SolidCAM 2015 Port Machining PDF

SolidCAM Application Tutorial:
Port Machining
SolidCAM + SolidWorks
The Complete Integrated Manufacturing Solution
Contents
Contents
1. Introduction................................................................................................................. 1
2. CAM-Part Definition.................................................................................................... 5
3. Stock and Target Definition...................................................................................... 13
4. iMachining Operation................................................................................................ 17
5. Roughing Operations................................................................................................ 23
6. Finishing Operations................................................................................................ 37
i
Introduction 1
About this course
The goal of this course is to teach you how to use SolidCAM’s Port Machining to machine a
simple and complex port. This tutorial covers the basic concepts of Port Machining. 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.
Prerequisites
Students attending this course are expected to have basic knowledge of the SolidCAM software.
Course design
This course is designed around a task-based approach to training. The guided exercises will teach you
the necessary commands and options to complete a machining task. The theoretical explanations
are embedded into these exercises to give an overview of the Port Machining capabilities.
Using this book

This tutorial is intended to be used in a classroom environment under the guidance of an
experienced instructor. It is also intended to be a self-study tutorial.
2
1. Introduction
Port Machining
The Port Machining operation is an easy to use method for machining ports with tapered lollipop
tool, and has collision checks for the entire tool (shank, arbor, and holder). You can choose to cut
the top only, the bottom only, and specify how much stock to leave on the entire port. It uses 3-Axis
machining as far into the port as possible, and then switches to 5-Axis motion. Smooth transitions
are created where the tool paths meet at the middle of the port. It provides both roughing and
finishing tool paths to make ports from castings or billet.
3
4
CAM-Part Definition
2
The CAM-Part definition process for the part consists of the following stages:
CAM-Part creation
CNC-Machine definition
Coordinate System definition
Stock and Target definition
• CAM-Part creation. At this stage, you have to define the CAM-Part name and location.
SolidCAM defines the necessary system files and a folder to allocate the place to store
SolidCAM data.
• CNC-controller definition. It is necessary to choose the CNC-controller. The controller
type influences the Coordinate System definition and the Geometry definition.
• Coordinate System definition. You have to define the Coordinate System, which is the
origin for all machining operations of the CAM-Part. You can create multiple CoordSys
positions and in each machining step select which CoordSys you want to use for the
operation.
• Stock and Target definition. It is necessary to define a boundary of the stock that is used
for the CAM-Part machining. SolidCAM enables you to define the model of the part in
its final stage after the machining.
The following exercises describe the full process of the CAM-Part definition. It is recommended to
go through 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.
1. Click Tools > SolidCAM > SolidCAM

Settings.
6
2. CAM-Part Definition
2. In the left pane, select CAM-Part.
3. Ensure that the settings are as shown in the

image:
This enables you to start

directly adding operations
in a new part.
4. In the left pane, select Automatic CAM-Part

definition. In the right pane, click the Milling tab.
5. Ensure that all check boxes are cleared except

for Use default CNC controller (skip controller
selection).
6. Double click the SolidWorks icon.
7. Browse to open the SolidWorks part Port.

SLDPRT.
8. Click Tools > SolidCAM > New >

Milling.
Define the CAM-Part in the Milling Part Data dialog box:
7
9. Inthe CNC-Machine list, click Hermle-C30_iTNC530_5X_TZeng.
Leave the fields of Program number & Subroutine number with the
default settings.
10. Click Define button in the Coordinate System tab to set

the coordinate system for this part.
11. In the Place CoordSys origin to list, click Top center of

model box.
12. Select the face as shown in the image.
13. Click
The CoordSys Data window displays.
8
14. Enter the parameters as shown in the image.
15. Click OK.
16. Click 1-Position > Add.
17. In the Place CoordSys origin to list, click CoordSys # 1.
19. Click
The CoordSys Data window displays.
20. Enter the parameters as shown in the image.
21. Click OK.
22. Click
9
23. Click Edit iMachining Database in the iMachining Data
section.
The iDatabase window displays.
24. Click the New icon to define a new machine.
25. Enter HERMLE_PORT as the machine name in the New

iMachining DB File window.
26. Click Save.
27. Enter the parameters as shown in the

image.
28. Click the Material DB tab.
29. Click the New icon.
30. Enter AL-6061-T6 as the material name in the New iMachining

DB File window.
31. Click Save.
10
32. Enter the MPa value of 460 as shown in the image.
33. Click Save & Exit.
34. Click
35. Right click CAM-Part (PORT_COMPLEX) > CAM-

Part Definition.
36. In the Machine Database list, click HERMLE_PORT.
37. In the Material Database list, click AL-6061-T6.
38. Click
The CAM part is now defined.
11
12
Stock and Target
Definition 3
To define the stock you have to follow the steps mentioned in this chapter.
1. Click the Feature Manager Design Tree icon.
2. Click Design Model > Solid Bodies(3) > Stock >
Show.
3. The selected stock should look as shown in the

image:
4. Click the SolidCAM Manager icon.
5. Right click Stock > Define.
14
3. Stock and Target Definition
6. In the Defined by list, click 3D Model.
7. Select the solids as shown in the image.
8. Enter the Facet tolerance value as 0.1 so that your

system does not create a big faceting file.
9. Click
10. Click Target > Define.
11. Select the solid as shown in the image.
12. Click
The stock and the target are now defined.
15
16
iMachining Operation
4
1. Right click Operations > Machine Setup.
The Machine Setup window displays.
2. Enter a value of 225 as shown in the image. This will

raise the part above the machining level.
3. Click OK.
5. Click Design Model > STOCK > Hide.
7. Right click Setup > Add Milling

Operation > 2D iMachining.
8. In the Technology list, click iRough.
18
4. iMachining Operation
9. Click Geometry.
10. In the CoordSys list, click MAC 1 (2-Position).
11. Click the New icon under CoordSys.
12. Select the two contours as shown in the

image.
13. Click Yes in the OK to accept? window both

the times.
14. Click
15. Click Tool > Select.
16. Click the Add Milling Tool icon.
17. Select END MILL.
18. Enter the parameters as shown in

the image.
19. Select the Holder check box.
20. Select HSK A 63 ER 32x80.
21. Click the iData tab.
22. In the Topology / Helical Angle list, click 35 (Standard).
19
23. Click Select.
24. Click Levels.
25. Click Upper Levels.
27. Click
28. Click Pocket depth.
29. Select the point on the face as shown in the image.
30. Click
31. Click Technology.
32. Set the Wall / island offset as 0.1.
33. Select the Floor check box.
20
4. iMachining Operation
34. Click Link.
35. Slide the Max. arc size slide bar to around 6.19764.
Ensure that the Advanced check box is selected.
36. Click the Save & Calculate icon.
37. Click the Exit icon.
38. Select the check box before the operation.
39. The tool path should look as

displayed in the image.
21
22
Roughing Operations
5
Before you start the roughing operation, you must make a few changes to close the holes as shown
in the image.
1. Right click > Edit part.
2. Click Insert > Surface > Offset.
3. Enter a value of 0 in the Offset Parameters field to make a copy of this surface.
24
5. Roughing operations
4. Select the five faces as shown in the video.
5. Click
7. Click Solid Bodies(3) > PART >Hide.
8. Click Insert > Surface > Untrim.
25
9. Select the two faces as shown in the image.
10. Select the Internal edges option in the Options

section.
11. Click
12. Click Insert > Surface > Untrim.
14. Select the All edges option in the Options section.
15. Click
You will now split this surface into two so that you get two single tubes for machining.
26
16. Click Insert > Curve > Split Line.
18. Click Design Model > Plane4 >Show.
19. Select the four faces as shown in the video.
20. Select the Intersection option in the Type of Split

section.
21. Click
22. Click Sketch > 3D Sketch.
23. Click the Line icon.
24. Select the two points as shown in the image.
25. Click
26. Click to come out of the sketch.
27
27. Click Insert > Surface > Fill.
28. Select the three edges as shown in the video.
29. Click
This will ensure that you have three distinct tubes available
for machining.
30. Click to finish editing the part.
32. Right click the previous operation > Add

Milling Operation > Port Machining.
28
33. In the Technology list, click Roughing.
34. Click Geometry.
35. Click the New icon under Machining surfaces.
36. Select the faces as shown in the video.
37. Click
38. Set the Offset value as 0.5.
40. Click the Add Milling Tool icon to add a new Lollipop Mill tool.
41. Enter the parameters as shown in

the image.
42. Select the Holder check box.
43. Select HSK A 63 ER 32x80 as the

holder.
44. Click Select.
29
45. Click Levels.
46. Click the Parallel to X option to get a

cylinder parallel to the X axis.
47. Click
48. Select the point as shown in the image.
49. Click
50. Enter the values in the Levels section as shown in the image.
51. Click Tool path parameters.
30
52. Enter the values as shown in the image.
53. Click the Sorting tab.
54. In the Output type list, click Top.
55. In the Machine to list, click Maximum from top.
56. Click Gouge check.
57. Click the New icon under Check surfaces.
59. Click
60. Click Clearance data.
61. Set a value of 5 in the Holder field.
31
64. Select the check box in front of the operation.

The tool path should look as
show in the image.
65. Click SolidVerify.
The part should look as shown in the image.
32
66. Click the Save & Copy icon.
67. Right click > Edit the operation.
68. Click Geometry.
70. Select the faces as shown in the image.
71. Click

show in the image.
75. Right click > Copy the operation.
76. Right click > Paste the operation.
33
78. Click Geometry.
80. Select the faces as shown in the video.
81. Click
84. In the Output type list, click Bottom.
85. In the Machine to list, click Maximum from bottom.
87. Click Solid Bodies(3) > PART >Show.
89. Select the New icon under Check surfaces.
90. Select the highlighted surface.
91. Click
34

show in the image.
35
36
Finishing Operations
6
1. Right click the operation > Add Milling Operation > Port Machining.
2. In the Technology list, click Spiral Finishing.
3. Click Geometry.
4. In the list, click faces.

The selected faces should look as shown
in the image. You have earlier used this
geometry in the roughing operation.
6. Right click the tool > Copy tool.
7. Change the Outside holder value to 115.
8. Click Select.
9. Click Levels.
10. Click the Parallel to X option to get a cylinder

parallel to the X axis.
11. Click
38
6. Finishing Operations
12. Select the point as shown in the image.
13. Click
14. Enter the values in the Levels section as shown in the image.
17. In the Output type list, click Top.
18. In the Machine to list, click Maximum from top.
20. In the Check surfaces list, click faces1.
39
show in the image.
24. Right click > Copy the operation.
25. Right click > Paste the operation.
27. In the Technology list, click Plunge Finishing.
28. Click Geometry.
29. In the list, click faces2.

40

show in the image.
35. Right click the operation > Copy.
36. Right click the operation > Paste.
41
37. Right click the operation > Edit.
38. In the Technology list, click Spiral

Finishing.
39. Click Geometry.
40. In the list, click faces3.

41. Change the Offset value to 0.
43. Select the tool with the Outside holder

value of 115.
45. Set the Maximum step over limit as 1.
42

show in the image.
43
SolidCAM Application Tutorial:
Port Machining
iMachining 2D 2.5D Milling HSS (High-Speed Surface Machining)
iMachining 3D Indexed Multi-Sided Machining HSM (High-Speed Machining)
Simultaneous 5-Axis Machining Turning & Advanced Mill-Turn Solid Probe
www.youtube.com/SolidCAMProfessor www.facebook.com/SolidCAM
www.youtube.com/SolidCAMiMachining
www.solidcam.com

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SolidCAM Application Tutorial:

3. Stock and Target Definition...................................................................................... 13

Using this book

Coordinate System definition

Stock and Target definition

1. Click Tools > SolidCAM > SolidCAM

2. In the left pane, select CAM-Part.

3. Ensure that the settings are as shown in the

This enables you to start

4. In the left pane, select Automatic CAM-Part

5. Ensure that all check boxes are cleared except

6. Double click the SolidWorks icon.

7. Browse to open the SolidWorks part Port.

8. Click Tools > SolidCAM > New >

Define the CAM-Part in the Milling Part Data dialog box:

10. Click Define button in the Coordinate System tab to set

11. In the Place CoordSys origin to list, click Top center of

12. Select the face as shown in the image.

The CoordSys Data window displays.

14. Enter the parameters as shown in the image.

15. Click OK.

16. Click 1-Position > Add.

17. In the Place CoordSys origin to list, click CoordSys # 1.

18. Select the face as shown in the image.

The CoordSys Data window displays.

20. Enter the parameters as shown in the image.

21. Click OK.

24. Click the New icon to define a new machine.

25. Enter HERMLE_PORT as the machine name in the New

26. Click Save.

27. Enter the parameters as shown in the

28. Click the Material DB tab.

29. Click the New icon.

30. Enter AL-6061-T6 as the material name in the New iMachining

31. Click Save.

32. Enter the MPa value of 460 as shown in the image.

33. Click Save & Exit.

35. Right click CAM-Part (PORT_COMPLEX) > CAM-

36. In the Machine Database list, click HERMLE_PORT.

37. In the Material Database list, click AL-6061-T6.

The CAM part is now defined.

1. Click the Feature Manager Design Tree icon.

3. The selected stock should look as shown in the

4. Click the SolidCAM Manager icon.

5. Right click Stock > Define.

6. In the Defined by list, click 3D Model.

7. Select the solids as shown in the image.

8. Enter the Facet tolerance value as 0.1 so that your

10. Click Target > Define.

11. Select the solid as shown in the image.

The stock and the target are now defined.

2. Enter a value of 225 as shown in the image. This will

3. Click OK.

4. Click the Feature Manager Design Tree icon.

5. Click Design Model > STOCK > Hide.

6. Click the SolidCAM Manager icon.

7. Right click Setup > Add Milling

8. In the Technology list, click iRough.

9. Click Geometry.