The complete integrated Manufacturing Solution inside SolidWorks

SolidCAM 2011 Mill-Turn Training Course

SolidCAM 2011 Mill-Turn Training Course

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Contents

Contents

1. Introduction
1.1 About this course.............................................................................................................................9 1.2 Mill-Turn Module Overview........................................................................................................11 1.3 CNC-machines...............................................................................................................................12 1.4 Basic Concepts...............................................................................................................................15 1.5 Process overview...........................................................................................................................15

2. CAM-Part Definition
Exercise #1: CAM-Part Definition............................................................................................19

3. Turning on Mill-Turn CNC-Machines
Exercise #2: Fixture definition...................................................................................................40 Exercise #3: Turning...................................................................................................................44

4. Milling on Mill-Turn CNC-Machines
4.1 Facial Milling..................................................................................................................................67 Exercise #4: Facial Milling..........................................................................................................68 4.2 Simultaneous 4-Axis Milling........................................................................................................85 Exercise #5: Simultaneous 4-Axis Milling................................................................................86 Exercise #6: Stopper Machining................................................................................................93 Exercise #7: Bushing Machining...............................................................................................95 Exercise #8: Shaft Machining.....................................................................................................96 4.3 Indexial Milling on Mill-Turn CNC-machines..........................................................................97 Exercise #9: Indexial Milling on 4-Axis CNC-Machines.......................................................99

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........278 Exercise #23: Rotary Cliche Machining................................................................................................................ Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines Exercise #21: Turbine Blade Machining..........168 Exercise #20: Shaft Machining...................................................................166 Exercise #19: Machining with Back Spindle..140 Exercise #13: Slotted Nut Machining.....................208 7.........................................................118 Exercise #12: Joint Part Machining..................................................................................................................................................................................162 5.........................145 Exercise #16: Console Machining...............................................................................................................................................................................141 Exercise #14: Connector Part Machining....1 CNC-machine model definition.............279 Exercise #24: Rotary Knife Machining..204 6.......................................................293 Document number: SCMTTCENG11001 6 .........159 Exercise #18: Milling of Pre-Machined Parts..................................................... Mill-Turn CNC-Machine definition 6...........................................157 Exercise #16: Milling of Pre-Machined Parts..............................116 Exercise #11: Indexial Milling on 4-Axis CNC-Machines....................................................................................................247 Exercise #22: Blade Machining.....Exercise #10: Bracket Machining...............................................................................................1 Working with Back Spindle.......... Back Spindle Use on Mill-Turn CNC-Machines 5...................................................................................................................................................................................................................................................................................................................143 Exercise #15: Indexial Milling on 5-Axis CNC-Machines................

Introduction 1 .

8 .

The SolidCAM 2. It contains a number of laboratory exercises to give you the opportunity to apply and practice the material covered by the guided exercises. Course design This course is designed around a task-based approach to training. About the CD The CD supplied together with this book contains copies of the various files that are used throughout this course. the Sim. The course must be preceded by the SolidCAM Turning Training Course. The Exercises folder contains the files that are required for doing guided and laboratory exercises.\SolidCAM2011\GPPTool folder.. Prerequisites Students attending this course are expected to have a basic knowledge of the SolidCAM software. The Machine files folder contains a number of pre-processors (CNC-controller configuration file) used through the exercises of this book. It is also intended to be a self-study tutorial. The SolidWorks files used for the exercises were prepared with SolidWorks 2011. in which the basic concepts of SolidCAM Turning are discussed.5D Milling Training Course is recommended but not necessary to be studied before this course for better understanding of Milling with the SolidCAM software. Using this book This tutorial is intended to be used in a classroom environment under the guidance of an experienced instructor. Copy the Exercises folder to your hard drive. Introduction 1. The Built Parts folder inside the Exercises contains completed manufacturing projects for each exercise. Copy the content of this folder into your . you can refer to the online help for information on the less frequently used options. This tutorial covers the basic concepts of Mill-Turn machining and is a supplement to the system documentation and online help.1 About this course The goal of this course is to teach you how to use SolidCAM to machine various parts using Mill-Turn CNC-machines. Once you have developed a good foundation in basic skills. 9 . The guided exercises will teach you the necessary commands and options to complete a machining task. The theoretical explanations are embedded into these exercises to give an overview of the SolidCAM Mill-Turn capabilities. For the last chapter of this course book. 5-Axis Milling knowledge provided by the SolidCAM Simultaneous 5-Axis User Guide is required. The laboratory exercises do not contain step-by-step instructions.1.

This style combined with the lamp icon is used for the SolidCAM functionality explanations embedded into the guided exercises. you may notice differences in the appearance of the menus and windows. Conventions used in this book This book uses the following typographic conventions: Bold Sans Serif This style is used to emphasize SolidCAM options. The action explanation is as follows.The CNC-machine folder contains the CNC-machine definition files used for the Simultaneous 5-axis milling exercises. Define CoordSys Position Explanation 10 . For example. Copy the CNC-machine definition folder named Mill_Turn_5_Axis from the CNC-machine folder into the machine definition folder on your hard drive (the default location is C:\Program Files\SolidCAM2011\Tables\MachSim\xml). If you are running on a different version of Windows. 10. click on the Change to opposite button. These differences do not affect the performance of the software. The mouse icon and numbered sans serif bold text indicates the beginning of the exercise action. commands or basic concepts. Windows® Vista The screenshots in this book were made using SolidCAM 2011 integrated with SolidWorks 2011 running on Windows® 7. The lamp icon is also used to emphasize notes.

• You can use the same coordinate system for milling as well as for turning without additional definition.1.2 Mill-Turn Module Overview The Mill-Turn module is intended for programming of 3-. identical to that of SolidCAM Milling. • The Mill-Turn module enables you to perform all types of Milling and Turning operations using the same post-processor. • Using the Mill-Turn module. DMU FD-series of DMG).and 5-axis Mill-Turn CNC-machines and especially for programming of 5-axis milling CNC-machines with turning capabilities (e.g. you just work in regular milling environment and can add turning operations as needed. 11 . This functionality provides you with a number of significant advantages: • The Mill-Turn module provides you with full functionality of the Coordinate System definition. 4. • You can define the Stock model to be used in SolidCAM Milling as well as in SolidCAM Turning operations. Introduction 1. you do not need to learn new rules.

The Mill-Turn CAM-Part is not strictly associated with the only type of machine on which it is intended to be manufactured. the flexibility of CAM-Part definition in terms of CNC-machine usage enables you to easily change the type of machines for parts. The type of the chosen CNC-machine though applies certain restrictions on the technology: for example. All types of Mill-Turn CNC-machines enable you to perform turning operations.3 CNC-machines SolidCAM supports all types of Mill-Turn CNC-machines. if your programming is intended for a 3-axis CNC-machine that supports the XZC coordinates. X Z The following types of milling operations are supported according the CNC-machine type: 3-Axis Mill-Turn machine Z X C 12 . In the Mill-Turn module. the tool path is not supposed to contain movements along the Y-axis (except for the movements that can be translated into the available axes of the machine). Such functionality enables you to create a required machining technology and then to adapt it for usage on a certain CNC-machine.1.

indexial and simultaneous milling operations using the XZC axes. Introduction This type of machine enables you to perform facial. indexial and simultaneous milling operations using the XYZC axes. C X Z 4-Axis Mill-Turn machine Y Z X C This type of machine enables you to perform facial. C Y X Z 13 .1.

indexial and simultaneous milling operations using the XYZCB axes. B C Y X Z 14 .5-Axis Mill-Turn machine X B Z Y C This type of machine enables you to perform facial.

• Geometry By selecting Edges. Technology. tool options. In short. Tool parameters and Strategies are defined in the operation. Curves. Fixture definition When the part is to contain Turning operations.1. This geometry is associated with the native SolidWorks model. etc.4 Basic Concepts Every manufacturing project in SolidCAM contains the following data: • CAM-Part The CAM-Part defines the general data of the workpiece. you can define the Stock model that will be used for milling operations and the Target model that has to be obtained after the machining. define a machining strategy and a number of technological parameters. During the operation definition you have to select the Geometry. Optionally. Operations definition SolidCAM enables you to define turning and milling operations. the coordinate system position. the clamping fixture has to be defined in order to supply SolidCAM with the information about fixing the part on the CNCmachine. Surfaces or Solids. Introduction 1. 15 .5 Process overview Three major stages of the SolidCAM Manufacturing Project creation process are: CAM-Part definition This stage includes the definition of the global parameters of the Manufacturing Project (CAM-Part). You have to define Coordinate Systems that describe the positioning of the part on the CNC-machine. operation means how you want to machine. • Operation An Operation is a single machining step in SolidCAM. choose the tool from the Part Tool Table (or define a new one). define what and where you are going to machine. This includes the model name. 1. CNC-controller.

16 .

CAM-Part Definition 2 .

you have to define the CAM-Part name and location. which is the origin for all machining operations of the CAM-Part. The controller type influences the Coordinate System definition and the Geometry definition. It is necessary to choose the CNC-controller. SolidCAM defines the necessary system files and a folder to allocate the place to store SolidCAM data. • CNC-controller definition. • Stock model definition. 18 . At this stage. You have to define the Coordinate System. SolidCAM enables you to define the model of the part in its final stage after the machining.The CAM-Part definition process consists of the following stages: CAM-Part creation CNC-controller definition Coordinate System definition Stock model definition Target model definition • CAM-Part creation. It is necessary to define a boundary of the stock that is used for the CAM-Part machining. You can create multiple CoordSys positions and in each machining step select which CoordSys you want to use for the operation. • Target model definition. • Coordinate System definition.

2. which are necessary for the part machining. 2. This model contains a number of features forming the solid body. 19 . 1. you have to create the CAM-Part for the model displayed on the illustration and define the Coordinate System. the Stock model and the Target model. The CAM-Part will be used in the exercises further on. click on the SolidCAM field in the main menu of SolidWorks and choose Mill-Turn from the New submenu or click on the Mill-Turn button on the SolidCAM New toolbar. CAM-Part Definition Exercise #1: CAM-Part Definition This exercise illustrates the process of the CAM-Part definition in SolidCAM. Start SolidCAM To activate SolidCAM.sldprt model located in the Exercises folder. In this exercise. SolidCAM is started and the New Mill-Turn Part dialog box is displayed. Load the SolidWorks model Load the Exercise1.

the name of the active SolidWorks document. 20 . define its location and measurement units. Directory Specify the location of the CAM-Part.New Mill-Turn Part dialog box This dialog box enables you to create a new CAM-Part. The Use Model file directory option enables you to automatically create CAM-Parts in the same folder where the original CAD model is located. You can then replace the SolidWorks design model upon which the CAM-Part is based with the updated SolidWorks design model. The name is. Model name This field shows the name and the location of the SolidWorks design model that you are using for the CAM-Part definition. CAM-Part name Enter a name for the CAM-Part. the chosen SolidWorks document is loaded into SolidWorks. In this case. by default. The default directory is the SolidCAM user directory defined in SolidCAM Settings. You can give any name to identify your machining project. SolidCAM automatically checks the correspondence of the dates of the CAM-Part and the original SolidWorks design model. With the Browse button you can choose any other SolidWorks document to define the CAM-Part. Enter the path or use the Browse button to define the location. When the date of the original SolidWorks model is later than the date of the CAM-Part creation. By default SolidCAM uses the name of the design model. Every time the CAM-Part is opened. this means that the SolidWorks original model has been updated.

CAM-Part name and Model name are defined. click on the OK button to confirm the CAM-Part creation. 21 . 3. The Mill-Turn Part Data dialog box is displayed. CAM-Part Definition Units This section enables you to define the measurement units to be used in the current CAM-Part. The CAM-Part is defined and its structure is created.2. Confirm the CAM-Part creation After the Directory.

Choose the CNC-controller Define the CNC-machine controller. This enables you to create auxiliary geometries (e. The Cavity subdirectory also contains the files that contain the clamping fixture.SLDPRT The Cavity.The structure of the CAM-Part The CAM-Part includes a number of data files represented on the illustration that displays the data included in the CAM-Part named Cavity. The Cavity subdirectory contains all the data generated for the CAM-Part. Cavity. There are two major components in this assembly: • DesignModel.prt file is located in the SolidCAM User directory. clamping and other tooling elements. 4. – a file that contains SolidCAM Coordinate System data and geometry data.g. SolidCAM copies the original SolidWorks model to the Cavity subdirectory and creates a SolidWorks assembly that has the same name as the CAM-Part (Cavity. Use a CNC-machine of the Nakamora-MT type. sketches) without making changes in the original design model.SLDASM CAM. You can also insert some additional components into the assembly file such as stock model. stock and target geometry. The SolidCAM CAM-Part uses the assembly environment of SolidWorks. Click on the arrow in the CNC-Machine area to display the list of post-processors installed on your system.sldprt • CAM. CNC-machine table.prt Cavity Cavity.SLDPRT DesignModel. Choose the Nakamora-MT CNC-controller from the list.sldasm). 22 .sldprt – a copy of the SolidWorks model file.

The Machine Coordinate System #1 (Position #1) can be used for turning operations as well as for all types of milling operations. Geometry Coordinate System The axes orientation for the Turning Coordinate System are defined in the CoordSys item of the submachine in the Machine ID file of the chosen CNC-controller. 23 . In the Turning mode. Define the Coordinate System Definition of the Machine Coordinate System is a mandatory step in the process of CAM-Part definition. You can define the position of the Coordinate System origin and the axes orientation by selecting model faces. SolidCAM uses the Turning Coordinate System created by rotating of the Machine Coordinate System #1 (Position #1) around the Z-axis. The Machine Coordinate System defines the origin for all machining operations on the CAM-Part.2. The CoordSys dialog box enables you to define the Coordinate System location and the orientation of the axes. vertices. you will need to make sure that you choose an appropriate submachine to generate the correct GCode. edges or SolidWorks Coordinate Systems. CAM-Part Definition 5. At the stage of operation definition. It corresponds with the built-in controller functions and can be used for various clamping positions in a variety of operations on the CAM-Part. Click on the Define button in the Coordinate System area of the Mill-Turn Part Data dialog box to define the Machine Coordinate System.

which results in more precise definition but may take more time to generate. The CoordSys origin will lie in the origin of the SolidWorks Coordinate System.SolidCAM enables you to define the CoordSys using the following methods: Select Face This method enables you to define a new CoordSys by selecting a face. and the Z-axis will be directed normally to the chosen view of the model. the Z-axis of the CoordSys is coincident with the axis of revolution of the specified cylindrical/conical surface. The CoordSys origin and the orientation of the axes is the same as in the original SolidWorks Coordinate System. Define This method enables you to define the CoordSys by picking points. The face can be planar or cylindrical/conical. For cylindrical or conical faces.and Y-axes. For planar faces. the Coordinate System is defined using the faceted model. You have to define the origin and the directions of the X. Normal to current view This option enables you to define the Coordinate System with the Z-axis normal to the model view you are facing on your screen. 24 . SolidCAM defines CoordSys with the Z-axis normal to the face. the Coordinate System is defined using CAD tools without faceting. When this check box is not selected. Select Coordinate System This method enables you to choose the SolidWorks Coordinate System defined in the design model file as the CoordSys. When the High precision check box is selected.

button to confirm the The CoordSys Data dialog box is displayed. With this option. The Z-axis of the CoordSys is coincident with the axis of revolution. select the High precision check box and click on the model face as shown. Click on the selection. With the Select Face mode chosen. and the Z-axis is directed backwards. This button enables you to reverse the Z-axis direction along the revolution axis. Select the model face Make sure that the Center of revolution face option is chosen for Place CoordSys origin to. 25 .2. the origin is placed automatically on the axis of revolution face. Now the CoordSys origin is located on the front face of the model and the Z-axis is directed forward along the revolution axis. Click on the Change to opposite button. Note that the CoordSys origin is automatically defined on the model back face. CAM-Part Definition 6.

In the SolidCAM CAM module. however. The default value is 1. The Plane box defines the default work plane for the operations using this CoordSys. If you use another number. 26 . Rotation is the angle of rotation around the main axes X. Some CNC-machines. • Y shows the Y-value of the CoordSys.7. have different axes definitions and require a GCode output with rotated XY-planes. For each Machine Coordinate System. etc. Y and Z. The parameter is defined by three coordinates of the distance vector. In other words. it enables you to define the location of the CAM-Part on the CNC-machine table. Origin based on Machine CoordSys parameter defines the location of the CAM-Part Coordinate System relative to the Machine Coordinate System. • X shows the X-value of the CoordSys. The Position field defines the sequential number of the Coordinate System. the GCode file contains the G-function that prompts the machine to use the specified number stored in the controller of your machine. • Z shows the Z-value of the CoordSys. you must always work on the XY-plane. Part upper level. Shift is the distance from the Machine Coordinate System to the location of the Position in the coordinate system and the orientation of the Machine Coordinate System. The Center of Rot. Define the CoordSys data The CoordSys Data dialog box enables you to define the Coordinate System values and machining levels such as Tool start level. several Position values can be defined for different positionings. Clearance level. as it is output to the GCode program. each such Position value is related to the Machine Coordinate System. CoordSys Data dialog box The Machine CoordSys number defines the number of the CoordSys in the CNC-machine.

The negative Z-direction can be used in case of milling of the part from the back side with the same Coordinate System in the main spindle or in case of using the back spindle. whereas those used for radial milling are measured around the Z-axis. facial and radial milling is performed using the same Coordinate System. the CoordSys data must be defined separately.2. CoordSys X Part Lower Level Y Z Part Upper Level Clearance level Tool Start Level Tool Z-level The Front tab displays levels for milling from the positive Z-direction. 27 . see Exercise #19. The Front and Rear tabs contain sets of facial machining levels describing the planes parallel to the XY-plane and located along the Z-axis. The Rear tab displays levels for milling from the negative Z-direction. But since the part levels used for facial milling are measured along the Z-axis. For more explanation. CAM-Part Definition In the Mill-Turn module.

The Radial tab contains a set of machining levels describing the virtual cylinders situated around the Z-axis. Tool Z-level Tool Start Level Clearance level Part Upper Level CoordSys X Z Y Part Lower Level These tabs contain the following parameters: • The Tool start level defines the Z-level at which the tool starts working. • The Clearance level is the Z-level to which the tool moves rapidly from one operation to another (in case the tool does not change). • The Part lower level defines the lower surface level of the part to be machined. • The Part upper level defines the height of the upper surface of the part to be machined. Tool Start level Rapid Movements area Clearance level Feed Movements area Part Upper level Part Lower level 28 .

Confirm the CoordSys Data dialog box with the OK button. It is highly recommended to send the tool to the reference point or to a point related to the reference point. Click on the Stock button. It is suppressed by default and not visible until you unsuppress it in the FeatureManager Design tree. The Mill-Turn Part Data dialog box is displayed. The CoordSys Manager dialog box is displayed in the PropertyManager area of SolidWorks. This dialog box enables you to define the Stock model of the CAM-Part to be machined. This planar surface provides you the possibility to select points that do not lie on the model entities. This level is related to the CoordSys position and you have to check if it is not over the limit switch of the machine. 29 . Confirm the CoordSys Manager dialog box by clicking on the button. Define the Stock model Define the boundaries of the stock material used for the CAM-Part. The Create planar surface at Part Lower level option enables you to generate a transparent planar surface at the minimal Z-level of the part so that its lower level plane is visible.2. This dialog box displays one Machine Coordinate System. CAM-Part Definition • The Tool Z-level is the height to which the tool moves before the rotation of the 4/5 axes to avoid collision between the tool and the workpiece. The Model dialog box is displayed. 8.

You can define the box stock by specifying offsets of the box faces from the selected solid body or coordinates of its boundaries relative to the CAM-Part Coordinate System. You can define the cylindrical stock by specifying offsets of the cylinder faces from the selected solid body or coordinates of its boundaries relative to the CAM-Part Coordinate System. perpendiculars are dropped from its end points to the axis of rotation to create the 2D geometry that will be revolved around the Z-axis to define material boundary. the Choose STL dialog box is displayed. SolidCAM generates a cylinder around it. When you choose this mode and click on the Define button. When you click on the solid body. • Revolved boundary around Z The Stock boundary is defined as a wireframe geometry chain using one of the model sketches in the ZX-plane. This box defines the geometry of the Stock. When the chain is selected. • Extruded boundary The Stock boundary is defined as a closed wireframe geometry chain using one of the model sketches in the XY-plane. SolidCAM generates a 3D box around it. This dialog box enables you to choose the STL file for the stock definition. This chain is extruded by the Z-axis to define the material boundary. • 3D Model The Stock boundary is defined by selecting a 3D model. 30 . • STL The Stock model is defined based on a STL file that exists in your system. • Box The Stock boundary is defined as a box surrounding the selected solid model.The following methods of Stock definition are available: • Cylinder The Stock boundary is defined as a cylinder surrounding the selected solid model. When you click on the solid body. This cylinder defines the geometry of the Stock.

In the Offsets section. • Set the Internal diameter offset to 0.2. Solid body Surrounding revolution body Envelope profile Choose the Cylinder mode from the Defined by list and click on the solid body to select it. SolidCAM generates a sketch containing the envelope of the selected solid body. 31 . When the Internal diameter value is different from 0. The Stock boundary is defined in this sketch. define the following offsets: • Set +Z to 0 and -Z to 30 to define the front and back offsets from the model. SolidCAM defines a cylinder. SolidCAM defines a tube. CAM-Part Definition When the Generate envelope check box is selected. • Set the External offset to 2.

The tighter is the tolerance. the better is the performance of the simulation. The triangulated model is used later in the tool path simulation. The Target model is the final shape of the CAM-Part after the machining. This parameter defines the accuracy of triangulation of the Target model. 9. The triangulated model is used later in the tool path simulation.01. Define the Target model Now you have to define the Target model. set the value to 0. the better is the performance of the simulation. In the Facet tolerance section.01. button to confirm Click on the the button to confirm the Model dialog box. set the Facet tolerance to 0. 32 . The tighter is the tolerance. It is used for gouge checking in the SolidVerify simulation. The Stock envelope sketch is added to the CAM component of the CAM-Part assembly and is displayed on the solid model. In the Target section of the Mill-Turn Part Data dialog box.The defined offsets are added to the cylindrical stock. This parameter defines the accuracy of triangulation of the Stock model.

CAM-Part Definition Target options • Envelope/Mirrored Envelope During the Target model definition. This function creates the envelope line of the specified solid bodies. The Envelope function takes into account all external model faces as well as internal faces. The Mirrored Envelope option generates the envelope sketch mirrored about the Z-axis in the ZX-plane. You can choose this option if your part will not contain Turning operations. Consider the revolution body surrounding the solid body. • None No sketch will be created during the Target model definition. This envelope is a profile of the part that has to be turned in order to create the model geometry. This sketch contains the geometry automatically generated by the Envelope function of SolidCAM. The Section sketch is created in the CAM component of the SolidCAM Part Assembly. Solid body Surrounding revolution body Envelope profile Section 33 . • Section In addition to the Envelope. The geometry created by the Envelope function can be used for the Geometry definition in SolidCAM operations. SolidCAM enables you to generate a sketch containing a Section of the Target model by the ZX-plane. This option is applicable for machines with lower turret. The section of this revolution body by the ZX-plane of the Turning Machine CoordSys is the envelope.2. SolidCAM creates the sketch in the CAM component of the CAM-Part assembly.

This dialog box enables you to define the 3D Model geometry by selecting the solid model elements. button. Click on the solid body. Confirm it with the The envelope sketch is added to the CAM component of the CAMPart assembly and is displayed on the solid model. The Target model dialog box is displayed again. The model is highlighted. Confirm the selection with the button. This dialog box enables you to define a 3D Model for the Target. The 3D Geometry dialog box is displayed. This sketch will be used later for the turning geometry definition. The Target model dialog box is displayed. 34 . Click on the Define 3D Model button.Choose Envelope in the Target options section and click on the Target button.

By rightclicking on it. Double-click on this subheader to load the Model dialog box that enables you to edit the definition of the Stock model. CoordSys Manager The Stock subheader displays the name of the Stock model defined for the CAM-Part. CAM-Part header Tool header Machining Process header Geometries header Fixtures header Operations header } Operations The SolidCAM Manager tree contains the following elements: • CAM-Part header This header displays the name of the current CAM-Part. The Machine subheader displays the CNC-machine controller defined for the CAM-Part. Double-click on this subheader to load the Target model dialog box that enables you to edit the definition of the Target model. The dialog box is closed and the SolidCAM Manager tree is displayed. SolidCAM Manager The SolidCAM Manager tree is the main interface feature of SolidCAM that displays complete information about the CAM-Part. Double-click on this subheader to display the Machine ID editor that enables you to view the parameters of the CNC-machine. 35 . Double-click on the CoordSys Manager subheader to display the dialog box that enables you to manage your Coordinate Systems. The Target subheader displays the name of the Target model defined for the CAM-Part. The defined CAM-Part is saved. click on the button. you can display the menu to manage your CAM-Parts.2. CAM-Part Definition 10. Save the CAM-Part In the Mill-Turn Part Data dialog box.

Double-click on this header to display the Part Tool Table. The clamping fixture. • Tool header This header displays the name of the current Tool Library. • Machining Process header This header displays the name of the current Machining Process table.The Settings subheader is also located under the CAM-Part header. 11. the definition of the CAM-Part is finished. The CAM-Part is closed. submachine. Double-click on this subheader to load the Part Settings dialog box that enables you to edit the settings defined for the current CAM-Part. • Fixtures header This header displays all the fixtures not used in the operations. • Operations header This header displays all SolidCAM operations defined for the current CAM-Part. 36 . The definition of Milling and Turning operations is covered in the coming exercises using this CAM-Part. • Geometries header This header displays all SolidCAM geometries that are not used in the operations. the tool and the coordinate system defined for the following operations. the submachine. tool and coordinate system subheaders display the clamping fixture. which is the list of tools available to use in the current CAM-Part. At this stage. Close the CAM-Part Right-click on the CAM-Part header in the SolidCAM Manager tree and choose Close from the menu.

Turning on Mill-Turn CNC-Machines 3 .

Face Turning Operation This operation enables you to perform turning of facial profiles. The resulting tool path can either use a single machine cycle.SolidCAM enables you to perform the following types of Turning operations. If the tool movements are generated by the program. Turning Operation types Turning Face Turning Drilling Threading Grooving Angled Grooving Cutoff Simultaneous Turning Turning Operation This operation enables you to turn a longitudinal or facial profile. Angled Grooving Operation This operation enables you to perform inclined grooves. The Tool angle parameter enables you to adjust the angle of the tool cutting the material. if they exist. Grooving Operation This operation enables you to perform a groove either on a longitudinal geometry (internal or external) or a facial geometry. or it can generate all the tool movements. 38 . generate all the tool movements (G0. to avoid gouging of the material. The principal working direction is the X-axis direction. if needed because of the tool shape. The geometry defined for this operation must be inclined relative to the Z-axis of the CAM-Part Coordinate System. G1) or generate several machine cycles. then minimum tool movements length is generated taking into account the material boundary in the beginning of the particular operation. The profile geometry is adjusted automatically by the program. The resulting tool path can either use the turning cycles of the CNC-machine.

This operation can be used only if the CNC-machine has a thread cycle. 39 . The tool tilting is defined by specifying lines that indicate the tool vector change. This operation is useful for machining of undercut areas in a single machining step. Threading Operation This operation enables you to perform threading. please refer to the SolidCAM Turning User Guide. chamfers and fillets can also be generated. Drilling Operation This operation enables you to perform a drilling action along the rotation axis. For more detailed explanation on the Turning operations. Turning on Mill-Turn CNC-Machines Cutoff Operation This operation enables you to perform cutoff machining. The cutting can be performed using CNC-machine cycles. This operation is used to cut the part or to perform a groove whose width is exactly the same as the tool width. Simultaneous Turning Operation This operation enables you to perform machining of curve-shaped tool paths using tilting capabilities of tools with round insert. There is no geometry definition for this type of operation since it is enough to define the drill start and end positions.3. The threading can be either longitudinal (internal or external) or facial. SolidCAM outputs the tool path for the threading exactly with the same length as the defined geometry without any checking for material collision.

The CAM-Part is loaded. The exercise uses the CAM-Part created in Exercise #1. 1. choose Exercise1.prz to load the CAM-Part prepared in the previous exercise. In this exercise. In the browser window.Exercise #2: Fixture definition Fixture definition is a mandatory step in definition of MillTurn CAM-Parts that contain Turning operations. or click on the Open button on the SolidCAM toolbar. 40 . you have to define the clamping fixture that holds the machined workpiece on the CNC-machine table. Load the CAM-Part Click SolidCAM. Open. You cannot add Turning operations if the fixture is not defined for the current CAM-Part.

This dialog box enables you to define the clamping device and related parameters.3. chuck position and dimensions. The Main/Sub options enable you to choose the location and orientation of the current fixture. Make sure that the Chuck (Standard) option is chosen in the Defined by section. This option enables you to define a standard three-step chuck by specifying the clamping method. 41 . Define the clamping fixture Right-click on the Operations header in SolidCAM Manager and choose Define Fixture. Turning on Mill-Turn CNC-Machines 2. The Model dialog box is displayed. Clamping method This section enables you to define how the clamping device will be attached to the workpiece.

use the default Main option and make sure that the default clamping option is chosen. Z CD diameter 42 . The value of 50 is displayed in the Clamping edit box. place the cursor in the Axial position edit box and pick the same model edge. To define the Clamping diameter. Chuck position The chuck positioning is defined with the Clamping diameter (CD) and Axial position (Z) parameters relative to the stock end face: The Clamping diameter (CD) and Axial position (Z) parameters can be defined by picking on the model. SolidCAM measures the X.In the Clamping method section. place the cursor in the Clamping diameter edit box and pick the edge of the back face of the model as shown. To define the Axial position. The value of -80 is displayed in the Axial position edit box.distances from the CoordSys origin to the picked positions and displays the values in the corresponding edit boxes. Now you need to define the dimensions of the chuck.and Z. Change this value to -90 to place the fixture 10 mm backwards from the end face of the model. Change this value to 52 to take into account the 2 mm offset defined for the cylindrical Stock model. When the model is picked.

• The Jaw height (JH) parameter defines the overall height of a single jaw. Turning on Mill-Turn CNC-Machines Chuck parameters • The Jaw width (JW) parameter defines the overall width of a single jaw. Click on the 43 button to confirm the Model dialog box. • Set the Step height (SH) value to 7. The clamping fixture is defined. • The Step height (SH) parameter defines the height of the lower step. • Set the Step width (SW) value to 8. Step Width Jaw Height Step Height Jaw Width Associativity is not maintained for chucks defined by parameters. Set the values in the Jaws parameters section as follows: • Set the Jaw width (JW) value to 24. • The Step width (SW) parameter defines the width of the lower step. • Set the Jaw height (JH) value to 21. .3.

In this exercise. you define a Turning operation to machine the external faces of the model and prepare it for the next Milling operations. Load the CAM-Part Open the Exercise2. you have to define the machining geometry.Exercise #3: Turning This exercise uses the CAM-Part created in Exercise #1 and #2. In the process of operation definition. Add an operation Right-click on the Operations header in SolidCAM Manager and choose Turning from the Add Turning submenu. the tool and the technological parameters. 1. 44 . The Turning Operation dialog box is displayed. 2.prz CAM-Part prepared in the previous exercise.

45 . Click on the Define button. When model entities are picked. edges and vertices. Define the Geometry Make sure that the Wireframe option is chosen on the Geometry page of the Turning Operation dialog box. The turning geometry has to be located in the ZX-plane and can be defined by selecting wireframe elements or solid model entities such as faces. vertices. • Solid This option enables you to define the turning geometry by selecting model entities such as faces. You have to define the machining geometry for the turning operation using the Envelope sketch that was automatically generated during the Target model definition described in Exercise #1.3. origin and sketch points. SolidCAM automatically defines the geometry on the envelope/section segment corresponding to the selected model elements. edges. Turning on Mill-Turn CNC-Machines 3. The following geometry definition options are available: • Wireframe Z X Geometry definition plane This option enables you to define the turning geometry by wireframe geometry selection.

The Geometry Edit dialog box is displayed in the SolidWorks PropertyManager area. Note the direction of the geometry. the geometry must be directed opposite to the Z-axis direction. In this operation. When you pick the first chain entity on the solid model. The selected entity is highlighted. The default Curve option enables you to create a chain by selecting model edges or wireframe sketch elements one after the other. This dialog box enables you to define and edit geometry chains. Picked position Geometry chain Direction Start point Click on the entity of the Envelope sketch as shown. 46 . The direction of the picked first chain entity is defined automatically from the start point to the picked position. SolidCAM determines the start point of the picked entity closest to the picked position.

Next element Start element 47 . End element Start element Auto-general SolidCAM highlights all entities that are connected to the last chain entity. the direction of the chain and the element up to which the chain is created. You have to select the entity along which you want the chain to continue. Turning on Mill-Turn CNC-Machines Click on the next sketch entity as shown. You can choose any model edge. In the Geometry Edit dialog box. vertex or sketch entity to determine the chain end.3. select the Auto-to check box and choose the Auto-general option. Auto-to The chain is selected by specifying the start curve.

define the end point of the chain. The complete selected chain is highlighted. 48 . It enables you to modify geometries defined for SolidCAM operations: extend/ trim and assign offsets. The Modify Geometry dialog box is displayed.With the Auto-to and the Auto-general options. button to finish the chain Click on the Accept Chain definition and confirm the Geometry Edit dialog box with the button. In this exercise. and also choose the geometry chains to be used in the operation (in case of multiple chain geometry). On the Geometry page of the Turning Operation dialog box. click on the Modify Geometry button. Click on the vertex as shown. the geometry has to be extended in order to enable the tool approach and retreat outside of the machining geometry.

the chain is trimmed from the start/end point up to the specified distance measured along the geometry chains. Turning on Mill-Turn CNC-Machines The Start Extension/Trimming and End Extension/Trimming sections enable you to define the length of the extension/trimming applied to the start/end of the geometry chain. 49 . End Extension Start Extension In the Start Extension/trimming and End Extension/trimming sections.3. The Distance option enables you to define the extension/trimming distance: when a positive value is defined. the chain is extended from the start/end point with straight lines of the specified length. set the Distance values to 2. Close the Modify Geometry dialog box with the button. when a negative value is defined.

4. Define the Tool Now you have to define the tool for the turning operation. 5. 50 . Click on the Select button on the Tool page of the Turning Operation dialog box. Submachine is a combination of turret and table on the CNC-machine that will be used to perform this operation. you need to choose an appropriate submachine. The structure and properties of this submachine are available in the Machine ID file of the chosen machine. Define the Submachine To generate the correct GCode for Turning operations. Make sure that the Turret_MainSpindle option is chosen in the Submachine section on the Geometry page of the Turning Operation dialog box.

Part Tool Table is a tool library that contains all the tools available for use with a specific CAM-Part.3. Choose the External Rough tool. The Part Tool Table is stored within the CAMPart. Click on the Add Turning Tool button. Turning on Mill-Turn CNC-Machines The Part Tool Table dialog box is displayed. 51 . The Part Tool Table dialog box provides you with choice of tools available for the current operation.

The Turning Operation dialog box is displayed.A new turning tool is defined with default parameters and added to the Part Tool Table. 52 . Click on the Select button to choose the defined tool for the current Turning operation. 6. This page enables you to specify the machining levels for the operation. please refer to the SolidCAM Turning User Guide. For a more detailed explanation of the turning tools parameters. Define the machining levels Switch to the Levels page of the Turning Operation dialog box.

SolidCAM enables you to define the distance at which the tool is positioned relative to the material in the beginning and in the end of the operation. until which the tool movements are performed in the Rapid mode. The Distance X and Distance Z parameters enable you to define different distance values in the X.3. Turning on Mill-Turn CNC-Machines Use the default Safety distance value (2).and Z-directions. Safety distance Safety distance When the Approach/Retreat distance check box is selected. the tool path passes are extended to ensure that the tool does not drop into the material in the Rapid mode in the beginning of machining and between one step down to another. the tool switches to the working feed and performs machining of the part. Safety distance This parameter defines the distance from the workpiece. Distance X Distance Z 53 . Upon reaching the Safety distance. In this manner.

7. at the end of the rough stage. This option enables you to perform longitudinal turning (the principal working direction is the Z-axis direction). Make sure that the External option is chosen in the area. if chosen. Make sure that the Long option is chosen in the Process type area. In the General tab. Mode 54 . This option enables you to perform the external longitudinal turning (above the geometry and parallel to the Z-axis). make sure that the Rough option is chosen in the Work type area. Define the technological parameters Switch to the Technology page of the Turning Operation dialog box. Semi-finishing and finishing passes are performed. Rough Work type The tool path movements are parallel to the Z-axis (longitudinal turning) or to the X-axis (facial turning).

Set the Distance X value to 0. Define the offset from the geometry that will remain after the roughing stage of the operation. Define the Step down for roughing.4 and the Distance Z value to 0. Turning on Mill-Turn CNC-Machines To define the parameters of the Rough machining.1. This option enables you to define different offsets from the geometry in the X. This parameter enables you to define the distance between each two successive roughing passes. 55 . The program chooses the sign of the delta-X and delta-Z vector components in such way that the offset geometry does not intersect with the profile geometry. choose the ZX-ABS option.3. switch to the Rough tab on the Technology page of the Turning Operation dialog box. Use the default value of 1. choose the ZX-ABS option. In the Rough offset section.and Z-axis directions. Distance Z Step down Distance X In the Rough offset area.

The operation data is saved and the tool path is calculated. The direction of machining is maintained throughout the tool path. 8. the finishing pass is performed as follows: the tool moves in the direction of the geometry. Choose the ISO-Turning method option from the Finish list. Calculate the operation Click on the Save & Calculate button in the Turning Operation dialog box. Finish A finishing pass is a single pass that is executed in the end of the operation. 56 .Switch to the Semi-Finish/Finish tab on the Technology page to define the finishing parameters. continuous tool path is calculated along the geometry in the specified direction. When the ISO-Turning method option is chosen.

Since all the View options of SolidWorks are available during the simulation. 57 . The tool path is simulated in the SolidWorks window. Simulate the operation in the Host CAD mode Click on the Simulate button in the Turning Operation dialog box. Note that the lead in and lead out movements and work feed movements are displayed with different colors.3. The Simulation control panel is displayed. you can see the tool path from different perspectives and zoom in on a certain area of the model. Host CAD simulation mode This mode enables you to display the tool path directly on the model in the SolidWorks window. Rotate the model to the side view by clicking on the button of the CAM Views toolbar and click on the Play button on the Simulation control panel. Turning on Mill-Turn CNC-Machines 9.

10. 58 . Click on the Play button. Simulate the operation in the SolidVerify mode Switch to the SolidVerify page on the Simulation control panel. Simulate the operation in the Turning mode Switch to the Turning page on the Simulation control panel. 11. Turning simulation mode This mode enables you to display the section view simulation of the turning tool path. The tool path is simulated.

The simulation is performed. This operation is also available by applying the combination of the Ctrl button and click-and-drag of the middle mouse button. This operation is also available by click-and-drag of the middle mouse button. The Top View button displays the top view of the simulation model. The stock model is displayed in the simulation window. 59 . During the machining simulation. SolidCAM subtracts the tool movements from the solid model of the stock using solid Boolean operations. The Front View button displays the front view of the simulation model. Turning on Mill-Turn CNC-Machines SolidVerify simulation mode This mode displays the simulation of machining on the solid model. The Move button moves the simulation model to any point on the screen. The remaining machined stock is a solid model that can be dynamically zoomed or rotated. The Isometric View button displays the isometric view of the simulation model. The Rotate button rotates the simulation model. Rotate the model to button the isometric view with the and click on the Play button. This operation is also available by applying the combination of the Shift button and click-and-drag of the middle mouse button. you can use the View buttons to place the simulation model properly on the screen. The 3D Stock model is used in this mode with the clamping fixture displayed. During the SolidVerify simulation. The Zoom button zooms in and out the image on the screen.3.

The CAM-Part is closed. The dialog box is closed. The Turning Operation dialog box is displayed. 13. Close the CAM-Part Right-click the CAM-Part header in SolidCAM Manager and choose Close from the menu. Close the Turning Operation dialog box In the Turning Operation dialog box click on the Exit button. on 60 . Close the simulation Click on the Exit button on the Simulation control panel.12. 14.

Milling on Mill-Turn CNC-Machines 4 .

thus clearing the area around the profile to a constant depth. this type of profiling generates several concentric profiles that start from the defined clear offset distance from the profile. 62 . Milling Operations Face Milling Profile Contour 3D Pocket Pocket Recognition 3D Milling 3D Engraving Thread Milling Slot T-Slot Drilling Drill Recognition Translated Surface 3D Drilling Toolbox HSR/HSM HSS Converting HSM to 5-Axis 5-Axis Multi-Axis Drilling iMachining Face Milling Operation This operation enables you to machine large flat surfaces with face mill tools. SolidCAM offers two types of profiling: • Milling a single profile to the specified constant or variable depth in one step or in several user-defined down steps. In profile milling you can optionally use tool radius compensation to the right or to the left side of the geometry.The Mill-Turn module enables you to use all types of milling operations to generate the tool path for the driven tools. and finish on the profile geometry. The profile geometry can be open or closed. Profile Operation You can mill on or along a contour. • Concentric profiles to the specified constant or variable depth.

When a profile geometry consists of one or more profiles and none of them are enclosed or intersect with one another.4. any profile that is enclosed or intersects with another profile is treated as an island. The slot can be pre-machined using rough and semi-finish cycles. each is milled as a separate pocket without islands. In this operation. you can mill a slot wider than the tool diameter. When a profile geometry consists of several profiles. You can define an unlimited number of islands within a single pocket. In Slot with variable depth. With available parameters for the right and left extension and the side step. 63 . Two types of slots can be defined: the Slot with constant depth operation machines the slot in several steps until the final depth is reached. Slot Operation This operation generates a tool path along the centerline to the right or to the left of one or more profiles. Milling on Mill-Turn CNC-Machines Contour 3D Operation This operation enables you to utilize the power of the 3D Engraving technology for the 3D contour machining. Pocket Operation In pocket milling. the depth profile is also defined by a 2D section. you remove material from the interior of a closed geometry. SolidCAM offers two types of pocketing: • Pocket without islands. The finish cut produces a tool path according to the specified scallop height on the floor of the slot. T-Slot Operation This operation enables you to machine slots in vertical walls with a slot mill tool. • Pocket with islands. SolidCAM enables you to prevent the gouging between the tool and the 3D contour.

and Post-processor program (GPPTool). If your CNC-machine has no canned drill cycles of its own. SolidCAM supports the canned drill cycles provided by your particular CNC-machine such as threading. they can be defined using the General Pre. peck. Drill Recognition Operation This operation performs powerful drill feature recognition and automatic Drill geometry creation using the AFRM module functionality. etc. boring. 64 .Drilling Operation This operation enables you to perform drills and other canned drill cycles. The initial values of the Milling levels sets are automatically recognized from the model. Pocket Recognition Operation This operation enables you to recognize the pocket features on the solid model and perform the machining of these features. This operation enables you to handle separate sets of Milling levels for each drill position. ream. they can be edited by the user. Thread Milling Operation This operation enables you to generate a helical tool path for the machining of internal and external threads with thread mills.

It can be used to manufacture molds. dies.4. This operation offers a wide range of roughing. Limit geometries can be projected on the translated surface. Translated Surface Operation A translated surface is generated by moving a section along a profile geometry. electrodes. semi-finishing and finishing strategies for free-form models. Milling on Mill-Turn CNC-Machines 3D Milling Operation You can perform 3-axis gouge-free machining on solid and surface models. outside or along the limit geometry. You can machine the resulting translated surface inside. 65 . while taking into account the solid model geometry. prototypes and other 3D Models. 3D Drilling Operation This operation enables you to perform drills and other canned drill cycles. SolidCAM uses the holes prepared in this operation for the descent during 3D Model roughing. The profile is projected on the surface. 3D Engraving Operation You can mill text or any other profile on a 3D geometry. The HSM module offers unique machining and linking strategies for generating high-speed tool paths. engraving the contour at a specified depth.

retracts do not go any higher than necessary. smooth. 66 . cutting tools. It provides easy selection of the surfaces to be machined. 5 Axis Operation This operation enables you to perform simultaneous 5-axis machining. HSS Operation SolidCAM HSS module is a high speed surface machining module for smooth and powerful machining of localized surface areas in the part. Sim. HSR/HSM Operation 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. Each such operation provides the user with a specific machining strategy optimal for a particular machining case. and gouge-free tool path. Angled where possible. The result of HSM is an efficient. SolidCAM enables collision checking between the tool and the machine components. The retracts to high Z-levels are kept to a minimum. cylinder heads. smoothed by arcs. including undercuts. turbine blades and impellers. For example. aerospace parts.5D Milling operations. It supports both standard and shaped tools.Toolbox Cycles Toolbox sub-operations are a set of 2. each one of these operations is intended for a specific machining case. with no need to define the boundaries. 5-axis machining strategies enable the use of SolidCAM for machining of complex geometry parts such as mold cores and cavities. thus minimizing air cutting and reducing machining time. a number of operations cover different strategies of the counterbore machining.

the same cavities can be machined using a tool of smaller length while tilting this tool to follow the same tool path. Using the cutting conditions produced by the Wizard. the iMachining Tool Path Generator calculates all the tool paths necessary to efficiently produce the target geometry from the given stock geometry. For example. 3D machining of deep cavities requires the use of tools of great length. iMachining SolidCAM iMachining is an advanced technology of high speed machining that generates optimized tool paths. 5 Axis Operation In some machining cases. Milling on Mill-Turn CNC-Machines Converting HSS/HSM to Sim.4. efficient cutting and high material removal rates. there is a need to perform machining of 3D parts using the 5-axis capabilities. The iMachining Technology Wizard enables you to define the optimum cutting conditions for sustainable high speed machining. 67 . which can cause tool breakage. Multi-Axis Drilling Operation This operation enables you to machine a series of drills that have different orientations. while reducing machining time and tool wear.

Y X Machine CoordSys #1 Z Machining Geometry 68 . The Geometry is defined directly on the solid model.4. In facial milling. the tool axis is parallel to the revolution axis of the part. Machine CoordSys #1 with the Z-axis collinear with the part revolution axis is used for this operation.1 Facial Milling SolidCAM enables you to perform facial milling on Mill-Turn CNC-machines.

69 . During the facial milling. Load the CAM-Part Load the Exercise3. Milling on Mill-Turn CNC-Machines Exercise #4: Facial Milling This exercise illustrates the capabilities of facial milling. Add an operation Right-click on the last operation in the SolidCAM Manager tree and choose Profile from the Add Milling submenu. the hexagon and the adjacent faces of the model are machined using the Profile operation. 1.prz CAM-Part prepared in the previous exercises. 2.4. The CAM-Part prepared in the previous exercises is used.

3. The Geometry has to be located in the plane parallel to the XY-plane of the Machine CoordSys #1. This Coordinate System enables you to perform the facial milling operation. Define the Geometry Click on the Define button on the Geometry page. The tool axis is parallel to the Z-axis of the Machine CoordSys #1.The Profile Operation dialog box is displayed. The Geometry section enables you to choose the appropriate Coordinate System for the operation and define the machining geometry. Y X Machine CoordSys #1 Z Machining Geometry 70 . The Machine CoordSys #1 is chosen by default for the operation.

This dialog box enables you to define several chains by selecting the model elements. In the Multi-Chain section. Confirm the chain definition by clicking on the button. click on the Add button. The Chains Selection dialog box is displayed in the SolidWorks PropertyManager area. The face is selected. Click on the your selection. and the chain icon is displayed in the Geometry Edit dialog box. 71 . The chains are created automatically from the selected elements. button to confirm The chain is generated. The geometry is defined for the operation.4. Milling on Mill-Turn CNC-Machines The Geometry Edit dialog box is displayed. Click on the front face of the model hexagon as shown.

Define the Tool Click on the Select button on the Tool page. For this operation. 72 . The Part Tool Table dialog box is displayed. you have to define a new milling tool. Currently.4. the Part Tool Table contains only one tool used for the Turning operation provided in the previous exercise. The Part Tool Table displays all the tools that can be used in the CAM-Part machining.

Now you need to define the tool holder. 5. Milling on Mill-Turn CNC-Machines Click on the Add Milling tool button. SolidCAM offers you a Ø6 End mill tool. A new milling tool is added to the Part Tool Table. • Set the Shoulder length to 40. Edit the Tool parameters By default.4. • Set the Total length to 60. Edit the tool definition as follows: • Set the Diameter to 10. Shoulder Length Cutting Length Outside Holder Length Total Length Diameter 73 . Choose the End mill tool. The Part Tool Table dialog box provides you with choice of tools suitable for profile milling. • Set the Cutting length to 35. • Set the Outside Holder length to 50.

This table contains a number of frequently used tool holder components. switch to the Holder page and select the Use holder check box. The Global holders table can be modified by the user. The Global tab displays the Global holders table. 74 . Click on the Select button in the Part Tool Table dialog box to confirm the tool definition. Choose the BT40 ER16x70 tool holder from the list by selecting its check box.In the Part Tool Table dialog box. The Global holders table is supplied within SolidCAM.

SolidCAM enables you to define the Lower level directly on the model. The Profile depth is calculated automatically relative to the Upper level. Define the Machining depth Switch to the Levels page and click on the Profile depth button. the Depth is updated. The Profile depth parameter is indirectly associative. Click on the model face as shown. The background of the parameter box defined associatively to the solid model changes to pink. The Lower level parameter is associative to the solid model. Confirm your selection by clicking on the button. Associativity enables SolidCAM to be synchronized with the solid model changes. The picked value (-10) is displayed in the Pick Lower level dialog box. The Profile depth value is calculated automatically as the difference between the Upper level and the Lower level values. When the Upper level or the Lower level is synchronized. The associativity is established for the Lower level. The Profile Operation dialog box is displayed. SolidCAM automatically updates the CAM data when the model is modified. 75 . Milling on Mill-Turn CNC-Machines 6.4. The Pick Lower level dialog box is displayed.

The chain geometry of the profile is displayed on the model with the chain direction indicated and a circle representing the tool relative to the geometry. – the tool cuts on the left side of the profile geometry. Center – the center of the tool moves on the profile geometry (No compensation G4x can be used with this option). Tool Side The Tool side option enables you to determine the tool position relative to the geometry. Right Left – the tool cuts on the right side of the profile geometry. Left Right Center The Geometry button displays the Modify Geometry dialog box that enables you to define the modification parameters of the geometry and to choose which geometry chains are active in the operation (in case of multiple chain geometry). Define the Tool side Switch to the Technology page of the Profile Operation dialog box.7. 76 .

choose the Right option form the Tool Side list. Now the tool is located outside the defined geometry. click on the Geometry button to check the tool location relative to the selected geometry. Confirm the Modify Geometry dialog box with the button.4. Milling on Mill-Turn CNC-Machines In the Modify section. 8. As you see. The Modify Geometry dialog box is displayed. the tool side offered by default is not suitable: the tool is located inside the defined geometry. 77 . In the Modify Geometry dialog box. The Tool side has to be changed. Define the Rough and Finish machining parameters SolidCAM enables you to perform rough and finish machining of the profile in a single Profile operation.

the last cut is performed at the Z-level defined by Profile depth: -10. The Step down parameter defines the distance between each two successive Z-levels. SolidCAM automatically calculates the actual step down to keep an equal distance between all passes. because the machining depth value is not divisible exactly by the Step down value. The distance between the Z-levels of the last cut and the preceding cut is smaller than that between the previous cuts. Max. This value is taken into account during the calculation of the actual step down so that it is not exceeded. With this value. Step down Actual Step down 78 . Set the Step down to 3. In this operation. -6. use the Equal step down option to keep an equal distance between all Z-levels. Step down. -9. Step down is replaced by Max. Select the Rough check box.Define the parameters of the Profile roughing. Equal step down This option enables you to perform all cuts at an equal Z-level distance one from the other. Define the Step down parameter for roughing. When the Equal step down check box is selected. Step down Upper level Step down Profile depth Profile roughing is performed in constant Z-passes. SolidCAM performs three cuts at the following Z-levels: -3.

Set the Step down for the profile finishing to 5 mm. Offsets The Wall offset and Floor offset parameters enable you to define the allowances that remain on the walls and the floor of the machined part till the profile finish machining. Milling on Mill-Turn CNC-Machines With the Max. Step down value set to 3. Step down Profile depth Wall offset Floor offset In the Offsets section. -10 with the Step down of 2.5. Four roughing passes will be performed at the followings Z-levels: -2.4. set the Wall offset and Floor offset values to 0.2.5. The allowance of 0. -5. Now you need to define the wall and floor offsets that will remain after the roughing passes. the actual step down is automatically calculated as the largest possible value within the bounds of 3 so that the machining depth can be divided exactly into equal Z-levels. 79 . This allowance is removed with a separate finishing cut in the end of the profile machining. These allowances can be removed with the finish passes in the same Profile operation or in an additional Profile operation with another tool. -7.2 mm is left on the walls and the floor of the steps during the profile roughing. Select the Finish check box to perform the finishing of the profile.5 mm.

Define the Lead in and the Lead out Switch to the Link page of the Profile Operation dialog box. The lead out strategy enables you to perform the retract movements outside the material. The lead in movement is necessary to prevent vertical entering of the tool into the material. With the lead in strategies the tool descends to the machining level outside of the material and then horizontally penetrates the material with the lead in movement. Normal The tool leads in to and out from the profile from a point normal to the profile. The length of the normal can be set in the Value field. This page enables you to define the way the tool approaches the profile and retreats away.9. Approach value 80 . The following options are available: None The tool leads in to and out from the milling level exactly adjacent to the start point of the profile.

the tool moves on a straight line to the start point of the profile. Under Lead in. the Pick button is activated so that you can select a position directly on the solid model. From this position. The length of the tangent can be set in the Value field.4. the strategy and parameters defined for Lead in are used for Lead out. When the Same as lead in check box is selected. When you select this option. User-defined The tool’s leads in/out trajectory is specified by a user-defined wireframe chain similar to the geometry definition. Approach value Normal Point The tool leads in/out from a picked position. choose the Tangent option from the list and set the Length value to 5. Select the Same as Lead in check box under Lead out. Milling on Mill-Turn CNC-Machines Arc The tool leads in to and out from the profile with a tangential arc. Approach value Tangent The tool leads in/out on a line tangent to the profile. 81 . The arc radius can be set in the Value field.

10. Define the technological parameters of facial milling Switch to the Motion Limits Control page and select the 4th Axis check box. Z). you receive the GCode output for the part machining in standard linear coordinates (X. Y. 4th axis type When the Diameter option is chosen. This check box enables you to define the technological parameters of facial milling on Mill-Turn CNC-machines. Y X Machine CoordSys #1 Z Machining Geometry The Face option enables you to perform milling using the rotary axis by translating the linear movements in the XY-plane into the rotary XCmovements. C X Machine CoordSys #1 Machining Geometry Z 82 .

Milling on Mill-Turn CNC-Machines Note that the technology offered by SolidCAM is universal: there is no limitations in terms of machines on which the part can be milled. you need to choose the Face option. the CoordSys position is zero for linear coordinates. Z). The blocks consist of rotary and linear movements according to the plane. • Cartesian This option appears only if the cartez_4x = Y is defined in the PRP file. the usability of this GCode is limited to machines with possibility of movements along three linear axes (X. choose the Split option to obtain the tool path in the XC-coordinates. But if you use the GCode output in the XYZ coordinates (the Diameter option). to enable the possibility of milling the part on 3-axis Mill-Turn CNC-machines that support only the XZC coordinates where the movements along the Y-axis is impossible. Choose the Face option. which makes this tool path compatible for all types of CNCmachines. the tool path is calculated in polar coordinates. The tool path lines and arcs are calculated in Cartesian coordinates. Y. In the Coordinate type section.4. • Polar When this option is chosen. 83 . The milling is processed using the rotary axis by translating the linear movements into the rotary-linear movements according to the plane. Therefore. Coordinate type This option enables you to determine whether the GCode will consist of split blocks or blocks in polar/Cartesian coordinates: • Split The tool path is split into many blocks according to the specified error.

Plane

This option offers you the choice of plane in which the translated rotarylinear movements are performed. The Rear check box enables the machining of the part from the negative Z-direction using the same Coordinate System. Make sure XC is chosen for Plane to perform all movements in these coordinates. Define the Tolerance.

Tolerance

The tool path lines and arcs are split into many blocks that do not exactly generate the required tool path. The Tolerance value defines the maximum allowed error; the smaller is the value of this field, the greater is the number of GCode blocks generated. Set the Tolerance value to 0.01. The definition of the basic technological parameters of the profile milling is finished.

11. Calculate the Tool path

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

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4. Milling on Mill-Turn CNC-Machines 12. Simulate the operation

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

When the simulation is finished, click on the Stop on next button on the Simulation control panel. The Stop on Next dialog box is displayed. This dialog box enables you to define specific points where the simulation process is stopped. Select the Z-change check box. This option stops the simulation at every change of the Z-coordinate of the tool. Play the simulation again. Every time the simulation stops on Z-change, click on button to continue. The Z-change option enables you to see the tool path the simulation in detail. Exit the simulation.

13. Close the operation dialog box

Click on the Exit button. The Profile Operation dialog box is closed.

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4.2 Simultaneous 4-Axis Milling
SolidCAM enables you to perform simultaneous 4-axis milling on Mill-Turn CNC-machines. Machine Coordinate System #1 Position #1 is used for the geometry definition for simultaneous 4-axis milling.

Y Machine CoordSys #1 Z X

The SolidCAM simultaneous 4-axis capabilities enable you to perform machining with the tool axis always intersecting with the part revolution axis.

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4. Milling on Mill-Turn CNC-Machines

Exercise #5: Simultaneous 4-Axis Milling
This exercise illustrates the SolidCAM capabilities for simultaneous 4-axis milling using Mill-Turn CNC-machines. This exercise uses the pre-machined CAM-Part defined in the previous exercises. The wrapped elliptical pocket is machined in this exercise.
1. Load the CAM-Part

Load the CAM-Part prepared in Exercises #1-4.

2. Add an operation

Right-click on the last operation in SolidCAM Manager and choose Pocket from the Add Milling submenu.

The Pocket Operation dialog box is displayed.
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3. Define the Geometry

On the Geometry page, click on the Define button to start the geometry definition.

The Geometry Edit dialog box is displayed. Select the model edge as shown.

The confirmation message is displayed.

Click on the Yes button. The Geometry Edit dialog box.

chain icon is displayed in the

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When the Wrap check box is selected. Click on the button to confirm the Geometry selection. you can wrap the selected profile geometry around any axis of the Coordinate System.4. The Pocket Operation dialog box is displayed. click on the Select button to add a new tool to the Part Tool Table and use it in the operation. select the Wrap check box. The selected geometry will be wrapped around the Z-axis. Define the Tool On the Tool page of the Pocket Operation dialog box. X Profile geometry wrapped around Z Z Y Choose Z from the Around list. SolidCAM enables you to perform radial milling using the same Coordinate System as for facial milling. Milling on Mill-Turn CNC-Machines Under Options. The Around list offers you the choice of axis around which the geometry is wrapped. 89 . 4.

When a new holder is chosen from the Global holders table. Table. it is copied to the local table to make a further use easier. 90 . Click on the Add Milling tool button to define a new milling tool.The Part Tool Table is displayed. The Local holders table contains the tool holders that were already used in the current CAM-Part. A new Ø6 End mill tool is added to the Part Tool Choose the BT40 ER16x70 tool holder from the Local holders table and click on the Select button to choose the tool for the operation. Choose the tool of the End mill type.

4. Click on the bottom face of the wrapped pocket as shown. 91 . SolidCAM substitutes the current levels with defaults received from the Radial set defined in the CoordSys Data dialog box. Confirm the level selection with the button. Define the Pocket depth Switch to the Levels page of the Pocket Operation dialog box. Click on the Pocket depth button to pick the Lower Level directly on the solid model. When the geometry for the operation is defined in the wrapping mode. The Pocket depth value (5) is automatically calculated according to the Upper and Lower levels. Milling on Mill-Turn CNC-Machines 5.

With this Geometry strategy. and the profile is cleaned up on each cutting depth.Set the Step down to 3 and select the Equal step down check box. Define the Pocket machining strategy Switch to the Technology page of the Pocket Operation dialog box. • Plunging pattern: the tool moves up and down in a drilling motion. SolidCAM offers the following strategies for the pocket machining: • Contour: the pocket is machined in a round pattern. Save & Calculate Click on the Save & Calculate button to save the operation data and calculate the tool path. Tool path 7. travelling inside the pocket. • Hatch+Finish: the pocket is machined in a linear pattern. • Hatch: the pocket is machined in a linear pattern. Use the default Contour strategy. 6. 92 . the tool moves at offsets parallel to the pocket contour.

Close the Pocket Operation dialog box with the Exit button. Play the simulation with the button. Close the CAM-Part Right-click on the CAM-Part header in SolidCAM Manager and choose the Close item from the menu. Close the Simulation control panel. Milling on Mill-Turn CNC-Machines 8. 9. Simulate the operation Click on the Simulate button and simulate the CAM-Part in the SolidVerify mode. 93 .4. the exercise is finished. At this stage.

3. The following steps have to be implemented in order to reach the final CAM-Part: 1. Define the clamping fixture Define the fixture for clamping of the part on the CNC-machine table. 94 . • Turning.Exercise #6: Stopper Machining Define the CAM-Part and operations for the machining of the stopper presented on the illustration on a Mill-Turn CNCmachine. the Machine Coordinate System. the Stock model and the Target model. This exercise reinforces the following skills: • CAM-Part definition.sldprt) is located in the Exercises folder. The SolidWorks model of the Stopper (Exercise6. • Facial milling. Define the CAM-Part At this stage. External turning Define a Turning operation to obtain the following revolution body. • Simultaneous 4-axis machining. 4. you have to define the CAM-Part. Facial milling of the pentahedron Machine the pentahedron using the facial milling feature. The Nakamora-MT CNC-controller has to be chosen for this exercise. 2. the CNC-controller.

Helical Slot machining Machine the helical slot wrapped on the cylindrical surface of the stopper using the simultaneous 4-axis milling. 6. Milling on Mill-Turn CNC-Machines 5. Pocket machining Machine the pocket wrapped on the cylindrical surface of the stopper using the simultaneous 4-axis milling.4. 95 .

The Nakamora-MT CNC-controller has to be chosen for this exercise. External turning Define a Turning operation to obtain the following revolution body. Define the clamping fixture Define the fixture for clamping of the part on the CNC-machine table. Machining of the inner faces Define a number of Turning Drilling operations to obtain the following model faces. • Turning. Define the CAM-Part At this stage. 4. 3. The SolidWorks model of the Bushing (Exercise7. the CNC-controller. 96 . Facial Drilling Machine the circular pattern of drills using the facial milling capabilities. 5. The following steps have to be implemented in order to reach the final CAM-Part: 1. • Facial milling.Exercise #7: Bushing Machining Define the CAM-Part and operations for the machining of the bushing presented on the illustration on a Mill-Turn CNC-machine. the Machine Coordinate System. 2. the Stock model and the Target model.sldprt) is located in the Exercises folder. This exercise reinforces the following skills: • CAM-Part definition. you have to define the CAM-Part.

97 . • Turning.4. 2. you have to define the CAM-Part. This exercise reinforces the following skills: • CAM-Part definition. 4. The following steps have to be implemented in order to reach the final CAM-Part: 1. The Nakamora-MT CNC-controller has to be chosen for this exercise. the Stock model and the Target model. Define the CAM-Part At this stage. Milling on Mill-Turn CNC-Machines Exercise #8: Shaft Machining Define the CAM-Part and operations for the machining of the shaft presented on the illustration on a Mill-Turn CNC-machine. The SolidWorks model of the Shaft (Exercise8. Define the clamping fixture Define the fixture for clamping of the part on the CNCmachine table. 3. Drilling Machine two holes using the facial milling capabilities. External turning Define a Turning operation to obtain the following revolution body. • Radial milling. the Machine Coordinate System. the CNC-controller.sldprt) is located in the Exercises folder. 5. Facial milling Machine the highlighted model faces using the facial milling capabilities. • Facial milling.

the indexial milling tool path that contains movements along the Y-axis cannot be executed on a 3-axis CNC-machine (XZC axes). indexial machining is performed using ZX-movements only. Z X C Positioning Machining During the indexial milling operations on the machines of this type. At the first stage. the tool axis must always intersect with the revolution axis of the part. the position of the Coordinate System must be defined in such a way that the Z-axis of the position will be located in the plane parallel to the XY-plane of the Machine Coordinate System. For example. Generally. This Coordinate System position is used later for the definition of operations. at the same time. The tool path that contains the movements illegal for the current CNC-machine will cause errors during postprocessing. During the operation programming.4. indexial milling on the machines of this type enables you to perform machining of key grooves with the symmetry plane intersecting with the part revolution axis. For machines of this type. In the CNC-machines of this type. The workflow of the indexial milling in the Mill-Turn module is similar to the indexial milling workflow in SolidCAM Milling. the positioning is performed using the C-axis (revolution axis). The geometry intended to be used in the indexial milling operation has to be located in the plane parallel to the XY-plane of the Coordinate System position. The positioning is performed by rotating the part around the revolution axis keeping the same tool orientation. All the operations and technology options are available. SolidCAM maintains the tool axis orientation parallel to the Z-axis of the Coordinate System position. the tool axis is always perpendicular to and intersecting with the spindle revolution axis. you have to define a specific position of the Machine Coordinate System.3 Indexial Milling on Mill-Turn CNC-machines SolidCAM enables you to perform indexial 4-axis milling operations on Mill-Turn CNC-machines. During the machining. Incorrect definition of the Coordinate System position causes illegal tool movements that result in errors during postprocessing. But. This applies restrictions on the range of machining methods that can be used. For example. 98 . the technology choice depends on the type and possibilities of your CNC-machine. Therefore. you have to take care that the generated tool path will contain only the linear/rotational movements supported by your CNC-machine. SolidCAM does not limit you in the machining methods used for indexial milling. because this type of machining can be performed with the ZX-movements only.

This means that the rotation angles between the axes of the Machine Coordinate System and Coordinate System position have to be kept within the range supported by the CNC-machine. C Y X Z The Coordinate System position has to be defined similar to the one defined for 3-axis machines. Milling on Mill-Turn CNC-Machines SolidCAM enables you to perform machining on 4-axis Mill-Turn CNC-machines (XYZC axes). This type of CNC-machines provides you with all the functionalities available on the 4-axis MillTurn CNC-machines. when the positioning is performed. The positioning in these machines is performed using the C-axis. the machining is performed using the XYZ axes. The 4-axis Mill-Turn CNC-machines provide you with all the possibilities of indexial milling around the revolution axis (C-axis). it provides the capability of indexial rotation around either Y-axis or X-axis. all 2. the Z-axis of the position must be located in the plane parallel to the XY-plane of the Machine Coordinate System. it provides the capability of Y-axis movements for milling. In addition. SolidCAM enables you to perform machining on 5-axis Mill-Turn CNC-machines (XYZCB axes). the capabilities of these machines are similar to those of a 3-axis Milling machine equipped with the rotary axis (4-axis milling CNC-machine). This type of CNC-machines provides you with all functionalities of 3-axis Mill-Turn CNCmachines. B C Y X Z 99 . In addition. The Coordinate System position for the indexial milling has to be defined according to the rotation limitations of the CNC-machine revolution axes. similar to the 3-axis Mill-Turn CNC-machines. With such Coordinate System position. Generally.5D and 3D Milling functionality is available.4.

The circular pattern of these two operations is used to machine the other faces and holes. 2. The Simulate command is also available for each operation separately by right-clicking on the operation icons in SolidCAM Manager. 1.Exercise #9: Indexial Milling on 4-Axis CNC-Machines This exercise covers the SolidCAM functionality of indexial 4-axis milling using 3-axis Mill-Turn CNC-machines. This command enables you to simulate the complete CAM-Part. The CAM-Part after the turning The complete CAM-Part after the milling The milling is performed in Profile and Drilling operations to machine each dodecahedron face and drill two holes on it. The exercise uses a CAM-Part with previously defined Turning operations. Simulate the CAM-Part This CAM-Part contains a number of turning operations for machining of the external and internal faces.prz file. Right-click on the Operations header in SolidCAM Manager and choose Simulate from the menu. 100 . Open the CAM-Part Open the Exercise9.

you need to define an additional CoordSys position to perform milling of the dodecahedron face. Close the Simulation control panel and return to SolidCAM Manager. Geometry Y Machining plane Z X CoordSys tree. 101 . Define an additional CoordSys position At this stage.4. These positions correspond to the Machine Coordinate System #1. SolidCAM enables you to define a number of CoordSys positions for indexial 4-axis milling directly on the solid model. Milling on Mill-Turn CNC-Machines Play the SolidVerify simulation. The geometry for the machining has to be located in the plane parallel to the XY-plane of such CoordSys position. In the SolidCAM Manager CoordSys Manager header. 3. double-click on the The CoordSys Manager dialog box is displayed in the SolidWorks PropertyManager area.

Note that you have to select the face that contains the line sketch that will be used in the next steps for the milling geometry definition. The CoordSys dialog box is displayed. and the axes X and Y are defined in accordance with the CNCmachine capabilities. In the Define CoordSys options section. The defined CoordSys Position #2 is displayed in the CoordSys Manager dialog box. choose the CoordSys #1 option from the Place CoordSys origin to list. Close this dialog box with the button. Click on the Confirm the CoordSys Data dialog box with the OK button. Rotate the model and click on its face as shown. right-click on the Machine Coordinate System #1 Position 1 and choose the Add command from the menu.In the CoordSys Manager dialog box. 102 . The system automatically creates the CoordSys position in which the Z-axis is normal to the selected faces. button to confirm the CoordSys dialog box. The origin of the CoordSys Position #2 is defined in the origin of the Machine Coordinate System #1.

The geometry is defined. 6. 5. Click on the Accept Chain button to confirm the chain selection. button.4. This CoordSys position is used for the profile milling of the dodecahedron face. Choose the Coordinate System position On the Geometry page. The Geometry Edit dialog box is displayed. Milling on Mill-Turn CNC-Machines 4. The Profile Operation dialog box is displayed. choose the Position #2 of the Machine Coordinate System #1 from the CoordSys list. Select the predefined sketch line as shown. Define the Geometry Click on the Define button. Add a Profile operation Right-click on the last Turning operation icon in SolidCAM Manager and choose Profile from the Add Milling submenu. Close the Geometry Edit dialog box with the 103 . Make sure that the selected geometry chain direction is from the model front face backwards.

Define the Tool Click on the Select button on the Tool page to choose a milling tool for the operation.7. End Mill Click on the Add Milling tool button and choose the tool. Click on the Select button to choose the tool for the operation. The Part Tool Table dialog box is displayed. Set the Diameter of the tool to 16. 104 . Choose the BT40 ER16x70 tool holder from the Global Holders Table.

Confirm your selection with the button. Define the machining levels Click on the Upper level button on the Levels page. This button enables you to define the plane where the machining will start directly on the solid model. Click on the model face that contains the profile geometry as shown. Switch to the Technology page of the Profile Operation dialog box. Click on the same model face. The Profile depth is calculated automatically according to the Upper and Lower level values. The value of the Lower level is displayed. Milling on Mill-Turn CNC-Machines 8. the center of the tool moves on the profile geometry. select the Rough check box. This option enables you to define the machining depth directly on the solid model. The value (25) of the Upper level is displayed in the Pick Upper level dialog box. button to return to the Profile Click on the Operation dialog box. Confirm your selection with the button. Click on the Geometry button. The 0 value of the Profile depth means that the machining is performed in a single Z-step. Click on the Profile depth button. Choose the Center option from the Tool side list. 9. 105 . When this option is chosen. Define the Tool side Define the tool position relative to the selected geometry. the tool completely covers the face to be milled. As you can see. On the Technology page.4.

set the Length value to 1. Close the simulation and exit from the Profile Operation dialog box. set the Length value to 10. Simulate the operation Click on the Simulate button and choose the SolidVerify mode for the simulation. 12. 106 . For Lead in. This tangential lead out movement enables the tool to completely machine the geometry. Define the Lead in and the Lead out On the Link page. choose the Tangent option for both Lead in and Lead out. Calculate the operation Click on the Save & Calculate button to save the operation data and calculate the tool path.10. The SolidCAM Manager dialog box is displayed. 11. For Lead out. The tool enters the material tangentially to the geometry from outside of the material. Play the simulation.

choose the same CoordSys Position #2) that was used in the previous operation. Choose the Coordinate System position On the Geometry page. 107 position (Machine CoordSys #1 . 14.4. The Drilling Operation dialog box is displayed. Add a Drilling operation Right-click on the last Profile operation in SolidCAM Manager and choose Drilling from the Add Milling submenu. Milling on Mill-Turn CNC-Machines 13.

Define the Drill geometry Click on the Define button to start the geometry definition. The Drill Geometry Selection dialog box is displayed. This facilitates selecting drill centers on spline surfaces. This dialog box enables you to select the drill positions. All selected points are shown in the list at the bottom of the dialog box. To remove a point from the list. you cannot pick a center position like you could on a circle or an arc.15. all curves and arcs of imported models are converted into splines by the exporting CAD system. Due to the nature of spline curves or surface boundaries. Select/Unselect drill centers You can switch between the Select/Unselect modes to add or remove drill positions from the geometry. Selecting modes (Select centers by) You can add drill positions to the current geometry using the following selection options: • Pick position You can define the drill positions one by one using the CAD point selection options. SolidCAM calculates the center position of an arc defined by three points positioned on the spline edges. • 3 Points on circumference Usually. 108 . or the Delete All option to remove all points. The Undo/Redo button deletes or restores the last selection. right-click on its name in the list and choose the Delete option from the menu.

Click on the model face as shown. The drill position is automatically defined in the circular edge center. CAD selection SolidCAM enables you to select the drill geometry with the Host CAD tools. 109 . • All circle/arc centers SolidCAM searches the solid model for arcs and circles parallel to the XY-plane of the current Coordinate System and adds all center points as drill positions to the geometry. For more information about the Drill Geometry Selection dialog box functionality. 16. Two circular edges are recognized on the chosen face and their center points are selected. Click on the Select button to choose the tool for the operation. The Drilling Operation dialog box is displayed. Define the Tool Click on the Select button on the Tool page. The Part Tool Table dialog box is displayed. Milling on Mill-Turn CNC-Machines • Multi-positions You can select circular edges of the solid model. please refer to the SolidCAM Milling User Guide. Add a Drill tool to the Part Tool Table and choose the BT40 ER16x70 tool holder from the Local Holders Table. Click on the button to confirm the geometry definition.4. Use the default Multi-positions option in the Select centers by field.

17. 110 . Define the Drilling levels On the Levels page. Depth type This option enables you to deepen the drilled hole in order to obtain a given diameter at the specified drill depth. Define the Depth type. • Full diameter The drill reaches the defined drill depth with the full diameter. Confirm the Pick Upper level dialog box by clicking on the button. The Delta depth parameter defines the offset for the cutting depth that can be changed with its associativity preserved. click on the Upper level button to define the upper machining level directly on the solid model. Click on the face as shown. The Delta depth value is always relative to the Depth defined for the operation. Set the Drill depth value to 15 and the Delta depth value to -1. Drill depth Drill depth Drill depth Diameter value Cutter tip Full diameter Diameter value • Cutter tip The drill tip reaches the defined drill depth.

The Diameter value can vary from 0 all the way up to the drill tool diameter. 18. Define the drilling cycle Switch to the Technology Drill cycle type button. A value greater than the drill tool diameter is automatically decreased to the drill tool diameter. choose the Full diameter option. Milling on Mill-Turn CNC-Machines • Diameter value The drill reaches the defined drill depth with the drill cone diameter specified in the edit box.4. page of the Drilling Operation dialog box and click on the 111 . In the Depth type section.

Peck. The drill travels in steps to the specified depth.The Drill Cycle dialog box is displayed. Boring. The drill travels in one single motion to the specified depth and retracts. This dialog enables you to define parameters of the chosen canned cycle. 112 . SolidCAM enables you to use the following types of drill canned cycles supported by the post-processor of the current CNC-controller: Drilling. Tapping. This sequence is repeated until it reaches the final depth. At each depth step the tool rapidly retracts to the safety distance. stop its spin motion and retracts rapidly. The Drill Options dialog is displayed. Set the Step down to 2 and click on the OK button to confirm the dialog box. Then the tool rapidly returns to the point where it continues drilling. click on the Data button to specify the pecking parameters. The boring tool travels in one single motion to the specified depth. Choose the Peck option. In the Drill cycle area. box box the drill Step down This option defines the depth that you want the tool to travel at each step. The tap travels in one single motion to the specified depth and then retracts reversing its spin direction.

Simulate the tool path in the SolidVerify mode. the definition of the operations is finished. The Operation Transformations dialog box is displayed. Define the pattern of operations At this stage. Now you have to define a circular pattern of operations around the revolution axis of the CAMPart in order to machine all of the dodecahedron faces. 20. The Simulation control panel is displayed. Operation 21. translating. select the last two operations (Profile and Drilling). and mirroring of the selected operations. Milling on Mill-Turn CNC-Machines 19. In the SolidCAM Manager tree. This dialog box enables you to perform various transformations such as rotating. 113 . Save and calculate the operation Click on the Save & Calculate button to save the operation data and calculate the drilling tool path. Close the Drilling dialog box. Right-click on these operations and choose the Transform option from the menu.4. Simulate the operation Click on the Simulate button. Close the Simulation control panel.

• New operation (add at end of operations tree) This option also enables you to add a copy of the selected operation and apply the transformation to the copied operation. The original operation can be suppressed by selecting the appropriate check box in the Options section. • New operation (add at current position in operations tree) This option enables you to add a copy of the selected operation and apply the transformation to the copied operation. The original operation can be suppressed by selecting the appropriate check box in the Options section. without effect on the original operation. In the Operation transformations section. The transformed copy is inserted immediately after the original operation in the SolidCAM Manager tree. enables you to define the placing of the new operation in the SolidCAM Manager tree. use the default Edit operation transformations option. without effect on the original operation. 114 .Operation transformations This section offers you the choice of whether the original operation will be transformed or its copy will be added for transformation and. in the latter case. The following options are available: • Edit operation transformations This option enables you to perform transformation of the selected operation. The transformed copy is inserted at the end of the operation list in the SolidCAM Manager tree.

4. Milling on Mill-Turn CNC-Machines

In the Options section, select the Include original operation check box. When this check box is selected, the original operation tool path is included in the transforming action. In this exercise, you need to define a circular pattern of the selected operations around the 4th axis. Click on the 4 Axis button. The Rotate List dialog box is displayed. In the Angle value box, type the value of 30°. This parameter defines the rotation angle for each pattern instance. Enter 11 for the number of instances. Click on the Add button. The specific value of the rotation angle is calculated for each instance of the pattern.

Confirm the Rotate List dialog box with the OK button. The operations to be transformed appear in the Operation Transformations dialog box.

Confirm the dialog box with the OK button.
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Note that the Profile and Drilling operations icons are marked with the icon. This icon means that the operations were transformed using the C-axis.

22. Simulate the operations

Right-click on the selected Profile and Drilling operations and choose Simulate from the menu. Simulate the tool path in the SolidVerify mode.

Note that the indexial machining of the part is performed as follows: cutting passes in milling operations are performed only along the Z-axis of the Machine Coordinate System, without movements in the XY-plane; drilling motion is performed along the X-axis of the Machine Coordinate System. The transformation of operations around the Z-axis is performed using the C-axis. Therefore, the GCode generated for this part can be used on any 3-axis CNC-machine (and also on machines with more than three coordinate axes).

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4. Milling on Mill-Turn CNC-Machines

Exercise #10: Bracket Machining
Define the CAM-Part and operations for the machining of the bracket presented on the illustration on a Mill-Turn CNCmachine. This exercise reinforces the following skills: • CAM-Part definition; • Turning; • Facial milling; • Indexial 4-axis machining. The SolidWorks model of the Bracket (Exercise10.sldprt) is located in the Exercises folder. The following steps have to be implemented in order to reach the final CAM-Part:

1. Define the CAM-Part

Define the CAM-Part, the CNC-controller, the Machine Coordinate System, the Stock model and the Target model. The Nakamora-MT CNC-controller has to be chosen for this exercise.
2. Define the clamping fixture

Define the fixture for clamping of the part on the CNC-machine table.

3. Turning of the cylindrical faces

Define a Turning operation to obtain the following revolution body.

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4. Drill three holes on the front face

Use two Drilling operations to machine three holes on the front face of the model.

5. Machine the side faces of the bracket

Define a Profile operation to machine the side faces of the bracket using the facial milling feature.

6. Machine the holes on the cylindrical face

Define a Drilling operation to machine holes radially located on the cylindrical model face. Use the indexial 4-axis feature and define a circular pattern of the operations to machine all the holes. Add a new CoordSys position to machine these holes.

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4. Milling on Mill-Turn CNC-Machines

Exercise #11: Indexial Milling on 4-Axis CNC-Machines
This exercise covers the process of CAM-Part definition and Milling on 4-axis Mill-Turn CNC-machines (supporting the XYZC coordinates). The following model of support is used. Since the CAM-Part definition process was explained in detail in Exercise #1, the details of this CAM-Part definition process are omitted.
1. Load the SolidWorks model

Load the Exercise11.sldprt model located in the Exercises folder. This model contains a number of features forming the solid body and sketches that are used in the CAM-Part definition.

2. Start a new SolidCAM Mill-Turn part

Click on SolidCAM in the main menu of SolidWorks and choose Mill-Turn from the New submenu. SolidCAM is started and the New Mill-Turn Part dialog box is displayed. Confirm this dialog box with the OK button. The Mill-Turn Part Data dialog box is displayed.

3. Define the CNC-controller

In this exercise, the CNC-machine of the Nakamora-MT type is used. Choose the Nakamora-MT CNC-controller from the list.

4. Define the Coordinate System

Click on the CoordSys button to start the Coordinate System definition. The CoordSys dialog box is displayed.

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Confirm this dialog with the button. Click on the Change to opposite button in the CoordSys dialog box. Close it with the button. OK The CoordSys Data dialog box is displayed. the box The CoordSys Manager dialog box is displayed in SolidWorks PropertyManager area. choose Center of revolution face. The Machine Coordinate System is defined on the front face of the model. Click on the Finish button to confirm the definition. 120 . The Z-axis of the Machine Coordinate System is collinear to the revolution axis of the part.In the Place CoordSys origin to list. Select the High precision check box and click on the cylindrical face of the model as shown.

Machine CoordSys #1 Position 2 Y Z C X Y X Machine CoordSys #1 Z Position 1 121 .4. The turning tool movements are located in the ZX-plane. C Y X Machine CoordSys #1 Z To perform the indexial milling of the upper face. Milling on Mill-Turn CNC-Machines Coordinate Systems SolidCAM enables you to define Machine Coordinate System #1 with the Z-axis directed along the revolution axis. you have to define a new indexial position under the Machine CoordSys #1. the pocket and the drills. where the axis of the milling tool is parallel to the Z-axis of the Machine Coordinate System. Y X Machine CoordSys #1 Z This Machine Coordinate System is used for Turning operations. The Machine Coordinate System #1 is also used for facial milling.

• Set the External to 0. • Set the Internal diameter to 40.5. Define the Stock model In the Mill-Turn Part Data dialog box. • Set the Right (+Z) value to 0. The external diameter of the stock is the same as the external diameter of the model.01. This offset enables you to have stock material at the back side of the model for clamping. Specify the following parameters in the dialog box: • Set the Left (-Z) value to 20. The stock used in this exercise is a tube with this internal diameter. The Mill-Turn Part Data dialog box is displayed. 122 . The Model dialog box is displayed in the SolidWorks PropertyManager area. Confirm the parameters with the button. The front face of the stock material is coincident with the front face of the model. click on the Stock button. Choose the Cylinder option and click on the solid body to select it. Set the Facet tolerance value to 0.

The Target model dialog box is displayed. Save the CAM-Part Click on the Save & Exit button in the Mill-Turn Part Data dialog box. Click on the solid body. 9. It is highlighted. Select the model edge as shown. The geometry is defined for the operation. 8. At this stage. The Mill-Turn Part Data dialog box is displayed. 123 . Define the Geometry In the Geometry page. The Profile Operation dialog box is displayed. The Target model dialog box is displayed. Define the Target model In the Mill-Turn Part Data dialog box. button.4. 7. Now you have to define a number of operations to machine the part. Click on the Accept Chain button in the Geometry Edit dialog box to confirm the chain selection. Milling on Mill-Turn CNC-Machines 6. Close the dialog box with the button. click on the Define button to start the definition. The Geometry Edit dialog box is displayed. The CAM-Part is saved and the SolidCAM Manager tree is displayed. choose the Envelope option under Target and click on the Target button. Define a Profile operation Define a new Profile operation to machine the step displayed on the illustration. Confirm the selection with the Confirm it with the button. Click on the Define 3D Model button to start the Target model definition. the CAM-Part definition is finished.

124 . The Part Tool Table dialog box is displayed. Define the Tool Click on the Select button on the Tool page.10. Add a new End Mill tool. Set the Diameter to 10. Switch to the Data tab on the Tool page to define the tool spin parameters for the operation. Choose the BT40 ER16x70 tool holder from the Global Holders Table. Click on the Select button to choose the defined tool for the operation.

The Feed finish check box enables you to optionally define different values for Feed XY and Feed finish. the specified Feed XY value is used for both rough and finish machining. • Spin finish The Spin finish check box enables you to optionally define different values for Spin rate and Spin finish. the specified Spin rate value is used for both rough and finish machining. Milling on Mill-Turn CNC-Machines Spin This parameter defines the spinning speed of the tool. When this check box is selected. F is the default and signifies Units per minute. the corresponding edit box is available so that you can edit its value. The spin value can be defined in two types of units: S and V. • Feed Z – the feed rate in the Z direction. It defines two spin values: • Spin rate – normal spin rate used in rough milling. Fz signifies Units per tooth and is calculated according to the following formula: Fz = F/(Number of Flutes * S) 125 . it is calculated according to the following formula: S V = (S * PI * Tool Diameter) / 1000 Feed This parameter defines the feed rate of the tool. The feed value can be defined in two types of units: F and Fz. – finish spin rate used in finish milling. When this check box is not selected. the corresponding edit box is available so that you can edit its value.4. When this check box is not selected. When this check box is selected. is the default and signifies Revolutions per Minute. V signifies material cutting speed in Meters per Minute in the Metric system or in Feet per Minute in the Inch system. • Feed finish – the feed rate used for finish milling. It defines three feed values: • Feed XY – the feed rate in the XY-plane.

2 mm will be left on the profile wall and floor during machining. Select the Clear offset check box. Confirm the selection and close the Pick Lower level dialog box with the button. If the tool is located at the wrong side. The offsets of 0. Define the Milling levels Click on the Profile depth button on the Levels page to define the machining depth directly on the solid model. Click on the model face as shown. Confirm the dialog box with the OK button. change the Tool side to Left. These offsets will be removed in a separate cut in the end of the profile machining. Set the Step down value to 5. 11. click on the Geometry button to check the tool location relative to the profile.Define the parameters as follows: • Set the Spin rate parameter to 1500. The material is removed in two Z-cuts. The Profile Operation dialog box is displayed again.2. Set the Wall offset and Floor offset to 0. 126 . Specify the technological parameters In the Modify section of the Technology page. Select the Rough check box in order to perform the rough machining of the profile. • Select the check box and set the Spin finish parameter to 2000. 12.

• Offset defines the distance from the geometry. • Step over defines the overlap of adjacent tool paths. 13. at which the milling starts. Step over Wall offset Clear offset Set the Offset value to 10 and the Step over value to 5. Set the Length value to 3 for Lead in and to 1 for Lead out. The tool starts milling the profile at the distance defined as Clear offset and finishes at the distance defined as Wall offset. Select the Finish check box to perform the finish machining of the profile. The profile will be machined in two equidistant profiles located at the offset of 5 mm. 127 . choose the Tangent option for Lead in and Lead out. Define the Lead in and Lead out On the Link page. Milling on Mill-Turn CNC-Machines Clear offset This option generates several concentric profiles with a constant depth that start at the defined clear offset distance from the profile and finish at the geometry of the profile. The Clear offset value should be equal or larger than the Wall offset value. Choose the Zigzag option. This option enables the tool to approach the material from outside tangentially to the profile.4. it determines the offset between two successive concentric profiles. Set the Step down value to 5. thus clearing the area around the profile.

close the Profile Operation dialog box with the Exit button. Add a new CoordSys position To machine the top face. Save and calculate At this stage. 128 . When the simulation is finished. Click on the Save & Calculate button to save the operation data and generate the tool path. you have to define an additional Coordinate System position related to the Machine CoordSys #1. Now SolidCAM can define CoordSys Position #2 related to Machine Coordinate System #1. the pocket and the drills. The CoordSys Manager dialog box is displayed. The Z-axis of this CoordSys position has to be normal to the top face. choose CoordSys #1. SolidCAM Manager The CoordSys dialog box is displayed. Double-click on the CoordSys Manager header in the tree. the definition of the technological parameters is finished. Simulate the operation Simulate the operation in the SolidVerify mode. 15. Note that the Mac CoordSys number is 1 and the Position number is 2. 16. Right-click on the MAC 1 item and choose Add from the menu.14. In the Place CoordSys origin to list.

The CoordSys Manager dialog box is displayed again. 129 . The CoordSys position origin is defined in the same location as that of the Machine CoordSys #1. Set the Part Upper level value to 35 in order to take into account the full cylinder of the stock.4. Milling on Mill-Turn CNC-Machines Select the High precision check box and click on the model face as shown. button to confirm the CoordSys Click on the position definition. The CoordSys Data dialog box is displayed. Confirm the CoordSys Data dialog box with the OK button. Close it with the button. The Part Upper level and Part Lower level values are determined automatically according to the solid model. The Z-axis of the position is normal to the selected face.

17. Click on the Define button. The Face Milling Geometry dialog box is displayed. 18. The Face Milling Operation dialog box is displayed. Right-click on the last Profile operation entry in the SolidCAM Manager tree and choose Face from the Add Milling submenu. This operation enables you to machine large flat surfaces with face mill tools. Add a new Face Milling operation Add a new Face Milling operation to machine the model face using CoordSys Position #2. 130 . choose the Machine CoordSys #1 Position #2. Define the Geometry On the Geometry page of the Face Milling Operation dialog box.

SolidCAM generates a number of chains surrounding the selected faces. Face Milling geometry • Faces This option enables you to define the Face Milling geometry by face selection. These chains are displayed in the Chain List section. Face Milling geometry Selected faces 131 . The rectangle chain is displayed in the Chain List section. When the model faces are selected. Milling on Mill-Turn CNC-Machines The Base Geometry Mode section enables you to define the face milling geometry using the following methods: • Model This option generates a rectangle located at the XY-plane and surrounding the Target model and selects it for the Face Milling geometry.4. The Define button and the related combo-box enable you either to define a new faces geometry with the Select Faces dialog box or to choose an already defined geometry from the list.

The defined chains are displayed in the Chain List section. The Define button and the related combo box enable you either to define a new profile geometry with the Geometry Edit dialog box or to choose an already defined geometry from the list. This dialog box enables you to define the face milling geometry by selecting the model faces. Face Milling geometry In the Base Geometry Mode section. choose the Faces option and click on the Define button. Confirm the Select Faces dialog box with the button. 132 . The Face Milling Geometry dialog box is displayed. The Select Faces dialog box is displayed. Confirm the Face Milling Geometry dialog box by clicking on the button. set the offset from the machined face to 1. In the Modify section. Select the model face as shown.• Profile This option enables you to define the Face Milling geometry by a profile.

Define the Tool Add a new Face Mill tool the Part Tool Table. holders table and click on the 20. Milling on Mill-Turn CNC-Machines 19. 133 . Define the Milling levels Click on the Face depth button on the Levels page.5.4. Set the Step down to 3. Define the Lower level directly on the solid model as shown. Choose the BT40 ER40x80 tool holder from the Global Select button to choose the tool for the operation.

134 . make sure that the Hatch machining strategy is chosen. Define the Lead in and Lead out On the Link page. This option enables the tool to approach the material from outside tangentially to the geometry.2. A 0. set the Floor offset value to 0.21. select the Same as Lead in check box. Set the Length value to 20. Select the Finish check box to perform the finishing cut that removes the remaining offset. Define the machining strategy On the Technology page.2 mm roughing offset is left on the machined face. In the Offsets section. This strategy enables you to machine the face in a linear pattern. 22. In Lead out section. choose the Tangent option for Lead in.

24. 25. Add a Pocket operation Define a new Pocket operation to machine the through pocket located on the face machined in the previous operation. 27. Milling on Mill-Turn CNC-Machines 23. Save and Calculate Click on the Save & Calculate button to save the operation data and calculate the tool path. close the Face Milling Operation dialog box. Simulate Simulate the tool path with the SolidVerify mode. 135 . 26. Define the Geometry Choose Machine CoordSys #1 Position #2 for the operation (the same Coordinate System position used for the previous operation). Define the Tool In the Part Tool Table. use the Auto-Constant Z button to complete the chain. When the simulation is finished. choose the Tool #1 (Ø10 End Mill) for the operation. In the Geometry Edit dialog box. Define the Geometry for the Pocket operation as shown.4.

28.2 mm is left on the wall of the pocket. select the Wall check box. the offset of 0. set the Wall offset to 0. In the Offsets section. choose the Helical option from the list. Define the Milling levels Define the Upper level on the face machined in the previous operation as shown. 29. Click on the Data button to define the Helical Ramping parameters. 30. Click on the Pocket depth button and pick the point on the model as shown. Set the Step down to 5 and select the Equal step down check box. Define the Wall offset Switch to the Technology page of the Pocket Operation dialog box. Set the Delta depth value to -1. Define the Ramping parameters In the Ramping section of the Link page. This offset is removed at the end of pocket machining in a separate cut. 136 . In the Finish section. This option enables the tool to plunge into the material along a helix at the automatically calculated point.2. With the specified Wall offset value.

Milling on Mill-Turn CNC-Machines The Helical Ramping dialog box is displayed. Confirm the Helical Ramping dialog box with the button. close the Pocket Operation dialog box. Save and Calculate Click on the Save & Calculate button in order to save the operation data and calculate the tool path. This dialog box enables you to define the ramping position and the related parameters for each chain used in the Pocket operation. therefore make sure that the Center cutting check box is selected. 32. When the simulation is finished.4. 33. 31. Simulate Simulate the tool path with the SolidVerify mode. The tool chosen for the operation has center cutting capabilities. Define a Drilling operation Define a new Drilling operation to machine four holes Ø4 located on the top face of the model. Set the Angle value to 5 and the Radius value to 1. 137 .

SolidCAM selects all drill centers on the selected face. 138 . Define the Geometry Choose Machine CoordSys #1 Position #2 used in the previous operation. click on the Define button to start the geometry definition. Set the Diameter to 4. Choose the BT40 ER16x70 tool holder from the Global holders table and click on the Select button to choose the tool for the operation. The coordinates of the selected hole centers are displayed in the Drill Geometry Selection dialog box. The Part Tool Table dialog box is displayed. Confirm the geometry selection with the 35. Add a Drill tool. The Drill Geometry Selection dialog box is displayed. Define the Tool button. choose the Multi-positions option and click on the top face of the model as shown. In the Select centers by area.34. Click on the Select button on the Tool page. In the Geometry area.

Milling on Mill-Turn CNC-Machines 36. In the same manner. 139 . 37. Save and Calculate Click on the Save & Calculate button to save the operation data and calculate the tool path. click on the Drill cycle type button to choose the drill cycle. The Drill Cycle dialog box is displayed. Set the Step down to 2 and click on the OK button to confirm the dialog box. Click on the Data button in the Drill cycle area to define the pecking parameters. 38. Define the Drill cycle On the Technology page. define the Drill depth by picking the drill cone vertex on the solid model.4. This dialog box enables you to define the parameters of the chosen canned drill cycle. The Drill Options dialog box is displayed. Choose the Peck option. Define the Milling levels Define the Upper level on the top face of the model as shown.

close the Drilling dialog box. Simulate Simulate the tool path in the SolidVerify mode.39. When the simulation is finished. Operation At this stage. 140 . the exercise is finished.

External turning Machine the external turning faces using the automatically generated envelope. • Turning. The following steps have to be implemented to reach the final CAM-Part: 1. • Indexial 4-axis milling on 4-axis machines. Milling on Mill-Turn CNC-Machines Exercise #12: Joint Part Machining Define the CAM-Part and operations for the machining of the joint part presented on the illustration on a Mill-Turn CNC-machine. the Coordinate System. This exercise reinforces the following skills: • CAM-Part definition. 3. 141 . The SolidWorks model of the Joint (Exercise12.sldprt) is located in the Exercises folder. 5. the CNC-controller. 2. Define the clamping fixture Define the fixture for clamping of the part on the CNCmachine table. Side slots machining Machine the two slots using the SolidCAM indexial milling capabilities. The Nakamora-MT CNC-controller has to be chosen for this exercise. Define the CAM-Part At this stage.4. the Stock model and the Target model. Drilling Machine the hole located on the spherical surface. 4. you have to define the CAM-Part.

External turning Define a Turning operation to obtain the following revolution body. the Stock model and the Target model. The following steps have to be implemented in order to reach the final CAM-Part: 1.sldprt) is located in the Exercises folder. 3. 2. The SolidWorks model of the Slotted Nut (Exercise13. Define the clamping fixture Define the fixture for clamping of the part on the CNC-machine table. • Indexial 4-axis machining. Define the CAM-Part At this stage you have to define the CAM-Part. The Nakamora-MT CNC-controller has to be chosen for this exercise. This exercise reinforces the following skills: • CAM-Part definition. • Turning. the CNC-controller. the Machine Coordinate System.Exercise #13: Slotted Nut Machining Define the CAM-Part and operations for the machining of the slotted nut presented on the illustration on a Mill-Turn CNCmachine. 142 .

4. 143 . 5. 6. Milling on Mill-Turn CNC-Machines 4. Internal turning Machine the internal faces of the model. Machine the slots Machine the slots located on the sides of the part. Machine the side faces Machine the side faces of the part.

This exercise reinforces the following skills: • CAM-Part definition. Define the CAM-Part Define the CAM-Part. • Turning. the Coordinate System. • Indexial 4-axis machining on 4-axis CNC-machines. 3. The Nakamora-MT CNC-controller has to be chosen for this exercise. The SolidWorks model of the Connector part (Exercise14. • Facial milling. 2.Exercise #14: Connector Part Machining Define the CAM-Part and operations for the machining of the Connector part presented on the illustration on a 4-axis Mill-Turn CNC-machine. Define the clamping fixture Define the fixture for clamping of the part on the CNCmachine table. the Stock model and the Target model. the CNC-controller. External turning Machine the external turning faces using the automatically generated envelope. The following steps have to be implemented in order to reach the final CAM-Part: 1.sldprt) is located in the Exercises folder. 144 .

5.4. Slot machining Machine the highlighted model faces. 145 . Milling on Mill-Turn CNC-Machines 4. Drilling Drill all the holes. Facial milling Machine the highlighted faces using the SolidCAM facial milling capabilities. 6.

Define the Coordinate System Click on the CoordSys button to start the Coordinate System definition. The following flange model is used. SolidCAM is started and the New Mill-Turn Part dialog box is displayed. The Mill-Turn Part Data dialog box is displayed. Load the SolidWorks model Load the Exercise15. 146 . Choose the Nakamora-MT CNC-controller from the list. 2. some details of the CAM-Part definition process are omitted in this exercise.sldprt model that is located in the Exercises folder. Start a new SolidCAM Mill-Turn part Click on SolidCAM in the main menu of SolidWorks and choose Mill-Turn from the New submenu. 4.Exercise #15: Indexial Milling on 5-Axis CNC-Machines This exercise covers the process of CAM-Part definition and Milling on 5-axis Mill-Turn CNC-machines (supporting the XYZCB coordinates). 1. Confirm this dialog box with the OK button. a CNC-machine of the Nakamora-MT type is used. Since the CAM-Part definition process was explained in detail in previous exercises. 3. Define the CNC-controller In this exercise. This model contains a number of features forming the solid body and a few sketches that are used for the CAM-Part definition.

The Machine Coordinate System is defined on the model front face. 147 . Click on the cylindrical face of the model as shown. OK The CoordSys Manager dialog box is displayed in the SolidWorks PropertyManager area. Milling on Mill-Turn CNC-Machines The CoordSys dialog box is displayed. Click on the Change to opposite button in the CoordSys dialog box. Click on the Finish button to confirm the Machine Coordinate System definition. The Z-axis of the Machine CoordSys is collinear with the revolution axis of the part.4. Close it with the button. The CoordSys Data dialog box is displayed.

Coordinate Systems for 5-axis Mill-Turn machines SolidCAM enables you to define Machine CoordSys #1 with the Z-axis directed along the revolution axis. you need to define two additional positions for Machine CoordSys #1. Y Z X Machine CoordSys #1 the milling tool is parallel to the Z-axis of the Machine Coordinate System. This Machine Coordinate System is used for Turning operations. X Y Z Machine CoordSys #1 Position 2 X Y Z Machine CoordSys #1 Position 3 Confirm the CoordSys Manager dialog box with the The Mill-Turn Part Data dialog box is displayed. 148 . C Machine CoordSys #1 is used also for facial milling. where the axis of Y X Machine CoordSys #1 Z To perform indexial milling of the inclined faces. the turning tool movements are performed in the ZX-plane. button.

01 and click on the Target button. Define the following offsets: • • • Set the Right (+Z) and Left (-Z) offsets to 0.4. The defined stock is a tube with the same diameter dimensions as the final part. Set the Internal diameter to 75. Select the solid body as the Target model. Set the External offset to 0. Milling on Mill-Turn CNC-Machines 5. 149 . Confirm the Model dialog box with the 6. Define the Stock model Click on the Stock button in the Mill-Turn Part Data dialog box. Only the inclined faces and holes have to be milled. set the Facet tolerance to 0.01. In the Target section. Choose the Cylinder option in the Model dialog box and click on the solid body to choose it for the Stock definition. Define the Target model button. Set the Facet tolerance value to 0.

The SolidCAM Manager tree is displayed. • Holes machining – machining of the pattern of holes Ø3 located on the inclined faces. • Step machining – machining of the steps around the inclined faces. Save the CAM-Part definition In the Mill-Turn Part Data dialog box. therefore additional Coordinate System positions of the Machine CoordSys #1 have to be defined in order to perform the machining. click on the Save & Exit button to confirm the CAM-Part definition.7. Technological overview The current CAM-Part requires the following operations: • Facial milling – machining of two inclined faces. All of these operations are performed using B-axis rotation. 150 .

double-click on the CoordSys Manager header to display the CoordSys Manager dialog box. right-click on the and choose the Add command the Place The CoordSys dialog box is displayed. add the CoordSys Position #3 related to Machine CoordSys #1 to machine the second inclined face. Confirm the CoordSys dialog box with the Close the CoordSys Data dialog box with the OK button. The CoordSys Position #2 is defined at the origin of the Machine CoordSys #1 with the Z-axis normal to the selected face. Add a Profile operation Add a new Milling Profile operation to machine the inclined face. In CoordSys origin to list. In the CoordSys Manager Machine CoordSys #1 item from the menu. Confirm the definition of the Coordinate System positions and close the CoordSys Manager dialog box with the button. choose CoordSys #1. Click on the model face as shown. Z In the same manner. Define additional CoordSys Positions In the SolidCAM Manager tree.4. 9. dialog box. 151 . Milling on Mill-Turn CNC-Machines 8. The SolidCAM Manager tree is displayed. button.

Confirm the definition with the button. Define the Geometry In the Geometry page.10. Click on the Accept Chain confirm the edge selection. Define the Tool side Operation Switch to the Technology page of the Profile dialog box. The tool has to be located inside the geometry. Select the model edge as shown. The Geometry Edit dialog box is displayed. Define the Milling levels Click on the Profile depth button. click on the Geometry button to check the tool location relative to the selected geometry. Define the Tool Define a new Ø16 End Mill for the operation. change the tool side. Define the Profile depth directly on the solid model by clicking on the face as shown. define the offset from the geometry. In the Modify section. 152 . choose Machine CoordSys #1 Position #2 from the list and click on the Define button. 12. 13. If it is not located correctly relative to the geometry. button to Confirm the geometry definition by clicking on the button. 11. In the Modify offset section.

The machining is performed at the specified offset. SolidCAM performs the finishing cut that overlaps the geometry. the finish is not performed because the Wall offset is 0. Set the Wall offset to 0. The machining is performed exactly on the Geometry defined by the Modify offset parameter. In this exercise. Define the Roughing parameters On the Technology page of the Profile Operation dialog box. With a negative offset value. Geometry 2 14.4. set the Offset value to 20 and the Step over value to 10. In the Clear offset area. Machining Geometry Modify offset Set the Modify offset value to -2. Make sure that the Finish check box is cleared. 153 Step over Clear offset . Milling on Mill-Turn CNC-Machines The Offset parameter enables you to define the offset for the machining geometry. select the Rough check box.

Confirm the edge selection with the Accept Chain dialog box. 19. Close the Profile Operation dialog box with the Exit button. Define the Geometry In the Geometry area. 16. Add a Profile operation Add a new Profile operation to machine the step located on the machined inclined face. Select the model edge as shown.15. For Lead out. Define the Lead in and the Lead out On the Link page. 18. The Geometry Edit dialog box is displayed. choose the Tangent option for Lead in and set the Length value to 10. 17. button in the Geometry Edit 154 . Simulate the operation Simulate the operation in the SolidVerify mode. Click on the Define button. choose the Machine CoordSys #1 Position #2. select the Same as Lead in check box. Save and Calculate Click on the Save & Calculate button to save the operation parameters and calculate the tool path. Confirm the geometry definition with the button.

Milling on Mill-Turn CNC-Machines 20. the step is machined in a single cut. 22.4. The tool has to be located inside the geometry. 21. if it is not located correctly. Use the inclined face for the Upper level definition. 155 . In the Profile Operation dialog box. choose the tool used in the previous operation (Ø16 End Mill). Define the Tool side In the Tool side section of the Technology page. select the Finish check box and set the Step down value to 1. With this value. click on the Geometry button to check the tool position relative to the selected geometry. Use the lower face of the step for the Profile depth definition. change the tool side. Define the Milling levels Define the Milling levels directly on the solid model. Define the Tool In the Part Tool Table.

Define the Lead in and the Lead out On the Link page. 25. In the Select centers by field. For Lead out. Add a Drilling operation Add a new Drilling operation to machine holes Ø3 located on the inclined face.23. 26. 156 . The Drill Geometry Selection dialog box is displayed. choose the Tangent option for Lead in and set the Value to 10. Define the Tool Define a new drilling tool Ø3 for the operation. Save and Calculate Click on the Save & Calculate button to save the operation parameters and calculate the tool path. SolidCAM automatically determines all centers of the holes located on the selected face. choose the Multi-positions option. Simulate the operation Simulate the operation in the SolidVerify mode. 28. Define the Geometry On the Geometry page. 24. select the Same as Lead in check box. Confirm the geometry selection by clicking on the button. 27. Select the inclined face as shown. choose Machine CoordSys #1 Position #2 for the operation. Click on the Define button to define the Geometry.

157 . Define the machining of the other side Repeat Steps #9-32 for the other inclined face of the model. 33. 31. Save and Calculate Click on the Save & Calculate button to save the operation parameters and calculate the tool path. Pick the drill cone vertex to define the Drill depth. Define the Drill cycle In the Technology page. Define the Upper level by clicking on the inclined face of the model as shown. Use Machine CoordSys #1 Position #3 for the operations. Milling on Mill-Turn CNC-Machines 29. Define the Milling levels Define the Upper level and the Drill depth directly on the solid model.4. In the Drill Options dialog box. 32. choose the Peck drill cycle for the operation. Simulate the operation Simulate the operation in the SolidVerify mode. 30. set the Step down to 2.

The following steps have to be implemented in order to reach the final CAM-Part: 1. 3. The Nakamora-MT CNC-controller has to be chosen for this exercise.sldprt) is located in the Exercises folder. External turning Machine the external turning faces using the automatically generated envelope.Exercise #16: Console Machining Define the CAM-Part and operations for the machining of the console presented on the illustration on a 5-axis Mill-Turn CNC-machine. 2. The SolidWorks model of the Console (Exercise16. the Stock model and the Target model. 158 . the Coordinate System. • Indexial 4-axis milling on 5-axis machines. • Turning. This exercise reinforces the following skills: • CAM-Part definition. Indexial milling Define a number of operations for indexial milling to machine the highlighted faces. the clamping fixture. the CNC-controller. you have to define the CAM-Part. Define the CAM-Part At this stage.

159 . Inclined faces machining Define a number of operations to machine the inclined faces. Milling on Mill-Turn CNC-Machines 4.4. Pocket machining Machine the pocket located on the inclined face. 6. Drilling Define a number of Drilling operations to machine all the holes on the model. 5.

• The Default configuration describing the final state of the part (used for the Target model definition). The goal of this exercise is to demonstrate the SolidCAM capability of milling of pre-machined parts on MillTurn CNC-machines. In this exercise. This exercise reinforces the following skills: • CAM-Part definition.sldprt) is located in the Exercises folder.Exercise #17: Milling of Pre-Machined Parts Define the CAM-Part and operations for the machining of the optical part presented on the illustration on a 4-axis Mill-Turn CNC-machine. The SolidWorks model (Exercise17. • Indexial and Simultaneous 4-axis milling on 4-axis machines. the milling is performed on the previously turned workpiece. • Facial milling on 4-axis machines. Stock Default The following steps have to be implemented in order to reach the final CAM-Part: 160 . This model contains two configurations: • The Stock configuration describing the part in the pre-turned stage (used for the Stock model definition).

You need to define the Stock model that describes the initial state of the workpiece to be machined and the Target model that describes the model after the machining. choose Default. the CAM-Part is defined. In the Configurations section of the 3D Geometry dialog box. At this stage. Use the 3D Model mode of the Stock model definition. Milling on Mill-Turn CNC-Machines 1. Click on the button in the Mill-Turn Part Data dialog box. In the Configurations section. Now you have to define milling operations to machine the part. choose Nakamora-MT from the CNC-controller list. The Stock configuration of the model is displayed. Confirm the Target model definition.01 for the Stock and Target model definition. Click on the Define button.4. Define the CAM-Part In the Mill-Turn Part Data dialog box. Click on the solid model to select it. The Default configuration of the model is displayed. Now you need to define the Target model. Set the Facet tolerance value to 0. This mode enables you to define the stock model via 3D model selection. there is no need to define the clamp geometry in this exercise. choose Stock. Define the Coordinate System using the Center of revolution face option as shown. 161 . Confirm the Stock model definition. Since the workpiece used for this part machining was previously turned. Click on the solid model to select it.

2. Facial milling

Machine the screw slot and four holes using the SolidCAM facial milling capabilities.

3. Machining of the side faces

Machine the side faces of the model. Define an additional position for Machine CoordSys #1. Use the Transform option to create a circular pattern of operations around the revolution axis.
4. Drilling on the side face

Machine two holes located on the side face of the model.

5. Slot machining

Machine the slot using indexial 4-axis milling capabilities of the Profile operation. Define an additional position for Machine CoordSys #1.

6. Radial holes machining

Machine three counterbore holes located on the cylindrical face. Define two additional positions for Machine CoordSys #1.

7. Pocket machining

Machine the pocket using simultaneous 4-axis milling capabilities of the Pocket operation. Define an additional position for Machine CoordSys #1.

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4. Milling on Mill-Turn CNC-Machines

Exercise #18: Milling of Pre-Machined Parts
Define the CAM-Part and operations for the machining of the part presented on the illustration on a 4-axis Mill-Turn CNC-machine. The goal of this exercise is to demonstrate the SolidCAM capability of milling of pre-machined parts on MillTurn CNC-machines. In this exercise, the milling is performed on the previously turned workpiece. This exercise reinforces the following skills: • CAM-Part definition; • Facial milling on 4-axis machines; • Indexial and Simultaneous 4-axis milling on 4-axis machines. The SolidWorks model (Exercise18.sldprt) is located in the Exercises folder. This model contains two configurations: • The Stock configuration describing the part in the pre-turned stage (used for the Stock model definition); • The Default configuration describing the final state of the part (used for the Target model definition).

Stock

Default

The following steps have to be implemented in order to reach the final CAM-Part:
1. Define the CAM-Part

At this stage, you have to define the CAM-Part, the CNC-controller, the Coordinate System, the Stock model and the Target model. Since turning is not performed in this exercise, there is no need to define the clamp geometry. The Nakamora-MT CNC-controller has to be chosen for this exercise.
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2. Facial milling

Machine the hexagon and six holes using the SolidCAM facial milling capabilities.

3. Machining of the side faces

Machine the side faces of the model. Define an additional position for Machine CoordSys #1. Use the Transform option to create a pattern of operations around the revolution axis.

4. Pocket machining

Machine the wrapped pocket using the simultaneous 4-axis milling capabilities of the Pocket operation.

5. Slot machining

Machine the slot using simultaneous 4-axis milling capabilities of the Profile operation.

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Back Spindle Use on Mill-Turn CNC-Machines

5

SolidCAM supports the use of the back spindle in the Mill-Turn module. This functionality enables you to use the back spindle of your CNC-machine for Turning and Milling machining with the part clamped in the main or back spindle. The part is transferred between the spindles, thus enabling you to complete the part machining from both sides in a single setup.

5.1 Working with Back Spindle
Each milling or turning operation can be performed with the part clamped in the main or back spindle. There are several typical operation sequences for working with the back spindle in SolidCAM: Operation sequence #1: General use There are three optional stages in this operation sequence: 1. SolidCAM Operations with Main spindle. At this stage, only the main spindle is used for milling and turning operations; this is the standard way of working in SolidCAM when the back spindle does not exist.

2. SolidCAM Operations with Back spindle. At this stage, the operations are performed with the back spindle only.

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the combined operations with the main and back spindle use enable you to avoid unnecessary tool change (in cases when the same tool can work with the main and back spindles). Machining with the main and back spindle Transferring the part to the back spindle 167 . Back Spindle Use on Mill-Turn CNC-Machines Operation sequence #2: Optimized tool use SolidCAM enables you to define a combined sequence of operations that uses intermittently the main and back spindles. The Machine Control Operation enables you to define the transfer of the machined part between the main and back spindles.5. In this sequence. In the beginning or end of all operations. Each operation in the sequence is related either to the main or to the back spindle. the finished part is ejected from the back spindle and the partly machined part is transferred from the main spindle to the back spindle.

Load the SolidWorks model Load the Exercise19. In the CoordSys Data dialog box.sldprt model located in the Exercises folder. In the Mill-Turn Part Data dialog box. 168 .Exercise #19: Machining with Back Spindle This exercise covers the process of CAM-Part and operations definition for machining of the part on a Mill-Turn CNC-machine using the back spindle. 2. Define the Coordinate System Define the Coordinate System as shown using the CoordSys dialog box. 1. choose the Nakamora-MT CNC-controller from the list. switch to the Rear tab. Start the Mill-Turn part definition Start SolidCAM and confirm the New Mill-Turn Part dialog box. 3.

• The Clearance level is the Z-level to which the tool moves rapidly from one operation to another (in case the tool does not change). The negative Z-direction can be used in case of milling of the part from the back side with the same Coordinate System in the main spindle or in case of using the back spindle. CoordSys X Tool Start Level Clearance level Part Upper level Y Part Lower level Z This tab contains the following parameters: • The Tool start level defines the Z-level at which the tool starts working. • The Part lower level defines the lower surface level of the part to be machined. Back Spindle Use on Mill-Turn CNC-Machines The Rear tab displays levels for machining from the negative Z-direction.5. 169 . • The Part upper level defines the height of the upper surface of the part to be machined. Tool Start level Rapid Movements area Clearance level Feed Movements area Part Upper level Part Lower level Confirm the CoordSys Data dialog box by clicking on the OK button.

set the Facet tolerance value to 0.4. Set the Right and Left offsets to 2 and the External diameter to 6. Define the Target model In the Target section of the Mill-Turn Part Data dialog box. Set the Facet tolerance value for the Stock model to 0. Define the Stock model Define the Stock model using the Cylinder option. Confirm the CAM-Part definition.01. SolidCAM created the Envelope sketch in the CAM component of the CAM-Part assembly. The sketch contains an envelope of the target model that will be used later for the turning geometry definition. During the Target model definition.01 and define the Target model using the Envelope option. 170 . 5.

Define the clamping fixture (main spindle) Right-click on the Operations header in SolidCAM Manager and choose Define Fixture from the Add Turning submenu.5. 171 . use the default Main option and make sure that the default clamping option is chosen. Back Spindle Use on Mill-Turn CNC-Machines 6. • Set the Step width (SW) and the Step height (SH) values to 14. To define the Axial position. The clamping fixture for the main spindle is defined. The value of -200 is displayed in the Axial position edit box. Define the dimensions of the chuck as follows: • Set the Jaw width (JW) and the Jaw height (JH) values to 42. pick the edge of the back face of the model. Set the Clamping diameter to 166. The Model dialog box is displayed. Change this value to -190. Make sure that the Chuck (Standard) option is chosen in the Defined by section. In the Clamping method section.

On the Geometry page. 172 . This submachine is a combination of turret and spindle used to perform this operation. Set the Start extension to 3 and the End extension to 1. you need to perform external turning of the part. make sure that Turret_MainSpindle is chosen for Submachine. Perform external turning At this stage. Define the geometry using the Envelope sketch as shown.7. Add a Turning operation.

switch to the Rough tab and choose Smooth for Rough type. at the end of every pass the tool continues moving along the geometry until it meets the previous pass. 173 . then it retreats from the material. Back Spindle Use on Mill-Turn CNC-Machines Add an External Rough tool and set the lengths of the cutting edges D1 and D2 to 5. When this option is chosen. A smooth material boundary results from this type of turning. On the Technology page of the Turning Operation dialog box.5.

Switch to the Semi-Finish/Finish tab and make sure that the Use Compensation check box is not selected. 174 . The radius of the tool nose will not be taken into account when calculating the tool movements. click on the Save & Copy button to perform an additional Turning operation that will remove the rest material remaining after this operation. Simulate it in the SolidVerify mode. Choose ISO-Turning method for Finish. choose the From negative Z option in the Material to be cut section to enable the tool movement in the negative Z-direction. On the Geometry page of the copied Turning Operation dialog box. Save and calculate the operation. In the Turning Operation dialog box. The copy of this operation is added in the SolidCAM Manager tree.

8. Save and calculate the operation. Simulate it in the SolidVerify mode. Set the Angle to 180. Set the Total Length to 150. . Back Spindle Use on Mill-Turn CNC-Machines Add an External Rough tool with the same parameters as the one used for the previous operation. Edit the following parameters: • • • 175 Set the diameter (D) to 42.5. Add a Drill tool. Perform drilling of the central hole Add a Turning Drilling operation to perform drilling of the hole in the center of the part. Set the Cutting edge direction to Left.

Switch to the Technology page to define the initial and final positions of the drilling.• • • Set the Outside Holder Length to 140. Save and calculate the operation. Simulate it in the SolidVerify mode. 176 . set the Z coordinate to -110. For the Drill end position. Use the CoordSys origin as the Drill start position. Set the Shoulder Length to 130. Set the Cuttng Length to 120.

Define the milling levels on the Levels page of the Profile Operation dialog box. The value (0) is displayed in the Milling levels area. 177 . Add an End mill of Ø20. Set the Shoulder length to 70. Perform facial milling Add a Milling Profile operation to perform machining of the dodecagon faces. Back Spindle Use on Mill-Turn CNC-Machines 9. Set the Outside holder length to 80. Define the geometry as shown. Edit the tool parameters as follows: • • • • Set the Total length to 90. Set the Cutting length to 60. Set the Profile depth to 45. Use the BT40 ER32x60 tool holder. Select the front model face to define the Upper level.5.

Save and calculate the operation. you have to perform finish machining of the profile. Simulate it in the SolidVerify mode. define the strategy with which the tool will approach the material and retreat away. 178 . For Lead in and Lead out. Set the Radius values to 5 for Lead in and 2 for Lead out. On the Technology page. On the Link page. set the Step down for finishing to 9.In this exercise. choose the Arc strategy.

Define the geometry as shown. On the Tool page. • Set the lengths of the cutting edges (D1 and D2) to 9. 179 . • Set the tool tip angle (a°) to 50. click on the button. For correct positioning of the tool. Set the Start extension to 3. Add an Internal Rough tool and edit the following parameters: • Set the height of the tool (D) to 120. Perform internal turning Add a Turning operation to perform internal turning of the part. set the Tool angle. Back Spindle Use on Mill-Turn CNC-Machines 10.5.

Choose ISO-Turning method for Finish. This enables you to perform internal longitudinal turning. Use the Half view button to display the interior of the part during the simulation. Save and calculate the operation. Simulate it in the SolidVerify mode.On the Technology page. 180 . make sure that Process type is set to Long and Mode to Internal. make sure that the Use Compensation check box is not selected. In the Semi-Finish/Finish tab. The radius of the tool nose will not be taken into account when calculating the tool movements.

In the Model dialog box. right-click on the last operation and choose Define Fixture. After. The clamping fixture for the back spindle is defined. you need to define the back spindle.5. Back Spindle Use on Mill-Turn CNC-Machines 11. The value of 0 is displayed in the Axial position edit box. pick the edge of the front face of the model. Define the clamping fixture (back spindle) For further machining of the part faces that require tool access from the front side. • Set the Step width (SW) and the Step height (SH) values to 14. Change this value to -10. Define the dimensions of the chuck as follows: • Set the Jaw width (JW) and the Jaw height (JH) values to 42. To define the Axial position. In the SolidCAM Manager tree. Clamping method section. 181 . choose the Sub option in the Set the Clamping diameter to 160.

right-click on the last operation and choose Machine Control from the Add Milling or Add Turning submenu. Transfer the part to the back spindle For further machining of the part faces that require tool access from the other side. In the SolidCAM Manager tree.12. 182 . you have to transfer the part to the back spindle.

tool change. 183 . Using this operation. The procedure is as follows: the jaws of the back spindle chuck will open. the part will be moved from the main spindle to the back spindle.5. Back Spindle Use on Mill-Turn CNC-Machines The Machine Control Operation dialog box is displayed. etc. the back spindle will be moved to the part. opening/closing the chuck jaws. the back spindle will be returned to its initial position. • Properties This section contains a list of parameters of devices to be modified. the jaws of the main spindle chuck will open to release the part. • Process In this section the various machine devices are added for performing actions such as movements. Choose the device to be managed and drag-and-drop it into the Process section. • Action on This section contains a list of available CNC-machine devices. its jaws will take the part and close. Machine Control Operation This operation enables you to manage and use the devices of the CNCmachine.

In the Properties section. Drag and drop the Chuck item from the Action on section into the Process section. In the Process section. In the Properties section. The Chuck item is displayed in the Process section. choose Open from the Value list. The Table item is displayed in the Process section.The first action you need to perform is open the jaws of the back spindle chuck. Drag and drop the Table item from the Action on section into the Process section. choose the BackSpindle item from the Value list to indicate that the action will be performed on the back spindle. select the Clamp check box under Chuck. 184 . Now you need to define the back spindle movement.

5. In the Process section. This parameter defines the absolute Z-coordinate of the front face of the jaws relative to the Coordinate System. set the Z value to -10. Z This coordinate is displayed on the model. select the Movement check box under Table. In the Properties section. 185 . Back Spindle Use on Mill-Turn CNC-Machines In the Properties section. choose the BackSpindle item from the Value list to indicate that the action will be performed on the back spindle.

186 . Drag and drop the Chuck item from the Action on section into the Process section. In the Properties section. Drag and drop the Chuck item from the Action on section into the Process section. choose Close from the Value list. In the Properties section. select the Clamp check box under Chuck. An additional Chuck item is displayed in the Process section. In the Process section. The next action you need to perform is open the jaws of the main spindle chuck. choose the BackSpindle item from the Value list to indicate that the action will be performed on the back spindle.The next action you need to perform is close the jaws of the back spindle chuck.

In the Process section.5. select the Clamp check box under Chuck. choose Open from the Value list. In the Properties section. Drag and drop the Table item from the Action on section into the Process section. 187 . make sure that the MainSpindle item is chosen in the Value list. Back Spindle Use on Mill-Turn CNC-Machines An additional Chuck item is displayed in the Process section. Now you need to return the back spindle to its initial position. choose the BackSpindle item from the Value list to indicate that the action will be performed on the back spindle. In the Properties section. An additional Table item is displayed in the Process section. In the Properties section.

The coordinates of the back spindle initial position are specified in the Machine ID file of your CNC-machine. Click on the Save button at the bottom of the Machine Control Operation dialog box. set the Z value to 1500. In the Properties section. Then click on the Exit button. 188 . The definition of this operation is completed. select the Movement check box under Table. Now you have to machine the rest of the part features using the back spindle.In the Process section.

Back Spindle Use on Mill-Turn CNC-Machines 13. On the Geometry page of the Turning Operation dialog box.5. 189 . Define the geometry as shown. Make sure that the geometry is directed to the back spindle. choose Turret_BackSpindle from the Submachine list. Perform turning of the back face Right-click on the back spindle entry in the SolidCAM Manager tree and add a Turning operation to machine the material that remains in the area where the part was clamped by the main spindle.

On the Technology page. Choose the From negative Z option in the Material to be cut section to enable the tool movement in the negative Z-direction. Choose the Tool #2 (Ext.Set the Start and End extension values to 3.rough tool) for the operation. make sure that Process type is set to Long and Mode to External to perform longitudinal external turning of the part. 190 .

Choose ISO-Turning method for Finish. Play the simulation of the operation in the SolidVerify mode. The radius of the tool nose will not be taken into account when calculating the tool movements. 191 .5. make sure that the Use Compensation check box is not selected. Back Spindle Use on Mill-Turn CNC-Machines In the Semi-Finish/Finish tab.

14. Choose the Tool #4 (Ø20 End mill) for the operation. Select the profile geometry as shown. choose Turret_ BackSpindle from the Submachine list. On the Geometry page of the Profile Operation dialog box. 192 . Perform facial milling from the rear side Add a new Profile operation to perform machining of the part rear faces. The Upper level value (-200) is displayed in the Milling levels section. Select the back face of the model to define the Upper level. On the Levels page of the Profile Operation dialog box. define the milling levels. Set the Profile depth value to 55.

choose the Arc strategy for Lead in and set the Radius value to 5. The linear movements will be performed in the XC-coordinates. Play the simulation of the operation in the SolidVerify mode. Back Spindle Use on Mill-Turn CNC-Machines In this operation. set the Step down for finishing to 5. Set the Coordinate type to Cartesian. Perform drilling of the part Add a new Turning Drilling operation to perform drilling of the hole in the center of the part from the back side. On the Geometry page. Use the Tool #3 for the operation. 193 . select the the 4th Axis check box to define the technological parameters of the facial milling. In the Coordinate type section. On the Technology page. On the Link page. choose the Face option to perform facial milling. select the Same as Lead in check box. choose the From negative Z option in the Material to be cut section to enable the tool movement in the negative Z-direction. On the Motion Limits Control page.5. Select the Rear check box that enables the machining of the part from the negative Z-direction using the same Coordinate System. 15. you have to perform finish machining of the profile. For Lead out.

The Tool change postition for this CAM-Part is defined at 200. 0. Set the Z coordinate for Drill start position to -200. For the Drill end position. 194 . But in the current operation the Tool change postition needs to be shifted to avoid tool crash with the material.Define the Tool change postition for the operation. switch to the Tool change postition tab. choose the User-defined option and set the Z value to -250. On the Technology page. define the initial and final position of drilling. On the Tool page. 20 (this data is provided in the Machine ID file). set the Z coordinate to -90. The Tool change postition will be shifted along the Z-axis 50 mm behind the model rear face to enable safe tool approach.

Set the Start extension to 15. 195 . choose the From negative Z option in the Material to be cut section. Perform internal turning from the rear side Add a Turning operation to machine the interior of the part from the back side.5. Back Spindle Use on Mill-Turn CNC-Machines Play the simulation of the operation in the SolidVerify mode. Define the geometry as shown. On the Geometry page. 16.

Set the tool tip angle (a°) to 50. set the Tool angle. Set the Cutting edge direction to Left. make sure that Process type is set to Long and Mode to Internal to perform longitudinal internal turning of the part. Set the lengths of the cutting edges (D1 and D2) to 8. 196 .Add an Internal Rough tool and edit the following parameters: • • • • Set the height of the tool (D) to 120. On the Technology page. On the Tool page. click on the button. For correct positioning of the tool.

Play the simulation of the operation in the SolidVerify mode. Choose ISO-Turning method for Finish.5. The radius of the tool nose will not be taken into account when calculating the tool movements. 197 . Back Spindle Use on Mill-Turn CNC-Machines In the Semi-Finish/Finish tab. make sure that the Use Compensation check box is not selected.

Define the Upper level by clicking on the model back face. Add an End mill of Ø18. choose Turret_BackSpindle from the Submachine list. Set the Shoulder length to 70. 198 . Set the Cutting length to 60. Use the BT40 ER32x60 tool holder. On the Geometry page of the Profile Operation dialog box.17. Perform facial pocket machining Add a new Profile operation to perform machine the pocket at the back side of the part. Select the geometry as shown. Set the Outside holder length to 80. Edit the tool parameters as follows: • • • • Set the Total length to 90. The value (-200) is displayed in the Pick Upper level dialog box.

The value (-10) is displayed in the Pick Lower level dialog box. set the Tool side to Right. Set the Offset value to 5 and the Step over value to On the Link page. Back Spindle Use on Mill-Turn CNC-Machines Define the Profile depth by clicking on the bottom face of the pocket. 4.5. Select the Finish check box and set the Step down for finishing to 5. Set the Radius values to 6 for Lead in and 2 for Lead out. Set the Wall and Floor offsets to 0. Select the Clear offset check box. 199 . On the Technology page. Select the Rough check box and set the Step down for rough machining to 5. choose the Arc strategy for Lead in and Lead out. Perform finishing of the profile.5.2.

you need to perform drilling of holes located on the face machined in the previous operation. 18. 200 . Add a Drilling operation for center drilling of the holes. choose the Face option to perform facial milling. The linear movements will be performed in the XC-coordinates. Play the simulation of the operation in the SolidVerify mode. On the Geometry page of the Drilling Operation dialog box. Perform drilling of the rear pocket holes At this stage. In the Coordinate type section. Select the Rear check box that enables the machining of the part from the negative Z-direction using the same Coordinate System. Define the geometry as shown. choose Turret_BackSpindle from the Submachine list.Axis On the Motion Limits Control page. select the the 4th check box to define the technological parameters of the facial milling. Set the Coordinate type to Cartesian.

In the Coordinate type section.5. choose the Face option to perform facial milling. select the the 4th Axis check box to define the technological parameters of the facial milling. choose the Diameter value option and set the value to 7. Define both the Upper level and the Drill depth by clicking on the model face as shown. 201 . Select the Rear check box that enables the machining of the part from the negative Z-direction using the same Coordinate System. Set the Coordinate type to Cartesian. For Depth type. Back Spindle Use on Mill-Turn CNC-Machines Add a new Ø10 Spot drill tool for the operation. On the Motion Limits Control page. The linear movements will be performed in the XC-coordinates.

Use the BT40 ER16x70 tool holder.Play the simulation of the operation in the SolidVerify mode. 202 . For Upper level definition. Set the Shoulder length to 40. Add a new Ø8. Choose the Drill2 geometry defined in the previous operation.8 Drill tool for the operation. For Drill depth. pick the vertex at the bottom of the hole as shown. Set the Outside holder length to 50. Set the Cutting length to 30. select the model face that was selected in the previous operation. Edit the tool parameters as follows: • • • • Set the Total length to 60. Define an additional Drilling operation to drill the holes.

In the Coordinate type section.5. choose the Face option to perform facial milling. The exercise is finished. select the the 4th Axis check box to define the technological parameters of the facial milling. The linear movements will be performed in the XC-coordinates. 203 . Back Spindle Use on Mill-Turn CNC-Machines On the Technology page. On the Motion Limits Control page. Select the Rear check box that enables the machining of the part from the negative Z-direction using the same Coordinate System. Play the simulation of the operation in the SolidVerify mode. choose Peck for Drill cycle type and set the Step down to 2. definition of the part machining operations is completed. At this stage. Set the Coordinate type to Cartesian.

204 . the Machine Coordinate System. • Facial milling. The Nakamora-MT CNC-controller has to be chosen for this exercise. 2. the main and the back spindle. External turning Define a Turning operation to perform external turning of the front faces. The following steps have to be implemented in order to reach the final CAM-Part: 1. you have to define the CAM-Part. • Machining of parts using the main and back spindle. This exercise reinforces the following skills: • CAM-Part definition. • Indexial milling.Exercise #20: Shaft Machining Define the CAM-Part and operations for the machining of the shaft part presented on the illustration on a Mill-Turn CNC-machine. 3. the Stock and the Target model. • Turning. Facial milling Define a Profile operation to machine the part faces using the facial milling feature. Define the CAM-Part At this stage. The SolidWorks model of the Shaft (Exercise20. the CNC-controller.sldprt) is located in the Exercises folder.

External turning Define a Turning operation to perform external turning of the rear faces. Use the Machine CoordSys #1 Position 1 for this operation. Transfer the part to the back spindle Define a Machine Control operation to transfer the part from the main to the back spindle for machining of the rear faces of the part. Use the Machine CoordSys #1 Position 1 for this operation. 8. Facial milling Define a Profile operation to machine the part rear faces using the facial milling feature. Back Spindle Use on Mill-Turn CNC-Machines 4. 6. Define an additional Coordinate System position for this operation. Use the Machine CoordSys #1 Position 3 for this operation.5. 9. 5. Define an additional Coordinate System position for this operation. 205 . Slot machining Define a Slot operation to machine the slot using the indexial milling capabilities. Indexial drilling Define two Drilling operations to machine the through hole located on the face machined in the previous operation. 7. Indexial drilling Define two Drilling operations to machine the through hole located on the face machined in the previous operation.

206 .

Mill-Turn CNC-Machine Definition 6 .

1. a model of CNC-machine needs to be defined.1 CNC-machine model definition To perform simulation of machining operations in the Machine simulation mode. The axes of this Coordinate System should be oriented according to the axes orientation of the CNC-machine. The image below shows a schematic model of a Mill-Turn CNC-machine built in SolidWorks. Each STL file has to be created using an output coordinate system located at the CNC-machine origin. For the Mill-Turn CNC-machine shown above. the X-axis is defined parallel to the turret support movements. When the CAD model of the CNC-machine is prepared. each one representing a different component of the CNC-machine. it can be exported into a number of STL files. 208 . An example of Mill-Turn CNC-machine model definition is described below. 6.6.1 Preparing a CNC-machine model Machine simulation requires a model of the CNC-machine in the STL format. the Z-axis is oriented along the spindle revolution axis. Such model can be supplied by a CNC-machine vendor or prepared by yourself in a CAD system.

When the coordinate system is defined. After the coordinate system is defined and all the CNC-machine components are placed into their initial state. Click on the Options button to define the additional parameters of export. Save As. Z=0.6. the CNC-machine model has to be exported into the STL format. Mill-Turn CNC-Machine definition For the Mill-Turn CNC-machine shown above. Note that for the spindle turret. the components performing translational axis movements have to be placed at X=0. The Save As dialog box is displayed. Choose the STL type for export of the model. move all the components into their initial state. for the rotary turret. the coordinate system origin of its station should be coincident with the CNC-machine origin. you have to define a new coordinate system located in the intersection of the front face of the spindle and the revolution axis of the spindle (CNCmachine origin). Y=0. Click File. the coordinate system origin of its first station should be coincident with the CNC-machine origin. 209 .

choose the defined coordinate system for the STL export.The Export Options dialog box is displayed. Confirm the Export Options dialog box with the OK button. 210 . Adjust the STL Resolution parameters according to your needs. This dialog box enables you to define parameters of the STL export (see SolidWorks Help for detailed explanation). This option ensures that exported parts maintain their original position in global space. relative to the origin. In the Output coordinate system list. Select the Do not translate STL output data to positive space check box.

A new CNC-machine definition is created. choose the location for the STL files and enter the name of the STL file for the CNC-machine assembly. they can be combined into a sub-assembly. It is recommended to try to define the CNC-machine with the minimum number of STL files. 6. A CNC-machine model consists of a number of components. Several separate STL files for all the CNC-machine assembly components are generated. This option creates a single STL file with all the components of a sub-assembly. 211 .1.exe. When assembly components always move together. the new coordinate system has to be defined in the sub-assembly in the location of the CNC-machine origin. In the Machine tab. Such sub-assemblies can be exported separately into STL files using the Save all components of an assembly in a single file option in the Export Options dialog box. All of these files will be used at the further stages of the CNC-machine definition.2 Defining the CNC-machine Load MachSim. click on the New Machine button. the criterion for putting several components into one STL file is the common movement of these components. Before the export of a sub-assembly. Confirm the export with the Save button. Mill-Turn CNC-Machine definition In the Save As dialog box. you can put several components together in one sub-assembly that is exported into a single STL file. To reduce the number of STL files.6.

Browse to the Machine definition folder and save the machine definition file with the CNC-machine name. Click on the Edit Machine in the Machine tab toolbar to start the definition of the components of the CNC-machine. Copy all the STL files generated from the CNCmachine model into the Machine definition folder. The name of this folder has to be assigned to the Machine Simulation Name parameter in the Machine ID file of the CNC-machine. The Save As dialog box is displayed. this Machine definition folder is the location of all files related to the CNC-machine definition. create a new folder with the name of your CNC-machine. The machine definition is saved as an XML file. Confirm the dialog box with the Save button. In the Machine definition tab. button At this stage. the initial CNC-machine definition is finished. 212 .In the XML folder located in the directory defined as the Directory for Machine simulation definition section in Machine simulation settings. click on the Save Machine button to save the empty machine definition.

The first group includes the CNC-machine base. all the components of the CNC-machine can be classified into two groups: non-moving components and moving components. etc. enter the name of the CNC-machine. The second group includes carriages. Non-moving component (housing) Moving components 213 . spindle unit. In the Name field. In the bottom part of the Machine tab. These parts provide the translational/rotational movements. Mill-Turn CNC-Machine definition Defining the name of the CNC-machine Select the root item of the CNC-machine definition tree. Generally. turret. Click on the Save Machine button. doors. Understanding the structure of the CNC-machine Before defining your CNC-machine components. controller.6. you have to analyze the machine kinematics. etc. the element properties table appears.

214 . All these components perform translational movements. the Y-axis support is the “parent” of the X-axis support because the X-axis support is mounted on the Y-axis support. the lower rotary turret mounted on a support part. the structure of this unit can be described as “parents-children” relations. and so forth. the spindle with fixture that holds the machined part. In the upper turret unit. In the Mill-Turn CNC-machine described above there are three units of moving components: the upper spindle turret mounted on a series of support devices. Similarly.In case of Mill-Turn CNC-machines. The spindle turret performs B-axis rotational movements. the housing is a non-moving component. This X-axis support is mounted on an inclined support that performs movements along the Y-axis. The Z-axis back wall is the “parent” of the Y-axis support because the Y-axis support (“child”) is mounted on the Z-axis back wall. This Y-axis support is mounted on the back wall that performs movements along the Z-axis. All the moving components can be classified according to the dependency of the movements. the relations between components are established as follows: the upper spindle turret is mounted on a support that performs movements along the X-axis. Y-axis support X-axis support Spindle turret Back wall Hierarchically.

Mill-Turn CNC-Machine definition In the lower turret unit. The rotary turret performs movements rotational movements around its axis. 215 . Spindle Rotary turret Rotary turret support The CNC-machine has to be defined according to the “parents-children” relations between the CNC-machine components. the relations between components are established as follows: the lower rotary turret is mounted on a support that performs movements along the X-axis. The spindle unit is a separate set of the CNC-machine components providing the revolution movements (C-axis). these relations determine the order of the components definition and the dependencies between them.6. The revolution of spindle movements does not affect the location of other components of the CNC-machine and does not depend on the location of other components.

Transform.e. In the Machine tab. i. Machine Transform. you need to add a coordinate transformation under the root item of the CNCmachine definition tree. Define its matrix in the element properties table as shown below: Now add the machine housing geometry. the housing. The machine_transform coordinate transformation item is displayed in the machine definition tree.Defining the CNC-machine housing At the first stage of the CNC-machine definition. 216 . you have to define the non-moving components of the machine. The Open dialog box is displayed. Choose the STL model of the housing located in the Machine definition folder. For correct view of the machine housing in the Machine Simulation. The transformation matrix of this item enables you to display the machine model in the Machine Simulation window correctly in terms of axes orientation. Right-click on the added coordinate transformation and choose the Add Geometry command from the list. right-click on the root item of the CNC-machine definition tree and choose Add Coord.

The machine housing geometry added without the coordinate transformation described above will be oriented in the Machine Simulation window as shown below.6. and the default housing component name is displayed in the CNC-machine definition tree. Mill-Turn CNC-Machine definition The housing part is displayed in the graphic area. 217 .

The order of the definition is as follows: “parents” have to be defined before “children”. this component is considered as a housing part. The element properties table also enables you to control the visibility and the visual properties (color. Choose the appropriate settings for the housing component and click on the Save Machine button to save the machine definition in the previously created XML file. several additional moving components (inclined support. reflectivity) of the CNC-machine components. 218 . In case of the Mill-Turn machine shown above. Z Axis Right-click on the machine_transform item and choose from the Add Transl. In the element properties table. define the orientation of the axis by specifying a vector with three coordinates. spindle turret carriage and spindle turret with tool holding system) will be mounted later. Moving components have to be defined according to their hierarchical “parents-children” dependencies. When the mh_ prefix appears in the ID of a CNC-machine component. On this wall. enter the following name: mh_Housing. The Z axis item appears under the coordinate transformation item in the machine definition tree. The components defined with this prefix can be hidden during the simulation using the Show/Hide machine housing button. In the ID field. transparency. the first component to be defined is the back wall performing the Z-axis translational movements. Axis submenu. Defining the translational axis (Z) When all the non-moving components of the CNC-machine are defined. you have to define the moving components.Select the component name in the tree to manage its properties in the element properties table. All the additional non-moving components are defined in the same manner.

6. The defined direction and limits values must correspond to those defined for the Z-axis in the Machine ID file of the CNC-machine. The tool movement in the positive Z-axis direction causes the back wall movement in the positive Z-direction. Z is set to 1. Mill-Turn CNC-Machine definition In this case. specify the geometry of the back wall performing the translational movement along the axis.00000 1. The machine limits data are provided in the machine documentation. In the Direction section of the element properties table. This vector defines the direction of the CNC component movement when the tool moves in the positive axis direction.00000. Therefore. Note that the direction is defined according to the tool movements along the axis. Set the Min Limit value to 0 and the Max Limit value to 800. When the translational axis parameters are defined. The movement of the back wall that performs the Z-axis movements is limited between the Min Limit and Max Limit values. the direction is defined with the following values: 0. Now you need to define the limitation of the translational movements along the axis. 219 . the defined translational axis is the Z-axis.00000 0.

The wall model is displayed in the graphic area. Use the sliders of the Axis Control tab to check the translational movements of the defined geometry along the axis. The Open dialog box is displayed. Rename the newly added component in the element properties table and adjust its visual properties. 220 .Right-click on the just defined axis item and choose Add Geometry from the menu. Click on the Save Machine button to save the machine definition in the XML file. Choose the STL model of the back wall. if necessary.

This vector defines the direction of the CNC component movement when the tool moves in the positive axis direction. Set the Min Limit to 0 and Max Limit to 80. Mill-Turn CNC-Machine definition Defining the translational axis (Y) The next component to be defined is the inclined support performing the Y-axis translational movements. specify the geometry of the part performing the translational movement along the axis. Y Axis.6. the direction is defined with the following values: 0. 221 . this part is the inclined support.00000.00000 1. The Y axis item appears under the Z axis item in the machine definition tree. In this case. In this case. Define the orientation of the axis by specifying a vector with three coordinates. the defined translational axis is the Y-axis. In the Limits section of the element properties table. axis. you have to specify the Min Limit and Max Limit values. The movement of the sliding carriage that performs the X-axis movements is limited between these values.00000 0. Right-click on the Z axis component and choose Add Transl. The defined direction and limits values must correspond to those defined for the Y-axis in the Machine ID file of the CNC-machine. The tool movement in the positive Y-axis direction causes the component movement in the positive Y-direction. Therefore. Note that the direction is defined according to the tool movements along the axis. When the translational axis parameters are defined.

Choose the STL model of the inclined support. Use the sliders of the Axis Control tab to check the translational movements of the defined geometry along the axis.In the CNC-machine definition tree. if necessary. right-click on the just defined axis item and choose Add Geometry from the menu. Click on the Save Machine button to save the machine definition in the XML file. The support model is displayed in the graphic area. The Open dialog box is displayed. 222 . Rename the newly added component in the element properties table and adjust its visual properties.

00000 0.6. Note that the direction is defined according to the tool movements along the axis. Define the orientation of the axis by specifying a vector with three coordinates.00000 0.00000. 1. The tool movement in the positive X-axis direction causes the carriage movement in the positive X-direction. Right-click on the Y axis component and choose Add Transl. specify the geometry of the support part performing the translational movement along the axis. Set the Min Limit to 0 and Max Limit to 500. The movement of the carriage that performs the X-axis movements is limited between these values. In this case. the direction is defined with the following values: This vector defines the direction of the CNC component movement when the tool moves in the positive axis direction. the defined translational axis is the X-axis. X Axis. When the translational axis parameters are defined. axis. The defined direction and limits values must correspond to those defined for the X-axis in the Machine ID file of the CNC-machine. 223 . The X axis item appears under the Y axis item in the machine definition tree. you have to specify the Min Limit and Max Limit values. Mill-Turn CNC-Machine definition Defining the translational axis (X) The next component to be defined is another support performing the X-axis translational movements. In the Limits section of the element properties table. Therefore.

Use the sliders of the Axis Control tab to check the translational movements of the defined geometry along the axis. Choose the STL model of the support.In the CNC-machine definition tree. Click on the Save Machine button to save the machine definition in the XML file. 224 . right-click on the just defined axis item and choose Add Geometry from the menu. Rename the newly added component in the element properties table and adjust its visual properties. The support model is displayed in the graphic area. The Open dialog box is displayed. if necessary.

Since the spindle turret performs rotation around the Y-axis. The defined direction. Add a new rotational axis to the X-axis. This will be the rotational axis of the spindle turret. In the Limits section. In the Center point section. A new rotational axis component is added into the machine definition tree. The coordinates of the center point and limits data are provided in the machine documentation. Mill-Turn CNC-Machine definition Defining the spindle turret The next component to be defined is the spindle turret mounted on the X-axis support. set the Z coordinate to 245. set Min Limit to -120 and Max Limit to 105.6. B Axis. in the Direction section set Y to 1. Define the center point of turret rotation. Right-click on the X axis component and choose Add Rot. center point and limits values must be the same as those defined for the B-axis in the Machine ID file of the CNC-machine. Define the rotational axis limits. Axis. 225 .

Add a geometry to the newly defined rotational axis. Rightclick on the B axis component and choose the Add Geometry command from the menu. Choose the STL model of the turret from the Open dialog box.

The spindle turret model is displayed in the graphic area.

Rename the newly added component in the element properties table and adjust its visual properties, if necessary. Use the sliders of the Axis Control tab to check the rotational movements of the defined geometry along the axis. Click on the Save Machine button to save the machine definition in the XML file.
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6. Mill-Turn CNC-Machine definition

Defining the tool position on the spindle turret Now you need to define a coordinate transformation for the tool position on the spindle turret. Add a new coordinate transformation item. This will be the coordinate system relative to which the tool position will be defined. Right-click on the B axis component and choose Add Coord. Transform, User-defined. Name the newly added transformation component This component is mandatory and serves for correct positioning of the tool on the turret.
station_transform.

Note that the station_transform name is hard-coded in SolidCAM and cannot be changed. The transformation matrix must be defined as follows:

Defining the tool holding system on the spindle turret The next component to be defined is the holder fixing the tool on the turret.
station_transform transform.

Add a new coordinate transformation under the item and name it adaptor_

Note that the adaptor_transform name is hard-coded in SolidCAM and cannot be changed.
227

Add a fixture component under the newly defined transformation item. Right-click on the adaptor_transform component and choose Add Dynamic Element, Fixture. Name the newly defined item TH_adaptor.

Note that the TH_adaptor name is hard-coded in SolidCAM and cannot be changed. This fixture corresponds to the tool holder saved in the STL format and defined in the Part Tool Table. You need to add as many TH_adaptor items into the machine definition tree as the number of tool holders used in the simulated CAM-Part. The holder geometry with the hard-coded name TH_adaptor is related to the holder STL file. In the process of the CNC-machine definition this file does not exist. It will be automatically created during the simulation. Every time during the simulation this file will be overwritten with the actual holder data. Click on the Save Machine button to save the machine definition in the XML file.

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6. Mill-Turn CNC-Machine definition

Defining the tool At this stage, you have to define the default tool and its kinematic relationship with the CNCmachine components. Add a new transformation under the adaptor_transform item. This will be the coordinate system used for correct positioning of the tool on the CNC-machine. Right-click on the adaptor_transform component and choose Add Coord. Transform, User-defined.

Name the newly defined component holder_transform.

Note that the holder_transform name is hard-coded in SolidCAM and cannot be changed.
229

Add the tool element to the holder_transform item and define its kinematic relationship with the CNC-machine components. Right-click on the holder_transform component and choose Add Dynamic Element, Tool. Name the newly defined component tool.

The tool geometry with the hard-coded name tool is related to the tool.stl file. In the process of the CNC-machine definition this file does not exist. It will be automatically created during the simulation. Every time during the simulation this file will be overwritten with the actual tool data. Click on the Save Machine button to save the machine definition in the XML file.

Defining the translational axis (Z1) Another moving unit to be defined on this machine model is the rotary turret with tool positions and its auxiliary devices. First, you need to define the support part on which the rotary turret is mounted. This component performs the Z-axis translational movements. Right-click on the machine_transform item and choose Z Axis from the Add Transl. Axis submenu. The Z axis item appears under the coordinate transformation item in the machine definition tree. In the element properties table, name the added component Z1.

230

Add another translational axis under Z1 and name it X1. 231 . In the Direction section of the element properties table.6. the Z value must be set to 1. In the Limits section. Mill-Turn CNC-Machine definition Define the orientation of the axis and the limitation of the translational movements along the axis.and X-axes. The defined direction and limits values must correspond to those defined for this axis in the Machine ID file of the CNC-machine. set the Min Limit value to 0 and the Max Limit value to 1010. Defining the translational axis (X1) The rotary turret support performs translational movements along both Z.

In the Limits section. The support model is displayed in the graphic area.Define the axis parameters. set the Min Limit value to 0 and the Max Limit value to 150. Specify the geometry of the support part performing the translational movement along the axis. The defined direction and limits values must correspond to those defined for this axis in the Machine ID file of the CNC-machine. Choose the STL model of the support part from the Open dialog box. In the Direction section of the element properties table. set the X value to -1. 232 .

A new rotational axis component is added into the machine definition tree. Name it rotary_turret_axis. Use the sliders of the Axis Control tab to check the translational movements of the defined geometry along the axis. Define the related parameters of the newly added component. 233 . This will be the rotational axis of the rotary turret. in the Direction section set X to -1. if necessary.6. Since the turret performs rotation around the X1 axis. Mill-Turn CNC-Machine definition Rename the newly added component in the element properties table and adjust its visual properties. This turret performs the tool change. Add a new rotational axis under the X1 axis. User-defined. Right-click on the X1 axis component and choose Add Rot. Axis. Click on the Save Machine Defining the rotary turret The next component to be defined is the rotary turret mounted on the just added support part. rotary_turret_axis button to save the machine definition in the XML file.

The turret model is displayed in the graphic area. Choose the STL model of the turret from the Open dialog box. In the Limits section. 234 . set the Z value to 90. In the Center point section. The defined direction. center point and limits values must correspond to those defined for this axis in the Machine ID file of the CNC-machine.Define the center point of turret rotation. Define the rotational axis limits. set Min Limit to 0 and Max Limit to 360. Add a geometry to the newly defined rotational axis.

Depending on the type and structure of the CNC-machine. relative to which the tool positions will be defined. Transform. This will be the rotary turret coordinate system. if necessary. Machine Coordinate System rotary_turret_transform Note that this component is optional and serves only for convenience of the tool positions definition on the current machine. Mill-Turn CNC-Machine definition Rename the newly added component in the element properties table and adjust its visual properties.6. 235 . Right-click on the rotary_turret_axis component and choose Add Coord. Defining the tool positions on the rotary turret Add a new coordinate transformation item. User-defined. Click on the Save Machine button to save the machine definition in the XML file. the tool positions can be defined relative to any other coordinate transformation. Name the newly added transformation component rotary_turret_transform. Use the sliders of the Axis Control tab to check the rotational movements of the defined geometry along the axis.

set the X value to 1. To place the origin of the tool position coordinate system relative to the turret coordinate system. The station_transformXXXX transformation matrix must be defined in such manner that its origin will coincide with Machine CoordSys when all machine axes are set to 0. In accordance with this numbering scheme. Transform. 236 . set the Shift value in the Z row to -90. Define the transformation matrix of the newly added transformation. you define the Z-distance from the Machine Coordinate System origin to the rotary_turret_transform origin. Name the component station_transform2101. • In the Y row. The station_transformXXXX name is hard-coded in SolidCAM and cannot be changed. • the last two characters define the number of the tool position on the rotary turret. set the Z value to 1. The XXXX characters stand for the following: • the first character is the device number of the turret from the turrets table. To define the axis direction in the tool position. User-defined. • In the Z row. • the second character is the number of tools simultaneously mounted at the current station. add as many station_transformXXXX items as you need according to the number of tool positions on your rotary turret.Define the transformation matrix as follows: By setting the Z value for Shift to 90. Right-click on the rotary_turret_transform component and choose Add Coord. Now you need to define a coordinate transformation for each tool position on the rotary turret. set the following values: • In the X row. set the Y value to 1.

6. the axis direction is calculated according to the following formula: Direction X Y Z X Y Z Shift 1 0 0 0 cos α sin α 0 -sin α cos α 0 sin α * R -cos α * R where R is the radius of the turret. 237 . when the tool position #1 is located as shown on the illustration below. Mill-Turn CNC-Machine definition In this case. α Tool position #1 Tool positions Click on the Save Machine button to save the machine definition in the XML file.

238 . The adaptor_transformXXXX name is hard-coded in SolidCAM and cannot be changed. Name it adaptor_transform2101. Add a new transformation under the station_transform2101 item. Add as many adaptor_transformXXXX items as you need according to the number of tool positions on your rotary turret. The XXXX characters inherit their values from the parent item in the tree (adaptor_transformXXXX). Name the newly defined item TH_adaptor2101. The TH_adaptorXXXX name is hard-coded in SolidCAM and cannot be changed.Defining the tool holding system The next component to be defined is the holder fixing the tool on the turret. Add as many adaptor_transformXXXX items as you need according to the number of tool positions on your rotary turret. Add a fixture component under the newly defined transformation item. The XXXX characters inherit their values from the parent item in the tree (station_transformXXXX). Fixture. Right-click on the adaptor_transform1101 component and choose Add Dynamic Element.

Add transformation under the adaptor_transform2101 item. Right-click on the holder_transform2A01 component and choose Add Dynamic Element. This will be the coordinate system used for correct positioning of the tool on the CNC-machine. User-defined. 239 . Add the tool elements to the holder_transformXXXX item and define their kinematic relationship with the CNC-machine components.6. you have to define the default tool and its kinematic relationship with the CNC-machine components. It will be automatically created during the simulation. Mill-Turn CNC-Machine definition This fixture corresponds to the tool holder saved in the STL format and defined in the Part Tool Table. Add as many holder_transformXXXX items as you need according to the number of tools you are using. Every time during the simulation this file will be overwritten with the actual holder data. The holder_transformXXXX name is hard-coded in SolidCAM and cannot be changed. Transform. Name newly holder_transform2A01. B. the defined component a new button to save the machine definition in the XML file. In the process of the CNC-machine definition this file does not exist. C. The XXXX characters stand for the following: • the first character is the number of turret from the turrets table. etc. • the second character (a letter) is the tool position (A. Tool. Click on the Save Machine Defining the tool At this stage. • the last two characters are the number of tool station. The holder geometry with the hard-coded name TH_adaptorXXXX is related to the holder STL file.) defined in the Part Tool Table. Right-click on the adaptor_transform2101 component and choose Add Coord.

The C axis item is added in the CNC-machine definition tree. Define the Direction and the Center point of the rotational axis. The tool geometry with the hardcoded name toolXXXX (the XXXX characters are inherited from the parent item in the tree) is related to the tool. These parameters determine the location and orientation of the rotational axis. In the process of the CNC-machine definition this file does not exist. Click on the Save Machine button to save the machine definition in the XML file.stl file. 240 . Axis submenu. Every time during the simulation this file will be overwritten with the actual tool data. right-click on the machine_transform item and choose the C Axis from the Add Rot. Defining the rotational axis (C) At this stage. In the CNC-machine definition tree.Name the newly defined component tool2A01. you have to define the spindle providing the C-axis rotation. It will be automatically created during the simulation.

00000.00000. In this case. In the Direction section. The defined direction. center point and limits values must correspond to those defined for this axis in the Machine ID file of the CNC-machine. Therefore the axis Direction parameters values are the following: 0. The Center point parameters define the location of the axis relative to the CNC-machine origin. In the CNC-machine definition tree. 241 . The positive direction of the spindle rotational axis is defined by the right hand rule. Therefore. the rotational axis is defined. For the tilting axis.00000 0. Note that the positive tool movement around the rotational axis (positive direction of the C-axis) is performed by the negative rotation of the spindle. the Center point values must be defined as follows: 0.00000 -1. the Min Limit value is -1000°. At this stage. Define the geometry of the spindle. Define the minimum and maximum rotation angle limits. the axis is located in the CNC-machine origin.00000 0. set Z to -1. the Max Limit value is 1000°. Mill-Turn CNC-Machine definition The spindle performs the rotation around the Z-axis.00000 0. right-click on the just defined rotational axis item and choose the Add Geometry command from the menu.6.

Choose the geometry STL file. Click on the Save Machine Defining the workpiece At this stage. The workpiece is attached to the spindle (C-axis). Name the newly-defined geometry component Spindle and adjust its visual properties. Workpiece Set. The spindle geometry is displayed in the graphic area. Use the sliders of the Axis Control tab to check the translational movements of the defined geometry along the axis. if necessary. right-click on the C axis item and choose Add Dynamic Element. you have to define the default workpiece and its kinematic relationship with the CNC-machine components. button to save the machine definition in the XML file. 242 . In the CNC-machine definition tree.

243 . Mill-Turn CNC-Machine definition The workpiece_transform component is added into the machine definition tree with the associated workpiece data. You can perform simulation of CAM-Part operations in the Machine Simulation mode. The CNC-machine definition is completed. The workpiece geometry with the hard-coded name workpiece_transform is related to the workpiece STL file.6. Every time during the simulation this file will be overwritten with the actual target model data. It will be automatically created during the simulation. In the process of the CNCmachine definition this file does not exist. Click on the Save Machine button to save the machine definition in the XML file.

244 .

Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines 7 .

SolidCAM enables you to perform Simultaneous 5-Axis machining on Mill-Turn CNC-machines. 246 . 5-Axis Machining User Guide. please refer to the SolidCAM Sim. For more detailed explanation on the Simultaneous 5-Axis operations.

In the Mill-Turn Part Data dialog box. Define the Coordinate System Define the Coordinate System as shown using the CoordSys dialog box. 247 .sldprt model located in the Exercises folder. choose the Mill_Turn_5_Axis CNC-controller from the list. Start the Mill-Turn part definition Start SolidCAM and confirm the New Mill-Turn Part dialog box. 1. This Coordinate System will be used for Milling and Turning operations. Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines Exercise #21: Turbine Blade Machining This exercise covers the process of CAM-Part and operations definition for Simultaneous 5-Axis machining of the part on a Mill-Turn CNC-machine.7. Load the SolidWorks model Load the Exercise21. 3. 2.

Now that the CAM-Part is defined. 248 . 4. 5. Define the Target model For further turning geometry definition.In the CoordSys Data dialog box. This parameter defines the location of the CAM-Part Coordinate System relative to the coordinate system of the CNCmachine. you have to define a number of operations for machining of the part using the Turning and Simultaneous 5-Axis Milling capabilities. In other words.01. it enables you to define the location of the CAM-Part on the CNC-machine table. Set the Facet tolerance value to 0. Select the solid body for the Target model definition. SolidCAM creates the Envelope sketch in the CAM component of the CAM-Part assembly. 6. The parameter is defined by three coordinates of the distance vector. you will need the envelope of the part. To generate the Envelope sketch during the Target model definition. set the Z coordinate in the Part’s origin position section to -200 for correct positioning of the part on the CNC-machine. Set the Facet tolerance value to 0. Define the Stock model Define the Stock model using the Cylinder option with all of the offsets set to 0.01 and click on the Target button. Save the CAM-Part Confirm the Mill-Turn Part Data dialog box to save the CAM-Part. During the Target model definition. choose the Envelope option under Target options in the Target section of the Mill-Turn Part Data dialog box.

To define the geometry for this operation. expand the CAM component. pick the same model edge. Perform external turning At this stage.5 to make the fixture hold the part’s end by 7. 8.5 mm. Define the dimensions of the chuck as follows: • Set the Jaw width (JW) and the Jaw height (JH) values to 36. • Set the Step width (SW) and the Step height (SH) values to 12. Change this value to -157. Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines 7. Add a Turning operation. prepare a sketch on the ZX-plane of the Coordinate System. pick the edge of the back face of the model as shown. The value of 80 is displayed in the Clamping diameter edit box. Right-click on the Plane_HomeZX1 item button in the menu. Define the clamping fixture Define the clamping fixture using the Chuck (Standard) option. In the FeatureManager Design tree. and click on the Insert Sketch 249 .7. The clamping fixture is defined. you need to perform external turning of the part. To specify the Clamping diameter. The value of -165 is displayed in the Axial position edit box. To define the Axial position.

Add an External Rough tool and set the lengths of the cutting edges D1 and D2 to 5. 250 . Set the Start and the End extension values to 2. 30 Using the sketched line and the vertical fragment of the Envelope sketch.Draw a horizontal line at the distance of 30 mm from the part centerline as shown. Now you have to define the tool holder. define the geometry for the operation.

switch to the Holder page and select the Use holder check box. Define the tool mounting. This tool holder is suitable for tool mounting on the Spindle type of turrets. 251 . Click on the Mounting button in the Part Tool Table dialog box. Choose the Spindle_Turret_Tool_Holder tool holder from the Global holders list by selecting its check box. The Mounting dialog box is displayed.7. Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines In the Part Tool Table dialog box.

-1) (-1. 0.Mounting of turning tools on turrets of the Spindle type is defined by two major parameters: the orientation of the tool’s cutting insert or back ) and the default tool direction vector face (front defined in the Machine ID file. For correct mounting of the tool. 0. Tool tip position Turret This option enables you to define Station the tool tip position relative to CoordSys the station Coordinate System for Machine Simulation. Default tool direction (0. 0. Z X X Z Set the Z value to -50 and the X value to -100. 1) (1. you need to specify the Tool tip position parameters. 0) Use the default tool orientation defined in the Mounting dialog box. 252 . 0) (0. 0.

type is On the Technology page of the Turning Operation dialog box. make sure that Process set to Long and Mode to External to perform external longitudinal turning. Simulate it in the SolidVerify mode.7. 253 . Save and calculate the operation. Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines Click on the Select button to confirm the tool definition.

5-Axis operation to perform rough machining of the turbine blade. you need to define a Sim. This dialog box enables you to define the parameters of the simultaneous 5-axis machining.9. choose General to perform a regular 5-axis operation. In the Technology list. Right-click on the Turning operation entry in the SolidCAM Manager tree and choose the Sim. 254 . Define a 5-Axis operation At this stage. The 5-Axis Operation dialog box is displayed. 5-Axis item from the Add Milling submenu.

7. Machining Angle in XY Machining Angle in Z Y Z α α X X 0° X Y 30° X Y 60° X Y 90° X Y X X X X 0° Y 30° Y 60° Y 90° Y 255 . The direction of the cuts is defined by two Machining angles. Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines 10. The angles In XY and In Z determine the direction of the tool path parallel cuts. Make sure that the Parallel cuts option is chosen in the Pattern section. Define the geometry Switch to the Geometry page to define the geometry for machining. Parallel cuts This option creates tool path cuts parallel to each other.

avoid cuts at exact edges option is chosen. Define the Drive surface offset.2.Under Machining angle. Select the model faces as shown. In the Area section. click on the Constant Z button. The geometry parameters are defined. click on the Define button in the Drive surface section. The machining is performed at the specified distance from the drive surface. Drive Surface offset Z Y X Set the Drive surface offset value to 0. Now you have to define the geometry by selecting the Drive surface – the model faces that will be machined in this operation. Under Geometry. make sure that the Full. The Select Faces dialog box is displayed. 256 . The generated tool path cuts will be parallel to the XY-plane. With this option. The offset is three-dimensional and expands the faces in every direction. the minimal distance between the edge and the tool path is equal to half of the Max. This option enables you to generate the tool path on the whole drive surface avoiding the drive surface edges. Step over value. The Drive surface offset parameter enables you to define a machining allowance for the drive surface. This dialog box enables you to define the geometry by selecting the model faces.

Set the Cutting length to 60. Set the Outside holder length to 80. Set the Corner radius to 4. Define the tool Switch to the Tool page to define the tool for the operation. Use the BT40 ER32x60 tool holder. Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines 11. Set the Shoulder length to 70. 257 .7. Edit the tool parameters as follows: • • • • • • Set the Diameter to 16. Set the Total length to 90. Add a Bull Nose Mill tool.

The Cylinder option enables you to define the Clearance area as a cylindrical surface enclosing the Drive surface. Define the machining levels Switch to the Levels page to define the machining levels for the operation.12. The Parallel to X. The tool performs a retract movement to the Clearance cylinder. Parallel to Y and Parallel to Z options enable you to define the cylinder axes only parallel to one of the Coordinate System axes (X. Under Clearance area. choose the Cylinder option from the Type list. Set the Radius value to 40 and make sure that the Parallel to Z option is chosen. Y or Z). 258 Radius . The Clearance area is the area where the tool movements can be performed with the rapid feed safely without contacting the material. and then a rapid movement along the cylinder surface. The Radius parameter enables you to specify the cylinder radius.

Step over 259 . Under Surface quality.7. Surface edge merge distance SolidCAM generates first tool paths for individual surfaces. This parameter defines the maximum distance between two consecutive cuts. The decision about merging is based on the Surface edge merge distance parameter. In the Surface quality tab. choose As value and set the value to 0.5. SolidCAM checks if a closed surface path can be built by connecting the start to the end. Max. set the Maximum step over value to 5. If all surface paths on a tool path slice are merged. Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines 13. The Surface edge merge distance parameter can be defined either as a numeric value (the As value option) or as a percentage of the tool diameter (the % of tool diameter option). this limit value must be greater than or equal to the Cut tolerance value. under Surface edge merge distance. Define the tool path parameters Switch to the Tool path parameters page. Then they are merged together to form the complete tool path. In both cases.

When the Spiral option is chosen. Choose Spiral for Cutting method. Front Move direction Tool Front 260 .Switch to the Sorting tab. Step over parameter. the tool contact point is located in the beginning of the tool corner radius (for bull nosed tools) in the direction of the tool movement. Step over Under Tool contact point. SolidCAM generates a spiral tool path around the drive surface according to the chosen pattern. It is recommended to use the Gouge checking options to avoid possible gouges. When the At front option is chosen. The spiral pitch is defined by the Max. All changes to tool orientation are performed around the contact point and may cause gouges. The Tool contact point section enables you to define the point on the tool surface that contacts with the drive surfaces during the machining. choose At front.

• Use Lead In The approach movement is performed to the cutting level using the specified Lead In options. button in the First entry The Lead In dialog box is displayed. Click on the section. This dialog box enables you to define the strategy of approach movement. SolidCAM enables you to use pre-defined Lead In/Lead Out strategies to perform the movements between cutting levels. • Use Lead Out The approach movement is performed from the cutting level using the specified Lead Out options.7. The First entry section enables you to define the first approach of the tool to the cutting area. The Last exit section enables you to define the last retreat of the tool from the cutting area after the machining. In the Approach/Retract tab. Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines 14. Define the Lead in and Lead out strategies. 261 . Define the tool path linking Switch to the Link page to define the linking of the tool path. choose the Use Lead In option from the First entry list and the Use Lead Out option from the Last exit list.

The Lead out parameters can be edited. You can change this strategy on the Default Lead In/Out page of the 5-Axis operation dialog box.Make sure that the Use default Lead In check box is selected. button in the Last exit The Lead Out dialog box is displayed. choose Variable. The default Lead in strategy will be used for approach movement. choose Vertical tangential arc. Confirm the dialog box by clicking on the OK button. 262 . This dialog box enables you to define the strategy of retreat movement. For Tool axis orientation. Vertical tangential arc SolidCAM performs the approach/ retreat movement with an arc tangential to the drive surface located in the plane of the tool axis. Click on the section. When this option is chosen. This option enables you to avoid marks on the part surface caused by the tool rotation at the start/end point of the cutting pass. Note that when the side tilting options are used. the plane of vertical tangential arc is not changed. Clear the Use default Lead Out check box. the tool axis orientation continuously changes during the approach/retreat movement. For Type.

make sure that Arc Sweep/Arc diameter option is chosen. Arc sweep/Arc diameter SolidCAM enables you to specify the diameter of the approach/retreat arc using the percentage of the Arc diameter to the Tool diameter. when a tool with the diameter of 10 mm is used and the percentage parameter is set to 200%. Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines In the Use the section. Arc diameter α Set the Height value to 20. For example. When the approach movement is Height performed with an arc. the resulting approach/retreat arc diameter is 20 mm. Height This parameter enables you to define the incremental height of the first point of the approach/retreat movement. The Arc Sweep parameter enables you to define the angle of the approach/retreat arc segment. Set the Arc diameter/Tool diameter value to 300. When the approach movement is performed with a line. the Height parameter enables you to perform a helical approach. 263 .7. the Height parameter enables you to perform inclined ramp approach.

set the Lag angle to cutting direction value to 20 and the Tilt angle at side of cutting direction value to 5. 15.Confirm the dialog box by clicking on the OK button. 264 . In the Tool axis direction section. make sure that the Tilted relative to cutting direction option is chosen. Define the tool tilting parameters Switch to the Tool axis control page to define the parameters related to the tilting of the tool during the machining. Under Angles.

Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines Tilted relative to cutting direction This option enables you to define the tool tilting relative to the cutting direction. The Tilt angle at side of cutting direction parameter is measured relative to surface normal. choose the Follow surface ISO lines direction option. Tilt angle at side of cutting direction Under Side tilt definition. Lag angle to cutting direction The Tilt angle at side of cutting direction parameter enables you to define the tool inclination in the direction determined by Side tilting options. The Lag angle to cutting direction parameter enables you to define the tool tilting in the direction of the cutting pass.7. This parameter is measured relative to surface normal. 265 .

Follow surface ISO lines direction The direction of the side tilting is chosen according to the direction of the U. You also have to define the strategy to avoid the possible collisions. 266 .and V-vectors of the drive surface. Define the gouge checking parameters Switch to the Gouge check page. It contains four tabs in which you can define four different sets of gouge checking parameters. Tilt angle at side of cutting direction Tilt angle at side of cutting direction V U 16. In each set you have to choose components of the tool holding system and model faces to check for possible collisions between them.

Under Strategy. only the colliding segments of the tool path are trimmed out. In the Tool section. the collisions between the check surfaces and the tool will be checked. SolidCAM trims the segments of the tool path where the collisions are detected. In the Geometry section. Set the Stock to leave value to 0. In the Clearance section of the Gouge check page. Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines In the Gouge 1 tab. In this set. clear the Drive surfaces check box. Use the default Don’t trim tool path option. the collisions between the drive surfaces and the tool will be checked. clear the Check surfaces check box. select the Enable check box. In the Tool section. Switch to the Gouge 2 tab and select the Enable check box.7.2. the distance the tool will keep from the check surface. To define the check surfaces. In this set. set the Arbor clearance value to 0. select all of the check boxes corresponding to the components of the tool. click on the Define button and select the model face as shown. choose Leaving out gouging points. The tool path updated by trimming will not contain gouges.2 and the Tool shaft clearance value to 0. In the Geometry section. When this strategy is used. select all of the check boxes corresponding to the components of the tool. 267 .e. i. This parameter enables you to define the allowance for the check surfaces. With this option.

SolidCAM considers the tool holder. The Tool Shaft clearance parameter defines the offset applied to the tool shaft cylinder from all sides. the arbor and the tool shaft to have a cylindrical shape. The Holder clearance parameter defines the offset applied to the tool holder cylinder from all sides. The Arbor clearance parameter defines the offset applied to the arbor cylinder from all sides. Holder Arbor Tool shaft Holder clearance Arbor clearance Tool shaft clearance 268 .

Switch to the Multi X 2 tab. Using this parameter. Define the motion limits control parameters Switch to the Motion limits control page. Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines 17. In the Multi X 1 tab. With this option. A new interpolated tool axis position is defined at each angle defined by the Interpolation angle step parameter. SolidCAM enables you to interpolate the angular movements. choose the Limit between -180 and +180 deg option for both First and Second rotation axis angle limit parameters.7. the angle coordinates in the output tool path are limited by the range from -180° to 180°. In the Move list writer section. set the Interpolation angle step value to 3. 269 .

18. 270 . This mode enables you to perform the machining simulation and tool path verification using the kinematics of the CNC-machine. calculate and simulate the operation Save and calculate the operation. Play the simulation by clicking on the Play Note that the device used for clamping of the part in the turning spindle of the machine is not displayed. Save. see chapter 6. For a detailed explanation of the CNC-machine model definition. button. Perform the simulation in the Machine simulation mode.

271 . Right-click on this operation again and choose Paste. This option enables you to limit the tool path by one or two points. You need to edit several parameters of this operation. click on the Data button in the Limit cuts between 2 points dialog box. 20. Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines 19. To define the first point.7. 5-Axis operation to perform machining of the area close to the blade base. 5-Axis operation in the SolidCAM Manager tree and choose Copy from the menu. choose the Limit cuts by one or two points option from the list. Click on the Points button to define the limiting points using the Limit cuts between 2 points dialog box. Define a 5-Axis operation Now you need to define an additional Sim. In the Area section. Right-click on the last Sim. The Select First Limit Point dialog box is displayed. The copied operation is pasted after the previous one. Define the geometry Switch to the Geometry page to define the geometry for machining. This dialog box enables you to enter the coordinates of the limiting points or define them directly by clicking on the solid model.

Define the second point as shown. 272 . Edit the tool parameters as follows: • • • • • • Set the Diameter to 8. Set the Outside holder length to 50. The coordinates of the selected point are displayed in the Select First Limit Point dialog box. 21. Define the tool Add a Bull Nose Mill tool.Select the first point on the model as shown. Set the Cutting length to 30. Set the Shoulder length to 40. Set the Total length to 60. Set the Corner Radius to 2.

In the Angles section. Tilt angle at side of cutting direction Tilt angle at side of cutting direction 273 . 22.7. set the Tilt angle at side of cutting direction value to 10. Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines Use the BT40 ER16x70 tool holder. Define the tool tilting parameters Switch to the Tool axis control page to define the parameters related to the tilting of the tool during the machining.

23. When this option is chosen. Save. Play the simulation by clicking on the Play button. the plane of the side tilting is orthogonal to the tool path direction for each cutting position.Under Side tilt definition. 274 . calculate and simulate the operation Save and calculate the operation. choose the Orthogonal to cut direction at each position option. Perform the simulation in the Machine simulation mode.

i. 5-Axis operation Define an additional Sim. 275 . In the Drive surface section. choose the Parallel to surface option from the list. Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines 24. Depending on the defined Tool tilting. The Edge surface section enables you to define the check surface geometry for the tool path generation. Drive surface Edge surface The drive and check surfaces have to be adjacent. Define a Sim. they must have a common edge. 25. 5-Axis operation to perform finishing of the blade. it is recommended to activate the gouge checking to make sure that the check surface will not be gouged. In the Pattern section. Parallel to surface This option enables you to generate the tool path on the drive surface parallel to the specified check surface. choose the Faces geometry defined in the previous operations. Define the geometry Switch to the Geometry page to define the geometry for machining.e.7.

Define the machining levels Switch to the Levels page and define the machining levels in the same manner as explained in Step #12: choose the Cylinder type and set the Radius to 40. Set the Cutting length to 30. 27. Set the Outside holder length to 50. Define the tool Add a Ball Nose Mill tool. click on the Define button to define the check surface geometry. Select the model faces as shown. Use the BT40 ER16x70 tool holder.In the Edge surface section. Make sure that the Parallel to Z option is chosen. Edit the tool parameters as follows: • • • • • Set the Diameter to 8. 26. Set the Shoulder length to 40. 276 . Set the Total length to 60.

The approach/retreat arc is generated in the plane orthogonal to the tool axis. Define the tool path linking Switch to the Link page to define the linking of the tool path.5. choose the Use Lead In option from the list. choose Spiral for Cutting method. In the Sorting tab. Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines 28. 277 . choose As value and set the value to 0. Reverse tangential arc The approach/retreat movement is performed with an arc tangential to the drive surface. 29. For First entry. like the Tangential arc option.7. Define the tool path parameters Switch to the Tool path parameters page. Choose the Reverse tangential arc strategy for approach movement. Under Surface edge merge distance. but with the direction of the approach/retreat arc reversed.

For Last exit. Define the tool tilting parameters Switch to the Tool axis control page to define the parameters related to the tilting of the tool during the machining. Tangential line SolidCAM performs the approach/retreat movement with a line tangential to the cutting pass. Choose the Tangential line strategy for retreat movement. Set the Lag angle to cutting direction value to 20 and the Tilt angle at side of cutting direction value to 10. choose the Follow surface ISO lines direction option. make sure that the Tilted relative to cutting direction option is chosen. 278 . 30. In the Tool axis direction section. choose the Use Lead Out option from the list. Under Side tilt definition.

32. 33. Perform the simulation in the Machine simulation mode. Define the motion limits control parameters Switch to the Motion limits control page and define the parameters in the same manner as explained in Step #17. At this stage. the exercise is completed. Play the simulation by clicking on the Play button. Define the gouge checking parameters Switch to the Gouge check page and define the parameters in the same manner as explained in Step #16. 279 . Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines 31. calculate and simulate the operation Save and calculate the operation.7. Save.

Simultaneous 5-Axis milling Define three 5-Axis operations to perform rough and finish machining of the blade faces presented on the illustration. The following steps have to be implemented in order to reach the final CAM-Part: 1. Define the CAM-Part At this stage. you have to define the CAM-Part. This exercise reinforces the following skills: • CAM-Part definition. the Machine Coordinate System. 2.sldprt) is located in the Exercises folder. 280 . • Simultaneous 5-Axis milling on Mill-Turn CNC-machines.Exercise #22: Blade Machining Define the CAM-Part and operations for Simultaneous 5-Axis machining of the blade part presented on the illustration on a Mill-Turn CNC-machine. the Stock model and the Target model. the CNC-controller. The SolidWorks model of the Blade (Exercise22. The Mill_Turn_5_Axis CNC-controller has to be chosen for this exercise.

set the Z coordinate in the Part’s origin position section to -200 for correct positioning of the part on the CNC-machine. In the Mill-Turn Part Data dialog box. Load the SolidWorks model Load the Exercise23. In the CoordSys Data dialog box. Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines Exercise #23: Rotary Cliche Machining This exercise covers the process of CAM-Part and operations definition for Simultaneous 5-Axis machining of the part on a Mill-Turn CNC-machine. 4. This model contains two configurations: Stock (used for the Stock model definition) and Default (used for the Target model defintion). Define the Stock model Switch to the Stock configuration and define the Stock model. dialog box.01. choose the Mill_Turn_5_Axis CNC-controller from the list. set the Facet 5.7. 2.sldprt model located in the Exercises folder. Define the Coordinate System Define the Coordinate System as shown using the CoordSys dialog box. 3. Define the Facet tolerance In the Mill-Turn Part Data tolerance value to 0. 281 . Start the Mill-Turn part definition Start SolidCAM and confirm the New Mill-Turn Part dialog box. 1.

6. Define the geometry by selecting the Drive surface – the model face that will be machined in this operation. Save the CAM-Part In the Mill-Turn Part Data dialog box. Define the geometry Switch to the Geometry page to define the geometry for machining. avoid cuts at exact edges option is chosen. Under Machining angle. click on the Constant Z button. 7. click on the button. 9. Define the geometry by selecting the Drive surface – the model face that will be machined in this operation. Choose None under Generate in the Target section of the Mill-Turn Part Data dialog box. Select the model cylindrical face as shown. 5-Axis operation to perform machining of the part cylindrical base. 282 . make sure that the Full. The generated tool paths will be parallel to the Z-axis. This option creates tool paths parallel to each other. Define a 5-Axis operation Define a Sim. If the face direction is incorrect. you can change it using the Reverse option in the right-click menu available on the face entry. 8. Define the Target model Switch to the Default configuration and define the Target model. Make sure that the Parallel cuts option is chosen in the Pattern section. there is no need to generate the Envelope sketch during the Target model definition. Now that the CAM-Part is defined. you have to define a number of operations for machining of the part using the Simultaneous 5-Axis Milling capabilities. Since the part will not contain turning operations. Note that you can check the drive face machining direction by selecting the Show direction for selected faces check box in the Faces section of the Select Faces dialog box. In the Area section.

7. set the Maximum step over value to 2 under Surface quality. This parameter defines the maximum distance between two consecutive cuts. 283 . Set the Diameter to 10. Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines 10. choose the Cylinder option from the Type list. 12. Set the Radius value to 50 and make sure that the Parallel to Z option is chosen. Set the Safety distance value to 4. Use the BT40 ER16x70 tool holder. Define the tool Add a Bull Nose Mill tool. Define the tool path parameters Switch to the Tool path parameters page. Under Clearance area. 11. Define the machining levels Switch to the Levels page to define the machining levels for the operation. In the Surface quality tab.

the spiral machining motions start with the first slice. Advanced options for spiral machining: Close contours When the First contour check box is selected. machining of the first slice is performed in a closed contour. In the Advanced options for spiral machining dialog box. When this check box is not selected. Likewise. choose the Regions option. choose the Spiral option for Cutting method and click on the Advanced button. The spiral machining motions start with the second slice. First contour Last contour For Machine by.In the Sorting tab. clear the check boxes in the Close section. when the Last contour check box is selected. 284 . machining of the last slice is performed in a closed contour.

The Machine by edit box enables you to choose the order of machining of certain areas. In the Approach/Retract tab. 5-axis operation. These options enable you to perform the first approach of the tool to the cutting level and the last retreat away using the specified Lead In/Lead Out options. Define the tool path linking Switch to the Link page to define the linking of the tool path. When the tool path is generated in many zones. 1 2 3 4 5 6 1 2 3 1 2 3 2 1 2 3 1 3 Lanes Regions The generated tool path usually has a topology of multiple contours (lanes) on the drive surfaces.7. 285 . Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines SolidCAM enables you to define the machining order for a Sim. it defines whether the surface will be machined by Lanes or by Regions. it might be preferable to machine all the regions independently. 13. choose the Use Lead In option from the First entry list and the Use Lead Out option from the Last exit list.

Choose the As value option and set the value to 7. All the movements below the Safety distance are performed with the specified cutting feed rate. Depending on the size of the gap.Switch to the Links tab. Clearance area When the gap area is detected. All the movements above the Safety distance are performed with the rapid feed rate. SolidCAM detects gaps along the cutting passes. The Gaps along cut section enables you to define the tool movements in such gap areas. a link movement between the pass segments is performed through the Clearance area. 286 . choose the Clearance area option for Small gaps. SolidCAM enables you to define different ways of movements in gap areas of different sizes. Under Gaps along cut. During the tool path linking. Set the Small gap size in % of tool diameter value to 80. Under Links between slices. choose the Clearance area option for Small moves. The maximum size for gaps to be considered as small can be specified either as a percentage of the tool diameter using the Small gap size in % of tool diameter parameter or by a Value. it is possible to choose two different options for large and small gap areas.

The maximum size for movement to be considered as small can be specified either as a percentage of the Max. SolidCAM enables you to define different ways of movements between passes spaced with different Max. 14. Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines The Links between slices option enables you to define the tool movements between cutting passes. it is possible to choose two different options for large and small movements between passes. Click on the Define button under Check surfaces 1 in the Geometry section to define the set of model faces that will be avoided by the tool during the machining. Define the gouge checking parameters Switch to the Gouge check page and enable the Gouge 1 tab by selecting the check box. choose the Not to be tilted. In other words.7. Define the tool tilting parameters Switch to the Tool axis control page to define the parameters related to the tilting of the tool during the machining. In the Tool axis direction section. stays normal to surface option. Depending on the Max. Step over. Step over using the Small move size in % of step over parameter or by a Value. the tool is always normal to the surfaces during the machining. This option enables you to keep the tool axis direction coincident with the surface normal at the cutting position. 287 . 15. Step over value.

a retract movement is added. Use the default Don’t trim tool path option. choose Leaving out gouging points.Select all of the model boss features as shown. Under Strategy. SolidCAM trims the segments of the tool path where the collisions are detected. With this option. 16. In the Multi X 2 tab. If the angle variation is greater than the specified value. When this strategy is used. only the colliding segments of the tool path are trimmed out. Define the motion limits control parameters Switch to the Motion limits control page. This parameter enables you to define the maximal angle variation between two successive tool positions. 288 . The tool path updated by trimming will not contain gouges. set the Angle change value to 120.

Save. Define the geometry Switch to the Geometry page to define the geometry for machining. Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines 17. Perform the tool path simulation in the Machine simulation mode. In the Pattern section.7. choose the Parallel to option from the list. 18. This option enables you to generate the tool path on the drive surface parallel to the specified check surface. 289 surface . calculate and simulate the operation Save and calculate the operation. Define the Drive surface geometry by selecting the face of the boss as shown. Define a 5-Axis operation Now you need to define an additional Sim. 19. 5-Axis operation to perform machining of the boss feature.

Define the tool Use the Tool #1 defined in the previous operation. make sure that the Zigzag option is chosen for Cutting method. When this option is chosen. then moves to the next cut and machines it in the opposite direction. 20.In the Edge surface section. The tool performs the machining of a cut in the specified direction. the machining direction changes from cut to cut. 21. 22. 290 . Define the machining levels Switch to the Levels page and define the machining levels in the same manner as in the previous operation (see Step #11). Define the tool path parameters Switch to the Tool path parameters page and proceed to the Sorting tab. Under Sorting. choose the geometry that was defined as the drive surface in previous operation (selected_faces).

Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines For Machine by. choose the Tilted relative to cutting direction option. In this operation. choose Tilting tool away with max. angle. Choose the Use side tilt angle option from the list. This option enables you to avoid the possible collisions by tool tilting. Define the tool tilting parameters Switch to the Tool axis control page to define the parameters related to the tilting of the tool during the machining. In the Geometry section. 24. you have to check for collisions between both drive and check surfaces and the tool. enable the Gouge 1 tab by selecting the check box. Set the Tilt angle at side of cutting direction value to 90. In the Tool axis direction section. Select the model faces for the check surfaces definition as shown. make sure that both the Drive surfaces and the Check surfaces check boxes are selected. select all of the check boxes corresponding to the components of the tool. In the Tool section. 23. use the default Lanes option. Under Strategy. Define the gouge checking parameters In the Gouge check page.7. 291 .

When the positive direction (+) is chosen. The tool tilting is performed to the left side relative to the cutting direction. 292 . The tilting angle is chosen automatically from the specified range. relative to the cutting direction. Check surface Tilting angle range Tilting angle Drive surface On the illustration. the tool tilting is performed to the left side relative to the cutting direction. SolidCAM enables you to choose side tilting direction and specify the range for the tilting angle. the tool tilting is performed at an automatically chosen angle to the right side relative to the cutting direction. the tool tilting is performed in the side direction. SolidCAM automatically chooses the direction of the side tilting and performs it at an angle from the specified range.Use side tilt angle With this option. When the negative direction (-) is chosen. The angle is located in a range from 0 to the specified value. When plus-minus direction (±) is defined. the possible collision of the tool with the check surface is detected and avoided by the side tilting.

Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines 25. The Rotate/Transform Tool Path dialog box is displayed.7. Select Transformation check box to enable the definition of parameters. you can have the same tool path repeated a given number of times by rotation around a specific axis. Switch to the Roughing page of the 5 Axis Operation dialog box and click on the Rotating button to define the parameters of the tool path rotation. Rotate the tool path Rotate the defined tool path to perform machining of the boss features around the Z-axis. the Use Rotation/ 293 . This dialog box enables you to define the parameters of rotation. The Rotating strategy is useful for parts with multiple identical elements arranged in a circular pattern. Instead of adding a separate operation and defining the same parameters for each of these patterns.

Y. Set the Number of steps value to 3 to repeat the tool path pattern thrice around the Z-axis.Make sure that Z-Axis is chosen for Rotary axis around.or Z-axis of the current Coordinate System or define a rotary axis vector by an end point (the start point is automatically considered to be in the Coordinate System origin). The tool path rotation must be performed around the Z-axis of the Coordinate System. Confirm the Rotate Tool Path dialog box by clicking on the OK button. You may choose between the X-. 294 . In other words. Number of steps This parameter enables you to define the number of instances of the circular pattern. Rotary axis around This option provides you the choice of the axis around which your tool path will be rotated. Rotation angle This parameter enables you to define the angle between two adjacent instances of the circular pattern. it defines how many times the initial tool path will be repeated around the rotation axis. Set the Rotation angle value to 120.

Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines 26.7. Save. the exercise is completed. calculate and simulate the operation Save and calculate the operation. At this stage. 295 . Perform the simulation in the Machine simulation mode.

you have to define the CAM-Part. the CNC-controller. Define the tool path circular pattern to machine the faces around the Z-axis. The Mill_Turn_5_Axis CNC-controller has to be chosen for this exercise. The SolidWorks model of the Rotary Knife (Exercise24. 296 . Define the CAM-Part At this stage. the Stock model and the Target model. This exercise reinforces the following skills: • CAM-Part definition. 3. The following steps have to be implemented in order to reach the final CAM-Part: 1.sldprt) is located in the Exercises folder. Machine the inclined faces Define a 5-Axis operation to perform machining of the external inclined faces.Exercise #24: Rotary Knife Machining Define the CAM-Part and operations for Simultaneous 5-Axis machining of the rotary knife part presented on the illustration on a Mill-Turn CNC-machine. the Machine Coordinate System. • Simultaneous 5-Axis milling on Mill-Turn CNC-machines. 2. Machine the cylindrical base Define a 5-Axis operation to perform machining of the cylindrical base of the part.

Simultaneous 5-Axis Milling on Mill-Turn CNC-Machines 4. Define the tool path circular pattern to machine the faces around the Z-axis. Machine the pocket Define a 5-Axis operation to perform machining of the internal inclined faces. Congratulations! You have successfully finished the SolidCAM 2011 Mill-Turn Training Course.7. 297 .

With its morphed spiral tool path. iMachining achieves these advantages by using Patent Pending. All rights reserved. Turning. “Controlled Stepover” technology and managing feed rates throughout the entire tool path. Highest level of SolidWorks integration SolidCAM provides the highest level of CAD integration. New revolutionary iMachining module The new SolidCAM iMachining™ module is a giant leap forward in CNC machining technology. SolidCAM supports the complete range of major manufacturing applications in Milling. the material being cut and the cutting tool data to provide optimal values of the cutting conditions. reducing cutting times by up to 70% and increasing tool life dramatically. ensuring constant tool load and allowing much deeper and more efficient cutting. single-window integration and full associativity to SolidWorks. Mill-Turn and WireEDM. . SolidCAM Professor Extensive SolidCAM Professor videos provide unlimited training for SolidCAM for both starting and advanced users. 2011 SolidCAM Ltd. iMachining™ brings efficiency to a new level for CAM users. controlled tool load at each point along the tool path. which considers the machine being used. All brands and product names are registred trademarks of their respective owners. The integration ensures the automatic update of tool paths for CAD revisions. with seamless.Supports the complete range of manufacturing applications inside SolidWorks SolidCAM is the leading and fastest growing developer of integrated CAM software solutions for the manufacturing industry. and automatic thin wall avoidance. SolidCAM powers up the user’s SolidWorks system into the best integrated CAD/CAM solution. moating of islands to enable continuous spiral cuts. totally integrated inside SolidWorks. even with multiple islands. iMachining™ is driven by a knowledge-based Technology Wizard.

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