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SolidCAM Mill-Turn Module
Transcript of SolidCAM Mill Turn
SolidCAM Mill-Turn Module
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Table of contents
1. Introduction................................................................................................................................3
2. Part definition.............................................................................................................................4
2.1. Home........................................................................................................................................5 2.1.1. Multi-sided Homes .........................................................................................................6 2.1.2. Projections Homes........................................................................................................15 2.1.3. Home data dialog ..........................................................................................................21 2.1.4. Home edit dialog...........................................................................................................23
2.2. Material boundaries ..............................................................................................................25
2.3. Clamp definition ...................................................................................................................27
2.4. Target definition ...................................................................................................................28
3. Turning Jobs .............................................................................................................................28
4. Milling Jobs ...............................................................................................................................31
4.1. Preparing the tool path for the facial milling....................................................................34 4.1.1. Multi-Sided.....................................................................................................................34 4.1.2. Projections......................................................................................................................35 4.1.3. 4-Axis options................................................................................................................36
4.2. Preparing the tool path for the indexial 4-axis milling ....................................................38 4.2.1. Multi-Sided.....................................................................................................................38 4.2.2. Projections......................................................................................................................40
4.3. Preparing the tool path for the simultaneous 4-axis milling .........................................42 4.3.1. Multi-Sided.....................................................................................................................42 4.3.2. Projections......................................................................................................................45 4.3.3. 4-Axis options................................................................................................................49
5. Example.....................................................................................................................................52 5.1 Configurations ...................................................................................................................52 5.2 Home ..................................................................................................................................53 5.3 Machining...........................................................................................................................54 5.3.1 Turning (TR_profile_T1)..............................................................................................54 5.3.2 Facial Milling (F_Facial_milling_T3) ..........................................................................54 5.3.3. Indexial 4_axis Milling (F_Step_T3) ..........................................................................55 5.3.4. Simultaneous 4-axis milling (P_Pockets_T2)............................................................56
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1. Introduction The Mill-Turn module enables you to prepare the tool path for turning and milling operations for mill-turn CNC centers. SolidCAM provides all turning operations as well as milling operations for driven tools on the face or the perimeter of the stock. The following types of machining are available in the Mill-Turn module: Turning
SolidCAM enables you to prepare the tool path for all turning operations: facial and radial, drilling, threading and grooving.
Facial Milling
SolidCAM enables you to perform all the milling operations on the front faces of the model. With such machining, the tool axis is always parallel to the revolution axis of the part.
Indexial 4 axis milling
SolidCAM enables you to perform all the milling operations on the non- radial faces of the model. The rotation axis of the CNC machine is used to set the part to the necessary position. The milling is performed with only 3-axial movement.
Simultaneous 4 axis milling
SolidCAM enables you to perform all the milling operations on the radial faces of the model. The rotation axis of the CNC machine is used simultaneously with 3-axis movements.
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2. Part definition In the CAM-Part, you have to specify all the information relevant to the machining project or workpiece you want to manufacture. The Milling Turning Part data dialog enables you to specify all these parameters.
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2.1. Home
Usually Mill-Turn CNC machines have only one machine home; the Z-axis of this home is the rotation axis of the spindle. The Machine home enables you to perform turning and milling operations.
The turning tool movements are located in the ZX plane of the Machine coordinate system. The axis of the milling tool used for the facial milling is parallel to the Z-axis of the Machine coordinate system. The axis of the milling tool used for radial milling (indexial and simultaneous 4-axis milling) is parallel to the X-axis of the Machine coordinate system. SolidCAM enables you to define the Machine Home (Mac-Home) and related Home positions directly on the solid model as well as on the planar views. There are two modes for the Home definition: Multi-Sided and Projections. The Multi-Sided mode enables you to define the Home and the related geometries directly on the solid model. The Projections mode enables you to define Homes and related geometries on the projected planar views.
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2.1.1. Multi-sided Homes
This option enables you to define the Home directly on the Solid Model. The first Home has to be defined with the Z-axis coincident to the rotation axis of the part.
The First Home in the Mill-Turn CAM-Part is used for turning; therefore the Z-axis of this home has to be coincident to the revolution axis of the part. The origin of the First Home is located on the revolution axis. The location and orientation of the Mac-Home enables you to prepare turning operations. The axis of the milling tool in SolidCAM is always parallel to the Z-axis. According to this criterion, the Mac-Home is suitable to perform the facial milling. For 4-axis indexial and simultaneous milling, you have to define a number of Home positions related to the Mac-Home. The Z-axes of these Home positions will be parallel to the axis of the corresponding milling tools.
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Home Position for indexial 4-axis milling Home Position for simultaneous 4-axis milling The Home positions are related to the Mac-Home by the Shift and Rotation parameters (this will be explained later).
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The Home dialog enables you to define the Home location and axis orientation.
• MAC-Home - this number corresponds with the built-in controller Home functions. It can be used for different clamping positions (main homes) in different operations on the CAM-Part.
• Position - this number defines the sequence number of the home. For each
Mac-Home (main home), several Positions can be defined for different part-positionings; each such Position is related to the main Home.
In the first Home definition, the default value of the Mac-Home and Position is 1. The Mac-Home and Position editbox are disabled.
There are three following options for the Home definition:
• Select Surface • Define • Select Coordinate system
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Select Surface SolidCAM enables you to define a Home by selecting a face. There are two types of faces:
• Planar face In this case the Z-axis of the Home will be normal to the face. This type can be used for the Home definition of 4-axis milling.
• Cylindrical/Conical face In this case the Z-axis of the Home will be coincident with the axis of the revolution of the specified cylindrical/conical surface. This face type enables you to define the Home suitable for turning and facial milling.
Pick Face This button enables you to select the surface on the model for the Home definition. Change to opposite/Change to original This button enables you to change the Z-axis of the home. Place Home origin to: This option enables you to automatically place the Home’s origin. SolidCAM calculates the model box - the optimal box surrounding the model. The model box is calculated according to the Z-direction defined by the selected face.
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There are two modes:
Center of Revolution Face The origin will be located at the intersection of the rotation axis of the part and the face of the model box with the maximal Z coordinate (the Z-axis is directed along the rotation axis).
Corner of model box The origin will be located in the corner of the model box with the following coordinates: (XMAX, YMAX, ZMIN)
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Define
SolidCAM enables you to define a Home by points. You have to define the Home’s origin and direction of Z- and X-axes.
The First Home in the Mill-Turn CAM-Part is used for turning; hence the Z-axis of this home has to be coincident to the revolution axis of the part. The origin of the First Home is located on the revolution axis. Such location and orientation enables you to prepare turning and facial milling using this home. For 4-axis indexial and simultaneous milling, you have to define a number of Home positions.
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Origin
Select the origin point on the graphic screen. When the origin is defined, the Z-axis will be automatically directed parallel to the rotation axis of the part. Z direction
Select a point relative to the origin that defines the Z-axis. X direction
Select a point (3rd point) that defines the plane. (The Y-axis will be 90 degrees to the X-axis; the selected point defines the plane).
After a point is selected, the next button is automatically activated. If you miss the selection, you can, at any time, select the button you want to define and continue automatically to the next button.
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Select Coordinate system
SolidCAM enables you to choose the coordinate system defined in the CAD model file as the home.
The Home origin and axes orientation will be the same as in the original SolidWorks coordinate system.
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Common fields for all Home definition methods Pick origin This button enables you to redefine the position for the Home origin. The Home will be moved to the new location; the direction of the axes will not be changed.
For the Home suitable for turning, facial milling and 4-axis simultaneous milling (Mill-Turn Home), the origin has to be located on the revolution axis of the part.
Pick X direction This button enables you to choose the direction of the X-Axis. With this option SolidCAM enables you rotate the home in the XY plane, therefore, the direction of the Z-axis and origin location will not be changed.
The orientation of the X-axis is very important for the geometry definition for turning. The geometry for turning has to be located in the ZX plane of the Home coordinate system. You have to direct the X-axis in such a way that all the edges and sketch entities in the geometry definition will be in the ZX plane.
Flip Around Z This button rotates the Home 90 degrees around the Z axis. Flip Around X This button rotates the Home 180 degrees around the X axis. The Z axis changes to the opposite direction.
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2.1.2. Projections Homes
When the Multi-sided home checkbox is not selected, SolidCAM enables you to define the Machine Home and Home Positions on the projections of the part like drawing views.
This method of Home definition will be useful when you do not have the solid model. The geometry is defined by the number of drawing views that can be imported DXF or 2D IGES files. In the Projections mode, you have to use a lot of imagination and knowledge in multi-axial positioning in order to define the correct coordinate for the Home positions.
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In this case, the Home is defined by one point specified on the appropriate projected view. This point describes the origin location. The X- and Y-axis will be adjusted automatically as shown below.
When you define a Home Position related to a Machine Home, you have to define the Shift and Rotation around parameters. These parameters describe the position and orientation of the new Home Position according to the Machine Home.
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Turning Home This button enables you to define the Mac-Home projection on the top view of the part clamped on the CNC machine. SolidCAM uses this Mac-Home projection for the turning operations.
The Pick Home Origin dialog enables you to define the Home’s origin location.
The axes orientation will be defined automatically.
The Z-axis is coincident to the revolution axis. The X-axis will be defined normal to the Z-axis in the plane of the view.
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SolidCAM enables you to define only one turning home in the Mill-Turn CAM-Part.
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Milling Home The Milling Home option enables you to define the second projection of the Mac-Home.
The direction of the axis will be defined automatically by SolidCAM as shown above. Therefore, the Mac-Home projection has to be defined on the appropriate view containing a front face geometry.
In addition, the Milling Home option enables you to define a number of the Home positions for indexial and simultaneous 4-axis milling. These positions are related to the Mac-Home.
The front face geometry has to be rotated according to the orientation of the part on the CNC.
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These Home positions have to be defined on the appropriate views displaying the geometry for the machining. The Home for the simultaneous 4-axis milling can be defined:
• On the view containing the projected geometry.
• On the view containing the unfolded revolution surface.
The Home Position location has to correspond with the location of the Mac-Home.
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Home dialog
The Home dialog enables you to define the Mac-Home and Position number:
• MAC-Home - this number corresponds with the built-in controller Home functions. It can be used for different clamping positions (main homes) in different operations on the CAM-Part.
• Position - this number defines the sequence number of the home. For each
MAC Home (main home), several Positions are defined for different part -positionings; each such Position is related to the main Home.
2.1.3. Home data dialog
• Number defines the Home number as it is used in SolidCAM. • X shows the X-value of the Home. • Y shows the Y-value of the Home. • Z shows the Z-value of the Home. • Machine home number defines the number of the home in the CNC-Machine.
The default value is 1. If you use another number, the G-code file will contain the
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G-function that tells the machine to use the specified number stored in the machine controller of your machine.
• The Tool start level defines the Z-level at which the tool will start. • The Clearance level is the Z-level to which the tool rapids when moving from
one job to another (in case the tool did not change). • The CAM-Part Upper level defines the height of the upper surface of the part to
be milled. • The CAM-Part Lower level defines the lower surface level of the part to be milled. • The Tool Z Level is the height that the tool moves to before the rotation of the
4/5 axes to avoid collision between the tool and the workpiece. This level is related to the home position and you have to check if it is not over the limit switch of the machine. It is highly recommended to send the tool to the reference point or to a point related to the reference point.
• The Shift is the distance from the main home (Mac home) to the location of this home in the coordinate system and the orientation of the main home.
• The Rotation is the rotation angle around the main axes X, Y and Z.
• The Shift and Rotation values have to be defined for the Home Positions according to the Mac-Home.
• For the first Position related to a new Mac Home number, the Shiftand Rotation around parameters will be always 0.
• Shift and Rotation for other Positions related to the same Mac Home number will be determined automatically within Multi-Sided mode. Within Projections mode the Shift and Rotation values must be defined manually.
• The 4-th axis field can be either On or Off. Click the mouse on this field to
choose On. The 4th-Axis will then be used when changing from the previous home to the current home.
• The Machining Plane defines the default plane of work for the jobs using this
home, as it is output to the G-code program. In the SolidCAM CAM module, you must always work on the XY-plane. Some CNC-machines, however, have different axes-definitions and require G-code output with rotated XY-planes. Choose one of the following options:
XY - The XY plane is the work plane; the Z-axis is the depth (G17). YZ - The YZ plane is the work plane; the X-axis is the depth (G18). XZ - The XZ plane is the work plane; the Y-axis is the depth (G19).
This option will only work correctly when your post-processor has been customized to support this function. Please contact customer support for further details.
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2.1.4. Home edit dialog
The Home Edit dialog enables you to manage Mac-Homes and Positions in the CAM-Part. Right click with the mouse to open the operation menu.
Add Home
This command enables you to add a new home to the current CAM-Part. The adding home steps were described earlier.
Edit Home
This command enables you to change the data of an existing home. It also enables you to change the home position. The Home Data dialog will be displayed for the selected Mac-home or position.
Move Home
This button enables you to move the actual Home. This option is disabled in the Multi-sided mode.
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Inquire Home
In the Inquire Home field, you can view the relevant information about a particular home position, but you cannot change anything.
Delete Home
This option removes an existing home. You can only delete homes if more than one home has been defined for the current CAM-Part. It is not possible to delete the first home and a home that is used for the milling operation. (The Delete item in the menu will be disabled in these cases).
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2.2. Material boundaries The Mill-Turn module enables you to define the stock model via the material boundaries definition like in the Turning module.
This option defines the boundaries of the stock material used for the CAM-Part.
• Draw The material boundaries are defined using the Chain selection menu.
If a single entity is chosen (using the Selected curves option), then perpendiculars are dropped automatically from the ends of the entity to the axis of rotation in order to define the material boundary.
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• Value
The Boundary dialog is displayed and you are prompted to enter the values of the Material Boundaries. The values should be entered relative to the home of the CAM-Part:
• Left: Enter the Z-value of the left material boundary. • Right: Enter the Z-value of the right material boundary. • Diameter: Enter the X-value of the diameter.
The Show button displays the defined material boundaries.
For a more detailed explanation, please refer to the appropriate topic in the SolidCAM Turning Help.
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2.3. Clamp definition This option defines the clamp boundaries using the Chain selection menu.
The clamp should either intersect or have a common edge with the material boundary.
For a more detailed explanation, please refer to the appropriate topic in the SolidCAM Turning Help.
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2.4. Target definition
SolidCAM enables you to define the Target model - the final shape of the CAM-Part after the machining. SolidCAM will use the Target model for:
• 3D simulation • Rest material calculation • Gouge checking in the SolidVerify simulation.
During all machining operations, the rest material that is left is removed in order to reach the Target model.
The Define 3D model button enables you to select the solid body in order to define the target model. The 3D model dialog enables you to select the solid body for the target model definition.
For a more detailed explanation, please refer to the appropriate topic in the SolidCAM Milling Help. 3. Turning Jobs
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SolidCAM enables you to perform all types of turning jobs using the defined turning Home.
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In the Multi-Sided mode, SolidCAM uses the first Mac-Home for all turning jobs. The geometry is defined directly on the solid model.
In the Projections mode, the specified Mac-Home is used for all the Turning Jobs. The Geometry has to be defined in ZX plane of the Mac-Home.
The turning jobs are the same in the Turning module and in the Mill-Turn module. For a more detailed explanation on the turning jobs, please refer to the SolidCAM Turning Help.
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4. Milling Jobs The Mill-Turn module enables you to use all types of milling Jobs in order to create the tool path for the driven tools.
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When the Job screen is displayed, you have to specify the Home that will be used.
The Geometry in the Job has to be defined using the appropriate Home.
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The 4-axis option in the milling Job screen displays the 4th Axis dialog.
This dialog enables you to define the specific technology parameters for the 4-axis milling. The parameters and options of this dialog will be explained later.
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4.1. Preparing the tool path for the facial milling
4.1.1. Multi-Sided
This mode enables you to use the first Mac-Home (the home used for turning) in order to implement facial milling operations. The geometry of the facial milling is defined directly on the solid model.
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4.1.2. Projections
This mode enables you to use projection views to perform the facial milling operations. SolidCAM enables you to choose the appropriate Home Position for the milling operation and define the milling geometry accordingly. The tool path will be calculated according to the specified Home Position.
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4.1.3. 4-Axis options The 4th axis dialog enables you to define the technology parameters of the facial milling.
4th Axis type
The Face type enables you to perform milling using the rotary-axis by translating the linear movement to the rotary movement.
Coordinate type
This field enables you to determine whether the G-code for simultaneous 4th axis milling consists of split blocks or blocks in Cartesian or Polar coordinates. It has the following options:
• Split In this option, the tool-path is split into many blocks according to the specified error. The blocks consist of rotary and linear movement according to the plane.
• Polar
This option appears only if the polar_4x = Yes is defined in the Mac file. The milling is processed using the rotary-axis. The tool-path lines and arcs are calculated in polar coordinates. The home position is zero for linear and rotary coordinates.
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• Cartesian
This option appears only if the cartez_4x = Yes is defined in the Mac file. The tool-path lines and arcs are calculated in Cartesian coordinates; the home position is zero for linear coordinates. The milling is processed using the rotary-axis by translating the linear movement to rotary-linear movement according to the plane.
Tolerance The tool-path lines and arcs are split into many blocks; these blocks do not exactly generate the required tool-path. The Tolerance field defines the maximum allowed error; the smaller the value of this field, the bigger the number of G-code blocks generated.
Parallel-To This option enables you to determine which axis (X or Y) on the screen is the linear axis.
X - The X axis on the screen is the linear axis. Y - The Y axis on the screen is the linear axis.
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4.2. Preparing the tool path for indexial 4-axis milling
4.2.1. Multi-Sided
SolidCAM enables you to define a number of Home Positions for indexial 4-axis milling directly on the solid model. These positions correspond with the Mac-home. The Shift and Rotation parameters will be calculated automatically.
The Geometry has to be related to the specified Home position and located on the XY-plane of the chosen Home.
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When the Job screen is displayed, you have to specify the Home that will be used.
After choosing the Home, you have to define the Job Geometry.
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4.2.2. Projections
In the Projections mode, the Geometry for 4-axis indexial milling has to be defined on the planar projected view. The Geometry used for the indexial 4-axis machining has to be defined in the XY plane of the specified Home. Therefore the Home Position and the Geometry have to be defined on the same projected view. Since the Home Position is related to the Machine Home by the specific Shift and Rotation values, the tool path will be also calculated considering the location of the Home Position relative to the Machine Home.
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When the Job screen is displayed, you have to specify the Home that will be used.
After choosing the Home, you have to define the Job Geometry.
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4.3. Preparing the tool path for simultaneous 4-axis milling
4.3.1. Multi-Sided SolidCAM enables you to define the geometry for simultaneous 4-axis milling directly on the solid model.
The Home position used for simultaneous 4-axis milling is oriented in such a way that the Z-axis will be parallel to the axis of the tool used for this operation.
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The Geometry is selected as a chain of edges or sketch entities. These chains can be either planar or 3D.
When the chain is defined, you have to select the Wrap checkbox in the Geometry Edit dialog.
This option enables SolidCAM to machine the defined geometry using simultaneous 4-axis movements.
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For the Home Position used for the simultaneous 4-axis milling, the Upper and Lower levels will be determined automatically and equal to the maximal part radius.
For the Job using this Home position, the Upper Job level will be defined equal to the Home Upper level.
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4.3.2. Projections The Home and Geometry for the simultaneous 4-axis milling can be defined in two ways:
• On the view containing the projected geometry.
In this case the geometry will be projected on the appropriate revolution surface.
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Only the range of 180 degrees is supported when you draw a top-view from any angle.
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• On the view containing the unfolding of the revolution surface.
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The full range of the angles of the perimeter is supported when you draw a layout of the cylindrical material. The geometry is wrapped by SolidCAM around the outside diameter. The length of the full unfolded cylindrical surface is equal to π*D, where D is the diameter of the cylinder.
The rotary-axis rotation is not limited to 360 degrees. Therefore the unfolding length can be more than π*D.
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4.3.3. 4-Axis options
There are two options available in the 4th Axis dialog to specify the technology parameters of the simultaneous 4-axis milling:
• Wrap
The full range of the angles of the perimeter is supported when you draw a layout of the cylindrical material. The geometry is wrapped by SolidCAM around the outside diameter by dividing each corresponding linear movement by the radius to generate the rotary-axis rotation. The rotary-axis rotation is therefore not limited to 360 degrees.
• Top
Only the range of 180 degrees is supported when you draw a top-view from any angle. SolidCAM splits each tool-movement into small movements to generate the required top-view drawing within a tolerance; every corresponding coordinate is projected on the top-view and then translated to rotary-axis rotation.
The Top type is not relevant for the Multi-sided mode.
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Coordinate type
This field enables you to determine whether the G-code for simultaneous 4th axis milling consists of split blocks or blocks in Cartesian or Polar coordinates. It has the following options:
Split
In this option, the tool-path is split into many blocks according to the specified error. The blocks consist of rotary and linear movement according to the plane.
Polar
This option appears only if the polar_4x = Yes is defined in the Mac file. The milling is processed using the rotary-axis. The tool-path lines and arcs are calculated in polar coordinates. The home position is zero for linear and rotary coordinates.
Cartesian
This option appears only if the cartez_4x = Yes is defined in the Mac file. The tool-path lines and arcs are calculated in Cartesian coordinates; the home position is zero for linear coordinates. The milling is processed using the rotary-axis by translating the linear movement to rotary-linear movement according to the plane.
Tolerance The tool-path lines and arcs are split into many blocks; the blocks do not exactly generate the required tool-path. The Tolerance field defines the maximum allowed error; the smaller the value of this field, the bigger the number of G-code blocks generated.
Center plane This field defines the height of the rotation axis of the part. Diameter This field defines the diameter used for the transformation of the linear movement into the rotary-axis angle. There are two options that can be used for the Projections mode:
Wrap - It defines the diameter used for calculating the drawing layout. Top - It defines an imaginary cylinder on which the top view drawing is projected.
Angle This field is active for Top; it defines the angle to which the material is rotated before the milling is started. Thus, this angle is added to all the calculated rotary angles.
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Parallel-To This option enables you to determine which axis (X or Y) on the screen is the linear axis.
X - The X axis on the screen is the linear axis. Y - The Y axis on the screen is the linear axis.
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5. Example
Load the CAM-Part mill_turn_example.prt located in the .../Parts folder.
5.1 Configurations The model was built using two SolidWorks configurations:
• Mill — the complete part for machining. This configuration is used for the milling geometries definition.
• Turn — in this configuration all the features machined with milling jobs
are suppressed. This configuration is used for the stock, clamping and turning geometry definitions.
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5.2 Home The Machine home (Home Position #1) for the part machining was defined at the intersection of the revolution axis with the front face. This Home was used in the turning job definition and for the facial milling.
In addition to the Machine home, the Home position #2 was defined. The origin of the Home position is located at the same location as the origin of the Machine home. The axis orientation of this Home position enables you to perform 4-axis milling (indexial and simultaneous).
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5.3 Machining
5.3.1 Turning (TR_profile_T1)
In this Job, SolidCAM uses Rough strategy to remove a bulk of material and then finishes the parts turning faces.
5.3.2 Facial Milling (F_Facial_milling_T3)
This Profile Job removes the material on the model front face. The End Mill ∅10 is used. The Arc approach strategy enables the tool to safely plunge into the material from the outside.
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5.3.3. Indexial 4_axis Milling (F_Step_T3)
This Profile Job machines the step on the radial face. The Home Position #2 was used. The Clear offset was used in order to machine the geometry in two passes. The Tangent approach strategy enables the tool to safely plunge into the material from the outside.
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5.3.4. Simultaneous 4-axis milling (P_Pockets_T2)
The Pocket Job uses the wrapped geometry in order to machine pockets located on the radial face. Both Home Position #2 and the 4-axis Wrap technology were used.
