Milling 2.
5 D
Setting up stock, target, co-
ordinate systems and adding
operations
Controlling system settings and file locations
Open part in SW
CAM Settings
• Cam Settings
• User directories - User Directory for Cam Parts - set up folder
where you want to store work
• User Directory for system additional files - set to same folder
• Default CNC- Controller set to XXXX
• G Code - turn on - In the cam part directory
• Automatic CAM -Part Definition
• Milling Tab - Turn off all check boxes
Setting up Stock, Target and Co ordinate Systems
• Go to SolidCAM Part tab
• In menu at top chose new Milling
• Stock and Target Model - Stock
• set how much larger than target stock material - select part
• Add box to CAD model (set stock +2 mm and +6 on base)
• Add box to CAD model - Accept with tick
• Coordinate System - Define
• Select origin
• Define X direction and Y direction
Note : Z should point vertically up away from stock (if not manipulate using flips)
set start levels and clearance levels - OK
• If you have multiple faces which have to be machined set up next co-
ordinate system .... Mach 2 etc
• Target - select finished part - tick
• Tick when finished
You should see a green tick next to stock and target and co-ordinate system to say
all are fully defined
Operation 1 - Face top face
• Go to operations - right click - add Milling operation - Face
Geometry - New
• Type - Profile - select top line on stock - Auto-to - Select auto constant Z,
accept chain
Tick to accept
Tool - Face Mill - Select (change dimensions of tool to match our tool) - Select
• Levels - Upper Level - select top of stock - tick
• Face depth - chose top surface of finished part - Tick
Levels - select step down = 1mm
• Technology - Hatch - floor offset 0.5mm tick Finish
Question - How many cuts required?
total material to remove = 2 mm
step down = 1 mm but as we finished 1 finish cut at 0.5 mm it will
take a cut of 1 mm, then 0.5 mm then 0.5 mm finishing cut
Misc Parameters - tick check gouges during calculation set tolerance to 0.2
• Save and calculate
• Exit
• Right click on operation and simulate -
• Solid Verify - turn speed down and run
Operation 2 - profile
• Go to last operation - Rt Click add milling operation - Profile
(going to mill round outside of block)
• Geometry - New select line on outside edge of block, Auto-to -
Auto constant z accept chain
Notice start point for cutter and direction of travel around path
Question should cutter be on left or right hand side of path?
On the tools tab - Select end mill diameter 14
To ensure the work-piece doesn't crash with the stock the depth of material cant be
longer than the cutting length of the tool. As the stock is 30 thick it is necessary to
use a Cl of 32 to cut down to the bottom face of the target.
Still on tool but now switch to data tab - using wk 27 notes calculate the spindle
speed and feed- rate for a 12 mm HSS end mill with 4 teeth cutting aluminium.
over write the local defaults in the cutting parameters for this operation.
Levels - Upper Level - This is where the cutter first encounters material. As
the stock material has already been faced down to the target level, this is now
top of target
Tick to accept
To select profile depth - select bottom edge of target
Technology - Technology tab, Which side of line selected profile do you
want the tool? (depends on where you start and direction of travel) in this
example though its the right.
It is necessary to decide on a strategy for how to remove the material -
In this case the intention is to leave 0.5 mm surplus on the outside wall
of the component. It would need too much machine power to machine
the whole profile depth of 30 mm in one pass so it is necessary to take a
number of passes. (called step down) for the machine power available
about 5mm should be assumed as a guideline for the maximum step
down value. This means six separate profile cuts to get down to the
bottom of the target.
A finishing operation will then cut the whole profile depth 30mm but will
just remove the 0.5 mm surplus material from around the outside of the
part. This is achieved using the following settings-
Using Solid Verify the cutting process is simulated.
Using Rest Material tab in simulation manager -
The target which is now exposed is coloured grey. Any material still to be
removed is coloured red (rest material)
Operation 3 - Internal pocket with island
To machine the pocket most efficiently it would be normal to rough out the basic
pocket shape with a large diameter tool. Unfortunately if the pocket has tight
internal rads. or indeed islands in close proximity to walls this means the large tool
will not be able to access those areas. The logic embedded in SoldCAM is
sufficiently powerful to avoid gouges by leaving those inaccessible areas un-
machined. Unfortunately that means additional operations with a more appropriate
sized cutter will be necessary to remove that material and indeed to complete any
finishing cuts. By Using the measure tool we can see the fillet between the island
and the floor is 3mm rad and the island is 8mm diameter. The gap between the
island and the nearest wall is just 8mm.
Suitable cutting tools would be:
Roughing - 16 mm bull nose with 3 mm fillet at the tip
Rest material (behind island) - 7mm diameter bull nose with 3mm fillet at the tip
Around outside of pocket to remove fillet - 5mm diameter end mill.
right click on last operation - add Milling Operation Pocket
Geometry - New
Geometry Tab
Select chain around outside of pocket using auto constant z
Select chain around island - Note ensure path direction around both chains
is in the same direction. If this is not so it is necessary to reverse the
direction of one of the chains by right clicking the chain and choosing
reverse.
Tool tab - Select appropriate sized tool and set up speeds and feed as per
previous example...
Levels tab - Upper level - select top of target
Pocket Depth - select bottom of pocket
Mis.c parameters tab - set gouge check tolerance
Simulate using solid verify - shows roughing operation as far as tool can reach
Adding a new Milling Operation - Pocket
Geometry - as for first roughing operation
Tool - bull nose 7 dia with 3 fillet
Levels - Pocket depth - as for roughing Operation
Technology - Choose rest this causes cutter to back for material which couldnt
be removed by roughing Operation.
It is necessary to say which sized cutter was used for proceeding tool so that
the software can work out where the roughing cut stopped.
When this operation is simulated some issues are revealed - notice the cusps
on the pocket floor - How could that be overcome?
Why is there a step on the outside of the pocket? - How could this be avoided ?
Remaining Operations
• This part has several operations remaining -
• Mill step on edge of block
• Drill hole
• Chamfer inside edge of pocket
• Turn stock over and set up on MAC 2 position 1 (How would the stock
be held in this orientation?)
• Face of new top surface
• Mill circular pocket
