the chamfering of model edges.

• HSM_Bound_target_T1_1

This operation illustrates the use of the Boundary machining strategy

for engraving on the model faces.

248
 9. Examples

Example #7: Rest machining

This example illustrates the use of the Rest machining strategy for the electrode
part shown below.

• HSM_RM_target_T1

This operation illustrates the use of the Rest machining strategy for
the machining of model corners.

• HSM_Bound_target_T1

This operation illustrates the use of the Boundary machining strategy

for optimal finishing of filleted corners.

249
Example #8: 3D Constant Step over machining

This example illustrates the use of the 3D Constant Step over machining strategy
for the machining of the mold core shown below.

• HSM_CS_target_T1

This operation illustrates the use of the 3D Constant Step over strategy
for the machining of the parting face of the core.

250
 9. Examples

Example #9: Pencil, Parallel Pencil and 3D Corner Offset

This example illustrates the use of Pencil, Parallel Pencil and 3D Corner Offset
strategies for the mold cavity shown below.

• HSM_Pen_target_T1

This operation illustrates the use of the Pencil milling strategy for the
machining of cavity corners in a single pass.

• HSM_PPen_target_T1

This operation illustrates the use of the Parallel Pencil milling strategy
for the machining of cavity corners in a number of passes.

• HSM_Crn_Ofs_target_T1

This operation illustrates the use of the 3D Corner Offset strategy for
the machining of the cavity part.

251
Example #10: Mold Cavity machining

This example illustrates the use of several SolidCAM HSM strategies to complete
the machining of the mold cavity shown below.

• HSM_R_Cont_target_T1

This operation performs Contour roughing of the cavity. An end mill

of Ø20 is used with the step down of 2 mm to perform fast and
productive roughing. The machining allowance of 0.5 mm remains
unmachined for further semi-finish and finish operations.

• HSM_RestR_target_T2

This operation performs Rest roughing of the cavity. A bull nosed

tool of Ø12 and corner radius of 1 mm is used with a step down of
1 mm to remove the steps left after the roughing. The same machining
allowance as in the roughing operation is used.

• HSM_CS_target_T3

This operation performs 3D Constant Step over semi-finishing of the

forming faces of the cavity. A ball nosed tool of Ø10 is used. The
machining allowance of 0.2 mm remains unmachined for further
finish operations.

252
 9. Examples

• HSM_RestR_target_T4

This operation uses the Rest roughing strategy for the semi-finish
machining of the model areas left unmachined after the previous
operations. A ball nosed tool of Ø4 is used with the step down of
0.4 mm. The machining allowance of 0.2 mm remains unmachined for
further finish operations.

• HSM_RM_target_T5

This operation uses the Rest machining strategy for finishing the model
corners. A ball nosed tool of Ø6 is used for the operation. A reference
tool of Ø10 is used to determine the model corners.

• HSM_Crn_Ofs_target_T6

The 3D Corner Offset strategy is used for the finish machining of the
cavity faces that are inside the constraint boundaries. The shape of
pencil milling passes, generated by this strategy, is used for the constant
step over machining of the cavity faces. A ball nosed tool of Ø6 is
used for the operation.

• HSM_Lin_target_T6

The Linear strategy is used to complete the finish machining of the

planar faces of the cavity that were not machined by the previous
operation. A ball nosed tool of Ø6 is used for the operation.

• HSM_CS_target_T7

The 3D Constant Step over strategy is used for the finish machining
of the blind cut on the cavity face. A ball nosed tool of Ø4 is used for
the operation.

• HSM_PPen_target_T8

The Parallel Pencil milling strategy is used for the finish machining of
the cavity corners in a number of steps. A ball nosed tool of Ø3 is
used for the operation.

253
Example #11: Aerospace part machining

This example illustrates the use of several SolidCAM HSM strategies to complete
the machining of the aerospace part shown below.

• F_profile_T1

This operation performs preliminary roughing using the Profile

operation. An end mill of Ø12 is used.

• HSM_R_Cont_target_T1

This operation performs the Contour roughing of the part. An end

mill of Ø12 is used with the step down of 2 mm to perform fast and
productive roughing. The machining allowance of 0.5 mm remains
unmachined for further semi-finish and finish operations.

• HSM_CZ_target_T3

This operation performs Constant Z finishing of the steep model

faces. A bull nosed tool of Ø8 and corner radius of 0.5 mm is used
for the operation.

254
 9. Examples

• HSM_CZF_target_T3

This operation performs Horizontal machining of the flat faces. A

bull nosed tool of Ø8 and corner radius of 0.5 mm is used for the
operation.

• HSM_CZ_target_T4

This operation performs Constant Z finishing of the side fillet and

chamfer faces using the Adaptive Step down option to perform the
machining with the necessary scallop. A ball nosed tool of Ø4 is used
for the operation.

• HSM_Bound_target_T5

This operation uses the Boundary machining strategy for the engraving
on the model faces with a chamfer mill.

255
Example #12: Electronic box machining

This example illustrates the use of several SolidCAM HSM strategies to complete
the machining of the electronic box shown below.

• HSM_R_Cont_target1_T1

This operation performs the Contour roughing of the part. An end

mill of Ø30 is used with the step down of 10 mm to perform fast and
productive roughing. The machining allowance of 0.5 mm remains
unmachined for further semi-finish and finish operations.

• HSM_RestR_target1_T2

This operation performs the Rest roughing of the part. A bull nosed
tool of Ø16 and corner radius of 1 mm is used with the step down of
5 mm to remove the steps left after the roughing. The same machining
allowance as in the roughing operation is used.

• HSM_CZ_target_T3

This operation performs Constant Z finishing of the upper vertical

model faces up to a certain depth. A bull nosed tool of Ø12 and corner
radius of 0.5 mm is used.

256
 9. Examples

• HSM_CZ_target_T3_1

This operation performs Constant Z finishing of the bottom vertical

model faces. A bull nosed tool of Ø12 and corner radius of 0.5 mm
is used.

• HSM_CZF_target1_T3

This operation performs Horizontal machining of the flat faces. A bull

nosed tool of Ø12 and corner radius of 0.5 mm is used.

• HSM_CZ_target1_T4

This operation performs Constant Z machining of the inclined faces.

A taper mill of 12° angle is used to perform the machining of the
inclined face with large step down (10 mm). Using such a tool enables
you to increase the productivity of the operation.

257
Example #13: Mold insert machining

This example illustrates the use of several

SolidCAM HSM strategies to complete the
machining of the mold insert.
• HSM_R_Cont_model_T1

This operation performs the

Contour roughing of the part.
An end mill of Ø25 is used
with the step down of 3 mm.
A machining allowance of
0.5 mm remains unmachined
for further semi-finish and
finish operations. The Detect
core areas option is used to
perform the approach into the
material from outside.
• HSM_RestR_model_T2

This operation performs the Rest roughing of the part. A bull nosed
tool of Ø12 and corner radius of 2 mm is used with the step down of
1.5 mm to remove the steps left after the roughing. The same machining
allowance as in the roughing operation is used.
• HSM_CZ_model_T3

This operation performs the Constant Z semi-finishing of the steep

faces (from 40° to 90°). A ball nosed tool of Ø8 is used for the
operation. The machining allowance of 0.2 mm remains unmachined
for further finish operations.
• HSM_Lin_model_T3

This operation performs the Linear semi-finishing of the shallow faces

(from 0° to 42°). A ball nosed tool of Ø8 is used for the operation.
The machining allowance of 0.2 mm remains unmachined for further
finish operations.

258
 9. Examples

• HSM_RM_model_T4

This operation uses the Rest machining strategy for semi-finishing of

the model corners. The semi-finishing of the model corners enables
you to avoid tool overload in the corner areas during further finishing.
A ball nosed tool of Ø6 is used for the operation. A reference tool of
Ø8 is used to determine the model corners. The machining allowance
of 0.2 mm remains unmachined for further finish operations.
• HSM_CZ_model_T4

This operation performs Constant Z finishing of the steep faces (from

40° to 90°). A ball nosed tool of Ø6 is used for the operation. The
Apply fillet surfaces option is used to generate a smooth tool path and
to avoid a sharp direction changes in the model corners.
• HSM_Lin_model_T4

This operation performs Linear finishing of the shallow faces (from 0°

to 42°). A ball nosed tool of Ø6 is used for the operation. The Apply
fillet surfaces option is used to generate a smooth tool path and to
avoid a sharp direction changes in the model corners.
• HSM_CZF_model_T5

This operation performs Horizontal machining of the flat face. An end

mill of Ø16 is used.
• HSM_CS_model_T6

This operation performs 3D Constant Step over machining of the

insert bottom faces; since these faces are horizontal, the machining is
limited to an angle range from 0° to 2°. A ball nosed tool of Ø4 is used
for the operation.
• HSM_RM_model_T6

This operation uses the Rest Machining strategy for finishing of the
model corners. A ball nosed tool of Ø4 is used for the operation. A
reference tool of Ø7.5 is used to determine the model corners.

259
Example #14: Mold cavity machining

This example illustrates the use of several SolidCAM HSM strategies to complete
the machining of the mold cavity shown below.

• HSM_R_Cont_target_T1

This operation performs Contour roughing of the cavity. An end mill

of Ø20 is used with the step down of 3 mm. A machining allowance of
0.5 mm remains unmachined for further semi-finish and finish
operations.
• HSM_RestR_target_T2

This operation performs Rest roughing of the cavity. A bull nosed

tool of Ø12 and corner radius of 2mm is used with the step down of
1.5 mm to remove the steps left after the roughing. The same machining
allowance as in roughing operation is used.
• HSM_CZ_target_T3

This operation performs Constant Z semi-finishing of the steep faces

(from 40° to 90°). A ball nosed tool of Ø10 is used for the operation.
The machining allowance of 0.25 mm remains unmachined for further
finish operations. The Apply fillet surfaces option is used.

260
 9. Examples

• HSM_Lin_target_T3

This operation performs Linear semi-finishing of the shallow faces

(from 0° to 42°). A ball nosed tool of Ø10 is used for the operation.
The machining allowance of 0.25 mm remains unmachined for further
finish operations. The Apply fillet surfaces option is used.
• HSM_RM_target_T4

This operation uses the Rest machining strategy for semi-finishing of

the model corners. The semi-finishing of the model corners enables
you to avoid tool overload in the corner areas during further finishing.
A ball nosed tool of Ø6 is used for the operation. A reference tool of
Ø12 is used to determine the model corners. A machining allowance
of 0.25 mm remains unmachined for further finish operations.
• HSM_CZ_target_T5

This operation performs Constant Z finishing of the steep faces (from

40° to 90°). A ball nosed tool of Ø8 is used for the operation. The
Apply fillet surfaces option is used.

• HSM_Lin_target_T5

This operation performs Linear finishing of the shallow faces (from 0°

to 42°). A ball nosed tool of Ø8 is used for the operation. The Apply
fillet surfaces option is used.

• HSM_RM_target_T6

This operation uses the Rest machining strategy for finishing of the
model corners. A ball nosed tool of Ø4 is used for the operation. A
reference tool of Ø10 is used to determine the model corners.
• HSM_Bound_target_T7

This operation uses Boundary machining strategy for the chamfering

of upper model edges. A chamfer drill tool is used for the operation.
The chamfer is defined by the external offset of the drive boundary
and by the Floor offset parameter.

261
Example #15: Mold core machining

This example illustrates the use of several SolidCAM HSM strategies to complete
the machining of the mold core shown below.

• HSM_R_Cont_target_T1

This operation performs Contour roughing of the core. An end mill

of Ø20 is used with the step down of 4 mm to perform fast and
productive roughing. The machining allowance of 0.5 mm remains
unmachined for further semi-finish and finish operations. The Detect
core areas option is used to perform the approach into the material
from outside.

• HSM_RestR_target_T2

This operation performs rest roughing of the core. A bull nosed tool
of Ø12 and corner radius of 2 mm is used with the step down of
2 mm to remove the steps left after the roughing. The same machining
allowance as in roughing operation is used. The Detect core areas
option is used to perform the approach into the material from outside.

• HSM_Lin_target_T3

This operation performs Linear semi-finishing of the core faces. A ball

nosed tool of Ø10 is used for the operation. The machining allowance
of 0.2 mm remains unmachined for further finish operations. The
Apply fillet surfaces option is used.

262
 9. Examples

• HSM_RM_target_T4

This operation uses the Rest machining strategy for semi-finishing of

the model corners. The semi-finishing of the model corners enables
you to avoid tool overload in the corner areas during further finishing.
A ball nosed tool of Ø6 is used for the operation. A reference tool of
Ø12 is used to determine the model corners. The machining allowance
of 0.2 mm remains unmachined for further finish operations.

• HSM_CZ_target_T5

This operation performs Constant Z finishing of the steep faces (from

30° to 90°). A ball nosed tool of Ø8 is used for the operation. The
Apply fillet surfaces option is used.

• HSM_Lin_target_T5

This operation performs Linear finishing of the shallow faces (from 0°

to 32°). A ball nosed tool of Ø8 is used for the operation. The Apply
fillet surfaces option is used.

• HSM_RM_target_T6

This operation uses the Rest machining strategy for finishing of the
model corners. A ball nosed tool of Ø4 is used for the operation. A
reference tool of Ø10 is used to determine the model corners.

• HSM_Bound_target_T7

This operation uses Boundary machining strategy for the chamfering

of upper model edges. A chamfer drill tool is used for the operation.
The chamfer is defined by the external offset of the drive boundary
and by the Wall offset parameter.

263
264
 Index

Index

Symbols

2D manually created boundaries 74

3D Constant step over 35, 156
3D Constant step over parameters 163, 165
3D Corner Offset 38, 164
3D manually created boundaries 86

Absolute height 201

Across option 60
Adaptive variable side step 159
Along option 60
Along surface 208
Angle 28, 86, 128, 132, 141
Aperture 77
Apply fillets 45
Approximation of arcs 239
Areas 153
Auto-created box of stock geometry 65, 71
Auto-created box of target geometry 65, 70
Auto-created outer silhouette 65, 73
Auto-created silhouette 65, 72
Automatically created boundaries 65, 70
Axial offset 121

Basic approaches 228

Bi-directional 181
Bi-directional Radial machining 182
Bi-directional Spiral machining 182
Bitangency angle 48, 151, 161
Boolean Operations dialog box 80
Boundaries definition 15
Boundary 46
Boundary box 66, 74

265
Boundary Definition 65
Boundary Machining 33
Boundary type 65

Calculation Speed 174

Center 67, 140, 145
Center Point 95
Check faces 90
Clearance level 191
Clearance parameters 217
Clear direction 61
Clear surface by 217
Clear surface within 217
Climb milling 181, 184
Clockwise direction 146
Combined boundary 66, 80
Combined strategies 21, 40
Combined strategy parameters 168
Constant Step over passes 172
Constant Z combined with 3D Constant Step over strategy 172
Constant Z combined with Horizontal strategy 168
Constant Z combined with Linear strategy 170
Constant Z Machining 25
Constant Z passes 168, 170, 172
Constrain parameters 95
Constraint boundaries 63
Contact Areas Only 87
Contact Point 95
Contour roughing 22, 125
Conventional milling 181, 184
CoordSys 43
CoordSys Data dialog box 43
CoordSys Manager dialog box 43
Counterclockwise direction 146
Created manually 66
Cross linear machining 28, 134, 136
Curls 219

266
 Index

Curve 61
Cutting direction 60, 62
Cutting feed 55

Detect Core areas 126, 192, 193, 213

Direction for Hatch Roughing 186
Direction for Rest Machining 187
Direction options 178
Down Mill 183
Down Mill parameters 230
Drive boundaries 33, 58
Drive boundaries for Morphed Machining 59
Drive boundaries for Offset cutting 61
Drive faces 90

Extensions 227
External 67
Extra parameters 238

Faces geometry 77
Faceting tolerance 44
Feed Rate 54
Filleting Tool Data 47
Fillet surfaces dialog box 46
Finishing strategies 20
Fitting options 221
Floor offset 87, 102
From first pass 189
Full vertical retract 216
Fully Trim Pass 222

General Link Parameters 177

Geometry definition 15, 43

267
H

Hatch roughing 23, 127

Helical machining 26, 137
Helix diameter 203
Helix ramping 203
Holder Clearance 53
Horizontal Leads 225
Horizontal link clearance 213
Horizontal Machining 27
Horizontal passes 168
Horizontal Step over 158

Include Corner Fillets option 92

Internal 67
Intersect operation 82
Islands at same time 190

Lead in/out radius 225

Lead out angle 227
Leads Parameters 220
Left clear offset 149
Limit depth 205
Limit Offsets number to 158
Limits 86
Linear Machining 28, 132
Linear passes 170
Link 176
Link by Z-level 194
Link clearance 212
Link down feed 55
Linking radius 211
Link parameters 15
Link per cluster 195
Link up feed 55

268
 Index

Machine the whole pass 221

Maintain milling direction 233
Max. acceptable angle 235
Max. depth of cut 153
Max. deviation 155
Maximum Radius 145
Max. ramp angle 200, 226
Max. stock thickness 198
Max. Trimming Distance 223
Merge % 233
Merge operation 81
Message 238
Min. depth of cut 153
Min diameter 87
Min. diameter 77
Minimal vertical retract 216, 217
Minimise Trimming 222
Minimize full wide cuts 193
Minimize reverse linking 192
Minimum Radius 145
Min Material 96
Min material depth 93
Min. pass length 197, 234
Min. Profile Diameter 196
Min. profile diameter to ramp on 202
Min. radius 142
Miscellaneous parameters 15
Morphed Machining 31, 147

Negative Wall offset 174

Non-spike allowance 236

Offset 27, 63, 69, 88, 129

Offset cutting 32, 149

269
Offset type 167
One Way 178
One way cutting with 3D Constant Step over strategy 179
One way cutting with Spiral machining strategy 179
Operation Options dialog box 238
Order passes 188
Overthickness 94, 161

Parallel Pencil Milling 37, 162

Parameter Info 17
Parameters 16
Parameters list 238
Part Tool Table 15, 51
Passes definition 15
Pass overlap 231
Pencil Milling 36, 160
Pencil Milling parameters 163, 165
Plunge ramping 203
Prefer climb milling option 185
Previous operations 131
Prismatic Part machining 39
Prismatic Part machining parameters 166
Profile Geometry 66, 79
Profile Passes 186
Profile ramping 202

Radial Machining 29, 139

Radius 219
Ramp height offset 202, 226
Ramp in extension 227
Ramping Parameters 199
Ramp out extension 227
Ramp when possible with angle 209, 210
Rapid feed 55
Raster Passes 186
Reference Tool 93

270
 Index

Refurbishment 197
Refurbishment parameters 234
Relative and absolute ramp height 200
Relative height 201
Remove Spikes 235
Resolution 48, 77, 88
Rest areas 66, 96
Rest Machining 34
Rest Machining parameters 150
Rest roughing 24, 130
Retract 190
Retracts Parameters 214
Retract Style 215
Return to home point 191
Reverse 180
Reverse Order 188
Right Clear offset 149
Roughing strategies 20

Safety 198
Safety distance 191
Scallop 114
Select Chain dialog box 85
Selected faces 66, 89
Select Faces dialog box 84
Shallow angle 232
Shallow areas 66, 91, 153
Shallow strategy 152
Shortest route 215, 218
Silhouette boundary 66, 76
Simple Ordering 188, 190
Smoothing parameters 219
Spikes 235
Spin 54
Spiral Machining 30, 143
Spiral on surface 152
Spline 208

271
Start from home point 191
Start hint 191
Start HSM Operation 13
Stay on surface within 207
Steep areas 153
Steep regions 187
Steep threshold 151
Step down 22, 23, 25, 125, 127, 167
Step over 28, 140, 148, 157, 167
Straight line 208
Strategy parameters 124
Stroke ordering 154
Subtract operation 82

Tangent 68
Tangential extension 133, 142
Target geometry 44
The boundary will be created on 75, 77, 86
Theoretical Rest areas 66, 92
Tool Contact Area 66, 93
Tool on working area 67
Tool selection 51
Trimming 223
Trim to ramp advance 210

Unfold 17
Unite 81
Up Mill 183
Up Mill parameters 230
Use approach points 204
User-defined boundary 66, 78
Use Tangential Ramp 209

Vertical leads 224

272
 Index

Vertical Step over 158

View Parameter Info 17

Wall offset 33, 87, 100

Z Limits 86

273
274