2015 SolidCAM Sim. 5-Axis-Milling User Guide


2/447


3/447

SolidCAM 2015

Simultaneous

5-Axis Machining

User Guide

©1995-2015 SolidCAM

All Rights Reserved.


4/447


5/447

Content

Contents

1. Introduction ................................................................................................................ 1

1.1 Adding a Sim. 5-Axis Operation ............................................................................................ 7

1.2 Sim. 5-Axis Operation dialog box ......................................................................................... 8

1.3 The stages of the Sim. 5-Axis Operation parameters denition .................................... 11

2. Coordsys ...................................................................................................................13

CoordSys page .....................................................................................................................................14

3. Geometry ...................................................................................................................15

3.1 Geometry................................................................................................................................. 16

3.1.1 Drive surface denition .........................................................................................173.1.2 Drive surface offset ................................................................................................ 18

3.1.3 Curves denition .....................................................................................................18

3.1.4 Work type .................................................................................................................19

3.1.5 Edge curve ............................................................................................................... 20

3.1.6 Edge surface ............................................................................................................ 20

3.1.7 Lead curve ................................................................................................................22

3.1.8 Start and End edge curve ...................................................................................... 23

3.1.9 Projection curves ....................................................................................................263.2 Area .......................................................................................................................................... 28

3.2.1 Full, avoid cuts at exact edges ...............................................................................28

3.2.2 Full, start and end at exact surface edges ............................................................ 29

3.2.3 Limit cuts by one or two points ...........................................................................31

3.2.4 Determined by number of cuts ............................................................................31

3.2.5 Use 2D Boundary ...................................................................................................33

4. Tool ............................................................................................................................35

4.1 Tool denition ........................................................................................................................ 36

4.1.1 Spin denition .........................................................................................................37

4.1.2 Feed denition .........................................................................................................37

4.1.3 Feed zone control ................................................................................................... 39

4.1.4 Feed rate optimization ...........................................................................................39

4.1.5 Rapid move parameters .........................................................................................40


6/447ii

5. Levels ........................................................................................................................43

5.1 Regular ..................................................................................................................................... 44

5.1.1 Clearance area ..........................................................................................................44

5.1.2 Machining levels ......................................................................................................47

5.2 Advanced .................................................................................................................................495.2.1 Arc t .......................................................................................................................49

5.2.2 Keep initial orientation until distance ..................................................................49

6. Tool path parameters ...............................................................................................51

6.1 Surface quality ......................................................................................................................... 52

6.1.1 Cut tolerance............................................................................................................ 52

6.1.2 Distance ....................................................................................................................53

6.1.3 Step over...................................................................................................................53

6.1.4 Synchronize points ................................................................................................. 54

6.1.5 Advanced options for surface quality ..................................................................55

6.2 Sorting ...................................................................................................................................... 56

6.2.1 Cutting method .......................................................................................................56

6.2.2 Direction of machining .........................................................................................59

6.2.3 Cut order ..................................................................................................................60

6.2.4 Machine by ............................................................................................................... 62

6.2.5 Enforce closed contours ........................................................................................626.2.6 Flip step over ........................................................................................................... 63

6.2.7 Start point ................................................................................................................63

6.3 Modify ......................................................................................................................................66

6.3.1 Surface edge merge distance ................................................................................. 66

6.3.2 Apply outer sharp corners ..................................................................................... 67

6.3.3 3D Tool compensation ..........................................................................................68

6.3.4 Round corners .........................................................................................................69

6.3.5 Angle range .............................................................................................................. 696.3.6 Extend/Trim ........................................................................................................... 71

7. Tool axis control .......................................................................................................75

7.1 Regular ..................................................................................................................................... 76

7.1.1 Output format .........................................................................................................76

7.1.2 Interpolation ............................................................................................................ 79


7/447

Content

7.1.3 Tilting strategies (Tool axis direction).................................................................. 80

7.1.4 Angle range ............................................................................................................111

7.2 Advanced ...............................................................................................................................113

7.2.1 Axial Shift ...............................................................................................................113

7.2.2 Tool contact point ................................................................................................114

8. Link ..........................................................................................................................117

8.1 Approach/Retract ................................................................................................................118

8.1.1 First entry ...............................................................................................................118

8.1.2 Last exit ..................................................................................................................121

8.1.3 Home position ......................................................................................................123

8.2 Links ....................................................................................................................................... 124

8.2.1 Gaps along cut.......................................................................................................124

8.2.2 Links between slices .............................................................................................127

8.3 Default Lead-In/Out ...........................................................................................................130

8.3.1 Type .........................................................................................................................130

8.3.2 Tool axis orientation .............................................................................................133

8.3.3 Approach/Retreat parameters (Use the...) ........................................................134

8.3.4 Height .....................................................................................................................136

8.3.5 Feed rate .................................................................................................................136

8.3.6 Same as Lead-In ....................................................................................................136

9. Gouge Check ..........................................................................................................137

9.1 Gouge checking ....................................................................................................................138

9.1.1 Tool .........................................................................................................................138

9.1.2 Geometry ...............................................................................................................139

9.1.3 Strategy ...................................................................................................................140

9.2 Clearance data .......................................................................................................................155

9.2.1 Clearance ................................................................................................................155

9.2.2 Remaining collisions .............................................................................................160

10. Roughing and More ................................................................................................161

10.1 Multi-passes ........................................................................................................................... 162

10.2 Depth cuts .............................................................................................................................165

10.3 Rotate and translate ............................................................................................................. 168


8/447iv

10.4 Stock denition.....................................................................................................................170

10.5 Plunging .................................................................................................................................173

10.6 Morph pocket .......................................................................................................................174

10.7 Area roughing .......................................................................................................................176

10.8 Sorting ....................................................................................................................................179

10.8.1 Reverse order of passes/tool path .....................................................................17910.8.2 Connect slices by shortest distance ....................................................................180

10.9 Links between passes ...........................................................................................................181

11. Machine Control .....................................................................................................185

11.1 Angle pairs .............................................................................................................................187

11.2 Machine limits .......................................................................................................................188

11.3 Pole handling ........................................................................................................................ 189

11.4 Move list writer .....................................................................................................................190

11.5 Tool repositioning ................................................................................................................191

11.6 Point interpolation ...............................................................................................................192

12. Misc. Parameters ....................................................................................................193

12.1 Message ..................................................................................................................................195

12.2 Extra parameters ..................................................................................................................195

12.3 Tool center based calculation .............................................................................................195

12.4 Smooth surface normals .....................................................................................................196

13. Multiaxis Roughing ................................................................................................197

13.1 Adding a Multiaxis Roughing Operation ..........................................................................198

13.2 CoordSys ...............................................................................................................................199

13.3 Geometry...............................................................................................................................200

13.3.1 Strategy ...................................................................................................................200

13.3.2 Floor surfaces ........................................................................................................201

13.3.3 Wall surfaces ..........................................................................................................20113.3.4 Ceiling surfaces......................................................................................................202

13.3.5 Stock to leave on ...................................................................................................202

13.4 Tool ........................................................................................................................................203

13.5 Levels .....................................................................................................................................204

13.5.1 Levels ......................................................................................................................204


9/447

Content

13.6 Constraint boundaries .........................................................................................................205

13.6.1 Boundary type .......................................................................................................206

13.6.2 Boundary name .....................................................................................................209

13.7 Tool path parameters ...........................................................................................................210

13.7.1 Surface quality .......................................................................................................210

13.7.2 Sorting ....................................................................................................................21213.7.3 Smoothing ..............................................................................................................213

13.7.4 Stock .......................................................................................................................215

13.8 Link ........................................................................................................................................216

13.8.1 Ramping .................................................................................................................216

13.8.2 Approach/Retreat .................................................................................................218

13.8.3 Links .......................................................................................................................219

13.9 Machine control....................................................................................................................221

13.10 Misc. parameters ...................................................................................................................222

14. SWARF Machining .................................................................................................223

14.1 Adding a SWARF Machining Operation ..........................................................................225

14.2 Coordsys ................................................................................................................................226

14.3 Geometry...............................................................................................................................226

14.3.1 Synchronize with tilt lines ....................................................................................227

14.3.2 Synchronize with (upper/lower) curves ............................................................227

14.3.3 Synchronize with main direction ........................................................................228

14.3.4 Automatic ...............................................................................................................228

14.3.5 Shortest distance ..................................................................................................229

14.4 Tool ........................................................................................................................................230

14.5 Levels .....................................................................................................................................232


14.6.1 General parameters .............................................................................................233

14.6.2 Corners parameters ..............................................................................................235

14.7 Tool axis control ...................................................................................................................236

14.8 Link ........................................................................................................................................238

14.9 Gouge check ......................................................................................................................... 239

14.9.1 Degouging ..............................................................................................................239

14.9.2 Avoid by relinking .................................................................................................240


10/447vi

14.9.3 Avoid by retracting ...............................................................................................240

14.9.4 Clearance data........................................................................................................240

14.10 Roughing and More .............................................................................................................241

14.10.1 Pattern slices ..........................................................................................................241

14.10.2 Pattern layers .........................................................................................................243

14.10.3 Sorting ....................................................................................................................24414.10.4 Rotate and Translate .............................................................................................244

14.10.5 Links between passes ...........................................................................................244

14.11 Machine control....................................................................................................................245

14.12 Misc. parameters ...................................................................................................................245

15. Multiaxis Drilling Operation ...................................................................................247

15.1 CoordSys page ......................................................................................................................249

15.2 Geometry page .....................................................................................................................25015.3 Tool page ...............................................................................................................................252

15.4 Levels page ............................................................................................................................253

15.4.1 Clearance area ........................................................................................................253

15.4.2 Levels ......................................................................................................................254

15.5 Technology page ..................................................................................................................258

15.5.1 Sorting ....................................................................................................................258

15.5.2 Sorting of cylindrical drilling patterns ...............................................................259

15.5.3 Drill cycle type .......................................................................................................26615.5.4 Use cycle .................................................................................................................266

15.6 Tool axis control page .........................................................................................................267

15.7 Gouge check page ................................................................................................................267

15.8 Machine control page ..........................................................................................................268

15.9 Misc. parameters page .........................................................................................................268

16. Contour 5-Axis Machining .....................................................................................269

16.1 Adding a Contour 5-Axis Machining Operation .............................................................270

16.2 Geometry...............................................................................................................................271

16.3 Tool ........................................................................................................................................272

16.4 Levels .....................................................................................................................................272



16.7 Link ........................................................................................................................................275


11/447

Content

v

16.8 Gouge check ......................................................................................................................... 275

16.9 Roughing and More ............................................................................................................. 276

16.10 Machine control....................................................................................................................276

16.11 Misc parameters....................................................................................................................277

17. Converting HSM to Sim. 5-Axis Milling ................................................................279

17.1 Source operation ..................................................................................................................282

17.2 Tool ........................................................................................................................................284

17.3 Levels ..................................................................................................................................... 285


17.5 Link ........................................................................................................................................289

17.6 Gouge check ......................................................................................................................... 290

17.7 Machine control.................................................................................................................... 291

17.8 Misc. parameters ...................................................................................................................291

18. Rotary Machining ...................................................................................................293

18.1 Adding a Rotary Machining Operation ............................................................................294

18.2 CoordSys ...............................................................................................................................295

18.3 Geometry...............................................................................................................................295

18.3.1 Strategy ...................................................................................................................295

18.3.2 Machining surfaces ...............................................................................................296

18.3.3 Offset ......................................................................................................................29618.3.4 Side shift .................................................................................................................296

18.3.5 Area .........................................................................................................................297

18.4 Tool ........................................................................................................................................298

18.5 Levels .....................................................................................................................................298


18.6.1 Surface quality .......................................................................................................299

18.6.2 Sorting ....................................................................................................................301

18.7 Tool axis control ...................................................................................................................30318.7.1 Output format .......................................................................................................303

18.7.2 Interpolation ..........................................................................................................303

18.8 Link ........................................................................................................................................304

18.9 Gouge check .........................................................................................................................304

18.10 Roughing and More .............................................................................................................305


12/447viii

18.11 Machine control....................................................................................................................306

18.12 Misc. parameters ...................................................................................................................306

19. Port Machining .......................................................................................................307

19.1 Adding a Port Machining Operation ................................................................................308

19.2 Geometry...............................................................................................................................310

19.3 Tool ........................................................................................................................................311

19.4 Levels .....................................................................................................................................312


19.5.1 Surface quality .......................................................................................................313

19.5.2 Sorting ....................................................................................................................315


19.7 Gouge check .........................................................................................................................319

19.8 Clearance data .......................................................................................................................320

19.9 Machine control....................................................................................................................321

19.10 Misc. parameters ...................................................................................................................321

20. Multiblade Machining .............................................................................................323

20.1 Adding a Multiblade Machining Operation .....................................................................324

20.2 Geometry...............................................................................................................................327

20.2.1 Strategy ...................................................................................................................327

20.2.2 Part denition .......................................................................................................32820.2.3 Stock to leave on ...................................................................................................328

20.2.4 Start offset ..............................................................................................................328

20.3 Tool ........................................................................................................................................329

20.4 Levels .....................................................................................................................................330

20.4.1 Clearance ................................................................................................................330

20.4.2 Levels ......................................................................................................................331


20.5.1 Surface quality .......................................................................................................33220.5.2 Technology ............................................................................................................333

20.5.3 Sorting ....................................................................................................................340

20.5.4 Edges ......................................................................................................................343


20.7 Link ........................................................................................................................................348

20.8 Gouge check .........................................................................................................................351


13/447

Content

i

20.8.1 Gouging ..................................................................................................................351

20.8.2 Clearance data ........................................................................................................352

20.9 Stock and Transformation ..................................................................................................353

20.9.1 Stock .......................................................................................................................353

20.9.2 Rotation ..................................................................................................................354

20.10 Machine control....................................................................................................................35620.11 Misc. parameters ...................................................................................................................356

21. Machine simulation ................................................................................................357

21.1 Machine simulation user interface .....................................................................................359

21.1.1 Simulation menu ...................................................................................................360

21.1.2 Simulation windows..............................................................................................372

21.1.3 Simulation toolbars ...............................................................................................384

21.2 Machine simulation settings ...............................................................................................38621.2.1 Directory for Machine simulation denition .................................................... 386

21.2.2 Tool path coordinates ..........................................................................................386

21.2.3 Solid verication ...................................................................................................387

21.2.4 Target loading ........................................................................................................387

21.2.5 Environment..........................................................................................................387

21.2.6 Machine preview ...................................................................................................387

21.2.7 Enable collision control .......................................................................................388

21.2.8 Collision detection mode .....................................................................................38921.2.9 Collision check in length-based mode ...............................................................389

21.2.10 Tool path color scheme .......................................................................................390

21.2.11 Embedded move list .............................................................................................390

21.2.12 Background ............................................................................................................390

21.2.13 File ...........................................................................................................................392

21.2.14 Position ...................................................................................................................392

22. CNC-machine definition.........................................................................................393

22.1 CNC-machine denition .....................................................................................................394

22.1.1 CNC-machine kinematic type .............................................................................394

22.1.2 Spindle direction ...................................................................................................396

22.1.3 Rotation axes direction.........................................................................................396

22.1.4 Rotation axes names .............................................................................................399

22.1.5 Rotation point .......................................................................................................400


14/447x

22.1.6 Translation axis limits ...........................................................................................400

22.1.7 Rotation axis limits ...............................................................................................401

22.1.8 Machine simulation name ....................................................................................402

22.2 CNC-machine model denition.........................................................................................403

22.2.1 Preparing a CNC-machine model ......................................................................403

22.2.2 Understanding the structure of the CNC-machine ........................................ 40622.2.3 Reviewing the CNC-machine properties ..........................................................408

22.2.4 Dening the CNC-machine housing .................................................................409

22.2.5 Dening the translational axis ............................................................................410

22.2.6 Dening the tool ...................................................................................................411

22.2.7 Dening the translational axis ............................................................................412

22.2.8 Dening the rotational axis .................................................................................413

22.2.9 Dening the magazine .........................................................................................415

22.2.10 Collision control....................................................................................................416

22.2.11 Dening the coordinate transformation ...........................................................417

22.2.12 XML le structure ................................................................................................419

23. Exercises .................................................................................................................427

Exercise #1: Advanced concepts of 5-Axis machining ..............................................................428

Exercise #2: Multiblade Machining ...............................................................................................429

Exercise #3: Mold Machining .........................................................................................................430

Exercise #4: Multiaxis Roughing ....................................................................................................431Exercise #5: Port Machining ...........................................................................................................432

Document number: SC5AUG1500SP3


15/447

1Introduction


16/4472

Welcome to the SolidCAM Sim. 5-Axis Machining module

Simultaneous 5-Axis machining is one of the most powerful modules of SolidCAM. It has the most

advanced control over all the aspects of tool path and collision checking. SolidCAM utilizes all theadvantages of Simultaneous 5-Axis machining and together with wide variety of Simultaneous5-Axis cutting strategies, collision control, and machine simulation provides a solid base for your

5-Axis solution.

The 5-Axis module provides the following advantages:

• Wide variety of Simultaneous 5-Axis cutting strategies gets you and up cutting instantly

• Specic applications solutions for SWARF, Multi-Blade, Port, Contour 5-Axis, Multiaxis

drilling, and Converting from HSM to Sim 5-Axis

• Flowline cutting produces a tool path that follows the natural shape of the component;particularly useful with blade type components

• Advanced tool tilting control and direct control on side tilting and lead/lag angles

• Multi-surface nish machining keeps the tool normal to the surface (or with speciedlead and lag) to provide full control and smooth surface nish

• Multi-pass roughing techniques using multiple cut increments in the Z or XY planes with the option to trim to boundary

• Automatic gouge avoidance strategies that check each part of the tool and the holder

• Realistic full 3D machine simulation with comprehensive collision and axis limitschecking

SolidCAM 5-Axis machining supports all 5-Axis machine tools including Table/Table, Table/Head

and Head/Head gantry machines and the latest Mill/Turn machining centers.


17/447

1. Introductio

Multiblade Machining

The Multiblade Machining operation easily

handles impellers and bladed disks, with multiplestrategies to efciently rough and nish each part

of these complex shapes. All the blade surfaces

are machined in a single operation. Various cuttingstrategies are supplied for roughing and nishingof the impeller parts. Multi-bladed parts are usedin many industries. This operation is specically

designed to generate the necessary tool paths forthe different multiblade congurations.

Port Machining

The Port Machining operation is an easy to use

method for machining ports with tapered lollipoptool, and has collision checks for the entire tool(shank, arbor, and holder). You can choose to cut

the top only, the bottom only, and specify howmuch stock to leave on the entire port. It uses3-Axis machining as far into the port as possible,

and then switches to 5-Axis motion. Smoothtransitions are created where the tool pathsmeet at the middle of the port. It provides bothroughing and nishing tool paths to make ports

from castings or billet.

Contour 5-Axis Machining

The Contour 5-Axis Machining operation tilts the tool along a chained 3D prole drive curve, whilaligning the tool axis according to the dened tilt lines, making it ideal for generating 5-Axis too

path for deburring and trimming.


18/4474

Swarf Machining

The SWARF Machining operation allows the side of the tool to be tilted over to machine the side wall at the correct angle. SWARF cutting uses the whole cutting length of the tool, resulting in

better surface quality and shorter machining time.

Multiaxis Drilling

The Multiaxis Drilling operation uses SolidCAM’s automatic hole recognition and then performsdrilling, tapping or boring cycles, at any hole direction easily and quickly. All the advanced linking,tilting and collision avoidance strategies available in other sim 5-Axis operations are also available inthis operation, to provide full control of the generated Sim 5-Axis drilling tool path.


19/447

1. Introductio

Converting HSM to Sim 5-Axis Milling

Converting HSM to Sim 5-Axis Milling operation convertsHSM 3D tool paths to full 5-Axis machining, collision-

protected tool paths. This maintains optimum contact pointbetween the tool and the part and enables the use of shorter

tools, for more stability and rigidity.

Multiaxis Roughing

SolidCAM provides you with the Multiaxis Roughing operation. This operation creates a multiaxtool path used to rough out pocket shaped geometries. You can specify the inputs for oor, wall an

ceiling surfaces which are used by SolidCAM to create the roughing tool path.

Rotary Machining

SolidCAM provides you with the Rotary Machining operation. This operation is designed t

generate rotary tool path to mill parts on a 4-axis machine. It can be used to mill cylindrical partlike bottle molds and core, electrodes, and wood work. The tool paths are directly calculated on 3D

geometry and not wrapped around.


20/4476

About this book

This book is intended for experienced SolidCAM users. If you are not familiar with the software,

start with the lessons in the Getting Started Manual and then contact your reseller for informationabout SolidCAM training classes.

About the Exercises The links are provided to download the CAM-Parts used for this book in the Exercises chapter.

The contents of this book and can be downloaded from the SolidCAM websitehttp://www.solidcam.com


21/447

1. Introductio

1.1 Adding a Sim. 5-Axis Operation

To add a Sim. 5-Axis Operation to the CAM-Part, right-click the Operations header in SolidCAMManager and choose the Sim. 5-Axis Milling command from the Add Milling Operation submenu.

You can also select the Sim.5-Axis Milling operationby clicking the SolidCAMOperations tab on theribbon.

Or, the SolidCAM Multiaxis

tab on the ribbon.

The default Sim. 5-Axis Milling dialog box is displayed.


22/4478

1.2 Sim. 5-Axis Operation dialog box

SolidCAM provides you with a number of Sim. 5-Axis operations designed for specic Sim. 5-Axismachining tasks. Each of these operations has a subset of parameters and options relevant for the

chosen technology. Using the operations ensures quick programming of specic Sim. 5-Axis tasks.

Technology

This section enables you to dene the type of the Sim. 5-Axis operation. SolidCAM provides you with the following types of the Sim. 5-Axis operation:

• Parallel cuts

This strategy enables you to generate the toolpath with cuts that are parallel to each other.

• Parallel to Curve(s)

This strategy enables you to perform the

machining along a lead curve. The generatedcuts are parallel to each other.

• Parallel to Surface

This strategy enables you to generate the toolpath on the drive surface parallel to the specied check surface.

• Perpendicular to Curve

This strategy enables you to generate the tool path orthogonal to a Lead curve.


23/447

1. Introductio

• Morph between two boundary curves

This strategy enables you to generate a morphed tool path between two leading curves. Thgenerated tool path is evenly spread over the drive surface.

• Morph between two adjacent surfaces

This strategy enables you to generate a morphed tool path on a drive surface enclose

by two check surfaces. The tool path is generated between the check surfaces and evenlspaced over the drive surface. This strategy can be used for the machining of impellers wittwisted blades.

• Projection

This strategy enables you to generate a tool path along a curve projected on the drivsurface.

User defined

This strategy projects the curve selected in the Projection curves section dow

onto the drive surfaces.

Radial

This strategy projects a radial pattern on the surface. It can be particularly effectivon circular shaped components and shallow areas.

Spiral

This strategy projects a spiral pattern on the surface.

Offset

This strategy projects the curve selected in the Projection curves section dowonto the drive surfaces and creates offsets on the sides of the projection curve.


24/44710

Parameter pages

The parameters of the Sim. 5-Axis operation are divided into a number of subgroups. Thesubgroups are displayed in a tree format on the left side of the Operation dialog box. When you

click a subgroup name in the tree, the parameters of the selected subgroup appear on the right sideof the dialog box.

• CoordSys

Dene the CoordSys position for the Sim. 5-Axis operation.

• Geometry

Choose a geometry for machining and dene the machining strategy and its parameters.

• Tool

Choose a tool for the operation and dene the related parameters such as feed and spin.

• Levels

Dene the Clearance area and the machining levels.

• Tool path parameters

Dene the machining parameters.

• Tool axis control

Dene the orientation of the tool axis during the Sim. 5-Axis machining.

• Link

The Link and Default Lead-In/Out pages enable you to dene how the Sim. 5-Axis cuttingpasses are linked to the complete tool path.

• Gouge check

Avoid the tool gouging of the selected drive surfaces and check surfaces.

• Roughing and More

Dene the parameters of the Sim. 5-Axis roughing.

• Machine control

Dene the parameters related to the kinematics and special characteristics of the CNC-

machine.

• Misc. parameters

Dene a number of miscellaneous parameters and options related to the Sim. 5-Axis tool

path calculation.


25/447

1. Introductio

1

1.3 The stages of the Sim. 5-Axis Operation parameters definition

The operation denition is divided into three major stages:

1. CoordSys , Geometry, Finish Parameters and Links – generation of the tool path fothe selected faces. Tool tilting and gouge checking are not performed at this stage.

2. Tool axis control – controlling the angle of the tool from the normal vector at everpoint along the tool path.

3. Gouge check – avoiding tool and holder collisions.

Tool path generation Tool axis control

Gouge check


26/44712


27/447

2Coordsys


28/44714

CoordSys page

On this page, you dene the Coordinate System appropriate for the operation. Choose an existingCoordinate System from the list or click the Define button to dene a

new one. The CoordSys Manager dialog box is displayed. This dialog

box enables you to dene a new Coordinate System directly on the solid

model.

When the Coordinate System is chosen for the operation, the model is

rotated to the selected CoordSys orientation.

For more information on the Coordinate System denition, refer to the

SolidCAM Milling User Guide.

The CoordSys denition must be the rst step in the

operation denition process.

In a Sim. 5-Axis operation, you have to choose only the Machine Coordinate Systems. The Sim.

5-Axis tool path generated relative to the Machine Coordinate System contains the tool pathpositions and tool axis orientation at each tool path position. The tool path is generated in the 4/5-

axes space relative to the Machine Coordinate System. The Machine Coordinate System is dened

relative to the center of the rotation of the machine (CNC-machine origin).


29/447

3Geometry


30/44716

The Geometry page enables you to dene the geometry and its parameters for machining.

3.1 Geometry

This section enables you to dene the geometry for the Sim. 5-Axis operation. All the machiningstrategies of the SolidCAM Sim. 5-Axis operation use a Drive surface geometry. For some strategies,

additional geometries must be dened.


31/447

3. Geometr

1

3.1.1 Drive surface definition

In the Drive surface section, choose the appropriate geometry from

the list or dene a new one by clicking the New icon ( ). The SelectFaces dialog box is displayed. This dialog box enables you to selectone or several faces of the SolidWorks model. Click on the appropriate

model faces. The selected faces are highlighted.

To remove selection, click on the selected face again or right-click theface name in the list (the face is highlighted) and choose the Unselect

option from the menu.

When transferring model les from one CAD system to another, thedirection of some of the surface normals might be reversed. For thisreason, SolidCAM provides you with the capability to display and editthe normals of model surfaces during the geometry selection.

You can also select surfaces based on colors. Click the Define buttonto open the Color window. You can choose a color of your choice andclick OK . Clicking on the Find Faces button will then automaticallypick up all the surfaces with the same color.

You can also pick up the surfaces using Pick from Model button. Clickthe Pick from Model button and then select a surface on the part. TheFind Faces button then automatically picks up all the surfaces that have the same RGB value.

The Show direction for highlighted faces only check

box enables you to display the surface normals for thespecic highlighted faces in the list.

The Show direction for selected faces check box enablesyou to display the normals direction for all the faces inthe list.

SolidCAM enables you to machine surfaces from the positive directio

of the surface normal. Sometimes surfaces are not oriented correctland you have to reverse their normal vectors. The Reverse/Reverse A

command enables you to reverse the direction of the surface norma vectors.


32/44718

3.1.2 Drive surface offset

The Drive surface offset parameter enables you to dene a machining allowance for the drivesurface. The machining is performed at the specied distance from the drive surface.

The offset is three-dimensional and expands the facesin every direction.

3.1.3 Curves definition

Some Sim. 5-Axis machining strategies use additional curve geometries forthe tool path generation. SolidCAM enables you to dene such geometriesusing the Geometry Edit dialog box.

For more information on the wireframe geometry selection, refer to theSolidCAM Milling User Guide.

Drive Surface

offset


33/447

3. Geometr

1

3.1.4 Work type

This section is available only for Parallel cuts strategy. It offers youtwo ways in which the tool path cuts can be performed:

• Linear

When this option is chosen, the tool path cuts are generated in the Linear manner, and thaxis chosen from the Around axis list is normal to the plane of machining.

• When the X-axis is chosen from the Around axis list, the machining is performed ithe YZ-plane;

• When the Y-axis is chosen from theAround axis list, the machining is

performed in the ZX-plane;

• When the Z-axis is chosen from theAround axis list, the machining isperformed in the XY-plane.

The Define angle by section enables you todene the angle of linear machining. Theangle can be dened by entering its value in

the edit box or by picking a line on the model.

This section is available only whenLinear is chosen for Work type.

• Constant

When this option is chosen, the tool pathcuts are generated in the Constant Z manneraround the axis chosen from the Around axis

list.

The Around axis list enables you to choose the axis( X , Y or Z ) around which the tool path cuts will begenerated.

α

Around axis

Around axis


34/44720

3.1.5 Edge curve

This section is available only for the Parallel to curves strategy.

The Edge curve section enables you to dene lead curve for theoperation using the Geometry Edit dialog box (see topic 3.1.3 ).

It is recommended to choose theDrive surface edge as the lead curvegeometry to get better placement of

the tool path.

3.1.6 Edge surface

This section is available only for Parallel to surface strategy. It enablesyou to generate the tool path on the Drive surface parallel to the

specied check surface.

The Edge surface section enables you to dene the check surfacesgeometry for the tool path generation.

Edge curve

Tool pathDrive surface

Edgesurface

Drivesurface


35/447

3. Geometr

2

The drive and check surfaces have to be adjacent, i.e. they must have a commoedge.

Depending on the dened Tool tilting (see topic 7.1.3 ) it is recommended tactivate the gouge checking (see chapter 21 ), to make sure that the check surfac

will not be gouged.

When a ball-nosed tool is used with thisstrategy, it is recommended to use the Tool center based calculation option.

With this option, the passes close to thecheck surface will be generated in such

way that the tool is tangent to both thedrive surface and the check surface. If thecalculation is not based on the tool center,

a wrong tool path is generated.

Advanced options

SolidCAM enables you to dene a numberof advanced options for the Parallel to surface strategy. Click the Advanced button to display thAdvanced Options of Surface Paths Pattern dialog box.

The Generate tool path front side option enables SolidCAMto take into account the normals of the dened checksurface.

When this check box is not selected, the tool path is

generated on the drive surface only from all the sides ofthe check surface.

When this check box is selected, SolidCAM generates thetool path taking into account the direction of the checksurface normals. The resulting tool path is located only atthe front side of the check surface.

Tool contact points


36/44722

SolidCAM automatically extends the passes tangentially to the drive surface edges. Using the Singleedge tool path tangent angle parameter you can change the extension direction. This option affectsonly the rst pass (close to the check surface); all other passes are extended tangentially.

3.1.7 Lead curve

This section is available only for Perpendicular to curve strategy, which

enables you to generate the tool path orthogonal to the Lead curve

dened in the Geometry section.

Note that when the selected curve is not a straight line, the

cuts are not parallel to each other.

The lead curve geometry does not have to be located on

the surface. During the tool path calculation, SolidCAMgenerates in each point of the lead curve virtual pointson the curve. The distance between these points isdetermined by the Step over (see topic 6.1.3 ). SolidCAMprojects these points onto the drive surface; the direction

of the projection is the normal vector of the curve at the virtual point. Where the normal vector intersects with thesurface, a virtual surface point is generated. The passes are

generated through these points, normal to the lead curve.

Single edge toolpath tangent angle

Single edge toolpath tangent angle

90°

90°

90°

Curve

Tool path


37/447

3. Geometr

2

If the cuts cross each other at the edge of the surface, caused by an inappropriatlead curve, you will not get an acceptable result.

The lead curve must be located exactly on or above the drive surface. If the curv

is not located above the surface, no tool path is generated. When only a part of thlead curve is located above the surface, only where the normal vector of the leacurve intersects with the drive surface a tool path is generated.

3.1.8 Start and End edge curve

The Start edge curve and End edge curve sections are available for thstrategy of Morph between two boundary curves. The rst strategcreates a morphed tool path between two leading curves. The generatetool path is evenly spread over the drive surface. The second strategcan be used for the machining of impellers with twisted blades.

These sections enableyou to dene theleading curves for themorphing using theGeometry Edit dialogbox (see topic 3.1.3 ).

It is recommended to choose the

Drive surface edges as the leadcurves geometry to get better

morphing of the tool path.

Leading curve

Drive surface

Tool path

Start edge curve

End edgcurveDrive surface


38/44724

Morph between two adjacent surfaces

The Start edge surfaces and End Edge surfaces sections enable you

to dene the check surfaces geometry for the tool path generation.

The drive and check surfaces have to be adjacent, i.e. they

must have a common edge.

Depending on the dened Tool tilting (see topic 7.1.3 ) it is recommendedto activate the gouge checking (see chapter 9 ), to make sure that thecheck surfaces will not be gouged.

When a ball-nosed tool is used with this strategy, it is recommendedto use the Tool center based calculation option. With this option,the passes close to the check surfaces are generated in such way thatthe tool is tangent to both the drive surface and the check surface. If

the calculation is not based on the tool center, a wrong tool path isgenerated.

Advanced options

SolidCAM enables you to dene a number of advancedoptions for the Morph between two adjacent surfaces strategy. Click the Advanced button to display theAdvanced Options of Surface Paths Pattern dialog box.

The Generate tool path front side option enablesSolidCAM to take into account normals of the dened check surfaces.

Tool contact points


39/447

3. Geometr

2

When this check box is not selected, the tool path is generated on thedrive surface from all sides of the check surfaces.

When this check box is selected, SolidCAM generates the tool path takinginto account the direction of the check surfaces normals. The resultingtool path is located between the check surfaces only.

SolidCAM automatically extends the passes tangentially to the drivesurface edges. Using the First surface tool path tangent angle and theSecond surface tool path tangent angle parameters, you can change theextension direction. The direction can be changed for the rst and lastpasses; all the internal passes are evenly morphed between them.

First surface toolpath tangent angle

Second surface tool

path tangent angle

First surface toolpath tangent angle

Second surface toolpath tangent angle


40/44726

3.1.9 Projection curves

This section is available only for the Projection strategy that enablesyou to generate a single tool path along a curve. The Projection curves

section enables you to dene the curves for the tool path generation.

The option of Projection curves is available only in Userdefined and Offset technologies.

Max. projection distance

When the Projection tool path strategy is chosen, the system gets projection curves lying on thedrive surfaces.

Due to tolerance issues in CAD systems, sometimes the curves do not lie exactly on the drivesurfaces. This error can be compensated by the Maximal projection distance value. For example,if the value is 0.1 mm, it allows to have the projection curve 0.1 mm away from the drive surfaces.

Direction

This section enables you to specify to which direction the curves are projected.

X, Y, Z: The curve direction is dened as parallel to one of the Coordinate system axes.

Line: The projection vector is dened by a line that you can pick directly on the solid model.Surface normal: This option projects the curve into the normal direction of the surfacebelow.

• If the curve/pattern lies exactly on the face, the tool path has the same shape and

position as the curve.

• If the curve/pattern lies above the drive surfaces, the tool path changes. The tool path

is built only on an interval between those normals that intersect the curve.

Drive surfaceProjection curve = Tool path


41/447

3. Geometr

2

The projection has to lie within the Max. projection distance to the drive surfaceOtherwise the curves cannot be considered for projecting.

Center point

This section enables you to dene the position of a center point

of the virtual circle that SolidCAM creates to generate radial/spiral passes.

The position can be dened manually by entering the coordinate values in the XYZ elds, picking the point directly on the solid

model using the button, or automatically by selecting theAuto detect option.

Radius

• Start: This option enables you to create a virtual inner circle that starts the tool path fromthis inner circle so that the tool does not rub at the converging point where the radius izero.

• End: This option enables you to to stop the tool path at the extreme end of the virtual outecircle.

• The Auto detect option enables you to detect the required maximum radius to automaticallmachine the surface.

Angle

This option denes an area based on two angles for the tool path calculation.

• Start: This parameters denes the starting angle of area denition for the tool patcalculation.

• End: This parameter denes the ending angle of area denition for the tool path calculation

The option of Angle is available only in the Projection (Radial ) technology.


42/44728

3.2 Area

The Area section enables you to dene the cutting area on the drive surface.

The following options are available to dene the area:

• Full, avoid cuts at exact edges

• Full, start and end at exact surface edges

• Determined by number of cuts

• Limit cuts by one or two points

All of these options are unavailable with the Projection strategy.

3.2.1 Full, avoid cuts at exact edges

This option enables you to generate the tool path on the whole drive surface avoiding the drivesurface edges. With this option, the minimal distance between the edge and the tool path is equal

to half of the Max. Step over.

This option can be used when the boundary of the drive surfaces is not smoothand has gaps. The half of the Max. Step over offset from the surface edge enablesyou to compensate these defects of the surface. In case of large gaps, SolidCAMenables you to handle them using the Gap along cuts option (see topic 8.2.1 ).

When the tool is oriented normally to the drive surface, make

sure that the tool diameter is greater than half of the Max. Stepover. Otherwise, unmachined areas are left at the drive surfaceedge. The image illustrates the use of this option. Note that the machining does not start at the exact edge of the surface. Therefore,the shape of the upper edge does not inuence the tool path.

Edge

Edge


43/447

3. Geometr

2

3.2.2 Full, start and end at exact surface edges

With this option, the tool path is generated on the whole surfacestarting and nishing exactly at the drive surface edges or at thenearest possible position.

Make sure that the surface edges are perfectly trimmed. Gaps cause unnecessarair movements of the tool during the machining, therefore the Full, avoid cuts aexact edges option (see topic 3.2.1 ) is preferable.

The number of cuts depends on the Max. Step over value. Since the rst and the last cuts arlocated exactly on the drive surface edges, SolidCAM modies the specied Max. Step over valu(see topic 6.1.3 ) to achieve equal distance between the cuts. The modied Max. Step over value usefor the tool path calculation is smaller than the specied one.

You can dene margins for the tool path calculation when working with the following strategieMorph between two boundary curves, Parallel to curve, Parallel to surface, and Morph between twadjacent surfaces.

Click the Margins button.

Edge

Edge


44/44730

The Margins dialog box is displayed. This dialog box enables you todene a margin for the drive surface edges. The machining starts andnishes at the specied distances from the drive surface edges.

Advanced parameter for margins

Tool path strategies that use edge curves and surfaces sometimes encounter difculties since CAD

systems deliver the drive surfaces and the edge geometry (curves or surfaces) only within accuracy.If you would like to start the tool path exactly at the zero distance to the edge geometry, this isproblematic, because the geometry can never be exactly aligned. To avoid this problem, SolidCAMprovides you with the Advanced parameter for margins option.

The option of Margins is not available for the Perpendicular to Curve strategy.

The Additional margin to overcome surface edge inaccuracies parameter enables you to

compensate the inaccuracy of the CAD model edges. For example, to get the tool path at the 5mm distance from the geometry, set the margin to 4.97 mm and the Additional margin to overcomesurface edge inaccuracies to 0.03.

The Add tool radius to margins option enables you to expand the cutting area, which is dened bymargins, by the tool radius distance.

Start margin

End margin

Drivesurface


45/447

3. Geometr

3

3.2.3 Limit cuts by one or two points

This option enables you to limit the tool path by one or two points.

Click the Points button to dene the limiting points with the Limit Cuts Between 2 Points dialobox. This dialog box enables you to enter the coordinates of the limiting points or dene themdirectly on the solid model.

The dened limiting pointsmust be located within theregion of the cuts.

3.2.4 Determined by number of cuts

This option enables you to limit the tool path by a number of cuts. The Number of cuts parameter denes the number of cutting

passes.

Start point End point

1

2

3


46/44732

When the Parallel to curve/Parallel to surface strategy is chosen for the geometry denition, theDetermined by number of cuts option generates the following tool path: the tool starts machiningfrom the dened curve/surface and performs the number of cuts dened with the correspondingparameter.

When the Morph between two adjacent surfaces strategyis chosen for the geometry denition, the area between thedened surfaces is divided by the number of cuts in sucha manner that the rst cut is performed at the Start edgesurface, and the last cut at the End edge surface.

This option is available only for the Parallel to Curve(s), Parallel to Surface,

Morph between two boundary curves and Morph between two adjacent surfaces strategies.

1

Parallel to curve Parallel to surface

23

1

2

3

4

4

1 2 3 4


47/447

3. Geometr

3

SolidCAM enables you to dene a margin, shifting the rst cut location.Click the Margins button to display the Margins dialog box.

The location of the rst cut is shifted by the distance specied by theStart Margin parameter.

The Start margin and End margin options are available only for the Morph betweetwo adjacent surfaces and Morph between two boundary curves technologieOnly one Margin parameter is available for Parallel to Curve(s) and Parallel t

Surface technologies.

3.2.5 Use 2D Boundary

SolidCAM provides you with a functionality to limit the machining

to specic model areas. The machining limitation is performed bya planar boundary that is projected on the model. The projectedboundary is “virtually” trimming the drive surfaces. All the contactpoints of the tool and drive surfaces are enclosed by this projectedboundary.

2D Boundary curves

SolidCAM enables you to dene a boundary based on a Working area geometry (closed loop omodel edges as well as sketch entities).

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

The New icon ( ) displays the Geometry Edit dialog box that enables you to dene the geometr

Using the Edit icon ( ), you can edit the geometry in the same dialog box.

The Show button enables you to display the already dened boundary directly on the solid model

Margin

12

34

5


48/44734

Projection direction

When a planar boundary is dened, SolidCAM

automatically projects the geometry onto thesolid model. The direction of the projectionis dened by a vector.

SolidCAM enables you to choose an axisof the Coordinate System as a projection

direction vector or dene a vector by anend point (the start point is automaticallyconsidered to be located in the CoordinateSystem origin).

2D Boundary

Machining area

Projectiondirection axis


49/447

4Tool


50/44736

4.1 Tool definition

The Tool page enables you to choose a tool for the operation from the Part Tool Table.

Click the Select button to display the Part Tool Table and choose a tool for the operation.

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


51/447

4. Too

3

Click the Data tab to display and dene the Spin and Feed parameters.

4.1.1 Spin definition

The Spin section enables you to dene the spinning speed of the tool.

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

the default that signies Revolutions per Minute. V signies material

cutting speed in Meters per Minute in the Metric system or in Feet per

Minute in the Inch system; it is calculated according to the following

formula:

V = (S * PI * Tool Diameter) / 1000

Spin rate denes the normal spin rate used for rough milling. Spin nish denes the nish rate usefor nish milling.

The Spin direction section enables you to choose between the clockwise ( CW ) or counterclockwis

( CCW ) direction.

4.1.2 Feed definition

The Feed section enables you to dene the tool feed for the Sim. 5-Axis

operation. The feed value can be dened in two types of units: F and

FZ. F is the default that signies Units per minute. FZ signies Units pertooth and is calculated according to the following formula:

FZ = F/(Number of Flutes * S)

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


52/44738

Cutting feed

This eld denes the cutting feed rate of the tool.

Feed Z

This eld denes the feed of the tool movements from the safety position to the cutting depth.

For Tap tools, SolidCAM automatically calculates the Feed Z ( F and FZ ) value

according to the following formulas:

F=Spin Rate * Pitch

FZ=Pitch

The calculated values are displayed in the Feed Z eld. These values cannot be

changed.

Retract feed

This eld denes the feed of the tool movements from the material to the retract level. The default

value of the Retract Feed is calculated according to the following formula:

Retract Feed=Cutting Feed * 2


53/447

4. Too

3

Click the Feed Control tab to display and dene the feed control parameters.

4.1.3 Feed zone control

Sometimes more than required material is left on the surface that needs to be removed with lowe

than the actual cutting feed rate. This lower feed rate is required to minimize the chances of too

breakage or tool wear. The Feed zone control parameter allows you to dene a volume to determin

an area in which a higher or lower percentage of the cutting feed rate can be set. Select the chec

box. The Feed control zone dialog box is displayed.

Feed Zone

You can choose the appropriate geometry from the list

or dene a new one by clicking the New icon ( ).

The Select Faces dialog box is displayed. This dialog

box enables you to dene the geometry for feed zone.

Offset

This eld enables you to put an additional offset value on the feed control geometry in order to le

the tool slow down before it enters the actual feed control geometry.

Feed rate percentage

The inside and outside feed rate percentage elds dene the feed rate inside and outside of the fee

control geometry as a percentage of the actual cutting feed rate.

4.1.4 Feed rate optimization

You can optimize the feed rate of different segments of the tool path. You dene the machinin

feed rate, and SolidCAM modies it according to the surface curvature. The surface curvature

calculated at each tool path position where the surface contact point of the tool is known.

This option is available only on single surfaces and cannot be used on the stitche

between surfaces.


54/44740

Select the check box. The Feed Rate Control Optimization

dialog box is displayed. This dialog box enables you to

dene the feed rate according to the surface radius. The

feed rate is dened as the percentage of the dened

Feed Rate of the cutting movements.

This section enables you to dene the feed rate for the at tool path segments where

the curvature radius is innite.

This section enables you to dene the feed rate for the tool path segments of large

radius (the radius value can be customized).

This section enables you to dene the feed rate for the tool path segments of small

radius (the radius value can be customized).

This section enables you to dene the feed rate for the sharp corners of the tool path

where the radius is equal to 0.

4.1.5 Rapid move parameters

Some 5-axis CNC-machines do not support synchronization between axis motors when the rapid

movement ( G0 ) is performed. The absence of synchronization causes the deviation between the

calculated path and the real tool movements. SolidCAM enables you to avoid the problems described

above by replacing all rapid movements ( G0 ) with non-rapid ones using a particular feed rate.

This option enables you to control the use of rapid feed ( G0 ). When the Rapid motion in G1 mode

check box is not selected, the resulting GCode contains rapid movements ( G0 ).

Example:

G0 X-2.942 Y75.567 Z24.402 A-88.436 B-26.482 M116

When the Rapid motion in G1 mode check box is selected, the resulting

GCode does not contain G0 commands. The rapid movements are

performed using the feed rate dened by the Rapid feed rate parameter.

Example: G1 X-2.942 Y75.567 Z24.402 A-88.436 B-26.482 F9998 M116


55/447

4. Too

4

First cut feed percentage

In some machining cases, the tool load is not uniform along the tool path; the maximum tool loa

is reached along the rst cutting pass. The First cut feed, % option enables you to change the feerate at the rst cutting path in order to optimize the cutting process. The feed rate is changed as

percentage of the dened feed rate (see topic 4.1.2 ).


56/44742


57/447

5Levels


58/44744

The Levels page enables you to dene the Clearance area and the machining levels.

5.1 Regular

The Regular tab enables you to dene the parameters for clearance area and machining levels.

5.1.1 Clearance area

The Clearance area is the area where the tool movements can be performed safely withoutcontacting the material. The tool movements in the Clearance area are performed with the rapid

feed.Depending on the drive surface or your machining strategy, you can choose different clearance areatypes:

• Plane

• Cylinder

• Sphere

Plane

This option enables you to dene the Clearance area by plane. The

tool performs a retract movement to the Clearance area plane, andthen a rapid movement in this plane.

The plane orientation is dened by a vector normal to the plane. Withthe In X , In Y and In Z options, SolidCAM enables you to dene this

vector as one of the Coordinate System axes (X, Y o

2015 SolidCAM Sim. 5-Axis-Milling User Guide

Documents

Transcript of 2015 SolidCAM Sim. 5-Axis-Milling User Guide