User Guide | SolidCAM 2023

HSM Machining
iMachining 2D
iMachining 3D
2.5D Milling
Indexial Multi-Sided
HSS Machining
3D High Speed Milling
Simultaneous 5-Axis
Turning
Advanced Mill-Turn
Swiss-Type
Solid Probe
SolidCAM 2023
HSM User Guide

©1995-2023 SolidCAM
All Rights Reserved.
Contents

1. Introduction and Basic Concepts

1.1 Start HSM Operation..................................................................................................................................................3
1.2 HSM Operation Overview.........................................................................................................................................4
1.3 Parameters and Values................................................................................................................................................4
2. Technology
2.1 Constant Z Machining................................................................................................................................................9
2.2 Hybrid Constant Z..................................................................................................................................................... 9
2.3 Helical Machining........................................................................................................................................................9
2.4 Horizontal Machining...............................................................................................................................................10
2.5 Linear Machining.......................................................................................................................................................10
2.6 Radial Machining.......................................................................................................................................................11
2.7 Spiral Machining........................................................................................................................................................11
2.8 Morphed Machining..................................................................................................................................................12
2.9 Offset Cutting............................................................................................................................................................12
2.10 Boundary Machining.................................................................................................................................................13
2.11 Rest Machining...........................................................................................................................................................13
2.12 Contour Rest Machining..........................................................................................................................................14
2.13 3D Constant Step Over Machining........................................................................................................................14
2.14 Pencil Milling..............................................................................................................................................................15
2.15 Parallel Pencil Milling................................................................................................................................................15
2.16 3D Corner Offset......................................................................................................................................................16
2.17 Prismatic Part Machining.........................................................................................................................................16
2.18 Combined Strategies.................................................................................................................................................17
2.19 Customize Menu........................................................................................................................................................17

3. Geometry
3.1 Geometry Definition................................................................................................................................................20
3.1.1 CoordSys...........................................................................................................................................................20
3.1.2 Target geometry...............................................................................................................................................20
3.1.3 Facet tolerance..................................................................................................................................................21
3.1.4 Micro Milling....................................................................................................................................................21
3.1.5 Apply fillets.......................................................................................................................................................21
3.1.6 Fillet Surfaces dialog box...............................................................................................................................22

4. Tool
4.1 Calculate Minimum Tool Length...............................................................................................................................26
4.2 Holder Clearance.......................................................................................................................................................26
4.3 Tool Selection............................................................................................................................................................27
4.4 Spin & Feed Rate Definition.....................................................................................................................................27

5. Boundaries
5.1 Introduction...............................................................................................................................................................30
5.1.1 Drive boundaries..............................................................................................................................................30
5.1.2 Constraint boundaries.....................................................................................................................................32

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 Contents

5.2 Boundary Definition.................................................................................................................................................33

5.2.1 Boundary type...................................................................................................................................................33
5.2.2 Boundary name................................................................................................................................................34
5.2.3 Boundary – tool relation.................................................................................................................................34
5.3 Automatically Created Boundaries.........................................................................................................................35
5.3.1 Auto-created box of target geometry............................................................................................................35
5.3.2 Auto-created box of stock geometry............................................................................................................36
5.3.3 Auto-created silhouette....................................................................................................................................36
5.3.4 Auto-created outer silhouette........................................................................................................................36
5.4 2D Manually Created Boundaries...........................................................................................................................37
5.4.1 Boundary box...................................................................................................................................................37
5.4.2 Silhouette boundary.........................................................................................................................................37
5.4.3 User-defined boundary...................................................................................................................................38
5.4.4 Combined boundary........................................................................................................................................38
5.4.5 Select Faces dialog box...................................................................................................................................40
5.4.6 Select Chain dialog box...................................................................................................................................41
5.5 3D Manually Created Boundaries..............................................................................................................................41
5.5.1 Common parameters for boundary definition............................................................................................41
5.5.2 Selected faces....................................................................................................................................................43
5.5.3 Shallow areas....................................................................................................................................................44
5.5.4 Theoretical rest areas.......................................................................................................................................44
5.5.5 Tool contact area..............................................................................................................................................45
5.5.6 Rest areas...........................................................................................................................................................46

6. Passes
6.1 Passes Parameters......................................................................................................................................................50
6.1.1 Wall offset..........................................................................................................................................................51
6.1.2 Floor offset.......................................................................................................................................................52
6.1.3 Cut Tolerance....................................................................................................................................................53
6.1.4 Step down..........................................................................................................................................................53
6.1.5 Step over............................................................................................................................................................53
6.1.6 Pass extension...................................................................................................................................................54
6.1.7 Offsets...............................................................................................................................................................55
6.1.8 Detect Flat Areas..............................................................................................................................................55
6.1.9 Limits.................................................................................................................................................................55
6.1.10 Point reduction...............................................................................................................................................56
6.1.11 Refine corners.................................................................................................................................................57
6.1.12 Smoothing.......................................................................................................................................................57
6.1.13 Max ramp angle..............................................................................................................................................57
6.1.14 Climb milling...................................................................................................................................................57
6.1.15 Detect core areas............................................................................................................................................57
6.1.16 Scallop.............................................................................................................................................................57
6.1.17 Tangential extension......................................................................................................................................57
6.1.18 Define angle by...............................................................................................................................................57
6.1.19 Step over..........................................................................................................................................................57
6.1.20 Clockwise........................................................................................................................................................58
6.1.21 Right/left clear offset......................................................................................................................................58

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 6.1.22 Bitengency angle............................................................................................................................................58
6.1.23 Steep threshold...............................................................................................................................................58
6.1.24 Extend steep areas..........................................................................................................................................58
6.1.25 Shallow areas strategy ...................................................................................................................................58
6.1.26 Depth of cut...................................................................................................................................................59
6.1.27 Areas................................................................................................................................................................59
6.1.28 Stroke ordering...............................................................................................................................................59
6.1.29 Reference tool................................................................................................................................................60
6.1.30 Variable stepover............................................................................................................................................60
6.1.31 Horizontal/Vertical step over......................................................................................................................60
6.1.32 Limit offsets number to................................................................................................................................60
6.1.33 Adaptive Variable Side Step..........................................................................................................................60
6.1.34 Overthickness.................................................................................................................................................60
6.1.35 Offset type......................................................................................................................................................60
6.1.36 Passes parameters for combined strategies................................................................................................61
6.2 Calculation Speed......................................................................................................................................................67
6.3 Smoothing parameters..............................................................................................................................................67
6.3.1 Max. radius.......................................................................................................................................................67
6.3.2 Profile tolerance...............................................................................................................................................67
6.3.3 Offset tolerance...............................................................................................................................................68
6.4 Adaptive Step Down Parameters............................................................................................................................68
6.5 Edit Passes Parameters.............................................................................................................................................70
6.6 Axial Offset................................................................................................................................................................72
6.7 Cross parameters........................................................................................................................................................73

7. Links
7.1 General Parameters...................................................................................................................................................77
7.1.1 Direction options........................................................................................................................................77
7.1.2 Order passes.................................................................................................................................................83
7.1.3 Retract...........................................................................................................................................................85
7.1.4 Start hint.......................................................................................................................................................86
7.1.5 Link by Z-level.............................................................................................................................................87
7.1.6 Link per cluster............................................................................................................................................87
7.1.7 Use dynamic stock.......................................................................................................................................88
7.1.8 Min. profile...................................................................................................................................................88
7.1.9 Refurbishment.............................................................................................................................................88
7.1.10 Safety.............................................................................................................................................................89
7.2 Ramping Parameters.................................................................................................................................................89
7.3 Strategy Parameters...................................................................................................................................................93
7.3.1 Stay on surface within.................................................................................................................................94
7.3.2 Stay down within.........................................................................................................................................94
7.3.3 Overlap closed passes.................................................................................................................................94
7.3.4 Along surface...............................................................................................................................................95
7.3.5 Linking radius..............................................................................................................................................97
7.3.6 Link clearance..............................................................................................................................................97
7.4 Retracts Parameters...................................................................................................................................................97

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 Contents

7.4.1 Style...............................................................................................................................................................98
7.4.2 Clearance......................................................................................................................................................98
7.4.3 Smoothing..................................................................................................................................................100
7.4.4 Curls............................................................................................................................................................100
7.5 Leads Parameters....................................................................................................................................................100
7.5.1 Fitting..........................................................................................................................................................101
7.5.2 Trimming....................................................................................................................................................102
7.5.3 Vertical leads..............................................................................................................................................103
7.5.4 Horizontal leads.........................................................................................................................................103
7.5.5 Extensions..................................................................................................................................................105
7.5.6 Basic approaches.......................................................................................................................................105
7.6 Down/Up Mill Parameters....................................................................................................................................106
7.7 Refurbishment Parameters.....................................................................................................................................108
7.7.1 Min. pass length........................................................................................................................................108
7.7.2 Spikes..........................................................................................................................................................108

8. Motion Control
8.1 4th Axis.....................................................................................................................................................................112
8.2 Approximation of Arcs..........................................................................................................................................113
8.3 5th Axis......................................................................................................................................................................113
8.4 Point Interpolation..................................................................................................................................................113

9. Miscellaneous Parameters
9.1 Message.....................................................................................................................................................................116
9.2 Extra Parameters.....................................................................................................................................................116
9.3 Flyout Window.........................................................................................................................................................116
10. Edit Tool Path
10.1.1 Boundaries.................................................................................................................................................118
10.1.2 Z-levels........................................................................................................................................................118
10.1.3 Boundaries & Z-levels..............................................................................................................................118
10.1 Tool...........................................................................................................................................................................118
10.2 Boundaries and Z-levels.........................................................................................................................................118
10.2.1 Boundary Type..........................................................................................................................................118
10.2.2 Boundary name.........................................................................................................................................119
10.2.3 Boundary offset.........................................................................................................................................119
10.2.4 Z-levels........................................................................................................................................................119
10.2.5 Keep tool path outside the Boundary.....................................................................................................119

Document number: SCHSMUGENG0023SP2

vii
Introduction and Basic
Concepts 1
Welcome to HSM Module!
HSM is a very powerful and market-proven high-speed machining (HSM) module for molds, tools and dies and
complex 3D parts. It offers unique machining and linking strategies for generating high-speed tool paths.
HSM module smooths the paths of both cutting moves and retracts wherever possible to maintain a continuous
machine tool motion–an essential requirement for maintaining higher feed rates and eliminating dwelling.
With the HSM module retracts to high Z-levels are kept to a minimum. Angled where possible, smoothed by arcs,
retracts do not go any higher than necessary, thus minimizing air cutting and reducing machining time.
The result of HSM is an efficient, smooth, and gouge-free tool path. This translates to increased surface quality, less
wear on your cutters, and a longer life for your machine tools.
With demands for ever-shorter lead and production times, lower costs and improved quality, HSM is a must in today’s
machine shops.

About this book

This book is intended for experienced CAM users. If you are not familiar with the software, start with the examples
in the Modules Overview manual and then contact your reseller for information about CAM training classes.

About the Examples

The CAM-Parts used for this book are attached in a ZIP archive. Extract the content of the Examples archive into
your hard drive. The SOLIDWORKS files used for the exercise were prepared with SOLIDWORKS2023.

Windows 10
The screenshots in this book were made using SolidCAM 2023 SP2 integrated with SOLIDWORKS 2023 running on
Windows 10. If you are running on a different version of Windows, you may notice differences in the appearance of
menus and windows. These differences do not affect the performance of the software.
The contents of this book and the examples can be downloaded from the SolidCAM website at http://www.solidcam.
com.

2
 1. Introduction

1.1 Start HSM Operation

To add an HSM Operation to the CAM-Part, right-click the Operations header in SolidCAM Manager and choose 3D
HSM command from the Add Milling Operation submenu.

You can also select the icons on SOLIDWORKS CommandManager tabs, either on SolidCAM 3D or SolidCAM
Operations tab.

HSM Linear machining operation dialog box is displayed.

3
1.2 HSM Operation Overview

The definition of an HSM operation consists of the following stages:

At the first stage, you have to choose one of the available machining strategies. The machining strategy defines the
technology that will be used for the machining. For more information on the machining strategies, refer to chapter 2.
At the Geometry definition stage, you have to specify the 3D model geometry that will be machined. For more
information on the geometry definition, refer to chapter 3.
The next stage enables you to choose from the TOOLKIT table a cutting tool that will be used for the operation. For
more information on the tool definition, refer to chapter 4.
The Boundaries definition page enables you to limit the operation machining to the specific model areas. For some
machining strategies an additional boundary defines the drive curve of the operation tool path. For more information
on the boundary definition, refer to chapter 5.
In the Passes definition, SolidCAM enables you to specify the technological parameters used for the tool passes
calculation. For more information on the passes definition, refer to chapter 6.
The Link parameters page enables you to define the tool link moves between cutting passes. For more information on
the link definition, refer to chapter 7.
The Motion control parameters page enables you to optimize the calculated tool path according to the kinematics and
special characteristics of your CNC-machine. For more information on these parameters definition, refer to chapter 8.
The Miscellaneous parameters page enables you to define the non-technological parameters related to the HSM
operation. For more information on the miscellaneous parameters definition, refer to chapter 9.

1.3 Parameters and Values

Most of the parameters used in the SolidCAM HSM operation receive default values according to built-in formulas
that define dependencies between the parameters. When a number of basic parameters such a tool diameter, corner
radius, offsets, etc., are defined, SolidCAM updates the values of dependent parameters.
SolidCAM provides you with a right-click edit box menu for certain
parameters.

View parameter Info

This command displays the Parameter Info dialog box. This dialog box shows the internal parameter name and the
related formula (if exists) or a static value.

4
 1. Introduction

The Unfold button displays a brief explanation of the parameter.

The button displays the flow chart of the parameter value

calculating.

Reset
When you manually change a parameter default value, the formula
assigned to the parameter is removed.

The Reset commands enable you to reset parameters to their default formulas and values.

• This parameter. This option resets the current parameter.

• This page. This option resets all the parameters at the current page.
• All. This option resets all the parameters of the current HSM operation.

5
6
Technology 2
The Technology section enables you to choose a or finish machining strategy to be applied.

The following strategies are available:

• Constant Z machining
• Hybrid Constant Z
• Helical machining
• Horizontal machining
• Linear machining
• Radial machining
• Spiral machining
• Morphed machining
• Offset cutting
• Boundary machining
• Rest machining
• Contour Rest machining
• 3D Constant step over
• Pencil milling
• Parallel pencil milling
• 3D Corner offset
• Prismatic Part machining
• Combined strategies:
• Constant Z with Horizontal machining
• Constant Z with Linear machining
• Constant Z with 3D Constant step over machining
• Constant Z and 3D Corner offset machining

8
 2. Technology

2.1 Constant Z Machining

Similar to Contour roughing, the Constant Z tool path is generated for a set of sections created at different Z-heights
determined by the Step down parameter. The generated sections are machined in a profile manner. The Constant Z
strategy is generally used for semi-finishing and finishing of steep model areas with the inclination angle between 30
and 90 degrees. Since the distance between passes is measured along the Z-axis of the Coordinate System, in shallow
areas (with smaller surface inclination angle) the Constant Z strategy is less effective.
The image above illustrates the Constant Z finishing. Note that the passes are densely spaced in steep areas. Where
the model faces get shallower, the passes become widely spaced, resulting in ineffective machining. Therefore, the
machining should be limited by the surface inclination angle to avoid the shallow areas machining.
These areas can be machined later with a different SolidCAM HSM strategy, e.g. 3D Constant step over.

2.2 Hybrid Constant Z

The Hybrid Constant Z is a finishing strategy that combines all the benefits of a traditional Constant Z operation with
a 3D pocketing routine that interacts with the main strategy whenever the shallow area between consecutive passes
allows the insertion of additional passes. This method allows an optimal finish over the entire part.

2.3 Helical Machining

With this strategy, SolidCAM generates a number of closed profile sections of the 3D Model geometry located at
different Z-levels, similar to the Constant Z strategy. Then these sections are joined in a continuous descending ramp
in order to generate the Helical machining tool path.

9
The tool path generated with the Helical machining strategy is controlled by two main parameters: Step down and
Max. ramp angle.

2.4 Horizontal Machining

With the Horizontal machining strategy, SolidCAM recognizes all the flat areas in the model and generates a tool path
for machining these areas.

This strategy generates a pocket-style (a number of equidistant profiles) tool path directly at the determined horizontal
faces (parallel to the XY-plane of the current Coordinate System). The distance between each two adjacent passes is
determined by the O  ffset parameters.

2.5 Linear Machining

Linear machining generates a tool path consisting of a set of parallel passes at a set angle with the distance between
the passes defined by the Step over parameter.

With the Linear machining strategy, SolidCAM generates a linear pattern of passes, where each pass is oriented at a
direction defined with the Angle value.

10
 2. Technology

This machining strategy is most effective on shallow (nearing horizontal) surfaces, or steeper surfaces inclined along
the passes direction. The Z-height of each point along a raster pass is the same as the Z-height of the triangulated
surfaces, with adjustments made for applied offsets and tool definition.
In the image above, the passes are oriented along the X-axis. The passes are evenly spaced on the shallow faces and on
the faces inclined along the passes direction. The passes on the side faces are widely spaced; Cross Linear machining
can be used to finish these areas.

2.6 Radial Machining

The Radial machining strategy enables you to generate a radial pattern of passes rotated around a central point.

This machining strategy is most effective on areas that include shallow curved surfaces and for model areas formed
by revolution bodies, as the passes are spaced along the XY-plane (step over), and not the Z-plane (step down). The
Z-height of each point along a radial pass is the same as the Z-height of the triangulated surfaces, with adjustments
made for applied offsets and tool definition.

2.7 Spiral Machining

The Spiral machining strategy enables you to generate a 3D spiral tool path over your model. This strategy is optimal
for model areas formed by revolution bodies.
The tool path is generated by projecting a planar spiral (located in the XY-plane of the current Coordinate System) on
the model.

11
2.8 Morphed Machining

Morphed machining passes are generated across the model faces in a close-to-parallel formation, rather like Linear
machining passes each path repeats the shape of the previous one and takes on some characteristics of the next one,
and so the paths “morph” or gradually change shape from one side of the patch to the other.

The shape and direction of the patch is defined by two drive boundary curves.

Drive boundary curves

2.9 Offset Cutting

This strategy is a particular case of the Morphed machining strategy (see topic 2.8). The Offset cutting strategy enables
you to generate a tool path using a single Drive curve. The tool path is generated between the Drive curve and a virtual
offset curve, generated at the specified offset from the Drive curve.
Tool path
Drive curve

12
 2. Technology

2.10 Boundary Machining

A Boundary machining strategy enables you to create the tool path by projecting the defined Drive boundary on the
model geometry. The Machining depth is defined relative to the model surfaces with the Wall offset parameter. The
tool path generated with the Boundary machining strategy can be used for engraving on model faces or for chamfer
machining along the model edges.

2.11 Rest Machining

Rest machining determines the model areas where material remains after the machining by a tool path, and generates
a set of passes to machine these areas.

Pencil milling vertical corners can cause both the flute of the tool and the radius to be in full contact with the material,
creating adverse cutting conditions. Rest machining picks the corners out from the top down, resulting in better
machining technique. Steep and shallow areas are both machined in a single tool path, with different rest machining
strategies.

13
2.12 Contour Rest Machining

Contour Rest machining enables you to use any combination of tools to remove rest material. It calculates flat areas
of geometry where material remains after the execution of a tool path and generates a set of contour passes (similar
to passes generated in Contour roughing operation pocket-style tool path) to remove the remaining material.

2.13 3D Constant Step Over Machining

3D Constant step over machining enables you generate a 3D tool path on the CAM-Part surfaces. The passes of the
tool path are located at a constant distance from each other, measured along the surface of the model.
Closed boundary

This is an ideal strategy to use on the boundaries generated by rest machining or in any case where you want to ensure
a constant distance between passes along the model faces.

Constant surface step over is performed on a closed profile of the Drive boundary. SolidCAM creates inward offsets
from this boundary.

14
 2. Technology

2.14 Pencil Milling

The Pencil milling strategy creates a tool path along internal corners and fillets with small radii, removing material that
was not reached in previous machining. This strategy is used to finish corners which might otherwise have cusp marks
left from previous machining operations. This strategy is useful for machining corners where the fillet radius is equal
to or smaller than the tool radius.

2.15 Parallel Pencil Milling

Parallel pencil milling is a combination of the Pencil milling strategy and the 3D Constant step over strategy. At the
first stage, SolidCAM generates a Pencil milling tool path. Then the generated pencil milling passes are used to create
3D Constant step over passes; the passes are generated as a number of offsets on both sides of the pencil milling
passes. In other words, the Parallel pencil milling strategy performs 3D Constant step over machining using Pencil
milling passes as drive curves to define the shape of passes.

This strategy is particularly useful when the previous cutting tool was not able to machine all the internal corner radii
to size. The multiple passes generated by this strategy will machine from the outside in to the corner, creating a good
surface finish.

15
2.16 3D Corner Offset

The 3D Corner offset strategy is similar to the Parallel pencil milling strategy. This strategy is also a combination of
the Pencil milling strategy and the 3D Constant step over strategy. SolidCAM generates a Pencil milling tool path and
uses it for the 3D Constant step over passes generation. These passes are generated as offsets from the Pencil milling
passes. In contrast to the Parallel pencil milling strategy, the number of offsets is not defined by user but determined
automatically in such a way that all the model within the boundary will be machined.

2.17 Prismatic Part Machining

The Prismatic Part machining strategy is designed especially for high-speed finishing of prismatic parts. This
strategy comprises the technology of the Constant Z and 3D Constant step over strategies by integrating these two
strategies into one smart functionality of prismatic part machining. The difference from the Combined Constant Z
with 3D Constant step over strategy is as follows: in the Combined strategy, the subsequent strategies are performed
successively one after the other.

In the Prismatic Part machining strategy, the machining is performed consistently according to the order of the walls
and flat faces along the Z-axis.

16
 2. Technology

2.18 Combined Strategies

SolidCAM enables you to combine two machining strategies in a single HSM operation: Constant Z with Horizontal,
Linear, 3D Constant step over or 3D Corner Offset machining. Two combined machining strategies share the Geometry,
Tool and Constraint boundaries data. The technological parameters for the passes calculation and linking are defined
separately for each strategy.

2.19 Customize Menu

SolidCAM allows you to see the most common operations in HSM. When you click on Customize Menu, you can
simplify the user interface by selecting the technologies you require for machining of the part. Only the selected
options are then displayed in the Technology list.

17
18
Geometry 3
The Geometry page enables you to define the 3D model geometry for the HSM operation.

3.1 Geometry Definition

The Target geometry section enables you to specify the appropriate Coordinate System for the operation and to define
the machining geometry.

3.1.1 CoordSys
SolidCAM enables you to define the Coordinate System for the operation by choosing it from combo-box or by
selecting it from the graphic screen by clicking the CoordSys button. The CoordSys Manager dialog box is displayed.
Together with this dialog box, SolidCAM displays the location and axis orientation of all Coordinate Systems defined
in the CAM-Part.
To get more information about the Coordinate System, right-click the
CoordSys entry in CoordSys Manager and choose the Inquire option from
the menu.
The CoordSys Data dialog box is displayed.
When the CoordSys is chosen for the operation, the model is rotated to the
appropriate orientation.
The CoordSys selection operation must be the first step in the geometry
definition process.

3.1.2Target geometry
After the Coordinate System is chosen, define the 3D Model geometry for
the HSM operation.
If you have already defined 3D Model geometries for this CAM-Part, you
can select a geometry from the list.
The Show button displays the chosen 3D model geometry in the SOLIDWORKSwindow.

enables you to define a new 3D Model geometry for the operation with the 3D Model Geometry dialog box.
enables you to edit an existing geometry.
enables you to view the available geometries on the model and choose the relevant one from the list.

20
 3. Geometry

For more information on 3D Geometry selection, refer to the SolidCAM Milling Help.

When you choose the geometry from the list, the related Coordinate System is chosen automatically.

3.1.3 Facet tolerance

Before the machining, SolidCAM generates a triangular mesh for all the faces of the 3D model geometry used for the
operation. Facet tolerance is the accuracy to which triangles fit the surfaces. The smaller the value the more accurate
the triangulation is, but the slower the calculation.
The 3D model geometry will be triangulated and the resulting facets will be saved. The triangulation is performed
on the 3D model geometry when you use it for the first time in a SolidCAM HSM operation. If you use the 3D
geometry in another operation, SolidCAM will check the tolerance of the existing geometry. It will not perform
another triangulation as long as the facets have been created with the same surface tolerance.

3.1.4 Micro Milling

Selecting the Micro Milling check box enables you to tighten the facet tolerance value for machining extremely small
parts. When you select the Micro Milling check box, the defined Facet tolerance value is automatically changed to half
of the defined value.

3.1.5 Apply fillets

This option automatically adds fillets to the internal model corners. Therefore, the tool does not have to dramatically
change direction during the machining, preventing damage to itself and to the model surfaces and enabling faster feed
rates and eventually better surface quality.

When the corner radius is smaller than or equal to By adding fillets, the corner radius becomes greater
the tool radius, the tool path consists of two lines than the tool radius and the tool path lines are then
connected with a sharp corner; at this corner point connected with an arc, resulting in a smooth tool
the tool sharply changes its direction. movement without sharp changes in direction.

Select the Apply fillets check box to automatically add fillets for the tool path generation.

Click to create a new fillets geometry. The Fillet Surfaces dialog box is displayed.
The Show button displays the chosen fillet geometry directly on the solid model

21
 Model without fillets Model with fillets

3.1.6 Fillet Surfaces dialog box

The Fillet Surfaces dialog box enables you to generate fillet geometry for the current 3D Model geometry used for
the HSM operation.

Boundary
The Boundary type section enables you to specify the boundary geometry for the fillet generation. The fillets will be
generated inside the specified 2D boundary.
SolidCAM enables you to choose the 2D boundary type from the list. 2D boundaries of the following types are
available: Auto-created silhouette, Auto-created outer silhouette, User-defined boundary, and Auto-created box of
target geometry option.

The latter option automatically generates a planar box surrounding the Target geometry.
The Boundary name section enables you to choose a 2D boundary geometry from the list or define a new one using
the New button. The appropriate dialog box will be displayed. You can edit an existing geometry with the Edit button.
The Show button displays the Select Chain dialog box, and the chains are displayed and highlighted in the graphic
window. If needed, you can unselect some of the automatically created chains.

Filleting Tool Data Angle

For the calculation of fillets, SolidCAM uses a virtual tool. The Filleting
tool data section enables you to specify the geometry parameters of this
tool.
• Tool diameter. This field enables you to specify the cutting
diameter of the virtual tool.
• Corner radius. This field enables you to specify the corner
radius of the virtual tool.
• Taper (°/side). This field enables you to specify the taper angle
of the tool’s flank. SolidCAM does not support tool with a
back taper, like a Dove tail tool.
• Cutting length. This field enables you to specify the length of
the cutting edge of the tool.
• Shank diameter. This field enables you to specify the shank
diameter.

22
 3. Geometry

• Outside holder length. This field enables you to specify the length of the visible part of the tool, from the tip
to the start of the tool holder.

General
• Tolerance. This parameter defines the tolerance of fillet surfaces triangulation. A lower value will give more
accurate results, but will increase the calculation time.
• R
 esolution. This is the “granularity” of the calculation. Using a smaller value will give finer detail but will
increase the calculation time.
• Minimum Z. This option sets the lowest Z-level the tool can reach.
• Number of facets. This is the number of flat faces (triangles) across the radially curved section of the fillet.
• Bitangency angle. This is the minimum angle required between the two normals at the contact points between
the tool and model faces, in order to decide to generate the fillet.

Bitangency angle

23
24
Tool 4
On the Tool page of the HSM operation dialog box, the following tool parameters are displayed:

• Type

• Number

• Tool offset

• Diameter

• Modified offset

• Corner radius

• Cutting length

• Outside holder

• Turret

4.1 Calculate Minimum Tool Length

This option enables you to calculate the minimal Outside holder length of the tool to avoid the holder gouging
with the model. When you select the Calculate minimum tool length check box and click the Save&Calculate icon,
SolidCAM calculates the recommended value and displays it in the Minimum tool length field.

This option is not available for the Rest machining strategy.

4.2 Holder Clearance

The Holder clearance parameter enables you to define how close the holder
can approach the material during the machining.

Force Change Tool

If two operations use the same tool, and the Force Change Tool checkbox is Holder Clearance

selected, the additional tool change commands are displayed in the generated
GCode. When this checkbox is selected, the tool returns to the safety position
in place of retract position once the machining is completed.

26
 4. Tool

4.3 Tool Selection

The Select button enables you to edit tool parameters or define the tool you want to use for this operation.
This button displays the TOOLKIT table. You can also add a new tool to be defined for the operation or choose another
tool from this table.

For more information on the tool definition, refer to the SolidCAM Milling Help.

4.4 Spin & Feed Rate Definition

The Data tab displays the spin and feed parameters that you can edit.

Feed Rate
The feed value can be defined in two types of units: F and FZ. F is the default that signifies Units per minute. FZ
signifies Units per tooth and is calculated according to the following formula:

27
FZ = F/(Number of Flutes * S)

The F/FZ buttons enable you to check the parameter values.

• Cutting. This field defines the feed rate of the cutting section of the tool path.
• Link down. The feed rate to be set for lead in moves.
• Link up. The feed rate to be set for lead out moves.
• R
 apid. This parameter enables you to define a feed rate for the retract sections of the tool path, where the tool
is not contacting with the material.

Spin
This field defines the spinning speed of the tool.
The spin value can be defined in two types of units: S and V.
S is the default and signifies Revolutions per Minute. V signifies Material cutting speed in Meters/Minute in the Metric
system or in Feet/Minute in the Inch system.
It is calculated according to the following formula:
V = (S * PI * Tool Diameter) / 1000

Gears
If the drive system of your CNC-Machine has two or more gears with different spin limitations, they can be individually
defined in the VMID’s Drive Unit settings. When more than one is defined, you can select your preferred gear for use
in the operation from the Gear list. By default, the gear is automatically selected according to each of the Spin values.
Only gears having the current Spin value within their range are shown in the list.
The first parameter enclosed in parentheses indicates the defined spin range; the second parameter indicates the
defined power.
Spin direction
The Spin direction section enables you to choose between the clockwise (CW) or counterclockwise (CCW) direction.
Offsets
The Length offset number parameter defines the number of the Length Offset Register of the current tool in the
Offset table of the CNC-machine.
Cutting conditions
This button enables you to update the cutting conditions defined for use of the current tool on the chosen CNC-
machine according to the parameters set in the TOOLKIT table.

28
Boundaries 5
5.1 Introduction

SolidCAM enables you to define two types of boundaries for the SolidCAM HSM operation tool path: drive boundaries
and constraint boundaries.

5.1.1 Drive boundaries

Drive boundaries are used to drive the shape of the tool path for the following strategies: 3D Constant step over,
Morphed machining, Offset cutting and Boundary machining.

Drive boundaries for Morphed machining

SolidCAM enables you to define drive boundary curves for the Morphed machining strategy.

You can choose existing geometries for the first and second drive curves from list or define a new one by clicking

. The Geometry Edit dialog box is displayed. For more information on geometry selection, refer to the SolidCAM
Milling Online Help.

The Show button displays the chosen drive curve geometry directly on the solid model.

30
 5. Boundaries

Make sure that the directions of both drive curves are the same in order to perform the correct machining.

Drive boundary curves

Cutting direction
This option enables you define the tool path direction between the drive curves.
• Across. The morphed tool path is performed across the drive curves; each cutting pass connects the
corresponding points on the drive curves. Drive boundary curves

• Along. The morphed tool path is performed along the drive curves. The tool path morphs between the shapes
of the drive curves gradually changing shape from the first Drive boundary curves
drive curve to the second.

Drive boundaries for Offset cutting

The Drive boundaries page of the HSM Offset cutting machining dialog
box enables you to define the curve and the related parameters.

Curve
This section enables you to define the Drive curve used for the tool path
definition.

31
Clear direction
This section enables you to specify the direction in which a virtual offset from the Drive curve is created. The offset
can be generated in the Right, Left or Both directions from the Drive curve.

Left
Drive curve

Right

Cutting direction
This section enables you to determine how the machining is performed. When the Along option is chosen, the
machining is performed along the Drive curve. The tool path morphs between the shapes of the Drive curve and the
offset curve, gradually changing shape from the first Drive curve to the offset curve. When the Across option is
chosen, the tool path is performed across the Drive curve; each cutting pass connects the corresponding points on the
Drive curve and offset curve.

Boundary – Tool Relation

The Boundary – Tool Relation section enables you to
define the position of the tool relative to the defined
boundary and the related parameters.

Along Across
5.1.2 Constraint boundaries
A constraint boundary enables you to limit the machining to specific model areas.

32
 5. Boundaries

Machining always takes place within a boundary or a set of boundaries. The boundaries define the limits of the tool
tip motion. The area actually machined can be extended beyond the boundary by as much as the tool shaft radius.
In the image the tool center is located at the edge of the boundary, therefore the tool extends
beyond the edge by tool radius. You can use the Offset feature to offset the tool inside by a
certain distance.
If there are several boundary contours then the operation will use all of them.

If one boundary is completely inside another, then it will act as an island. The area enclosed by the outer boundary,
minus the area defined the inner boundary, will be machined.

You can extend this to define more complicated shapes by having islands within islands.

5.2 Boundary Definition

Two types of boundaries are available in the boundary type section:

5.2.1 Boundary type

The following boundary types are available:

Created automatically
This option enables you to automatically create the boundary using the stock or target models.
The following types of automatically created boundaries are supported in SolidCAM:
• Auto-created box of target geometry

• Auto-created box of stock geometry

• Auto-created silhouette

• Auto-created outer silhouette

Created manually
This option enables you to define the constraint boundary that limits the tool path by creating a 2D area above the
model in the XY-plane of the current Coordinate system or by an automatically generated 3D curve mapped on the
surface.

33
The following types of 2D boundaries are supported:
• Boundary box

• Silhouette boundary

• User-defined boundary

• Combined boundary

The following types of 3D boundaries are supported:

• Selected faces

• Shallow areas

• Theoretical rest areas

• Tool contact areas

• Rest areas

5.2.2 Boundary name

This section enables you to define a new boundary geometry or choose an already defined one from the list.

• displays the appropriate dialog box for the geometry definition.

• displays the Select Chain dialog box enabling you to choose the necessary chains for the boundary. The
chosen boundaries are displayed and highlighted in the graphic window.

5.2.3 Boundary – tool relation

This option controls how the tool is positioned relative to the boundaries. This option is relevant only for 2D
boundaries.

Internal Boundary

The tool machines inside the boundary.

Tool

External Boundary

The tool machines outside the boundary.

Tool

Centered Boundary

The tool center is positioned on the boundary.

Tool

34
 5. Boundaries

Tangent Unmachined area

The Internal/External/Centered methods of the boundary definition

have several limitations. In some cases, the limitation of the tool path by
planar boundary results in unmachined areas or corners rounding.
The Tangent option enables you to avoid these problems. Boundary – Tool Relation: Internal

When this option is chosen, SolidCAM generates the tool path boundaries
by projecting the planar working area on the 3D model. The tool path
is limited in such a way that the tool is tangent to the model faces at the
boundary. Unmachined
area
This option enables you to machine the exact boundary taking the
geometry into account.
Boundary – Tool Relation: Centered
The tool is tangent
to the projection
of the working area Tool path rounding
onto the model faces

Boundary – Tool Relation: External

Boundary – Tool Relation: Tangent

Offset value
This value enables you to specify the offset of the tool center.
A positive offset value enlarges the boundary; a negative value reduces the boundary
to be machined.
-
None +
This value enables you to specify the offset of self-intersected geometries. -
+
This option is available only on the Drive boundaries page, when the Technology is
selected as Boundary machining.

5.3 Automatically Created Boundaries

The following types of automatic boundaries are available:

5.3.1 Auto-created box of target geometry

With this option SolidCAM automatically generates a rectangular box surrounding the target model. The tool path is
limited to the area contained in this box.

Target Model

35
5.3.2 Auto-created box of stock geometry
With this option SolidCAM automatically generates a rectangular box surrounding the stock model. The tool path is
limited to the area contained in this box.

Stock Model

Target Model

5.3.3 Auto-created silhouette

With this option, SolidCAM automatically generates a silhouette boundary of the target model. A silhouette boundary
is a projection of the outer and inner contours of the target model onto the XY-plane.

Target Model

5.3.4 Auto-created outer silhouette

With this option, SolidCAM automatically generates an outer silhouette boundary of the target model. In this case, an
outer silhouette boundary is a projection of the outer contours only onto the XY-plane.

Target Model

36
 5. Boundaries

5.4 2D Manually Created Boundaries

Following types are available:

5.4.1 Boundary box

A Boundary Box is a rectangular box surrounding the selected model geometry. SolidCAM enables you to limit the
machining passes to the area contained in the Boundary box.
The Boundary Box dialog box enables you to define a necessary parameters
and choose the model elements for the bounding box calculation.

The boundary will be created on

This option enables you to select the faces for which a bounding box is generated. Click the Select button to display
the Select Faces dialog box.
The Show button displays the already selected faces geometry.
The table section displays the automatically calculated minimum and maximum coordinates, center and length of the
bounding box.

SolidCAM enables you to change the XY-coordinates of the minimum and maximum coordinates of
the bounding box.

When the geometry for the bounding box generation is defined, click . The boundary chains will be generated
and the Select Chain dialog box will be displayed.

5.4.2 Silhouette boundary

A Silhouette boundary is a projection of the face edges onto the XY-plane. In other words, it is the shape that you see
when you looking at a set of surfaces down the tool axis.

The Silhouette Boundary dialog box enables you to define the parameters
and choose the solid model elements for the silhouette boundary calculation.

The boundary will be created on

This option enables you to choose a faces geometry to generate a silhouette boundary. SolidCAM enables you either
to choose an already existing Faces geometry from the list or define a new one with the Select button.
The Select Faces dialog box will be displayed. The Show button displays the selected face geometry.

37
 • Min. diameter

This value defines the spanning of the boundary, the distance between two points on either side. Boundaries
that have a diameter smaller than this are discarded.
• Aperture

This value defines the fuzziness of the Silhouette. Decrease the value to bring it into sharper focus; increase
it to close up unwanted gaps between boundaries.
• Resolution

This value defines the granularity of the calculation: a small value results in a more detailed boundary, but it
is slower to calculate.

When the geometry for the silhouette boundary generation is defined, click . The boundary chains will be
generated and the Select Chain dialog box will be displayed.

5.4.3 User-defined boundary

SolidCAM enables you to define a user-defined boundary based on a Working area geometry (closed loop of model
edges as well as sketch entities).
For more information on Working area geometry, refer to the SolidCAM Milling Help.
SolidCAM automatically projects the selected geometry on the XY-plane and defines the 2D boundary.
The Geometry Edit dialog box enables you to define the geometry.

5.4.4 Combined boundary

This option enables you to define the boundary by performing a number of boolean operations between working area
geometries and boundaries. Click the New icon.
The Boolean Operations dialog box is displayed.

Coordinate System
This field enables you to choose the Coordinate System where the source geometries for the boolean operation are
located. The resulting combined geometry will be created in the chosen coordinate system.

38
 5. Boundaries

Configurations
This field enables you to choose the SOLIDWORKS configuration where the source user-defined geometries for the
boolean operation are located.

Operation type
Source geometries
This field enables you to define the type of the boolean operation. The following
boolean operations are available:
• Unite

This option enables you to unite selected geometries into a single one. All
internal segments are removed; the resulting geometry is outer profile.
Geometry 1 Geometry 2

Resulting geometry

• Merge Source geometries

This option enables you to merge a number of geometries, created by

different methods, into a single one.

Geometry 1 Geometry 2

Resulting geometry

Geometry 3

• Subtract Source geometries

This option enables you to perform subtraction of two geometries. The

order of the geometry selection is important; the second selected geometry
is subtracted from the first selected one.

Geometry 1 Geometry 2

Resulting geometry

39
 Intersect Source geometries

This option enables you to perform intersection of two geometries.

Geometry 1 Geometry 2

Resulting geometry
The Accept button performs the chosen operation with the geometries chosen in
the Geometries section.

Geometries
The Geometries section displays all the available working area geometries classified
by the definition method.

This section enables you to choose the appropriate geometries for the boolean
operation. Select the check box near the geometry name in order to choose it for
the boolean operation.

When you click button, the resulting geometry is displayed in the list under the
Combined 2D header. SolidCAM enables you to edit the name of the created
geometry. The newly created geometry is automatically chosen for the further
boolean operation.

The resulting combined geometry is always a 2D geometry even if

one or more of the input geometries is a 3D boundary.
The right-click menu available on the list items enables you to perform the following
operations:
• Accept. This button enables you to perform the chosen boolean operation
with the selected geometries.
• Unselect All. This option unselects all the chosen geometries.
• Delete. This option enables you to delete combined geometries generated in the current session of the Boolean
Geometries dialog box.

5.4.5 Select Faces dialog box

This dialog box enables you to select one or several faces of the SOLIDWORKSmodel. The selected Face tags will
be displayed in the dialog box.

40
 5. Boundaries

If you have chosen wrong entities, use the Unselect option to undo your selection. You can also right-click on the
entity name (the object will be highlighted) and choose the Unselect option from the menu.
The Reverse/Reverse all option enables you to change the direction of the normal vectors of the selected faces.
The CAD Selection option enables you to select faces with the SOLIDWORKStools.

5.4.6 Select Chain dialog box

Depending on the boundary type, SolidCAM generates a number of chains for the selected faces. The Select Chain
dialog box enables you to select the chains for the boundary.

Profile geometry
SolidCAM enables you to define a user-defined boundary based on a Profile geometry. All the HSM strategies enable
you to use closed profile geometries. The Boundary machining strategy enables you to use also open profiles for the
boundary definition; this feature is useful for single-contour text engraving or for chamfering.
For more information on Profile geometry, refer to the SolidCAM Milling Online Help.
SolidCAM automatically projects the selected geometry on the XY-plane and defines the 2D boundary.
The Geometry Edit dialog box enables you to define the geometry.

5.5 3D Manually Created Boundaries

5.5.1 Common parameters for boundary definition

The boundary will be created on

• Selected faces. This option enables you to choose a faces geometry to generate a boundary of the defined
type. SolidCAM enables you either to choose an already existing Faces geometry from the list or define a new
one with the Select button. The Select Faces dialog is displayed. The Show button displays the selected face
geometry.
• Whole model. With this option, SolidCAM generates boundaries of the chosen type for all the model faces.

Limits
• Z Limits
Set the machining range along the Z-axis by definition of upper and lower limits. Boundaries will be
generated within this range.

41
 • Angle
Set the contact angle range of your tool by setting the minimum and maximum contact angle. Boundaries
will be generated around areas where the angle is within that range.
For Shallow Area boundaries the range should typically be between 0 and 30 degrees, but where surfaces
are very close to the minimum or maximum angle, you may get an undesirably jagged edge so you may
want to alter the range slightly. Alternatively, you can sometimes prevent formation of jagged edges by
giving the boundary a small offset.
• Contact Areas Only
This option should be selected to choose only boundaries that are in contact with the model surface.

Boundaries
• Wall offset
This value defines the distance at which the boundaries and therefore the tool will be away from the
surface, similar to the Wall offset parameter on the Passes page.
For roughing and semi-finishing operations, this value must be greater than zero. The calculations are
based on a modified tool, the surface of which is offset to be larger than the actual tool. This will leave
material on the part.
For finishing operations, the value must be set to zero. The calculations are based on the dimensions of
the defined tool with no offset.
In special circumstances, such as producing electrodes with a spark gap, this value can be smaller than
zero. The tool will remove material at a level below the designated surface. The calculations are based on a
modified tool, offset smaller than the one used.
• Floor offset
This value defines the distance away from the surface at which the boundaries will be in the tool axis
direction.
The boundary is calculated using the Wall offset. The resulting boundary is updated by offsetting along the
tool axis by a distance equal to the Floor offset.
• Min Diameter
This value defines the spanning of the boundary, the distance between two points on either side. Boundaries
that have a diameter smaller than this are discarded.
• Offset
The boundaries are calculated and then offset by this amount. It may be advantageous sometimes to set a
small offset value to prevent jagged boundary edges where surface area is at angle similar to the Contact
Angle.

In Rest areas with no offset, the exact boundary area would be machined, resulting in marks or even cusps
around the edge. For Theoretical rest areas, the boundaries are offset outwards along the surface by this
amount after they have been made; a good surface finish is ensured at the edges of the rest areas. Without
offsetting, the exact Theoretical rest area would be machined, probably leaving marks or even cusps (of
just under the minimum material depth value) around the edge. The offsetting makes the boundaries
smoother, so a tool path made using them is less jagged.
• Resolution
This value defines the granularity of the calculation. A small value results in a more detailed boundary but
it will be slower to calculate.

42
 5. Boundaries

5.5.2 Selected faces

This option enables you to define the boundary by selecting drive and check faces similar to the Working area definition
for 3D Milling operations.

Under Boundary name, click the Define button to start the boundary definition. The Selected faces dialog box
enables you to define the drive and check faces.

Name
This section enables you to define the boundary name and the tolerance that is used for the boundary creation.

Drive faces
This section enables you to define Drive faces – the set of faces to be milled. The tool path is generated only for
machining of these faces. The Define button displays the Select Faces dialog box used for the faces selection. The
Offset edit box enables you to define the offset for the Drive faces. When the offset is defined, the machining is
performed at the specified offset from the Drive faces. Check face
Drive face
Drive faces offset

Check faces
This section enables you to define Check faces – the set of faces to be avoided during the generation of the tool path.
The Define button displays the Select Faces dialog box used for the faces selection. The Offset edit box enables you
to define the offset for the Check faces. When the offset is defined, the machining is performed at the specified offset
from the Check faces. Check faces offset
Check face

Drive face

43
5.5.3 Shallow areas
With this option, SolidCAM enables you to automatically
determine shallow areas in the model and define boundaries
around them.

The tool has to be chosen for the operation

before the shallow areas boundary definition.
The Select faces dialog box enables you to choose the
necessary model faces. When the faces are chosen and the
dialog box is confirmed, the Shallow Areas dialog box is
displayed.
This dialog box enables you to define a number of parameters for the shallow areas boundary generation.

5.5.4 Theoretical rest areas

You can create 3D boundaries from rest areas left by an imaginary reference tool. This gives good results when used
for semi-finish and finish machining operations. You can then use these boundaries to limit another SolidCAM HSM
operation performed with a tool of an equal or smaller size.

The Select faces dialog box enables you to choose the necessary model faces. When the faces are chosen and the
dialog box is confirmed, the Theoretical Rest Areas dialog box is displayed.
This dialog box enables you to define a number of parameters for the theoretical rest material areas generation.

Limits
• Include Corner Fillets

In corner area, the angle is degenerate. Use this option to include or exclude all corner areas from the rest area
boundaries.
• Min material depth

The smallest amount of material to be found in areas included in the rest area boundary prior to rest machining.
If the reference tool left parts of the material with less than this amount, those material areas would not be
included in the rest area boundaries.
The Min material depth should be greater than the cusp height left by the passes of the imaginary reference
tool path. If the Min material depth is smaller than the cusp height left by the passes of the imaginary
reference tool path the whole area machined by the reference tool will be included in the rest area boundary.

44
 5. Boundaries

Reference Tool
This section enables you to specify the tool with which the theoretical rest areas will be calculated. This tool is usually
larger than the tool that will be used to cut the rest areas. The reference tool is used to represent an imaginary tool
path, and the rest areas are created assuming that the tool path had been created.
Define the size of the tool by inserting values into the Tool diameter and Corner radius fields.

5.5.5 Tool contact area

Tool contact area detection enables you to create 3D boundaries around areas where the tool is in contact with the
selected surface or surfaces.

Tool contact area boundaries do not work on vertical or near-vertical surfaces. The steepest angle you
should use for best results is 80 degrees.

The surface has to be selected as shown below.

If a Tool contact area boundary is created from this selection, there will be offset from the edges where the selected
surface is adjacent to another surface. The tool can only reach the edges where there are no other surfaces to hinder
its movement.

The Select faces dialog box enables you to choose the necessary model faces. When the faces are chosen and the
dialog box is confirmed, the Tool Contact Areas dialog box is displayed.
This dialog box enables you to define the parameters for the boundary calculation.

Boundaries

Overthickness

This option is available only for Tool contact area boundaries. Overthickness is an extra offset that can be
applied to the tool in addition to the set Wall offset when you wish to calculate with a tool slightly larger than
the one you intended to use, to create smooth filleted edges.

45
 Constrain

This option enables you to limit the tool motion in two ways:
• Center point
The point of contact between the tool and the surfaces always lies within
the boundary.

• Contact point
The edge of the tool always lies within the boundary.

5.5.6 Rest areas

This option enables you to define rest material left unmachined after any machining
strategy to create 3D boundaries. You can then use these boundaries to limit the
operation tool path, made with a tool of an equal or smaller size to these specific
areas.

46
 5. Boundaries

The Select faces dialog box enables you to choose the necessary model faces. When the faces are chosen and the
dialog box is confirmed, the Rest Areas dialog box is displayed.
This dialog box enables you to define the parameters for the rest areas calculation.

Previous operations
SolidCAM enables you to choose any previous HSM operation for the Rest areas calculation.

Min. material depth

This value defines the granularity of the calculation. A small value results in a more detailed boundary but it will be
slower to calculate.

47
48
Passes 6
The Passes page enables you to define the technological parameters needed to generate the tool path for the HSM
operation.

Common Parameters
The Passes parameters for the various machining strategies vary slightly, but most of them are the same. The following
section is a general overview of the common parameters for all the HSM strategies.
The following tabs are available:
• Passes parameters

• Smoothing parameters

• Adaptive step down parameters

• Edit Passes parameters

• Cross parameters

• Axial offset parametes

The Advanced check box displays the additional tabs with advanced parameters.

6.1 Passes Parameters

The Passes tab displays the major parameters that affect the generation of tool path passes.

50
 6. Passes

6.1.1 Wall offset Wall

offset
This option enables you modify the tool diameter. The machining is performed
using the modified tool.

Positive value

The tool is moved away from the machining surface by the defined value. The
offset is left unmachined on the surfaces. Generally, positive values are used for
roughing and semi-finishing operations to leave an allowance for further finishing
operations.

No offset

The tool with the specified diameter is used for the tool path calculation. The
machining is performed directly on the model surfaces. Generally, zero offset is
used for finishing operations.

Negative value Wall

offset
The tool is moved deeper into the material penetrating the machining surface by
the specified value.
This option is used in special circumstances, such as producing electrodes
with a spark gap. The tool will remove material at a level below the designated
surface. The calculations are based on a modified tool smaller than the one used.

Since the calculations for negative values are based on a modified tool which is smaller than the one
used, the offset must be equal to or smaller than the corner radius of the tool. Where the offset is
greater than the corner radius of the tool, surfaces at angles near to 45° are unfavorably affected as the
corner of the tool impacts on the machined surface, since the offset at the corners is in fact greater than
the value set (see image). Surfaces that are horizontal or vertical are not affected.

51
 If a negative value (e.g. –1 mm) is applied to a tool without corner radius, the real offset at the corners
of the tool will be considerably greater than 1 mm (–1.4 mm appx.). This is obviously incorrect. If you
want to simulate a negative offset with a slot mill, start by defining
a bull-nosed tool with the corner radius equal to the negative value
of the offset – corner radius of 1 mm is used with negative offset
of –1 mm.

1 mm

~1.4 mm

If you define an end mill, the offset will be greater than the value
set on surfaces nearing 45 degrees.

Using a bull-nosed tool with a positive corner radius equal to the

desired negative offset, you will achieve better and more accurate
results.

6.1.2 Floor offset

This offset is applied to the tool and has the effect of lifting (positive value) or
dropping (negative value) the tool along the tool axis. As a result, Floor offset has
its greatest effect on horizontal surfaces and no effect on vertical surfaces. By
default, this value is equal to that of Wall offset.
Floor
offset
The tool path is calculated taking into account the tool plus Wall offset. The
resulting tool path is calculated by offsetting along the tool axis by the distance
equal to the specified Floor offset value.

52
 6. Passes

6.1.3 Cut Tolerance

All machining operations have a tolerance, which is the accuracy of the calculation. The smaller is the value, the more
accurate is the tool path.

Surface

Cut with high tolerance

Cut with low tolerance

The tolerance is the maximum amount that the tool can deviate from the surface.
Using the slider, you can adjust the tolerance within the range defined on the 3D HSM page in SolidCAM Settings >
Defaults > Tolerance.

6.1.4 Step down

The Step down parameter defines the spacing of the passes along the tool axis. This parameter is different from
Adaptive step down, which adjusts the passes to get the best fit to the edges of a surface. The passes are spaced at the
distance set, regardless of the XY-value of each position
Step down
(unless the Adaptive step down check box is selected).

6.1.5 Step over

Step over is the distance between two adjacent passes.
In the 3D Constant step over strategy, the value of the
Step over is constant.

In Morphed machining and Offset cutting strategies, the

actual Step over can vary, and this parameter defines the
maximal step over value.
Step over
For all the strategies, Step over is measured in the XY-
plane, but for the 3D Constant step over strategy, Step
over is measured along the surface.

This parameter is available for Hybrid Constant Z, Linear machining, Radial machining, Spiral
machining, Morphed machining, Offset cutting, Rest machining, Contour Rest machining, 3D
Constant step over, and Prismatic Part machining.

53
6.1.6 Pass extension
This option enables you to extend the tool path beyond the boundary to enable the tool movement into the cut with
machining feed rather than rapid feed.
The Linear tool path shown below is created with the zero pass extension:

The Linear tool path shown below is created with 5 mm pass extension:

The Pass extension parameter is available for Linear machining and Radial machining technologies.

54
 6. Passes

6.1.7 Offsets
Each Z-level comprises a “surface profile” and a series of concentric offset profiles. The minimum and maximum
offset values define the range of the size of spaces between the passes. SolidCAM will choose the largest value
possible within that range that does not leave unwanted upstands between the passes.

Offset

The Min. Offset value should be greater than the Offset tolerance parameter and smaller than the tool shaft radius; the
Max. Offset value is calculated automatically.

This parameter is available only for the technology of Horizontal machining.

6.1.8 Detect Flat Areas

Detect Flat Areas inserts a tool path level on the flat area of the part and then carries the Z level slices at the
programmed Z step. With this option enabled, each stepdown is adjusted to match the flat areas such that the
requested axial stock to leave is also the stock left in these areas.

This option is available only for the technology of Constant Z machining.

6.1.9 Limits
The limits are the highest and lowest Z-positions for the tool – the range
in which it can move. You can set the limits By target or By stock.
• Z-Bottom limit. This parameter enables you to define the lower
Z-level of the machining. The default value is automatically set
at the lowest point of the model.
This limit is used to limit the passes to level ranges or to
prevent the tool from falling indefinitely if it moved off the
edges of the model surface. When the tool moves off the surface, it continues at the Z-Bottom limit and
falls no further.
• Z-Top limit. This parameter defines the upper machining level. The default value is automatically determined
at the highest point of the model.
• Delta. This parameter allows you to set a value for machining above or below the values specified in Z-Top and
Z-Bottom limits.

• CoAngle. This parameter defines the contact angle alignment to be used when making cross machining passes.

55
 This option is available only for the Linear machining technology.

• Angle. SolidCAM enables you to limit the surface angles within a range most appropriate to the strategy. The
Constant Z strategy, for example, is most effective on steeper surfaces, because the spaces between the passes
are calculated according to the Step down value, and on surfaces where there is little Z-level change, the spaces
between the passes are greater, therefore you may get unsatisfactory results. You can limit the work area to
surface angles between, for example, 30 and 90 degrees.
The angle is measured between the two normals at the contact points
between the tool and model faces. The angle of 0 means coincidence of
surface normal and tool axis (horizontal surface).

• Contact areas only

When this check box is selected, the tool path is only created where the tool is in contact with model faces.
The examples below show the result of Constant Z strategy with and without the Contact areas only
option.
When this check box is selected, the machining is limited to the
actual surfaces of your geometry.

When this check box is not selected, the outer edge of the base
surface is machined as well as the central boss.

6.1.10 Point reduction

SolidCAM enables you to optimize the tool path by reducing the number of points.
The Fit arcs option enables you to activate the fitting of arcs to the machining passes according to the specified
Tolerance value.

The Tolerance value is the chordal deviation to be used for point reduction and arc fitting.
Using the slider, you can adjust the tolerance within the range defined on the 3D HSM page in SolidCAM Settings >
Defaults > Tolerance.

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 6. Passes

6.1.11 Refine corners

When Horizontal machining is selected as the technology, this option enables you to refine corner positions to provide
a smoother tool path.

6.1.12 Smoothing
This check box enables you to round the tool path corners.

6.1.13 Max ramp angle

This parameter defines the maximum angle (measured from horizontal) for ramping. The descent angle of the ramping
helix will be no greater than this value.

6.1.14 Climb milling

When this option is selected, the Helical machining passes will be climb milled. When this option is not selected, the
milling direction for all the passes is reversed, so that they will be conventionally milled.

6.1.15 Detect core areas

This option causes the tool to start from the outside of the model rather than take a full width cut in the center of the
component. The areas are machined from outside inwards.

The passes for the Z-Top level machining are not usually included in the operation tool path. Adjust the
Z-Top level by adding the Step down value to the current Z-Top level value when you want to include
the top level passes in the operation tool path.

6.1.16 Scallop
This option enables you to control the distance between the tool path lines by the cusp height you want to achieve on
the finished model. SolidCAM adjusts the distance between the single lines of the 2D pattern (before projection on
the model) to the topology of the model to match the specified scallop height.

6.1.17 Tangential extension

This option enables you to extend the passes tangentially to the model faces by a length defined by the Pass extension
parameter. When the check box is not selected, the extension passes are generated as a projection of the initial pattern
(either linear or radial) on the solid model faces.
When the check box is selected, the extension passes are generated tangentially to the solid model faces.

6.1.18 Define angle by

This option enables you to define the angle of the hatch passes relative to the X-axis of the current Coordinate
System. The angle can be defined by entering its Value in the edit box or by picking a Line on the model.

6.1.19 Step over

Step over is the spacing between the passes along the circumference of the circle. The passes are spaced according to
the Step over value measured along the circle defined by the Maximum Radius value.
• Center: You must specify the XY-position of the center point of the radial pattern of passes. The Radial passes
will start or end in this center point.
• Angle: The minimum and maximum angles enables you to define start and end of the pattern passes. These
parameters control the angle span of the operation, that is, how much of a complete circle will be machined.

57
 • Radii: The Min. radius and Max. radius values enable you to limit the tool path in the radial direction. You
can define the radii by entering the values or by clicking the buttons and picking points on the model. The
X- and Y-coordinates of this point are displayed in the Select a coordinate dialog box. When this dialog
box is confirmed, the radius value appears in the appropriate edit box calculated as the distance from the
defined center point of the radial pattern of passes. You can use the Min. radius value to protect the part
faces from over-machining in the central point and around it. Alternatively, you can define boundaries to
limit the machining.

6.1.20 Clockwise
This option enables you to define the direction of the spiral. When this check box is selected, SolidCAM generates a
spiral tool path in the clockwise direction. When this check box is selected, SolidCAM generates a spiral tool path in
the counterclockwise direction.

6.1.21 Right/left clear offset

These parameters enable you to define the offset distance used for the virtual offset curve calculation. SolidCAM
enables you to define separate values for the Left clear offset and Right Clear offset.

6.1.22 Bitengency angle

This parameter defines the minimum angle required between the two normals at the contact points between the tool
and model faces in order to perform the Rest machining.
For Pencil milling, the bitengency angle is the minimum angle required between the two normals at the contact points
between the tool and model faces, in order to decide to perform the pencil milling. The default value of the Bitangency
angle parameter is 20°. Generally, with this value SolidCAM detects all the corners without fillets and with fillet radii
smaller than the tool radius. To detect corners with fillets radii greater than the tool radius you can either use the
Overthickness parameter or decrease the Bitangency angle value. Note that decreasing the Bitangency angle value can
result in the occurrence of unnecessary passes.

6.1.23 Steep threshold

This parameter enables you to specify the angle at which SolidCAM splits steep areas from shallow areas. The angle is
measured from horizontal, so that 0° represents a horizontal surface and 90° represents a vertical face.
Setting the value to 90° will mean that all areas will be treated as shallow and the passes in the rest material areas will
run along the corner.
Setting the value to 0° will mean that all areas will be treated as steep and the passes in the rest material areas will run
across the corner.
Setting the value to 45° will mean that areas where the slope is between 0 and 45° will be treated as shallow and the
passes will run along the corner. Areas where the slope is between 45 and 90° will be treated as steep and the passes
will run across the corner.

6.1.24 Extend steep areas

Extend steep areas option allows you to extend the tool path in steep areas. The extension depends on the tool
selected and tool contact point on the machining surface. The extension is approximately equal to the tool radius.
This option is available only when the option All is selected in the Areas section.

6.1.25 Shallow areas strategy

This option enables you to choose the machining strategy to be used in shallow areas (i.e. those below the Steep
Threshold value). The following options are available:
• Linear: This option enables you to perform links between passes using straight line motions.

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 6. Passes

• Spiral on surface: This option links the passes with smooth curved paths resulting in continuous passes and
reducing the rapid moves. The spiral linking move is projected into the rest corner up to the maximal depth
of the cut specified.
• Spiral:This option joins some passes using smooth curved paths. This results in passes that are continuous,
and reduces the use of linking moves. The spiral linking move will cut across the corner, avoiding the large
volume of material that lies in the centre of the rest area. Corner areas may not be fully finished.

This option is disabled when the option of Steep is selected in the Areas section.

6.1.26 Depth of cut

This parameter specifies the minimum and maximum depth of material to be removed from the areas to be machined.
Value set in the Min. depth of cut field specifies areas in which the depth of material to be cut is smaller than this will
be ignored. Min. depth of cut can also be useful in situations where a fillet radius of the part is approximately equal
to the radius of the reference tool, i.e. places where, in theory, there is no material to be removed. If unwanted passes
are created in such areas, increasing the value of Min. depth of cut may improve the situation.
Max. depth of cut field specifies the maximum depth of material that can be cut. Areas in which the depth of material
is greater than this value will be ignored. This parameter is used to avoid situations where the cutter may otherwise
attempt to make deep cuts. This may result in some rest area material not being removed; by creating further sets of
rest machining passes, using smaller reference tools, you can clear such areas.

6.1.27 Areas
This option enables you to decide whether to perform the machining in the steep areas only, in the shallow areas only
or in both of them. This option is enabled when the Steep threshold is set to 45 degrees.
• All: The machining is performed in both steep and shallow areas.
• Steep: The machining is performed only in the steep areas (the surface inclination is greater than the Steep
threshold value).
• Shallow: The machining is performed only in the shallow areas (the surface inclination is smaller than the
Steep threshold value).

6.1.28 Stroke ordering

This option enables you to control how the passes are merged, in order to generate better rest machining passes. The
available strategies are:
• None: Passes are not combined; uncut material might be left in corners where several sets of passes converge.
• Planar: SolidCAM looks at the passes from the tool axis direction (from +Z) and connects passes that have a
direction change with an angle smaller than the Max. deviation value.
• Angular: The system looks at the passes in 3D and connects passes that have a direction change with an angle
smaller than the Max. deviation value.
• User-defined: The passes are neither combined nor split into steep and shallow sections. The option of Max.
deviation is disabled in this strategy.

Max. deviation
When Rest machining passes approach a sharp change of direction, they can be made continuous round the corner, or
can be split into separate segments. The value of Max. deviation is used to determine whether the passes are split (if
the angle of deviation of the passes is larger than the Max. deviation value) or continuous (if the angle of deviation
of the passes is smaller than the Max. deviation value).

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6.1.29 Reference tool
The reference tool diameter and corner radius can be defined in this section.
• Diameter: This parameter defines the diameter of the reference tool.
• Corner: This parameter defines the corner radius of the reference tool. Since the reference tool is ball-nosed,
the corner radius is equal to half of the reference tool diameter.

6.1.30 Variable stepover

For most geometries a constant stepover is not ideal. For areas where the surface inclination is large, the 3-dimensional
distance between parallel cuts or different revolutions of the spiral gets stretched, which increases the cusp height.
Variable stepover feature adapts the stepover distance to counteract this effect. This option is disabled when the check
box is unchecked.

6.1.31 Horizontal/Vertical step over

The Horizontal and Vertical step over parameters determine the distance between passes. The two step over types
relate to the direction in which the step over is being measured. Where passes are offset horizontally, the horizontal
step over distance is used while for passes that are offset vertically, the vertical Step over distance is used. Where the
step direction is neither vertical nor horizontal, the average of the two values is used.

6.1.32 Limit offsets number to

The Limit offsets number to parameter enables you to limit the number of offsets of a drive boundary profile. Select
the Limit offsets number to check box and set the offsets number.

6.1.33 Adaptive Variable Side Step

If the Adaptive variable side step check box is selected, step over will be taken from the horizontal plane only, that is,
a 2D offset. With this option, only the horizontal step over value is used, the vertical step over value is not relevant.

6.1.34 Overthickness
This parameter enables you to define an extra thickness that can be temporarily applied to the tool in addition to the
normal Wall offset.
You can use the Overthickness parameter to generate a tool path along fillets whose radius is greater than the tool
radius. For example, if you have a filleted corner of radius 8 mm and you want to create a Pencil milling tool path
along it with the 10 mm diameter ball-nosed tool, you can set the Overthickness value to 4 mm.
The Pencil milling tool path is calculated for a ball-nosed tool with the diameter of 18 mm (which will detect this
fillet), and then projected back onto the surface to make a tool path for the 10 mm diameter tool.
Since this is an offset value, it is specified in exactly the same manner as other offsets, except that it is added to the
defined tool size, in addition to any surface offset, during calculations.

6.1.35 Offset type

This option enables you to define an offset between adjacent Constant Z passes. When the Upper option is chosen,
the upper Constant Z pass is offset and trimmed to the lower Constant Z pass. When the Lower option is chosen, the
lower Constant Z pass is offset and trimmed to the upper Constant Z pass. When Both is selected, both passes are
offset together.

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 6. Passes

6.1.36 Passes parameters for combined strategies

Constant Z combined with Horizontal strategy

The Constant Z passes page defines the parameters of the Constant Z machining strategy.

The Horizontal passes page defines the parameters of the Horizontal machining strategy.

The following parameters defined on the Constant Z Passes page are automatically assigned with the same values on
the Horizontal passes page:

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 • Wall offset

• Floor offset

• Tolerance

• Limits

• Smoothing parameters

• Adaptive step down parameters

• Edit passes parameters

When these parameters are edited on the Constant Z passes page, their values are updated automatically on the
Horizontal passes page. But when edited on the Horizontal passes pages, the values in the Constant Z passes page
remain unchanged.
Two Link pages located under the Constant Z passes and Horizontal passes pages define the links relevant for each
of these strategies.
On the Link page for Horizontal passes, there is the Machining order tab that enables you to define the order in which
the Constant Z and Horizontal machining will be performed. The default option is Constant Z First.
When the tool has finished performing the passes of the first machining strategy, it goes up to the Clearance level,
then descends back to the machining surface to continue with the next strategy.

Constant Z combined with Linear strategy

The Constant Z passes page defines the parameters of the Constant Z machining strategy.

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 6. Passes

The Linear passes page defines the parameters of the Linear machining strategy.

The following parameters defined on the Constant Z Passes page are automatically assigned the same values on the
Linear passes page:

• Wall offset

• Floor offset

• Tolerance

• Limits

• Smoothing parameters

• Adaptive step down parameters

• Edit passes parameters

When these parameters are edited on the Constant Z passes page, their values are updated automatically on the Linear
passes page. But when edited on the Linear passes page, the values in the Constant Z passes page remain unchanged.

Two Link pages located under the Constant Z passes and Linear passes pages define the links relevant for each of
these strategies.
On the Link page for Linear passes, there is the Machining order tab that enables you to define the order in which the
Constant Z and Linear machining will be performed. The default option is Constant Z First.

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When the tool has finished performing the passes of the first machining strategy, it goes up to the Clearance level,
then descends back to the machining surface to continue with the next strategy.

Constant Z combined with 3D Constant Step over strategy

The Constant Z passes page defines the parameters of the Constant Z machining strategy.

The Constant Step over passes page defines the parameters of the 3D Constant Step over machining strategy.

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 6. Passes

The following parameters defined on the Constant Z Passes page are automatically assigned the same values on the
Constant Step over passes page:

• Wall offset

• Floor offset

• Tolerance

• Limits

• Smoothing parameters

• Adaptive step down parameters

• Edit passes parameters

When these parameters are edited on the Constant Z passes page, their values are updated automatically on the
Constant Step over page. But when edited on the Linear passes page, the values in the Constant Z passes page remain
unchanged.
Two Link pages located under the Constant Z passes and Constant Step over passes pages define the links relevant
for each of these strategies.
On the Link page for Constant step over passes, there is the Machining order tab that enables you to define the order
in which the Constant Z and Constant step over machining will be performed. The default option is Constant Z First.
When the tool has finished performing the passes of the first machining strategy, it goes up to the Clearance level,
then descends back to the machining surface to continue with the next strategy.

Constant Z combined with 3D Corner offset strategy

The Constant Z passes page defines the parameters of the Constant Z machining strategy, which is used for semi-
finishing and finishing of steep model areas.

65
The Pencil passes page defines the parameters of the Pencil milling strategy, which is used for removing material
along internal corners and fillets with small radii that was not reached in previous operations.

The Corner Offset passes page defines the parameters of the 3D Corner offset machining strategy, which is used in
order to machine all the internal corner radii to size.

Two Link pages, which are located under the Constant Z passes and the Corner Offset passes pages, define the linking
of the tool path for each of these strategies.
In the Link page for Corner Offset passes, the Machining order tab enables you to define the order in which the
Constant Z and Corner offset passes will be performed.

When the tool has finished performing the passes of the first machining strategy, it goes up to the Clearance level,
then descends back to the machining surface to continue with the next strategy.

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 6. Passes

6.2 Calculation Speed

Tool paths for three basic tool types (end mill, ball-nosed and bull-nosed) are calculated by completely different
machining algorithms. This means that calculation speed may differ for the same operation and geometry, but with a
different tool type. For example, using a bull-nosed tool with a smaller corner radius will result in longer calculation
time.
Calculation speed depends also on the tolerance. Setting a tolerance for a tool path defines the worst case value; the
actual tolerance may, in some circumstances, be significantly tighter. That is particularly true for Contour roughing
and Constant Z machining operations when a bull-nosed tool with a small corner radius is used. The results are often
more accurate than required and calculation is slower.
When a positive Wall offset is defined, the machining algorithm uses a tool with larger corner and shaft radii than the
original one. When a small Wall offset is applied to an end mill, the tool used by the algorithm is bull-nosed with a
small corner radius. That tool with applied Wall offset has different algorithmic characteristics, as mentioned above,
and calculation time may change.
The only other instance in which the tool type may change when applying a Wall offset is when a negative Wall offset
equal to or exceeding the corner radius is applied to a bull-nosed tool. Then an end mill is used in the machining
algorithm, and a result may be reached faster. However, there are instances where applying a negative Wall offset,
which is significantly greater than the corner radius, does not produce satisfactory results.

6.3 Smoothing parameters

The Smoothing tab enables you to round the tool path corners.

This option enables the tool to maintain a higher feed rate and reduces wear on the tool. This feature is often used in
rough machining.

Tool path without smoothing

Tool path with smoothing

6.3.1 Max. radius

A curve can be approximated as an arc. The Max. radius parameter defines the maximum arc radius allowed.

6.3.2 Profile tolerance

This value is the maximum distance that the smoothed outer profile will diverge from the actual profile. Set the Profile
tolerance to a low or zero value to reduce the amount of material missed.

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6.3.3 Offset tolerance
This value is the maximum distance that the smoothed profile offset will diverge from the inner (offset) profiles. This
parameter is identical to the Profile tolerance, except that it refers only to the inner (offset) profiles and not to the
outer profile. The Offset tolerance is measured between any given smoothed profile (excluding the outermost one)
and the sharp corner of an imaginary profile drawn without smoothing, but at the same offset as the smoothed one.
Unlike the Profile tolerance parameter, above, changing this value does not mean you miss material.

Profile
tolerance
Original Smoothed
tool path tool path

Offset
tolerance

6.4 Adaptive Step Down Parameters

In areas where the horizontal distance between the passes is significant, Adaptive step down can be used to insert extra
passes and reduce the horizontal distance.
In areas where the passes on the topmost edges of a surface would fall too close or too far away from that edge,
Adaptive step down will add extra passes to compensate. So the Step down value controls the maximum Z-distance
between the passes for the entire surface, while Adaptive step down adjusts those values for best fitting the surfaces.

Adaptive step down

passes

Adaptive step down is not chosen Adaptive step down is chosen

The Adapt Step down by list enables you to select the mode of the adaptive step down:
• None

Passes are applied without Adaptive step down, and some material may be left on the top faces.
• Automatically insert extra passes

A pass is inserted to cut the top face; the next step down will be calculated from this pass.
• Minimum step down

This parameter specifies the minimum step down value to be used, which means that passes will be no less
than this distance from each other.

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 6. Passes

• Precision

This parameter controls how accurately the system finds the appropriate height to insert a new slice.
• Profile step-in

This parameter defines the maximal XY-distance between cutting profiles located on two successive
Z-levels. When SolidCAM calculates the cutting profile at a given Z-level, the distance to the cutting profile
on the previous Z-level is calculated.
If the calculated value is greater than the defined Profile step-in, SolidCAM inserts an additional Z-level
and calculates the cutting profile in such way that the distance between cutting profiles located on two
successive Z-levels will be smaller than the specified Profile Step in value.
Large cusp Small cusps

Inserted
Z-level

Without Profile step-in With Profile step-in

• Scallop

The cusp that remains after the machining can be defined either by combination of the Min. step down and
Profile step in parameters or by combination of the Min. step down and Scallop parameters. Therefore, the
Profile step in and Scallop parameters are mutually exclusive.

Profile step in Cusp

Cusp

Min. step down

Machined surface
Machined surface
Scallop

When the combination of the Scallop and Min. step down parameters is used for the operation definition,
SolidCAM performs the parameters validation according to the criteria below.
• The Scallop value must be positive;
• The Scallop value must be smaller than that of the Min. step down parameter.
If the Scallop parameter does not match the validation criteria, the Error Parameters dialog box is displayed during
the operation calculation. This dialog box specifies the parameters defined incorrectly and prompts you to edit these
parameters definition.
• User-defined Cut levels

The cut levels can be edited manually and inserted in the User-defined cut levels table. Type the Z-levels of
your choice into the Z column of the table. The values will be sorted in the decreasing order.
Passes are applied without Adaptive step down, and some material may be left on the top faces.

This option is available for technologies of Hybrid Constant Z, Prismatic Part machining and Helical
machining.

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 • Use drive curve
This option enables you to use a drive curve to determine the heights at which passes are calculated. Click

and choose any open or closed curve to define the geometry.

Using this option maintains consistency while machining a curve, automatically giving a smaller step down in
the shallower areas.

When you choose the Use drive curve option, the Step down parameter cannot be defined manually.

6.5 Edit Passes Parameters

If you start the machining with a formed stock instead of a rectangular or cylindrical block of material, you could
trim the passes to the formed stock faces to avoid unnecessary air cutting. The tool path trimming is used either when
you use a casting as stock for the part machining or you use the updated stock resulting from a number of previous
operations.
For example, suppose you want to machine by Contour roughing the following model:

Using the Contour roughing strategy, you get the following tool path.

Rather than starting from a cylindrical block of material, you start with the casting shown below.

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 6. Passes

The resulting trimmed tool path is shown below.

The Edit Passes page enables you to define the parameters for the trimming of passes.

Edit using surfaces

By selecting this check box, you can limit the machining by using the Updated Stock model or by defining an offset
from the operation geometry.

Overthickness

This parameter defines an extra thickness that can be temporarily applied to the tool and can be set when
editing passes. The use of this parameter can help create better trimmed passes. A negative value will cause
the system to select only passes that are below the model faces by the specified amount, while a positive value
will select all passes that are within the specified distance from the model faces.

Axial overthickness

This parameter defines the value applied to the cutter and has the effect of lifting (positive thickness) or
dropping (negative thickness) the cutter along the tool axis. As a result, axial thickness has its greatest effect
on horizontal surfaces and has no effect on vertical surfaces. By default this value is the same as the horizontal
thickness.

Pass Extension

In this field you can define the length of Pass extension. The trimmed passes will be extended in each
direction by the value specified in this field. This allows the cutter to move into the cut at Machining Feed rate
instead of Rapid feed rate. This option is not available in HM Roughing strategy.

Stock definition style

This option enables you to specify the method of machining area definition.
• When the Target geometry option is chosen, SolidCAM adds the Overthickness value as an offset to the target
geometry of current operation. This offset target is used as a stock.
• When the Auto updated stock/Automatically option is chosen, SolidCAM calculates the updated stock model
after all the previous operations. The Overthickness value is added as offset to the stock, which will be used
as stock for the current operation.
• When the Stock by *.FCT file option is chosen, machining is performed in the area defined by an offset
from the updated stock, defined in FCT file located in the CAM-Part folder. The offset is defined by the
Overthickness parameter.

71
 • When the Stock by *.STL file option is chosen, machining is performed in the area defined by an offset
from the updated stock, defined in STL file located in the CAM-Part folder. The offset is defined by the
Overthickness parameter.

• Show
This button displays the difference between the updated stock model and the target geometry used in
the operation.

Gouge check while linking

This option enables you to automatically detect and avoid the possible collisions between the tool and the surfaces of
a solid model geometry during the tool path linking only.
Any geometry can be selected for the gouge checking, but this functionality is intended for consideration of your part
fixtures when the tool is moving from one pass to the next.
After clicking the Gouge check while linking check box, the geometry can be defined by the following methods:
3D Model: When Use STL file is disabled (default), the geometry is defined via solid model selection. You can choose
an available geometry from the drop-down list. The Three points button displays the Browse Geometries dialog box
that enables you to visualize the geometry during the selection process; the selected geometry is highlighted in the
SOLIDWORKS Graphics Area. The New button displays the 3D Geometry dialog box that enables you to define a
new geometry. The Edit button enables you to edit an existing geometry.
STL:When Use STL file is enabled, the geometry is defined using a STL file that exists on your computer. You can
choose an available STL file from the drop-down list; files located in the CAM-Part folder will appear in the list. The
New button displays the Choose STL dialog box that enables you to define a new STL file from any location on your
computer.
The Show button displays in the SOLIDWORKS Graphics Area the chosen geometry (either 3D Model or STL) for
which its surfaces will be protected during the tool path linking only.

6.6 Axial Offset

This page enables you to axially offset the tool path (one or several times). The tool path can be generated by any of
the HSM finish strategies, except for Constant Z and Rest machining.

When the Axial offset check box is selected, you have to define the following parameters:
• Axial offset

This parameter defines the distance between two successive tool path passes.
• Number of offsets Tool path Axial offset

This parameter enables you to define how many Number of offsets = 3

times the offset of the tool path is performed. This
final number of tool path passes is equal to Number
of offsets +1.

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 6. Passes

The tool path passes are generated in the positive Z-direction. The machining is performed from the upper instance
to the lower.
The Axial offset feature enables you to perform the semi-finish and finish machining in a number of equidistant
vertical steps. It can be used for engraving in a number of vertical steps with the Boundary machining strategy or for
removing the machining allowance by a finishing strategy in a number of vertical steps.

6.7 Cross parameters

Cross linear machining

SolidCAM automatically determines the areas where the Linear machining passes are sparsely spaced and performs in
these areas an additional Linear tool path in a direction perpendicular to the direction of the initial Linear tool path.
The passes parameters used for the Cross linear machining definition are the same as those used for the initial Linear
machining.

Initial Linear machining tool path

Cross linear machining tool path

Combined Linear and Cross linear machining tool path

Cross page
The Cross tab enables you to define the order of performing Linear and Cross linear machining.
• None

Cross linear machining is not performed.

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 • Before

Cross linear machining is performed before the main Linear machining.

• After

Cross linear machining is performed after the main Linear machining.

• Only

Only Cross linear machining is performed; the main Linear machining is not performed.

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Links 7
The Link page of HSM operations enables you to define the way how the generated passes are linked together into a
tool path.

In the image, the link movements are in green, the rapid movements are in red and the machining passes are in blue.

Following are the linking parameters that can be defined by you:

• General parameters

• Ramping parameters

• Strategy parameters

• Retracts parameters

• Leads parameters

• Down/Up Mill parameters

• Refurbishment parameters

Some of the parameters pages can be disabled unless you check the Advanced option in the right upper part of the
dialog box.

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 7. Links

7.1 General Parameters

The General page enables you to set the general parameters of the tool path linking

7.1.1 Direction options

This parameters group enables you to define the direction of the machining.

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One way Machining pass
Linking pass

With this option, machining is performed in one direction, but there is no

guarantee that this will be consistently climb or conventional milling. It is up
to you to check the tool path and respond by selecting the Reverse check
box, if needed, for the desired milling style.
A one way hatch path has many retractions; after the machining pass the
tool has to perform air movement to the start point of the next pass (shown
in red).

• One way cutting with Radial Machining strategy. The radial

arrows indicate the direction of the passes themselves, while the
circular arrow indicates the ordering of the passes.

• One way cutting with Spiral machining strategy. The spiral pass is
limited by a boundary. The circular arrow indicates the direction of
the passes themselves, while the radial arrow indicates the ordering
of the passes. Passes are machined in the clockwise direction, moving
outwards.
•

• One way cutting with 3D Constant Step over strategy. The passes are
limited by a boundary, with another boundary inside it. The passes are
ordered in a one way direction to perform climb milling. The inner
circular arrow indicates the direction for the passes adjacent to the inner
boundaries.
The outer circular arrow indicates the direction for outer boundaries.
In this example, most machining passes are performed in the
counterclockwise direction, working from the farthest offsets outwards
to the outer boundary, then rapidly moving to machine the farthest offset
of the inner boundary and working inwards towards the inner boundary.

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 7. Links

Reverse

The Reverse option results in the direction of passes being

reversed.
The example below shows one-way radial passes with the
reversed direction; the passes will be climb milled.

The example shows a reversed one way spiral passes.

Bi-directional

With this option, each pass is machined in the opposite direction to the previous pass. A short linking motion (shown
in green) connects the two ends - this is often called zigzag machining.

Machining pass
Linking pass

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Both Climb milling and Conventional milling methods are used in the bi-directional tool path.

Bi-directional milling

Bi-directional Radial machining:

Bi-directional Spiral machining:

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Bi-directional 3D Constant Step over machining:

Down mill/Up mill

These options enables you to perform the machining downwards or upwards. Flat pieces are machined in the direction
defined by the Reverse parameter.

This option is available for strategies where the Z-level varies along a pass. This option is not available
for the Constant Z and Horizontal strategies.
The Down/Up mill page enables you to define the parameters of the down and up milling.
• Down mill direction

• Up mill direction

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The image below shows the direction of the Radial machining passes when the Down/Up Mill options are used.

Down mill

Up mill

Climb/Conventional milling

These options enables you to set the tool path direction in such a manner that the climb/conventional milling will be
performed.

Climb milling Conventional milling

These options are available for the Constant Z and Horizontal strategies.

Prefer climb milling

If this option is selected, the Pencil milling passes will usually be climb milled. A decision is made as to whether the
material is mainly on the left or the right of the tool as it goes along a pass. The direction is then chosen so that most
material is on the right.
When this option is not selected, the milling direction for all the passes is reversed, so that they will probably be
conventionally milled.

This option is available for the Pencil milling strategy.

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Direction for Rest machining

Steep regions

This section enables you to define the direction of the steep areas machining.
SolidCAM enables you to choose the following options:
• Climb milling

• Conventional milling

• Bi-directional

7.1.2 Order passes

Some passes allow you to specify the direction of the pass ordering. When no option is selected, the passes are linked
in an efficient way to limit the rapid travel between passes. Where several separate areas are machined, each area will
be machined to completion, before machining of the next area is started.
The passes will be linked in the most efficient way. Below is shown a set of Linear passes, linked in the default order
(starting from the top left-hand corner) to minimize the rapid travel between the passes.

Reverse order

This option enables you to reverse the order of the tool path relative to the default order.

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 Simple ordering

Passes will be linked in the order of their creation. Parts of

a specific pass divided by a boundary will be linked together
with a rapid movement. This option enables you to maintain
the order of the passes, but increases the number of air
movements.

Cross simple ordering

When the Cross linear machining is performed, simple

ordering is applied to the cross linear passes.

Order of 3D Constant Step over passes

From first pass

When this option is not chosen, the passes are machined from the smallest of the outside boundary offsets to
the outer boundary and then from the largest offset of the internal boundary to the inside.

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When this option is chosen, the machining is performed in the reverse order. The machining starts from the
internal boundary outside. After that the machining is performed from the outer boundary inside.

If you reverse the order or the direction, conventional milling will be performed. If you reverse both, climb
milling will be performed again.

Islands at same time

If the original boundaries have islands, SolidCAM will normally machine inwards from the outer boundary,
then outwards from the island boundary.
When this option is chosen, SolidCAM performs machining while swapping between the outer and the island
boundary offsets, ensuring that each is never more than one pass ahead of the other.

Simple ordering

Passes will be linked in the order of their creation. Parts of a specific pass divided by a boundary will be linked
together with a rapid movement. This option enables you to maintain the order of the passes, but increases
the number of air movements.

Optimize lead positions

When this option is chosen, the start point of the pass is adjusted to minimize the length of the lead move.
When it is not selected, the lead move connects to the natural start point of the pass.

7.1.3 Retract

The image below shows a set of linked one way Hatch roughing passes along a flat horizontal surface.

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The Retract section enables you to define a number of parameters of the start and end of the tool path.

Start from home point/Return to home point

These options enable SolidCAM to start/finish the operation tool path in the specified home point. The XYZ boxes
defines the location of this point.

Clearance level

This field defines the plane where the rapid movements of the operation (between passes) will be performed. The
Clearance level value can be set according to the Part clearance level or according to the automatically calculated
Optimized clearance level.

Safety distance

This field defines the distance to the Upper level at which the tool will start moving at the Z feed rate you have entered
for the tool. Movements from the Clearance level to this height are performed in rapid mode.

7.1.4 Start hint

Enter the XY-coordinates of the starting position of the tool; the tool will move to this position at the beginning of
the tool path. The default value for the Start hint is the center of your model. On larger models, where there is a great
distance from the center of the model and your current work area, you may want to change these values. If there is
more than one set of passes to be linked, the linking will start with the passes closest to the Start hint point.

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7.1.5 Link by Z-level

The Link by Z-level option enables you to perform all the passes at a specific Z-level before moving to the next one.
This will frequently result in occurrence of air movements between different areas of the same Z-level.

1 2
3 4
5 6
7 8

By default the option is not chosen. It means that the passes are linked in such a manner that each area is machined
completely before moving to the next one.

This option is only available for the Constant Z and Horizontal technologies.

7.1.6 Link per cluster

When you link machining passes that are made up of several different clusters of passes, in corners, for example, the
Link per cluster option allows each corner to be machined before the tool moves to another corner. If you do not
select this option, the machine may need to make a number of rapid feed rate moves to connect the clusters of passes.

This option is available for the technology of Horizontal machining.

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7.1.7 Use dynamic stock

The Use dynamic stock option enables you to use the dynamic stock slices.
For all tool path linking operations, the stock lying outside the boundary is automatically protected when calculating
linking motions. For roughing operations, uncut stock within the constraint boundary is also protected.
The uncut stock can either be modelled as a static stock resulting in faster but less optimal tool path or a dynamic
stock, which works slower but produces a better tool path.
A dynamic stock is the updated stock, therefore when avoiding collisions, linking is calculated according to the
machined stock resulting in a more accurate tool path.

This option is available for the technology of Horizontal machining.

7.1.8 Min. profile

The diameter of a profile is its “span”, which is the largest distance between two points of the profile. Any profile that
is smaller than this value will not be machined to avoid difficulties in ramping the tool into this space. The default Min.
profile value is slightly smaller than that of the flat part of the end mill tool (and zero for ball-nosed tools).

For example, if the set of surfaces has a hole about the size of the tool you want to use, you will get a column of
profiles that appear to “fall” through the hole down to the lowest Z-level. If you do not want these profiles, you can
use the Min. profile parameter.

This option is available for the Constant Z and Horizontal machining strategies.

7.1.9 Refurbishment

Min. pass length

The Min. pass length parameter enables you to define the minimal length of the pass that will be linked. Passes with
length smaller than this parameter will not be linked. This option enables you to avoid the machining of extremely
short passes and increases the machining performance.

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This option is available for the Constant Z machining strategy.

7.1.10 Safety

Max. stock thickness

The Max. stock thickness parameter enables you to control the order of Constant Z machining of several cutting
areas.
When the distance between cutting areas is smaller than the specified Max. stock thickness value, the machining is
ordered by cutting levels. In this case SolidCAM machines all of these cutting areas at the specific cutting level, and
then moves down to the next level.
When the distance between cutting areas is greater than the specified Max. stock thickness value, the machining is
ordered by cutting areas. In this case SolidCAM machines a specific cutting area at all of the cutting levels, and then
moves to the next cutting area.

This option is available for the Constant Z machining strategy.

7.2 Ramping Parameters

The Ramping page enables you to control the ramping aspects of the tool path.

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Ramping is used when the tool moves from one machining level down to the next one; the tool moves downwards
into the material at an angle.

This page is available for all roughing strategies and Constant Z, Horizontal, and 3D Constant step over
strategies.

Ramp height offset

Angle

Max. ramp angle

The Ramp angle is calculated automatically and depends on the model geometry and the tool type. The Max. ramp
angle parameter enables you to limit this angle.

The dimensions and type of tool you are using and the power of your machine tool will determine an appropriate
ramp angle. The angle used on a profile will often be shallower than this, as the ramp always steps forward by at least
the shaft radius of the tool.

If a profile is very small, then the angle used might have to be larger than you specify. In this case
you can avoid the machining of short profiles with the Min. profile diameter parameter located in the
General page.

Relative and absolute ramp height

SolidCAM enables you to define also the relative or absolute start position for the ramp motion with the Ramp height
offset/Ramp height parameter measured from the Coordinate System origin.

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 7. Links

• Relative height
Ramp height offset
With this option, the start position of the ramp motion for the
upper Constant Step over pass is defined relative to the first
point of the pass using the Ramp height offset parameter.

• Absolute height

With this option, the start position of the ramp motion is

defined with the absolute Ramp height value measured from
Ramp height
the Coordinate System origin.

These options are available only for the 3D Constant

step over machining, when Helix and Profile ramping
strategies are used.

CoordSys

Ramp height offset

This parameter defines the height used in the ramping motion to the
first upper profile. It ensures that the tool has fully slowed down from
rapid speeds before touching the material so that it enters the material at a ramping angle.
SolidCAM enables you to perform the ramp movement either with a profile, or with a helix (spiral).

Profile ramping

The tool performs the downward movements to the specific Z-level

around the contour of the profile.

Min. profile diameter to ramp on

SolidCAM enables you to avoid ramp movements along small

profiles, as a very tight tool motion would counterbalance any
advantages gained by ramping for the smoothness of transition;
by setting a minimum profile diameter (span) you will be able to
ensure that small profiles will not be ramped down to.

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Helix ramping

The tool performs the downward movements to the specific Z-level in a corkscrew fashion, ensuring a smooth
movement. Helix ramping also puts less load on the tool than profile ramping.

Helix diameter

This is the diameter of the ramping helix. In cases where the profile is too small for a helix ramp of this
diameter, Profile ramping is used.

This option is available for the Morphed machining, Radial machining, Linear machining, Spiral
machining, and 3D Constant step over technologies.

Plunge ramping

The tool performs the downward movements to the specific Z-level in a vertical movement.

To define the approach points, click the Define button. The Ramping Geometry Selection dialog box is displayed. This
dialog box enables you to define the approach points by picking on the solid model.

The content of this dialog box is similar to that of the Drill Geometry Selection dialog box used
for drilling geometry definition (for more information, refer to SolidCAM Milling Help).

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Limit depth

This check box controls the maximum depth at which the cutting in the current area will be performed. When
this check box is selected, the Z-coordinate of the lowest approach point defines the maximum depth at
which the cutting will be performed; the tool will not descend lower than the Z-level of this point.
Approach point

Depth limit

7.3 Strategy Parameters

The Strategy pages enables you to define the following parameters related to the linking strategy.
• Stay on surface within

• Stay down within

• Overlap closed passes

• Along surface

• Linking radius

• Link clearance

• Horizontal link clearance

• Trim to ramp advance

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7.3.1 Stay on surface within

The Stay on surface within parameter enables you to control the way how the tool moves from the end point of a
pass to the start point of the next one. When the distance between these points is greater than the specified parameter
value, the tool movement is performed at the Clearance plane, using rapid feed.
When the distance between the points is smaller than the parameter value, the tool moves with cutting feed directly
on the model face.
This option enables you to decrease the number of air movements between
the passes of the tool path.

To control the manner of the link movement between passes when the tool moves on surface, use the Along surface
option.

7.3.2 Stay down within

The Stay down within parameter enables you to control the point of choosing between retracting or staying on
the surface. When the distance between the end point of a pass and the start point of the next one is less than the
specified parameter value, the cutting tool stays on the surface. If the distance is greater than the specified parameter
value, the cutting tool retracts to the clearance plane.

This option is disabled when Shortest route is selected from the Style section in the Retracts tab. This
option is available for the Constant Z machining, Helical machining, Horizontal machining, Boundary
machining, Rest machining, Pencil milling, and Parallel pencil milling strategies.

7.3.3 Overlap closed passes

In case of island machining, the Overlap closed passes parameter enables you to overlap two closed passes by the
specified Overlap distance. The advantage of this option is that no material is left for machining between the gap of
two closed passes.

This option is available for the Constant Z machining, Hybrid Constant step over, Parallel pencil milling,
3D Constant step over, 3D Corner offset, Prismatic Part machining, and Combine Constant Z with
strategies.

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7.3.4 Along surface

When the tool moves on the surface, links between passes can be:
• Straight line

When this option is active, a direct connection is made on the surface

in a straight line.

• Spline curve

When this option is active, a spline connection is made along the

surface. The movement is smooth; there are no sharp corners so there
is little change of speed of the tool throughout the length of the link.

These options are available for the Linear machining, Spiral

machining, Radial machining, Boundary machining, and Pencil
milling strategies.


Ramp when possible with angle

The Ramp when possible with angle option enables you to perform the connection along the surface at the specified
angle.

Ramp angle

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 • Use Tangential Ramp

This option enables you to perform the angled link movements in a smooth S-curve. With this option the
transition between passes is performed smoothly without sharp corners.
Ramp angle

• Trim to ramp advance

This option enables you generate a helical style finish when linking Constant Z passes.
When this check box is selected, the Constant Z pass above which a ramp linking movement is performed is
trimmed by the length of the ramping move. In such a way a helical style tool path is generated, avoiding the
unnecessary cutting moves at the already machined areas and maintaining a constant tool load.
When this check box is not selected, the whole Constant Z passes are linked with the ramp movements.
Constant Z passes Ramp movements

The Ramp when possible with angle option only has effect on passes that consist of closed loops at
different Z-heights, such as Constant Z and 3D Constant step over passes.

Constant Z passes Ramp movements

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7.3.5 Linking radius

Using this parameter, SolidCAM enables you to generate S-shaped curves linking the adjacent closed passes of
the contour machining. The value defines the radius of the link arc. If you set the Linking radius to 0 or turn
off Smoothing then a simpler, straight-lined route will link each loop.

Linking radius

When the radius is set to zero, straight line link movements are performed.

This option is available for the technology of Horizontal machining.

7.3.6 Link clearance

With this parameter, SolidCAM enables you to maintain a horizontal clearance from the bounding profile when
moving horizontally from one location to another. The value defines the minimal distance from the bounding
profile.

This option is available for the technology of Horizontal machining.

7.4 Retracts Parameters

This page enables you to control retract movements between passes of the tool path.
• Style

• Clearance

• Smoothing

• Curls

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7.4.1 Style

The Style options enable you to define the way how the retract movements are performed between passes.

Shortest route

The tool performs a direct movement from one pass to

another. SolidCAM generates a curved retract movement
trajectory. The minimum height of the retract movement
is controlled by the Clear surface by parameter, and the
curve's profile is controlled by the Smoothing and Curls
parameters.
This style is chosen by default, as it creates the shortest
retract movements. However, some machine tools are
unable to perform the rapid movement effectively along a curved path; in these cases you can choose one of the other
two retract styles.

Minimal vertical retract

The tool moves vertically to the minimum Z-level where

the safe rapid movement can be performed, moves along
this plane in a straight line and drops down vertically to the
start point of the ramp movement to the next pass. The
minimum height of the retract is controlled by the Clear
surface by parameter.

Full vertical retract

The tool moves vertically up to the clearance plane, rapidly moves at this level in a straight line, and drops down
vertically to the start point of the ramp movement to the next pass.

7.4.2 Clearance

The Clearance parameters apply both to the lead in and the lead out components of retract motions.

Clear surface within

This option affects the tool path when the Shortest route style is chosen. It specifies the distance the tool moves away
from the surface with the cutting feed rate, before the rapid movement starts.
The distance is measured from the end of the lead out arc to the point where the tool is guaranteed to be clear of the
surface.

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Minimum rapid length

This option is used to specify a limit. If the 2D distance between the ends of the lead moves is less than this value, a
3D connecting move at lead feed rate is used. Otherwise a retract move is used.

Clear surface by

This is the minimum distance by which the tool will be clear of the surface during its rapid linking motion. All points
of the tool – on both the tip and the side have to avoid the surface by this distance.
For Minimal vertical retract motions, the tool lifts up to a height that ensures clearance.

Clear surface by

For Shortest route motions, the tool is lifted up above the surface to ensure the clearance, then it performs rapid
motion maintaining the Clear surface within distance.

Clear surface by

This clearance is applied in addition to any wall offset that you have already specified for the tool.
In particular, with a negative wall offset, the clearance is above the reduced surface and not the real
surface – so you should set this value higher to prevent the tool from gouging the surface.

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7.4.3 Smoothing

Radius Radius
SolidCAM enables to round sharp corners of the retract
motions when the Shortest route option is used by adding
a vertical curve of a defined radius. This makes the tool
movement smoother and enables higher feed rates.

7.4.4 Curls

SolidCAM enables you to add arcs in the end if the lead-out movements and in the beginning of the lead in movements.
The Curl over radius and Curl down radius define the radius of these arcs.
Curl down radius
Curl up radius Rapid movement
Lead in movement
Lead out movement

Cutting pass

The Curls options affect the tool path when the linking style is Shortest route.

7.5 Leads Parameters

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The parameters located on this page enable you to control the lead in and lead out motions.
• Fitting

• Trimming

• Basic Approaches

• Extensions

• Vertical leads

• Horizontal leads

The Stay on surface within parameter located on the Strategy page enables you to define the maximum
distance between passes to stay on the surface and when to perform a retract movement.

The style of the retract movement can be defined on the Retracts page.

7.5.1 Fitting

You define here how the lead in and lead out arcs of the retract movements fit to the machining pass.

Lead in/Lead out arc

Tool pass

Machine the whole pass

With this option the complete pass is machined. The arc can be applied at the end of the pass, without trimming of
the pass.

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The arc can be inserted only if it can be done safely without gouging the part faces. When the arc is conflicting with
the model geometry, a straight vertical lead in/out movement is performed.

Minimize trimming

This option enables you to perform the arc retract movement with minimal possible trimming of the cutting tool pass.
The retract pass is as close to the surface as possible, maintaining a minimum distance from the surface to fit the arc
of the defined radius.

Fully trim pass

In cases where it is crucial to prevent over-machining, this is a good and cautious strategy modification. The pass is
trimmed back so the entire arc fits into it, but no nearer than a full machine pass link would be.

Minimize trimming

Fully trim pass

7.5.2 Trimming

When a lead arc is added to a horizontal machining

pass, the length of pass trimmed off will be at most
the radius of the arc. However, when adding an arc
to a steep finishing pass, the length of pass trimmed
(trimming distance) will be much greater. Trimming
distance

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Such trimming of the passes can result in the occurrence of large unmachined areas. To avoid this, SolidCAM enables
you to limit the trimming distance with the Max. trimming distance parameter. If the trimming distance exceeds this
value, then no arc is used; the whole pass is machined, and a straight vertical motion is added.

This option affects the path when the Lead fitting is Minimize trimming or Fully trim pass.

7.5.3 Vertical leads

The Vertical leads parameters enable you to define the radius of the arcs located in a vertical plane used to enter and
leave the machining pass.

Rapid movement

Lead in radius

Lead out radius

Cutting pass

7.5.4 Horizontal leads

SolidCAM enables you to perform Horizontal lead in/out movements to provide you with smooth entering/exiting
from the material.
Using horizontal leads the tool path can be set up so that the tool approaches and leaves machining passes tangentially
using helical moves. Note that if the requested radius (Lead in or Lead out) is too large, then the horizontal lead is
omitted, and only vertical leads are used.

Lead in/out radius

These parameters enable you to define the radius of the arcs, located in a horizontal plane, used to enter and leave the
machining pass.

Lead in
radius

Lead out
radius

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Max. ramp angle

SolidCAM enables you to perform ramp down movements during the arc lead in. The Max. ramp angle parameter
enables you to limit the maximum angle (measured from the horizontal plane) for ramping.

Ramp height offset

The ramp height offset is an extra height used in the ramping motion down from a top profile. It ensures that the tool
has fully slowed down from rapid speeds before touching the material, and that it enters the material smoothly at the
ramping angle.

Ramp height
Ramp offset
angle

The Max. ramp angle and Ramp height offset parameters are available for the Constant Z technology.

Lead out angle

SolidCAM enables you to perform inclined upwards movements during the arc lead out. The Lead out angle parameter
enables you to define the angle of inclined lead out movement. The angle is measured from horizontal plane.

Lead out
angle

The Lead out angle parameter is available for the Constant Z strategies.

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7.5.5 Extensions

Ramp in extension

The ramp in height offset is an extra height used in the ramping motion down from a top profile. It ensures
that the tool has fully slowed down from rapid speeds before touching the material so that it enters the
material smoothly at the ramping angle.

Ramp out extension

The ramp out height offset is an extra height used in the ramping motion. It ensures that the tool speeds up
to rapid speeds gradually.

7.5.6 Basic approaches

The Basic horizontal approaches check box enables you to perform a separate lead in/lead out movement for each
Z-level pass in Constant Z machining. This functionality is useful for smooth entrance into the material from outside
in semi-finish machining of steep model areas.
When this check box is not selected, the tool enters the material according to the defined approach/retreat parameters,
and the Z-level passes are machined successively one after the other without exits from the material.
When this check box is selected, the tool exits from the material after machining of each Z-level pass and enters again
on the next Z-level pass.

Basic horizontal approaches Basic horizontal approaches

check box is not selected check box is selected

• The Lead in angle parameter defines the angle between the tool approach line and the line tangent to the
Z-level pass in the start point of the machining.
• The Lead out angle parameter defines the angle
between the tool retreat line and the line tangent to
the Z-level pass in the end point of the machining.
• The Linear extension parameter defines the length
of the tool horizontal approach line.

Lead out Lead in

angle angle

Linear extension

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7.6 Down/Up Mill Parameters

This page enables you to define the parameters of the Down/Up milling.

Down/Up milling options should be first selected on the General page, to have the parameters on this
page operable.

Pass overlap

When a pass is broken in order to perform down and up movements, each segment can be extended, from the point
where pass segments are connected, so that they overlap. This ensures a smoother finish.

No Pass overlap

Pass overlap Passes connect point

Since both pass segments are extended by the Pass overlap value, the actual length of overlap is twice
the defined value.

Shallow angle

Model areas with the inclination angles less than the Shallow angle value are considered as shallow. Such areas can be
machined in either direction, as obviously up or down milling is irrelevant, and in these areas the tool path will be less
broken up.

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The image below illustrates the case when the inclination angles of the model faces are greater than the defined
Shallow angle value.

In the image below, the Shallow angle value has been increased resulting in no break up of the tool path.

Merge %

SolidCAM enables you to machine some segments of the tool path upwards where downward movement is preferred,
and vice versa, to avoid too much fragmentation.
The Merge % parameter defines the limit length of the opposite segments as a relative percentage of the whole pass.
When the percentage of the segments length where the direction of the machining to be changed is less than the
defined value, the direction will not be changed.

Maintain milling direction

This option affects the ordering of Linear, Radial, Spiral and 3D Constant Step over passes. It ensures that all segments
will either be climb milled or conventionally milled, if selected.
When the Maintain milling direction check box is not selected, passes will be either climb or conventional passes,
depending on the relative position of the tool at the time.

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7.7 Refurbishment Parameters

This page enables you to define a number of parameters of the tool path refurbishment.

7.7.1 Min. pass length

The Min. pass length parameter enables you to define the minimal length of the pass that will be linked. Passes with
length less than this parameter will not be linked.
This option enables you to avoid the machining of extremely short passes and increases the machining performance.

7.7.2 Spikes

Sometimes at the end of a pass, where one surface is adjacent to another Spike
at a very steep angle, there is a sharp jump. This can happen where the tool
touches a steep wall and is lifted to the top, or where it "falls off" a high
ledge and drops to the bottom. SolidCAM enables you to remove these
spikes.

Remove Spikes

This option enables you to remove sharp jumps (spikes) from the tool path.

Spikes
removed

• Max. acceptable angle

Spikes or jumps with an angle greater than this value are removed from the tool path. The angle is measured
from the horizontal plane.

Remove first/last spikes only

When this option is active, only spikes at the beginning and end of passes are removed. There will be no spike removal
on a looped pass if this option is active, as there is no pass end.

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• Non-spike allowance

You can trim off any small horizontal areas left at the top or bottom of the spike. The value here is the
maximum length of horizontal pass that will be removed from the tool path.

Horizontal passes Horizontal passes

at the top of spikes trimmed

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Motion Control 8
Using the parameters of the Motion control page, you can optimize the calculated tool path according to the kinematics
and special characteristics of your CNC-machine.

The default values of these parameters are defined in the VMID file of your CNC-machine.
The interface of the Motion control page may vary depending on the parameters of your CNC-machine.

8.1 4th Axis

This option enables you to project the portion of the 5th axis back onto the selected 4th axis.
Selecting the Indexial option allows you to set a rotational angle value to extend the working area of machines having
a limitation in one of the linear axis in the working plane.
Selecting the Face Sim option enables you to perform milling using the rotary axis by translating the linear movements
in the XY-plane into the rotary XC-movements.

Note that the technology offered by SolidCAM is universal: there is no limitations in terms of machines
on which the part can be milled. But if you use the GCode output in the XYZ coordinates (the Diameter
option), the usability of this GCode is limited to machines with possibility of movements along three
linear axes (X, Y, Z). Therefore, to enable the possibility of milling the part on 3-axis Mill-Turn CNC-
machines that support only the XZC coordinates where the movements along the Y-axis is impossible,
you need to choose the Face option.
• The option of Coordinate type enables you to determine whether the GCode will consist of split blocks
or blocks in polar/Cartesian coordinates. When you select the option of Polar, the tool path is calculated
in polar coordinates. When you select the option of Cartesian, the tool path lines and arcs are calculated
in Cartesian coordinates; the CoordSys position is zero for linear coordinates. The milling is processed
using the rotary axis by translating the linear movements into the rotary-linear movements according to
the plane.
• The option of Plane, allows you to choose the appropriate plane i.e, XC,YC, or ZC.

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 8. Motion Control

8.2 Approximation of Arcs

This option enables you to control the process of arcs approximation at the operation level.
The Approximate arcs by lines check box enables you to control the existence of arcs in the GCode output for the
current operation.
When this check box is selected, SolidCAM approximates all tool path arcs by lines. The precision of the approximation
depends on the Max Chord Length and Max Arc Angle parameters defined on the Controller Definition page
of the VMID file; the resulting GCode does not contain arcs.
When this check box is not selected, the resulting GCode might contain arcs.

8.3 5th Axis

For a 5-axis machine, the tool axis vector can always be mapped into two different angle pairs. During the tool path
generation, SolidCAM calculates for each tool axis orientation both of these two angle pairs; only one of the two has
to be chosen for the GCode generation.
Some machines can only use one of the angle pairs due to mechanical limitations. In this case the angle pair will then
be chosen as the First angle pair or Second angle pair.

8.4 Point Interpolation

The point interpolation provides the ability to create intermediate points by setting a certain maximum angle step
distance (for 5-axis motions) or by splitting long linear motions (3-axis and 5-axis tool paths) for feed rate moves and
rapid rate moves.

Interpolation for distance

Using this option, SolidCAM enables you to perform interpolation for the linear tool movements. When this option is
active, a new interpolated tool position is defined at each distance, defined by the Interpolation for distance parameter.
E.g. when the linear tool movement is performed from 0, 0, 0 to 0, 0, 100 and the Interpolation for distance option
is used with the Distance value of 10, SolidCAM adds 9 tool positions between start and end positions (0, 0, 10, then
0, 0, 20 etc.).

Rapid feed rate moves

When this option is activated, all rapid motions (on clearance area and rapid distance) are converted into a feed motion
with the given value.

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Miscellaneous
Parameters 9
This page displays the non-technological parameters related to the HSM operations.

9.1 Message

This field enables you to type a message that will appear in the generated GCode file.

G43G0 X-49.464 Y-38.768 Z12. S1000 M3

(Upper Face Milling)
(--------------------------)
(P-POCK-T2 - POCKET)
(--------------------------)
G0 X-49.464 Y-38.768
Z10.

9.2 Extra Parameters

This table contains certain parameters only when special operation options have been implemented in the postprocessor
you are using for this CAM-Part.
For more information on additional parameters definition, refer to the SolidCAM Machine ID Reference Guide.

9.3 Flyout Window

If you prefer working with a larger window, the Flyout Window option displays the Operation Option window.

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 1

Edit Tool Path 10

The operation of Edit HSR/HSM Tool Path enables you to easily edit/trim or modify the generated tool path, using
Boundaries, and Z levels.
This option is available in the SolidCAM Tree after the HSR/HSM operation is calculated.
Right click the operation you want to edit and select Edit HSR/HSM Tool Path. This opens the Edit HSR/HSM window.
Once you click the Save icon in the Operations window, the original operation is supressed in the SolidCAM Manager
Tree and the edited operation is created below it with the Edit icon on it.

Source operation

The Source operation page of Edit HSR/HSM operations window displays the name of the operation which is currently
open for editing.
The Edit Toolpath Strategy section enables you to define the tool path editing strategy using Boundaries, Z-level, and
Boundaries & Z-level.

10.1.1 Boundaries

When you select the Boundaries option, you can trim a set of finish passes using a 2D or 3D boundary on the
Boundaries and Z-levels page. The 3D boundaries are theoretical rest areas, rest areas, shallow areas, tool contact
areas. Working with 3D Boundaries function, gives a better result on steep faces.

The section of Z-levels is unavailable on the Boundaries and Z-levels page when the Boundaries
option is chosen on the Source operation page.

10.1.2 Z-levels

The z-limits are the highest and lowest positions for the cutter - the range in which it can move during the pass – and
can be altered to modify the passes after they have been created. When you choose this option, the tool path is edited
only between the sepcified Z-levels values that you set on the Boundaries and Z-levels page.

The section of Boundaries is unavailable on the Boundaries and Z-levels page when the Z-levels
option is chosen on the Source operation page.

10.1.3 Boundaries & Z-levels

When you select this option, the tool path is edited using the chosen boundary and the specified Z-levels.

10.1 Tool

The Tool tab displays the tool used in the operation. The tool parameters cannot be edited in the Edit HSR/HSM
Operations window.

On the Data tab, only the options of Link down, Link up and Rapid are available for editing.

10.2 Boundaries and Z-levels

This page enables you to define the boundaries and z-levels to edit the tool path.

10.2.1 Boundary Type

The Boundary type section enables you to create the boundary automatically or manually.

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 10. Edit Tool Path

10.2.2 Boundary name

The Boundary name section enables you to define a new boundary or choose an existing one.

10.2.3 Boundary offset

The Boundary offset section enables you to apply an additional positive or negative offset value to the defined
boundary.

10.2.4 Z-levels

The Z-levels section enables you to specify the maximum and minimum z-limits for editing the tool path.

10.2.5 Keep tool path outside the Boundary

When this check box is selected, everything inside the trimming boundary is trimmed while the tool path is kept
outside the selected boundaries.

When this check box is not selected, all exterior pass information is removed while the tool path is created only inside
the selected boundaries.

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User Guide | SolidCAM 2023

HSM Machining

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