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STARTED
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SolidCAM iMachining
SolidCAM iMachining is an intelligent High Speed Machining CAM software,
designed to produce fast and safe CNC programs to machine mechanical parts. The
word fast here means significantly faster than traditional machining at its best. The
word safe here means without the risk of breaking tools or subjecting the machine to
excessive wear, whilst increasing tool life.

To achieve these goals, iMachining uses advanced, patent pending, algorithms

to generate smooth tangent tool paths, coupled with matching conditions, that
together keep the mechanical and thermal load on the tool constant, whilst
cutting thin chips at high cutting speeds and deeper than standard cuts (up to
4 times diameter).

iMachining Tool paths

iMachining generates Morphing Spiral
tool paths, which spiral either outwardly
from some central point of a walled
area, gradually adopting the form of and
nearing the contour of the outside walls,
or inwardly from an outside contour
of an area to some central point or
inner contour of an island. In this way,
iMachining manages to cut irregularly
shaped areas with a single continuous
spiral.

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iMachining uses proprietary Constant Load

One-Way tool paths to machine narrow
passages, separating channels and tight
corners. It uses proprietary topology
analysis algorithms and channels to
subdivide the area into a few large
irregularly shaped sub-areas and then
machines each of them by a suitable
morphing spiral, achieving over 80% of
the volume being machined by spiral tool
paths. Since spiral tool paths have between 50% and 100% higher material removal
rate (MRR) than one-way tool paths, and since iMachining has the only tool path in the
industry that maintains a constant load on the tool, it achieves the highest MRR in the
industry.

The iMachining Technology Wizard

A significant part of the iMachining system is devoted to calculate matching values
of Feed, Spindle Speed, Axial Depth of cut, Cutting Angle and (Undeformed) Chip
Thickness, based on the mechanical properties of the workpiece and tool whilst
keeping within the boundaries of the machine capabilities (Spindle Speed, Power,
Rigidity and Maximum Feeds). The iMachining Technology Wizard, which is responsible for
these calculations, provides the user with the means of selecting the level of machining
aggressiveness most suitable to the specific machine and set up conditions and to their
production requirements (quantity, schedule and tooling costs).
An additional critical task performed by
the Wizard is dynamically adjusting the
Feed to compensate for the dynamically
varying cutting angle a bi-product of the
morphing spiral, thus achieving constant
tool load, which increases tool life.

Exercise #1: iMachining Walk Through

This example is a step-by-step guide on the definition process of SolidCAMs

iMachining technology to machine the part above. The rough and finish machining
of the outside contour, center pocket and pocket ledge is performed. The machining
is performed on a 3-axis CNC-machine.
The following steps have to be implemented in order to reach the final CAM-Part:
1. Define the CAM-Part
Open the

iMachining_WalkThrough.sldprt file located in C:\Program Files\

SolidCAM2012\User\Getting_Started_Examples\SW. Define the CAM-Part, the
CNC-controller (gMilling_Haas_SS_3x), the Machine Coordinate System,

the Stock model and the Target model.

The Stock model and the Target model should be defined as shown.

3D Model Stock

Target

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2. Define the machine and work material parameters

Right-click on the Operations header in the SolidCAM Manager tree and add
a new iMachining operation.
When the first iMachining operation is added to your CAMPart, you need to define the machine and material parameters
for the iMachining Database.

The buttons at the bottom left enable you to manage machine

definitions in the list.

button enables you to add new

The New
machine definitions.

button enables you to delete the

The Delete
existing machine definitions from the list.

The Save As
button enables you to save the
defined machine definitions under specified
names in specified locations.

The Revert
button enables you to return all
the edited parameters to their default values.

Click on the New button to add a new

machine definition.
Enter the name for the new iMachining
database file and click on the Save button.
The Haas_SS_New machine definition is added into the list.
In the General section, define the major machine parameters. The
parameters marked with yellow highlight are mandatory.

Set the Spindle Speed Max to 12000 rpm and the Feed Rate Max to 21160 mm/
min (833 inch/min).
For Reposition Feed Rate, set
10000 mm/min (400 inch/min)
3800 mm/min (150 inch/min).

the value for XY movements to

and the value for Z movements to

Set the Spindle Power Max to 20 kW (25 Hp).

The Leaders in Integrated CAM

Click on the Next button to define the work material.

Choose the Aluminum_100BHN_60HRB option.

Click on the Finish button to confirm the machine and

material parameters definition.
If you are running a demo version of
SolidCAM, select the default Haas_SS database
and choose Aluminum_100BHN_60HRB for
material definition.
Now that you have created a Machine Database for
iMachining, on creating new CAM-Parts you can select
the machine and material database in the CAM-Part
definition dialog box.

3. Define the rough machining of the outside contour

When you have confirmed the machine and material definition, the
dialog box is displayed.

iMachining Operation

Use the default iRough technology to machine the outside contour of the
part.
Click on the Define button on the Geometry page of the iMachining Operation
dialog box to define the machining geometry for the operation.
iMachining geometry definition

The geometry in iMachining is defined as a pocket that can

be open, closed and semi-closed (containing open edges).
The pocket can contain internal chains treated as islands or
used for safe tool entry.

Closed pocket

The geometry is
defined as a single
closed chain on the
pocket contour. The
material is cleared
out from the interior
of the defined geometry.

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Closed pocket with island(s)

The geometry is defined as several

closed chains: the first chain is the
pocket contour and the rest are the
internal chains on island contours.
Note that the order is important:
the pocket chain is the first chain
selected; then the island chains are
selected.
Closed pocket with entry chain

Similar to Closed pocket with island(s).

The geometry is defined as several
closed chains: the first chain is the
pocket contour, the second is an
internal chain on island contour,
which is marked as open. This open
internal chain is considered as a
precut area that has already been
machined prior to this operation.
The tool will plunge inside this
open area and start machining the
remaining material.
To mark a chain as open, right-click
on its name in the Chain List section
and choose Mark chain as open.
Note that the chain selection order
is important.

 Open pocket

The geometry is defined as

a single chain on the pocket
contour. This chain is marked
as open. The material is cleared
out from the interior of the
defined geometry with the tool
approaching from the outside
(pocket without walls).
Open pocket with island(s)

The geometry is defined as

several chains: the first chain
is the pocket contour (marked
as open) and the rest are
the internal chains on island
contours.
Note that the chain selection
order is important.
Pocket with open edge(s)

The geometry is defined as

a single closed chain on the
pocket contour. One or several
edges are marked as open: the
tool approach from the outside
is enabled. The material is
cleared out from the interior of
the defined geometry with the
tool approaching through one
of the open edges.

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The Leaders in Integrated CAM

To mark an edge as open, right-click

on the chain name in the Chain List
section and choose Mark open edges.
The Mark open edges dialog box is
displayed. Select the required edge
on the solid model and confirm the
dialog box.

In this operation, the geometry is

defined as an open pocket with
an island.
Select two chains as shown. Mark
the outer chain (Chain #1) as open
to enable the tool approach from
outside.
In the Levels section of the Geometry Edit dialog box, click on the
button to define the lower machining level for the operation.

Depth

Pick the machining depth on the bottom edge

of the model as shown.
You can also define the upper and
lower machining levels on the Levels
page of the iMachining Operation
dialog box.

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Add an end mill of 9.5 mm (0.375). Define the tool parameters as

follows:

Set the Total length to 76 mm (3);

Set the Outside holder length to 29 mm (1.125);

Set the Shoulder length to 29 mm (1.125);

Set the Cutting length to 25 mm (1);

Set the Number of flutes to 4.

Helical
Angle

Switch to the iData tab and choose the 45 (Medium)

value for the Helical angle parameter. This parameter
affects the cutting conditions and step down values
generated by the iMachining Wizard.

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The Leaders in Integrated CAM

Click on the Select button to confirm the tool definition.

Define the milling levels. In addition to the depth specified at the stage
of the geometry definition, define the Delta depth on the Levels page of the
iMachining Operation dialog box to perform machining deeper than the part
bottom edge. Set the value to -0.76 mm (-0.03).

Switch to the Technology Wizard page of the iMachining Operation dialog

box. This Wizard automatically calculates the cutting conditions for the
iMachining technology taking into account the tool data and milling levels
defined for the operation.

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Step down
When the Automatic option is chosen, the step down is
calculated by the wizard in accordance with the cutting
depth defined for the operation.
When the User-defined option is chosen, the step down can
be defined by specifying its value or by setting the number
of steps required to achieve the cutting depth.
The table below displays the number of steps, the step
down value and the number of Axial contact points (ACP)
calculated automatically by the Wizard.
Output cutting data
This section displays two sets of data related to the current
cutting condition (the spinning speed and feed rate of the
tool, the step over range, the material cutting speed, etc.).
Machining level
When you move this slider in the increasing direction
(to the right), the values in the Output cutting data section
automatically increase, and vice versa. The Machining level
slider enables you to set the cutting conditions optimal for
your machining case.
In this operation, use the default position of the Machining level slider (3).

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The Leaders in Integrated CAM

Click Save & Calculate, then

click Simulate. Run the
operation simulation in the
HostCAD and SolidVerify modes.
The simulated tool path is
performed as follows: the
corners are cleared first, then
the entire contour is machined.

4. Define the finish machining of the outside contour

Click on the Save & Copy button at the bottom of the iMachining Operation
dialog box to create a copy of the newly added iMachining operation. The
copied operation will perform finishing of the outside contour. When the
copied operation dialog box is displayed, choose iFinish for Technology.

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Switch to the Technology page. In the iRest data tab, note that the previous
operation appears in the Parent operation combo box, which
means that the technological parameters of the current operation are
inherited from the previous parent operation.

iRough_outside

Save and calculate the operation.

Simulate the operation in the
SolidVerify mode. The finishing is
performed in a single cutting pass.

5. Define the rough and finish machining of the center pocket

Add a new iMachining operation for machining of the center pocket.
Choose iRough for Technology and define the geometry on the lower contour
of the pocket as shown.
Pick the bottom face of the
pocket for the machining depth
definition.
Use the end mill tool defined in
the previous operation and the
default Technology Wizard settings.

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The Leaders in Integrated CAM

On the Link page, the default value of the Ramping angle of 2.5 is used for
the operation. The Helical ramping into the pocket will be performed at the
angle of 2.5 degrees.

Save and calculate the operation. Simulate it in the SolidVerify mode. The
tool performs the helical entry and then the pocket roughing tool path.

Save and copy the newly added iMachining operation to perform

finishing of the center pocket. Choose iFinish for Technology. In the iRest data
tab of the for Technology page, the previous iRough_centerPocket operation
appears as the parent operation.

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Save and calculate the operation. Simulate it in the SolidVerify mode. The
rest material is cleared from the pocket corners before the final finishing
pass is performed.

6. Define the rough and finish machining of the pocket ledge

Add a new iMachining operation for machining of the pocket ledge.
Choose iRough for Technology and define the geometry as closed chain on
the lower contour of the ledge as shown; mark the selected edge as open.

Pick the bottom face of the ledge for the machining depth definition.
Use the end mill tool defined in the previous operations and the default
Technology Wizard settings.

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The Leaders in Integrated CAM

Save and calculate the operation. Simulate it in the SolidVerify mode. The
tool approaches from outside and performs the roughing tool path, first
removing the material from the middle of the ledge and then clearing its
corners.

Save and copy the newly added iMachining operation to perform finishing
of the center pocket. Choose iFinish for Technology.
Save and calculate the operation. Simulate it in the
finishing is performed in a single cutting pass.

Congratulations!

SolidVerify

mode. The

You have successfully completed the iMachining exercise!

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Exercise #2: iMachining of a Bracket

This example illustrates the use of SolidCAMs iMachining technology to machine the
part above. There are standard 2.5D tool paths (Drilling & Profile) and 3D tool paths
(HSR & HSS) to aid in the complete CNC program. The machining is performed on a
3-axis CNC-machine in two setups, from both sides of the part.
Activate file iMachining.prt. For 2.5D customers without HSR/
HSS, please open the iMachining_25D_Only.prt example that does not
contain the 3D operations.
The following SolidCAM operations are created to perform the machining:

Outside shape machining (iRough_Outside; iFinish_Outside)

These iMachining operations perform the cutting of the outside shape of
the part. An end mill of 12.7 mm (0.5) is used. Two chains are defined, with
the first being the Stock boundary and the second being the profile around
the part. The Stock chain is marked as open, which specifies the tool should
machine from this chain, collapsing towards the part profile. iRough has a
0.25 mm (0.01) allowance on the wall, and the iFinish operation finishes
the profile. Both operations have a -0.63 mm (-0.025) delta depth, so the
tool machines deeper than the part.

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Through pockets machining

(iRough_ThroughPockets; iFinish_ThroughPockets)
These iMachining operations perform the cutting of the five circular
through pockets. An end mill of 12.7 mm (0.5) is used. Five chains are
defined to represent the five closed pockets. Since the pockets are closed,
with no PreDrilling or EntryChain defined, helical ramping is used to enter
the bottom of the pocket. iRough has a 0.25 mm (0.01) allowance on the
wall, and the iFinish operation finishes the profile. Both operations have a
-0.63 mm (-0.025) delta depth, so the tool machines deeper than the part.

Rough machining of angled surfaces

(HSR_R_Rough_Chamfer)
This HSR operation performs the rough cutting of the four large chamfers
on the ribs. An end mill of 12.7 mm (0.5) is used. Two boundaries are
picked off the edges the make up the chamfer and the Tool Relations is set
as centered. A 1.27 mm (0.05) step down is used and 0.127 mm (0.005)
allowance on the surfaces.

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Pocket machining (iRough_Pockets; iFinish_Pockets)

These iMachining operations perform the cutting on the three semi-open
pockets and the 7 closed pockets. A bull nose mill of 10 mm (0.375)
and corner radius of 1.6 mm (0.0625) is used. Since all the 10 pockets are
located on the same Z-Level, they can be machined all in one operation.
Three chains have edges marked as Open and Wall, Open edges allow the
tool to enter from these edges. Four of the closed chains use the through
pockets as an Entry chain (an Entry chain is a chain inside the pocket, similar
to an Island, but marked as open). The last two chains are simple closed
pockets with helical ramping. iRough has a 0.25 mm (0.01) allowance on
the wall, and the iFinish operation finishes the profile.

Finish machining of angled surfaces (HSS_PC_Lin_faces)

This HSS operation performs the finishing cut on the four large chamfers
on the ribs. A bull nose mill of 10 mm (0.375) and corner radius of
1.6 mm (0.0625) is used. A simple Linear strategy is used with a 0.5 mm
(0.02) step over. Customized linking is used to have short repositions and
smooth transitions when starting the cut.

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Bottom ledge machining (iRough_Face_BackLedge)

This iMachining operation finishes the bottom ledge on the underside of
the part. An end mill of 12.7 mm (0.5) is used. Two chains are defined,
with the first being the Stock boundary and the second being the bottom of
the floor radius. The Stock chain is marked as open, which specifies the tool
should machine from this chain, collapsing towards the radius. The floor
radius is not machined at this stage.

Cutting excess material from through hole

(iRough_back_centerHole)
This iMachining operation machines away the excess material from the
center through hole of the part. This excess material was used for clamping
from the first side. An end mill of 12.7 mm (0.5) is used. A single closed
chain is defined and a 0.25 mm (0.01) allowance is used for the wall, since
the wall was finished at the stage of the top side machining.

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Bottom face machining (iRough_Face_Back)

This iMachining operation finishes the circular face on the underside of the
part. An end mill of 12.7 mm (0.5) is used. Two chains are defined, with
the first being the outside boundary of the face and the second being an
offset edge created in Sketch1 in the assembly. The first chain is marked as
open, and the second offset chain is closed. A spiral tool path is performed
from the outside, collapsing towards the inner chain.

Floor radius finishing (F_backRadius)

This Profile operation finishes the 6.35 mm (0.25) floor radius on the
underside of the part. A ball mill of 12.7 mm (0.5)t is used. The chain
is the bottom edge of the radius and the Tool side is set to center. The
0.13 mm (0.005) floor offset is left after the first roughing pass and then
removed with the finishing pass. A 0.25 mm (0.01) Lead in/out arc is used.

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The Leaders in Integrated CAM

Parts used
iMchining_WalkThrough.sldprt
iMachining1.prz
iMachining_25D_Only.prt

Documents Details
Page

Subject

General description

iMachining Walk Through exercise #1

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iMachining Of a bracket exercise number #2

User Remarks
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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. SolidCAM supports the complete range of major manufacturing
applications in Milling, Turning, Mill-Turn and WireEDM, totally integrated inside SolidWorks.

The Revolutionary iMachining module

The new SolidCAM iMachining module is a giant leap forward in CNC machining
technology, reducing cutting times by up to 70% and increasing tool life dramatically.
iMachining achieves these advantages by using Patent Pending, Controlled Stepover
technology and managing feed rates throughout the entire toolpath, ensuring
constant tool load and allowing much deeper and more efcient cutting.
iMachining is driven by a knowledge-based Technology Wizard, which considers the machine
being used, the material being cut and the cutting tool data to provide optimal values of the
cutting conditions. With its morphed spiral toolpath, controlled tool load at each point along the
tool path, moating of islands to enable continuous spiral cuts, even with multiple islands, and
automatic thin wall avoidance, iMachining brings efciency to a new level for CAM users.

Highest level of SolidWorks integration

SolidCAM provides the highest level of CAD integration, with seamless, singlewindow integration and full associativity to SolidWorks. The integration
ensures the automatic update of tool paths for CAD revisions.
SolidCAM powers up the users SolidWorks system into the best integrated CAD/CAM solution.

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