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The complete integrated machining system

SolidCAM+SolidWorks

www.solidcam.com

Power and Ease of Use - the winning combination

SolidCAM2008 R

Getting started

www.solidcam.com

• Don’t go for less. Go for Gold. SolidCAM is the de-facto standard Gold-Certified integrated CAM-Engine for SolidWorks. SolidCAM provides seamless, single-window integration and full associativity to the SolidWorks design model. All machining operations are defined, calculated and verified, without leaving the SolidWorks window. SolidCAM is widely used in the mechanical manufacturing, electronics, medical, consumer products, machine design, automotive and aerospace industries, as well as in mold and die and rapid prototyping shops. Today successful manufacturing companies are using integrated CAD/ CAM systems to get to market faster and reduce costs. With SolidCAM’s seamless single-window integration in SolidWorks, any size organization can reap the benefits of the integrated SolidWorks and SolidCAM solution. SolidWorks + SolidCAM is the Dream-Team for design and Manufacturing. SolidCAM supports the complete set of manufacturing technologies. Following is a brief description of the main SolidCAM modules. SolidCAM

SolidCAM+SolidWorks = The complete integrated machining system

• 2.5D Milling SolidCAM provides both interactive and automated powerful 2.5D milling operations on SolidWorks models. SolidCAM offers one of the best pocketing algorithms in the market. Full tool path control and powerful algorithms ensure that the user can manufacture the way he needs to. Operations can be easily re-ordered, rotated, mirrored, etc. SolidCAM’s automatic feature- recognition and machining module automates the manufacturing of parts with multiple drills and complex holes. All your needs for successful production machining are provided directly inside SolidWorks with an easy and straightforward interface. SolidCAM is successfully used in production environments by thousands of manufacturing companies and job shops.
• 3D Milling SolidCAM’s 3D Milling can be used both for prismatic parts and for complex 3D models. For prismatic parts SolidCAM analyzes the model and automatically recognizes pockets and profiles to be machined using Z-constant machining strategies. For complex 3D models, SolidCAM offers powerful 3D machining, including integrated rest material options.

SolidCAM+SolidWorks = The complete integrated machining system SolidCAM provides intelligent and powerful 5-axis machining strategies, including swarfing and trimming, for machining of complex geometry parts including mold cores and cavities, aerospace parts, cutting tools, cylinder heads, turbine blades and impellers. SolidCAM provides a realistic simulation of the complete machine tool, enabling collision checking between the tool and the machine components.

• High Speed Machining (HSM) Module SolidCAM HSM is a very powerful and market-proven high-speed-machining module (HSM) for molds, tools and dies and complex 3D parts. The HSM module offers unique machining and linking strategies for generating high- speed toolpaths. SolidCAM’s HSM module smooths the paths of both cutting moves and retracts wherever possible to maintain a continuous machine tool motion– an essential requirement for maintaining higher feedrates and eliminating dwelling. With SolidCAM HSM module, retracts to high Z levels are kept to a minimum. Angled where possible, smoothed by arcs, retracts do not go any higher than necessary – thus minimizing aircutting and reducing machining time. Any HSM 3D machining strategy can be controlled by specifying the surface slope-angle to be machined or by specifying the machining boundary. SolidCAM HSM module provides a comprehensive set of boundary creation tools, including Silhouette boundaries, Cutter Contact Area boundaries, Shallow boundaries, Theoretical Rest Area boundaries, Rest Area boundaries and User-defined boundaries. SolidCAM HSM module is a powerful solution for all users who demand advanced high speed machining capabilities. It can also be used to improve the productivity of older CNC’s with reduced air-cutting and smoothing arcs that maintain continuous machine tool motion.

The result of HSM is an efficient, smooth, and gouge-free tool path. This translates to increased surface quality, less wear on your cutters, and a longer life for your machine tools. With demands for ever-shorter lead and production times, lower costs and improved quality, High Speed Machining (HSM) is a must in today’s machine shops.

• Turning and Mill-Turn SolidCAM has a very strong capability in turning, grooving and Mill-Turn. As in milling, a rest-machining capability is built in all turning operations. SolidCAM supports all machine turning cycles. SolidCAM provides special support for the advanced machining technologies of ISCAR’s Turn-Groove tools.

2.5d Milling The 2_5D_Milling_1.prz example illustrates the use of SolidCAM 2.5D Milling to machine the cover part shown above. The machining is performed on a 3-axis CNC machine in two setups, one for the top faces and one for bottom faces. The following SolidCAM operations are created to perform the machining:

• Top face machining (FM_profile_T1) This Face Milling operation performs the machining of the top face of the cover. An end mill of Ø20 is used. The machining is performed in two passes - rough and finish. A machining allowance of 0.2 mm remains unmachined at the floor, after the rough pass, and is removed during the finishing pass.
• External faces machining (F_profile1_T2; F_profile2_T2) These operations perform the profile machining of the external contour of the cover. An end mill of Ø16 is used. The Clear offset option is used at the roughing stage to perform the machining in a number of equidistant offsets from the machining geometry. The machining allowance is left unmachined during the roughing operation and removed at the finishing stage.
• Bolt seats machining (F_profile3_T3) This operation is used to remove the material at the bolt seat areas. An end mill of Ø8 is used for the operation.

SolidCAM+SolidWorks = The complete integrated machining system

• Bottom face machining (FM_profile4_T1) This Face Milling operation performs the machining of the bottom face of the cover. This operation uses the second Coordinate system; it means that the second setup has to be performed at the CNC machine before the machining. The used tool and the machining strategy are similar to the FM_profile_T1 operation.
• Internal faces roughing (P_profile5_T2; P_profile6_T2) These Pocket operations perform the rough machining of the internal faces of the cover. An end mill of Ø16 is used. The rough machining is divided into two operations to perform the machining with the optimal tool path The machining allowance is left unmachined for further finish operations.
• Internal faces rest machining (P_profile6_T4) This operation uses the rest material machining technique in order to machine the areas left inaccessible for the large tools used in the previous operations. An end mill of smaller diameter (Ø8) is used.
• Internal faces finishing (F_profile5_T4; F_profile7_T4) These operations perform the wall finishing of the internal pocket area of the cover part. An end mill of Ø6 is used.
• Floor faces finishing (F_profile7_T3; P_profile6_T4_1) These operations perform the floor finishing of the internal pocket area of the cover part. End mill tools of Ø6 and Ø8 are used.
• Slot machining (S_slot_T5) This Slot Milling operation performs the machining of the groove at the bottom face of the cover. An end mill of Ø1.5 is used.
• Holes machining D_drill_T6; D_drill_T These Drill operations perform the сenter drilling and drilling of the four holes of Ø5 located at the bottom face of the cover.
• Threaded holes machining (D_drill1_T6; D_drill1_T8; D_drill1_T9) These Drill operations perform the сenter drilling, drilling and threading of the M2 holes located at the pads. For more information see Exercise #3 of the SolidCAM 2.5D Milling Training Course.

SolidCAM+SolidWorks = The complete integrated machining system

• Connector pocket machining (P_profile4_T1; P_profile5_T2; F_profile13_T2; F_profile6_T2; P_profile4_T A number of Profile and Pocket operations are used to perform the rough and finish machining of the connector pocket. End mill tools of Ø10; Ø and Ø4 are used. The Rest material strategy is used in the last operation to complete the machining of the connector faces.
• Machine screw head areas (F_profile7_T3) This operation performs the rough and finish machining of the screw head areas. An end mill tool of Ø4 is used.
• Top and Bottom face machining (FM_profile1_T1; FM_facemill1_T1) Two Face Milling operation enable you generate the tool path for roughing and finishing of the top and bottom faces. Note that the second operation is used with the second Coordinate System, it means that the second setup has to be performed at the CNC machine before the machining.
• Internal faces roughing (P_profile11_T1; P_profile12_T1) These Pocket operations perform the roughing of the complex pocket formed by the internal faces of the part. An end mill tool of Ø10 is used.
• Internal faces roughing (F_profile11_T4; F_profile12_T4; P_profile8_T4; F_profile9_T4) These Pocket and Profile operations perform the finish machining of the wall and floor faces if the complex pocket roughed at the previous stage. An end mill tool of Ø4 is used.
• Holes machining (D_drill_T5; D_drill1_T5; D_drill2_T5; D_drill_T6; D_drill1_T7; D_drill2_T8; These Drill operations perform center drilling and drilling of holes located on the cover part faces. For more information see Exercise #8 of the SolidCAM 2.5D Milling Training Course.

FEATUrE rECogniTion The drill_pocket_recognition.prz example illustrates the use of SolidCAM Automatic Feature Recognition to machine the mold base part shown above. The machining is performed on a 3-axis CNC machine. The following SolidCAM operations are created to perform the machining:

• Top face machining (FM_facemill_T1) This Face Milling operation performs the machining of the top face of the cover. A face mill of Ø40 is used.
• Pockets machining (PR_selected_faces_T2) This Pocket Recognition operation automatically recognizes all the pocket areas in the model and performs their machining. An end mill of Ø is used. The Open Pocket machining is used to perform the approach movement from an automatically calculated point outside of the material. The tool descends to the necessary depth outside of the material and then moves horizontally into the material. A special machining strategy is applied to the through pockets; they are deepened in order to completely machine the pocket.

3 d Milling The 3D_Milling_1.prz example illustrates the use of SolidCAM 3D Milling for the machining of the mold core shown above. The following SolidCAM operations are created to perform the machining:

• Roughing (3DR_target_T1) This operation removes the bulk of material using the Contour roughing strategy. An end mill of Ø20 is used. The machining is performed at the constant-Z levels defined, using the Step down value of 5 mm. A machining allowance of 0.5 mm remain unmachined for further finish operations.
• Rest material machining (3DR_target_T2) This operation performs the rest material machining of the areas that were inaccessible to the tool in the previous operation. An end mill tool of smaller diameter (Ø16) is used. The Contour roughing strategy is utilized in combination with the Rest material mode of the Working area definition in order to obtain optimal and effective tool path removing the cusps left after the previous operation. A machining allowance of 0.5 mm remains unmachined for further finish operations.

SolidCAM+SolidWorks = The complete integrated machining system

• Steep areas finishing (3DF_CZ_target_T3) This operation performs the Constant-Z finishing of the steep areas of the core. With this strategy, SolidCAM machines a number of planar sections, parallel to the XY plane, using profile machining. A ball nose mill of Ø10 is used. The machining is performed for the steep areas, with inclination angle from 30° to 90°
• Shallow areas finishing (3DF_CS_target_T3) This operation performs the Constant Stepover finishing of the shallow areas of the core. With this 3D Milling strategy SolidCAM generates a number of tool paths, at specified constant offset (Step over) from each other, measured along the surface. The machining is performed for the shallow areas, with inclination angle from 0° to 32°. A ball nose mill of Ø10 is used.
• Parting surface finishing (3DF_Lin_target_T3) This operation performs the Linear finishing of the parting surface of the core. In linear finishing, SolidCAM generates a line pattern on a 2D plane above the model and then projects it on the 3D Model. The Step over value determines the constant distance between adjacent lines of the linear pattern, created on the 2D plane before being projected. A ball nose mill of Ø10 is used. The defined Drive/Check surfaces enable you to perform the machining of the parting surfaces only, avoiding unnecessary contact with the already machined faces. For more information see Exercise #1 and Exercise #10 of the SolidCAM 3D Milling Training Course.

SolidCAM+SolidWorks = The complete integrated machining system

• Vertical walls finishing (3DF_CZ_target_T4) This operation performs the Constant-Z Wall finishing of the vertical walls areas of the part. With this strategy, SolidCAM generates a number of profile passes along the Z-axis, with a constant Step down. An end mill of Ø4 is used.
• Horizontal floor finishing (3DF_CZ_target_T4_1) This operation performs the Constant-Z Floor finishing of the horizontal floor areas of the part. With this strategy, SolidCAM generates a number of pocket passes on the horizontal faces, parallel to the XY-plane of the current Coordinate System. An end mill of Ø4 is used. For more information see Exercise #18 of the SolidCAM 3D Milling Training Course.

HigH SPEEd MACHining The hsm_1.prz example illustrates the use of several SolidCAM High Speed Machining (HSM) strategies to machine the mold cavity shown above. The following SolidCAM operations are created to perform the machining:

• Rough machining (HSM_R_Cont_target_T1A) This operation performs contour roughing of the cavity. An end mill of Ø20 is used with a Step down of 3 mm. A machining allowance of 0.5 mm remain unmachined for further semi-finish and finish operations.
• Rest roughing (HSM_RestR_target_T2A) This operation performs rest roughing of the cavity. A bull nosed tool of Ø12 and corner radius of 2 mm is used with a Step down of 1.5 mm to remove the steps left after the roughing. The same machining allowance as in roughing operation is used.
• Steep faces semi-finishing (HSM_CZ_target_T3A) This operation performs Constant Z semi-finishing of the steep faces (from 40° to 90°). A ball nosed tool of Ø10 is used for the operation. A machining allowance of 0.25 mm remain unmachined for further finish operations. The Apply fillet surfaces option is used to add virtual fillets that will smooth the tool path at the corners.