SolidCAM Simultaneous 5-axis Machining User’s Guide

©1995-2005 SolidCAM LTD. All Rights Reserved.

SolidCAM2005 Milling Manual

5-axis Machining

Contents
1. Introduction ............................................................................................................................... 5 2. User Interface ........................................................................................................................... 6 2.1 Adding a 5-axis Operation....................................................................................................6 2.2 5-axis Operation user interface ............................................................................................8 2.3 Stages of the Simultaneous 5-axis Operations parameters definition ............................... 10 3. CoordSys Page ...................................................................................................................... 11 4. Tool Page ................................................................................................................................ 12 5. Levels Page ............................................................................................................................ 14 6. Geometry Page ...................................................................................................................... 17 6.1 Drive surface selection ....................................................................................................... 18 6.2 Cut Controls: ...................................................................................................................... 20 6.2.1 Parallel cuts .................................................................................................................. 20 Exercise 1:.................................................................................................................... 23 Exercise 2:.................................................................................................................... 25 6.2.2 Cuts along curve ........................................................................................................... 26 Exercise 3:.................................................................................................................... 27 Exercise 4:.................................................................................................................... 28 6.2.3 Morph between two curves ........................................................................................... 30 Exercise 5:.................................................................................................................... 32 Exercise 6:.................................................................................................................... 34 6.2.4 Parallel to curve ............................................................................................................ 36 Exercise 7:.................................................................................................................... 37 Exercise 8:.................................................................................................................... 38 6.2.5 Project curves ............................................................................................................... 40 Exercise 9:.................................................................................................................... 41 Exercise 10:.................................................................................................................. 43 6.2.6 Morph between two surfaces ........................................................................................ 45 Exercise 11:.................................................................................................................. 46 Exercise 12:.................................................................................................................. 48 6.2.7 Parallel to surface ......................................................................................................... 50 Exercise 13:.................................................................................................................. 52 6.3 Flip Stepover ...................................................................................................................... 54 Exercise 14:.................................................................................................................. 55 6.4 Cutting Method ................................................................................................................... 56 6.5 Cut Order ........................................................................................................................... 58 Exercise 15:.................................................................................................................. 60
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SolidCAM2005 Milling Manual

6.6 Direction for One Way machining ...................................................................................... 62 Exercise 16:.................................................................................................................. 64 6.7 Cutting Area ....................................................................................................................... 65 Exercise 17:.................................................................................................................. 67 6.8 Start Point .......................................................................................................................... 69 7. Finish Parameters page: ........................................................................................................ 71 7.1 Tool Contact point .............................................................................................................. 72 Exercise 18:.................................................................................................................. 75 7.2 Lead in / Lead out .............................................................................................................. 79 Exercise 19:.................................................................................................................. 82 Exercise 20:.................................................................................................................. 86 7.3 Round surface by tool radius ............................................................................................. 92 7.4 Stock to leave..................................................................................................................... 94 7.5 Multi Passes ....................................................................................................................... 95 7.6 Surface Quality................................................................................................................... 97 7.6.1 Chaining Tolerance ....................................................................................................... 97 7.6.2 Cut tolerance ................................................................................................................ 98 7.6.3 Distance ........................................................................................................................ 99 7.6.4 Stepover ..................................................................................................................... 100 8. Gaps Page............................................................................................................................ 101 8.1 Gap Along Cut.................................................................................................................. 101 8.1.1 Gap Size as % of tool diameter .................................................................................. 102 8.1.2 Direct .......................................................................................................................... 102 8.1.3 Broken ........................................................................................................................ 103 8.1.4 Retract ........................................................................................................................ 103 8.1.5 Follow Surface ............................................................................................................ 104 8.2 Gaps between cut (Gap Size as % Of Stepover) ............................................................. 105 8.2.1 Gap Size as % of Stepover......................................................................................... 105 8.2.2 Direct .......................................................................................................................... 106 8.2.3 Broken ........................................................................................................................ 106 8.2.4 Retract ........................................................................................................................ 107 8.2.5 Follow surface ............................................................................................................. 107 9. Tool axis control page ........................................................................................................... 108 9.1 Output format ................................................................................................................... 109 9.2 Maximum angle change ................................................................................................... 110 9.3 Tilting strategies (Toll axis direction) ................................................................................ 111 9.3.1 Tool axis is not tilted and stays normal to the surface ................................................ 111 9.3.2 Tool axis will be tilted relative to cutting direction ...................................................... 112 9.3.3 Tool axis will be tilted with the angle .......................................................................... 114
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......5............................................................................................................ 131 10...................... Additional parameter Page .......................................................................................................................1 Retracting tool along tool axis.......... 116 9............. 147 13.................................................................... 144 10..................................................2 At the beginning of all: Single Surface 5 Axis Flowline ..............................2 Check Arbor and Check Holder ............................................5.......................... 144 11............................................................................ 146 13..................................................................5...........3 Tilting tool away with max angle .........7 Check Surfaces .. 114 9...........................................1 XZ Limit........ 126 9....................3.................................................................3.................................................................. 147 13.........3......5 Strategy ..2 Moving tool away ..............4 Conical angles from leading curve................. 128 10............................5......................................... Gouge Check page .............5...................................................................... 132 10.......................................SolidCAM2005 Milling Manual 5-axis Machining 9..............................................................3 XY Limit: ................................. 141 10.....7 Tool axis will be tilted through curve ............................4 Tool ............................. 134 10............................................................................. 127 10.5.......................5......5................................................................................................... 143 10............................................................................................................4..............................................................6 Tool axis will be tilted through point .............. 132 10...................................................................................................................................... 145 12..............................3....... 126 9...............................4 Tool axis will be tilted with fixed angle to axis ...................5 Stop tool path calculation.............................1 Tool Tip and Tool Shaft ............................................................................................................................. 128 10..............................................4 Side tilt definition ...................... 123 9............................ 129 10..........................................3...................................1 Single Surface versus Multi Surface Machining in 5 Axis ......................5....3................................................................ 133 10.................................. 144 10..................4............................................................1 Clearance ................................................9 Tilted from point away...... 123 9.............. 115 9........... 125 9............................................................................................... Stock Page .......................................................... 143 10...2 YZ Limit................................3 Gouge pages............................................................................................................ Appendix .............................. 131 10......................................................8 Stock to leave.................... 127 9........................8 Tool axis will be tilted through lines ...........................4 Leaving out gouging points ................................. 124 9....................................................................5 Tool axis direction limit parameters .................6 Drive Surfaces............ 147 Document number: SC5AUG06001 4 ... 117 9...................................................................5 Tool axis will tilted around axis ...2 Check gouge between positions ..... 131 10......................................................................

better surface finish and improved life span of tools. Introduction Simultaneous 5-Axis machining is becoming more and more popular due to the need for reduced machining time.5-axis Machining SolidCAM2005 Milling Manual 1. 5 . SolidCAM provides a realistic simulation of the whole machine tool. A number of intelligent and powerful 5axis machining strategies enable the use of SolidCAM for machining of such complex geometry parts as turbine blades and impellers. provides a solid base for your 5-Axis solution. showing the motion of all rotational and linear axes. SolidCAM utilizes all the advantages of Simultaneous 5-Axis machining and together with collision control and machine simulation.

mostly for undercut areas. It is also possible to use the standard tools in this operation in order to create a 3D finish tool path. in this case the operation generates 3 axis G-Code and it is not possible to tilt the tool. This operation is available for 3 axis.1 Adding a 5-axis Operation 5-axis (3) This operation performs 3-axis operations using special tools such as Lollipop and T-cutter.SolidCAM2005 Milling Manual 5-axis Machining 2. 4 axis and 5 axis CNC-machines. User Interface 2. 6 .

the output will be performed with the @line_5x and @move_5x commands. 7 . SolidCAM positions the tool to the proper working angle using 5-axis capabilities and then performs the 4-axis machining. the output will be performed with the @line_4x and @move_4x commands. The output from this operation depends on the CNC machine type. 5-axis (5) This operation is used for 5-axis finish and supports all kinds of 5-axis operations. The tool can be tilted to any possible direction that the machine supports. The only tilt strategies that are available are those that support this type of tilting (4-axis). For the 5-axis machine. All the tilt strategies are available. The tool will be normal to the center line but will not necessarily cross the center line. This type of operation is available only for postprocessors that support 5-axis machining.5-axis Machining SolidCAM2005 Milling Manual 5-axis (4) This operation is used for 4-axis finish operations such as turbine blade profiles on the outside diameter and spiral parts. For the 4-axis machine. The user has complete control over all the cutting parameters. This operation generates 4-axis G-code and is available for 4-axis and 5-axis CNC-machines. This Operation type is unavailable for 3-axis CNC-machine types. With such output. The operation generates 5 axis G-code. The @line_5x and @move_5x commands will be used in the output.

The sub-groups are displayed in a tree format on the left side of the 5-axis Operation dialog box. Define the machining parameters such as the Cut control.SolidCAM2005 Milling Manual 5-axis Machining 2. • Geometry SolidCAM enables you to choose a drive surface for the machining. Cuting area. • CoordSys Page Define the CoordSys Position for the 5-axis machining.2 5-axis Operation user interface The following 5-axis Operation dialog is displayed on the screen: The parameters of the 5-axis Milling Operation are divided into a number of sub-groups. • Tool Data Page Choose a tool for the operation and define tool-related parameters such as feed and spin. 8 . • Levels Page Define Milling levels such as Clearance plane and Safety distance. When you click on an item in the tree. the parameters of the selected sub-group appear on the right side of the Operation dialog box. Cutting method etc.

• Miscellaneous parameters This page contains special functions for custom applications. • Tool axis control Define the tool orientation relative to the surface normal. 9 .5-axis Machining SolidCAM2005 Milling Manual • Finish Parameters This page enables you to define the machining parameters such as Cut tolerances. Generally. these parameters are defined in the first definition of the postprocessor for this machine and usually it is not necessary to change these values. The defaults are determined by the MAC-file (machine definition parameters). • Gouge check This page contains all the options to avoid the tool gouging selected drive surfaces and check surfaces. • Gaps Page Surfaces defining the work piece can have gaps and holes. The Motion Limit control page enables you to change the parameters locally for the current operation. For example you can choose to have small gaps ignored and milled without the tool retracting and big gaps detected with the tool retracting back to the rapid plane and skipping the gap. Stock to leave. • Motion Limit control This page is related to CNC machine definitions. • Stock Page Stock definition can be provided in this page. All tool moves in the air that do not remove material will be trimmed using this given stock definition. Run tool etc. Such options are set within this dialog. In such cases you can choose between several options. Entry and Exit moves are also defined here.

Finish Parameters and Gaps – the type of finish tool paths generated along the selected faces is defined. Tool tilting and gouging are not taken into account at this stage. Tool axis control .SolidCAM2005 Milling Manual 5-axis Machining 2.3 Stages of the Simultaneous 5-axis Operations parameters definition The process of the Operation parameters definition for the tool path creation is divided into 3 stages: 1. Geometry. 3. Tool path generation Tool axis control Gouge check 10 .controls the angle of the tool from the normal vector in every point along the tool path. 2. Gouge check –the gouge strategies that SolidCAM has to take into account to avoid tool and holder crashes are defined.

After the CoordSys selection. SolidCAM enables you to generate the G-Code according to the center of the rotation of the machine. The CoordSys selection operation must be the first step in the Operation definition process. In 5 axis (4) and 5 axis (5) operations. The Machine CoordSys definition contains data of the Machine CoordSys location relative to the center of the rotation of the machine. 11 . CoordSys Page Choose the appropriate CoordSys position for the operation.5-axis Machining SolidCAM2005 Milling Manual 3. Therefore. SolidCAM enables you to choose only the Machine Coordinate systems. The CoordSys Position can be chosen either direcly on the model or from the list. SolidCAM enables you to choose both the Machine Coordinate systems and CoordSys Positions for the operation. the model will be rotated to the selected CoordSys orientation. In the 5 axis (3) Operation.

SolidCAM2005 Milling Manual 5-axis Machining 4. Tool Page The Data button enables you to choose a tool from the Part Tool Table. 12 .

Feed Z The feed that SolidCAM will use to move from the safety position to the depth point. Feed Rates If this switch is set. The feed rate optimizer uses the machining feed rate supplied by the user and modifies this feed rate based on the surface curvature. Spin Finish The spindle speed for the cutting operation.5-axis Machining SolidCAM2005 Milling Manual Feed Finish This field gets the default from the Feed Finish parameter in the Tool Data dialog. Retract Rate The feed that SolidCAM will use to move the tool from the material to the retract level. This function works only on single surfaces and can’t be used to connect 2 surfaces 13 . If the user changes this value it will not change the related field in the Tool Data dialog. The surface curvature is calculated at each tool path position where the surface contact point of the tool is known. then the feed rate optimizer is utilized.

In some cases like turbine blade machining around the X axis.SolidCAM2005 Milling Manual 5-axis Machining 5. it might be better to have the clearance plane defined in the X axis. 14 . Setting the clearance plane height in the X axis will make the YZ plane the parallel plane and the given X value will be the clearance value over this plane. Levels Page Clearance Plane The clearance plane is a Z coordinate value and presents an absolute plane at this height which is parallel to the XY plane. The tool moves from and to this clearance plane to make major repositionings.

The tool then approaches the surface with the cutting feed rate. The tool then moves in a rapid motion with some orientation to the safety distance.5-axis Machining SolidCAM2005 Milling Manual Clearance plane Safety distance Retract distance Retract distance Retract Distance and Safety Distance The tool changes its orientation at the clearance plane (machine tables or spindles are turned) and then it moves down to the part to the retract distance. When this option is not active. Rapid Retract This option enables you to perform the retract movement with the rapid feed.). Rapid feed Retract Rate Retract distance Safety distance 15 . the tool will be moved to the safety distance with the defined Retract Feed (see topic 4.

This command shifts each point of the tool path in the vector direction of the tool.SolidCAM2005 Milling Manual 5-axis Machining When the Rapid Retract option is active. Rapid feed Retract distance Safety distance Depth The Depth defines a further offset of the tool in the axial direction (especially for swarf operations). 16 . The start position of the cutting will also be shifted. The gouge control will take out all the gouges that result from this shift. the retract movement will be performed with the Rapid Feed.

In the Morph and Parallel to curve strategies. and than select the edges. The different strategies available are: • Parallel cuts • Cut along curve • Morph between 2 curves • Parallel to curve • Project curve • Morph between 2 surfaces • Parallel to surface between 2 curves For all the above strategies.5-axis Machining SolidCAM2005 Milling Manual 6. select the drive surface and the related geometries. Select the faces first. Geometry Page This page enables you to select the faces to be machined and the machining strategy. 17 . Do not use sketches to define these types of geometries. the curves have to be part of the surface external boundaries.

This dialog enables you to select one or several faces of the SolidWorks model.1 Drive surface selection Click on the Define button.SolidCAM2005 Milling Manual 5-axis Machining 6. use the Unselect option to undo your selection. The selected Face tags will be displayed in the dialog. If you chose wrong entities. 18 . The Choose faces dialog will be displayed. You can also right click on the entity name (the object will be highlighted) and choose the Unselect option from the menu.

Sometimes surfaces are not oriented correctly and you have to reverse their normals. If the tool is machining one of the faces from the wrong direction.5-axis Machining SolidCAM2005 Milling Manual SolidCAM enables you to machine surfaces from the positive direction of the surface normals. The Reverse/Reverse All command enables you to reverse the direction of the surface normals. 19 . return to the Geometry definition and use the Reverse command. You have to select the faces for the 5 axis operation and calculate the operation. SolidCAM does not enable you to see the surface direction.

With constant X Y X Changing the Machining angle in the Z parameter to 90 degrees creates tool paths parallel to the Y axis. The direction of the cuts is defined by two angles. 6.2 Cut Controls: The Exercises of the Cut control option are located in the Exercises\Cut_Control folder. The angles in X. The X-distance is constant. The pictures in the dialog show how the desired cutting direction is set using the angles.1 Parallel cuts The Parallel cuts option will create tool paths that are parallel to each other. Imagine slicing an apple: You can slice it with a knife parallel from top to bottom or from the left side to the right side. 20 . Y and Z determine the direction of the parallel cuts of the tool path.2.SolidCAM2005 Milling Manual 5-axis Machining 6.

Y to 0 degrees creates circular tool paths. With constant Z Z X Changing the Machining angle in Z and the Machining angle in X. The Z-distance is constant. Y to 90 degrees creates tool paths parallel to the X axis. The Y-distance is constant. 21 .5-axis Machining SolidCAM2005 Milling Manual With constant Y Y X Changing the Machining angle in Z and the Machining angle in X.

In this setup you can enter any angle to get the required tool path. The Constant Z button.SolidCAM2005 Milling Manual 5-axis Machining Fast orientation buttons Th following buttons enable you to expedite the definition of the orientation of the parallel cuts. 22 . The Parallel button.

5-axis Machining SolidCAM2005 Milling Manual Exercise 1: 1. Use the Parallel Cuts strategy and define the necessary parameters in order to cut the cylinder normal to the direction of the center line. 23 . Load the CAM-Part: Exercises\Cut_control\parallel_cuts.prt 2. In order to cut the cylinder and the top face you have to use a different angle (inclination). Simulate the operations and check the parameters used to control the Machining angles for the Parallel Cuts strategy. Create some operations to practice this task. 3. 4. Add operations for the machining of other cylinders.

SolidCAM2005 Milling Manual 5-axis Machining Change Parallel cuts to spiral This option enables you to substitute the parallel cuts with the spiral cuts with the pitch equal to the defined Step over. The option is not chosen The option is chosen 24 .

Simulate the operations and check the parameters used to control the Machining angles for the Parallel Cuts strategy. Calculate and simulate the operation. 3. In the Geometry page.prt 2. 4. 5. Note that the parallel cuts of the operation were changed to spiral movements. 25 . choose the Change parallel cuts to spiral option. Load the CAM-Part: Exercises\Cut_control\parallel_cuts.5-axis Machining SolidCAM2005 Milling Manual Exercise 2: 1. Edit the operation rotate around z 45 deg.

2. The curve geometry does not have to be located on the surface or on the edges of the surface. The selected chain could be a planar or a 3D sketch. SolidCAM creates a plane nornal to the curve. This kind of tool path is popular for milling engines ports or internal curved surfaces. the cuts can cross over each other and the result will be unacceptable. In each point of the leading curve.SolidCAM2005 Milling Manual 5-axis Machining 6. Curve Tool path 90° 90° 90° 26 .2 Cuts along curve The Cuts along curve option enables the user to select a leading curve. so the cuts do not have to be parallel to each other. The tool path will be created at the intersection of this plane with the drive surface. The generated tool path is orthogonal to this leading curve. If a wrong leading curve is selected.

27 . Load the SolidWorks document: Exercises\Cut_control\cone. Choose the circle segment contained in the Lead_ curve sketch as a lead curve.5-axis Machining SolidCAM2005 Milling Manual Exercise 3: 1. 3. Define a new CAM-Part. For the CoordSys definition. Calculate and Simulate the Operation. Define the conical face as the drive surface. 5. 4.sldprt 2. Use the Fanuc_4x_x postprocessor. Define the Machine CoordSys with the X-axis directed along the cone centerline and the Z-axis directed upwards. Start a new 5-axis Operation and choose the Cuts Along Curve strategy. use the home_ definition sketch. 6.

sldprt 2. 28 . Define the CoordSys on the top face of the model. Create a new CAM-Part. 4. Load the SolidWorks document: Exercises\Cut_control\cone. Define the internal face of the manifold as the Drive Surface and the sketch segment containd in the Center_line sketch as a Lead curve. Start a new 5-axis Operation and choose the Cuts Along Curve strategy.SolidCAM2005 Milling Manual 5-axis Machining Exercise 4: 1. 5. 3. Use the Fanuc_5x CNC controller.

Calculate and Simulate the Operation. 29 . The simulation can be performed using either 3D or HostCAD simulation modes.5-axis Machining SolidCAM2005 Milling Manual 6.

2. The more accurate the guiding curves are to the real surface edges. the better this function works. click on the Upper and Lower button.SolidCAM2005 Milling Manual 5-axis Machining 6. This option is very suitable for machining steep areas for mould making. To select the first (upper) and second (lower) curve.3 Morph between two curves The Morph between two curves option will create swarf cuts morphing between two leading curves. First curve Tool path Second curve 30 .

The reason for these jumps is that SolidCAM did not find a point on the surface after creating a circle with the tolerance size on a plane normal to the point on the curve. SolidCAM will check the distance from the curve to the surface and if Lower Edge curve the distance is bigger than 0.03 and the option that moves the tool exactly on the edges of the surface is used.5-axis Machining SolidCAM2005 Milling Manual It is very important to define the geometry for the Upper and Lower Edge curves correctly. SolidCAM generates the tool path from the Upper Edge curve till the Lower Edge curve. tool jumps can result. 31 . Upper Edge curve It is recommended to select the edges of the surface as the geometry of the Upper and Lower Edge curves.

Select the model edge for the Upper Edge curve geometry as shown. 3. 4. Load the CAM-Part: Exercises\Cut_control\air_console. 32 . Create a new 5-Axis Operation using the Morph between two curves strategy. Define the Drive Surface as shown.SolidCAM2005 Milling Manual 5-axis Machining Exercise 5: 1.prt 2.

Calculate and Simulate the operation. Make a note to select the short edge as shown. Select the model edge for the Lower Edge curve geometry as shown. 33 . 6. Save.5-axis Machining SolidCAM2005 Milling Manual 5.

Select the model edge for the Upper Edge curve geometry as shown. This option is used due to the inequality of the distance between the upper and lower curves of the blade.prt 2. 3. Make a note to select the geometry accurately without gaps.SolidCAM2005 Milling Manual 5-axis Machining Exercise 6: 1. Create a new 5-Axis Operation using the Morph between two curves strategy. Define the Drive Surface as shown. 34 . The accurate selection results in a more accurate tool path without tool jumps. 4. Load the CAM-Part: Exercises\Cut_control\impeller.

Calculate and Simulate the operation. Select the short edge as shown .5-axis Machining SolidCAM2005 Milling Manual 5. 35 . 6.the absence of this edge in the geometry causes an inaccurate tool path. Select the model edge for the Lower Edge curve geometry as shown. Save.

4 Parallel to curve The Parallel to curve option will align the cut direction along a leading curve.2.SolidCAM2005 Milling Manual 5-axis Machining 6. Tool path Curve 36 . Click Single Edge and select the curve.

4. 3. Select the model edge as shown as the Curve geometry. calculate and simulate the operation. Create a new 5-Axis Operation using the Parallel to curve strategy. 2. Save. Load the CAM-Part: Exercises\Cut_control\air_console. 37 .prt. 5. Define the Drive Surface as shown.5-axis Machining SolidCAM2005 Milling Manual Exercise 7: 1.

Load the CAM-Part: Exercises\Cut_control\impeller. 4.prt 2. 3. Define the Drive Surface as shown.SolidCAM2005 Milling Manual 5-axis Machining Exercise 8: 1. Select the model edge for the Lower Edge curve geometry as shown. 38 . Create a new 5-Axis Operation using the Parallel to curve strategy.

the absence of this edge in the geometry causes an inaccurate tool path.5-axis Machining SolidCAM2005 Milling Manual Select the short edge as shown . 39 . calculate and simulate the operation. Save. 5.

Click on the Projection curve button to define a curve. 40 .2. The tool will move with the center on the selected geometry.5 Project curves Project curves generates a single tool path along a curve.SolidCAM2005 Milling Manual 5-axis Machining 6. SolidCAM will not check the curve against the surface to check if it is a good curve. If the point is not on the surface the point will be eliminated from the tool path and handled like a gap. Curve & Tool path The projected curve is a result of the projection of the specified curve onto the selected surface. The calculation algorithm tries to retrieve the vector to each point of the curve according to the surface normal in this point. It is not possible to get the tool path in the left or the right side.

2. 3.5-axis Machining SolidCAM2005 Milling Manual Exercise 9: 1. 41 . Create a new 5-Axis Operation using the Project curves strategy. Load the CAM-Part: Exercises\Cut_control\Solidcam. Define the Drive Surface as shown.prt.

SolidCAM2005 Milling Manual 5-axis Machining 4. Select the model edges of the text for the Projection curves geometry as shown. 5. calculate and simulate the operation. Save. 42 .

43 . Create a new 5-Axis Operation using the Project curves strategy.5-axis Machining SolidCAM2005 Milling Manual Exercise 10: 1.prt. Define the Drive Surface as shown. 2. 3. Load the CAM-Part: Exercises\Cut_control\3D_engraving.

44 . This curve has to be created in the middle of the selected face and projected on the surface or created exactly on the surface. Select the curve in the middle of the surface as the Projected curve geometry.SolidCAM2005 Milling Manual 5-axis Machining 4. Save. calculate and simulate the operation. 5.

If the calculation is not based on the tool center. Lower edge surface For proper machining. Parameters page. SolidCAM will create tool path morphing between two leading curves.6 Morph between two surfaces Upper edge surface Drive surface This option is similar to the Morph between two curves option. the Morph between two surface option enables you to choose two surfaces adjacent to the drive surface. The option is located on the Misc. the Calc based on tool center option must be enabled.5-axis Machining SolidCAM2005 Milling Manual 6. The common boundaries of these surfaces and the drive surface will be used as the leading curves. In contrast to the Morph between two curves option where the leading curves are directly selected on the model.2. 45 . a wrong tool path will be generated.

Load the CAM-Part: Exercises\Cut_control\insert. 3. 46 .prt.SolidCAM2005 Milling Manual 5-axis Machining Exercise 11: 1. Define the Drive Surface as shown. Create a new 5-Axis Operation using the Morph between two surfaces strategy. 2.

Save.5-axis Machining SolidCAM2005 Milling Manual 4. Select the lower fillet as shown to define the Lower Edge surface geometry. calculate and simulate the operation. 47 . 5. 6. Select the upper fillet as shown to define the Upper Edge surface geometry.

SolidCAM2005 Milling Manual

5-axis Machining

Exercise 12: 1. Load the CAM-Part: Exercises\Cut_control\air_console.prt.

2. Create a new 5-Axis Operation using the Morph between two surfaces strategy. 3. Define the Drive Surface as shown. Select all the tangential side faces of the pocket.

4. Select all the adjacent top faces as shown to define the Upper Edge surface geometry.

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5. Select all the faces of the lower fillet as shown to define the Lower Edge surface geometry.

6. Save, calculate and simulate the operation.

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5-axis Machining

6.2.7 Parallel to surface

Drive surface

Edge surface

This option is similar to the Parallel to curve option. SolidCAM will align the cut direction along a leading curve. In contrast to the Parallel to curve option where the leading curve was directly selected on the model, the Parallel to surface option enables you to choose the surface adjacent to the drive surface. The common boundary of this surface and the drive surface will be used as the leading curve.

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The tool has to be a sphere mill and the Calc based on tool center option has to be activated in the Misc.5-axis Machining SolidCAM2005 Milling Manual You can work with margins. Tool center Margin Margin 51 . Parameters page.

Create a new 5-Axis Operation using the Parallel to surface strategy.SolidCAM2005 Milling Manual 5-axis Machining Exercise 13: 1. Define the Drive Surface as shown. 52 . Load the CAM-Part: Exercises\Cut_control\insert. 2. 3.prt.

The jumps in the top side of the face are created because SolidCAM did not find a vector from the surface in the geometry point. SolidCAM finds the common edges between the drive and edge surfaces and defines the leading curve for the tool path.5-axis Machining SolidCAM2005 Milling Manual 4. Switch to the Finish parameters page and set the Step Over to 5. 5. Select the lower fillet as shown to define the Single Edge surface geometry. 53 . calculate and simulate the operation. 6. All these points are eliminated and the gap control handles this gap in a later step of the calculation. The tool path is a result of the offset of the leading curve along the drive surface. Save.

begins at the edge. This can change the machining direction from the outside to the inside or from the left to the right. 54 .SolidCAM2005 Milling Manual 5-axis Machining 6. Flip step over The machining begins at the top of the With the Flip Step over option the machining workpiece.3 Flip Stepover changes the start cutting direction.

prt prepared in Exercise 11. note that the cutting is performed from the upper boundary of the drive surface downwards. During the simulation. 5. Note that the cutting direction was changed: the cutting was performed from the lower boundary of the drive surface upwards. 4. Load the CAM-Part: Exercises\Cut_control\insert. Simulate the Operation. calculate and simulate the Operation. Save. 3. In the Geometry page make sure that the Flip step over checkbox is not activated.5-axis Machining SolidCAM2005 Milling Manual Exercise 14: 1. Activate the Flip step over checkbox. Do not close the CAM-Part. 2. 6. 55 .

4 Cutting Method SolidCAM enables you to choose the following Cutting methods: • One way • Zig Zag If you have a closed geometry and you select one way machining. the tool will always move around the part in the same direction. One Way Zig Zag 56 .SolidCAM2005 Milling Manual 5-axis Machining 6.

5-axis Machining SolidCAM2005 Milling Manual If the geometry is not completely closed. then it is recommended to set the option Enforce closed contours. 57 .

• From Center Away .Sets a default cut order.5 Cut Order In the cut order menu you can choose between three options: • Standard .The machining begins in the center of the surface. 58 .SolidCAM2005 Milling Manual 5-axis Machining 6.

59 .The machining begins from outside the surface.5-axis Machining SolidCAM2005 Milling Manual • From outside to center .

You will see that the tool path starts from the center and moves sequentially one step up and one step down. 2. Edit the 5-axis operation. Calculate and simulate the operation. 5. 3. Use the CAM-Part prepared in Exercise 14. Make sure that the Flip step over checkbox is not active in the Geometry page. Set the Cut order to the From center away option.SolidCAM2005 Milling Manual 5-axis Machining Exercise 15: 1. 60 . 4.

8. Set the Cut order to the From outside to center option. moves to the bottom and then moves to the second top and so on. Calculate and simulate the operation.5-axis Machining SolidCAM2005 Milling Manual 6. Do not close the CAM-Part. 7. As you can see the tool path starts from the top. 61 .

62 .6 Direction for One Way machining This option is available only for the One way Cutting method. The Clockwise and Counter clockwise options are not for the spindle rotation.SolidCAM2005 Milling Manual 5-axis Machining 6. They are used to determine whether the tool should move around a closed surface model in clockwise or counter clockwise direction. • Ccwise This option enables you to perform the machining in counter clockwise direction.

Climb milling is preferred when milling heat treated alloys. • Climb The tool movement and the tool rotation have the same direction. Tool rotation Tool movement direction • Conventional The tool movement is opposite to the tool rotation.5-axis Machining SolidCAM2005 Milling Manual • Cwise This option enables you to perform the machining in clockwise direction. Tool rotation Tool movement direction 63 . Conventional milling is preferred for milling of castings or forgings with very rough surfaces. Otherwise chipping can result when milling hot rolled materials due to the hardened layer on the surface.

Calculate and simulate the operation. 3. 64 . So you can use the CW or CCW to get the requested tool path direction. Switch to the Geometry page and choose the Cwise for the Direction for one way machining option. When the tool path is normal to the surface. Use the CAM-Part prepared in Exercise 15. 4. As you can see the tool path works in the opposite direction. it is not so clear what is the conventional or climb milling direction.SolidCAM2005 Milling Manual 5-axis Machining Exercise 16: 1. Edit the 5-axis operation. 2.

The CAM-Part is located in the Exercises/Cutting_area folder. start and end at exact surface edge If this option is chosen.5-axis Machining SolidCAM2005 Milling Manual 6. Simulate the appropriate operation of Exercise18.7 Cutting Area SolidCAM enables you to choose the following options for the Cutting area: • Full. Edge Edge 65 . the tool path will be generated on the whole surface and exactly to the surface edge or to the nearest possible position.

Point 2 66 . avoid cuts at exact edges With this option the tool path will be generated on the whole surface but avoids the surface edges. The Data button displays the Limit cuts between two points dialog. Simulate the appropriate operation of Exercise18. The CAM-Part is located in the Exercises/Cutting_ area folder. Simulate the appropriate operation of Exercise18. This dialog enables you to define point coordinates Point 1 or pick the points from the workplane.SolidCAM2005 Milling Manual 5-axis Machining • Full. The CAM-Part located in the Exercises/Cutting_ area folder. Edge Edge • Limit cuts by one or two points This option enables you to limit the machining between one or two points.

Edit the 5-axis operation. 3. avoid cuts at exact edges. 2. This option is set to Full. Simulate the operation. 67 . 4.5-axis Machining SolidCAM2005 Milling Manual Exercise 17: 1. start and end at exact surface edges. Use the CAM-Part prepared in Exercise 16. Note that the tool path does not reach the edges of the drive surface because of the Cutting area option. Switch to the Geometry page and set the Cutting area option to the Full.

SolidCAM2005 Milling Manual 5-axis Machining 5. 68 . Calculate and simulate the operation. Note that the first and last cuts are performed exactly on the drive surface edges.

5axmsurf tries to find the nearest possible position next to your point. The Start point option enables you to choose a new start point where the machining begins. In this window you can enter X.5-axis Machining SolidCAM2005 Milling Manual 6. Click on the Data button. Depending on the geometry. 69 . The coordinates will be calculated with the stepover and the angle you set. With the Rotate by option you can relocate the start position for the following cut.8 Start Point Examples of the Start Point option are located in the Exercises\Start_Point folder. Y and Z coordinates for your new point or select a point in your geometry.

The CAM-Part is located in the Exercises\Start_Point folder. Simlate operations of Exercise4 . 70 .SolidCAM2005 Milling Manual 5-axis Machining Original start point New start point Default tool path start position Tool path start position with new start point 20° 20° 20° Start points This is a tool path start position with a new start point and a 20 degrees rotation angle.

5-axis Machining SolidCAM2005 Milling Manual 7. Finish Parameters page: 71 .

72 . Radius is every point on the round radius surface.SolidCAM2005 Milling Manual 5-axis Machining 7. At a surface point with a given surface normal direction. the tool can always be placed tangentially. but only in the move direction. Move direction Radius Center Front You can see the touching points in the above picture. Front is the point where the flat part of the tool ends and the radius starts.1 Tool Contact point Examples of the Tool Contact point option are located in the Exercises\Tool_Contact_point folder. Center is exactly in the middle of the tool. This parameter defines the contact point of the tool and drive surfaces.

the difference is that for a bull nose tool. In such a case. the tip of the tool is never used as the touch point on the drive surfaces. then the tip of the tool touches the surface’s contact point.5-axis Machining SolidCAM2005 Milling Manual AT CENTER If this parameter is set to AT CENTER. the tool and surface are not tangential anymore and the tool will gouge the surface. This situation must be avoided by setting the first gouge check strategy to retract the tool from the drive surfaces. then the tangentiality is maintained like in the case of AUTO. Move direction Tool Path Tool Radius 73 . then the tool will be tilted around this tip point. If the tool axis orientation is changed due to tilting options. Move direction Tool Center AT RADIUS If this parameter is set to AT RADIUS.

the tool can be placed tangentially at a surface point with a given surface normal direction. the operations of Exercise13. Move direction Tool Front AUTO If the AUTO option is chosen. Simulate Move direction Touch points 74 . In this case. Setting the gouge control is critical when working with this option. this fixed point is the beginning of the radius of a bull nose tool in the direction of the tool motion.SolidCAM2005 Milling Manual 5-axis Machining AT FRONT The option AT FRONT is similar to AT CENTER and forces the tool touching point to be always a fixed point on the tool. All changes to the tool orientation are done around this pivot point which can cause gouging of the drive surfaces. If the user changes the orientation of the tool. The CAM-Part is located in the Exercises\Tool_ Contact_point folder. then the surface contact point remains and the contact point on the tool moves from the tip of the tool to the radius of the tool still maintaining the tangentiality between the tool and the surface.

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Exercise 18: 1. Load the CAM-Part: Exercises\Tool_Contact_point\blade.prt.

2. Simulate the CAM-Part. This part is machined using the 4 axis CNC machine. The blade is twisted and if the tool is positioned tangentially to the surface, the tool path will not be parallel. It is possible to define a parallel tool path by using the Run tool option. 3. Edit the 5-axis operation and switch to the Finish parameters page. 4. Set the Tool Contact point option to At center.

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5. Calculate and simulate the operation. It is recommended to use 3D simulation mode to perform the simulation of the tool path with the tool displayed.

The tool center is coincident to the drive surface along the whole length of the tool path. This causes gouges, so this option has to be used together with the gouge control options.

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6. If a flat tool is used for rough face milling, the At Front option enables you to mill the front part of the tool. Change the Tool Contact point option to At Front.

7. Calculate and simulate the operation. It is recommended to use the 3D simulation mode to perform the simulation of the tool path with the tool displayed.

The front of the tool is placed on the point and the angle results from the vector of this point. (Later on we will see how we can tilt the tool more in the cutting direction to get better cutting conditions). 8. To use the At radius option we have to define the tool with corner radius for the operation. Change the Corner Radius to 2.

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It is recommended to use the 3D simulation mode to perform the simulation of the tool path with the tool displayed. Note that the tool corner radius is tangent to the drive surface along the whole length of the tool path.SolidCAM2005 Milling Manual 5-axis Machining 9.Calculate and simulate the operation. 78 . Set the Tool Contact point option to At radius. 10. Make a note that the corner radius of the tool is tangent to the surface. Note that the tool path is not parallel because SolidCAM tries to put the radius tangential to the surface normal.

79 . The Lead in / Lead out dialog enables you to define the parameters of Lead in / Lead out.2 Lead in / Lead out This switch turns on and off the tangential entry and exit moves.5-axis Machining SolidCAM2005 Milling Manual 7.

Lead in Tool Path Lead out Tool Path 90° Lead in 80 .This parameter specifies the ratio of the lead in/out arc diameter to Don’t plunge with tool This option enables you to perform the arc approach in the plane normal to the tool vector in the entry point. The approach/retreat movements are performed by an arc with the following parameters: – The sweep angle of the lead in/out arc from the entry point on the tool path.SolidCAM2005 Milling Manual 5-axis Machining Lead in/Lead out– These checkboxes enable you to define the lead in/out. Arc sweep Arc sweep Lead in point Tool path Lead in arc the tool diameter. Arc diameter / Tool diameter % .

5-axis Machining SolidCAM2005 Milling Manual When this option is not chosen. Tool Path Lead in Lead in Tool Path 90° Lead in Lead out 90° 81 . the approach arc plane will be normal to the previous plane.

Drive surface Upper edge surface Lower edge surface 82 . Choose the Morph between 2 surfaces option in the Cut Control field. Choose the Drive.prt Now we will see how to use the entry and exit arc moves. Load the CAM-Part Exercises\Lead_in_Lead_out\insert. 2. Set the following parameters in the Finish page.SolidCAM2005 Milling Manual 5-axis Machining Exercise 19: 1. Upper edge and Lower edge surface as shown.

5-axis Machining SolidCAM2005 Milling Manual Choose the Zigzag option in the Cutting method field. Switch to the Finish parameters page and set the following parameters: Set the Step Over value to 3. 3. 83 . Choose the Standard option in the Cut Order field. 4. Activate the Lead in/Lead out checkbox and click on the Lead in/Lead out button in order to define the Lead in/Lead out parameters.

6. In the Lead in/Lead out dialog activate both the Lead in and Lead out sections. Switch to the Gaps page and set the following parameters: 84 .SolidCAM2005 Milling Manual 5-axis Machining 5. Set the Arc Sweep to 90 and Arc diameter/Tool diameter to 200 in both sections.

Display the Lead in/Lead out dialog and activate the Plunge with Z-Axis option. 8. The arcs are parallel to the tool path direction in the entry point.5-axis Machining SolidCAM2005 Milling Manual 7. 9. As you can see. As you can see the entry and exit arc are rotated 90 degrees and are now normal to the tool path direction in the Lead in/Lead out point. 85 . The arc size is double the tool radius. Calculate and simulate the operation. the entry and exit movements are performed by arcs. Calculate and simulate the operation.

2. Click on the Constant Z button to define the Machining Angle. Start a new 5-axis Operation and choose Tool #1 from the Part Tool table.SolidCAM2005 Milling Manual 5-axis Machining Exercise 20: 1. 3. 86 . Choose the One Way option in the Cutting Method field.prt We will now see how the gouge checking affects the entry and exit arcs. Set the following parameters in the Geometry page: Choose the Parallel Cuts option for the Cut Control. Load the CAM-Part Exercises\Lead_in_Lead_out\Undercut.

Define the Drive surface as shown below. 87 . Check the Lead in/Lead out checkbox. 5. Switch to the Finish parameters page and set the following parameters: Set Step Over to 6.5-axis Machining SolidCAM2005 Milling Manual 4.

In the Strategy field. angle option. The Gouge check options will be explained later.SolidCAM2005 Milling Manual 5-axis Machining 6. Inactivate the Check surfaces option. choose the Tilting tool away with max. 88 . 7. Switch to the Gouge 2 page and define the following parameters: Activate the Enable/Disable checkbox. Inactivate the Drive surfaces option. Switch to the Gouge check page and define the following parameters: Activate the Enable/Disable checkbox.

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8. Define the Check surfaces as shown below.

Check surfaces The chosen strategy enables the user to avoid gouging by retracting the tool along the tool axis.

9. Switch to the Tool Axis Control page.

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10. Set the following options: Choose the Tilted relative to cutting direction option in the Tool axis direction combo-box. Set the Tilt angle at side of cutting direction value to 90. Choose the Follow surface iso direction option in the Side tilt direction combobox.

11.Calculate and simulate the operation.

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We can see arcs in every tool path depth in the right side approach and only one in the left side. This is because the gouge check sees that the tool will gouge to the left wall and moves the tool along the vector of the tool center till this gouge is finished. In this part all the paths move to a safe point (in the same point in this part) and then adds the exit arc. The gouge algorithm and the Entry/Exit algorithms protect the part from gouging. 12.Close the simulation. 13.Choose the Leaving out gouging points option in the Strategy field of the Gouge check page. 14.Calculate and simulate the operation.

As you can see the arc is mirrored and moved out from the corner and the part is gouge protected.

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this switch is used in the presence of a ball cutter. Such fish tails are removed by turning on this switch. then also cylinder or torus cutters are used together with this switch. The fillet generation is independent of the tool type and shape. Such areas will be left out from the tool path generation. If swarf machining is applied (side cutting). The surface model is rounded (filletted) in the direction of tool path slices with a radius to avoid small radii and inner sharp corners. lollipop cutter or a conical cutter with a ball tip.3 Round surface by tool radius This switch can be set to find small radius areas and inner sharp edges in the surface model. The Round surface by tool radius option is not active.SolidCAM2005 Milling Manual 5-axis Machining 7. Inside corners can cause “fish tails” in tool paths. This flag can also be considered as a fillet generator. In most cases. The applied radius is the main tool radius plus the current stock to leave value. 92 .

5-axis Machining SolidCAM2005 Milling Manual The Round surface by tool radius option is active. 93 .

94 .4 Stock to leave The Stock to leave parameter describes the stock to be left on the finishing surfaces. Stock to leave For example.g.SolidCAM2005 Milling Manual 5-axis Machining 7. if this value is set to 0. then the tool will not come closer than 0. for cutting electrodes.2 units. This parameter can also be negative.2 units to the surface. there will be remaining stock on the surface of about 0. e.2 units. Simulate the operations of Exercise14. The CAM-Part is located in the Exercises\Stock_to_leave folder. Therefore. after the machining.

The Finishing passes section enables you to define a number of finishing passes. 95 .5 Multi Passes This switch can be turned on to calculate multiple tool path passes on the same geometry.5-axis Machining SolidCAM2005 Milling Manual 7. The Multi passes dialog enables you to define the following parameters: The Roughing passes section enables you to define a number of rough passes (specified by the Number parameter) with the specified spacing (the Spacing parameter) between them.

With the Constant Stepover option Without the Constant Stepover option 96 . pass 1 pass 2 pass 3 pass 4 – this option enables you to define the order of execution of the 1 2 3 4 pass pass pass pass With Constant Stepover Without Constant Stepover When this option is turned off. Simulate Exercise16. all the rough and finish passes will be done at the current height level before moving to the next height level. each pass will be finished for all height levels before moving to the next pass.SolidCAM2005 Milling Manual 5-axis Machining Constant step over at each pass roughing and finish passes. When the Constant step over at each pass option is not selected. The CAM-Part is located in the Exercises\Multi_Passes folder.

then this value can be set to 100 times of the cut tolerance and will increase the calculation speed drastically. Simulate Exercise5.6 Surface Quality 7.6. The tool path will not be as good. The CAM-Part is located in the Exercises\Chaining_tolerance.1 Chaining Tolerance The chaining tolerance is an internal value for the tool path generation and should be 1 to 10 times the cut tolerance. 97 . Using higher values in the chaining tolerance can cause inaccuracies.5-axis Machining SolidCAM2005 Milling Manual 7. If you have untrimmed simple surfaces. but the calculation time will be faster.

A tight Cut tolerance gives you more tool path points on the drive surface.2 Cut tolerance The Cut tolerance is the tolerance for the accuracy of the tool path. the surface is rougher but the calculation time is much faster. After the machining. A loose Cut tolerance generates less points on the tool path.SolidCAM2005 Milling Manual 5-axis Machining 7. Therefore the generated tool path is more accurate.6. Loose Cut tolerance Tight Cut tolerance 98 . The result of the machining is a very good surface quality but the calculation time is increased.

5-axis Machining SolidCAM2005 Milling Manual 7. You have more points on round surfaces because the tool path always changes direction.3 Distance Whether you have more or less points depends on the Cut tolerance.6. Although the Cut tolerance is the same you get more points on straight or flat surfaces. Setting a small value gives more points whereas a high value gives fewer points. Use the Distance option to get more points on flat surfaces. Result without distance Result with distance 99 .

6. Small stepover Big Stepover 100 .4 Stepover The Stepover is the distance between two neighboring parallel cuts.SolidCAM2005 Milling Manual 5-axis Machining 7.

Gaps Page The tangential entry and exit switch add 90° arc moves to the beginning and end of each tool path section. 8. 101 . An example of the Gap Along Cut option is located in the Exercises\ Gap_Along_Cut folder. The limit for ignoring the gap can be entered as the gap size as a % of the tool diameter. The plane of the arc is automatically determined perpendicular to the surface. then you can ignore the gap and move the tool connecting the two sides of the gap or retract the tool to the rapid plane and skip the gap. then come back from the rapid plane to the other side of the gap and pursue the machining.5-axis Machining SolidCAM2005 Milling Manual 8.1 Gap Along Cut If gaps along a tool path are detected. The diameter of this arc is determined in relation to the currently used tool diameter.

the tool will go back from the end to the start and connect the tool path to closed loops. The gap size is set to 50% of the tool diameter. All gaps along the tool path segment. Tool path Tool path > Gap size Tool path < Gap size Here you can see that if the motion is bigger than the gap size. If the motion is smaller than the gap size. The tool path in the gap is a straight line and the tool moves in machining speed.2 Direct If you choose Direct.1. then the threshold is 10% of 20mm. the tool path is set to “broken”. The tool diameter is 20 mm so the small gaps are 10 mm and smaller and the big gaps are over 10 mm. which are smaller than this threshold value. All other gaps that are larger than this value are larger gaps and the action defined for large gaps is performed. The value is defined as the percentage of the tool diameter.1 Gap Size as % of tool diameter The value in the field Gap Size as % of tool diameter sets the threshold for small and large gaps along a tool path segment. which is 2mm.SolidCAM2005 Milling Manual 5-axis Machining 8. if the tool diameter is 20mm and the gap size is set to 10%. If the Gap size is bigger than the tool path length. the tool uses the shortest way to the other side of the gap without any retracting movements. All gaps greater than 2mm are considered large gaps. 8. 102 . the tool movement is Direct.1. are considered as small gaps and the action defined for small gaps is executed.g. E. All gaps smaller than 2mm are considered small gaps.

the appropriate operation of in the 8.1. As you can see the short retraction is way above the gap. With rapid speed.3 Broken If you choose Broken and a gap is detected. 103 .5-axis Machining SolidCAM2005 Milling Manual Here you can see the Direct tool path between the two drive surfaces.4 Retract With the Retract mode the tool moves back to the rapid plane. the appropriate Operation of Exercise19 The CAM-Part is located in the Exercises\Gap_Along_Cut folder. Only the return to the drive surface has machining speed. The retracting direction is the tool axis. the tool retracts a litt le bit. the tool leaves the drive surface and moves over to the next tool path point with machining speed. The tool movement has rapid speed.1. Simulate Exercise19 The CAM-Part is located Exercises\Gap_Along_Cut folder. Simulate 8.

1.SolidCAM2005 Milling Manual 5-axis Machining Here you can see the tool retracting to the rapid plane. It leaves and enters the drive surfaces along its axis.5 Follow Surface SolidCAM performs the machining of the gap area tangentially to the surfaces close to the gap. the appropriate Operation of in the 104 . 8. Simulate the appropriate Operation of Exercise19 The CAM-Part is located in the Exercises\Gap_Along_Cut folder. Simulate Exercise19 The CAM-Part is located Exercises\Gap_Along_Cut folder.

you can ignore the gap and move the tool connecting the two sides of the gap or retract the tool to the rapid plane. the gap is the step over move).2.g. 8. 105 .15mm.1mm.1 Gap Size as % of Stepover This value defines the threshold value to recognize a gap as a percentage of the user given maximum stepover value (in this case. The limit for ignoring the gap can be entered as the gap size as a % of the maximum stepover.2 Gaps between cut (Gap Size as % Of Stepover) If gaps between a tool path are detected. E. That means all step over moves from one tool path slice to the next slice are checked against 0. skip the gap and then come back from the rapid plane to the other side of the gap and pursue the machining. if this value is set to 150% and the maximum step over value is 0.15 mm and it is then determined whether the gap is smaller or larger than this value.5-axis Machining SolidCAM2005 Milling Manual 8. the gap threshold is 0.

2.SolidCAM2005 Milling Manual 5-axis Machining 8. the tool uses the shortest way to the other side of the gap without any retracting movements. The tool path in the gap is a straight line and the tool moves in machining speed. 8.3 Broken If you choose Broken and a gap is detected. With rapid speed the tool leaves the drive surface and moves over to the next tool path point with machining speed. The retracting direction is the tool axis.2. the tool retracts a little bit.2 Direct If you choose Direct. 106 . As you can see the short retraction is way above the gap. Here you can see the Direct toolpath between the two drive surfaces.

5-axis Machining SolidCAM2005 Milling Manual 8.2. The tool movement has rapid speed. Here you can see the tool retracting to the rapid plane.5 Follow surface 107 . It leaves and enters the drive surfaces along its axis.4 Retract With Retract the tool moves back to the rapid plane. 8. Only the return to the drive surface has machining speed.2.

SolidCAM2005 Milling Manual 5-axis Machining 9. Tool axis control page 108 .

This output can be used with 4. e.1. 109 . the tool axis direction must be defined by the user. In case of 5-axis Operation type. around X.g. In case of 3 axis.g. Y or Z. e. top view is 0.1 Output format The output format can be set to 3. the simultaneous 5-axis output will be performed. 4-axis and 5-axis. In case of 3-axis Operation type. In case of 4-axis Operation type. As explained previously.and 5 axes-CNC Machines. the rotary axis must be selected. In case of 4 axis output. the G-code will set the 5-axis to the correct position and then simultaneous 4-axis tool path will be performed. the tool axis direction is defined according to the Machine CoordSys and the Position used for the Operation.5-axis Machining SolidCAM2005 Milling Manual 9. 4 or 5 axis. The output format is the property of this operation. SolidCAM generates the output for simultaneous 4-axis movement. If you use this output with z 5-axis CNC machine.0. SolidCAM has three types of 5-axis Operations: 3-axis.

Increasing the maximum angle step generates more points. decreasing the value generates less points.2 Maximum angle change The maximum angle step is the maximum angle value between two tool path points on the surface. Big maximum step angle Small maximum Step angle 110 . The number of points generated depends on the surface blending and the maximum angle step.SolidCAM2005 Milling Manual 5-axis Machining 9.

Tool Axis: Surface normal 111 .1 Tool axis is not tilted and stays normal to the surface Simulate the appropriate Operation of Exercise9 The CAM-Part is located in the Exercises\Tilting_ strategies folder.3 Tilting strategies (Tool axis direction) Exercises of the Tilting strategies are located in the Exercises\Tilting_strategies folder.3. 9.5-axis Machining SolidCAM2005 Milling Manual 9.

Both are shown below.2 Tool axis will be tilted relative to cutting direction This option enables you to change the lag angle of the cutting direction as well as the lag angle at the side of the cutting direction.3. 45° Surface Normal Tool Axis tti Cu ng tion rec di Simulate the appropriate Operation of Exercise9 The CAM-Part is located in the Exercises\Tilting_strategies folder. The tool axis is tilted only with a lag angle of 45° to the cutting direction and 0° at the side of the cutting direction.SolidCAM2005 Milling Manual 5-axis Machining 9. 112 .

The CAM-Part is located in the Exercises\Tilting_ strategies folder. 113 .5-axis Machining SolidCAM2005 Milling Manual Tool Axis Cutting direction 45° Surface Normal 45° Z-Axis 45° Tool Axis Simulate the appropriate Operation of Exercise9. The tool axis is tilted with a lag angle of 45° to the cutting direction and 45° at the side of the cutting direction.

Z Axis 15° Tool Axis The tool axis is tilted 15 degrees towards the main Z axis.SolidCAM2005 Milling Manual 5-axis Machining 9. The CAM-Part is located in the Exercises\Tilting_ strategies folder.3. the tool axis is tilted 45 degrees from the surface normal direction towards the Y axis. In the above case.3. The CAM-Part is located in the Exercises\Tilting_ strategies folder. 114 .3 Tool axis will be tilted with the angle Tool Axis 45° Tilt Axis Simulate the appropriate Operation of Exercise9. Surface Normal 9.4 Tool axis will be tilted with fixed angle to axis Simulate the appropriate Operation of Exercise9.

The tool axis direction is the same like the surface normal but tilted with a 45 degrees angle around the main Z axis.3. Z Axis Tool Axis 45° Z-Axis 45° Tool Axis 115 . The CAM-Part is located in the Exercises\Tilting_ strategies folder.5 Tool axis will be tilted around axis Simulate the appropriate Operation of Exercise9.5-axis Machining SolidCAM2005 Milling Manual 9.

The CAM-Part is located in the Exercises\Tilting_ strategies folder. 116 .3. Tool Axis direction Point The tool axis is always aligned to the point above the work piece.6 Tool axis will be tilted through point Simulate the appropriate Operation of Exercise9.SolidCAM2005 Milling Manual 5-axis Machining 9.

main direction • From start to end • Automatic curve 117 .3. Curve Curve tilt type SolidCAM enables you to choose the following options for the Curve tilt type: • Closest point • Angle from point • Angle from spindle.7 Tool axis will be tilted through curve Simulate the appropriate Operation of Exercise9. The tool axis is always aligned to the curve above the workpiece. The CAM-Part is located in the Exercises\Tilting_ strategies folder.5-axis Machining SolidCAM2005 Milling Manual 9.

You can see that the tool axis has the same direction like the shortest 3D distance between the surface and the present tool path point.SolidCAM2005 Milling Manual 5-axis Machining Closest point The direction of your tool axis here is the same like the shortest distance between your present tool path point and the tilt curve. The following example shows a wavy surface with a tilt curve above. Curve Tool path point Tool Axis direction 118 . So the 3D-length is used.

The Positive angle lets the axis tilt against the main axis. The main axis is usually the Z-axis. With negative angles the tool axis tilts from the main axis. Curve 25º Maximum angle Tool Axis direction 119 .5-axis Machining SolidCAM2005 Milling Manual Fixed tilt angle You can set an additive tilt angle to your present tool axis direction. Maximum tilt is reached when the tool axis is parallel to the main axis.

So the 2D distance is used. Shortest 2D distance Curve Tool Axis direction 120 . You can see that the tool axis has the same direction like the projected distance between the surface and present tool path point.SolidCAM2005 Milling Manual 5-axis Machining Angle from curve The direction of your tool axis here is the projected length between your present tool path point and the tilt curve. The following example shows a wavy surface with an tilt curve above.

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The view from the top shows the shortest 2D distance between the tilt curve and the tool path point. The tool axis always has the same direction.

Tool Path point

st te or Sh 2D s di ta nc e

Curve

Tool Axis direction

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From Start to end This tilt type is used for generating tool paths for tube milling. The tube milling is usually machined in z-constant cuts and the result is cut slices. The amount of the z constant cuts depends on the maximum stepover. Now the tilt curve will be divided by the number of slices of the tool path. Every slice is now aligned to its point on the curve. Make sure that the beginning of the curve is on the right side. Click the tilt curve and select the curve from your geometry. The curve tilt type is from the start to the end .

Tool Axis direction Tilt curve Curve points

In this example the maximum step over is 10 mm. The tool path for the tube has 10 slices. So the curve has 10 points. Now every cut is aligned to its point on the curve..

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9.3.8 Tool axis will be tilted through lines

Simulate the appropriate Operations of Exercise9 and Exercise8 The CAM-Part is located in the Exercises\Tilting_strategies folder. Line Tool Axis Tool Axis Line

Line Tool Axis Line

Tool Axis

9.3.9 Tilted from point away

Simulate the appropriate Operation of Exercise9 The CAM-Part is located in the Exercises\Tilting_strategies folder. The tool axis is always aligned from the point.
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Point

g. E. Side milling is aimed to get a line contact between the tool and the surface.4 Side tilt definition This parameter defines the side tilting direction when the tilt strategy is set to relative to cutting dir. The Ortho to cut dir at each contour option is similar to Ortho to cut dir at each pos. The side tilt direction is determined by an orthogonal line from the current surface contact point to the lower edge curve. if the spindle main direction vector is the z axis and side tilting of 90 degrees from surface normal takes place. The side tilting always happens from the view defined by the spindle main direction vector. Use the Ortho to cut dir at each pos if the side tilt direction should be defined by the tool path moving direction and orthogonal direction to this move direction. Instead it is set for a complete contour segment.SolidCAM2005 Milling Manual 5-axis Machining 9. The option Ortho to cut dir at each pos can be used only if the Cut strategy is Parallel cuts or Morph between 2 curves. then the tool axis orientation is 124 . The difference is that the side tilt direction is not individually defined at each tool path position. If any surface does not have a compatible u and v direction with the neighboring surfaces. then this function tries to correct this automatically. The option Use spindle main direction uses the machine definitions spindle main direction vector definition as the reference for finding the side tilt direction. The function Approximate sets the formula to calculate the side direction at each position of the contour. Side tilting definition is an important setting to define a proper side milling with the tool. The definition of the side tilt direction is a user option with the following interpretation: The option Follow surface iso directions is a good choice if linear surfaces are present. Multiple surfaces can be used here.

This option gives the user the freedom of defining the side tilting direction manually by just passing lines.5 Tool axis direction limit parameters The Data button displays the Limits dialog. The only difference is that the user can set any user defined direction instead of the spindle main dir.5-axis Machining SolidCAM2005 Milling Manual the surface normal rotated 90 degrees towards the spindle main direction. The option Use tilt line definition utilizes user given tilt line elements as the side tilt direction. such a rotation can be handled by a machine tool without utilizing the C axis. 125 . 9. In practical terms. The next option Use user defined dir is the same like the previously described spindle main direction option.

Tool axis In this example you can see that the minimum tool limit angle is a1 = 40 degrees and the maximum angle is a2 = 95 degrees. B2=120° B1=30° Z X 9.1 XZ Limit This switch is set to true to limit the tool on the XY plane between angle b1 and b2.5.SolidCAM2005 Milling Manual 5-axis Machining 9. B2=95° B1=40° Z X 126 .2 YZ Limit This switch is set to true to limit the tool on the YZ plane between angle a1 and a2. Tool axis In this example you can see that the minimum tool limit angle b1 = 30 degrees and the maximum angle b2 = 120 degrees.5. You can use any angle between 0 and 360 degrees.

This function works especially for tube milling. In this example you can see that the minimum tool limit angle c1 is 40 degrees and the maximum angle c2 is 95 degrees. Slices Surface normal w1 w2 127 . C1=40° C1=40° Y X 9. imagine 2 cones with different opening angles w1 and w2. In this example you have a limit angle w1 = 10° and w2 = 10°.3 XY Limit: This switch is set to true to limit the tool on the XY plane between angle c1 and c2. The orientation of the cones is redefined by subsequent tool path slices. You can use any angle between 0 and 360 degrees. The angles start from the tool path slice normal vector.5.5-axis Machining SolidCAM2005 Milling Manual 9. You can use any angle between 0 and 180 degrees. The tool axis direction is between these 2 cones.5.4 Conical angles from leading curve This switch is set to true to limit the tool between two angles which are orthogonal to the leading curve. In other words.

ball.SolidCAM2005 Milling Manual 5-axis Machining 10. Holder Arbor Holder clearance Arbor clearance 128 . 10. Gouge checking for complicated swarf motions between two tool positions is under development. Further check surfaces can be selected to avoid gouges with surfaces that are not going to be machined. The check is done at each calculated tool position. Gouge Check page The gouge checking option looks at the generated tool path and the end surfaces to decide whether the tool tip or shaft is gouging the surfaces. The gouge checking is supported for all tool types (flat.1 Clearance Clearance is a virtual stock added to your holder and arbor diameter. conical and bull nose).

The 5 axis sweep moves from one position to the next position and is then used to check for collisions with drive and check surfaces. False True 129 . This switch is set to true to activate the collision check between tool path positions.2 Check gouge between positions Exercises of Check gouge between positions option are located in the Exercises\Gouge_Check folder.5-axis Machining SolidCAM2005 Milling Manual 10.

If the option is checked. If the option is not checked.01. 130 .SolidCAM2005 Milling Manual 5-axis Machining Position 1 Position 2 Position 2 Position 1 No gouge check between positions With gouge check between positions SolidCAM sets this field as the default to avoid problems of gouging check surfaces along movements. If the tolerance is 0. the checking will be done at every end point of the tool path. the gouge check will be done in steps of the Cut tolerance defined in the Finish Parameters page. the check will be performed every 0.01 of mm (or inch) along the tool path. Using this option will slow down the calculation but it is important if you are using check surfaces.

10. Both switches are set to false to turn off collision checking with the tool tip and shaft.4 Tool Here you can activate the gouge check for the Tool Tip.4.3 Gouge pages SolidCAM enables you to set a number of parameter sets for the gouge check. 131 . Arbor and Holder. Tool Shaft.5-axis Machining SolidCAM2005 Milling Manual 10. Please note that the holder and arbor are considered cylindrical. Gouge of holder switch is used to turn on gouge checking of tool holders and arbors defined within the tool definition page. the collision checking will be performed with the defined parameters. It is also possible to give a clearance to the arbor and the holder. Please note that the gouge checking is only from the tool tip up to the shoulder and not overall.1 Tool Tip and Tool Shaft Both switches are set to true if collision checking should be performed with the tool tip and shaft. When the page is enabled. The non-cylindrical holder shape of the backplot function can mislead the user. 10.

2 Check Arbor and Check Holder Both switches should be set to true if the collision checking is performed with the arbor and holder. Both switches are set to false to turn off collision checking with the arbor and holder. 10.4. 132 .5 Strategy Examples of the Check gouge between positions option are located in the Exercises\Gouge_Check folder.SolidCAM2005 Milling Manual 5-axis Machining 10. This function sets the collision elimination strategy for the first collision checking block.

Actually this surface point may indicate remaining stock. because there is a surface area that ought to be machined but after retraction.1 Retracting tool along tool axis If control by retracting tool along tool axis is selected. 133 . The CAM-Part is located in the Exercises\Gouge_ check folder. that is not the case. The retract distance is shown to the user.5. You can turn the find and report option on and off. Another line connects the calculated tool position before retraction and the surface point used for calculating the tool position. Also a red line is drawn which shows the retraction move.5-axis Machining SolidCAM2005 Milling Manual 10. The resulting tool path is then gouge free. Retracting direction Tool axis Check surface Drive surface Here you can see the tool retracting along the tool axis. Simulate the appropriate Operation of Exercise11. then the gouge is avoided by retracting the tool.

the tool moves away only in the selected retracting direction. 134 .5. and Z axis. the tool always uses the shortest distance to go around the check surface. If you select “move tool in –X “ the affected tool path points will be moved away only in –X direction until the check surface ends and the tool is able to pass. X. New tool path points X-direction Check surface Old tool path points Drive surface Here a gouge is detected.SolidCAM2005 Milling Manual 5-axis Machining 10.2 Moving the tool away This option assigns the direction in which the tool has to move away. From the point a gouge is detected. When retracting. Y. retracting the tool away from the origin and retracting the tool to cut center. retracting the tool along the surface. Parameters: Here you can choose between the following available retracting options.

135 . Here the tool retracts in X or Z. Retract tool in XZ: Simulate the appropriate Operation of Exercise11 The CAM-Part is located in the Exercises\Gouge_ check folder.5-axis Machining SolidCAM2005 Milling Manual Retract tool in XY: Simulate the appropriate Operation of Exercise11 The CAM-Part is located in the Exercises\Gouge_ check folder. Here the tool retracts in X or Y.

Here the tool retracts in Y or Z. Retract tool in +Z: Simulate the appropriate operation of Exercise11. Here the tool retracts only in +Z. The CAM-Part is located in the Exercises\Gouge_ check folder. The CAM-Part is located in the Exercises\Gouge_ check folder. 136 .SolidCAM2005 Milling Manual 5-axis Machining Retract tool in YZ: Simulate the appropriate operation of Exercise11.

Here the tool retracts only in -Z. The CAM-Part is located in the Exercises\Gouge_ check folder. Retract tool in –X: Simulate the appropriate operation of Exercise11. 137 . Here the tool retracts only in -X. The CAM-Part is located in the Exercises\Gouge_ check folder.5-axis Machining SolidCAM2005 Milling Manual Retract tool in –Z: Simulate the appropriate operation of Exercise11.

Here the tool retracts only in +X (Operation 7). 138 . The CAM-Part is located in the Exercises\Gouge_ check folder.SolidCAM2005 Milling Manual 5-axis Machining Retract tool in +X: Simulate the appropriate operation of Exercise11. The CAM-Part is located in the Exercises\Gouge_ check folder. Here the tool retracts only in -Y. Retract tool in –Y: Simulate the appropriate operation of Exercise11.

Retract tool along surface normal: Simulate the appropriate operation of Exercise11. Here the tool retracts only in +Y. Tool axis Surface normal 139 .5-axis Machining SolidCAM2005 Milling Manual Retract tool in +Y: Simulate the appropriate operation of Exercise11. The CAM-Part is located in the Exercises\Gouge_ check folder. The CAM-Part is located in the Exercises\Gouge_ check folder.

Cut center Drive surface Check surface 140 .SolidCAM2005 Milling Manual 5-axis Machining Retract tool away from orign: Simulate the appropriate operation of Exercise11. To avoid the gouge the cutter will be tilted to the cut center. This drawing shows a simple cutout through a tube. The cut center is the center point of your enclosed geometry. The CAM-Part is located in the Exercises\Gouge_ check folder. The green drive surface is machined in parallel Z-cuts. The red surface is the check surface. Tool axis Surface normal Origin Retract tool cut to center: You need this gouge check option for Tool path tube milling. With the gouge check the cutter retracts along the check surface to the cut center.

angle is selected. Tool Axis +65° -65° Surface normal 141 . Parameters Use side tilt angle: The tool tilts horizontally with a 65 degrees angle orthogonal to the surface normal. This main parameter contains a std vector of 4 independent collision control operations where each of them can be defined individually by the user. angle to prevent gouging: The gouge checking requires a lot of computing time.3 Tilting tool away with max angle If control by tilting tool away with max.5. tilt angles etc.5-axis Machining SolidCAM2005 Milling Manual 10. Below you can see the options that are given with the option with tilting tool away with max. then the gouge is avoided by tilting the tool. to create a gouge free tool path and use the gouge checking find and report option just to prove that there are no gouges. So the best approach is to use limit angles.

-90° Surface normal +90° Tool Axis Use lead/lag angle and side tilt angle -90° Tool Axis +90° Surface normal +90° -90° The tool tilts horizontally and vertically with a 90 degrees angle orthogonal to the surface normal.SolidCAM2005 Milling Manual 5-axis Machining Use lead/lag angle: The tool tilts horizontally with a 90 degrees angle orthogonal to the surface normal. 142 .

the tool path will be created only until the first gouge is detected.4 Leaving out gouging points Activating this option will cause the tool path to be trimmed when a collision is detected.5-axis Machining SolidCAM2005 Milling Manual 10. Drive surface Stop position Tool path 143 .5. The tool path was created until the stop position. Check surface 10. First gouge Here you can see that the next cut would cause contact with the check Check surface surface.5 Stop tool path calculation If you select the option Avoid by leaving out the tool.5.

SolidCAM2005 Milling Manual 5-axis Machining 10. if collision control operation Nr. 10.6 Drive Surfaces This switch should be set to true if collision control is performed with the drive surfaces passed by the user.8 Stock to leave Stock to leave defines a minimum distance between the tool and check surface. 10.g. 0. 3 is used. then the user needs to pass Check Surfaces 3 as geometry to the interface.5 mm Check surface 144 .7 Check Surfaces This switch should be set to true if collision control is performed with the check surfaces passed by the user. E.

then the surfaces or triangle meshes must be provided to the library to define the stock or remaining stock from the last operation. 145 . E.5-axis Machining SolidCAM2005 Milling Manual 11. All the tool path segments out of the stock definition will be filtered out. This information is then used to allow only tool path segments that are removing chip (material) from this given stock. the stock definition will allow the library to eliminate air cuts.g. Stock Page If this switch is set to true. if multiple cuts are used.

SolidCAM2005 Milling Manual 5-axis Machining 12. Ignore all closed contours switch ignores all closed shapes in the geometry and machines only open areas. Create multiple pockets creates several pocket operations with tilted tool planes for each tool section instead of one 5axmsurf operation. This “base operation” can be any 3 axis or 5 axis operation. Read last operation flag reads the last operation in the operation manager and creates a 5 axis tool path based on that. 146 . Additional parameter Page The following parameters in this page are implemented to handle very exceptional cases. In such a case 5axmsurf is used to modify the tool angles or to do a gouge checking. Set Y axis machining limit restricts the angle output of SolidCAM calculation to a certain machine limit. Please ignore this page unless you are advised otherwise.

Appendix 13.5-axis Machining SolidCAM2005 Milling Manual 13. Surface XYZpoints in CAD/CAM-systems are afterwards usually defined by a 2-Parameter representation. 147 . There are more issues to explain but it seems to be more reasonable to deal with one point of interest.and Z-coordinate can be calculated from a unique pair of U and V. These parameters are called U and V: Surface point (U. 13.V) Interpolation points Parameter V Parameter U Each surface point s X-. This publication tries to as easily and clearly as possible address one common question about 5 Axis machining of multiple surfaces. Y.1 Single Surface versus Multi Surface Machining in 5 Axis Due to increased availability and lower pricing of 5 Axis Milling machines and recent developments from the controller side (Fanuc etc.).2 At the beginning of all: Single Surface 5 Axis Flowline Machining CAD surfaces are generally built on customer-defined interpolation points. the need for information about 5 Axis machining has recently increased dramatically.

In some rare cases the cutter is aligned with the Y axis.SolidCAM2005 Milling Manual 5-axis Machining Each surface point is associated with a surface normal that is always perpendicular to the surface at that point. Surface Normal In 3 axis machining this surface normal for a ball end mill points to the cutter center. The cutter axis always comes from one direction. Z 148 . usually it is aligned with Z.

a 5 axis flow line tool path is shown which is mainly calculated in the u-direction. but this will be discussed later): A Flowline 5 Axis tool path follows only the u-direction and v-direction of the surface. This kind of machining is called a single-surface 5 axis flow line tool path.5-axis Machining SolidCAM2005 Milling Manual In 5 Axis machining the surface normal may not only determine the cutter center but the cutter orientation as well (there are other ways to control the tool axis to achieve a 5 axis machining tool path. In the subsequent figure. As soon as the surface edge is reached the tool steps in v and then continues movement in reversed udirection to achieve a Zig-Zag tool path. During movement. Tool movement in V-direction Tool movement in U-direction Parameter V 149 Parameter U . the tool axis direction is changed in every single point of the tool path according to the local surface normal.

SolidCAM2005 Milling Manual 5-axis Machining On a real machine the machine has to move its axis to rotate the tool to the required direction as shown below. 150 .

5-axis Machining SolidCAM2005 Milling Manual 151 .

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