SOLIDCAM - THE LEADERS IN INTEGRATED CAMThe complete integrated Manufacturing Solution inside SolidWorks

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SOLIDCAM 2010MILLING USER GUIDE

SolidCAM 2010

Milling User Guide

1995-2010 SolidCAM

All Rights Reserved.

Contents

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Contents

1. SolidCAM Basics

1.1 Installing the SolidCAM Software .................................................................................................... 24

1.1.1 System requirements ................................................................................................................. 241.1.2 Supported CAD systems ......................................................................................................... 241.1.3 SolidCAM Single License installation .................................................................................... 251.1.4 SolidCAM Network License Installation .............................................................................. 29

1.2 Basic Concepts ..................................................................................................................................... 31

1.3 Starting SolidCAM............................................................................................................................... 31

1.4 SolidCAM Interface ............................................................................................................................ 32

1.4.1 SolidCAM Manager .................................................................................................................. 321.4.2 Coordinate System .................................................................................................................... 37

1.5 Getting Help ......................................................................................................................................... 38

2. CAM-Part

2.1 Starting a new Milling CAM-Part ...................................................................................................... 40

2.1.1 New Milling Part dialog box.................................................................................................... 412.1.2 The structure of the CAM-Part.............................................................................................. 422.1.3 Milling Part Data dialog box ................................................................................................... 42

2.2 Coordinate System ............................................................................................................................... 43

2.2.1 Defining the Coordinate System (CoordSys)........................................................................ 432.2.2 CoordSys dialog box ................................................................................................................. 442.2.3 Defining the Coordinate Systems for 3-axis CNC-machine .............................................. 502.2.4 Defining the Coordinate Systems for 4-axis CNC-machine .............................................. 512.2.5 Defining the Coordinate Systems for 5-axis CNC-machine .............................................. 522.2.6 Coordinate System definition methods ................................................................................. 532.2.7 CoordSys Data dialog box ....................................................................................................... 54

62.2.8 SolidCAM Coordinate System ................................................................................................ 562.3 CoordSys Manager .............................................................................................................................. 57

2.4 Stock and Target Model ...................................................................................................................... 59

2.4.1 Stock model ............................................................................................................................... 602.4.2 Target model .............................................................................................................................. 622.4.3 Common controls for Stock model and Target model dialog boxes ................................ 622.4.4 Associativity of Stock and Target models ............................................................................. 63

2.5 Tool Options ........................................................................................................................................ 65

2.6 Mac Options ......................................................................................................................................... 67

2.7 Work Material ....................................................................................................................................... 67

2.8 CNC-Controller and Axis Type ......................................................................................................... 68

2.8.1 Axis type ..................................................................................................................................... 682.9 Default GCode numbers .................................................................................................................... 70

2.10 Part Settings ........................................................................................................................................ 72

2.10.1 Units .......................................................................................................................................... 742.10.2 Synchronization ....................................................................................................................... 752.10.3 Interoperational tool movements ......................................................................................... 782.10.4 Update Stock calculation ....................................................................................................... 792.10.5 Automatic CAM-Part definition ........................................................................................... 822.10.6 Machining Process .................................................................................................................. 832.10.7 Tool path simulation ............................................................................................................... 842.10.8 GCode generation ................................................................................................................... 852.10.9 Template defaults .................................................................................................................... 892.10.10 Tool coolant ........................................................................................................................... 912.10.11 Gouge check .......................................................................................................................... 91

2.11 Compressed CAM-Part .................................................................................................................... 92

2.11.1 Compressed CAM-Part file format ...................................................................................... 922.11.2 Creating a new compressed CAM-Part ............................................................................... 922.11.3 Converting CAM-Parts to Compressed mode ................................................................... 932.11.4 Opening/Closing Compressed CAM-Parts ........................................................................ 93

Contents

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2.12 Managing CAM-Parts ....................................................................................................................... 95

2.12.1 SolidCAM menu ...................................................................................................................... 952.12.2 CAM-Part menu ...................................................................................................................... 99

2.13 CAM-Part Documentation ............................................................................................................ 103

2.13.1 Documentation Editor ......................................................................................................... 1032.14 Tool sheet documentation .............................................................................................................. 105

2.14.1 Generating the tool sheet .................................................................................................... 1062.14.2 Capturing the CAM-Part image .......................................................................................... 1062.14.3 Definition of tool sheet parameters .................................................................................. 1072.14.4 The output file ....................................................................................................................... 1102.14.5 Show Last Tool Sheet ........................................................................................................... 1132.14.6 Tool sheet template definition in the XLS format........................................................... 114

2.15 Cleanup CAM-Part .......................................................................................................................... 129

2.16 SolidCAM controls in SolidWorks environment ........................................................................ 130

2.16.1 SolidCAM tab in SolidWorks CommandManager ........................................................... 1302.16.2 SolidCAM toolbars in SolidWorks environment ............................................................. 134

2.17 Milling-STL CAM-Part ................................................................................................................... 136

2.17.1 Starting a new Milling-STL CAM-Part .............................................................................. 1362.17.2 Coordinate System definition .............................................................................................. 1382.17.3 Stock model definition ......................................................................................................... 1392.17.4 Target model definition........................................................................................................ 139

2.18 Support of DriveWorks .................................................................................................................. 140

3. Tools

3.1 User-Defined Tool Types ................................................................................................................. 144

3.1.1 End mill .................................................................................................................................... 1453.1.2 Ball nose mill............................................................................................................................ 1463.1.3 Bull nose mill ........................................................................................................................... 1473.1.4 Dove tail mill ........................................................................................................................... 148

83.1.5 Face mill ....................................................................................................................................1493.1.6 Slot mill ..................................................................................................................................... 1503.1.7 Taper mill ................................................................................................................................. 1513.1.8 Engraving tool ......................................................................................................................... 1533.1.9 Tap tool.....................................................................................................................................1543.1.10 Lollipop mill .......................................................................................................................... 1553.1.11 Thread mill ............................................................................................................................. 1573.1.12 Thread taper .......................................................................................................................... 1593.1.13 Drill .........................................................................................................................................1593.1.14 Center drill ............................................................................................................................. 1603.1.15 Spot drill ................................................................................................................................. 1623.1.16 Chamfer drill .......................................................................................................................... 1633.1.17 Reamer .................................................................................................................................... 1643.1.18 Bore .........................................................................................................................................1653.1.19 Shaped Tools ......................................................................................................................... 1663.1.20 Add new tool types ............................................................................................................... 1663.1.21 Tool type options .................................................................................................................. 167

3.2 Tool Libraries ..................................................................................................................................... 168

3.3 Working with the Part Tool Table ................................................................................................... 169

3.4 Working with the Current Tool Library ......................................................................................... 170

3.5 Managing Tool Libraries ................................................................................................................... 171

3.5.1 Edit Tool Library .................................................................................................................... 1713.5.2 Create Tool Library ................................................................................................................. 1713.5.3 Copy Tool Library ................................................................................................................... 1723.5.4 Delete Tool Library ................................................................................................................ 173

3.6 Tool Table dialog box ....................................................................................................................... 174

3.6.1 Tools Filter ............................................................................................................................... 1743.6.2 Tool range ................................................................................................................................ 1753.6.3 Show ..........................................................................................................................................1763.6.4 View ..........................................................................................................................................1773.6.5 Edit ............................................................................................................................................177

Contents

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3.7 Managing tools ................................................................................................................................... 180

3.8 Tool data .............................................................................................................................................184

3.8.1 Tool Topology page ................................................................................................................ 1853.8.2 Default Tool Data page .......................................................................................................... 1903.8.3 Tool Message page .................................................................................................................. 1953.8.4 Tool Coolant page ................................................................................................................... 1963.8.5 Holder page .............................................................................................................................. 1973.8.6 Shape page................................................................................................................................ 198

3.9 Tool Holding system ......................................................................................................................... 200

3.9.1 Tool Holders dialog box ........................................................................................................ 2003.9.2 Tool Holder Geometry definition ........................................................................................ 2043.9.3 Tool Holder segments ............................................................................................................ 2053.9.4 Using Tool Holders ................................................................................................................ 206

3.10 Shaped Tools ....................................................................................................................................208

3.10.1 Shaped Tools dialog box ...................................................................................................... 2083.10.2 Shaped tool geometry definition ........................................................................................ 2113.10.3 Shaped Tool segments .......................................................................................................... 2113.10.4 Using Shaped tools ............................................................................................................... 213

3.11 Spin and Feed defaults .................................................................................................................... 215

4. Geometry

4.1 Introduction .......................................................................................................................................218

4.2 Drilling geometry ............................................................................................................................... 219

4.2.1 Defining a Drilling geometry ................................................................................................ 2194.2.2 Editing a Drilling geometry ................................................................................................... 2204.2.3 Drill Geometry Selection dialog box ................................................................................... 2204.2.4 Around 4th Axis Drill Geometry Selection dialog box .................................................... 224

4.3 3D Model geometry .......................................................................................................................... 227

4.3.1 Defining a 3D Model geometry ............................................................................................ 2274.3.2 Editing a 3D Model geometry .............................................................................................. 228

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4.4 Wireframe geometry ......................................................................................................................... 229

4.4.1 Defining the Profile/Pocket geometry ................................................................................ 2294.4.2 Defining the Working Area ................................................................................................... 2304.4.3 Defining the Slot geometry ................................................................................................... 2304.4.4 Defining the Section geometry ............................................................................................. 2314.4.5 Defining the Limit geometry ................................................................................................. 232

4.5 Editing chain geometries .................................................................................................................. 233

4.5.1 Geometry Name ..................................................................................................................... 2334.5.2 Configurations ......................................................................................................................... 2334.5.3 Adding a Chain ........................................................................................................................ 2334.5.4 Managing chains ...................................................................................................................... 2344.5.5 Chain direction ........................................................................................................................ 2354.5.6 Selecting single entities ........................................................................................................... 2354.5.7 Automatic selection ................................................................................................................ 2404.5.8 Chain buttons .......................................................................................................................... 2424.5.9 Options .....................................................................................................................................2434.5.10 Gap control ............................................................................................................................ 2434.5.11 Add Multi-Chain ................................................................................................................... 2444.5.12 Mark Open Edges dialog box ............................................................................................. 244

4.6 Chains Selection dialog box ............................................................................................................. 246

4.6.1 Chains Direction dialog box .................................................................................................. 2484.6.2 Chain sorting ........................................................................................................................... 249

4.7 Managing geometries ........................................................................................................................ 251

4.7.1 Synchronization of the Wireframe geometry ..................................................................... 2524.7.2 Synchronization of the 3D Model geometry ..................................................................... 2564.7.3 Boolean operations ................................................................................................................. 258

Contents

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5. Operations

5.1 Adding an operation .......................................................................................................................... 262

5.2 SolidCAM Operation Interface ....................................................................................................... 263

5.2.1 Operation name ...................................................................................................................... 2655.2.2 Template ................................................................................................................................... 2675.2.3 Info ............................................................................................................................................2795.2.4 Operation buttons ................................................................................................................... 2805.2.5 Calculator ................................................................................................................................. 2835.2.6 Geometry page ........................................................................................................................ 2865.2.7 Tool page .................................................................................................................................. 2885.2.8 Levels page ............................................................................................................................... 2935.2.9 Technology page ..................................................................................................................... 3005.2.10 Advanced Technology page ................................................................................................ 3005.2.11 Link page ................................................................................................................................ 3085.2.12 Miscellaneous parameters page ........................................................................................... 308

5.3 Working with operations .................................................................................................................. 311

5.3.1 Add Operation ........................................................................................................................ 3115.3.2 Add Operation from Template ............................................................................................. 3125.3.3 Add Operations from Process Template ............................................................................ 3125.3.4 Add Machining Process ......................................................................................................... 3135.3.5 Create Template ...................................................................................................................... 3135.3.6 Edit ............................................................................................................................................3135.3.7 Calculate/Calculate All ........................................................................................................... 3135.3.8 GCode/GCode All ................................................................................................................. 3135.3.9 Calculate & GCode All .......................................................................................................... 3135.3.10 Tool Sheet .............................................................................................................................. 3145.3.11 Simulate .................................................................................................................................. 3145.3.12 Simulate External .................................................................................................................. 3145.3.13 File ...........................................................................................................................................3145.3.14 Operation Group .................................................................................................................. 314

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5.3.15 Cut/Copy/Paste .................................................................................................................... 3155.3.16 Rename ................................................................................................................................... 3155.3.17 Change tool ............................................................................................................................ 3165.3.18 Change tool data ................................................................................................................... 3165.3.19 Info ..........................................................................................................................................3175.3.20 Delete/Delete All ................................................................................................................. 3175.3.21 Suppress/Unsuppress .......................................................................................................... 317

5.4 Managing Operations in the SolidCAM Manager tree ................................................................ 320

5.4.1 Operation Sequence ............................................................................................................... 3205.4.2 Undo Sequence........................................................................................................................ 3205.4.3 Split............................................................................................................................................3205.4.4 Expand tree .............................................................................................................................. 3225.4.5 Collapse tree ............................................................................................................................. 3225.4.6 Show/Hide Tools in tree ....................................................................................................... 3225.4.7 Show/Hide CoordSys in tree ................................................................................................ 3235.4.8 Automatic Sorting ................................................................................................................... 324

5.5 Operation Transformations ............................................................................................................. 326

5.5.1 Operation transformations .................................................................................................... 3275.5.2 Options .....................................................................................................................................3285.5.3 Transformations table ............................................................................................................ 3285.5.4 Transformation buttons ......................................................................................................... 329

5.6 Fixture .................................................................................................................................................334

5.6.1 Fixture dialog box ................................................................................................................... 335

6. 2.5D Milling

6.1 Profile Operation ............................................................................................................................... 338

6.1.1 Levels page ............................................................................................................................... 3396.1.2 Technology page ..................................................................................................................... 3396.1.3 Link page .................................................................................................................................. 362

6.2 Face Milling Operation ..................................................................................................................... 371

Contents

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6.2.1 Geometry page ........................................................................................................................ 3716.2.2 Technology page ..................................................................................................................... 3746.2.3 Link page .................................................................................................................................. 385

6.3 Contour 3D Operation ..................................................................................................................... 387

6.3.1 Technology page ..................................................................................................................... 3876.3.2 Link page .................................................................................................................................. 391

6.4 Pocket Operation ............................................................................................................................... 393

6.4.1 Geometry page ........................................................................................................................ 3946.4.2 Levels page ............................................................................................................................... 3956.4.3 Technology page ..................................................................................................................... 3966.4.4 Link page .................................................................................................................................. 417

6.5 Pocket Recognition Operation ........................................................................................................ 433

6.5.1 Geometry page ........................................................................................................................ 4336.5.2 Levels page ............................................................................................................................... 4396.5.3 Technology page ..................................................................................................................... 4406.5.4 Link page .................................................................................................................................. 444

6.6 Drilling Operation ............................................................................................................................. 445

6.6.1 Tool page .................................................................................................................................. 4456.6.2 Levels page ............................................................................................................................... 4476.6.3 Technology page ..................................................................................................................... 448

6.7 Drill Recognition Operation ............................................................................................................ 473

6.7.1 Geometry page ........................................................................................................................ 4736.7.2 Levels page ............................................................................................................................... 4796.7.3 Technology page ..................................................................................................................... 484

6.8 Thread Milling Operation ................................................................................................................ 487

6.8.1 Tool page .................................................................................................................................. 4876.8.2 Levels page ............................................................................................................................... 4886.8.3 Technology page ..................................................................................................................... 4896.8.4 Link page .................................................................................................................................. 492

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6.9 Slot Operation .................................................................................................................................... 493

6.9.1 Technology page ..................................................................................................................... 4946.9.2 Pre-drilling geometry generation .......................................................................................... 501

6.10 T-Slot Operation .............................................................................................................................. 503

6.10.1 Tool page ................................................................................................................................ 5046.10.2 Technology page ................................................................................................................... 5056.10.3 Link page ................................................................................................................................ 510

6.11 Translated Surface Operation ........................................................................................................ 511

6.11.1 Technology page ................................................................................................................... 5116.11.2 Link page ................................................................................................................................ 522

7. 3D Milling

7.1 3D Milling Operation ........................................................................................................................ 524

7.1.1 Geometry page ........................................................................................................................ 5247.1.2 Technology page ..................................................................................................................... 5377.1.3 Roughing .................................................................................................................................. 5387.1.4 Hatch roughing ........................................................................................................................ 5537.1.5 Contour roughing ................................................................................................................... 5537.1.6 Plunging pattern ...................................................................................................................... 5537.1.7 Semi-Finish/Finish ................................................................................................................. 5547.1.8 Semi-Finish/Finish strategies ................................................................................................ 5607.1.9 Linear Finish strategy ............................................................................................................. 5607.1.10 Offset Cutting Finish strategy............................................................................................. 5647.1.11 Spiral finish strategy ............................................................................................................. 5677.1.12 Circular Pocket finish strategy ............................................................................................ 5717.1.13 Constant Z Finish Strategy .................................................................................................. 5737.1.14 Constant Step over strategy................................................................................................. 5807.1.15 Pencil milling ......................................................................................................................... 5857.1.16 Tolerance page ....................................................................................................................... 589

Contents

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7.2 3D Engraving Operation.................................................................................................................. 591

7.2.1 Technology page ..................................................................................................................... 5917.2.2 Tolerance page ......................................................................................................................... 594

7.3 3D Drilling Operation ...................................................................................................................... 595

7.3.1 Geometry page ........................................................................................................................ 5957.3.2 Tool page .................................................................................................................................. 5967.3.3 Levels page ............................................................................................................................... 5977.3.4 Technology page ..................................................................................................................... 597

8. Machining Processes

8.1 Introduction & Basic concepts ........................................................................................................ 600

8.1.1 Operation templates ............................................................................................................... 6008.1.2 Parameters & Expressions ..................................................................................................... 6018.1.3 Default sets .............................................................................................................................. 6028.1.4 Machining Process Table ....................................................................................................... 602

8.2 Creating Machining Processes ......................................................................................................... 603

8.3 Defining Machining Process Table ................................................................................................. 604

8.3.1 Adding MAC file(s) ................................................................................................................. 6048.4 Machining Process Table Manager ................................................................................................. 606

8.4.1 Managing Machining Process Tables ................................................................................... 6078.4.2 Machining Process Group Types .......................................................................................... 609

8.5 Managing Machining Processes ....................................................................................................... 611

8.6 Machining Process Define Manager ............................................................................................... 612

8.6.1 Operation Templates page ..................................................................................................... 6128.6.2 Defining operation templates ................................................................................................ 6128.6.3 Managing operation templates .............................................................................................. 6138.6.4 Parametric field menu ............................................................................................................. 6158.6.5 Default Sets page..................................................................................................................... 6168.6.6 Parameters & Expressions Tables ........................................................................................ 617

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8.6.7 Add new parameter ................................................................................................................ 6198.6.8 Variables and expressions ...................................................................................................... 6198.6.9 Parametric tool definition ...................................................................................................... 624

8.7 Using the Machining Processes ....................................................................................................... 626

8.8 Inserting the Machining Process ..................................................................................................... 627

8.8.1 Choosing the tool .................................................................................................................... 6298.9 Machining Process Insert Manager ................................................................................................. 630

8.9.1 Operation Templates Page..................................................................................................... 6308.9.2 Default Sets Page .................................................................................................................... 6318.9.3 Parameters Table ..................................................................................................................... 6328.9.4 Operation Points ..................................................................................................................... 6328.9.5 Parameters definition .............................................................................................................. 632

9. Automatic Feature Recognition and Machining (AFRM)

9.1 Introduction and Basic Concepts .................................................................................................... 636

9.2 Preparation to Holes Recognition ................................................................................................... 638

9.2.1 Definition of Coordinate Systems ....................................................................................... 6389.2.2 Target model ............................................................................................................................ 638

9.3 Start Holes Recognition .................................................................................................................... 639

9.4 Holes Recognition User Interface ................................................................................................... 640

9.4.1 Holes Recognition Manager .................................................................................................. 6409.4.2 Holes Recognition Toolbar.................................................................................................... 641

9.5 Hole Feature Model ........................................................................................................................... 643

9.5.1 Cylindrical Hole Feature segment ......................................................................................... 6449.5.2 Cone Hole Feature segment .................................................................................................. 6449.5.3 Chamfer Hole Feature segment ............................................................................................ 6459.5.4 Planar Hole Feature segment ................................................................................................ 6459.5.5 Torus Hole Feature segment ................................................................................................. 6459.5.6 Sphere Hole Feature segment ............................................................................................... 6469.5.7 Compound Holes processing ................................................................................................ 646

Contents

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9.5.8 Disconnected Holes processing ............................................................................................ 6479.5.9 Reaming recognition ............................................................................................................... 6479.5.10 Hole Feature Shapes and Groups....................................................................................... 6479.5.11 Hole Features page ............................................................................................................... 648

9.6 Preparing Hole Features for machining ......................................................................................... 653

9.6.1 Undercut processing ............................................................................................................... 6539.6.2 Undercut substitution ............................................................................................................. 6549.6.3 Segments Union ...................................................................................................................... 6579.6.4 Machinable Hole Features ..................................................................................................... 6599.6.5 Machinable Hole Feature conversion .................................................................................. 6659.6.6 Machinable Hole Features page ............................................................................................ 673

9.7 Feature Sets .........................................................................................................................................682

9.7.1 Creating Feature Sets .............................................................................................................. 6829.7.2 Assigning Hole Features to Feature Sets ............................................................................. 6829.7.3 Automatic CoordSys Positions definition ........................................................................... 6839.7.4 Feature Sets page ..................................................................................................................... 6859.7.5 Compatible/Incompatible Hole features ............................................................................ 6859.7.6 Operating Feature Sets ........................................................................................................... 6869.7.7 Defining the CoordSys Position origin location for the Feature Set .............................. 687

9.8 Technology .........................................................................................................................................689

9.8.1 Choosing a Technological Solution ...................................................................................... 6899.8.2 Choosing the tool .................................................................................................................... 6909.8.3 Technology Page ..................................................................................................................... 6979.8.4 Managing Technology ............................................................................................................ 698

9.9 Generating Operations ..................................................................................................................... 701

9.10 Technology Database ...................................................................................................................... 702

9.10.1 Global and Local Technology databases ........................................................................... 7039.10.2 Technology Database interface ........................................................................................... 7049.10.3 Configurations page .............................................................................................................. 7049.10.4 Current Configuration .......................................................................................................... 7059.10.5 Segments page ....................................................................................................................... 706

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9.10.6 Conditions .............................................................................................................................. 7079.10.7 Variables ................................................................................................................................. 7109.10.8 Defining a new technological solution .............................................................................. 7139.10.9 Holes Recognition Functions.............................................................................................. 714

9.11 Holes Recognition Settings ............................................................................................................ 716

9.11.1 System settings ...................................................................................................................... 7169.11.2 Part settings ............................................................................................................................ 719

10. Simulation

10.1 Introduction ..................................................................................................................................... 722

10.1.1 Simulation control panel ...................................................................................................... 72210.1.2 Simulation modes .................................................................................................................. 72410.1.3 Simulation controls ............................................................................................................... 724

10.2 2D simulation mode ........................................................................................................................ 725

10.2.1 Simulation toolbar ................................................................................................................. 72510.2.2 Simulation control panel ...................................................................................................... 725

10.3 Host CAD simulation mode .......................................................................................................... 727

10.4 3D simulation mode ........................................................................................................................ 728

10.4.1 Simulation toolbar ................................................................................................................. 72810.4.2 Simulation menu ................................................................................................................... 729

10.5 SolidVerify simulation mode .......................................................................................................... 730

10.5.1 Simulation control panel ...................................................................................................... 73010.5.2 Simulation toolbar ................................................................................................................. 73110.5.3 Selection mode ...................................................................................................................... 73710.5.4 Measurement ......................................................................................................................... 73810.5.5 Updated Stock model ........................................................................................................... 73810.5.6 Simulation menu ................................................................................................................... 740

10.6 SolidVerify for 3D simulation mode ............................................................................................ 747

10.6.1 Simulation control panel ...................................................................................................... 74810.6.2 Rendering of the simulation model ................................................................................... 748

Contents

19

10.6.3 Simulation toolbar ................................................................................................................. 75010.6.4 Simulation menu ................................................................................................................... 750

10.7 Rest Material simulation mode ...................................................................................................... 751

10.8 RapidVerify simulation mode ........................................................................................................ 752

10.8.1 RapidVerify control panel .................................................................................................... 75210.8.2 Updated Stock Model ........................................................................................................... 75310.8.3 Simulation control panel ...................................................................................................... 75310.8.4 Simulation toolbar ................................................................................................................. 75410.8.5 Simulation menu ................................................................................................................... 754

10.9 Machine Simulation ......................................................................................................................... 755

10.9.1 Simulation menu ................................................................................................................... 75610.9.2 Simulation windows .............................................................................................................. 76810.9.3 Simulation toolbars ............................................................................................................... 77910.9.4 CNC-machine definition parameters ................................................................................. 78110.9.5 CNC-machine model definition ......................................................................................... 798

10.10 External Simulation ....................................................................................................................... 833

10.10.1 Show SolidCAM Manager ................................................................................................. 83410.10.2 Run as main process/Run as background process ........................................................ 83510.10.3 Simulation toolbar .............................................................................................................. 835

11. GCode

11.1 Generate ............................................................................................................................................839

11.2 List .....................................................................................................................................................841

11.3 Copy ..................................................................................................................................................841

11.4 Print ...................................................................................................................................................841

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12. SolidCAM Settings

12.1 Introduction ..................................................................................................................................... 844

12.2 User Directories settings ................................................................................................................ 848

12.2.1 User Directory for SolidCAM Parts .................................................................................. 84812.2.2 User Directory for SolidCAM Tables ................................................................................ 84812.2.3 Excel file for Threading tables ............................................................................................ 848

12.3 Default CNC-controller settings ................................................................................................... 849

12.3.1 Post-processor files directory .............................................................................................. 84912.3.2 CNC-controllers .................................................................................................................... 849

12.4 Units settings ....................................................................................................................................850

12.4.1 Metric/Inch ........................................................................................................................... 85012.4.2 Approximation ...................................................................................................................... 85012.4.3 Chain selection ...................................................................................................................... 85112.4.4 Fillet size for last cut ............................................................................................................. 85212.4.5 Tool Start and Clearance Levels ......................................................................................... 852

12.5 Synchronization settings ................................................................................................................. 853

12.5.1 Synchronization of CAM geometry with design model ................................................. 85312.5.2 Synchronization tolerance ................................................................................................... 85412.5.3 Synchronization of design model with original model ................................................... 85412.5.4 Synchronization when design model configuration changes ......................................... 854

12.6 Compressed CAM-Part settings .................................................................................................... 855

12.7 Tool Settings .....................................................................................................................................856

12.7.1 Update Part Tool Table according to Machine Tool Table ............................................ 85612.7.2 Print in documentation Only used tools ........................................................................ 85612.7.3 Show in SolidCAM Manager ............................................................................................... 85712.7.4 Import tools ........................................................................................................................... 85712.7.5 Set Tool as Permanent when user changes the tool number ......................................... 857

12.8 Color settings ................................................................................................................................... 858

12.9 Default Geometry Names .............................................................................................................. 860

Contents

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12.10 Interoperational tool movements ............................................................................................... 861

12.11 AutoSave settings .......................................................................................................................... 862

12.12 Automatic CAM-Part definition ................................................................................................. 863

12.12.1 Automatic Stock model definition ................................................................................... 86312.12.2 Automatic Target model definition .................................................................................. 86412.12.3 Definition of Coordinate System ..................................................................................... 864

12.13 Tool path simulation settings ....................................................................................................... 865

12.14 Machine simulation settings ......................................................................................................... 866

12.14.1 Directory for Machine simulation definition .................................................................. 86612.14.2 Tool path coordinates ........................................................................................................ 86612.14.3 Background .......................................................................................................................... 86612.14.4 Enable collision control ..................................................................................................... 86812.14.5 Solid verification ................................................................................................................. 86812.14.6 Environment ....................................................................................................................... 869

12.15 DNC settings ................................................................................................................................. 869

12.16 Editors settings .............................................................................................................................. 870

12.17 External program settings ............................................................................................................ 871

12.18 Machining Process settings .......................................................................................................... 872

12.18.1 On MP insertion (for milling only) .................................................................................. 87212.18.2 Operation name in SolidCAM Manager ......................................................................... 87212.18.3 Update extra parameters on CNC-controller change ................................................... 872

12.19 User interface settings ................................................................................................................... 873

12.20 CoordSys settings .......................................................................................................................... 874

12.21 GCode Generation ........................................................................................................................ 875

12.22 Tool search .....................................................................................................................................878

12.23 Internal Post-processor ................................................................................................................ 878

12.24 SolidCAM Manager settings ........................................................................................................ 879

12.25 Template defaults .......................................................................................................................... 879

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12.26 Miscellaneous settings ................................................................................................................... 880

12.27 Tool coolant ................................................................................................................................... 881

12.28 Gouge check................................................................................................................................... 881

12.29 CAM Messages .............................................................................................................................. 882

Appendix ...................................................................................................................................................883

Index ..........................................................................................................................................................889

1SolidCAM is a powerful CAM product that has been designed especially for the shop floor. SolidCAM supports the complete range of major manufacturing applications including 2.5D Milling, 3D Milling, Turning, Turning with Driven tools and Wire EDM, in one integrated solution. Machining operations can be defined on 2D Design Drawings as well as on 3D Solid and Surface Models. SolidCAM also has a powerful general post-processor tool that enables the easy customization of the GCode file output to various types of CNC-controllers.

This chapter discusses some basic concepts and terminology used throughout SolidCAM.

Installing SolidCAM Starting SolidCAM SolidCAM Basic Concepts SolidCAM Interface Getting Help

SolidCAMBasics

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1.1 Installing the SolidCAM Software

1.1.1 System requirements

Supported Operating Systems

Microsoft Windows 7 x32/x64 Professional and Ultimate editionsMicrosoft Windows Vista x32/x64 Business and Ultimate editions with Service Pack 1Microsoft Windows XP Professional with Service Pack 2 or 3

Microsoft Windows XP Professional x64 Edition

CPU

Intel Core, Intel Core2 Duo, Intel Core Quad, Quad-core Intel Xeon, AMD Phenom, AMD Phenom II, AMD Athlon X2 Dual-Core - class processor

RAM

2 GB RAM or more (4 GB or more for x64 operating system is recommended for large CAM-Parts machining)

Video

A OpenGL workstation graphics card (512 MB RAM recommended) and latest driver

Other

Mouse or other pointing device;

CD drive;

Internet Explorer version 6 if you are using the SolidCAM Online Help; For viewing the Whats New manual, Adobe Acrobat version 9 or higher is

recommended.

1.1.2 Supported CAD systems

The following CAD systems are supported by SolidCAM 2010:

SolidWorks 2006, 2007, 2008, 2009, 2010;

SolidWorks 64-bit version is supported.

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1. SolidCAM Basics

Autodesk Inventor 2008, 2009, 2010;

Bentley Microstation/J Modeler;

Autodesk Mechanical Desktop 2005;

Autodesk AutoCAD 2005.

1.1.3 SolidCAM Single License installation

1. Insert the SolidCAM Installation CD into the computer CD drive; the installation starts automatically.

You can also start the installation by running the Setup.exe file. This file is located in the SolidCAMXXXX/Disk1 folder on the SolidCAM Installation CD (XXXX stands for the current version of SolidCAM).

2. The Choose Setup Language dialog box is displayed.

Choose English.

When you have to install a localized version of SolidCAM, choose the appropriate language from the combo box.

The installation procedure is continued.

3. The following message is displayed.

Close all running applications and confirm the message with the OK button.

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4. The Installing SolidCAM dialog box is displayed. Click on the Next button.

5. The Choose Destination Location dialog box is displayed.

This dialog box enables you to choose the destination folder for SolidCAM. You have to either confirm the default destination folder (C:\Program Files\SolidCAMXXXX) with the Next button or choose another destination folder with the Browse button and confirm it with the Next button.

6. The Select Components dialog box is displayed.

Choose the necessary SolidCAM components and confirm your choice with the Next button.

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1. SolidCAM Basics

Make a note that the Program Files component cannot be cleared.

7. The Select Program Folder dialog box is displayed.

Confirm the default Program Folder name SolidCAMXXXX with the Next button.

SolidCAM installation is continued.

8. When the installation is finished, the Choose Language dialog box is displayed.

Choose English and click on the OK button.

When you install a localized version of SolidCAM, choose the appropriate language from the combo box.

9. SolidCAM installs drivers for the hardware key. When the drivers are installed, the following message is displayed.

Click on the OK button.

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10. When SolidCAM is connected to the defined CAD system (SolidWorks), the following message is displayed.

Click on the OK button.

11. The following dialog box is displayed.

Click on the Finish button.

The installation is finished.

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1. SolidCAM Basics

1.1.4 SolidCAM Network License Installation

SolidCAM enables you to install several SolidCAM copies through your network and use network licensing to manage them. In this case, the SolidCAM Network hardware key has to be connected to the server. The License Manager has to be installed on the network server computer, which distributes SolidCAM Licenses to client computers. When the SolidCAM software runs on a client computer, it obtains the necessary license from the server.

Setting up the SolidCAM License Server

SolidCAM network licensing supports TCP/IP network protocol.

1. SolidCAM Network hardware keys are available in two configurations: for USB port or for LPT port. Connect your SolidCAM Network hardware key to the correct port of your server.

2. Install SolidCAM software on the server as explained in topic 1.1.3. During the installation, the necessary driver for the hardware key is automatically installed.

3. After the SolidCAM installation, the server must be restarted.

4. Install the License Manager software by running Lmsetup.exe application located in the ..\SolidCAMXXXX\Util folder.

5. Check the IP address of the server in the network by clicking on the Start button located at the Windows taskbar and then choosing the Command Prompt item from the All Programs/Accessories submenu. The Command Prompt window is displayed.

6. Type the ipconfig command and confirm it with the Enter key.

The IP address of the server will be displayed.

SolidCAM Client Computers

SolidCAMLicense Server

SolidCAM Networkhardware key

SolidCAM Licenses

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Setting SolidCAM licenses on client computers

1. Install SolidCAM on client computer as described in topic 1.1.3.

2. Copy the NethaspTCPIP.ini file located in the ..\SolidCAMXXXX\Util folder to the ..\SolidCAMXXXX\Solidcam folder.

3. Rename the copied file from NethaspTCPIP.ini to Nethasp.ini.

4. Open the renamed Nethasp.ini file in the Notepad editor. The [NH_TCPIP] section in this file contains the following string: NH_SERVER_ADDR = XX.XX.XX.XX; This parameter should define the IP address of the License Server. Type the IP address of the server instead of XX.XX.XX.XX, for example: 72.14.207.99. Save the Nethasp.ini file and close the Notepad application.

After the License Manager is installed on the SolidCAM Licensing server and SolidCAM Licenses are configured on each client computer, the SolidCAM software can be launched.

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1. SolidCAM Basics

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, including the model name, the Coordinate System, 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 Starting SolidCAM

To start SolidCAM, click on the SolidCAM field in the main menu of SolidWorks and choose Milling from the New submenu.

SolidCAM is started.

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1.4 SolidCAM Interface

1.4.1 SolidCAM Manager

After the CAM-Part is loaded, the SolidCAM Manager is displayed in the left part of the screen.

The SolidCAM Manager tree is the main interface feature of SolidCAM. It displays complete information about the CAM-Part and contains the following headers:

CAM-Partheader

This header displays the name of the current SolidCAM CAM-Part. By right-clicking on it, you can display the menu to manage your CAM-Parts. The CoordSys Manager, Stock, Target, and Settings subheaders are located under the CAM-Part header.

Double-clicking on this header displays the Milling Part Data dialog box.

For more information on CAM-Parts, please refer to Chapter 2.

CAM-Part header

Operations

Tool header

Machining Processheader

Geometries header

Operations header }

SolidWorks window

SolidCAMtoolbars

Coordinate System

MachiningSolid model

SolidCAMManager

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1. SolidCAM Basics

Toolheader

This header displays the name of the current Tool Table. By right-clicking on it, you can activate the menu to manage the Tool Libraries.

Double-clicking on this header displays the Part Tool Table.

For more information on Tools, please refer to Chapter 3.

MachiningProcessheader

This header displays the name of the current Machining Process Table. By right-clicking on it, you can activate the menu to manage the MP Tables.

Double-clicking on this header displays the Current Machining Process Table.

For more information on Machining Processes, please refer to Chapter 8.

Geometriesheader

This header displays all SolidCAM geometries not used in the operations. You can view the list of these geometries by clicking on the + icon near the Geometries header. You can display the geometries managing menu by right-clicking on the Geometries header. You can also open the relevant menu by right-clicking on each geometry name.

Double-clicking on a geometry name displays the selected geometry.

For more information on Geometries, please refer to Chapter 4.

Operationsheader

This header shows you all the SolidCAM operations defined for the current CAM-Part. The operations managing menu is available by right-clicking on the Operations header. You can also open the relevant menu by right-clicking on each operation name.

Double-clicking on an operation name enables you to edit the operation parameters in the operation dialog box.

For more information on operations, please refer to Chapter 5.

Item search in SolidCAM Manager

The SolidCAM Manager search system works similarly to a regular Windows searching functionality. To activate it, click anywhere in the SolidCAM Manager area and press Ctrl+F. The Find dialog box is displayed, and you can set the parameters for searching.

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Look in

You may look for the required items in the whole CAM-Part or only in its operations, coordinate systems or geometries taken separately.

Whole items only

Select this check box if you want to check the availability of whole items as opposed to partial output.

Match case

This check box enables you to determine the case sensitivity of the search.

Direction

You may also decide whether the search results will be displayed from bottom to top or from top to bottom of the SolidCAM Manager tree.

Find next

Click this button if you want to view the search results one by one.

Find all

Click this button if you prefer to have all of the search results to be displayed simultaneously.

General

The whole line where the sought-for word appears is highlighted in the SolidCAM Manager tree. When you close the Find dialog box, these lines remain highlighted.

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1. SolidCAM Basics

Display of tool path for CAM-Part operations

SolidCAM enables you to display the tool path of CAM-Part operations directly on the SolidWorks model from SolidCAM Manager. The tool path can be rotated, zoomed or panned.

Display of tool path for several operations

Each operation entry in SolidCAM Manager has a related tool path visibility check box, which can be selected to display the tool path of the corresponding operation.

When several operations are selected in SolidCAM Manager, clicking on the check box related to one of the selected operations changes the tool path visibility status for all the selected operations, and the tool path of all these operations is displayed on the model.

When one of the tool path visibility check boxes related to selected operations is clicked again, the tool path display and the check boxes are cleared.

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Display of tool path for all operations

The tool path visibility check box located near the Operations header enables you to control the tool path visibility status for all the operations defined for the CAM-Part.

When this check box is selected, the tool path visibility check boxes are selected for all the operations and SolidCAM displays the tool path for all of the operations.

When this check box is cleared, SolidCAM clears the tool path display and the tool path visibility check boxes for all the operations.

When a CAM-Part contains operations with different status of the tool path visibility, the tool path visibility check box related to the Operations header has a solid black fill.

When the mixed tool path visibility check box related to the Operations header is clicked again, it is cleared; the tool path display and all the related tool path visibility check boxes are cleared.

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1. SolidCAM Basics

1.4.2 Coordinate System

The Coordinate System is shown on the model. It defines the origin for all the machining operations of the CAM-Part.

For more information on Coordinate Systems, see topic 2.2.

Coordinate System

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1.5 Getting Help

SolidCAM Online Help enables you to get online help about various options in SolidCAM. The Help is installed in the Documentation folder after the standard installation procedure.

The Help is available via the SolidWorks Help menu. Click on the Help item in the main menu of SolidWorks and choose the SolidCAM Help Topics, Milling items from the submenu.

SolidCAM Help is fully context-sensitive. You can get a Help topic for each SolidCAM dialog box by pressing the F1 key. To get information about a specific dialog box area like field or button, click on the question mark in the upper-right corner of the dialog box and then click on the field or button you need. The Online Help is displayed and then the appropriate topic is explained.

The Machining Portfolio is also available in the Documentation folder. This document provides an overview of various features of SolidCAM.

2CAM-PartAt the stage of the CAM-Part definition, you have to specify all the information relevant to the machining project or workpiece you want to manufacture. The CAM-Part folder includes all machining geometries, operation definitions and generated GCode files.

The parameters and values defined at the CAM-Part level, such as Coordinate System, Milling levels and Tools will serve as default values for separate machining operations. All specified parameters can be changed in single operations.

Starting a new Milling CAM-Part Managing CAM-Parts Defining the Coordinate System Defining the Stock model Defining the Target model CAM-Part Documentation

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2.1 Starting a new Milling CAM-Part

After the SolidWorks model is loaded, do the following:

1. Click on the SolidCAM item in the SolidWorks menu. The SolidCAM main menu is displayed.

2. Choose the New option from the menu to define a new CAM-Part.

3. Choose the Milling type of new CAM-Part from the submenu.

or

1. In the SolidWorks CommandManager, click on the SolidCAM tab.

2. Click on the arrow near the New button.

3. Choose the Milling type of new CAM-Part from the list.

or

1. Right-click on the frame of the SolidWorks window to display the list of available toolbars.

2. Choose the SolidCAM New toolbar from the list.

3. Click on the Milling button on the SolidCAM New toolbar.

The New Milling Part dialog box is displayed.

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2. CAM-Part

When you start to program a CAM-Part, you have to decide on:

What type of CNC-machine you are going to use (3-, 4- or 5-axis);

Where you are going to clamp this part;

Where your Coordinate System positions are located (on a 4- or 5-axis CNC-machine, every clamping position is represented by the Coordinate System to which all additional positionings are related).

2.1.1 New Milling Part dialog box

When you create a new CAM-Part, you have to enter a name for the CAM-Part and for the model that contains the CAM-Parts geometry.

Directory

In this field, you specify the location of the CAM-Part. The default directory is the SolidCAM user directory (defined in the SolidCAM Settings). You can enter the path or use the Browse button to define the location.

The Use Model file directory option enables you to automatically create CAM-Parts in the same folder where the original CAD model is located.

Name

In this field, you enter the name for the CAM-Part. You can give any name to identify your machining project. By default, the name of the design model is used.

Model name

This field shows the name and the location of the SolidWorks design model that you are using for the CAM-Part definition. The default name is that of the active SolidWorks document. With the Browse button, you can choose any other SolidWorks document to define the CAM-Part. The chosen document is loaded into SolidWorks.

Every time the CAM-Part is opened, SolidCAM automatically checks the correspondence of the dates of the CAM-Part and the original SolidWorks design model. When the date of the original SolidWorks model is later than the date of the CAM-Part creation, this means that the SolidWorks original model has been updated. You can then replace the SolidWorks design model on which the CAM-Part is based with the updated SolidWorks design model.

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After the Directory, Name and Model name fields are defined, click on the OK button to confirm the CAM-Part creation. The CAM-Part is defined and its structure is created. The Milling Part Data dialog box (see topic 2.1.3) is displayed.

2.1.2 The structure of the CAM-Part

The Cavity CAM-Part includes the following data:

The Cavity.prt file located in the SolidCAM User directory.

The Cavity subdirectory containing all the data generated for the CAM-Part.

SolidCAM copies the original SolidWorks model to the Cavity subdirectory and creates a SolidWorks assembly that has the same name as the CAM-Part (Cavity.sldasm). There are two components in this assembly:

DesignModel.sldprt a copy of the SolidWorks model file.

CAM.sldprt a file that contains SolidCAM Coordinate Systems and geometry data.

SolidCAM CAM-Part uses the assembly environment of SolidWorks. This enables you to create auxiliary geometries (e.g. sketches) without making changes in the original design model. You can also insert some additional components into the assembly file such as stock model, CNC-machine table, clamping and other tooling elements.

2.1.3 Milling Part Data dialog box

In this dialog box, you specify all the information relevant to the machining project or workpiece you want to manufacture. The parameters and values defined at the CAM-Part level will later serve as default values for machining levels, etc. Naturally, all parameters can be changed in single machining operations.

Cavity.prt

Cavity.SLDASM

CAM.SLDPRT

DesignModel.SLDPRT

Cavity

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2. CAM-Part