the MILL-TURN Edge
SolidCAM Application Tutorial
Port Machining
SolidCAM + SOLIDWORKS
The Complete Integrated Manufacturing Solution
Contents
1. Introduction................................................................................................................. 1
2. CAM-Part Definition.................................................................................................... 5
3. Stock and Target Definition...................................................................................... 13
4. iMachining Operation................................................................................................ 19
5. Roughing Operations................................................................................................ 27
6. Finishing Operations................................................................................................ 45
i
Introduction 1
About this course
The goal of this course is to teach you how to use SolidCAM’s Port Machining to machine a
simple and complex port. This tutorial covers the basic concepts of Port Machining. Once you have
developed a good foundation in basic skills, you can refer to the online help for information on the
less frequently used options.
Prerequisites
Students attending this course are expected to have basic knowledge of the SolidCAM software.
Course design
This course is designed around a task-based approach to training. The guided exercises will teach you
the necessary commands and options to complete a machining task. The theoretical explanations
are embedded into these exercises to give an overview of the Port Machining capabilities.
Using this book
This tutorial is intended to be used in a classroom environment under the guidance of an
experienced instructor. It is also intended to be a self-study tutorial.
This book is made with SOLIDWORKS 2020 and SolidCAM 2020 SP0.
2
1. Introduction
Port Machining
The Port Machining operation is an easy to use method for machining ports with tapered lollipop
tool, and has collision checks for the entire tool (shank, arbor, and holder). You can choose to cut
the top only, the bottom only, and specify how much stock to leave on the entire port. It uses 3-Axis
machining as far into the port as possible, and then switches to 5-Axis motion. Smooth transitions
are created where the tool paths meet at the middle of the port. It provides both roughing and
finishing tool paths to make ports from castings or billet.
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4
CAM-Part Definition
2
The CAM-Part definition process for the part consists of the following stages:
CAM-Part creation
CNC-Machine definition
Coordinate System definition
Stock and Target definition
• CAM-Part creation. At this stage, you have to define the CAM-Part name and location.
SolidCAM defines the necessary system files and a folder to allocate the place to store
SolidCAM data.
• CNC-controller definition. It is necessary to choose the CNC-controller. The controller
type influences the Coordinate System definition and the Geometry definition.
• Coordinate System definition. You have to define the Coordinate System, which is the
origin for all machining operations of the CAM-Part. You can create multiple CoordSys
positions and in each machining step select which CoordSys you want to use for the
operation.
• Stock and Target definition. It is necessary to define a boundary of the stock that is used
for the CAM-Part machining. SolidCAM enables you to define the model of the part in
its final stage after the machining.
The following exercises describe the full process of the CAM-Part definition. It is recommended to
go through the stages in order to understand how the CAM-Part features are built. For this purpose,
you have to turn off the automatic CAM-Part definition.
1. Browse to open the SOLIDWORKS part PORT.SLDPRT.
2. Click Tools > SolidCAM > SolidCAM
Settings.
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2. CAM-Part Definition
3. In the left pane, select CAM-Part.
4. Ensure that the settings are as shown in the
image:
This enables you to start
directly adding operations
in a new part.
5. In the left pane, select Automatic CAM-Part
definition. In the right pane, click the Milling tab.
6. Ensure that all check boxes are cleared.
7. Click OK.
8. Click Tools > SolidCAM > New > Milling.
The Milling Part Data dialog box displays.
9. Define the CAM-Part in the Milling Part Data dialog box:
7
10. In the CNC-Machine list, click table_table_exercise.
11. Click
the CoordSys button in the Define section to set the
coordinate system for this part.
12. In the Place CoordSys origin to list, click Top center of
model box.
13. Select the face as shown in the image.
The coordinate system is set and should look as displayed in
the image.
14. Click
The CoordSys Data window displays.
8
2. CAM-Part Definition
15. Enter the parameters as shown in the image.
16. Click OK.
17. Click 1-Position > Add.
18. In the Place CoordSys origin to list, select CoordSys # 1.
19. Select the face as shown in the image.
The coordinate system is set and should look
as displayed in the below image.
20. Click
The CoordSys Data window displays.
9
Enter the parameters as shown in the image.
21. Click
22. The defined UCS should look as displayed in the below image.
23. Click in the CoordSys Manager window.
24. Click Edit iMachining Database in the iMachining Data section.
The iMachining Database window displays.
25. Right click Machines > New Machine to define a new machine.
10
2. CAM-Part Definition
A new machine is added.
26. In the left pane, right click New Machine to change the name.
27. Enter HERMLE_PORT as the machine Name.
28. Enter the parameters as shown in the image.
29. Click Apply.
30. Right click Materials > New Material to define a new material.
A new material is added.
31. In the left pane, right click New Material to change the name.
32. Enter AL-6061-T6 as the material Name.
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33. Enter the MPa value of 460 as shown in the image.
34. Click Save & Exit.
35. Click in the Milling Part Data window.
36. Right click on CAM-Part > CAM-Part Definition.
37. Inthe Edit iMachining Database, select the machine and
material you defined.
38. Set the Machining level at 6.
39. Click in the Milling Part Data window.
The CAM part is now defined.
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Stock and Target
Definition 3
To define the stock you have to follow the steps mentioned in this chapter.
1. Click
2. Click Design Model > Solid Bodies(3) > Stock >
Show.
3. The selected stock should look as shown in the image.
4. To have a better visualization of the selected
stock, right click PART > Body Display >
Wireframe. The stock then looks as shown.
14
3. Stock and Target Definition
5. Turn back the PART to Default Display.
6. Click
7. Right click Stock > Define.
8. In the Defined by list, select 3D Model.
9. Select the solids as shown in the image.
10. Enter
the Facet tolerance value as 0.1 so that your
system does not create a big faceting file.
11. Click the Show button in the Stock dialog box.
12. The 3D representation of the stock is displayed in the
Stock model : stock window as shown in the image.
13. Close the Stock model : stock window.
14. Click
15. Click Target > Define.
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16. Select the solid as shown in the image.
17. Click the Show button in the Target dialog box.
18. The 3D representation of the target is displayed
in the Target model : target window as shown in the
image.
19. Close the Target model : target window.
20. Click
The stock and the target are now defined.
Next, you must switch on the visibility of some sketches that are required for different machining
operations.
21. Click
22. Right click > Show SPINE 1, SPINE 2, and Spine 3.
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3. Stock and Target Definition
The selected sketches should look as highlighted in the orange rectangular in the below image.
The part is now ready to add machining operations.
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18
iMachining Operation
4
Before you define the iMachining operation, you must first define machine setup.
1. Right click Operations > Machine
Setup > Add at start of operations tree.
The Machine Setup window displays.
2. Click Table_Pos1 [MAC 1 (1-Position)] and enter a value of 125 the Z field. This will raise the
part above the machining level.
3. Click to see how the mounted part looks on the machine.
4. The part is displayed in the Machine Preview window and looks as shown in the below image.
5. Close the Machine Preview window.
6. Click OK in the Machine setup
window.
7. Click
8. Click Design Model > STOCK >
Hide.
9. Click
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4. iMachining Operation
10. Right click Setup > Add Milling Operation > 2D
iMachining.
You can also add the 2D iMachining operation by clicking SolidCAM Operations > iMachining >
2DMachining.
Or, by clicking SolidCAM 2.5D > 2D iMachining.
11. In the Technology list, click iRough.
12. On the Dashboard page, select MAC 1 (2-Position) from the list.
13. Click Geometry.
14. Click under CoordSys.
15. Select the contours as
shown in the image. If
the Smart Face check boxis selected in the Chain
section, SolidCAM automatically extracts the
boundary curve.
16. Click Yes in the OK to accept? window both
the times.
17. Click
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18. Click Tool > Select.
19. Click
20. Select END MILL.
21. Enter the parameters as shown in
the image.
22. Select the Holder check box.
23. Select BT40 ER 32x60.
24. Click the iData tab.
25. In the Topology / Helical Angle list,
click 35 (Standard).
26. Click
27. Click Levels.
28. Click Upper Level.
29. Select the face as shown in the image.
30. Click
31. Click Pocket depth.
22
4. iMachining Operation
32. Select the face as shown in the image.
33. Click
34. Ensure that the Levels values are set
similar as displayed in the image.
35. Click Technology.
36. Set the Wall / island offset as 0.1.
37. In the Finish section, select the Floor check box.
38. Click Link.
39. Slide the Max. arc size slide bar to around 6.19764.
Ensure that the Advanced check box is selected.
40. Click
41. Click
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42. Click
The tool path should look as displayed in the image.
43. Click SolidVerify.
44. Click Settings > Accuracy.
45. Set the accuracy values as shown in the image.
46. Click OK.
47. Run the simulation in solidverify mode.
24
4. iMachining Operation
The simulation should look as displayed in the image.
48. Close the Simulation window.
49. Click to close the operations manager.
You have completed the iMachining operation.
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26
Roughing Operations
5
Before you start the roughing operation, you must make a few changes to close the holes as shown
in the image.
1. Right click > Edit part.
2. Click Insert > Surface > Offset.
3. Enter a value of 0 in the Offset Parameters field to make a copy
of this surface.
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5. Roughing operations
4. Select the faces as shown in video 1.flv. This video can be found in the extracted folder of this
tutorial.
5. Click
6. Click
7. Click Solid Bodies(3) > PART >Hide.
8. Click Insert > Surface > Untrim.
9. Select the faces as shown in the below image.
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10. Select the Internal edges option in the Options section.
11. Click
12. Click Insert > Surface > Untrim.
13. Select the face as shown in the image.
14. Select the All edges option in the Options section.
15. Click
You will now split this surface into two so that you get two single tubes for machining.
16. Click Insert > Curve > Split Line.
17. Click
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5. Roughing operations
18. Click Design Model > Plane4.
19. Click once in the section highlighted in green color.
20. Select the Intersection option in the Type of Split
section.
21. Select
the faces as shown in video2.flv. This video
can be found in the extracted folder of this tutorial.
22. Click
23. Click Sketch > 3D Sketch.
24. Click the Line icon.
25. Create the line as shown in the image by selecting the highlighted points.
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26. Click the esc (escape) key on your keyboard.
27. Click to come out of the sketch.
28. Click Insert > Surface > Fill.
Ensure that in the Feature Manager Design
Tree, Surface-Fill3, 3DSketch3 is switched on.
29. Select the edges as shown in video3.flv. This video can be found in the extracted folder of
this tutorial.
30. Click
This will ensure that you have three distinct tubes available for machining.
31. Click to finish editing the part.
32. Click
33. Right click the previous operation > Add Milling Operation > Port Machining.
34. In the Technology list, click Roughing.
35. Click Geometry.
36. Click under Machining surfaces.
37. Select the faces as shown in the video4.flv. This video can be found in the extracted folder of
this tutorial.
38. Click under User-defined Spine.
32
5. Roughing operations
39. Select the spine as shown in the image.
40. Click
41. Click
42. Set the Offset value as 0.5.
43. Click Tool > Select.
44. Click and select a lollipop mill tool.
45. Enter the parameters as shown in the image.
46. Select the Holder check box.
47. Select HSK A 63 ER 32x80 as the
holder.
48. Click
49. Click Levels.
50. Click the Parallel to X option to get a cylinder parallel to the X axis.
51. Click next to Through point.
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52. Select the point as shown in the image.
53. Click
54. The defined values must look as displayed in the image.
55. Enter the Retract distance value as 50 in the Levels section.
56. Click Tool path parameters.
57. Enter the values as shown in the image.
58. Click the Sorting tab.
59. In the Output type list, click Top.
60. In the Machine to list, click Maximum from top.
61. Click Tool axis control.
62. Unselect the Minimize tilting check box.
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5. Roughing operations
63. Click Gouge check.
64. Select the Check surfaces check box.
65. Ensure that in the Feature Manager Design Tree, PART is switched on.
66. Click under Check surfaces.
67. Select the faces as shown in the image.
68. Click
69. Click Clearance data.
70. Enter the parameters as shown in the
image.
71. Click
72. Click
73. Click in the Simulation window.
The tool path should look as shown in the
image.
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74. Close the Simulation window.
75. Click
76. Click Geometry.
77. Click under Machining surfaces.
78. Select the faces as shown in the image.
79. Click under User-defined Spine.
80. Select the spine as shown in the image.
81. Click
82. Click
83. Click Gouge check.
84. Select the Check surfaces check box.
85. Click under Check surfaces.
36
5. Roughing operations
86. Select the faces as shown in the image.
87. Click
88. Click Clearance data.
89. Enter the parameters as shown in the
image.
90. Click
91. Click
92. Click in the Simulation window.
The tool path should look as show in the image.
93. Click
94. Click to come out of the Operations Manager.
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95. Right click > Copy the operation.
96. Right click > Paste the operation.
97. Right click > Edit the operation.
98. Click Geometry.
99. Click under Machining surfaces.
100. Select the faces as shown in video5.flv. This video can be found in the extracted folder of
this tutorial.
101. Click under User-defined Spine.
102. Select the spine as shown in the image.
103. Click
104. Click
105. Click Tool path parameters.
106. Click the Sorting tab.
107. In the Output type list, click Bottom.
108. In the Machine to list, click Maximum from bottom.
109. Click
110. Click Solid Bodies(3) > PART >Show.
38
5. Roughing operations
111. Click Tool axis control.
112. Unselect the Minimize tilting check box.
113. Click Gouge check.
114. Click under Check surfaces.
115. Select the highlighted surface.
116. Click
117. Click Clearance data.
118. Enter the parameters as shown in the
image.
119. Click
120. Click
121. Click in the Simulation window.
The tool path should look as shown in the image.
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Before you add the next operation, ensure that Spine 3 is selected in the FeatureManager Design
tree.
122. Switch on the PART.
123. Right click the operation > Add Milling Operation > 3D HSR.
124. In the Technology list, click Contour roughing.
125. Click CoordSys on Geometry page.
126. Click 2-Position > Add.
127. In the Place CoordSys origin to list, click Top center of model box.
128. Select the face as shown in the image.
129. In the Modify by pick section, select the Pick XY origin check
box.
130. Select the point as shown in the image.
40
5. Roughing operations
131. In the Modify by flip section, click the Flip around Z button twice.
132. Click
The CoordSys Data window displays.
133. Enter the parameters as shown in the image.
134. Click
135. Click to close the CoordSys Manager window.
136. Ensure that MAC 1 3-Position is selected as the coordinate system.
137. Click Tool > Select.
138. Click
139. Select BULL NOSE MILL as the tool.
140. Enter the parameters as shown in
the image.
141. Select the Holder check box.
142. Select HSK A 63 ER 32x80.
143. Click
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144. Click Constraint boundaries.
145. Select the Created manually option.
146. In the list, click User-defined boundary.
147. Click under Boundary name.
148. Select the boundary as shown in the image.
149. Click Yes in OK to accept? window.
150. Click
151. Click Passes.
152. Enter the parameters as shown in the
image.
153. Click Z-Top.
42
5. Roughing operations
154. Select the point as shown in the image.
155. Click
156. Click the Adaptive step down tab.
157. In the Adapt Step down by list, click None.
158. Click Link.
159. Click the Ramping tab.
160. Enter the parameters as shown in the
image.
161. Click the Retracts tab.
162. Select the Minimal vertical retract
option.
163. Click
164. Click
165. Click in the
Simulation window.
The tool path should
look as show in the
image.
43
166. Click to close the Simulation window.
167. Click to come out of the Operations Manager.
You have now completed the roughing operations and, in the next chapter you will define the
finishing operations.
44
Finishing Operations
6
1. Right click the operation > Add Milling Operation > Port Machining.
2. In the Technology list, click Spiral Finishing.
3. Click Geometry.
4. In the list, click faces.
The selected faces should look as shown
in the image. You have earlier used this
geometry in the roughing operation. The
name in your file may differ than what is
mentioned in the tutorial. Therefore, from
the list, select the faces as shown in the
image.
5. In the User-defined Spine list, click
contour 1.
The selected contour should look as shown in
the image. You have earlier used this contour in
the roughing operation. The name in your file
may differ than what is mentioned in the tutorial.
Therefore, from the list, select the contour as
shown in the image.
6. Click Tool > Select.
7. Select
the LOLLIPOP MILL tool with the parameters
shown in the image.
8. Click Levels.
9. Clickthe Parallel to X option to get a cylinder parallel
to the X axis.
46
6. Finishing Operations
10. Click
11. Select the point as shown in the image.
12. Click
13. Click Levels.
14. Enter the value of 50 in the Retract
distance field.
15. Click Tool path parameters.
16. Click the Sorting tab.
17. In the Output type list, click Top.
18. In the Machine to list, click Maximum from top.
19. Click Gouge check.
20. In the Check surfaces list, click faces1.
The selected face should be as shown in the image. The
name in your file may differ than what is mentioned in
the tutorial. Therefore, from the list, select the faces as
shown in the image.
21. Click Clearance data.
47
22. Enter the parameters as shown in the
image.
23. Click
24. Click
25. Click in the Simulation window.
The tool path should look as show in the image.
26. Click
27. Click
28. Right click > Copy the operation.
29. Right click > Paste the operation.
30. Right click > Edit the operation.
31. In the Technology list, click Plunge Finishing.
32. Click Geometry.
48
6. Finishing Operations
33. In the list, click faces2.
The selected faces should look as shown
in the image. You have earlier used this
geometry in the roughing operation. The
name in your file may differ than what is
mentioned in the tutorial. Therefore, from
the list, select the faces as shown in the
image.
34. In the User-defined Spine list, click
contour 2.
The selected contour should look as shown in
the image. You have earlier used this contour in
the roughing operation. The name in your file
may differ than what is mentioned in the tutorial.
Therefore, from the list, select the contour as
shown in the image.
35. Click Tool > Select.
36. Select
the LOLLIPOP MILL tool with the
parameters shown in the image.
37. Click Levels.
38. Ensure that the Through point values are as shown in the
image.
39. Click Tool path parameters.
40. Set the Maximum step value as 1.
49
41. Click the Sorting tab.
42. In the Output type list, click Top.
43. In the Machine to list, click Mid point.
44. Click Gouge check.
45. Click under Check surfaces.
46. Select the highlighted faces.
47. Click
48. Click Clearance data.
49. Enter the parameters as shown in the
image.
50. Click
51. Click
52. Click in the Simulation window.
50
6. Finishing Operations
The tool path should look as show in the image.
53. Click
54. Click
55. Right click the operation > Copy.
56. Right click the operation > Paste.
57. Right click the operation > Edit.
58. In the Technology list, click Spiral Finishing.
59. Click Geometry.
60. In the list, click faces4.
The selected faces should look as shown
in the image. You have earlier used this
geometry in the roughing operation. The
name in your file may differ than what is
mentioned in the tutorial. Therefore, from
the list, select the faces as shown in the
image.
51
61. In the User-defined Spine list, click contour 3.
The selected contour should look as shown in
the image. You have earlier used this contour in
the roughing operation. The name in your file
may differ than what is mentioned in the tutorial.
Therefore, from the list, select the contour as
shown in the image.
62. Change the Offset value to 0.
63. Click Tool path parameters.
64. Set the Maximum step limit as 1.
65. Click the Sorting tab.
66. In the Output type list, click Bottom.
67. In the Machine to list, click Maximum from bottom.
68. Click Gouge check.
69. In the Check surfaces list, click faces5.
The selected face must look as shown in the image. The
name in your file may differ than what is mentioned in
the tutorial. Therefore, from the list, select the faces as
shown in the image.
52
6. Finishing Operations
70. Click Clearance data.
71. Enter the parameters as shown in the
image.
72. Click
73. Click
74. Click in the Simulation window.
The tool path should look as show in the image.
75. Click
76. Click
77. Right click the operation > Add Milling Operation > 3D HSM.
78. In the Technology list, click Helical machining.
79. In the CoordSys list, click MAC 1 (3-Position) as the user coordinate system.
80. Click Tool > Select.
81. Select the same LOLLIPOP MILL tool that was used for the previous spiral finishing
operation.
53
82. Click Constraint boundaries.
83. Select the Created manually option.
84. In the list, click User-defined boundary.
85. In the Boundary name list, click contour.
The selected boundary must look as shown in the
image. The name in your file may differ than what
is mentioned in the tutorial. Therefore, from the
list, select the contour as shown in the image.
86. Click Passes.
87. Enter the parameters as shown in the
image.
88. Click Z-Top.
89. Select the point as shown in the image.
90. Click
54
6. Finishing Operations
91. Select the Adaptive step down tab.
92. Enter the parameters as shown in the image.
93. Click Link.
94. Click the Retracts tab.
95. Select the Minimal vertical retract option.
96. Click
97. Click
98. Click in the Simulation window.
The tool path should look as shown in the image.
99. Run the simulation for all the operations in SolidVerify mode.
55
The simulation must look like as shown in the image.
Run the machine simulation.
Once the simulation is over, it must look as shown in the image.
100. Click
101. Click
End of the tutorial.
56
SolidCAM Application Tutorial
Port Machining
the MILL-TURN Edge
iMachining 2D 2.5D Milling HSS (High-Speed Surface Machining)
iMachining 3D Indexial Multi-Sided Machining HSM (High-Speed Machining)
Sim. 5-Axis Machining Turning & Advanced Mill-Turn Solid Probe
www.youtube.com/SolidCAMProfessor
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www.youtube.com/SolidCAMiMachining
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