SolidCAM Training Course

2.5D Milling
iMachining 2D & 3D | 2.5D Milling | HSS | HSM | Indexial Multi-Sided | Simultaneous 5-Axis | Turning & Mill-Turn | Solid Probe

SolidCAM + SOLIDWORKS
The Complete Integrated Manufacturing Solution
 SolidCAM 2021
Milling Training Course
2.5D Milling

©1995-2021 SolidCAM
All Rights Reserved.
 Contents

Contents

1. Introduction

1.1 About this Course.........................................................................................................2

1.2 Basic Concepts..............................................................................................................4
1.3 Process Overview.........................................................................................................4

2. CAM-Part Definition

Exercise #1: CAM-Part Definition....................................................................................9

3. SolidCAM 2.5D Operations

Exercise #2: Cover Machining......................................................................................... 32

Exercise #3: Cover Machining......................................................................................... 89
Exercise #4: Bracket Machining.................................................................................... 157
Exercise #5: Electronic Box Machining....................................................................... 159
Exercise #6: Clamp Machining...................................................................................... 163
Exercise #7: Basic Part Machining................................................................................ 170
Exercise #8: Cover Machining....................................................................................... 174
Exercise #9: Mounting Base Machining....................................................................... 180
Exercise #10: Support Machining................................................................................. 189
Exercise #11: Engraving................................................................................................. 201

4. Indexial 4-Axis Milling

Exercise #12: Frame Machining.................................................................................... 213

Exercise #13: Mounting Machining.............................................................................. 233

5. Indexial 5-Axis Milling

Exercise #14: Clamp Machining.................................................................................... 244

v
6. ToolBox

Exercise #15: Standard Cycles Machining................................................................... 255

7. Automatic Feature Recognition

Exercise #16: Pocket Recognition................................................................................. 276

Exercise #17: Mounting Box Machining..................................................................... 283
Exercise #18: Drill Recognition.................................................................................... 285
Exercise #19: Electronic Box Machining..................................................................... 307
Exercise #20: Edge Deburring Recognition............................................................... 309

Document number: SCMTCENG0021SP1

vi
Introduction 1
1.1 About this Course

The goal of this course is to teach you how to use SolidCAM to machine various parts applying
2.5D Milling technologies. This course covers the basic concepts of SolidCAM 2.5D machining
and is a supplement to the system documentation and online help. Once you have developed
a good foundation in basic skills, you can refer to the online help for information on the less
frequently used options.
Course design
This course is designed around a task-based approach to training. With the guided exercises you
will learn the commands and options necessary to complete a machining task. The theoretical
explanations are embedded into these exercises to give an overview of the SolidCAM 2.5D
Milling capabilities.
Using this training book
This training book is intended to be used both in a classroom environment under the guidance
of an experienced instructor and as self-study material. It contains a number of laboratory
exercises to enable you to apply and practice the material covered by the guided exercises. The
laboratory exercises do not contain step-by-step instructions.
Training materials
The file archive supplied with this book contains copies of various files that are used throughout
this course. The Exercises folder contains the files that are required for guided and laboratory
exercises. The Built Parts folder inside the Exercises contains the final manufacturing projects
for each exercise. Unpack the complete Exercises folder on your computer. The SOLIDWORKS
files used for the exercises were prepared with SOLIDWORKS 2020.
Windows 10
The screenshots in this book were made using SolidCAM 2021 SP1 integrated with SOLIDWORKS
2020 running on Windows 10. If you are running on a different version of Windows, you may
notice differences in the appearance of the menus and windows. These differences do not affect
the performance of the software.

2
 1. Introduction

Conventions used in this book

This book uses the following typographic conventions:
This style is used to emphasize SolidCAM
Bold Sans Serif options, commands or basic concepts. For
example, click the Change to opposite
button.
10. Define CoordSys Position The mouse icon and numbered sans serif
bold text indicate the beginning of the
exercise action.
This style combined with the lamp icon
Explanation is used for the SolidCAM functionality
explanations embedded into the guided
exercises. The lamp icon is also used to
emphasize notes.

3
1.2 Basic Concepts

Every manufacturing project in SolidCAM contains the following data:

• CAM-Part – The CAM-Part defines the general data of the workpiece. This includes the
model name, the coordinate system position, tool options, CNC-controller, etc.
• Geometry – By selecting Edges, Curves, Surfaces or Solids, define what and where you
are going to machine. This geometry is associated with the native SOLIDWORKS
model.
• Operation – An Operation is a single machining step in SolidCAM. Technology, Tool
parameters and Strategies are defined in the Operation. In short, Operation means how
you want to machine.

1.3 Process Overview

The major stages of the SolidCAM manufacturing project creation process are the following:

CAM-Part definition
This stage includes the definition of the global parameters of the Manufacturing
Project (CAM-Part). You have to define a number of Coordinate Systems that describe
the positioning of the part on the CNC-machine.
Optionally, you can define the Stock model and Target model to be used for the rest
material calculation. The Stock model describes the initial state of the workpiece that
has to be machined. The Target model describes the one that has to be reached after
the machining. After every operation, SolidCAM calculates how much material was
actually removed from the CAM-Part and how much material remains unmachined (rest
material). The rest material information enables SolidCAM to automatically optimize
the tool path and avoid the air cutting.

Operations definition
SolidCAM enables you to define a number of milling operations. During an operation
definition you have to select the Geometry, choose the tool from the Part Tool Table
(or define a new one), define a machining strategy and a number of technological
parameters.

4
CAM-Part Definition 2
The CAM-Part definition process includes the following stages:

CAM-Part creation

CNC-controller definition

Coordinate system definition

Stock model definition

Target model defintion

• CAM-Part creation. According to default settings, the CAM-Part name and location
are defined automatically. However, you can define them manually, if you choose
the manual option. At this stage, SolidCAM defines the necessary system files and a
folder to allocate the place to store SolidCAM data.
• CNC-controller definition. Choosing a CNC-controller is a necessary step. The
controller type influences the Coordinate System definition and the Geometry
definition.
• Coordinate system definition. You have to define the Coordinate System – the origin
for all machining operations of the CAM-Part.
• Stock model definition. SolidCAM enables you to define the stock model that
describes the initial state of the workpiece to be machined.
• Target model definition. SolidCAM enables you to define the model of the part in its
final state after the machining.
The following exercises describe the full process of the CAM-Part definition. It is recommended
to complete the stages in order to understand how the CAM-Part features are built. For this
purpose, you have to turn off the automatic CAM-Part definition.

6
 2. CAM-Part Definition

Before you start, select SolidCAM Settings command from SolidCAM main ribbon.

The SolidCAM Settings dialog box is displayed.

In the left pane, select CAM-Part. Select the Auto select project location check box. In the left
pane, select Automatic CAM-Part definition.
In the right pane, click the Milling tab and clear check boxes under the following sections:
Definition of CNC-Controller, Definition of CoordSys, Definition of Stock, and Definition of
Target.

Then you have to turn off the default templates loading.

7
In the left pane, select Defaults > Template. In the right pane, under 2.5D Milling, clear all the
check boxes next to the template names.

Click OK to confirm your choice.

These settings can be turned back on at any time.

8
 2. CAM-Part Definition

Exercise #1: CAM-Part Definition

This exercise illustrates the CAM-Part definition process in

SolidCAM. In this exercise, you have to create the CAM-
Part for the cover model displayed and define the Coordinate
System, the Stock model and Target model that are necessary
for the part machining. The CAM-Part will be used in the
exercises further on.
When you start to program a CAM-Part, you have to
decide what workpiece you are going to use. This decision
determines the number and the type of operations that are
used to reach the final part shape.
In this exercise, the box stock is used. The box dimensions include offsets from the actual model.

At the next stage, you have to decide on what type of CNC-machine you are going to use

(3-, 4- or 5-axis). In this exercise, a 3-axis

CNC-machine is chosen for the machining.
With a CNC-machine of this type, all the
required faces of the cover part can be
machined using a single positioning.

9
 1. Load the SOLIDWORKS model
Load the Exercise1.sldprt model located in the Exercises folder.
This model contains a number of features forming the solid body of the cover.

2. Start SolidCAM
To activate SolidCAM, click Tools in the main menu of SOLIDWORKS and then
choose SolidCAM > New > Milling.

SolidCAM is started, and the Milling Part Data dialog box is

displayed.

10
 2. CAM-Part Definition

3. Choose the CNC-Machine

Select the CNC-machine controller. Click the arrow to
display the list of post-processors installed on your
system.
In this exercise, use a 3-Axis CNC-machine with
the AWEA1000-Fanuc CNC-controller. Choose the
AWEA1000-Fanuc CNC-controller from the list.

4. Start the Coordinate System definition

Click the CoordSys button in the Define area to define
the Machine Coordinate System.

To complete the CAM-Part definition, you need to define the

Machine Coordinate System. The Machine Coordinate System
defines the origin for all machining operations of the CAM-Part. It
corresponds with the built-in controller functions.
You can define the Coordinate System origin position and axes
orientation by selecting model faces, vertices, edges, or
SOLIDWORKS Coordinate Systems. The geometry for the
machining can also be defined directly on the solid model.
Coordinate
System
Z
Y

11
 The Z-direction of the Machine Coordinate System is parallel to the
revolution axis of the tool.

Z Y
Machine
Coordinate
System
X
In SolidCAM, the tool approaches
from the positive direction of the Z-axis (like on a vertical CNC-
machine).

Z
Y
X X
Y
Coordinate
Coordinate
System
System Z

For 3-Axis CNC milling machines, each Machine Coordinate System

means separate clamping. If you need to machine the part from
different sides, use several Machine Coordinate Systems with the
Z-axis oriented normally to the machined sides.
In this exercise, it is enough to
Z
define one Machine Coordinate
Y X
System with the Z-axis oriented
Coordinate
upwards. System
Such coordinate system enables
you to machine the part with a
single clamping.

12
 2. CAM-Part Definition

The CoordSys dialog box enables you to define the Coordinate System location and
the orientation of the axes.

SolidCAM enables you to define the CoordSys using the following

methods:
Select face

This method enables you to define a new

CoordSys by selecting a face. The face can be
planar or cylindrical/conical. For planar faces,
SolidCAM defines CoordSys with the Z-axis
normal to the face. For cylindrical or conical
faces, the Z-axis of the CoordSys is coincident
with the axis of revolution of the specified
cylindrical/conical surface.
Define
This method enables you to define the
Coordinate System by selecting points. You
have to define the origin and the direction of
the X- and Y-axes.
Select Coordinate System
This method enables you to choose the
SOLIDWORKS Coordinate System defined
in the design model file as the CoordSys. The
CoordSys origin and axes orientation are the same as those of the
original SOLIDWORKS Coordinate System.
SolidCAM keeps the CAM coordinate system associative with the
chosen CAD coordinate system. This means that any change made
to the CAD coordinate system automatically updates the CAM
coordinate system.

Normal to current view

This option enables you to define the Coordinate System with the
Z-axis normal to the model view you are facing on your screen.
The CoordSys origin will lie in the origin of the SOLIDWORKS
Coordinate System, and the Z-axis will be directed normally to the
chosen view of the model.

13
 By 3 points (associative)

This option enables you to define the Coordinate System by selecting

any three points.

5. Select the model face

Choose the Top corner of model box

option from the Place Coordsys origin
to list.

With the Select face method chosen,

click on the model face as shown.
The CoordSys origin is automatically
defined in the top corner of the model
box. The Z-axis of the CoordSys is
normal to the selected face.

Model box

SolidCAM calculates the box surrounding the model. The upper

plane of the model box is parallel to the XY-plane of the defined
CoordSys.
The CoordSys is located in the corner of the model box.
Coordinate
System
Z
Y
X

14
 2. CAM-Part Definition

Confirm by clicking . The Coordinate System is defined.

The CoordSys Data dialog box is displayed.

6. CoordSys Data
This dialog box enables you to define the machining levels such as Tool start level,
Clearance level, Part Upper level, etc.

CoordSys Data dialog box

The Machine CoordSys Number (MAC Number) defines the number

of the Coordinate System in the CNC-machine. The default value is
1. If you use another number, the GCode file contains the G-function
that prompts the machine to use the specified number stored in the
machine controller of your machine.
The Position field defines the sequential number of the CoordSys.
The Edit Coordsys button enables you to change the CoordSys
location or orientation of the axes with the CoordSys dialog box.
The Create planar surface at Part Lower level option enables you to
generate a transparent planar surface at the minimal Z-level of the
part so that its lower level plane is visible.

15
 This planar surface provides you the possibility to select points that
do not lie on the model entities. It is suppressed by default and not
visible until you unsuppress it in the FeatureManager Design tree.
The Planar and Rear Levels sections contain sets of facial machining
levels describing the planes parallel to the XY-plane and located along
the Z-axis.
The Levels: Planar section displays levels for milling from the positive
Z-direction.
The Levels: Radial section contains a set of machining levels
describing the virtual cylinders situated around the Z-axis.
The Levels: Rear section displays levels for milling from the negative
Z-direction. The negative Z-direction can be used in case of milling
of the part from the back side with the same Coordinate System in
the main spindle or in case of using the back spindle.
These sections contain the following parameters:
• The Tool start level defines the Z-level at which the tool starts
working.
• The Clearance level is the Z-level to which the tool moves rapidly
from one operation to another (in case the tool does not change).
• The Part Upper level defines the height of the upper surface of
the part to be milled.
• The Part Lower level defines the lower surface level of the part to
be milled.

Tool start
level
Rapid movements area
Part Upper
Clearance Feed movements area level
level Part Lower
level

• The Tool Z-level parameter defines the height to which the tool
moves before the rotation of the 4/5 axes to avoid collision
between the tool and the workpiece. This level is related to the
CoordSys position and you have to check if it is not over the limit
switch of the machine. It is highly recommended to send the tool
to the reference point or to a point related to the reference point.

16
 2. CAM-Part Definition

Shiftis the distance along each axis (X, Y, Z) from the Machine
Coordinate System to the location of the Position in the coordinate
system and the orientation of the Machine Coordinate System.
Rotation is the angle of rotation around the main axes X, Y and Z.
The Plane box defines the default work plane for the operations
using this CoordSys, as it is output to the GCode program. In the
SolidCAM CAM module, you must always work on the XY-plane.
Some CNC-machines, however, have different axes definitions and
require a GCode output with rotated XY-planes.

Confirm the CoordSys Data dialog box by clicking .

The CoordSys Manager dialog box is displayed. This
dialog box displays the Machine CoordSys.
Confirm the CoordSys Manager dialog box with .
The Milling Part Data dialog box is displayed again.

7. Define the Stock model

For each Milling project, you can define the Stock model,
which is the workpiece that is placed on the machine
before you start machining the CAM-Part.

Click the Stock button in the Define section

of the Milling Part Data dialog box.

The Stock dialog box is displayed.

17
 This dialog box enables you to choose the mode of the Stock model definition.

Stock Model Definition Modes

• Box – in this mode SolidCAM automatically determines the box

surrounding the model.
• Extruded boundary – this mode enables you to define the 2D
stock geometry by selecting a chain of geometrical elements
(lines, arcs, splines, edges, etc.).
• 3D Model – this mode enables you to define the stock model via
3D model selection.
• Cylinder – this mode enables you to define the stock model as a
cylinder (or a tube) surrounding the selected solid model.
• STL – this mode enables you to define the stock model based on
a STL file that exists in your system. When you choose this mode,
the STL file section becomes available. By clicking the Browse
button, you can choose the STL file for the stock definition.

Choose the Box mode from the Defined by list. The appearing
parameters enable you to select a solid body for the surrounding
box calculation.

18
 2. CAM-Part Definition

Optionally, offsets from the model can be defined. In this exercise, define the stock
model offsets as follows:
• For the X+, X-, Y+ and Y- offsets, use the
values of 2
• For the Z+ offset, set the value to 0.25
• For the Z- offset, set the value to 5
Click on the solid body. One of its faces is
highlighted.

SolidCAM automatically generates the surrounding box.

Confirm the Stock model definition by clicking . The Milling Part Data dialog box
is displayed.

8. Define the Target model

SolidCAM enables you to define the Target model, which is the final shape of the
CAM-Part after the machining. The program uses the Target model for gouge
checking in the SolidVerify simulation.

19
 Click the Target button in the Define area of the Milling Part Data dialog box.
The Target dialog box is displayed.

Click on the solid body to choose the target. The solid body is highlighted, and the
Solid 1 icon appears in the Selection section. The target model is defined.

Confirm the Target dialog box with .

The Milling Part Data dialog box is displayed.

9. Save the CAM-Part data

Confirm the Milling Part Data dialog box by clicking .

The Milling Part Data dialog box is closed, and the SolidCAM Manager is displayed.
The defined CAM-Part is saved.

At this stage, the definition of the CAM-Part is finished. The definition of Milling
operations is covered in the following exercise using this CAM-Part.

20
 2. CAM-Part Definition

The SolidCAM Manager tree is the main interface feature of SolidCAM

that displays complete information about the CAM-Part.

The SolidCAM Manager tree contains the following elements:

• CAM-Part header

This header displays the name of the current CAM-Part. By right-

clicking it, you can display the menu to manage your CAM-Parts.
The Machine subheader is located under the CAM-Part header.
Double-click this subheader to review your machine configuration
and parameters.

21
 The CoordSys Manager subheader is located under the CAM-
Part header. Double-click this subheader to display the CoordSys
Manager dialog box that enables you to manage your Coordinate
Systems.
The Stock and Target subheaders are located under the CAM-Part
header. Double-click these subheaders to load the Stock/Target
dialog boxes that enable you to change the definition of the
Stock/Target models.
The Updated stock subheader is located under the Target header.
Right-click this subheader to display the menu that enables you to
calculate the updated stock and rest material.
The Settings subheader is also located under the CAM-Part
header. Double-click this subheader to load the Part Settings
dialog box that enables you to edit the settings defined for the
current CAM-Part.
• Tool header

This header displays the name of the current Tool Library.

Double-click this header to display the Part Tool Table, which is
the list of tools available to use in the current CAM-Part.
• Machining Process header

This header displays the name of the current Machining Process

table.
• Hole Wizard Process header

This header can recognise and process the holes created with
SOLIDWORKS Hole Wizard feature and perform machining of
the holes automatically.
• Geometries header

This header displays all SolidCAM geometries that are not used
in the operations.
• Fixtures header

This header displays available fixtures. By right-clicking it, you can

display the menu to define and manage your fixtures.
• Operations header

This header displays all SolidCAM operations and setups defined

for the current CAM-Part.

22
 2. CAM-Part Definition

• Setup header

This header displays all SolidCAM operations defined for the

current setup.

10. Close the CAM-Part

Right-click the CAM-Part header in the
SolidCAM Manager tree and choose Close
from the menu.
The CAM-Part is closed.

23
SolidCAM 2.5D
Operations 3
SolidCAM offers you the following types of 2.5D Milling operations:

2.5D Milling Operations

Face Milling Slot

Profile T-Slot

Contour 3D Translated Surface

Thread Milling ToolBox Cycles

Engraving Edge Deburring Recognition

Pocket Drilling

Pocket Recognition Multi-depth Drilling

Drill Recognition

In SolidCAM, an operation is a single machining step. A workpiece is usually manufactured

using several machining steps and technologies. For each of these steps you can define a separate
operation. An operation can be very complex, but it always uses one tool, one major geometry and
executes one machining type, e.g. Profile Milling or Drilling. You can edit any single machining
operation, change the operation sequence and generate the GCode, combining and splitting the
operation list of your CAM-Part.
The Machining Geometry has to be defined for each operation. The Geometry prompts
SolidCAM what and where you want to machine.
• A Geometry for Profile, Pocket, Contour 3D, Slot and T-Slot operations, Engraving and
ToolBox cycles consists of a number of chains. Chain geometries are defined by selecting
the following entities: edges of models, 2D curves, 3D curves, circles, lines and splines.
Each chain is composed of one or more entities and defines an open or closed contour.
• A Geometry for Face Milling operations can be defined by selecting solid models, faces
or chains of model elements.
• A Geometry for Drilling and Thread Milling operations consists of one or more points
(drilling centers) that can be defined by a number of methods directly on the solid model.

26
 3. SolidCAM 2.5D Operations

• A Geometry for Drill Recognition, Pocket Recognition, and Chamfer Recognition

operations is determined automatically by SolidCAM Automatic Feature Recognition
functionality.

Face Milling Operation

This operation enables you to machine large flat surfaces with
face mill tools.

Profile Operation
You can mill on or along a contour. The profile geometry can
be open or closed. In profile milling you can optionally use
tool radius compensation to the right or to the left side of the
geometry. SolidCAM offers two types of profiling:
• Milling a single profile to the specified constant or
variable depth in one step or in several user-defined
down steps.
• Concentric profiles to the specified constant or variable
depth; this type of profiling generates several concentric
profiles that start from the defined clear offset distance
from the profile, and finish on the profile geometry,
thus clearing the area around the profile to a constant
depth.

Contour 3D Operation
This operation enables you to utilize the power of the 3D
Engraving technology for the 3D contour machining. In this
operation, SolidCAM enables you to prevent the gouging
between the tool and the 3D contour.

27
Pocket Operation
In pocket milling, you have to remove material from the
interior of a closed geometry. SolidCAM offers two types of
pocketing:
• When a profile geometry consists of one or more
profiles and none of them are enclosed or intersect
with one another, each is milled as a separate pocket
without islands.
• When a profile geometry consists of several profiles,
any profile that is enclosed or intersects with another
profile is treated as an island. You can define an
unlimited number of islands within a single pocket.
Drilling Operation
This operation enables you to perform drills and other
canned drill cycles. SolidCAM supports the canned drill cycles
provided by your particular CNC-machine such as threading,
peck, ream, boring, etc. If your CNC-machine has no canned
drill cycles of its own, they can be defined using the VMID
Editor. In the Technology list, you can choose the option of
Thread milling to save and copy a drilling operation and then
change the operation to a thread mill operation.
In the Technology list, select either a 2D Drill, 3D Drill, Thread Milling or Multi-depth Drilling
option. The dialog box parameters are changed according to your selection.
When a Drilling Operation is opened and Thread Milling is selected under Technology, all the
Drilling Operations are saved and copied into the new Thread Milling operation. However, you
must re-select the tool for this new Thread Milling operation.

Multi-depth Drilling
Multi-depth drilling is very useful for deep hole drilling and drilling
through cross holes. In this operation, you have full control of Drilling
operations at every depth. The Multi-depth drilling operation enables
you to define manually the areas where the feed rate changes. You can
manually control the Spin rate/direction and coolant control during the
retract and engage movements.
In the Technology list, select either a 2D Drill, 3D Drill, Thread Milling
or Multi-depth Drilling option. The dialog box parameters are changed
according to your selection.

28
 3. SolidCAM 2.5D Operations

When a Drilling Operation is opened and Thread Milling is selected under Technology, all the
Drilling Operations are saved and copied into the new Thread Milling operation. However, you
must re-select the tool for this new Thread Milling operation.

Thread Milling Operation

This operation enables you to generate a helical tool path for the
machining of internal and external threads with thread mills.
In the Technology list, select either a 2D Drill, 3D Drill, Thread
Milling or Multi-depth Drilling option. The dialog box parameters
are changed according to your selection.
When a Thread Milling Operation is opened and one of the Drilling operations is selected
under Technology, all the Thread Milling Operations are saved and copied into the new Drilling
operation. However, you must re-select the tool for this new Drilling operation.

Slot Operation
This operation generates a tool path along the centerline to the
right or to the left of one or more profiles. Two types of slots can
be defined: the Slot with constant depth operation machines the
slot in several steps until the final depth is reached. In Slot with
variable depth, the depth profile is also defined by a 2D section.
The slot can be pre-machined using rough and semi-finish cycles.
The finish cut produces a tool path according to the specified
scallop height on the floor of the slot.
With available parameters for the right and left extension and the
side step, you can mill a slot wider than the tool diameter. All slot
technologies in Toolbox Cycles operations are enabled to use Pre-Drill operations.
T-Slot Operation
This operation enables you to machine slots in vertical walls
with a slot mill tool.

29
Translated Surface
This operation enables you to generate translated surface by
moving a section along a profile geometry. Limit geometries
can be projected on the translated surface. You can machine
the resulting translated surface inside, outside or along the limit
geometry.

ToolBox Cycles
This operation enables you to choose a machining scenario
intended for a specific machining case from a set of pre-defined
2.5D Milling operations.

Engraving
This operation enables you to mill text or any other profile on
a 2D or 3D geometry. Both 2D and 3D Engraving strategies
are available.

Pocket Recognition
This operation recognizes automatically pocket features at
the target model and creates the necessary machining.

30
 3. SolidCAM 2.5D Operations

Drill Recognition
This operation carries out a highly efficient drill recognition
and geometry creation with the functionality of the AFRM-
module (Automatic Feature Recognition and Machining). In
this operation drilling on different levels can be carried out.
The drilling levels are automatically recognized, but may be
edited by the user.

Edge Deburring Recognition

This operation recognizes automatically chamfer features at
the target model and creates the necessary machining.

31
Exercise #2: Cover Machining

In this exercise, you use the CAM-Part defined in the

Exercise #1. You have to define several 2.5D operations
in order to machine the model external faces, pocket and
holes in the corners.
In the process of definition of operations, you have
to define the machining geometry, the tool and several
technological parameters.

1. Open the CAM-Part

In the main SOLIDWORKS menu,
choose Tools > SolidCAM > Open or
click Open on any of SolidCAM
toolbars.

In the browser window, choose Exercise1 – the CAM-Part prepared in the previous
exercise.
The CAM-Part is loaded.

32
 3. SolidCAM 2.5D Operations

2. Add a Face Milling operation

In SolidCAM Manager, right-click the Operations header and choose Face from the
Add Milling Operation submenu.

The Face Milling Operation dialog box is displayed.

In this operation, the upper face is machined.

33
 3. Define the Face Milling geometry
Face Milling Geometry can be defined in two ways:
• Face Milling geometry can be based on the actual
Updated Stock boundary thereby assuring full
coverage of the stock face at any stage of machining.
• The traditional way of defining Geometry.
You can set the Geometry to Stock based boundary or Part
based boundary as default in the SolidCAM settings.
Stock Based boundary – The Geometry is based on the
existing updated stock. The Geometry field is disabled and
named as Updated Stock by default.
Part based boundary – This section enables you to choose the
appropriate Coordinate System and to define the Machining
Geometry for the operation.
Click Part based boundary and then click .

The Face Milling Geometry dialog box is displayed.

The Type section enables you to define the face milling geometry using
the following methods:
• Model

This option generates

a rectangle located
at the XY-plane and
surrounding the Target
model and selects it
for the Face Milling
geometry. The rectangle
chain is displayed in the
Chain List section. Face Milling geometry

34
 3. SolidCAM 2.5D Operations

• Faces

This option enables you to define the Face Milling geometry by

face selection. The Define button and the related box enable you
either to define a new faces geometry with the Select Faces dialog
box or choose an already defined geometry from the list. When
the model faces are selected, SolidCAM generates a number of
chains surrounding the selected faces. These chains are displayed
in the Chain List section.
Selected faces

Face Milling geometry

• Profile

This option enables you to define the Face Milling geometry

by a profile. The Define button and the related box enable you
either to define a new profile geometry with the Geometry Edit
dialog box or choose an already defined geometry from the list.
The defined chains are displayed in the Chain List section.

Face Milling geometry

In the Type section, use the default Model option for the Face Milling
geometry definition. Click the Define button in Base Geometry
section. The 3D Geometry dialog box is displayed.

35
 This dialog box enables you to define the 33D Model geometry:
The CAD selection button enables you to select
the 3D geometry with SOLIDWORKS tools.
You can select an object by clicking on it.
When an object is selected, its icon is displayed
in the list in the bottom of the dialog box. To
unselect the object, click on it again or right-
click its icon in the list of selected elements
and choose Unselect from the menu.
To remove selection from all objects in the list,
click Unselect all.

Click on the solid model to select it. The model

is highlighted, and its icon appears in the list.
Confirm the 3D Geometry dialog box by clicking
. The Face Milling Geometry dialog box is
displayed again.
The rectangle is generated surrounding the
target model at the XY-plane.
Confirm the Face Milling Geometry dialog box
by clicking .

36
 3. SolidCAM 2.5D Operations

The geometry is defined for the operation.

4. Define the Tool

Switch to the Tool page of the Face Milling Operation dialog box. Start the tool
definition by clicking the Select button.

The TOOLKIT dialog box is displayed at the Part Tool Library level.

The Library Toolbar contains all tools available for use to machine
a specific CAM-Part. This dialog box enables you to add, import, and
manage the tool items to the Part Tool Library of your CAM-Part.
Currently, the Part Tool Table is empty. Define a new tool suitable for face milling.
The available tools are displayed in the Library Selection Pane.

37
 This pane enables you to add a new tool to the tool library choosing from the tools
available for the current operation. In this operation, a face mill of Ø100 will be
used.

Face mill

This tool type is used for machining of large flat surfaces. A tool of
this type is defined with the parameters shown in the image.
Arbor Diameter
Total Length

Shoulder
Outside
Length
Holder
Length

Cutting
Length Taper
Angle

Tip Diameter

Diameter

Double click on the Face mill tool icon. A new Face mill is added in the Data Pane.
When a new tool is added, the Data Pane is populated with the default parameters
of the tool. The below image explains the right hand side of the TOOLKIT dialog
box.

38
 3. SolidCAM 2.5D Operations

From the Data Toolbar, select the Topology data icon.

In the Tool parameters section, edit the following parameters:
• Set the Diameter to 100
• Set the Shoulder diameter to 80
• Set the Arbor diameter to 80
Ensure the other
parameters are also
the same as shown in
the below image.

Click to confirm
t h e t o o l
parameters and
choose the tool for the
operation.

5. Define the Face depth

Switch to the Levels page of
the Face Milling Operation
dialog box. Click the Face
depth button in the Milling
levels area. This button enables
you to define the Operation
Lower level directly on the
solid model. The depth is
calculated automatically as
the difference between the
Z-values of the Operation
Upper and Lower levels.

The Pick Lower level dialog

box is displayed.

39
 6. Select the model face as shown.
The lower level value (0) is determined
and displayed in the Pick Lower level
dialog box.

Confirm this dialog box with .

The Face depth value is displayed
in the Milling levels area. The
green background of the edit
box means that the parameter
is associative to the model.
Associativity enables the selected
level to be synchronized with the solid model changes; SolidCAM automatically
updates the CAM data when the model is modified.

7. Define the technological parameters

Switch to the Technology page of the Face Milling Operation dialog box. In the
Technology section, choose the One Pass option.

40
 3. SolidCAM 2.5D Operations

One Pass machining technology

SolidCAM performs the face milling

in one pass. The direction and
location of the pass are calculated
automatically according to the face
geometry, in order to generate an
optimal tool movement with the
tool covering the whole geometry.
Selecting the One Pass option
automatically opens the One pass
tab that enables you to define the
machining parameters.

The Tool path modifications section enables you to define the angle
between the tool path and the geometry,
and the shift from the central line.
The User-defined angle option enables you
to determine the angle of the tool path.
Enter the value of angle in the Absolute
angle edit box.

When the option of Automatic optimal

angle is selected, SolidCAM automatically
calculates the optimal angle of hatching to expedite the machining
process. The tool path always follows the length of the face no
matter what angle the machined surface is facing.
Using the Automatic optimal angle option, you can change the angle
by entering a different value in the Delta from text field.
The Shift from center option shifts the generated tool path from the
center of part by the specified distance.

41
 The Extension section enables you to define the tool path extension
over the face edges. The extension can be
defined either by percentage of the tool
diameter (the % of tool diameter option) or
by value (the Value option).

Use the One pass option with default parameters.

8. Save and Calculate

Click .
The Face Milling operation data is saved, and the tool path is calculated.
The preview of the calculated tool path is
displayed on the solid model.

9. Simulate

Click in the Face Milling Operation dialog box. The

Simulation control panel is displayed.

Switch to the SolidVerify page and clear the Single color

check box. This option enables you to display all tool paths
in one color, regardless of the chosen tool color. By
clearing it, you can display tool paths in colors according to
the tool color. Start the simulation with .

The solid stock model defined in Exercise #1 is used in the SolidVerify

simulation mode. During the machining simulation process, SolidCAM
subtracts the tool movements (using solid Boolean operations) from the
solid model of the stock. The remaining machined stock is a solid model
that can be dynamically zoomed or rotated. It can also be compared to
the target model in order to show the rest material.

42
 3. SolidCAM 2.5D Operations

During the simulation, you can rotate , move , or zoom the

model. Use these options to see the machining area in details.
The Single step mode can be used to simulate the next tool movement
by clicking or by using the space bar on your keyboard.
Close the simulation with . The Face Milling Operation dialog box is displayed.
Close this dialog box with .

Click the check box next to the defined Face Milling Operation to hide the preview
of the tool path.

43
 10. Add an operation
Right-click the Operations header in
SolidCAM Manager and choose Profile from
the Add Milling Operation submenu.

The Profile Operation dialog box is displayed.

In this operation, the external profile is machined.

11. Define the Geometry

The first step of definition of each operation is the Geometry selection. At this
stage, you have to define the Geometry for the Profile operation using the solid
model geometry.

44
 3. SolidCAM 2.5D Operations

Click in the Geometry page of the Profile Operation dialog box.

The Geometry Edit dialog box is displayed. This dialog box

enables you to add and edit geometry chains.
When this dialog box is displayed, you can select solid model
entities for the Geometry definition.

45
 Chain Selection Options

You can define the geometry by selecting edges,

sketch segments and points on the contour. The
following options are available:
Curve

This option enables you to create a

continuous geometry chain by choosing its
successive entities automatically or manually.
If none of the additional options (Up to
Entity, Tangent propagation, Constant Z
Propagation) is selected, you can choose the chain entities manually
one by one.

Associativity: SolidCAM keeps the associativity to any edge or sketch

entity. Any change made to the model or sketch automatically updates
the selected geometry.
Smart Face

When you select the Smart Face check box, it allows you to pick
a geometry directly from the face that automatically recognizes all
open edges, holes, bosses or semi-open pockets or a completely open
pocket. The option of Smart face is not checked by default. When
any of the option of Filter for circle/arc selection is used, Smart face
remains unchecked and is disabled. When Smart face is checked, you
can pick the face and sync works on that entire face. However, if a
filter is used selecting Smart face, Smart face option automatically
unchecks and disables. If Smart face is used and you want to delete
a hole that was picked using Smart face, a message pops up saying
“Uncheck Smart face to delete holes”. The moment you delete holes,
Smart face is again disabled. You can enable Smart face again if all
holes are removed.

46
 3. SolidCAM 2.5D Operations

Up to Entity

With this option, the chain is selected by specifying the start curve,
the direction of the chain and the element up to which the chain is
created. SolidCAM enables you to choose any model edge, vertex or
sketch entity to determine the chain end.
End entity

Start entity Selected chain

When the end item is chosen, SolidCAM determines the chain

according to the rules of the chosen selection mode (Tangent
propagation and/or Constant Z Propagation). The chain selection is
terminated when the selected end item is reached.
If the chosen end item cannot be reached by the chain flow, the chain
definition is terminated when the start chain segment is reached. The
chain is automatically closed.
End entity

Start entity Selected chain

The confirmation message is displayed.

The Up to Entity option is useful if you do not want

to define a closed chain, but an open chain up to a
certain element.

47
 Tangent propagation

SolidCAM automatically selects the next entity tangent to the current

one. If there is no any, it highlights all entities connected to the last
chain entity. You have to select the entity along which you want the
chain to continue.
Constant Z Propagation

This option identifies only entities on the same XY-plane with the
previously selected chain entity. You are only prompted to identify
the next chain element when two entities on the same Z-level are
connected to the chain.
The system tolerance for this option can be set in the SolidCAM
Settings.

You are required to enter a positive and negative Z-deviation into the
Delta Z Tolerance edit boxes. Only entities within this range are
identified as the next possible entity of the chain.

1. Pick start curve - select the start entity of the chain.

2. Pick point in chain direction - indicate the chain direction by
choosing a point on the selected start entity of the chain.
3. You are prompted to select one of the possible curves if
the system detects that more than one entity can be the next
element of the chain. Indicate your choice.

48
 3. SolidCAM 2.5D Operations

4. When the system can close the chain, the confirmation

message is displayed.

Choose Yes to accept. If you answer No, you can continue the
chain selection: for example, undo the last step or cancel the
chain selection.
The combination of Constant Z and Tangent Propagation options
enables you to choose entities which continue the chain with either
tangent or having the same Z-level entities.

Curve + Close corners

This option enables you to close the gaps between successive chain
entities irrespective of the Gap minimum
and Gap maximum values (defined in the
Defaults > Geometry section of SolidCAM
Settings) by virtually extending the
entities up to their intersection.
Splines and arcs are extended by lines
tangential to the arc/spline at its end
point.

Associativity:When the model used for the geometry definition

is modified, SolidCAM enables you to synchronize the geometry
with the updated model. During the synchronization, the program
determines gap areas created using the Curve + Close Corners option
and regenerates the extension of the chain elements so as to close
the gaps.

49
 Loop

This option enables you to select a loop by picking one of the model
edges.
Loop #2

Loop #1

1. Pick an edge shared by two model faces. Two faces to which this
edge belongs are determined, and their loops are highlighted.
The first determined loop is considered to be the primary and
is highlighted with yellow color. The second loop is considered
to be the secondary and is highlighted with blue color.
2. Choose one of the loops. Click on any other edge forming
the face. You are prompted to accept the chain that is now
highlighted with yellow color. Accept the chain with the Yes
button. A closed geometry chain is defined on this loop, and
the secondary loop is rejected.
Associativity: SolidCAM keeps the associativity to any edge or sketch
entity. Any change made to the model or sketch automatically updates
the selected geometry.
Point to point

This option enables you to connect specified points with a straight

line.

50
 3. SolidCAM 2.5D Operations

Associativity: SolidCAM does not keep the associativity to any

selected point. The program saves the X-, Y- and Z-coordinates of
the selected points. Any change made to the model or sketch does
not update the selected geometry.
You cannot select a point that is not located on a
SOLIDWORKS entity (if you need to select such a
point, add a planar surface under the model and
select the points on that surface).
The following rules apply to the virtual line selection using the Point
to point option:

• When you select a virtual line between two edges, the line
behaves as a spring. Whenever the model is changed and
synchronized, the geometry is updated with the model.
• When you select a sequence of several virtual lines, only the points
connected to model edges or sketch elements are updated, but all
other points stay fixed at the defined X-, Y- and Z-positions.
Arc by points

This option enables you to create a chain segment on an arc up to a

specific point on the arc.

Second Third
point point

First
point

Associativity: SolidCAM does not keep the associativity to any

selected arcs by points. SolidCAM saves the X-, Y- and Z-coordinates
of the selected points. Any change made to the model or sketch does
not update the selected geometry.

51
 In this exercise, the geometry must be defined as shown.
The red arrow indicates the direction of
the geometry.

In SolidCAM operations, the direction of the chain geometry is used

for the tool path calculation.
In Profile milling, the tool moves in the direction of the geometry by
default. In this exercise, the
Tool revolution
combination of the geometry direction
direction and the clockwise Tool movement
direction
direction of the tool revolution
enables you to perform climb
milling.
When you pick the first chain
entity on the solid model,
Geometry
SolidCAM determines the start direction
point of the picked entity
closest to the picked position. The direction of the picked first chain
entity is defined automatically from the start point to the picked
position.
Starting point
Direction

Picked position

Geometry chain

52
 3. SolidCAM 2.5D Operations

Choose the Loop option in the Chain section and click on the model edge as shown.

Notice that the picked position must be close to the start point of the
geometry.
Two faces shared by the selected edge are determined, and their loops are
highlighted. The arrow indicates the direction of the selected chain.

The confirmation message is displayed. Confirm it with

Yes.

The chain icon is displayed in the Chain List section.

At this stage, the Geometry is defined. Confirm the Geometry selection with .
The Profile Operation dialog box is displayed.

53
 12. Define the Tool
At this stage, you have to define the tool for the Profile
milling.
Switch to the Tool page of the Profile Operation dialog box
and click the Select button.
The Part Tool Table with the tool used in the previous
operation is displayed.
In this Profile operation, an End mill of Ø16 will be used.

End Mill/Bull Nose Mill/Ball Nose Mill

These tool types are used for the definition of rough/finish mills.
The tool shapes and basic parameters are shown below:

54
 3. SolidCAM 2.5D Operations

Double click the End Mill tool to choose it for the operation.

From the Data Toolbar, select the Topology data icon. In the Tool parameters
section, set the Diameter value to 16.
Set all the other parameters as shown in the image.

Click to confirm the tool parameters and choose the tool for the operation.

13. Define the Feed and Spin parameters

Switch to the Data tab in the Tool section of the Profile Operation dialog box.

55
 Set the Spin rate (used in rough milling) value to 6000. The Spin finish (used in finish
milling) value is automatically set to 6000.

The Spin finish check box enables you to optionally define different
values for Spin rate and Spin finish. When this check box is selected,
the corresponding edit box is available so that you can edit its value.
When this check box is not selected, the specified Spin rate value is
used for both rough and finish machining.

Set the Feed XY (feed rate for XY movements) to 1500

and the Feed Z (feed rate for Z movements) to 250.
Select the check box near the Feed finish (feed rate for
finish milling) parameter and set the value to 1800.

The Feed finish check box enables you to optionally define different
values for Feed XY and Feed finish. When this check box is selected,
the corresponding edit box is available so that you can edit its value.
When this check box is not selected, the specified Feed XY value is
used for both rough and finish machining.

14. Define the Milling levels

Switch to the Levels page of the Profile Operation dialog box.

56
 3. SolidCAM 2.5D Operations

SolidCAM enables you to define the milling levels using the solid model data.
SolidCAM supports the machining of geometries with different depths in a single
operation. This option is available for Profile, Contour 3D, Pocket, Slot and T-Slot
operations.
Choosing the Constant icon in the Milling levels section, enables you to set the
Upper level, Lower level and Step down values.
Choosing the Variable icon displays the Variable levels button. Clicking Variable
levels displays the Levels dialog box.
The Variable levels option can help simplify the task of programming, especially
when you want to use the same tool to perform the machining of many geometries
having different depths. Such a task can now be achieved in just one operation.

Upper level

This parameter defines the Z-level

at which the machining starts. To
define the upper level, you can select
the options of By stock, By target or
User defined from the list. Coord. System
Z
X

Y
Upper
Profile depth Level
Profile

This parameter defines the Z-level Depth

below which the tool does not mill.
This plane is not penetrated in any milling strategy.

Click the Upper level button in the Milling levels area. The Pick Upper level dialog
box is displayed.
Select the model face as shown.

The Upper level value (0) is determined and displayed in the Pick Upper level dialog
box. Confirm this dialog box by clicking .

57
 Right Left Center

Click the Profile depth button in the Milling levels area. The Pick Lower level dialog
box is displayed.
Pick the bottom edge of the model as shown. The Lower level value (-10) is
determined and displayed in the Pick
Lower level dialog box. Confirm this
dialog box with

Now you need to define the Delta depth.

The Delta parameter defines the offset for the cutting depth that can
be changed with its associativity preserved. The Delta value is always
relative to the Profile depth defined for the operation.

Set the Delta value to -1.

The milling levels are defined.

58
 3. SolidCAM 2.5D Operations

15. Define the technological parameters

Switch to the Technology page of the
Profile Operation dialog box.

First, you need to make sure that the

tool position relative to the geometry
is correct. In the Modify section, check
the Tool side option.

Modify

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

59
 In this case, the default Left option meets the requirements of climb milling. Click
the Geometry button to check the tool position.

This tool position is correct. Click to close the Modify Geometry dialog box. The
Profile Operation dialog box is displayed again.

SolidCAM enables you to perform the rough and finish machining of the profile in
a single Profile operation.
Define the parameters of the Profile roughing. Select the Rough check box. Define
the Step down parameter for roughing.

Step down
Step down
Profile roughing is performed
Upper
in constant Z-passes. The Step level
down parameter defines the
distance between each two
successive Z-levels. Profile
depth

Set the Step down to 5. With this value, SolidCAM performs two cuts at the following
Z-levels: -5, -10; the last cut is performed at the Z-level defined by Profile depth.
Now you need to define the wall offset that will remain after the roughing passes.

60
 3. SolidCAM 2.5D Operations

Offsets

The Wall offset and Floor offset parameters enable you to define the
allowances that remain on the walls and the floor of the machined
part till the profile finish machining. These allowances can be removed
with the finish passes in the same Profile operation or in an additional
Profile operation with another tool.

Step down
Wall offset
Profile depth

Floor offset

In the Offsets section, set the Wall offset value to 0.5. The allowance of 0.5 mm
will be left on the model walls during the profile roughing. This allowance will be
removed with a separate finishing cut in the end of the profile machining.
Select the Finish check box to perform the finishing of the profile.

16. Define the Lead in and Lead out

Switch to the Link page of the Profile Operation dialog box.
This page enables you to define the way the tool approaches the profile and retreats
away.

61
 Profile Lead in and Lead out

The lead-in movement is necessary to prevent vertical entering of the

tool into the material. With the lead-in strategies the tool descends
to the machining level outside of the material and then horizontally
penetrates the material with the lead-in movement. The lead-out
strategy enables you to perform the retract movements outside the
material.
The following options are available:
• None

The tool leads in to and out from

the milling level exactly adjacent
to the start point of the profile.

• Normal

The tool leads in to and out from the

profile from a point normal to the
profile. The length of the normal Normal
Length
can be set in the Normal length
Tangent
field. The distance between the Extension
normal and material is set in the
Tangent extension field.
• Arc

The tool leads in to and out

Radius
from the profile with a tangential
arc. The arc radius can be set in
Tangent
the Radius field. The length of Extension
the extension can be set in the
Tangent extension field. The arc
angle is set in the Arc angle field.
The Flip check box is available for selection when Tool side is
chosen as Center on the Technology page. When this check box
is selected, the lead move is flipped to the opposite side from its
initial orientation, as if it was mirrored relative to the tool path.
This option is available only for Normal and Arc Lead in types.

62
 3. SolidCAM 2.5D Operations

• Tangent

The tool leads in/out on a line Length

tangent to the profile. The length of
Tangent
the tangent can be set in the Length Extension
field. The distance to the material
can be set in the Tangent extension
field.
• Point

The tool leads in/out from a

user-defined position. From this
position, the tool moves on a
straight line to the start point of Tangent
the profile. When you select this Extension

option, the Pick button is activated

so that you can select a position
directly on the solid model. The
distance between the point and material is set in the Tangent
extension field.

The Lead In/Out with Points are fully associative. You can
associate the point location to Vertex, Circular edge center, Sketch
point, Sketch arc center, Work axis and Cylindrical face axis. The
Points will synchronize and update the tool path if the location of
the point on the solid model is changed.
• User-defined

The tool leads in/out from a user-defined position. When you

select this option, you can define a geometry of the tool approach
to the material.

63
 When the Same as Lead in check box is selected, the strategy and
parameters defined for Lead in are used for Lead out.

For Lead in, use the default Arc option. Set the Tangent extension value to 5 and the
Radius value to 2.

Under Lead out, select the Same

as Lead in check box.

The definition of the basic

technological parameters of
profile milling is finished.

17. Calculate the Tool path

Click . The Profile operation data is saved, and the tool path is calculated. The
preview of the calculated tool path is displayed on the solid model.

18. Simulate the operation

The preview of the tool path can also be activated using the Host CAD simulation
mode in Simulation control panel.
Click the Simulate button in the Profile
Operation dialog box. The Simulation
control panel is displayed. Switch to the
Host CAD simulation mode and click .

64
 3. SolidCAM 2.5D Operations

The Host CAD simulation mode enables you to display the tool path
directly on the model in the SOLIDWORKS window. Since all the View
options of SolidCAM are active during the simulation, you can see the
tool path from different perspectives and zoom on a certain area of the
model.
Switch to the SolidVerify page and start the simulation with the .
When the simulation is finished, play the it step by step using .
Close the simulation with the . The Profile Operation dialog box is displayed.
Close the Profile Operation dialog box.

19. Add a Pocket operation

The Pocket operation is used for the internal
pocket machining. Right-click the Operations
header and choose Pocket from the Add
Milling Operation submenu.

The Pocket Operation dialog box is displayed.

65
 20. Define the Geometry
The geometry for a Pocket operation is generally represented by closed chains. In
this exercise, you have to define a chain using the solid model edges.
Click in the Geometry page to start the geometry definition. The Geometry
Edit dialog box is displayed.

Using the Tangent Propagation option, define the chain as shown.

Confirm the geometry definition by clicking .

The Pocket Operation dialog box is displayed.

21. Define the Tool

Switch to the Tool page and click the Select button.
In this Profile operation, an End mill of Ø8 will be used.
Choose the End mill tool for the operation and set the Diameter value to 8.

Click to confirm the tool parameters and choose the tool for the operation.

22. Define the Milling levels

Switch to the Levels page of the Pocket Operation dialog box and define upper and
lower levels of machining directly on
the solid model.

66
 3. SolidCAM 2.5D Operations

Define the Upper level as shown. The Upper level value (0) is determined.
Define the Pocket depth by clicking on the pocket bottom face as shown. The
Pocket depth value (8) is determined.

Set the Step down value to 4 to perform the pocket machining in two equal steps.

The default Constant depth icon indicates that the pocket will be machined at
a constant depth.

23. Define the technological parameters

Switch to the Technology page of the Pocket
Operation dialog box. In the Offsets section, set the
Wall offset and the Floor offset values to 0.2. These
offsets remain unmachined during roughing and are
removed with the further finishing.
In the Finish area, select the Wall and Floor check
boxes. These options enable you to perform finishing
of the Wall offset and Floor offset that remain after the
roughing.

67
 Define the machining strategy. Make sure that the default Contour option is chosen
in the Technology section.
When the Contour strategy is chosen, the tool moves on
offsets parallel to the pocket contour.

Switch to the Contour tab to display the Contour parameters. This page enables you
to define the parameters of the Contour strategy.

Contour parameters

Start from
• Inside

This option allows you to

work in a pocket area starting
from the middle of the
pocket and cutting towards
the outside border of the
pocket.

• Outside

This option allows you to

work in a pocket area starting
from the outside border of the pocket and cutting towards the
middle of the pocket.

68
 3. SolidCAM 2.5D Operations

Corner
• None

The tool path is formed with sharp

corners between one direction and
the next.

• Fillet

This option connects each direction

with a given radius allowing for a
smoother transition between path
directions.
The Min. corner radius option enables
you to define the minimal value of the
corner radius.

If the given radius is too large for a specific corner, it

produces the largest possible radius at that point.
Sometimes the fillet option can leave some material.
This particularly happens if the given radius is large.
• Loop

This option ensures that the

connecting points on the path are
cleaned using a smooth transition.
The tool path forms a loop in the
corner, preventing an abrupt change
of direction.

69
 • Sharp

This option ensures that using a

short and simple movement cleans
the connecting points on the path.
Although this produces a sharp
movement by the tool, the path itself
is slightly shorter than the smooth
corner option. This can help cut
down on machining time.

This option is not recommended for high-speed

cutting.

Direction

This option enables

you to choose climb or
conventional milling for
the roughing operation.

Climb milling Conventional milling

Adjacent passes connection

This option enables you to choose the method of the tool movement
within the pocket from one tool path pass to the next one.

• Smooth

The tool performs an arc movement

from one tool path pass to the next
one. The connection points may not lie
on one line, thus forming an angle with
the line normal to the tool path.

70
 3. SolidCAM 2.5D Operations

• Linear

The tool performs normal approach

from one tool path pass to the next
one.

• Rounded

The tool performs an arc movement

from one tool path pass to the next
one. The connection points are located
on the line, which is normal to the tool
path.

Exit material

This option controls the tool movements

between the working areas.

Exit material check box not Exit material check box

selected selected

When the tool moves from The tool exits the material
one working area to the next, and travels rapidly above the
it moves through the full material to the next working
material around the island to area as shown above. The
get to the next working area lead in path is the Lead in you
as shown above. define.

71
 Connect islands

This option enables you to keep the

same cutting direction (conventional or
climb milling) throughout the entire tool
path where possible. This is particularly
important in high-speed cutting.

This operation will be performed with the default Contour parameters.

24. Define the Ramping strategy

Switch to the Link page of the Pocket Operation dialog box. Define the strategy
with which the tool is plunging into the material during the pocket roughing.

The following Ramping strategies are available for rough machining

of pockets:
• None

The tool enters the material vertically at the pocket start point
chosen automatically by the SolidCAM pocket algorithm.
• Vertical

The tool enters the material vertically at a user-defined position.

From this position, the tool moves to the pocket start point
calculated by the pocket algorithm. Click the Pick button to
specify the position where the tool plunges into the material.
• Angle

The tool moves to the pocket start point at a specified ramp angle.
Enter the ramping angle value into the Angle edit box. The start
point must be selected using the Points button.
SolidCAM does not check the ramping movement against the
pocket contour. Check the tool path simulation to make sure that
the tool does not gouge the pocket walls or islands.
• Helical

The tool descends from the safety distance above the Upper level
to the material in a circular motion until the step down is reached
using the user-defined radius. When the tool reaches the step
down depth, it machines all the material at the step down depth.
Click the Points button to set the helical ramping parameters.

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 3. SolidCAM 2.5D Operations

• Linear

The Linear ramping follows the same rules as the Helical ramping.
The difference is that the descent is performed in a linear zigzag
fashion rather than in a circular one.

Choose the Helical option. This option enables you to define the ramping position
and the related parameters for each chain used in the Pocket operation.

Helical Ramping Parameters

The Tool step down parameter defines

the distance between each two adjacent
turns of the tool helical movement.
The Angle parameter defines the ramping
angle.
The Radius parameter defines the radius
of the descending helix.
Center cutting

If your tool has center cutting capabilities, select the Center

cutting check box. In the Angle field, enter the descent angle that
you would like the tool to follow. In the Radius field, enter the
radius of the tool path helix.
The working order is as follows:
• The tool descends from the safety distance above the Upper level
to the material in a circular motion until the step down is reached
using the user-defined radius.
• When the tool reaches the step down depth, it machines all the
material at the step down depth.
• When the machining is completed at this depth, the tool goes up
to the Clearance level.
• At this stage, the tool repositions itself at the Z safety distance
above the previous step down depth and repeats the Helical Lead
in to the next working depth.
• This process repeats itself until the final depth has been machined.

73
 If the tool does not have center cutting capabilities, do not select the
Center cutting check box. In the Tool step down field, enter the depth
of the step down of the tool. The result of this action is the same as
with a center cutting tool except for the following differences:
• The tool descends from the safety distance above the Upper level
to the material in a circular motion up to the Tool Step down.
• At this point, the tool clears a circular path. Then it descends to
the next Tool step down.
• This is repeated until the tool reaches the CAM-Part step down
depth.
• When the tool reaches the step down depth, it machines all the
material on that step down depth.
• When the machining is completed at this depth, the tool goes up
to the Clearance level.
• At this stage, the tool repositions itself at the Z safety distance
above the previous step down depth and repeat the Helical Lead
in to the next working depth.
• This process repeats itself until the final depth has been machined.
To define the ramping position, click the Points button. The Ramping
points dialog box is displayed.
Chains

This section displays the list of all geometry

chains defined for the operation. All the chain
entries are displayed under the Chains header.
You can select chain entries in the list.

74
 3. SolidCAM 2.5D Operations

When the Chains header is selected, SolidCAM displays the tool path
and default ramping positions for all of the chains. The circles
represent the default helical ramping movement defined for each
chain.
Tool path start position Ramping position

When a chain entry is selected, SolidCAM displays the tool path

and the default ramping position for this chain. This position is
automatically defined at the start position of the tool path segment
relevant for the current chain. You can change this position by picking
a point on the model or by entering the new position coordinates into
the X, Y, Z dialog box. The schematic circle facilitates the definition
of the position.
When the position is picked, it is marked on the model with a blue
dot. The coordinates of the picked point are displayed in the X, Y, Z
dialog box. The circle of the tool path color represents the helical
movement of the tool plunging.
When the ramping position is defined, the tool descends into the
material at the specified ramping position with helical movements
according to the defined parameters. When it reaches the level of the
first cutting pass, it moves to the start position of the tool path and
performs machining of the pocket.
Ramping Position

The Set default button enables you to replace the currently defined
ramping position for the selected chain by the default ramping
position located at the tool path start position.

75
 The Auto next button provides you with the selection mode that
enables you to define the ramping positions for all of the chains one
by one.
Pre-Drill Operations

Upon selecting the Pre-Drilling Operations check box, the definition

windows are activated. When a Drill operation is chosen from the list,
the associated X- and Y-coordinates appear in the Drill positions list.
The drill diameter and positions data are used for the approach point
calculations.

Confirm the Ramping points dialog box with .

25. Define the Lead in and Lead out

The Lead in and Lead out strategies are used for defining the horizontal approach/
retreat of the tool to/from the geometry in the finish machining of the part walls.

Pocket Lead in and Lead out

The following Lead in and Lead out strategies are available for pocket
machining:
• None

The tool leads in to and out from the

milling level exactly adjacent to the
start point of the geometry.

• Normal

The tool leads in and out at the last

point of the geometry with a movement
normal to the pocket contour. The
length of the normal can be set in the
Length field. The distance between the
normal and start of the geometry is set
in the Tangent extension
field.

Tangent
Extension Normal Length

76
 3. SolidCAM 2.5D Operations

• Arc

The tool leads in to and out from

the geometry with a circular motion,
tangent to the last entity of the
pocket contour. The arc radius can
be set in the Radius field. The length
of the extension can be set in the
Tangent extension field. The arc
angle is set in the Arc angle field.

Tangent
Extension
Radius

• Tangent

The tool leads in to and out from the

pocket wall in a movement tangent to
the last profile entity. The length of
the tangent can be set in the Length
field. The distance to the material can
be set in the Tangent extension field.

When the Same as Lead in check box is selected, the strategy and
parameters defined for Lead in
are used for Lead out.

Tangent
Extension Length

77
 Under Lead in, choose the Arc option from the list and set the Tangent extension
value to 3 and the Radius value to 2.

Under Lead out, select the Same as Lead in check box.

26. Calculate the Tool path

Click . The Pocket operation data is saved, and the tool path is calculated.

27. Simulate the operation

Simulate the operation in the SolidVerify
and Host CAD simulation modes.

28. Add a Drilling operation

This Drilling operation is used to perform
the preliminary center drilling of the four
holes in the corners of the model.
Right-click the last Profile operation in
SolidCAM Manager and choose Drilling from
the Add Milling Operation submenu.

78
 3. SolidCAM 2.5D Operations

The Drilling Operation dialog box is displayed.

Define the Drill geometry

Make sure that the Technology is set to the default 2D drill
option.
In the Geometry area, click .
The Drill Geometry Selection dialog box is displayed in the SOLIDWORKS
PropertyManager area. This dialog box enables you to select the geometry for
drilling directly on the solid model.

SolidCAM enables you to select the drill centers using the following
options:

79
 • Pick position
You can define drill centers one by one
directly on the solid model.
• 3 Points on circumference
Usually, all curves and arcs of imported
models are converted into splines by the
exporting CAD system. Due to the nature
of spline curves or surface boundaries, you
cannot pick a center position like you could
on a circle or an arc. SolidCAM calculates
the center position of an arc defined by
three points positioned on the spline edges.
This facilitates selecting drill centers on
spline surfaces.
• Multi-positions
You can select the model face. SolidCAM
automatically recognizes all arcs/circles
located on the selected face and selects the
center points as drill positions.
• All circle/arc centers
SolidCAM searches the solid model for
arcs and circles and adds all center points
as drill positions to the geometry.

Choose the All circle/arc centers option and click the corresponding button.
Four drill positions are selected.
Their coordinates are displayed in
bottom part of the Drill Geometry
Selection dialog box.

Click to confirm the geometry selection. The Drilling Operation dialog box is
displayed.

80
 3. SolidCAM 2.5D Operations

29. Define the Tool

Switch to the Tool page of the Drilling Operation dialog box and click the Select
button.
The TOOLKIT window is displayed.

Click the Drilling Tools icon in the Library Toolbar. Double click the Spot drill
tool to add it in Tool Item Manager.

Spot Drill

This tool type is used for center drilling and chamfering in Drilling
operations. A tool of this type is defined with the parameters shown
in the image.
Arbor Diameter

Diameter

Total
Outside
Length
Shoulder Holder
Length
Angle

Cutting Length

81
 A Spot drill of Ø6 is used in this operation.

Click to choose the tool for the operation.

The Drilling Operation dialog box is displayed. Click the Data tab.
Define the spin and the feed for the operation.
• Set the Spin rate to 1200
• Set the Feed Z to 200

30. Define the center drilling depth

Switch to the Levels page of the Drilling
Operation dialog box. Click the Drill depth
button and select the upper face of the model.
The Drill depth value (0) appears in the relevant
edit box.
To perform the drilling down to the specified diameter of the tool, use the Depth
type option.

82
 3. SolidCAM 2.5D Operations

Depth Type

This option enables you to deepen the drilled hole in order to obtain
a given diameter at the specified drill depth.

Depth Depth Depth

Diameter
value

Cutter tip Full diameter Diameter value

• Cutter tip

The drill tip reaches the defined drill depth.

• Full diameter

The drill reaches the defined drill depth with the full diameter.
• Diameter value

The drill reaches the defined drill depth with the drill cone
diameter specified in the edit box.
The Diameter value can vary from 0 all the way up to the drill tool
diameter. A value greater than the drill tool diameter is
automatically decreased to the drill tool diameter.

Choose the Diameter value option and set the value to 5.

83
 In this manner, the drilling is performed till the tool diameter of 5 mm is reached at
the depth of 0.

Drill Depth (0)

Diameter_value (5)

In accordance with these parameters, SolidCAM calculates the centering depth using
the following formula: Diameter_value Centering_depth
Diameter_value / 2 α
Centering_depth =
tan(α/2)

If Diameter_value is 5 mm, and

α is 90°, the centering depth is
calculated as follows:
5/2
Centering_depth = = 2.5
tan(90/2)

31. Calculate the tool path

Click . The Drilling operation data is saved, and the tool path is calculated.

32. Simulate the operation

Simulate the operation in the
SolidVerify simulation mode.

84
 3. SolidCAM 2.5D Operations

33. Add a Drilling operation

Add another Drilling operation to perform the through drilling of the holes.
Right-click the last Drilling operation and choose Drilling from the Add Milling
Operation submenu. The Drilling Operation dialog box is displayed.

34. Define the Geometry

This operation is using the geometry that was defined in
the previous center drilling operation. Choose the drill
geometry from the list in the Geometry area.

Each geometry defined in SolidCAM has a

unique name. When the geometry is being defined, it is assigned a default
name that can be changed. Using this name, you can choose the geometry
for a specific operation.

35. Define the Tool

Define a new Drill tool of Ø4 for this operation.

Click to choose the tool for the operation.

The Drilling Operation dialog
box is displayed. Click the Data
tab in the Tool page.
Define the spin and feed for
the operation.

85
 • Set the Spin rate to 3000
• Set the Feed Z to 360

36. Define the Drilling depth

The overall height of the model is
10 mm plus the 5 mm bottom offset
defined for the stock. The drilling has
to be performed deeper than this depth
in order to enable the tool to exit from
the material and perform the through
drilling.
Switch to the Levels page.
Define the Upper level by clicking on the
top face of the model as shown.
Height
Define the Drill depth. Rotate the model
and select the bottom face as shown.

Since the Z- offset defined for the stock model is 5

mm, set the Delta value to -5.
To perform the through drilling, choose the Full
diameter option in the Depth type area. With this
option, the drilling is performed until the full diameter
is reached at the specified drill depth. This means that
the conical part of the tool exits from the material.

86
 3. SolidCAM 2.5D Operations

37. Define the Drilling type

SolidCAM enables you to use a number of drill canned cycles supported by your
CNC-controller. In this operation, the pecking canned cycle is used for chip
breaking. With this cycle, the chip breaking is accomplished by slight retracts of the
tool during the drilling process.
Switch to the Technology page and click the Drill cycle type button. Available drill
cycles are displayed.
Select the Peck option. The cycle is chosen for the operation.

Click the Data button to define the pecking parameters. The Drill
options dialog box is displayed.

Set the Step down to 1.5 in order to define the depth of each pecking
movement.

Confirm the data with the OK button.

38. Calculate the tool path

Click . The Drilling operation data is saved, and the tool path is calculated.

87
 39. Simulate the operation
Simulate the operation in the SolidVerify simulation mode.

Since in the previous operation the drilling diameter was greater than
that in this operation, the drilling results in a chamfer on the drilled
holes.

Now you have successfully finished the exercise.

88
 3. SolidCAM 2.5D Operations

Exercise #3: Cover Machining

In this exercise, a number of SolidCAM 2.5D operations are used for the cover part machining.

The cover is machined on the 3-Axis milling CNC-machine using the machining vice. The part
is machined using two setups.

At the first stage, the workpiece is positioned in the vice as shown below.

89
The highlighted faces are machined.

At the next stage, the rest of the cover faces are machined using the second positioning.

90
 3. SolidCAM 2.5D Operations

1. Load the SOLIDWORKS model

Load the Exercise3.sldprt model that is located in the Exercises folder.

This model contains a number of features forming the solid body of the cover.

2. Start SolidCAM
To activate SolidCAM, click Tools in the main menu of SOLIDWORKS and then
choose SolidCAM > New > Milling.

SolidCAM is started, and the Milling Part Data dialog box is displayed.

3. Choose the CNC-controller

Select the CNC-machine controller. Click the arrow to display the list of post-
processors installed on your system.
In this exercise, you use a 3-Axis CNC-machine with the AWEA1000-Fanuc CNC-
controller. Choose the AWEA1000-Fanuc CNC-controller from the list.

91
 4. Define the Stock model
In this exercise, you have to define the Stock model before you define the Coordinate
System in order to use the workpiece for the CoordSys definition.
Click the Stock button in the Define section of the Milling Part Data dialog box.
The Stock dialog box is displayed.

When the Coordinate System is not defined,

SolidCAM enables you to use only the Box method
of the Stock model definition.

SolidCAM generates the stock box surrounding the model

with the specified allowances. In the Expand box at section,
set the value of the Z- parameter direction to 5. This allowance
is used for the first clamping. Set the value of 2 for the rest of
the directions.
Click on the model. The face is highlighted, and the box
surrounding the model is displayed.

Click the Add box to CAD model button. The stock model box is added into the
CAM component of the CAM-Part assembly as a 3D Sketch feature.

Confirm the Stock dialog box with . The Milling Part Data dialog box is displayed.

92
 3. SolidCAM 2.5D Operations

5. Define the Coordinate System

Click the CoordSys button in the Define area to start the Coordinate System
definition.
The CoordSys dialog box is displayed.
In the Definition options list, choose the Define option.

This mode enables you to define the Coordinate System by

picking three points on the solid model. At first, you have
to define the Coordinate System origin location and then the
points for the X- and Y-directions.
Pick the origin point in the stock box corner as shown.

93
 Click on the stock model edge as shown to define the X-axis of the Coordinate
System.

Click on the stock model edge as shown to define the Y-axis of the Coordinate
System.

94
 3. SolidCAM 2.5D Operations

When a point is selected, the next button is automatically activated. If

you miss the selection, you can at any time select the button you want to
define and continue automatically to the next button.
Confirm the Coordinate System definition with . The model is rotated,
and the Coordinate System is displayed.
The CoordSys Data dialog box is displayed.

Define the Part Lower level directly on the solid model. This
parameter defines the lower surface level of the part to be
milled.
In the Levels: Planar section, click the Part Lower level
button.
Rotate the model and select the lower face that is milled using
the first positioning as shown.

The Z-coordinate of the face (-12) is displayed in the Pick

Part Lower level dialog box.

Confirm this dialog box by clicking .

Confirm the CoordSys Data dialog box by clicking .

95
 The icon of the defined Coordinate System is displayed in the CoordSys Manager
dialog box.
Confirm the CoordSys Manager dialog box with . The Milling Part Data dialog
box is displayed again.

6. Define the Target model

Click the Target button in the Stock & Target section of the Milling Part Data dialog
box.
The Target dialog box is displayed.
This dialog box enables you to define a 3D model for the
Target.

Click on the solid body to select a target model. The solid

body is highlighted.
Confirm the Target dialog box with .
The Milling Part Data dialog box is displayed.

7. Save the CAM-Part data

In the Milling Part Data dialog box, click .

The Milling Part Data dialog box is closed, and SolidCAM Manager is displayed. The
defined CAM-Part is saved.

At this stage, the definition of the CAM-Part is finished.

At the next stage, you have to define several operations to machine the cover part.
Using the first defined Coordinate System (first Setup), you have to perform the
following operations:

96
 3. SolidCAM 2.5D Operations

Upper face machining

Upper profile machining

Lower profile machining

Hole pads machining

Then the part has to be rotated and clamped again. With the second Setup, the
following operations are performed:

97
 Upper face machining

Pocket machining

Slot machining

Holes machining

8. Add a Face Milling operation

In SolidCAM Manager, right-click the Operations header and choose Face from the
Add Milling Operation submenu. The Face Milling operation is used for the upper
face machining.
The Face Milling Operation dialog box is displayed.

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 3. SolidCAM 2.5D Operations

9. Define the Face Milling geometry

Click in the Geometry page. The Face Milling Geometry

dialog box is displayed.
Using the default Model option, click the Define button and
pick on the solid model to select a face.
Confirm the 3D Geometry dialog box with .
In the Face Milling Geometry dialog box, define the 3 mm
offset to machine over the stock edges. In the Modify section,
set the Offset value to 3.
Confirm the Face Milling Geometry dialog box by clicking .
The geometry is defined for the operation.

10. Define the Tool

Define a new Face mill of Ø40 for this operation and edit the following parameters:
• Set the Shoulder length to 27.5
• Set the Cutting length to 10

99
 SolidCAM enables you to define a variety of tool holders to help you check and
prevent all possible collisions between the tool holding system and the workpiece.
This feature also enables you to see a more realistic simulation in the SolidVerify
simulation.

Select the Holder icon from the Library Toolbar. Double click the Holder icon
to display the available holders.

The SolidCAM tool holder is defined by combining two components.

The first component is the tool adaptor mounted on the spindle unit
of the milling machine. The second component can consist of
various types of extensions and reductions like collet chucks, arbors,
shanks and other components that you may have.

Tool adaptor

Extensions and reductions

SolidCAM enables you to define the Tool adaptor in the *.vmid file
under Machine Definition > Devices > Spindle > Stations.

100
 3. SolidCAM 2.5D Operations

Expand BT40 section and double click the BT40 ER32×60 collet chuck by clicking its
check box. This collet chuck is suitable for the chosen tool diameter (40 mm).

Choose the defined tool for the operation by clicking . The Face Milling
Operation dialog box is displayed.

11. Define the Face depth

Switch to the Levels page of the Face
Milling Operation dialog box. Click the
Face depth button in the Milling levels
area and select the model face as shown.

The Face depth (2) is calculated.

101
 12. Define the technological parameters
Switch to the Technology page of the
Face Milling Operation dialog box. In
the Technology section, use the Hatch
option.

Hatch Machining Technology

The machining is performed

in a linear pattern.

The Hatch page enables you to define the hatching parameters.

102
 3. SolidCAM 2.5D Operations

• Hatch angle

When the Automatic optional angle option is chosen, SolidCAM

automatically calculates the optimal angle of hatching to expedite
the machining. The tool path always follows the length of the face
no matter what angle the machined surface is facing.

The Delta from

parameter enables
you to change the
hatching angle. Delta angle

Optimal direction

When the User-defined angle option is chosen, you can determine

the angle of the tool path.

Angle

103
 • Cutting direction

The One Way option enables you to create the tool path with only
one-directional movements.
The Zigzag option enables you to create the tool path with
bidirectional movements.

One Way Zigzag

• Cutting order

The Side to side option creates a tool path that starts the cutting
on one side of the geometry, machines the face according to
the Cutting direction and then performs its last cutting pass on
the side opposite of the starting side. Selecting the Side to side
option unchecks and enables the Classic spacing option in the
Technology page.

The Side to middle option creates a tool path that starts the
cutting on one side of the face geometry and then moves to the
opposite side before making the next cut. Each successive series
of opposing parallel passes step inward until the last cutting pass
is performed in the middle.
• Extension

During face milling, the tool path is extended over the edges of
the machined face. The Extension section enables you to define
the extension both along the tool path (the Along section) and
across the tool path (the Across section).
The extension can be defined either by percentage of the tool
diameter (the % of tool diameter option) or by value (the Value
option).

Extension across
the tool path

Extension along
the tool path

104
 3. SolidCAM 2.5D Operations

• Corner

When the None option is chosen, the tool

path is formed with sharp corners between
one direction and the next.

The Fillet option connects each direction

with a given radius allowing for a smoother
transition between path directions.

• Approach

When the Roll in option is selected, the tool approaches the

material while rolling into it with an arc movement. The Approach
distance parameter enables you to define the length of the arc’s
linear extension.

Click the Hatch tab to define the machining parameters.

In the Hatch angle section, switch
to the Automatic optimal angle
option.
Switch back to the Technology tab.
Notice that in the Overlap section
the % of tool diameter option is
chosen and the value is set to 30,
and the Equal step over and
Classic spacing check boxes are
selected.

105
 Overlap

This section enables you to define the tool overlapping between two
successive passes. This option can be defined as Percentage of the
tool diameter or as a Value.

0.5D 0.2D
Overlap 0.5D Overlap 0.2D

Equal Step Over

This option enables you

to generate the hatch tool
path spaced evenly with the
automatically calculated Overlap
value, which is nearest to the
specified Min. Overlap value but
not smaller than this value.
Overlapping Overlapping
When this check box is not
selected, the distance between
the last pass and the one before it
can be smaller than that between
all of the other passes.
When this check box is selected,
the evenly spaced hatch tool
path is generated. The overlap
Overlapping Overlapping
between two successive passes
is not smaller than the specified
Min. Overlap value.

This option is available only for the Hatch strategy.

106
 3. SolidCAM 2.5D Operations

Define the roughing offset that remains on the floor of the face. This offset is left
unmachined during the rough face machining and removed during the face finishing.
In the Offsets section, set the Floor offset value to
0.2. Make sure that the Finish check box is selected to
perform finishing of the face in this operation. This
option enables you to remove the remaining offset
with the last cutting pass.

13. Define the Lead in and Lead out

Switch to the Link page of the Face Milling dialog box to define the way the tool
approaches the material and retreats away.
In the Lead in section, use the default Tangent option. This option enables the tool
to approach the material on a line tangent to the profile. In the Length field, set the
length of the tangent to 5.
In the Lead out section, select the Same as Lead in check box.

14. Save and Calculate

Click . The Face Milling operation data is saved, and the tool path is calculated.

15. Simulate
Click the Simulate button in the Face Milling Operation dialog box. The Simulation
control panel is displayed.
Switch to the SolidVerify page and start the simulation with .
Close the simulation with . The Face Milling Operation dialog box is displayed.

107
 Close this dialog box with .

16. Add a Profile operation

At this stage, you have to define a Profile
operation in order to machine the upper profile
of the cover.
In SolidCAM Manager, add a new Profile
operation.

17. Define the Geometry

Click in the Geometry page of the Profile Operation

dialog box. The Geometry Edit dialog box is displayed.
Click the Add button in the Multi-chain section.
The Chains Selection dialog box is displayed. This dialog
box enables you to pick a number of chains from the model
by selecting the model elements. SolidCAM automatically
creates chains from the selected elements.
Click on the top face of the model as shown.

108
 3. SolidCAM 2.5D Operations

The face is selected, and its boundary is highlighted.

Click to choose the selected chain as the geometry. The Geometry Edit dialog
box is displayed.
Confirm the geometry definition with . The geometry is defined for the
operation.

18. Define the Tool

Add a new End mill tool of Ø16 for the operation.

Select the BT40 ER32×60 collet chuck as the holder.

Confirm the tool selection by clicking .

19. Define the Profile depth

Switch to the Levels page. In the same manner as explained in previous steps, define
the Profile depth by clicking on the model face as shown below.

109
 20. Define the technological parameters
Switch to the Technology page. In the
Modify section, set the Tool side to
Right. Click the Geometry button to
check the tool position relative to the
geometry.
Close the Modify Geometry dialog box
with the .

Now you have to define the roughing and finishing parameters. SolidCAM Profile
operation enables you to perform the rough and finish machining in the single
operation.

Select the Rough check box. Set the Step down

value to 3.5. The profile is machined in two equal
Z-steps.

In the Offsets section, set the Wall offset and the

Floor offset to 0.2. These allowances are removed
during the finish machining.

Select the Clear offset check box. Set the

Offset value to 5 and the Step over value to 2.5.

Clear Offset

This option generates several concentric profiles with a constant

depth that start from the defined clear offset distance from the
profile and finish up to the geometry of the profile, thus clearing the
area around the profile.
The Offset defines the distance from the geometry at which the
milling starts. The Clear offset value should be equal to or larger than
the Wall offset value. The tool starts milling the profile at the distance
defined by the Clear offset and finishes at the distance defined by the
Wall offset; the overlap of the adjacent tool paths is defined by the
Step over parameter.

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 3. SolidCAM 2.5D Operations

The Step over parameter defines the overlap of adjacent tool paths.
It determines the offset between two successive concentric profiles.

Geometry

Wall offset

Clear offset
Step over

In the Finish section, set the Step down value to 7. The 0.2 mm allowances that
remain after the roughing will be removed
in one step.

21. Define the Lead in and Lead out

Switch to the Link page. In the
Lead in section, choose the
Tangent option. With this option,
the tool approaches the material
tangentially to the geometry in the
start point. Set the Length value
to 12.
In the Lead out section, select the Same as Lead in check box.

22. Save and Calculate

Click . The Profile operation data is saved, and the tool path is calculated.

23. Simulate
Click the Simulate button in the Profile Operation dialog box. The Simulation
control panel is displayed.

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 Switch to the SolidVerify page and start the simulation with .

The SolidVerify simulation mode enables you to measure distances

directly on solid bodies in the SolidVerify window. This feature
enables checking the linear dimensions of the part during simulation.

Click on the toolbar. The Measure Distance dialog

box is displayed.
Click on the top face of the cover and then on the
horizontal face machined in the current operation.

The coordinates of the pocket points and the result distance are displayed in the
Measure Distance dialog box.

SolidCAM displays the measured distance value and

Delta values for the X-, Y- and Z-axes. In this case, the
Delta Z parameter displays the depth of the machined
face relative to the cover top face (5).
Close the simulation with the . The Profile Operation
dialog box is displayed.
Close the Profile Operation dialog box with .

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 3. SolidCAM 2.5D Operations

24. Add a Profile operation

At this stage, you have to define a
Profile operation in order to machine
the lower profile of the cover.
In SolidCAM Manager, add a new
Profile operation.

25. Define the Geometry

Click in the Geometry page. The Geometry Edit dialog box is displayed.
Click on the workpiece edge as shown to define the first entity of the chain.

In the Chain section, choose the Constant Z Propagation option. The closed chain
is automatically selected.
The confirmation message is displayed.
Confirm it by clicking Yes.

Confirm the geometry with .

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 26. Define the Tool
In this operation, use the
same tool as in the previous
operation (Ø16 End mill).

27. Define the Profile depth

You have to define a new Upper level for the operation taking into account the
already machined faces. Switch to the Levels page and click the Upper level button
in the Milling levels area.
Define the Upper level by clicking on the model face as shown.

Confirm the definition of the Upper level with .

In the same manner as explained in the
previous steps, define the Profile depth by
clicking on the model vertex as shown.

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 3. SolidCAM 2.5D Operations

28. Define the technological parameters

Switch to the Technology page of the Profile Operation dialog box. In the Modify
section, click the Geometry button to adjust the tool position relative to the geometry.

Close the Modify Geometry dialog box with .

Now you have to define the parameters of profile roughing and finishing.
Select the Rough check box. Set the Step down value to
2.5. The profile is machined in two equal Z-steps.

In the Offsets section, set the Wall offset value to 0.5.

This allowance is removed during the finish machining.
Select the Finish check box and set the Step down
value to 5. The 0.5 mm allowance that remains after the
roughing is removed in one step.

29. Define the Lead in and Lead out

Switch to the Link page of the Profile
Operation dialog box. In the Lead in
section, use the default Arc option.
The tool approaches the material
tangentially to the geometry at the start
point. Set the Radius value to 12.
In the Lead out section, select the Same
as Lead in check box.

30. Save and Calculate

Click . The Profile operation data is saved, and the tool path is calculated.

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

32. Add a Profile operation

At this stage, you have to define a new Profile
operation to machine four hole pads.
In SolidCAM Manager, add a new Profile
operation.

33. Define the Geometry

In the Geometry page, click . The

Geometry Edit dialog box is
displayed.
Click on the model edge as shown.
Click on the next model edges as shown below
to complete the chain.

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 3. SolidCAM 2.5D Operations

In the Chain List section, click to confirm the chain selection.

In the same mannner, define the geometry for the rest of the pads. Make sure that
all the selected chains have the same direction. Confirm the geometry definition by
clicking .

34. Define the Tool

Define a new tool for the operation. Use an End mill of Ø8 with the BT40 ER32×60
tool holder.

35. Define the Milling levels

In this operation, the machining starts at the Z-level of the already machined faces.
The upper level has to be defined.

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 Define the Upper level by clicking on the already machined model face as shown.

In the same manner as explained earlier, define the Profile depth by clicking on the
pad face as shownn.

36. Define the technological parameters

Select the Rough check box. Set the Step down value to 3. The
profile is machined in one Z-step.
In the Offsets section, set the Wall offset value to 0.5. This
allowance is removed during the finish machining.
Select the Clear offset check box. Set the Offset value to 5 and
the Step over value to 4.5.
Select the Finish check box and set the Step down value to 3.
The 0.5 mm allowance remaining after the roughing will be
removed in one step.

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 3. SolidCAM 2.5D Operations

37. Define the Lead in and Lead out

Set the Arc option for Lead in. Set the
Radius value to 2. In the Lead out
section, select the Same as Lead in
check box. The tool leads in/leads out
to the profile with a tangential arc.

Save and Calculate

Click . The Profile operation data

is saved, and the tool path is calculated.

38. Simulate
Click the Simulate button in the Profile Operation dialog box. The Simulation
control panel is displayed.
Switch to the SolidVerify page and start
the simulation with
Close the simulation with . The
Profile Operation dialog box is
displayed.
Close the Profile Operation dialog box
with
At this point, the machining of the external cover
faces is finished. At the next stages you have to
machine the internal faces.

39. Define a New Coordinate System

The machining of the internal model faces
requires another positioning. The part has to
be rotated and clamped in a vice as shown.
SolidCAM enables you to define the second
Coordinate System.

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 Double-click the CoordSys Manager header in SolidCAM Manager. The CoordSys
Manager dialog box is displayed.

Click the Add button. The CoordSys dialog box is displayedd.

In the Mac CoordSys number field, set the value to 2. Changing
of the Mac CoordSys number means that a new clamping is
used.
Make sure that the default Select face mode is chosen.
When this mode is chosen, SolidCAM enables you to define
a new Coordinate System by selecting a planar face. In this
case, the Z-axis of the Coordinate System is normal to the
selected face.
The Coordinate System origin is placed according to the Place
CoordSys origin to setting. Make sure that the Top corner of
model box option is chosen.

Rotate the model and click on its bottom face as shown below.

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 3. SolidCAM 2.5D Operations

In this case, the box surrounding the model is calculated.

The upper plane of the model box is parallel to the XY-plane of the
defined CoordSys.
The CoordSys is located in the corner of the model box with the
following coordinates: (XMIN, YMIN, ZMAX).

Now you have to move the origin of the Coordinate System from the automatically
defined position to the corner of the workpiece.
Select the Pick origin check box in the Modify by pick section of the CoordSys
dialog box.
Click on the corner of the workpiece (stock model) as shown to choose it for the
origin. The origin is moved to the new location.

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 Confirm the CoordSys dialog box by clicking .

The CoordSys Data dialog box

is displayed.

SolidCAM automatically determines the Part Upper level and the Part Lower level
parameters relative to the Coordinate System location.
Confirm the dialog box with .

The CoordSys Manager dialog box is displayed.

Two Machine Coordinate Systems are listed in the CoordSys

Manager dialog box. Using them you can program operations
for different positions (clamping). The Machine Coordinate
System #2 is used for the machining of the back face and the
internal faces.
Click to confirm the CoordSys Manager dialog box.

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 3. SolidCAM 2.5D Operations

40. Add a new Face Milling operation

Add a new Face Milling operation to perform the back face milling.

41. Define the Geometry

Since this operation is performed with the second Coordinate
System position, choose the Machine Coordinate System #2.
Choose MAC 2 from the CoordSys list in the Geometry section.
Click to start the geometry definition. The Face Milling
Geometry dialog box is displayed.
In the Type section, use the default Model option for the Face Milling geometry
definition. Click the Define button. The 3D Geometry dialog box is displayed.
Click on the solid model to select it. The model is highlighted, and its icon appears
in the list. Confirm the 3D Geometry dialog box by clicking . The Face Milling
Geometry dialog box is displayed again.

The rectangle is generated surrounding the Target model at the XY-plane.

Define the 3 mm offset to extend the
machined surface over the stock edges.
In the Modify section, set the Offset
value to 3.

Click to confirm the Face Milling Geometry dialog box. The geometry is defined
for the operation.

42. Define the Tool

Use the Ø40 Face mill used in previous operations.

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 Click the Select button in the Tool page. Choose the Face mill tool that was defined
for the first face milling operation.
The Face Milling Operation dialog box is displayed.

43. Define the Milling levels

In this operation, the machining starts on the top face of the workpiece (Z=0 of the
Machine Coordinate System #2) and ends on the back face of the cover part (Z=-5
of the Machine Coordinate System #2).
Define the Upper level by clicking on the workpiece
corner as shown.
Define the Face depth directly on the solid model by
clicking on its bottom face as shown beloww.

Set the Step down to 2.5.

44. Define the technological parameters

Switch to the Technology page of the
Face Milling Operation dialog box. In the
Technology section, use the Hatch option
and click the Hatch tab.
In the Hatch angle section, switch to the Automatic optimal angle option.
Switch back to the Technology tab. Note that in the Overlap section the % of tool
diameter option is chosen, and the value is set to 30.

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 3. SolidCAM 2.5D Operations

Define the roughing offset that remains on the floor of the face. This offset is being
left unmachined during the rough face machining and is removed during the face
finishing.
In the Offsets section, set the Floor offset value
to 0.2. Select the Finish check box to perform
finishing of the face in this operation. This
check box enables you to remove the remaining
offset with the last cutting pass.

45. Define the Lead in and Lead out

Switch to the Link page of the
Face Milling Operation dialog
box to define the way the tool
approaches the material and
retreats away.
In the Lead in section, use the
Tangent option. This option
enables the tool to approach the material on a line tangent to the profile. In the
Length field, set the length of the tangent to 5.

In the Lead out section, select the Same as Lead in check box.

46. Save and Calculate

Click .
SolidCAM notifies you that the upper level chosen for the operation is above the
CoordSys Upper level.

Confirm this message with the Yes button. The operation data is saved, and the tool
path is calculated.

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 47. Simulate
Simulate the operation in the SolidVerify
mode.

The bottom face machining is finished. Now you have to perform the pocket
machining.

Pocket machining overview

The pocket is machined in several technological steps:

The rough machining of the
upper part of the pocket.
The machining is performed
until the Z-level of the pads is
reached.

The rough machining of the

pocket with islands (pads).
The machining is performed
from the upper face of the
pads till the pocket floor.
At this stage, two operations
are used to perform the
machining with two tools of
big and small diameter.
The finish machining of the
outside wall of the pocket.

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 3. SolidCAM 2.5D Operations

The finish machining of the

island walls.

The finish machining of the

island top face.

The finish machining of the

pocket floor.

48. Add a Pocket operation

Add a new Pocket operation to perform the rough machining of the upper part of
the pocket down to the pads height.

49. Define the Geometry

Choose the Machine Coordinate System #2 and define the geometry as shown
below using the Constant Z Propagation option.

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 50. Define the Tool
Choose the already defined Ø16 End mill for the pocket rough machining operation.

51. Define the Pocket depthh

Define the Pocket depth directly on
the solid model. Use the top face of
the pads for the definition.
SolidCAM uses the constant-Z passes
for the Pocket generation. The Step
down parameter enables you to
define the distance between each two
successive Z-levels.
Set the Step down value to 2. The pocket is machined in two Z-levels.

52. Define the technological parameters

Switch to the Technology page of the Pocket Operation dialog box. Make sure that
the default Contour option is chosen in the Technology section.
In the Offsets section, set the Wall offset and the Floor offset values to 0.2. These
offsets remain unmachined during roughing and are
removed with the further finishing.

53. Define the Ramping strategy

Switch to the Link page of the Pocket Operation
dialog box. In the Ramping section, choose the Helical
option.
Set the Radius of the descent helix to 3.

54. Define the Lead out

In the Lead out section, choose the Arc option and set the Radius value to 2.

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 3. SolidCAM 2.5D Operations

With a circular motion tangent to the last entity of the pocket contour,
the tool retreats from the profile. The radius of the arc must be
specified.

Radius

55. Save and Calculate

Click . The Pocket operation data is saved, and the tool path is calculated.

56. Simulate
Perform the simulation of the Pocket
operation in the SolidVerify mode.
During the simulation, notice
the helical lead in movement.

57. Add a new Pocket operation

Add a new Pocket operation to machine the bottom
part of the pocket including two islands (pads for
the circuit board installing).

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 58. Define the Geometry
Choose the Machine Coordinate System #2 for the operation.
In the same manner as explained in the Step #17 of this exercise, define the multi-
chain geometry by clicking on the
pocket bottom face as shown below.
SolidCAM automatically determines
the edges of the selected face and
defines chains on them. The first chain
is the external boundary of the pocket.
All closed chains inside the first chain
of each pocket are automatically treated
as pocket islands. Overlapping chains
are milled as separate pockets, not as
islands. To select multiple pockets with
islands, continue adding chains to the
geometry.

59. Define the Tool

Choose the Ø16 End mill for the operation.

60. Define the Milling levelss

The machining in this operation starts
at the Z-level of the top faces of the
pads and ends on the bottom face of
the pocket.
Define the Upper level by selecting the
top face of the pads as shown.
Define the Lower level by selecting the
bottom face of the pocket.

Set the Step down to 2.

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 3. SolidCAM 2.5D Operations

61. Define the technological parameters

Make sure that the default Contour option is chosen in the Technology section.
In the Offsets section of the Technology page,
set the Wall offset, Island offset and Floor offset
values to 0.2. These offsets remain unmachined
during roughing and are removed in the next
finishing operations.

Wall offset – the roughing offset

remaining on the wall of the pocket.

Island offset – the roughing offset

remaining on the pocket’s islands.

Floor offset – the roughing offset

remaining on the floor of the pocket.

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 62. Define the Ramping strategy

In the Ramping section of the Link page, choose the

Helical option. Set the Radius of the descent helix to
3.

63. Define the Lead out

In the Lead out section, choose the Arc

option. Set the Radius value to 2.

64. Save and Calculate

Click . The Pocket operation data

is saved, and the tool path is calculated.

65. Simulate

Perform the Pocket operation

simulation in the SolidVerify mode.

Make a note that the pocket geometry is not completely machined because the tool is too
large to reach some model areas. In order to complete the machining, you have to perform an
additional Pocket operation with a tool of a smaller diameter in the areas that were not machined
in the current Pocket operation.

66. Add a new Pocket operation

Add a new Pocket operation. SolidCAM enables
you to use the existing operations as templates
for new ones. In this case, the last created Pocket
operation is used to define a new Pocket operation
from the template. In the Operation name section, choose the last defined operation
name (P_contour4) from the list.
All the parameters of the chosen operation are copied to the current one.

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 3. SolidCAM 2.5D Operations

67. Define the Tool

Define a new tool for the operation.
Click the Select button in the Tool page.
Define a new End mill tool with the following parameters.

Select BT40 ER32x60 collet chuck as the holder.

Click to choose the defined tool.

68. Define the Rest material parameters

In the Rest Material/Chamfer section of
the Technology page, choose the Rest
option from the list.

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 During the machining, when a large tool is used, the tool leaves
material in areas that it cannot enter.
Unmachined area Machined area

Geometry

The Rest material option enables you to remove the material from
these areas without defining a new geometry.

The new Rest tab appears and opens the page automatically.
Notice that the Separate areas option is
chosen by default in the Milling type box.
When this option is chosen, SolidCAM
performs the machining only in areas that
were not machined with the previous tool.
Define the diameter of the end mill that was
used in the previous operation. Click the
Previous tool diameter button.

The TOOLKIT window is displayed with all the

tools used in the operations of the current CAM-Part. Choose the Ø16 End mill

used in the previous operation and click .

In the Previous wall offset field, set the value of 0.2. This offset was defined in the
previous Pocket operation.
Define the Extension/Overlap parameter – the overlap distance that you would like
to start from and end with the previous larger end mill. Set the Extension/Overlap
value to 1.

69. Save and Calculate

Click . The Pocket operation data is saved, and the tool path is calculated.

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 3. SolidCAM 2.5D Operations

70. Simulate
Play the simulation of the Pocket
operation in the SolidVerify mode.
Notice that the machining is performed
only in the areas that were not machined
in the previous operation.

At this stage, the rough machining of the pocket is

completed, and you have to program the finishing
operations.

71. Add a Profile operation

A Profile operation is used for the finish
machining of the pocket walls.

72. Define the Geometry

In the Geometry page, click to view the
geometries defined for the current Coordinate System.
The Browse Geometries dialog box is displayed with a
list of geometries defined for this CAM-Part associated
with the current Coordinate System. You can click
entries in the list to display the corresponding geometries on the model.
Choose the contour3 geometry from the list.

Confirm the Browse Geometries dialog box by clicking .

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 73. Define the Tool
Choose the already existing Ø6 End mill.

74. Define the Profile depth

Define the Profile depth by clicking on
the bottom face of the pocket.

75. Define the technological parameters

In this operation, use the Equal step down option to keep an equal distance between
all Z-levels.

Equal Step down Max.

Step down
This option enables you to perform
all cuts at an equal Z-level distance
one from the other. SolidCAM
automatically calculates the actual
step down to keep an equal distance
between all passes.
When the Equal step down check
box is selected, Step down is
replaced by Max step down. This
value is taken into account during Actual Step down
the calculation of the actual step
down so that it is not exceeded.

Select the Equal step down check box.

Select the Finish check box and set the Max step down
value to 3.

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 3. SolidCAM 2.5D Operations

In the Depth type area, choose the Helical option.

The Helical milling option enables you to enhance the productivity of

profile machining by avoiding lead in/out movements at each Z-level
and eliminating unnecessary rapid
movements.
With the Helical option, the tool
performs spiral movements around
the geometry with continuous
lowering along the Z-axis.
For each turn around the geometry,
the tool moves downward along
the Z-axis according to the step down value. When the Profile depth
is reached by the spiral movements, SolidCAM performs the last cut
with the constant-Z movement at the Profile depth.

Step Down

76. Define the Lead in and Lead out

Choose the Normal option in the Lead in
section of the Link page and set the Normal
length value to 5. In the Lead out section,
select the Same as Lead in check box. The tool approaches the material with the
movement normal to the pocket contour and retreats in the same way.

77. Save and Calculate

Click . The Profile operation data is saved, and the tool path is calculated.

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 78. Simulate
Play the simulation in the SolidVerify mode.

79. Add a Profile operation

Add a new Profile operation to machine the walls of the islands.

80. Define the Geometry

Choose the Machine Coordinate System #2 for the operation and click in the
Geometry page. The Geometry Edit dialog box is displayed.

Select the edge of the island as shown below.

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 3. SolidCAM 2.5D Operations

Make sure that the chain direction is clockwise. Such direction enables you to
perform the climb milling of the profile.

In the Chain section, choose the Constant Z Propagation option. The chain is
automatically completed.
The confirmation message is displayed. Confirm it by
clicking Yes. The first chain is defined.
Select the edge of the other island as shown below.

Make sure that the chain direction is clockwise. Such direction enables you to
perform the climb milling of the profile.
In the Chain section, choose the Constant Z Propagation option. The chain is
automatically completed and the confirmation message is displayed. Confirm it by
clicking the Yes button.

139
 The first selected entity in the geometry chain defines the approach
location for the whole chain. In this case, the internal edges of the
pads are chosen in order to prevent the collision between the tool
and pocket wall during the lead in movement.
Confirm the Geometry definition with .

81. Define the Tool

Choose the Ø6 End mill for the operation.

82. Define the Milling levelss

Define the operation Upper level
directly on the solid model by clicking
on the top face of the pad as shown.

Define the Profile depth by clicking on the bottom face of the pocket.

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 3. SolidCAM 2.5D Operations

83. Define the technological parameters

In the Technology page, make sure the Finish check box is selected and set the Step
down value to 4.

In the Depth type area, set the Helical option.

84. Define the Lead in and Lead out

Choose the Arc option in the Lead in section and set the Radius value to 2. In the
Lead out section, select the Same as Lead in check box. The tool approaches the
material with an arc movement tangential to the geometry and retreats in the same
way.

85. Save and Calculate

Click . The Profile operation data is saved, and the tool path is calculated.

86. Simulate
Play the simulation in the SolidVerify mode.

87. Add a Face Milling operation

Add a new Face Milling operation to machine
the top faces of the pads.

141
 88. Define the geometry
In the Geometry page, choose the Coordinate System #2 (MAC 2) and click to
define the geometry for this milling operation.
In the Face Milling Geometry dialog box, choose the Faces
option in the Type section and then click the Define button.
The Select Faces dialog box is displayed.

Click on the surfaces of both pads and confirm your selection by clicking .

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 3. SolidCAM 2.5D Operations

The Face Milling Geometry dialog box is displayed again. In order to machine these
two faces separately, click the Separate button in the Chain List section.
Two separate chains are created.

Confirm the geometry definition by clicking .

89. Define the tool

Choose Ø8 End mill for the operation.

90. Milling levels

Define the operation Upper level directly on the
solid model by clicking on the top face of the pad.
Define the Face depth value by clicking on the same
face.

91. Define the technological parameters

In the Technology page, choose the One Pass strategy from the list.

92. Save and Calculate

Click . The operation data is saved, and

tool path is calculated.

93. Simulate
Play the simulation in the SolidVerify mode.

143
At the next stage you have to machine the pocket floor.

94. Add a Pocket operation

Define a new Pocket operation to perform the finish machining of the pocket floor.

95. Define the geometry

Use the already defined geometry contour4.

96. Define the tool

Choose the Ø6 End mill for the operation.

97. Define the Milling levels

Define the operation Upper level directly on the bottom face of the pocket. Define
the Pocket depth value by clicking on the same face to perform the machining in a
single Z-level.

98. Define the technological parameters

Make sure that the default Contour strategy is chosen in the Technology page.
In the Offsets section, set the Wall offset and Island offset values to 0.1. Such offset
prevents the contact between the tool and the already finally machined wall and
island surfaces during the floor machining.

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 3. SolidCAM 2.5D Operations

99. Save and Calculate

Click . The Profile operation data is saved and the tool path is calculated.

100. Simulate
Play the simulation in the SolidVerify mode.

101. Add a Slot operation

Add a new Slot operation to machine the slot on the bottom face of the cover
model.

In SolidCAM Manager, right-click the Operations header and choose the Slot item
from the Add Milling Operation submenu.
The Slot Operation dialog box is displayed.

145
 102. Define the Geometry
Choose the Machine Coordinate System #2 for the operation and define the
geometry for the slot as shown.
Make sure that the chain direction is clockwise to perform the climb milling.

103. Define the Tool

Define a new Ø1.5 End mill.
Edit the following tool parameters:
• Set the Total tool length to 20
• Set the Outside holder length to 15
• Set the Shoulder length to 12
• Set the Cutting length to 10
Choose the BT40 ER16x70 collet chuck as the holder.

104. Define the technological parameters

In the Tool side area, choose the Right option to machine the slot at the right side
of the selected geometry.
In the Slot levels area, click the Depth button to define the slot depth directly on
the solid model.

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 3. SolidCAM 2.5D Operations

Click on the bottom face of the slot and confirm the definition with .
The Slot depth (1.5 mm) is determined.
Set the Step down value to 0.5.

105. Save and Calculate

Click . The Slot operation data is saved, and the tool path is calculated.

106. Simulate
Play the simulation in the SolidVerify
mode.

At the final stage of the cover part, you have to perform several operations to machine the holes
located on the bottom face and pads.

107. Define a Drilling operation

Define a new Drilling operation for the center drilling of the holes located on the
bottom face of the cover.

147
 108. Define the Geometry
In the Geometry page, choose the Machine Coordinate System #2 for the operation
and click to start the definition of drill positions.
The Drill Geometry Selection dialog box is displayed..
Choose the Multi-positions option in the Select
centers by section.

Click on the bottom model face as shown below.

All the circular edges located on the selected face are collected, and the drill positions
are determined. Confirm the geometry selection with .

109. Define the Tool

In the Tool page, click the Select button.
Define a new SPOT DRILL tool with the following parameters.

Select BT40 ER16x70 as the holder.

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 3. SolidCAM 2.5D Operations

Click to confirm the tool for operation.

110. Define the Drilling depth

In the Milling levels area, set the Drill depth to 0.

To perform center drilling, use the Depth type
option. In the Depth type section, choose the
Diameter value option and set the value to 5.5 mm.

The center drilling operation is performed until

the specified diameter is reached at the upper level
(the top face of the model). The upper diameter
of the center drilling cone is greater than the
drilled hole diameter; this means that the 0.25 mm
chamfer is performed at the hole edge.

111. Save and Calculate

Click . The Drilling operation data is saved, and the tool path is calculated.

112. Simulate
Play the simulation of the center drilling
in the SolidVerify mode.

113. Add a Drilling operation

In SolidCAM Manager, add a new Drilling operation to drill the holes center-drilled
at the previous stage.
Choose the same Drill geometry used in the previous operation.

149
 114. Define the Tool
Define a Ø5 Drill tool with following parameters for the operation.

Select BT40 ER 16x70 as the holder.

115. Define the Drilling depth

In the Levels page, define the Upper level by
clicking on the model upper face. Define the
Drill depth by clicking on the model face as
shown.
Set the Delta value to -1.
To perform through drilling, use the Depth type
option. In the Depth type section, choose the
Full diameter option. The drilling is performed
until the given diameter is reached at the specified Drill depth. This means that the
conical part of the tool exits from the material.

116. Save and Calculate

Click . The Drilling operation data is saved, and the tool path is calculated.

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 3. SolidCAM 2.5D Operations

117. Simulate
Play the simulation of the drilling in the
SolidVerify mode.

At the next stage, you have to perform a number of drilling operations (center drilling, drilling,
tapping) for eight holes located on the pads top faces.

118. Add a Drilling operation

Add a new Drilling operation to perform the center drilling of the pad holes.

119. Define the Geometry

In the same manner as explained in Step #108, define the geometry for the drilling.
Use the Machine Coordinate System #2 for the operation.

120. Define the Tool

Use the earlier defined Ø6 Spot Drill tool.

151
 121. Define the Drilling depth
In the Levels page, define the Upper
level by clicking on the top face of the
pad.
Set the Drill depth value to 1.

122. Save and Calculate

Click . The Drilling operation data is saved, and the tool path is calculated.

123. Add a Drilling operation

Add a new Drilling operation to perform the drilling of the pad holes.
In the Geometry area, choose the drill1 geometry defined in Step #119.

124. Define the Tool

Define a Ø1.6 Drill tool for the operation with following parameters. This tool
enables you to perform preliminary drilling for the M2 tapping. Select the holder as
BT40 ER 16x70.

125. Define the Milling levels

In the Levels page, define the Upper level in the same manner as explained in Step
#121.

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 3. SolidCAM 2.5D Operations

Define the Drill depth directly on the solid model. Pick the lower vertex of the hole
cone as shown to define the depth.

126. Define the Drill cycle type

Click the Drill cycle type button in the Technology page.

The Drill Cycles panel is displayed.
Choose the Peck type to perform the pecking canned
cycle.
Click the Data button to define the pecking parameters.
The Drill options dialog box is displayed. Set
the Step down value for pecking to 0.5.
Confirm the dialog box with OK.

127. Save and Calculate

Click . The operation data is saved, and the tool path is calculated.

153
 128. Add a Drilling operation
Add a new Drilling operation to perform the tapping of the pads holes.
In the Geometry area, choose the drill1 geometry defined in Step #119.
Add a new Ø2 Tap tool for the operation. Select the holder as BT40 ER 16x70.

Tap Tool

This tool is intended for the machining of internal threads in Drilling

operations.
The tool consists of two parts: cylindrical and conical, and is defined
by the following major parameters presented on the illustration.

Arbor Diameter

Total
Length
Outside
Holder
Length Chamfer Cutting
Length Length

Tip Diameter
Diameter

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 3. SolidCAM 2.5D Operations

When the Tap tool is used in the operation, the

Tapping drill cycle is chosen automatically.

129. Define the Drilling depth

In the Levels page, define the Upper level in the same manner as explained in Step
#121.

Set the Drill depth to 4.

130. Save and Calculate

Click . The Drilling operation data is saved, and the tool path is calculated.

Simulate

Click . The Simulation control

panel is displayed.
SolidCAM enables you to simulate
several operations together. Holding
the Shift key, select the last three
operations in SolidCAM Manager
(center drilling, drilling and tapping of
the pad holes) and play the simulation.

At this stage, programming of the machining operations is completed. Now you have to generate
the GCode to send it to the CNC-machine controller.

155
 131. Generate the GCode
SolidCAM enables you to generate the GCode for several operations or for the
complete CAM-Part.
Right-click the Operations header in SolidCAM Manager and choose the Generate
command from the GCode All submenu.

Alternatively, you can choose GCode icon from the SolidCAM Operations toolbar.

The GCode is generated for the complete CAM-Part. The generated GCode is
displayed in the Notepad window.

At this stage, the exercise is completed.

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 3. SolidCAM 2.5D Operations

Exercise #4: Bracket Machining

Define the CAM-Part and operations for the machining of

the bracket presented on the illustration on a Milling CNC-
machine.
This exercise reinforces the following skills:
• CAM-Part definition
• Face milling
• Pocket machining
• Profile machining
• Drilling
The SOLIDWORKS model of the Bracket (Exercise4.sldprt) is located in the Exercises folder.
The following steps have to be implemented in order to reach the final CAM-Part:

1. Define the CAM-Part

At this stage, you have to define the CAM-Part, CNC-controller, Machine Coordinate
System, the Stock and Target models.
The AWEA1000-Fanuc CNC-controller has to be chosen for this exercise.

2. Machine the top face

Define a Face Milling operation to machine the top
face of the bracket.

3. Machine the side faces

Perform the Profile rough and finish machining of
the bracket side faces.

157
 4. Machine the open pockets
Define a Profile operation to perform the
machining of the open areas as shown.

5. Machine the pocket

Define a Pocket operation to perform rough and
finish machining of the pocket located on the top
face of the bracket.

6. Pre-machine the cylindrical hole

Define two Drilling operations to perform the
center drilling and preliminary drilling for the
further pocket operation.

7. Machine the cylindrical hole

Perform two Pocket operations to machine the
faces of the through hole.
Use the pre-drilled hole to perform the safe lead in
movement of the tool into the material.

8. Machine the holes

Perform center drilling and drilling of the holes.

9. Machine the bottom face

Define a Face Milling operation to machine the
bottom face of the bracket.
This operation requires different clamping, so
define and use a new Coordinate System with the
Z-axis oriented normally to the bottom face.

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 3. SolidCAM 2.5D Operations

Exercise #5: Electronic Box Machining

Define the CAM-Part and operations for

machining of the electronic box presented
on the illustration on Milling CNC-
machine.
This exercise reinforces the following skills:
• CAM-Part definition
• Face milling
• Pocket machining
• Profile machining
• Rest material machining
• Drilling
The SOLIDWORKS model of the Electronic Box (Exercise5.sldprt) is located in the Exercises
folder.
The following steps have to be implemented in order to reach the final CAM-Part:

1. Define the CAM-Part

At this stage, you have to define the CAM-Part, CNC-controller (AWEA1000-Fanuc),
Machine Coordinate System, the Stock and Target models.

2. Machine the top face

Define a Face Milling operation to machine the top face of the electronic box part
with the Hatch strategy.

159
 3. Machine the side faces
Define two Profile operations to perform rough machining of the external faces.

4. Machine the pocket

Define two Pocket operations to perform rough machining of the internal pocket
faces with a tool of large diameter.

5. Perform the pocket finish machining

Define a number of Pocket operations to perform finish machining of the internal
pocket faces. Choose the Tool according to the minimal radius of the model fillets.

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 3. SolidCAM 2.5D Operations

During the wall finish machining, use the Rest Material strategy to remove the bulk
of material in the corners.

6. Perform finish machining of the external faces

At the first stage, perform the rest material machining of the corner faces to remove
the bulk of the material.

Define a number of Profile operations to machine the external faces.

161
 7. Machine the holes
Define a number of Drilling operations
to perform the center drilling, drilling,
and tapping of the holes. Use a Pocket
operation for counterboring of the
holes.

8. Machine the bottom face

Define a Face Milling operation to
machine the bottom face of the
electronic box part using the Hatch
strategy.
This operation requires different
clamping, so define and use a new
Coordinate System with the Z-axis
oriented normally to the bottom face.

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 3. SolidCAM 2.5D Operations

Exercise #6: Clamp Machining

Define the CAM-Part and operations for the machining of the clamp part presented on the
illustration on a Milling CNC-machine.

This exercise reinforces the following skills:

• CAM-Part definition
• Multi-sided machining using 2.5-axis CNC-machine
• Profile machining
• Open pocket machining
• Drilling
The SOLIDWORKS model of the Clamp (Exercise6.sldprt) is
located in the Exercises folder.
The following steps have to be implemented in order to obtain the
final CAM-Part:

1. Define the CAM-Part

At this stage you have to define the CAM-Part, CNC-controller (AWEA1000-Fanuc),
Machine Coordinate System, the Stock and Target models.
Make a note that the workpiece used for this part is the box exactly surrounding the
clamp model without an offset.

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 2. Holes machining
Perform a number of Drilling operations to
machine the holes.
Use the appropriate Machine Coordinate
System defined for the positioning shown
below.

3. Open pocket machining

Add a Machine Coordinate System for the
positioning shown below to machine the open
pocket.

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 3. SolidCAM 2.5D Operations

Add a new Pocket operation. In this operation, the open pocket machining strategy
will be used.
Select the open pocket geometry chain as shown.

Click to confirm the selected chain. The Close Chain dialog box is displayed.

Close Chain dialog box

This dialog box is displayed when you confirm an open chain

definition in the Geometry Edit dialog box.
When you confirm this dialog box with the Yes button, the chain is
closed with a line that connects the start and the end points of the
chain. The Mark line as open edge check box enables you to mark
the connecting line as open edge to perform open pocket machining.
When you click the No button, SolidCAM returns to the geometry
definition and enables you to close the chain manually by the model
element selection.

165
 Select the Mark line as open edge check box and confirm the dialog box with OK.
The open edge is marked.
Confirm the Geometry Edit dialog box by
clicking .
Choose the Ø6 End mill for the operation.
Select the upper face of the model as the Upper
level and the pocket floor as the Pocket depth.

In the Technology page, choose the

Contour machining strategy. Switch
to the Open pocket tab to define
the parameters of the open pocket
machining. The open pocket extension
can also be user-defined as tangent
angle from the wall. Define the
extension of the tool path beyond the
open edge.

Select the Use profile strategy check box.

Use Profile Strategy

This option enables you to perform

the open pocket machining in a
Profile manner. The tool path at a
specific Z-level consists of several
equidistant profiles starting from
outside the model at the distance
defined by the Extension parameter.
The tool moves on offsets parallel to
the pocket geometry.
The following options enable you to define the tool path direction
and linking:

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 3. SolidCAM 2.5D Operations

• When the One way option is chosen, the tool finishes one profile
pass, then rapidly moves (G0) to
the safety distance and then to the
start of the next cutting pass. The
cutting direction (either climb or
conventional) is preserved for
each cutting pass.

• When the Zigzag option is chosen,

the tool finishes one profile pass
and then moves directly to the next
pass. The machining is performed
without leaving the material, thus
constantly switching between
climb and conventional milling.

Use the default One way option.

Select the Approach from outside check box.

Approach from outside

This option enables the tool

to approach from outside
of the material in the open
pocket areas, if possible.
Such approach enables
you to decrease the tool
loading when plunging into
the material. This option
enables you to perform the
approach movement from
the automatically calculated
point outside of the material. The tool moves to the required depth
outside of the material and then plunges into the material.

Switch back to the Technology tab. In the Offsets section, set the Wall offset and the
Floor offset to 0.2. To remove these offsets with the finishing cut, select the Wall and
Floor check boxes in the Finish section.

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 4. Hole machining
Define two Drilling operations to perform
center drilling and drilling of the hole located
at the bottom of the open pocket. Use the
same Machine Coordinate System (positioning)
as in the previous operation.

5. Step machining
Define a Profile operation to machine the step.
Define the Machine Coordinate System for the
positioning shown below.

Use the Point to point option in the Geometry Edit dialog box to define the geometry.

Point to Point mode

This option enables you to connect the specified points. The points are
connected by
a straight line.
This option is
useful when it
is impossible
to define the
geometry using
the model
edges.

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 3. SolidCAM 2.5D Operations

In this exercise, it is impossible to define the straight geometry for

the Profile Milling using the model edges. The Point to point option
enables you to define the geometry by two points located on the
model vertices.

Use the Zigzag method for Depth cutting type to connect the successive Z-level
passes directly from the end of a pass to the beginning of the next pass.

Depth cutting type

When the One way option is chosen,

the cutting passes are oriented in the
same direction, and the connection
between them is performed through
the Operation Clearance level. At the
end of each pass the tool performs
a retreat movement to the Operation
Clearance level, a horizontal
movement at rapid feed to the start
point of the next pass and then
descends to the Z-level of the next pass. The same cutting direction
(climb or conventional) is kept along the whole tool path.
When the Zigzag option is chosen, the tool path is performed in a
zigzag manner, with the tool path
direction changing from one pass to
the next. The passes located at two
successive Z-levels are connected
directly from the end of one pass to
the beginning of the next pass.

The Zigzag option cannot be used together with the

Clear offset technology.

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Exercise #7: Basic Part Machining

Define the CAM-Part and operations for the machining

of the basic part presented on the illustration on a Milling
CNC-machine.
This exercise reinforces the following skills:
• CAM-Part definition
• Pocket machining
• Profile machining
• Rest material machining
• Face milling
• Drilling
The SOLIDWORKS model of the Basic part (Exercise7.
sldprt) is located in the Exercises folder.

The following steps have to be implemented in order to

reach the final CAM-Part:

1. Define the CAM-Part

At this stage, you have to define the CAM-Part, CNC-controller (AWEA1000-Fanuc),
Machine Coordinate System, the Stock and Target models.

2. Upper cusp machining

Define two Profile operations to remove the bulk of material and perform the
rough and the finish machining of the cusp.

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 3. SolidCAM 2.5D Operations

3. Step machining
Perform the rough and finish machining of the
step faces using the Profile operation.

4. External contour machining

Define a Profile operation to perform the
rough and finish machining of the external
model faces.

5. Connector opening machining

Define a Pocket operation to perform the
rough machining of the connector opening
faces.

6. Connector pocket machining

Define a number of Pocket and Profile
operations to perform the roughing and
finishing of the connector pocket.

171
 7. Connector opening finish machining
Use the Pocket rest material strategy to perform
the finish machining of the connector opening
faces.

8. Machine screw head areas

Define a Profile operation to perform the
rough and finish machining of the screw head
areas.

9. Top face machining

Use the Face milling Hatch strategy to perform
the rough and finish machining of the top face.

10. Bottom face machining

Use the Face milling Hatch strategy to perform
the rough and finish machining of the bottom
face of the Cover part.
Note that this operation and the following ones
use a new positioning and therefore you have
to define a new Machine Coordinate System.

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 3. SolidCAM 2.5D Operations

11. Pocket rough machining

Use a Pocket operation to perform the rough machining of the highlighted faces.

12. Wall finish machining

Define two Profile operations to perform
the finish machining of the wall faces of the
pockets.

13. Bottom pocket machining

Perform the rough and finish machining of the
bottom pocket with the island.

14. Hole machining

Define a number of Drilling operations to
machine holes located on the cover part faces.

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Exercise #8: Cover Machining

Machine the hole and chamfer on the pre-machined cover

part presented on the illustration on a Milling CNC-machine.
This exercise reinforces the following skills:
• 3D contour machining

The part file (Exercise8.prz) is located in the Exercises

folder. This file contains the defined CAM-Part. The model
used for the part definition contains two configurations:
Default (model with the hole and chamfer features) and Stock (hole and chamfer features
suppressed).

Default Stock

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

1. Open the CAM-Part

Open the Exercise8.prz file located in the Exercises folder.

2. Add a Contour 3D operation

Add a new Contour 3D operation to perform machining of the hole on the upper
face of the part.
The Contour 3D Operation dialog box is displayed.

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 3. SolidCAM 2.5D Operations

A through hole located on a convex surface can be machined in

several methods, such as Profile machining and Contour 3D
machining. Profile milling used for machining of such holes results in
a great number of tool path passes with unavoidable air cutting,
because it yields a planar tool path parallel to the XY-plane. Contour
3D machining enables you to generate a curved tool path in three-
dimensional space. Therefore, in this exercise the Contour 3D
operation is used for hole machining to optimize the tool path and
avoid redundant tool movements.

Profile Machining

Profile 3D Machining

3. Define the Geometryy

Define the geometry chain on
the upper edge of the hole as
shown.

175
 4. Define the Tool
Add a new Ø10 End mill tool for the operation.

5. Define the technological parameters

In the Modify section, click the
Geometry button to check the position
of the tool relative to the geometry.
In this case, the default Left option set
for Tool side meets the requirements of
the climb milling. Close the Modify
Geometry dialog box by clicking .

In the Offsets section, set the Wall offset value to 0.2. The allowance of 0.2 mm will
be left on the hole wall during the roughing. This allowance will be removed with
a separate finishing cut in the end of the machining.
Select the Rough check box. Set the Step down to 2. The hole will be machined in
three equidistant rough passes.
Select the Finish check box. Set the Step down to 6. The finishing will be performed
in a single pass.

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 3. SolidCAM 2.5D Operations

6. Define the Lead in and Lead out

For Lead in, choose the Arc option and use the default Radius value of 2. For Lead
out, select the Same as Lead in check box.

7. Simulate the operation

Perform the simulation of the operation in the SolidVerify mode.

8. Add a Contour 3D operation

Add a new Contour 3D operation to perform chamfering of the upper face of the
cover.

9. Define the Geometry

Define the geometry chain on the upper edge of the face as shown.

177
 10. Define the Tool
Add a new Ø10 Spot drill tool for the operation.

11. Define the Milling levels

In the Levels page, set Depth to 0.

12. Define the technological parameters

In the Modify section of the Technology page, set the Tool side to Right. Click the
Geometry button to check the tool position relative to the geometry.

Close the Modify Geometry dialog box by clicking .

Select the Rough check box. Set the Step down to 0.
In the Chamfer section, select the check box and switch to the Chamfer tab.

178
 3. SolidCAM 2.5D Operations

Set the Cutting diameter value to 2.

Cutting Profile depth

Diameter (Chamfer depth)

13. Define the Lead in and Lead out

For Lead in, choose the Arc option and use the default Radius value of 2. For Lead
out, select the Same as Lead in check box.

14. Simulate the operation

Perform the simulation of the operation in the SolidVerify mode.

179
Exercise #9: Mounting Base Machining

Define the CAM-Part and operations for the machining of

the mounting base presented on the illustration on a Milling
CNC-machine.
This exercise reinforces the following skills:
• CAM-Part definition
• Pocket machining
• Drafted profile machining
• T-slot milling
• Drilling

The SOLIDWORKS model of the Mounting base

(Exercise9.sldprt) is located in the Exercises folder.
The following steps have to be implemented in order to obtain the final CAM-Part:

1. Define the CAM-Part

At this stage, you have to define the CAM-Part, CNC-controller (Awea1000-Fanuc),
Machine Coordinate System, the Stock and Target models.

2. Contour machining
Define a Profile operation to machine the mounting
base external faces.

3. Top face machining

Define a Face Milling operation to machine
the top face of the mounting base.

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 3. SolidCAM 2.5D Operations

4. Pocket machining
Define a Pocket operation to perform rough
and finish machining of the pocket faces.

Use the lower edges of the islands

for the internal chains definition,
because the walls are drafted.
Use a Bull nose tool of Ø8 with Corner radius
of 0.2 mm for machining of the pocket.

5. Profile machining for islands

Define a Profile operation for two draft angled walls of the islands. Use the Bull
nose tool of Ø8 already defined in Step #4.

Define the geometry as shown.

Select the Finish option in the
Technology page and set the Step down
value to 0.1.

Switch to the Advanced tab and click the Wall draft angle button.

181
 Wall Draft Angle

When this check box is selected, the inclined wall machining is

performed.

• External wall angle

This parameter defines the draft angle of the wall measured from
the Z-axis direction as shown.
For the inclined wall machining, each cutting pass located at a
specific Z-level is generated according to the specified External
wall angle value.

• External corner type

This option enables you to define how the cutting passes are
connected during the external corners machining. There are three
ways to connect between the cutting passes:

182
 3. SolidCAM 2.5D Operations

Sharp corner: the tool path is calculated to perform the machining

of a sharp corner. This option affects only the machining of
geometry sharp corners.

Conical fillet: the tool path is calculated to perform the machining

of the corner with a conical fillet; the radius of the tool path
rounding increases from one pass to the next. This option affects
only the machining of sharp geometry corners.

this option affects the machining of both of

Cylindrical fillet:
sharp and filleted corners of the geometry. The machining of
sharp corners is performed similar to the Conical fillet option. For
the filleted corners, the tool path is calculated to perform the
machining of the corner with a cylindrical fillet; the radius of the
tool path rounding is the same for all the cutting passes.

In the new dialog box, check the Wall draft angle option.

183
 Set the External wall angle to 8.
In the Cut from area, select the Bottom to top
option.

6. T-Slot machining
In SolidCAM Manager, right-
click the Operations header and
choose T-Slot Operation from
the Add Milling Operation
submenu.
The T-Slot Operation dialog box
is displayed.
Define two geometry chains as shown. Make sure the direction of the chains
geometry is the same as on the illustration.

Add a new Slot mill tool.

Slot Mill

This type of tool can be used for all types of machining from simple
2.5D undercuts up to 5-axis simultaneous machining.

184
 3. SolidCAM 2.5D Operations

A tool of this type is defined with the parameters shown in the image.

Arbor
Diameter

Total
Length Outside
Holder

Cutting
Corner Radius Length
Diameter

Edit the tool parameters as follows:

• Set Diameter to 36
• Set Corner radius to 0
• Set Cutting length to 3
Add the BT40 ER32x80 tool holder.
Confirm the tool definition by

clicking .
In the Tool page, click the Data tab.
Select the Offsets option and the Top tool offset
number check box.

The Length offset number defines the length offset register of the
current tool in the Offset table of the CNC-machine.
The Top tool offset number defines the register number of the upper
cutting edge of the T-slot mill. This option enables SolidCAM to
automatically take into account the minor size differences between
the defined tool and the one actually used for cutting the workpiece,
if there are any.

185
 7. Define the Milling levels
Define the Ceiling (Upper level) for slot
machining by clicking on the model
face as shown.
Confirm the value (-4.5) in the Pick
Upper level dialog box.

Define the Depth of the T-slot by

clicking on the model as shown.

The depth value calculated in the Depth area is 6.

8. Define the technological parameters

Define the rough parameters in the Technology page. To perform roughing of the
slot, select the Rough check box.
To perform the rough machining of the slot, you have to specify offsets on the slot
geometry. These offsets are removed with the finishing cut.

The Wall offset option defines the offset that remains on the slot wall
after roughing.

Wall Offset

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 3. SolidCAM 2.5D Operations

The Ceiling offset option defines the offset that remains on the slot
ceiling after roughing.

Ceiling
Offset

The Floor offset option defines the offset that remains on the slot
floor after roughing.

Floor
Offset

Set all of the offsets to 0.2

Define the finishing parameters.

Select the Finish check box. Notice that the Ceiling, Wall
and Floor check boxes are selected by default. These
check boxes define the offsets (Ceiling, Wall and Floor,
respectively) to be removed with the finishing pass. Set
the Cutting depth overlap value for finishing to 2.

187
 Cutting depth overlap

This parameter defines the overlap of each two adjacent tool paths in
both rough and finish machining of the slot.

Cutting depth
overlap Cutting depth
overlap

9. Define the Lead in and Lead out

For Lead in, select the Tangent option and set the Tangent extension to 12. For Lead
out, select the Same as Lead in check box.

10. Simulate the operation

Perform the simulation of the operation
in the SolidVerify mode.

11. Holes machining

Define several Drilling operations to perform the machining of the countersink
holes located on the top face of the mounting plate.

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 3. SolidCAM 2.5D Operations

Exercise #10: Support Machining

Machine the threads on the pre-machined support

part presented on the illustration on a Milling CNC-
machine.
This exercise reinforces the following skills:
• Threading
• Creating shaped tools

The part file (Exercise10.prz) is located in the

Exercises folder. This file contains the defined CAM-Part.

The following steps have to be implemented in order to perform the internal and external
threading:

1. Open the CAM-Part

Open the Exercise10.prz file located in the Exercises folder.

2. Add a Thread Milling Operation

Add a new Thread Milling operation to perform threading of the internal surface
of the part.
The Thread Milling Operation dialog box is displayed.

3. Define the Geometry

Define the geometry by clicking on the internal
surface of the part.
The tread milling position is selected, and its
coordinates are displayed in the Drill Geometry
Selection dialog box.

189
 4. Define the Tool
Switch to the Tool page of the Thread Milling Operation dialog box and click the
Select button.

The available tools are displayed in the TOOLKIT.

Choose the Thread Mill tool for the operation.

Thread Mill

This tool type is used for threading in Thread Milling operations. A

tool of this type is defined with the parameters shown in the image.
Arbor
Diameter

Outside
Holder Total
Length Length

Shoulder
Length

Thread
Cutting
Cutting Diameter Length

In the Tool Parameters

section, select the Metric
(ISO) option from the list.

The Threading Type: Metric (ISO) dialog box is displayed.

190
 3. SolidCAM 2.5D Operations

Select the M64 x 4.0 standard from the list and click OK.

Define the tool parameters as shown in the image.

Click to select the tool for the

operation.

The tool is displayed in the illustration area. This picture is generic; it does not
reflect the specified parameters.

191
 You can edit its appearance by adding a shaped tool to the Tool Library.
Click the Select button.

5. Add a Shaped tool

In the Shape Type list, select Sketch (2D).
The editing box for shaped tools is
displayed.

You can see in the above image that three cylinders are already defined by default.
You must add some cone shapes below cylinder 1.
Right click Cylinder 1 > Add shape below
and select the cone shape as shown in the
image.
The Cons1 page is added.

192
 3. SolidCAM 2.5D Operations

Edit the cone dimensions as follows:

• Select Top diameter and click the small box
that highlights

• Click Edit.

• Set the Top diameter

to 20 and click OK.
• Choose the Auto-
calculate option
for the Bottom
diameter

• Set the Height value

to 2 in the same manner you edited the top diameter value.
• Set the Angle to 120 in the same manner you edited the top diameter value.
The Bottom diameter is calculated automatically
and set to 13.0718.
Right-click Cons1 > Add shape above and
select the same cone shape you used for adding
the first cone. Edit its dimensions as follows:
• Choose the Auto-calculate option for the Top diameter
• Set the Bottom diameter to 20
• Set the Height value to 2
• Set the Angle to -120
Repeat these steps six more times until you have defined total eight cones. For cone
3, 5, and 7 use the same parameters as were defined for cone 1. for cone 4, 6,and 8
use the parameters that were defined for cone 2.
In the same manner as described above, edit the values of Cylinder1 and Cylinder2
with the following parameters:

193
 • For Cylinder1, set the Diameter to 12 and the Height to 50
• For Cylinder2, set the Diameter to 16
and the Height to 30
• Right click Cylinder3 and delete it as it
is not required
The final tool shape is as shown on the picture.

Confirm the new shaped tool by clicking

The new tool shape is now displayed in the tool picture section and visible during
simulation.

6. Define the Milling levels

Define the operation Upper level directly on the
solid model by clicking on the top of the part.
Define the Thread depth by clicking on the
bottom face of the part.
In the Depth definition area, set the Delta value to -4.

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 3. SolidCAM 2.5D Operations

7. Define the technological parameters

In the Technology page, make sure the default Internal type is chosen in the Thread
Data area. Set the Major thread diameter value to 64. In the Cut from section, select
Top to bottom. When the Compensation check box is selected, the tool radius
compensation options G4x of the CNC-controller are used in the GCode.

8. Define the Lead in

Switch to the Link page. Under Lead in/out arc, clear the Start from the center check
box.

Start from the center

This option enables you to start

threading from the center of the
geometry. When this option is cleared,
the tool starts machining from a safety
distance, which allows to avoid air
cutting and save machining time.

Set other parameters as shown in the image.

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 9. Simulate the operation
Perform the simulation of the
operation in the Host CAD mode.
Set the CAM-Part in the Top view to
observe that the tool approaches the
material not in the center.
Perform the simulation of the
operation in the SolidVerify mode.

10. Add a Thread Milling Operation

Add a new Thread Milling operation to perform small internal threads.

11. Define the Geometry

Define the geometry by clicking on the upper
surface of the model containing the holes.

12. Define the Tool

Define a new Thread mill selecting the M14x1.5
standard from the Metric (ISO) table.

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 3. SolidCAM 2.5D Operations

13. Define the Milling levelss

Define the operation Upper level directly on the solid model by clicking on the small
pocket surface as shown.

Define the Thread depth by clicking on the model bottom face.

14. Define the technological parameters

In the Technology page, make sure the default Internal type is chosen in the Thread
data area. Set the Major thread diameter value to 14. In the Cut from section, select
Top to bottom.

15. Define the Lead in

Switch to the Link page. Under Lead in/out arc, make sure that the Start from the
center check box is selected.

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 Set the other parameters as shown in the image.

16. Simulate the operation

Perform the simulation of the operation in the SolidVerify mode.

17. Add a Thread Milling operation

Add a new Thread Milling operation to perform threading of the external surface
of the part.

18. Define the Geometry

Use the drill geometry defined in the first operation.

19. Define the Tool

Define a new Thread mill.
In the Tool parameters area, select User and set 4 as the value.

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 3. SolidCAM 2.5D Operations

• Set the Cutting diameter to 20

• Set the Number of teeth to 4
• Set the Arbor diameter to 16
• Set the Total length, Outside holder, and Shoulder length to 86
• Set the Thread cutting length to 16
Add a new shaped tool with a shorter shaft, defining the Cylinder1 height as 40 mm.

20. Define the Milling levels

Define the operation Upper level directly on the solid model by clicking on the top
face of the part as shown.
Define the Thread depth by clicking on the
model surface as shown.

21. Define the technological parameters

In the Technology page,
choose the External type in
the Thread data area. Set the
Nominal value to 86.

In the Cut from area, choose

the Top to bottom option.

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 22. Define the Lead in
Switch to the Link page. Set the
parameters as shown in the image.
Under Lead in/out arc, set the Arc
radius value to 2.

23. Save and Calculate

Click . The Threading operation

data is saved, and the tool path is
calculated.

24. Simulate the operation

Perform the simulation of the operation
in the SolidVerify mode.

At this stage, the exercise is completed.

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 3. SolidCAM 2.5D Operations

Exercise #11: Engraving

This exercise demonstrates the use of engraving with the

text carved on the solid model or typed in using a computer
keyboard.
This exercise reinforces the following skill:
• Engraving
The part file (Exercise11.prz) is located in the Exercises
folder. This file contains the defined CAM-Part.
The following steps have to be implemented in order to
perform text engraving:

1. Open the CAM-Part

Open the Exercise11.prz file located in the Exercises folder.

2. Add an Engraving Operation

Add a new Engraving operation to perform machining of the inscription on the
upper face of the part.
The Engraving Operation dialog box is displayed. Make sure that the default 2D
Engraving technology is selected.

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 3. Define the Geometry
The geometry for this operation is a set of closed chains comprising the letters.
Click in the Geometry page. In the Geometry Edit dialog box, ensure that 104
is selected from the Configurations list. Click the Add button in the Multi-chain
section. The Chains Selection dialog box is displayed.
In the Type section, choose the Faces option. All
chains found on the selected face will be added to
the geometry. To exclude from the geometry the
external chain formed by the face edges, apply a filter.
Choose the Loops filter option, and it will expand the
entire section. Clear the check box near the External
loops option. Now only letters will be included in the
geometry.
Click on the face that contains the letter. The face is
highlighted.
Click to choose the selected chains as the
geometry. The Geometry Edit dialog box is displayed.
Zoom in the selected face. Some letters consist of
two chains, internal and external, and the internal
chains are not selected automatically.

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 3. SolidCAM 2.5D Operations

In the Geometry Edit dialog box, select the Constant Z Propagation option from the
Chain section. Click on the internal chain of the letter “o”.
Accept closing the open chain. The internal chain is added
to the geometry.
Select again the Constant Z Propagation option from the
Chain section. Click on the internal chain of the letter “d”.
Accept closing the open chain. Repeat the same steps with
all letters that include internal chains: “o,” “d,” “A,” “D,”
and “R.”
Confirm the geometry definition with .

4. Define the Tool

Switch to the Tool page of the Engraving Operation dialog box and click the Select
button.
Choose the Engraving tool for the operation.

Engraving tool

This tool type is used for engraving. A tool of this type is defined
with the parameters shown in the image.

Arbor Diameter

Total
Length
Diameter Outside
Holder
Shoulder Length
Length

Cutting
Length Angle

Tip Diameter Corner Radius

An Engraving tool of Ø6 will be used.

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 Edit the following tool parameters:
• Set the Tip diameter to 0.1
• Set the Taper angle to 15

Click to edit the tool data:

• Set the Feed XY to 1000
• Set the Feed Z to 300
• Set the Spin rate to 5000

5. Define the Milling levels

Define the Upper level directly on the part surface. Define the Engraving depth on
the floor of the engraved text.

6. Define the technological parameters

Switch to the Technology page.
In the Modify section, choose Left in the Tool side list.
Select the Fill area option and choose Contour from the list.

Fill area

Hatch

When this option is chosen, the tool moves inside the closed
contour in linear movements.

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 3. SolidCAM 2.5D Operations

Contour

When this option is chosen, the tool moves on offsets parallel to

the geometry contour. The distance between two consecutive cuts
is defined by the Step over value.
Middle line only

When this option is chosen, the tool moves along the center line
of the closed contour. When this option is selected, the Tool side
is always set as Center. Selecting the V-Carving check box, creates
a 3D tool path from 2D fonts. This also sets the Min. contact
angle to 60. Set the Min. contact angle to 60 or less for improved
results. When V-Carving check box is enabled, the Engraving
depth on the Levels page is set to 0 and locked from editing
because the depth varies. The varying depth, which is the result of
the operation maintaining the font appearance on the engraving
surface, is determined automatically by the tool tip geometry and
width of the font.

Set the Step over value to 0.05.

The default Floor finish option enables you to perform finishing on the bottom of
the engraved text.

7. Save and Calculate

Click . The Engraving operation data is saved, and the tool path is calculated.

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 8. Simulate the operation
Perform the simulation of the operation in the SolidVerify mode.

9. Add an Engraving Operation

Add another Engraving operation.

10. Define the Geometry

The geometry for this operation is the text typed in directly from your keyboard.

Click in the Geometry page. In the Geometry Edit dialog box, click the Add
button in the Text section.
In the Text definition dialog box, click the Edit button in the
Text definition section. The Draw Tools dialog box is displayed.
Click the text symbol and draw a rectangle to define a
text frame.

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 3. SolidCAM 2.5D Operations

Type in the text that you want to engrave, for example “SolidCAM 2021.” Use the
toolbar icons to change the text properties: font, size, alignment, and so on.
Click to confirm the text.
In the Reference point section, click the Pick point button. Select the reference point
directly on the model, clicking the point in the beginning of the sketch line.
Click the Resume button in the SolidCAM dialog box.

The point coordinates are displayed in the Pick reference

point dialog box. Confirm the point selection by clicking
. The coordinates of left bottom corner of the engraved
text frame will be in this point.
Click the Preview button to see how the text fits the available
space. SolidCAM creates a number of chains on the model
surface.

Click Resume and accept the chains by clicking . The Geometry Edit dialog box
is displayed.

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 The Chain List section contains the Text item which
includes all selected chains. This item can be edited and
modified every time you need to make a change.
Click to choose the selected geometry for the
operation.

11. Define the Tool

Use the same Engraving tool of Ø6 as in the previous operation.

12. Define the Milling levels

Set the Engraving depth value to 0.2.

13. Define the technological parameters

Switch to the Technology page.
In the Modify section, choose Center in the Tool side list. The tool tip will be
positioned exactly on the geometry.

14. Save and Calculate

Click . The Engraving operation data is saved, and the tool path is calculated.

15. Simulate the operation

Perform the simulation of both the operations in the SolidVerify mode.

At this stage, the exercise is completed.

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Indexial 4-Axis
Milling 4
SolidCAM enables you to perform indexial 4-axis milling on vertical or horizontal CNC-
machines with a 4th axis rotary table.

The 4th axis rotation is used for the positioning of the part. When the part is positioned to
the required orientation, the 4th axis is locked and the machining is performed using 3-axis
movements.

For each clamping, SolidCAM enables you to define the Machine Coordinate System with X-axis
(for vertical machines) or Y-axis (for horizontal machines) parallel to the revolution axis of the
rotary table.

Machine
Machine Coordinate Y
Coordinate System
X
Z System
Y Z

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 4. Indexial 4-Axis Milling

Within one clamping (Machine Coordinate System), SolidCAM enables you to define a number
of positions around the revolution axis. For vertical machines the X-axis of these positions is
parallel to the X-axis of the Machine Coordinate System.
Machine Coordinate System

Z
Y

Positions

Z Z
Y Y
Z Y

X X
X

For horizontal machines, the Y-axis of these positions is parallel to the Y-axis of the Machine
Coordinate System.
Machine Coordinate System

Y
X Z

Positions
Y Y
Y
X Z X Z
X Z

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For each position, SolidCAM automatically determines the Shift and the Rotation parameters
relative to the Machine Coordinate System.

Machine
Coordinate Rotation X
System
Z Y'
Z Y Z' Y
Y'
X Position
Z' X'
Shift Z
Shift X X
Shift Y X'

The Shift components (Shift X, Shift Y and Shift Z) describe the shifting of the position relative
to the Machine Coordinate System.
The Rotation components (Rotation around X, Rotation around Y and Rotation around Z)
describe the axis orientation of the position relative to the Machine Coordinate System.
Positions can be defined only around the revolution axis. For vertical machines only positions
around X-axis can be added, so the Rotation around Y and Rotation around Z values are 0. The
Rotation around X parameter can be different from 0. For horizontal machines only positions
around Y-axis can be added, so the Rotation around X and Rotation around Z values are 0. The
Rotation around Y parameter can be different from 0.

Machine Coordinate Systems and their positions are used for the geometry definition. Before
the geometry definition you have to choose the Coordinate System position. The geometry has
to be located in the plane parallel to the XY-plane of the chosen CoordSys.

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 4. Indexial 4-Axis Milling

Exercise #12: Frame Machining

In this exercise, indexial 4-axis operations are used for the frame part machining.

The frame is machined from the pre-machined stock on a vertical 4-axis milling CNC-machine
using a special jig.

The jig with the clamped workpiece is placed on the rotary table of the machine. Such clamping
enables you to machine four sides of the model using the rotation of the 4th axis.

The tail used for the part clamping is removed

in a separate operation using a 3-axis CNC-
machine.

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 1. Load the SOLIDWORKS model
Load the Exercise12.sldprt model located in the Exercises folder.
The model contains three configurations:
• Default
The original design model without changes.

• Stock
The stock model that is used for the SolidCAM stock definition.

• Machining
The machining model with a tail that was not removed. This configuration
is used for the SolidCAM geometries definition.

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 4. Indexial 4-Axis Milling

2. Start a new project

To start a new project, click the SolidCAM in the Tool menu of SOLIDWORKS and
choose Milling from the New submenu. The Milling Part Data dialog box is displayed.

3. Define the CNC-controller

Choose a CNC-machine controller. Click the arrow in the CNC-Machine section to
display the list of post-processors installed on your system.
In this exercise, use a vertical 4-axis CNC-machine with the Haas CNC-controller.
Choose the gMill_Haas_4x_eval CNC-controller from the list.

4. Define the Machine Coordinate System

Click the CoordSys button in the Define section of the Milling Part Data dialog box
to start the Coordinate System definition.

The CoordSys dialog box is displayed.

SolidCAM assigns the first Position number to the Machine
Coordinate System by default.

Make sure that the default Select face option is chosen. Select
the Top corner of model box option in the Place CoordSys
origin to list.

Click on the model bottom face as shown.

215
 The Machine Coordinate System #1 is automatically defined in the top corner of the
model box. Click .
The CoordSys Data dialog box is displayed.
SolidCAM automatically determines the Shift and Rotation
values. For the first Position related to a new Machine
Coordinate System, the Shift and Rotation parameters values
are always 0.

Close this dialog box with . The CoordSys Manager

dialog box is displayed.

5. Define the CoordSys positions

Now you have to define several additional Positions around
the Machine Coordinate System #1.
In CoordSys Manager, click the Add button.

The CoordSys dialog box is displayed again.

SolidCAM assigns the next sequential number to the position.

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 4. Indexial 4-Axis Milling

Click on the model face as shown.

The origin is automatically placed in the top corner of the model. The Z-axis is
directed outwards normally to the selected face. The X-axis direction is the same as
the direction of the X-axis of the Machine Coordinate System (Position #1).
Click to confirm the position location. The CoordSys Data dialog box is
displayed.
The Part Upper level (0) and the Part Lower level (-100) are
automatically determined on the model.
The Shift and Rotation parameters are defined automatically
for the Position #2. The Shift Z is -35; the Shift X and Shift Y
are 0. The Rotation around X is -90; other Rotation values are
0.
Machine Coordinate System

Z Position #1

Rotation X X
-90° Y
Shift Z
35 Position #2

Z X

Confirm the dialog box with .

217
 In the same manner, define Position #3 and Position #4 using the model faces as
shown.

Position #3 Position #4
Shift (0,100,-35) Shift (0,100,0)
Rotation (180,0,0) Rotation (90,0,0)
Confirm the CoordSys Manager dialog box with .

6. Define the Stock model

Click the Stock button in the Define area. The Stock dialog box is displayed.
Select the 3D Model option in the Defined by section. This
option enables you to define the stock model by picking solid
bodies.
In the Configurations section, switch to the Stock
configuration.
The model is displayed in the Stock configuration.
Click on the model to select it for the stock model. Close the
Stock dialog box with .

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 4. Indexial 4-Axis Milling

7. Define the Target model

In the Milling Part Data dialog box, click the Target button.
The Target dialog box is displayed.
In the Configuration section, choose the Machining
configuration that describes the model after the machining.

The configuration is changed. Click on the model as shown.

Close the Target dialog box with

Click to save the CAM-Part data and close the Milling Part Data dialog box.
Click the SolidCAM Manager tab.

8. Define the Fixture

SolidCAM enables you to define the Part fixtures such as clamps, vises, jig plates,
etc. This feature allows you to get a more realistic picture during the simulation and
check possible collisions between the cutting tools and fixtures.
At first, you have to add the model of the clamping device to the CAM-Part assembly.

It is recommended to copy your clamp model files into the CAM-Part

folder before insertion into the CAM-Part assembly.

219
 Click the Insert command in the SOLIDWORKS menu and choose the Existing
Part/Assembly option from the Component sub-menu.

The Insert Component dialog box is displayed.

Click the Browse button and choose the Clamp.sldprt file.
This file contains the model of the clamping device.
Confirm the component insertion with . The model is
added.

Align the model as shown below using the Mate or the

SmartMates option.

220
 4. Indexial 4-Axis Milling

In SolidCAM Manager, right-click the Fixtures header and choose the Define Fixture
command from the menu.
The Model dialog box is displayed.

This dialog box enables you to define the fixture by selecting solid bodies of the
CAM-Part assembly components.
Click on the clamping device model as shown.

Confirm the Model dialog box with .

To choose this new fixture for future operations,
right-click Setup and choose the Edit command
from the menu.

221
 The Machine setup dialog box is displayed.
Until this moment, no
fixture has been chosen
for operation, therefore
the Fixture cell in the table
contains the None field.
Click this field and choose
the clamping fixture option
for the fixture that you have
defined earlier.
In the Z cell, type in 35 to
raise the model 35 mm above
the machine table. Confirm the dialog box by clicking OK.

9. Define a Pocket operation

Define a Pocket operation to perform the rough
machining of the highlighted faces.

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 4. Indexial 4-Axis Milling

Choose the Coordinate System Position #1 in the Geometry page of the Pocket
Operation dialog box.

Define the Geometry as shown.

Define a new End mill tool of Ø10 and
choose it for the operation. Choose the
appropriate tool holder.

Define the Pocket depth on the top

face of the pad as shown.
Set the Wall offset and the Floor offset
values to 0.2 to leave allowance for the
next finishing operation.
Use the Helical Ramping strategy. Set
the Radius value to 5.

10. Define a Pocket operation

Define a Pocket operation to perform
the rough machining of the highlighted
faces.
The Coordinate System Position #1
has to be chosen in the Geometry page
of the Pocket Operation dialog box.

223
 Define the Geometry as shown.
Choose the Tool #1 (Ø10 End mill) for
the operation.
Define the Upper level for the
operation on the top face of the
pad (used in the previous operation
for the Pocket depth definition).

Define the Pocket depth on the bottom face as shown.

Set the Wall offset and the Floor offset values to 0.2 to leave allowance for the
further finishing.
Use the Helical Ramping strategy. Set the Radius value to 5.

11. Define a Pocket operation

Define a Pocket operation to perform
the rough machining of the highlighted
faces.
Choose the Coordinate System
Position #1 in the Geometry page of
the Pocket Operation dialog box.

224
 4. Indexial 4-Axis Milling

Define the Geometry as shown.

Choose the Tool #1 (Ø10 End mill) for
the operation.
Define the Upper level for the operation
using the bottom face of the previously
machined pocket. Pick the Pocket
depth as shown.

Set the Delta value for the Pocket Depth to -1 to perform the through pocket
machining.
Set the Wall offset value to 0.2 to leave allowance for the further finishing.
Use the Helical Ramping strategy. Set the Radius value to 5.

12. Define a Profile operation

Define a Profile operation to perform
the finish machining of the highlighted
faces.
Choose the Coordinate System
Position #1 in the Geometry page of
the Profile Operation dialog box.
Use the geometry defined in Step #9.
Choose the Tool #1 (Ø10 End mill) for
the operation.
Use the same milling levels that were defined in Step #9.

225
 Choose the Arc strategy for Lead in and select the Same as Lead in check box under
Lead out.

13. Define a Profile operation

Define a Profile operation to perform the
finish machining of the highlighted faces.
Choose the Coordinate System Position #1 in
the Geometry page of the Profile Operation
dialog box.
Use the geometry defined in Step #10
Choose the Tool #1 (Ø10 End mill) for the
operation.
Use the same milling levels used in Step #10. Set the Clear offset and the Step
over parameters to perform the machining of the bottom face in several concentric
profiles.
Choose the Arc strategy for Lead in and select the Same as lead in check box under
Lead out.

14. Define a Profile operation

Define a Profile operation to perform the
finish machining of the highlighted faces.
Choose the Coordinate System Position #1 in
the Geometry page of the Profile Operation
dialog box.
Use the geometry defined in Step #11.
Choose the Tool #1 (Ø10 End mill) for the
operation.
Use the same milling levels used in Step #11.
Choose the Arc strategy for Lead in and select the Same as lead in check box under
Lead out.

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 4. Indexial 4-Axis Milling

15. Define a Pocket operation

In the same manner as explained in Step #9,
define a Pocket operation to perform the
rough machining of the highlighted faces.
Use the Coordinate System Position #3 for
the operation.

16. Define a Pocket operation

In the same manner as explained in Step
#10, define a Pocket operation to perform
the rough machining of the highlighted
faces.
Use the Coordinate System Position #3 for
the operation.

17. Define a Profile operation

In the same manner as explained in Step
#12, define a Profile operation to perform
the finish machining of the highlighted
faces.
Use the geometry defined in Step #15.
Use the Coordinate System Position #3 for
the operation.

227
 18. Define a Profile operation
In the same manner as explained in Step
#13, define a Profile operation to perform
the finish machining of the highlighted
faces. Use the Coordinate System Position
#3 for the operation.

Use the geometry defined in Step #16.

Choose the Tool #1 (Ø10 End mill) for the
operation.
Set the Clear offset and the Step over values
to perform the machining of the bottom face in several concentric profiles.

19. Define a Pocket operation

Define a Pocket operation to perform the rough and

finish machining of two connector openings.
Use the Coordinate System Position #4 for the
operation. Define the geometry as shown.

Define a new End mill tool of Ø6 for the operation. Choose the appropriate tool
holder.

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 4. Indexial 4-Axis Milling

20. Define a Pocket operation

Define a Pocket operation to perform the rough and
finish machining of the highlighted pocket faces.
Use the Coordinate System Position #2 for the
operation. Define the geometry for the operation as
shown.
Choose the Tool #1 (Ø10 End mill) for the operation.
In the Finish section of the Technology
page, select the Wall and the Floor check
boxes to perform finishing of the walls and the floor
of the pocket.

Pocket wall finishing

Wall finishing can be performed in a single cut at the whole depth or

in a number of cuts at each step down.
• Total depth

When this option is chosen, the

wall finishing is performed in
a single cut at the whole depth.

229
 • Each step down

When this option is chosen, the wall finishing is performed in

several successive cuts at each step down.

The options of the Depth section are available only

when the wall finishing is performed in the operation
(the Wall check box is selected).

Under Depth, choose the Each step down option.

21. Perform the holes machining

Define several Drilling operations to perform
center drilling, drilling and threading of the holes.
Using the Coordinate System Position #1, perform
the machining of the M3 holes.
Use a Ø6 spot drill (with 90° tool tip angle), a Ø2.5
drill and a Ø3 tap tool. Choose the appropriate tool
holders.
Using the Coordinate System Position #2, perform the machining of the M6 holes.
Use the Ø6 spot drill (with 90° tool tip angle); a Ø5 drill and a Ø6 tap tool. Choose
the appropriate tool holders.

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 4. Indexial 4-Axis Milling

22. Perform the chamfer machining

At this stage, you have to define a

Profile operation for the 0.5 mm
chamfer machining.
Choose the geometry defined in Step
#9 for the operation. This geometry is
defined using the Coordinate System
Position #1.

Define a Chamfer mill tool of Ø6 for

the operation.

Chamfer mill

This tool is used for chamfering. A tool of this type is defined with
the parameters shown in the image.
Arbor Diameter

Total
Length Outside
Shoulder
Holder
Length
Length Cutting
Length
Angle

Diameter

For the chamfer machining, set the value of

the chamfer depth in the Profile depth field.
In this case, set the value of 0.5.
Cutting Profile depth
In the Rest material/Chamfer section, choose Diameter (Chamfer depth)
the Chamfer option from the list. A new page
under the Chamfer tab is displayed.
Define the Cutting diameter, which is the
diameter of the tool coincident with the
geometry at the chamfer depth.

231
 Set the Cutting diameter value to 2.

In the Link section of the Profile Operation dialog box, choose the Arc strategy for
Lead in and select the Same as Lead in check box under Lead out.

In the same manner, define a new Profile operation to machine another chamfer of
0.5 mm using Coordinate System Position #3.

23. Simulate the tool path

Simulate the CAM-Part in the SolidVerify mode.
SolidCAM displays the fixture and checks the possible gouges during the simulation.
In the SolidVerify simulation, the tool is shown going around the part (rather than
rotating the part as it actually occurs in the CNC-machine). Therefore, for all CNC-
machine types, the simulation looks the same.

At this stage, you have completed the exercise.

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 4. Indexial 4-Axis Milling

Exercise #13: Mounting Machining

Define the CAM-Part and operations for machining of the mounting part shown below on the
4-axis vertical milling CNC-machine.

This exercise reinforces the following skills:

• CAM-Part definition
• Face milling
• Pocket machining
• Drilling
The SOLIDWORKS model of the Mounting part (Exercise13.
sldprt) is located in the Exercises folder.

The mounting is machined from the stock pre-machined by turning.

The following steps have to be implemented in order to obtain the
final CAM-Part:

1. Define the CAM-Part

At this stage, you have to define the CAM-Part, CNC-controller (gMill_Haas_4x_
eval), Machine Coordinate System, the Stock and Target models.

Machine Coordinate System definition

In this exercise, the Machine Coordinate

System has to be defined in the center of the
revolution face as shown.

233
 Using the Flip options in the CoordSys dialog box, rotate the
Coordinate System so that the X-axis is
collinear with the revolution axis and the
Z-axis is directed upwards as shown.
Z
Define an additional Machine Coordinate
System #2 to machine the back faces of
the mounting part. Y
X

Define the Stock and the Target models using the configurations of the original
SOLIDWORKS model.

2. Face milling
Define a Face Milling operation with the Hatch strategy
to machine the shown face.
Use the Machine Coordinate System #1 (Position #1)
for the machining.

3. Holes machining
Define three Drilling operations to perform center
drilling, drilling and threading of the M6 holes.

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 4. Indexial 4-Axis Milling

4. Define the operation pattern

Now you have to define a circular pattern of the operations around the revolution
axis (4th axis) of the CAM-Part in order to machine all the sides.
In SolidCAM Manager, select all the defined
operations holding the Shift or Ctrl keys.
Right-click one of the selected operations
and choose the Transform option from the
menu.

The Operation Transformations dialog box is displayed.

This dialog box enables you to perform various transformations, such as rotating,
translating, and mirroring of the selected operations.

Operation transformations
This section offers you the choice of whether the original operation
will be transformed or its copy will be added for transformation
and, in the latter case, enables you to define the placing of the new
operation in the SolidCAM Manager tree.
The following options are available:
• Edit operation transformations

This option enables you to perform transformation of the

selected operation.

235
 • New operation (add at current position in operations tree)

This option enables you to add a copy of the selected operation

and apply the transformation to the copied operation, without
effect on the original operation. The transformed copy is inserted
immediately after the original operation in the SolidCAM Manager
tree. The original operation can be suppressed by selecting the
appropriate check box in the Options section.
• New operation (add at end of operations tree)

This option also enables you to add a copy of the selected

operation and apply the transformation to the copied operation,
without effect on the original operation. The transformed copy is
inserted at the end of the operation list in the SolidCAM Manager
tree. The original operation can be suppressed by selecting the
appropriate check box in the Options section.

In the Operation transformations section, use the default Edit

operation transformations option.
In this exercise, you need to define a circular pattern of the selected
operations around the 4th axis. Click the 4 Axis button.
The Rotate List dialog box is displayed.
Select the Include original operation check box. When this check box
is selected, the original operation tool path is included in the
transforming action.
In the Angle field, type in the value of 120°. This parameter defines
the rotation angle for each pattern instance. In the Steps
field, enter 2 for the number of instances.
Click the Insert button. The specific value of the rotation
angle is calculated for each instance of the pattern.

236
 4. Indexial 4-Axis Milling

Confirm the Rotate List dialog box with the OK button.

The operations to be transformed appear in the Operation Transformations dialog
box.

Confirm this dialog box with the OK button.

Note that the icons of the transformed operations are marked with the icon.
This icon means that the operations were patterned using the 4th axis.

5. Simulate the transformed operations

Play the simulation of the transformed operations in the SolidVerify mode.

237
 6. Remove the clamping tail
Define a Face Milling operation with the Hatch
strategy using the Machine Coordinate System
#2 to remove the tail that was necessary for the
part clamping at the 4th axis operations.

7. Machine the back side

Machine the pocket faces on the back side of
the mounting.
Define several Pocket operations to perform
rough and finish machining of the pockets.
Use the Machine Coordinate System #2 for the
operations.

238
Indexial 5-Axis
Milling 5
SolidCAM enables you to perform indexial 5-axis milling using either vertical or horizontal
5-axis CNC-machines.
The 4th and 5th axis rotation is used for
positioning of a part. When the part is
positioned to the necessary orientation, the 4th
and the 5th axes are locked and machining is
performed with 3-axis movements.
For each clamping, SolidCAM enables you to
define the Machine Coordinate System.

Machine
Coordinate
System

240
 5. Indexial 5-Axis Milling

SolidCAM enables you to perform indexial 5-axis milling using either vertical or horizontal
5-axis CNC-machines.

Machine Coordinate System

Z
Y

Z Y
Positions

Z Z
Y Y

X X

The 4th and 5th axis rotation is used for positioning of a part. When the part is positioned to
the necessary orientation, the 4th and the 5th axes are locked and machining is performed with
3-axis movements.
For each clamping, SolidCAM enables you to define the Machine Coordinate System.

241
For each clamping (Machine Coordinate System), SolidCAM enables you to define a number of
related positions around the Machine CoordSys. Take care of the machine limitations (angles or
undercuts).

Shift X
Machine
Coordinate Z Y
System

Shift Z

X'

Position
Y' Z'

Shift Y

Machine X'
Z Y
Coordinate Position
System Y' Z'
X
Rotation:
X= 0
Y= -90
Z= 180

242
 5. Indexial 5-Axis Milling

For each position, SolidCAM automatically determines the Shift and Rotation parameters relative
to the Machine Coordinate System.
Machine Coordinate Systems and their positions are used for the geometry definition. Before
the geometry definition you have to choose the Coordinate System position. The geometry has
to be located in the plane parallel to the XY-plane of the chosen CoordSys.

243
Exercise #14: Clamp Machining

Define the CAM-Part and operations for the machining of the clamp shown below on the 5-axis
vertical milling CNC-machine.

This exercise reinforces the following skills:

• CAM-Part definition
• Face milling
• Pocket machining
• Profile machining
• Drilling
• Indexial 5-axis machining
The SOLIDWORKS model of the Clamp (Exercise14.sldprt) is located in the Exercises folder.
The model contains two SOLIDWORKS configurations:
• Machining
This configuration represents the model after the machining.
• Stock
This configuration represents the pre-machined
workpiece before machining. The dovetail is pre-
machined to perform simple clamping of the part
during the machining.

1. Define the CAM-Part

At this stage, you have to define the CAM-Part, CNC-controller (TTC_Hermle_C20_
full), Machine Coordinate System and its Positions, the Stock and Target models.

244
 5. Indexial 5-Axis Milling

Coordinate System definition

Define Machine Coordinate Systems #1 and #2 and related positions

using the previously defined Stock model.

Machine Coordinate
System #1
Position #1

Machine Coordinate
System #1
Position #2

Machine Coordinate
System #1
Position #3

245
 Machine Coordinate
System #1
Position #4

Machine Coordinate
System #1
Position #5

Machine Coordinate
System #2
Position #1

Define the Stock model using the Stock configuration of the CAM-Part assembly.
Define the Target model using the Machining configuration of the CAM-Part
assembly.

2. Top face machining

Define a Face Milling operation with the Hatch
strategy to machine the top inclined face of the clamp.
Use the Machine Coordinate System #1 (Position #2)
for the operation.

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 5. Indexial 5-Axis Milling

3. Back face machining

Define a Face Milling operation with the Hatch
strategy to machine the back inclined face
of the clamp. Use the Machine Coordinate
System #1 (Position #3) for the operation.

4. Front face machining

Define a Face Milling operation with the Hatch
strategy to machine the front inclined face of the
clamp. Use the Machine Coordinate System #1
(Position #4) for the operation.

5. Openings machining
Define a Profile operation to machine two openings
located on the front inclined face of the clamp. Use
the Machine Coordinate System #1 (Position #4) for
the operation.

6. Slot machining
Define a number of operations to machine the slot
faces located on the top inclined face of the clamp.
Use the Machine Coordinate System #1 (Position #2)
for the operation.

7. Hole machining
Define a number of operations to machine the
inclined counterbore hole located on the top inclined
face of the clamp. Use the Machine Coordinate
System #1 (Position #5) for the operation.

247
 8. Bottom face machining
Define a Face Milling operation with the Hatch
strategy to machine the bottom inclined face of
the clamp. Use the Machine Coordinate System #2
(Position #1) for the operation.

248
ToolBox 6
ToolBox sub-operations are a set of 2.5D Milling operations, each intended for a specific
machining case. Some operations cover different strategies of slots machining. Each sub-
operation provides you with a specific machining strategy optimal for a particular machining
case.
These operations are combined in a single dialog box as sub-operations.
SolidCAM offers you the following types of ToolBox Cycles:

ToolBox Cycles

Flattened Surface
Spiral Open Slot Temporary Bridges
on Cylinder

Spiral Open Slot Wide Simple Corner Rib Cut

Spiral Closed Slot Wide Flattened Surface

Broaching
on Corner

Additional ZigZag Slot Roll into Closed Slot Simple Boss

Simple Slot Simple Multi Bosses Spiral Pocket

Roll into Open Slot One Side Open Slot Wood Cutting

Closed Slot Ruled Surface Angled Cylinder

Spine Slot O-Ring Thin Wall Machining

250
 6. Toolbox

Spiral Open Slot

This strategy enables you to perform machining of open slots. The
geometry consists of two chains. The machining is performed in a
spiral manner.

Spiral Open Slot Wide

This strategy enables you to perform machining of wide open slots.
The first cutting pass is performed in the spiral manner along the
determined spine of the slot, and then the machining of the slot
walls is performed by a number of profiles equidistant to the slot
geometry.

Spiral Closed Slot Wide

This strategy enables you to perform the machining of wide closed
slots. The first cutting pass is performed in the spiral manner along
the determined spine of the slot, and then the machining of the slot
walls is performed along the slot geometry.

Additional Zigzag Slot

This strategy enables you to machine long slots. The tool path starts
from the slot center approaching it in a zigzag movement and goes
toward the walls.

Simple Slot
This strategy enables you to perform one-pass machining of the
slots with the width equal to or smaller than double diameter of
the tool.

Roll into open slot

This strategy enables you to machine an open slot starting from
the slot center to the walls, while rolling in the material with an arc
movement.

251
Closed Slot
This strategy enables you perform machining of a closed slot with
the width equal to the tool diameter. The machining is performed in
the zigzag manner; the last cut is horizontal to clean the slot floor.

Spine Slot
This strategy enables you to perform machining of a slot opened
from one side. SolidCAM automatically determines the spine of the
slot and performs the machining according to the spine’s shape. In
this sub-operation, the tool approaches the material along the spine
and then machines the walls of the slot.

Temporary Bridges
This strategy enables you to machine the profile of a pocket while
preserving the rest of the material fixed to the wall using small thin
bridges. Inner material will be hammered for shorter machining
time.

Simple Corner
This strategy enables you to perform machining of an open corner
area in a number of equidistant cutting passes..

Broaching
This strategy enables you to perform broaching of holes.

Roll into closed slot

This strategy enables you to machine a closed slot starting from
the slot center to the walls, while rolling in the material with an arc
movement.

252
 6. Toolbox

Simple Multi Bosses

This strategy enables you to perform the machining of several
bosses starting from one face. The machining is performed in a
number of equidistant Clear Offset passes parallel to the selected
bosses geometry. The cutting passes are generated for the whole
geometry combined from the initial bosses.

One Side Open Slot

This strategy enables you to machine an one-sided slot using
two chains: a main chain and a drive chain. A spiral tool path is
generated during this sub-operation.

Ruled
This strategy enables you to perform the machining of an analytical
ruled surface defined by two open contours. The cutting passes are
evenly distributed between the defined contours.

O-Ring
This strategy enables you to machine O-Ring slots.

Flattened Surface on Cylinder

This strategy enables you to perform machining of the flattened
surface on a cylinder.

Rib Cut
This strategy enables you to machine a rib upper surface in a single
pass shifted from the center line by a specified value. This is a safe
method of cutting the upper face of a thin wall.

253
Flattened Surface on Corner
This strategy enables you to machine an angled plane using a defined
working area in order to prevent air cuts.

Simple Boss
This strategy enables you to perform machining of a boss located on
a model face. The machining is performed in a number of equidistant
cutting passes parallel to the boss geometry. The passes are cut with
the outer contour of the initial face.
Spiral Pocket
This strategy enables you to perform machining of the closed pocket
areas using spiral techniques. With this strategy, the tool penetrates into
the material in the automatically calculated point inside the pocket with
a helix. Then the tool performs the spiral cutting pass morphing from
the penetration point to the closed area walls.

Wood Cutting
This strategy uses a special tool called “saw” to cut off a block of wood
in a single pass. The First Step down parameter defines the depth of
cutting.

Angled Cylinder
In this cycle, the cylinder top is cut to create an angled surface. The
cutting is performed by parallel cuts with a defined Step over.

Thin Wall Machining

This strategy enables you to machine thin walls while removing
gradually the excess material from either side of the wall. The method
can be chosen from two options: Alternating steps or Supporting steps.

254
 6. Toolbox

Exercise #15: Standard Cycles Machining

This exercise illustrates the usage of

Standard Cycles to machine twenty four
sample blocks located on a plate. Each
block represents a specific machining
case machined in a cycle with customized
parameters.

The part file (Exercise15.prz) is located in

the Exercises folder. This file contains the
pre-defined CAM-Part.

1. Open the CAM-Part

Open the Exercise15.prz file located in the Exercises folder.

2. Spiral open slot machining

In the SolidCAM 2.5D toolbar, choose ToolBox Cycles.
Alternatively, you can right-click the Operations header in SolidCAM Manager and
select Add Milling Operation > ToolBox Cycles.

255
 The ToolBox cycles operation dialog box is displayed.
Make sure the default Spiral open slot strategy is chosen in the top left corner under
Technology.

Click to define a new geometry.

Choose a pair of chains as shown.

Confirm the geometry by clicking .

Add a new End mill of Ø10.
Select the Milling levels directly on the model.

In the Technology page, under Offsets, set Wall offset to 0.5. Under Extension, set
% of tool diameter to 80. Under
Finish, select the Wall finish
option.
Click the Save icon.

256
 6. Toolbox

3. Wide spiral open slot machining

In the same manner as described in the previous step, define a new ToolBox Cycles
operation.
Under Technology, select the Spiral open slot wide strategy.

Define a new geometry, selecting a pair of

chains on the wide slot edges.
Use the same tool as in the previous operation.
In the Technology page, under Offsets, set Wall
offset to 1. Under Finish, select the Wall finish
option.
Click the Save icon.

4. Wide spiral closed slot machining

Define a new ToolBox Cycles operation.
Under Technology, select the Spiral closed slot wide strategy.
Define a new geometry, selecting the open chain as shown.

257
 Use the same tool as in the previous operation. Click the Save icon.

5. Additional Zigzag slot machining

Define a new ToolBox Cycles operation.
Under Technology, select the Additional Zigzag Slot strategy.
Define a new geometry, selecting the closed chain as shown.

Use the same tool as in the previous operation.

Click the Save icon.

6. Simple Slot machining

Define a new ToolBox Cycles operation.

Under Technology, select the Simple Slot strategy.
Define a new geometry, selecting a pair of chains on the slot edges.
Add a new End mill of Ø16.
Click the Save icon.

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 6. Toolbox

7. Open slot machined by rolling

Define a new ToolBox Cycles operation.
Under Technology, select the Roll into open slot strategy.
Define a new geometry selecting a pair of chains as shown.

Add a new End mill of Ø12.

In the Technology page, set the Step down to 10. This slot will be machined in one
pass. Set the Approach distance to 1.25. Under Extension, set % of tool diameter
to 60.
Click the Save icon.

8. Closed Slot machining

Define a new ToolBox Cycles operation.

Under Technology, select the Closed Slot strategy.

Define a new geometry, selecting the closed chain as show.
Use the previously defined End mill of Ø12. Click the Save icon.

In the Closed Slot cycle, the tool diameter should be equal to the slot
width.

259
 9. Spine Slot machining
Define a new ToolBox Cycles operation.
Under Technology, select the Spine Slot strategy.
Define a new geometry, selecting the open chain as shown.

Define a new End mill tool of Ø8.

In the Technology page, set the Step down to 10. This slot will be machined in one
pass. Set the Tolerance to 1. Under Extension, set % of tool diameter to 10.

10. Temporary Bridges machining

Define a new ToolBox Cycles operation.
Under Technology, select the Temporary Bridges strategy.
Define a new geometry, selecting the closed chain as shown.

Define a new End mill of Ø10 for this operation and edit the following parameters:
• Set the Shoulder length to 60
• Set the Cutting length to 60

260
 6. Toolbox

11. Simple corner machining

Define a new ToolBox Cycles operation.
Under Technology, select the Simple Corner strategy.
Define a new geometry, selecting the open chain as shown.

Use the previously defined Tool #1 of Ø10.

12. Broaching
Define a new ToolBox Cycles operation.
Under Technology, select the Broaching strategy.
Define a new geometry, selecting a linear chain as shown.

With this operation, only a Broaching tool is available.

261
 Broaching Tool

The tool of this type can only be used within the Broaching sub-
operation. It is not available for defining or choosing in any other
operation.
Arbor
Diameter

Total Cutting
Length Length Outside
Holder
Shoulder Length
Length

Width Depth

Corner Radius

Add a new Broaching tool and set its Width and Depth to 6.
In the Technology page, set the Tool side to Left.

13. Closed slot machined by rolling

Define a new ToolBox Cycles operation.
Under Technology, select the Roll into closed slot strategy.
Define a new geometry, selecting the open chain as shown.

Use the previously defined Tool #1 of Ø10.

262
 6. Toolbox

In the Technology page, set the Approach distance value to 1.25. Under Extension,
set % of tool diameter to 60.

14. Simple Multi Bosses machining

Define a new ToolBox Cycles operation.
Under Technology, select the Simple Multi Bosses strategy.
Define a new geometry, selecting the closed chains as shown.

Use the previously defined Tool #1 of Ø10.

In the Technology page, set the Step down value to 10. Under Clear offset, set Offset
to 30.

15. One Side Open Slot machining

Define a new ToolBox Cycles operation.
Under Technology, select the One Side Open Slot strategy.
Define a new geometry, selecting a pair of open chains: the first one is considered
main, and the second one is the drive chain.

Use the same tool as in the previous operations.

263
 16. Ruled Surface machining
Define a new ToolBox Cycles operation.
Under Technology, select the Ruled strategy.
Define a new geometry, selecting a pair of open chains on the slot edges.

Use the same tool as in the previous operations.

17. O-ring machining

Define a new ToolBox Cycles operation.
Under Technology, select the O-Ring strategy.
Define a new geometry, selecting a pair of closed chains as shown. The first chain is
considered external and the second one – internal.

Add a new End mill of Ø4.

18. Surface flattening on cylinder

Define a new ToolBox Cycles operation.
Under Technology, select the Flattened surface on cylinder strategy.
For this operation, define a new Coordinate System position with the origin located
on the cylinder revolution axis.

264
 6. Toolbox

Define a new geometry, selecting the linear open chain as shown.

Use the previously defined Tool #1 of Ø10.

On the Technology page, in the Clear offset section, click the Offset button and pick
the farther edge on the solid model. Set the Step over value to 3.
Place the mouse cursor in the Cylinder diameter edit box and pick the external
cylinder surface. The edit box is updated and set to 30.

19. Rib cutting

Define a new ToolBox Cycles operation.
Under Technology, select the Rib cut strategy.
Define a new geometry, selecting the edge as shown.

Use the same tool as in the previous operation.

In the Technology page, use the default parameters. The tool is shifted from the
center line by 10% of its radius.

265
 20. Surface flattening on corner
Define a new ToolBox Cycles operation.
Under Technology, select the Flattened surface on corner strategy.
For this operation, define a new Coordinate
System position with the origin located on the
flattened surface plane.
Define a new geometry, selecting a straight line
chain.
In the Working area section, click the Define
button to assign a triangle working area to the
selected line.

The Working area dialog box is

displayed. Make sure the Start angle
and End angle are 45°.
Use the same tool as in the previous
operation.
Define the Upper level by clicking on
the upper edge of the flattened plane.
Define the Depth by clicking on the
lower edge of the flattened plane.
On the Technology page, in the Clear offset
section, click the Offset button and pick the
farther edge on the solid model. Set the Step over value to 2.

266
 6. Toolbox

21. Simple Boss Machining

Define a new ToolBox Cycles operation.
Under Technology, select the Simple Boss strategy.
In the Coordinate System #1, define a new geometry using the Multi-chain option.
A pair of closed chains is selected automatically, where the first chain is considered
external and the second one is internal.

Use the same tool as in the previous operation.

22. Spiral pocket machining

Define a new ToolBox Cycles operation.
Under Technology, select the Spiral pocket strategy.
Define a new geometry, selecting the closed chain as shown.

Use the same tool as in the previous operation.

267
 23. Wood cutting
Define a new ToolBox Cycles operation.
Under Technology, select the Wood cutting strategy.

Define a new geometry, selecting the open chain.

Add a new Saw tool of Ø40. Set the Shank width to 20.

268
 6. Toolbox

Saw Tool

This tool type can only be used with the Wood cutting sub-operation.
It is not available for defining or choosing in any other operation.
A tool of this type is defined with the parameters shown in the image.

Shank Width
Outside
Holder
Diameter
Total Internal
Length Diameter

Blade Saw
Thickness Thickness

24. Cylinder top cutting

Define a new ToolBox Cycles operation.
Under Technology, select the Angled cylinder
strategy.
Define a new Coordinate System position with
the origin located at the cylinder revolution axis.
Define a new geometry, selecting the closed
chain as shown.
Use the previously defined Tool #1 of Ø10.
In the Levels page, click the Depth button and select the depth of the cut directly
on the solid model.
In the Technology page, set the Max step down to 4. Choose the Zigzag direction of
cuts. Under Extension, set % of tool diameter to 60.

269
 25. Thin Wall Machining
Define a new ToolBox Cycles operation and select the Thin Wall Machining strategy.
Define a new geometry, selecting two edges as shown.

Use the same tool as in the previous operation.

In the Technology page, use the default Alternating steps strategy for roughing
passes. Set the Step down to 6. Click the Offset button to clear the offset up to the
block edge.
Pick the edge as shown.
Edit manually the Offset value to 28.

270
 6. Toolbox

Simulate the operations

Right-click the Operations header and choose Simulate to play simulation for all
ToolBox operations.

Now you have successfully finished the exercise.

271
272
Automatic Feature
Recognition 7
This chapter covers the following types of 2.5D Milling operations performed using the
Automatic Feature Recognition module (AFRM) functionality:
Pocket Recognition Operation
This operation enables you to recognize pocket features on a solid model and perform machining
of these features.

Chamfer Recognition Operation

This operation enables you to recognize the chamfer features on the solid model and perform
machining of these features. The geometry creation process is similar to that of Pocket
Recognition operation. The chamfer mill tool works on all edges maintaining the user-defined
safety offset from the corners.

274
 7. Automatic Feature Recognition

Drill Recognition Operation

This operation performs powerful drill feature recognition and automatic Drill geometry
creation. This operation enables you to handle separate sets of Milling levels for each drill
position. The initial values of the Milling levels sets are automatically recognized from the model;
they can be edited by the user.

A Geometry for Pocket, Chamfer, and Drill Recognition operations is determined automatically
by SolidCAM AFRM functionality.

275
Exercise #16: Pocket Recognition

This exercise illustrates the SolidCAM functionality of

automatic pocket recognition and machining.
This exercise reinforces the following skills:
• Automatic pocket recognition and
machining
The following steps have to be implemented in order
to reach the final CAM-Part:

1. Open the CAM-Part

Open the Exercise16.prz file located in the Exercises folder. This file contains the
pre-defined CAM-Part.

2. Add a Pocket Recognition operation

Right-click the Operations header in SolidCAM Manager and choose Pocket
Recognition from the Add Milling Operation submenu.

Alternatively, you can choose the Pocket Recognition icon from the SolidCAM
AFRM ribbon. The Pocket Recognition Operation dialog box is displayed.

276
 7. Automatic Feature Recognition

3. Define the Geometry

In the Geometry page, click .

The Select Faces dialog box is displayed. This dialog
box enables you to define the parameters of the pocket
feature recognition geometry.
First, you need to set the pocket recognition filters and
then the mode of geometry selection.
Make sure that the Through Pocket check box is
selected.

Through Pocket

When this check box is selected with the Selection Mode set to Solid
Body, the recognition of through pocket features is also performed.
Through Pockets

Only the through pocket features where the upper loop is identical to
the lower loop are recognized. The Upper loop
through pocket features that cannot be
machined with the current CoordSys
position cannot be selected.
In the Circular Pocket diameter filter
section, make sure that the Apply filter
check box is selected. Lower loop

277
 Circular Pocket diameter filter

When the Apply filter check box is selected with the Selection mode
set to Solid Body, circular pocket features can be selected according to
their diameter. All circular pocket features with the diameter greater
than the specified Min. Diameter value will be selected. Using this
option, you can avoid machining of drill features that are supposed
to be machined in other operations (Drilling, Drill recognition, etc.).
The Min. Diameter parameter defines the minimum diameter of the
pocket features. You can enter the value in the edit box or pick a cylindrical
surface or a circular edge on the solid model when the cursor is placed in the
Min. Diameter edit box.

The Min. Face area parameter enables you to set a value to avoid
picking up very small areas or faces that cannot be machined.
When the Circular Pocket check box is not selected, all recognized
circular pocket areas suitable for the current Coordinate System are
selected.

Generally, all the through holes of this part are

recognized as circular pockets. In this operation, not
all of these holes will be machined, only four column
holes located in the corners of the top face.
Place the cursor in the Min. Diameter edit box and then
pick the edge of the column hole on the solid model.
The circular edge diameter of 42 mm is displayed in
the edit box. Edit the diameter by setting the value to
40. All of the holes with the diameter smaller than the
specified value will not be machined.
Define the mode of geometry selection.

Selection Mode

This section enables you to set the mode of the geometry selection.
The following selection modes are available:
• Solid Body

This mode enables you to perform automatic recognition of

pocket features on the picked solid body. All planar faces are
recognized with the surface normal vector oriented parallel to the
Z-axis of the current CoordSys.

278
 7. Automatic Feature Recognition

The planar faces that cannot be machined with the current

CoordSys position (undercuts) cannot be selected (the selection is
rejected). All the through pocket areas are recognized according
to the Through pocket option.
Z

Selected faces

Undercut face
(selection rejected)

• Face

This mode enables you to pick single planar faces. When a face is
picked, SolidCAM checks the parallel relation between the surface
normal vector of the picked face and the positive direction of the
Z-axis of the current CoordSys. If they are not parallel, the face
is not selected. The undercut faces that cannot be machined with
the current CoordSys position are also not selected. The selection
is working in the toggling mode: the first click on a face selects it,
the next click on the selected face removes the selection.
• Through Pocket Chain

This mode enables you to select the through pockets by picking

one of the edges of the lower loop of the pocket area. When
the edge is picked, the complete geometry of the through pocket
is automatically selected. The lower loop is highlighted on the
model. The selection is working in the toggling mode: the first
click on an edge selects the loop, the next click on an edge of the
already selected loop removes the selection.

279
 Under Selection mode, use the default Solid Body option.
Click on the solid model. SolidCAM generates the list of elements that suit your
filter settings.
Click the Solid1 element in the list. All the recognized model
features that take part in this geometry are highlighted. The
geometry includes all the planar faces, through pockets of
slots, and circular through pockets of column holes. Each
model element is accompanied by its Z-level value enclosed
in parentheses.

Confirm the Select Faces dialog box by clicking .

4. Define the Tool

Add an End mill of Ø16 for the operation. Define the tool parameters as follows:
• Set the Total length to 130
• Set the Outside holder length to 120
• Set the Shoulder length to 110
• Set the Cutting length to 100
Choose the tool for the operation.

280
 7. Automatic Feature Recognition

5. Define the machining levels

Define the Upper level by clicking on the upper model face as shown.

The cutting depth is calculated automatically for each

recognized feature according to the solid model.
Select the Equal step down option and set the Max
step down value to 5.

6. Define the technological parameters

Switch to the Technology page. All the parameters in this page are identical to those
used in the Pocket operation.
Use the default parameters of pocket machining.
Since the recognized geometry contains open
pocket areas, the Open pocket tab is made
available. Switch to the Open pocket page and
select the Approach from outside check box.
With this option, the approach to the open
pocket areas is performed from the outside of
the material.

281
 7. Define the Ramping strategy
In the Link page, choose the Helical ramping strategy and set the Radius to 5.
The chosen ramping strategy affects the close pocket areas where the horizontal
approach from outside (defined in the previous step) is impossible.

8. Calculate the tool path

Click .

9. Simulate the operation

Simulate the operation in the SolidVerify mode.

Now you have successfully finished the exercise.

282
 7. Automatic Feature Recognition

Exercise #17: Mounting Box Machining

In this exercise, the SolidCAM functionality of

automatic pocket recognition and machining is
used for rough milling of the mounting box inner
surfaces.
This exercise reinforces the following skills:
• CAM-Part definition
• Profile machining
• Automatic pocket recognition and machining
• Rest material machining
The SOLIDWORKS model of the mounting box part (Exercise17.sldprt) is located in the
Exercises folder.

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

1. Define the CAM-Part

At this stage, you have to define the CAM-Part, CNC-controller (AWEA1000-Fanuc),
Machine Coordinate System, the Stock and Target models.

2. External contour machining

Define a Profile operation to perform
rough machining of the external
contour of the part. Use an End mill
tool of Ø20.

3. Pocket roughing
Define a Pocket Recognition operation
to remove the bulk of material and
perform the rough machining of
the part inner surfaces. Use the End
mill tool of Ø20 used in the previous
operation.

283
 4. Pocket rest material machining
Define a Pocket Recognition operation
to perform the rest material machining
of the part inner surfaces. Use an End
mill tool of Ø10.

284
 7. Automatic Feature Recognition

Exercise #18: Drill Recognition

This exercise illustrates the SolidCAM functionality

of automatic drill recognition and machining.
This exercise reinforces the following skills:
• Automatic drill recognition and
machining
The following steps have to be implemented in
order to reach the final CAM-Part:

1. Open the CAM-Part

Open the Exercise18.prz file located in the Exercises folder. This file contains the
CAM-Part machined in the Pocket Recognition exercise.

2. Add a Drill Recognition operation

Add a new Drill Recognition operation to perform center drilling of holes.
The Drill Recognition Operation dialog box is displayed.

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 3. Define the Geometry
In the Geometry page, click .
SolidCAM parses the solid model and recognizes all of
its hole features.
The HR Drill Geometry Selection dialog box is displayed. This
dialog box enables you to specify the holes to be included in
the operation geometry.
In this operation, you will perform the center drilling of all
the holes that can be machined using the defined CoordSys
position, except for the column holes that were machined in
the previous operation as through pocket features.
In the Hole Type section, make sure that both the Through
and Blind check boxes are selected. In this operation, both
through and blind holes will be drilled.
The HR Drill Geometry Selection dialog box enables you to
filter the hole features to be machined by diameter, upper
level and height.
Select the Hole Diameter check box.

Hole Diameter (d)

When this section is activated, the hole features are filtered according
to the diameter of the hole. With this filter, only the hole features with
the Hole Diameter value within the specified range are recognized.
The From and To values enable you to define the Diameter range by
entering the values or by picking on the solid model.
When the cursor is placed in the From/To edit box, you can specify the
diameter value by picking a specific cylindrical surface or a circular
edge on the solid model.

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 7. Automatic Feature Recognition

When a cylindrical surface or a circular edge is picked, its diameter is

calculated and inserted into the corresponding edit box replacing the
previous value.
The edit box changes the background color to indicate the associativity
field (by default, pink). When you remove the automatically
determined value, the edit box background turns white again.

Define the upper limit for the diameter range. Place the cursor in the To edit box and
pick the edge of the column hole as shown. The
diameter of the hole (42 mm) is displayed in the edit
box.

Edit the diameter by setting the value to 40.

In this operation, the holes will be machined irrespective of their upper levels. Make
sure that the Hole Upper level check box is not selected.

Hole Upper level (u)

When this section is activated, the hole features are filtered according
to the Upper level. With this filter, only the hole features with the
Upper level value within the specified range are recognized.

The From and To values enable you to define the Upper level range
by entering the values or by picking on the solid model. When the
cursor is placed in the From/To edit box, you can specify the Upper
level value by picking on the solid model. When a model point is
picked, the Z-value of the picked position is calculated and inserted
into the corresponding edit box replacing the previous value. The
edit box changes the background color to indicate the associativity
field (by default, pink).

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 When you remove the automatically determined value, the edit box
background turns white again.

In this operation, the holes of all heights will be machined. Make sure that the Hole
height check box is not selected.

Hole Height (h)

When this section is activated, the hole features are filtered according
to the Hole height. With this filter, only the hole features with the
Hole height value within the specified range are recognized.

The From and To values enable you to define the Hole height range
by entering the values or by picking on the solid model. When the
cursor is placed in the From/To edit box, you can specify the Hole
height value by picking on the solid model. When a model point is
picked, the Z-value of the picked position is calculated and inserted
into the corresponding edit box replacing the previous value. The
edit box changes the background color to indicate the associativity
field (by default, pink). When you remove the automatically
determined value, the edit box background turns white again.

Click the Find Holes button. The hole features that match
the specified filter criteria are determined. These features are
listed in the Holes Tree section.

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 7. Automatic Feature Recognition

Click the Preview button. The hole features are highlighted on the model.

Holes Tree

In this list, the recognized hole features are classified by Shapes and
Groups. A Shape contains all the hole features with the same
topology; within a Shape, the Groups include all the hole features
with the same parameter values (Upper Level, Height and Diameter).
For each Group, the Upper level (u) and Height (h) are displayed in
parentheses. When you select a Shape or a Group item in the list, the
hole features that belong to this Shape or Group are highlighted on
the model.

Confirm the HR Drill Geometry Selection dialog box by clicking .

4. Define the Tool

Add a new Spot drill tool of Ø16. Define the tool parameters as follows:
• Set the Total length to 70
• Set the Outside holder length to 60
• Set the Shoulder length to 50
Choose the tool for the operation.

5. Define the Levels

Click the Depth edit button in the Levels page.

The Depth Edit dialog box is displayed. This dialog box enables
you to edit the Milling Levels parameters (Upper Level, Drill Depth,
Delta Depth) for each drill separately.

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 Notice the list of drill instances displayed in the Holes Tree section.

Holes Tree

This section displays the list of all drill instances chosen for the
geometry. All the drill instances in the list are structured into Groups
with the same Upper Level, Drill Depth, Delta Depth and Depth Type.
For each Group in the list, the drill instances data are displayed in
parentheses. Each drill instance in the list is accompanied by the
X- and Y-coordinates of the drilling position. Selecting the check
boxes next to each element in the list enables you to include the hole
features, Shapes or Groups into the geometry.
Do not confuse the Group classification in this dialog
box with that taking place at the stage of geometry
definition.

By default, the Depth Edit dialog box displays the parameter values recognized from
the solid model. Now you need to define the Upper Level, Drill/Chamfer Depth and
Depth Type parameters for each group of drill instances separately.

Select the Group1 item in the Holes Tree section. The drill instances that belong to
this group are highlighted on the model.

First, define the upper level for drilling.

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 7. Automatic Feature Recognition

Upper Level (u)

This value can be applied to a single hole, a group or all holes.

The edit box displays the Upper Level value of the selected item (a
group or a hole). You can enter the value or pick it directly from the
model (when the cursor is placed in the edit box). SolidCAM enables
you to pick planar faces parallel to the XY-plane of the Coordinate
System, model vertices and sketch points. When a model is picked,
the Z-value of the picked position is displayed in the edit box. The
edit box has pink background, which means that the parameter is
defined associatively to the solid model. When the edit box value is
typed in, it is not associative to the model; in this case the edit box
has white background.
The Apply button enables you to apply the defined Upper Level
value to the selected list item (a group or a hole). When a new Upper
Level value is applied, SolidCAM checks the Holes Tree items and
reorganizes them into groups according to the changed parameters.
SolidCAM checks all the groups to find a group with identical Upper
Level, Drill Depth, Delta Depth and Depth Type parameters. If such
group is found, the program adds the updated drill to this group.
In case of absence of a suitable group, a new group is created; the
updated drill instance is added to this group.

Leave the Upper Level value unchanged (-24).

Define the Depth Type.

Depth Type

This parameter can be defined for a single

hole, a group or all holes. You can define the
diameter on the conical part of the drilling
tool that will reach the specified drilling
depth during the machining. You can also
deepen a drilled hole in order to obtain a
given diameter at the specified drill depth.

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 The following options are available:
• Cutter Tip

The drill tip reaches the defined drilling depth.

• Full Diameter

The drill reaches the defined drilling depth with the full diameter.
• Auto Chamfer/Spot drill

When this option is selected, the Drill depth section changes to

Chamfer depth. The drill tip reaches the drilling depth, which is
calculated automatically, according to the value set in the Chamfer
depth section. To apply the Spot drill that only touches the hole
edges, set this value to 0. To apply the Auto Chamfer, set a defined
value in the Chamfer depth field.
• Diameter Value

The drill reaches the defined drilling depth with the drill cone
diameter specified by the Diameter Value parameter.
The Apply button enables you to apply the defined Depth Type to
the selected list item (a group or a hole). When a new Depth Type
is applied, SolidCAM checks the Holes Tree items and reorganizes
them into groups according to the changed parameters. The program
checks all groups to find a group with identical Upper Level, Drill
Depth, Delta Depth and Depth Type parameters. If such group is
found, the program adds the updated drill to this group. In case of
absence of a suitable group, a new group is created; the updated drill
instance is added to this group.

Choose the Auto Chamfer option for Depth Type. The Drill depth section name
changes to Chamfer depth. This type should be applied to all hole features in the
operation. Select the All checkbox and click the Apply button.

Notice that if you do not click the Apply button after editing values, the
change does not take effect.

Define the depth of the chamfering.

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 7. Automatic Feature Recognition

Drill/Chamfer Depth (d)

This value can be applied to a single hole, a group or all holes.

The edit box displays the Drill/Chamfer depth value of the selected
item (a group or a hole). The edit box enables you enter the value
or pick the value directly from the model (when the cursor is placed
in the edit box). You can pick drill faces or edges. The program
determines the depth of the picked drill according to the defined
Upper Level and displays the value in the edit box.

The edit box has pink background, which means that the parameter
is defined associatively to the solid model. When the edit box value
is typed in, it is not associative to the model; in this case the edit box
has white background.
The Apply button enables you to apply the defined Drill Depth value
to the selected list item (a group or a hole). When a new Drill Depth
value is applied, SolidCAM checks the Holes Tree items and
reorganizes them into groups according to the changed parameters.
The program checks all groups to find a group with identical Upper
Level, Drill Depth, Delta Depth and Depth Type parameters. If such
group is found, the program adds the updated drill to this group. In
case of absence of a suitable group, a new group is created; the
updated drill instance is added to this group.

Set the Chamfer depth value to 0.2, select the All check box
and click the Apply button.
Apply the changes and confirm the Depth Edit dialog box
with .

6. Define the sorting of drill positions

Switch to the Technology page.
Use the advanced sorting option to sort the drill positions
of the geometry. Under Sorting, choose the Advanced
option and click .

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 The Advanced Sorting dialog box is displayed. This dialog box enables you to define
the parameters of sorting of drill positions for machining of linear and circular drill
patterns.

Linear sorting of drill positions

The Linear tab contains sorting methods appropriate for machining

of linear drill patterns.
Linear pattern

According to linear sorting methods, the machining is performed

either by rows of drill positions with the same Y-coordinate or
by columns of drill positions with the same X-coordinate. The
Tolerance parameter enables you to define the tolerance that is used
to determine if a drill position belongs to the current row/column or
to a different row/column.
When the machining is performed by rows, SolidCAM determines
the first drill position for each row (the start position of the first
row is the start position of the whole pattern). For each next drill
position, the program determines the Y-coordinate and compares it
with the Y-coordinate of the first drill position of the current row.
If the linear deviation is within the specified Tolerance limit, the
program considers this position to belong to the current row. If the
deviation exceeds the Tolerance value, the drill position is rejected
from the current row; later this position will be checked again for
belonging to next rows.
In the similar manner, when the machining is performed by columns,
the specified Tolerance value is used to determine whether a specific
drill position belongs to the current column. In this case, the deviation
of X-coordinates between the first drill position in the column and
the current drill position is compared with the Tolerance value.

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 7. Automatic Feature Recognition

Choose the option in the Linear tab of the Advanced Sorting dialog box, and
set the Tolerance value to 5.

When this option is chosen, SolidCAM determines the position with

the minimal X- and Y-coordinates and accepts it as the start position
of the drill sequence. From this
position, the program continues
the machining of the drills with
the same Y-coordinate; the
machining is performed in the
direction of increasing
X-coordinates.
When the last position of
the current Y-coordinate
is machined, the program
passes to the next Y-coordinate (in the increasing order)
and continues the machining of the next row from the position with the
maximal X-coordinate to the position with the minimal X-coordinate
(decreasing order), and so on. In such manner, the machining of two
successive rows is performed in the opposite order: each odd row is
machined in the direction of increasing X-coordinates, each even row
is machined in the direction of decreasing X-coordinates.
The rows are machined in the direction of increasing Y-coordinates.

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 In the Advanced Sorting dialog box, click the OK button to confirm the definition
of sorting parameters.
Click the Show Sorted button to preview the sorted drill positions on the solid
model.
Close the Show
Geometry dialog box
with .

7. Calculate the tool path

Click .

8. Simulate the operation

Simulate the operation in the SolidVerify mode.

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 7. Automatic Feature Recognition

9. Machine the Ø6.8 holes

Add a new Drill Recognition operation to
perform drilling of the Ø6.8 holes.
In the HR Drill Geometry Selection dialog box,
activate the Hole Diameter section. Place the
cursor in the From edit box and pick the hole
edge as shown.
The diameter value (6.8) is displayed in both
From and To edit boxes defining the range for
the Hole Diameter filter.

Click the Find Holes button. The holes of the specified diameter are highlighted on
the model.

Confirm the HR Drill Geometry Selection dialog box by clicking .

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 Add a new Ø6.8 Drill tool.

Click the Depth Edit button in the Levels page. The Depth Edit
dialog box is displayed. Note that the values of the Upper Level
(-24) and Drill Depth (26.29) parameters are offered you as defaults.
These values are recognized automatically on the model.

Confirm the Depth Edit dialog box dialog box by clicking

In the Technology page, choose the Advanced sort option under
Sorting and click the button.

In the Linear tab of the Advanced Sorting dialog box, choose the option.

When this option is chosen, SolidCAM determines the position with the
minimal X- and Y-coordinates and
accepts it as the start position of the
drill sequence. From this position, the
program continues the machining of
the drills with the same X-coordinate;
the machining is performed in the
direction of increasing Y-coordinates.

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 7. Automatic Feature Recognition
When the last position of the current X-coordinate is machined, the
program passes to the next X-coordinate (in the increasing order) and
continues the machining of the next column from the position with the
maximal Y-coordinate to the position with the minimal Y-coordinate
(decreasing order), and so on. In such manner, the machining of two
successive columns is performed in the opposite order: each odd column is
machined in the direction of increasing Y-coordinates, each even column is
machined in the direction of decreasing Y-coordinates.
The columns are ordered in the direction of increasing X-coordinates.

Click the Show Sorted button to preview the sorted drill positions on the solid model.

Under Drill cycle, click the Drill cycle type button and choose the Peck type from the list.
Click the Data button to define the pecking parameters.
In the displayed Drill Options dialog box, set the Step down
value to 2 and confirm the dialog box with the OK button.
Save and calculate the operation.

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 10. Machine the Ø8 holes
Add a new Drill Recognition operation to perform drilling of the Ø8 holes.
In the HR Drill Geometry Selection dialog box, activate the Hole Diameter section.
Define the range for the Hole Diameter filter as explained in the previous step. The
values of 8 mm are displayed in the Hole Diameter section.

Add a new Drill tool. The diameter of the drilling tool must be smaller than the
diameter of the holes, because these holes will be reamed at the next stage.

You can define the diameter of the tool by clicking on the entity to be
machined with this tool
directly on the solid
model. Place the cursor
in the Diameter edit
box in the Topology
page of the Part Tool
Table and pick the edge
of the hole as shown.

The Diameter value

(7.8) is displayed in the
edit box.
In the Technology page, choose
the Advanced option under Sorting and click the button.

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 7. Automatic Feature Recognition

In the Linear tab of the Advanced Sorting dialog box, choose the option,
set the Tolerance value to 2 and click the Show sorted
button.

Under Drill cycle, choose the Peck cycle type and set
the Step down value to 2.
Save and calculate the operation.

11. Machine the Ø4.2 holes

Add a new Drill Recognition operation to perform drilling of the Ø4.2 holes.

In the HR Drill Geometry Selection dialog box, define the range for the Hole Diameter
filter as explained in the previous steps. The values of 4.2 mm will be displayed in
the Hole Diameter section.
Add a new Ø4.2 Drill tool.

301
 In the Technology page, choose the Advanced option under Sorting and click the
button.

In the Linear tab of the Advanced Sorting dialog box, choose the option and
click the Show Sorted button.

Under Drill cycle, choose the Peck cycle type and set the Step down value to 2.
Save and calculate the operation.

12. Machine the Ø13.5 holes

In the same manner as explained in the previous steps, perform drilling of the set
of Ø13.5 holes.

Use the Default drill sorting option.

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 7. Automatic Feature Recognition

13. Machine the Ø6.5 holes

In the same manner as explained in the previous steps, perform drilling of the set
of Ø6.5 holes.

Use the option of Advanced drill sorting.

When this option is chosen, SolidCAM determines the

position with the minimal X- and Y-coordinates
and accepts it as the start position of the drill
sequence. From this position, the program
continues the machining of the drills with the
same Y-coordinate; the machining is performed
in the direction of increasing X-coordinates.
When the last position of the
current Y-coordinate is machined,
the program passes to the next
Y-coordinate (in the increasing
order) and continues the machining of the next row from the
position with the minimal X-coordinate to the position with the
maximal X-coordinate (increasing order) and so on. In such manner,
the machining of the rows is performed in the same direction of
increasing X-coordinates.
The ordering of rows is performed in the direction of increasing
Y-coordinates.

303
 Click the Show Sorted button to preview the sorted drill positions on the solid
model.

14. Perform reaming of the Ø8 holes

Add a new Drill Recognition operation to perform reaming of the Ø8 holes.
Use the Drill_r2 geometry defined in Step #10.
Add a new Ø8 Reamer tool.

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 7. Automatic Feature Recognition

Reamer

This tool is used to machine precise holes in Drilling operations.

A tool of this type is defined with the parameters shown in the image.
Selecting a reamer tool in a drilling operation, automatically displays
the correct default cycle for reamers.
Arbor
Diameter

Total
Outside
Length
Holder
Length
Cutting
Length

Tip Diameter Chamfer

Length
Diameter

To define the depth, pick the model face as shown.

The Drill depth value (12) is displayed. Click the Apply button.

305
 Define the sorting of drill positions as explained in Step #10. Click .

15. Simulate the operations

Simulate the operations defined in Steps #9 – #14 in the SolidVerify mode.

Now you have successfully finished the exercise.

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 7. Automatic Feature Recognition

Exercise #19: Electronic Box Machining

In this exercise, the SolidCAM functionality of automatic

drill recognition and machining is used for rough milling
of the electronic box hole features.
This exercise reinforces the following skills:
• Automatic drill recognition and machining
The electronic box part file (Exercise19.prz) is located in
the Exercises folder. This file contains the defined CAM-
Part. The model used for the part definition contains two
configurations: Default (model with hole features) and
Stock (hole features suppressed).

Default Stock

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

16. Center drilling

Define a Drill Recognition
operation to perform center
drilling of all hole features. Use a
Spot drill tool of Ø2.5.

307
 17. Drilling
Define a Drill Recognition
operation to perform drilling
of the Ø1.2 holes. Use a Drill
tool of Ø1.2.

18. Drilling
Define a Drill Recognition
operation to perform drilling
of the Ø1.8 holes. Use a Drill
tool of Ø1.8.

19. Drilling
Define a Drill Recognition
operation to perform drilling
of the Ø2.2 holes. Use a Drill
tool of Ø2.2.

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 7. Automatic Feature Recognition

Exercise #20: Edge Deburring Recognition

This exercise illustrates the SolidCAM functionality of automatic chamfer recognition and
machining.
This exercise reinforces the following skills:
• Automatic chamfer recognition and
machining
The following steps have to be implemented in
order to reach the final CAM-Part:

1. Open the CAM-Part

Open the Exercise20.prz file located in
the Exercises folder. This file contains
the CAM-Part machined in the Pocket Recognition and Drill Recognition exercises.

2. Add a Chamfer Recognition operation

Right-click the Operations header in SolidCAM Manager and choose Edge Deburring
Recognition from the Add Milling Operation submenu.

The Edge Deburring Recognition Operation dialog box is displayed.

3. Define the Geometry

In the Geometry page, click the button.

The Select Faces dialog box is displayed. This dialog box enables you to define the
parameters of the chamfer feature recognition geometry.

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 First, you need to set the chamfer recognition filters and then the mode of geometry
selection.
In the Circular Pocket diameter filter section, make sure
that the Apply filter check box is selected.

Circular Pocket diameter filter

When this check box is selected with the Selection mode set to Solid
Body, circular pocket features can be selected according to their
diameter. All circular pocket features with the diameter greater than
the specified Min. Diameter value will be selected for chamfering.
The Min. Diameter parameter defines the minimum diameter of the
pocket features. You can enter the value in the edit box or pick a cylindrical
surface or a circular edge on the solid model when the cursor is placed in the
Min. Diameter edit box.

When the Ignore edges followed by fillet check box is selected,

chamfering will not be performed on any solid model edge featuring
a fillet.
When the Ignore floor-wall angle less than check box is selected,
chamfering will not be performed in the already existing chamfers at
the edges of floors and/or the edges of angled walls.

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 7. Automatic Feature Recognition

When the Apply filter check box is not selected, all recognized circular
pocket areas suitable for the current Coordinate System are selected.

Set the Min. Diameter value to 20. All of the holes with the diameter smaller than the
specified value will not be chamfered.
Define the mode of geometry selection. Under Selection mode, use the default
Solid Body option.

Click on the solid model. SolidCAM generates the list of elements that suit your
filter settings.
Click the Solid1 element in the list. All the recognized model
features that take part in this geometry are highlighted. The
geometry includes all the planar faces, through pockets of
slots, and circular through pockets of column holes. Each
model element is accompanied by its Z-level value enclosed
in parentheses.

Confirm the Select Faces dialog box by clicking .

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 4. Define the Tool
Add a Chamfer mill of Ø10
for the operation. Define the
tool parameters as follows:
• Set the Total length to
100

• Set the Outside holder

length to 60

Choose the HSK A 63 ER

40x80 collect chuck.

Select the tool for the

operation.

5. Define the machining levels

Define the Chamfer depth by setting the value to 0.5.

6. Define the technological parameters

Switch to the Technology page. Set the Cutting diameter value to 2. The chamfer depth
will be reached with the tool diameter of 2 mm.

Safety offset

For geometries that consist of open chains,

Safety offset is the offset that prevents the
tool gouging with the vertical wall.
SolidCAM automatically calculates the
optimal value of the Safety offset.

Set the Safety offset value to 2.

7. Define the Link in and Link out

In the Link page, select the Normal option from Lead in list and set the Normal length
to 3. Select the Same as Lead in check box in the Lead out section.

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 7. Automatic Feature Recognition

8. Calculate the tool path

Click .

9. Simulate the operation

Simulate the operation in the SolidVerify
mode.
Now you have successfully finished the
exercise.

Congratulations!
You have successfully finished the 2.5D Milling part of the SolidCAM 2021 Milling Training
Course.

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 SolidCAM Training Course
2.5D Milling

iMachining 2D 2.5D Milling HSS (High-Speed Surface Machining)

iMachining 3D Indexial Multi-Sided Machining HSM (High-Speed Machining)

Sim. 5-Axis Machining Turning & Advanced Mill-Turn Solid Probe

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