SolidCAM imachining SolidCAM imachining is an intelligent High Speed Machining CAM software, designed to produce fast and safe CNC programs to machine mechanical parts. The word fast here means significantly faster than traditional machining at its best. The word safe here means without the risk of breaking tools or subjecting the machine to excessive wear, whilst increasing tool life. To achieve these goals, imachining uses advanced, patent pending, algorithms to generate smooth tangent tool paths, coupled with matching conditions, that together keep the mechanical and thermal load on the tool constant, whilst cutting thin chips at high cutting speeds and deeper than standard cuts (up to 4 times diameter). imachining Tool paths imachining generates Morphing Spiral tool paths, which spiral either outwardly from some central point of a walled area, gradually adopting the form of and nearing the contour of the outside walls, or inwardly from an outside contour of an area to some central point or inner contour of an island. In this way, imachining manages to cut irregularly shaped areas with a single continuous spiral. 2
The Leaders in Integrated CAM imachining uses proprietary Constant Load One-Way tool paths to machine narrow passages, separating channels and tight corners. It uses proprietary topology analysis algorithms and channels to subdivide the area into a few large irregularly shaped sub-areas and then machines each of them by a suitable morphing spiral, achieving over 80% of the volume being machined by spiral tool paths. Since spiral tool paths have between 50% and 100% higher material removal rate (MRR) than one-way tool paths, and since imachining has the only tool path in the industry that maintains a constant load on the tool, it achieves the highest MRR in the industry. The imachining Technology Wizard A significant part of the imachining system is devoted to calculate matching values of Feed, Spindle Speed, Axial Depth of cut, Cutting Angle and (Undeformed) Chip Thickness, based on the mechanical properties of the workpiece and tool whilst keeping within the boundaries of the machine capabilities (Spindle Speed, Power, Rigidity and Maximum Feeds). The imachining Technology Wizard, which is responsible for these calculations, provides the user with the means of selecting the level of machining aggressiveness most suitable to the specific machine and set up conditions and to their production requirements (quantity, schedule and tooling costs). An additional critical task performed by the Wizard is dynamically adjusting the Feed to compensate for the dynamically varying cutting angle a bi-product of the morphing spiral, thus achieving constant tool load, which increases tool life. 3
Exercise #1: imachining Walk Through This example is a step-by-step guide on the definition process of SolidCAM s imachining technology to machine the part above. The rough and finish machining of the outside contour, center pocket and pocket ledge is performed. The machining is performed on a 3-axis CNC-machine. The following steps have to be implemented in order to reach the final CAM-Part: 1. Define the CAM-Part Open the imachining_walkthrough.sldprt file located in C:\Program Files\ SolidCAM2011\User\Getting_Started_Examples\SW. Define the CAM-Part, the CNC-controller (gmilling_haas_ss_3x), the Machine Coordinate System, the Stock model and the Target model. The Stock model and the Target model should be defined as shown. 3D Model Stock Target 4
The Leaders in Integrated CAM 2. Define the machine and work material parameters Right-click on the Operations header in the SolidCAM Manager tree and add a new imachining operation. When the first imachining operation is added to your CAM- Part, you need to define the machine and material parameters for the imachining Database. The buttons at the bottom left enable you to manage machine definitions in the list. The New button enables you to add new machine definitions. The Delete button enables you to delete the existing machine definitions from the list. The Save As button enables you to save the defined machine definitions under specified names in specified locations. The Revert button enables you to return all the edited parameters to their default values. 5
Click on the New button to add a new machine definition. Enter the name for the new imachining database file and click on the Save button. The Haas_SS_New machine definition is added into the list. In the General section, define the major machine parameters. The parameters marked with yellow highlight are mandatory. Set the Spindle Speed Max to 12000 rpm and the Feed Rate Max to 21160 mm/min (833 inch/min). For Reposition Feed Rate, set the value for XY movements to 10000 mm/min (400 inch/min) and the value for Z movements to 3800 mm/min (150 inch/min). Set the Spindle Power Max to 20 kw (25 Hp). 6
The Leaders in Integrated CAM Click on the Next button to define the work material. Choose the Aluminum_100BHN_60HRB option. Click on the Finish button to confirm the machine and material parameters definition. If you are running a demo version of SolidCAM, select the default Haas_SS database and choose Aluminum_100BHN_60HRB for material definition. Now that you have created a Machine Database for imachining, on creating new CAM-Parts you can select the machine and material database in the CAM-Part definition dialog box. 7
3. Define the rough machining of the outside contour When you have confirmed the machine and material definition, the imachining Operation dialog box is displayed. Use the default irough technology to machine the outside contour of the part. Click on the Define button on the Geometry page of the imachining Operation dialog box to define the machining geometry for the operation. imachining geometry definition The geometry in imachining is defined as a pocket that can be open, closed and semi-closed (containing open edges). The pocket can contain internal chains treated as islands or used for safe tool entry. Closed pocket 8 The geometry is defined as a single closed chain on the pocket contour. The material is cleared out from the interior of the defined geometry.
The Leaders in Integrated CAM Closed pocket with island(s) The geometry is defined as several closed chains: the first chain is the pocket contour and the rest are the internal chains on island contours. Note that the order is important: the pocket chain is the first chain selected; then the island chains are selected. Closed pocket with entry chain Similar to Closed pocket with island(s). The geometry is defined as several closed chains: the first chain is the pocket contour, the second is an internal chain on island contour, which is marked as open. This open internal chain is considered as a precut area that has already been machined prior to this operation. The tool will plunge inside this open area and start machining the remaining material. To mark a chain as open, right-click on its name in the Chain List section and choose Mark chain as open. Note that the chain selection order is important. 9
Open pocket The geometry is defined as a single chain on the pocket contour. This chain is marked as open. The material is cleared out from the interior of the defined geometry with the tool approaching from the outside (pocket without walls). Open pocket with island(s) The geometry is defined as several chains: the first chain is the pocket contour (marked as open) and the rest are the internal chains on island contours. Note that the chain selection order is important. Pocket with open edge(s) The geometry is defined as a single closed chain on the pocket contour. One or several edges are marked as open: the tool approach from the outside is enabled. The material is cleared out from the interior of the defined geometry with the tool approaching through one of the open edges. 10
The Leaders in Integrated CAM To mark an edge as open, rightclick on the chain name in the Chain List section and choose Mark open edges. The Mark open edges dialog box is displayed. Select the required edge on the solid model and confirm the dialog box. In this operation, the geometry is defined as an open pocket with an island. Select two chains as shown. Mark the outer chain (Chain #1) as open to enable the tool approach from outside. In the Levels section of the Geometry Edit dialog box, click on the Depth button to define the lower machining level for the operation. Pick the machining depth on the bottom edge of the model as shown. You can also define the upper and lower machining levels on the Levels page of the imachining Operation dialog box. 11
Add an end mill of Ø9.5 mm (0.375 ). Define the tool parameters as follows: Set the Total length to 76 mm (3 ); Set the Outside holder length to 29 mm (1.125 ); Set the Shoulder length to 29 mm (1.125 ); Set the Cutting length to 25 mm (1 ); Set the Number of flutes to 4. Helical Angle Switch to the idata tab and choose the 45 (Medium) value for the Helical angle parameter. This parameter affects the cutting conditions and step down values generated by the imachining Wizard. 12
The Leaders in Integrated CAM Click on the Select button to confirm the tool definition. Define the milling levels. In addition to the depth specified at the stage of the geometry definition, define the Delta depth on the Levels page of the imachining Operation dialog box to perform machining deeper than the part bottom edge. Set the value to -0.76 mm (-0.03 ). Switch to the Technology Wizard page of the imachining Operation dialog box. This Wizard automatically calculates the cutting conditions for the imachining technology taking into account the tool data and milling levels defined for the operation. 13
Step down When the Automatic option is chosen, the step down is calculated by the wizard in accordance with the cutting depth defined for the operation. When the User-defined option is chosen, the step down can be defined by specifying its value or by setting the number of steps required to achieve the cutting depth. The table below displays the number of steps, the step down value and the number of Axial contact points (ACP) calculated automatically by the Wizard. Output cutting data This section displays two sets of data related to the current cutting condition (the spinning speed and feed rate of the tool, the step over range, the material cutting speed, etc.). Machining level When you move this slider in the increasing direction (to the right), the values in the Output cutting data section automatically increase, and vice versa. The Machining level slider enables you to set the cutting conditions optimal for your machining case. In this operation, use the default position of the Machining level slider (3). 14
The Leaders in Integrated CAM Click Save & Calculate, then click Simulate. Run the operation simulation in the HostCAD and SolidVerify modes. The simulated tool path is performed as follows: the corners are cleared first, then the entire contour is machined. 4. Define the finish machining of the outside contour Click on the Save & Copy button at the bottom of the imachining Operation dialog box to create a copy of the newly added imachining operation. The copied operation will perform finishing of the outside contour. When the copied operation dialog box is displayed, choose ifinish for Technology. 15
Switch to the Technology page. In the irest data tab, note that the previous irough_outside operation appears in the Parent operation combo box, which means that the technological parameters of the current operation are inherited from the previous parent operation. Save and calculate the operation. Simulate the operation in the SolidVerify mode. The finishing is performed in a single cutting pass. 5. Define the rough and finish machining of the center pocket Add a new imachining operation for machining of the center pocket. Choose irough for Technology and define the geometry on the lower contour of the pocket as shown. Pick the bottom face of the pocket for the machining depth definition. 16 Use the end mill tool defined in the previous operation and the default Technology Wizard settings.
The Leaders in Integrated CAM On the Link page, the default value of the Ramping angle of 2.5 is used for the operation. The Helical ramping into the pocket will be performed at the angle of 2.5 degrees. Save and calculate the operation. Simulate it in the SolidVerify mode. The tool performs the helical entry and then the pocket roughing tool path. Save and copy the newly added imachining operation to perform finishing of the center pocket. Choose ifinish for Technology. In the irest data tab of the for Technology page, the previous irough_centerpocket operation appears as the parent operation. 17
Save and calculate the operation. Simulate it in the SolidVerify mode. The rest material is cleared from the pocket corners before the final finishing pass is performed. 6. Define the rough and finish machining of the pocket ledge Add a new imachining operation for machining of the pocket ledge. Choose irough for Technology and define the geometry as closed chain on the lower contour of the ledge as shown; mark the selected edge as open. Pick the bottom face of the ledge for the machining depth definition. Use the end mill tool defined in the previous operations and the default Technology Wizard settings. 18
The Leaders in Integrated CAM Save and calculate the operation. Simulate it in the SolidVerify mode. The tool approaches from outside and performs the roughing tool path, first removing the material from the middle of the ledge and then clearing its corners. Save and copy the newly added imachining operation to perform finishing of the center pocket. Choose ifinish for Technology. Save and calculate the operation. Simulate it in the SolidVerify mode. The finishing is performed in a single cutting pass. Congratulations! You have successfully completed the imachining exercise! 19
Exercise #2: imachining of a Bracket This example illustrates the use of SolidCAM s imachining technology to machine the part above. There are standard 2.5D tool paths (Drilling & Profile) and 3D tool paths (HSR & HSS) to aid in the complete CNC program. The machining is performed on a 3-axis CNC-machine in two setups, from both sides of the part. For 2.5D customers without HSR/HSS, please open the imachining_25d_only.prt example that does not contain the 3D operations. The following SolidCAM operations are created to perform the machining: Outside shape machining (irough_outside; ifinish_outside) These imachining operations perform the cutting of the outside shape of the part. An end mill of Ø12.7 mm (0.5 ) is used. Two chains are defined, with the first being the Stock boundary and the second being the profile around the part. The Stock chain is marked as open, which specifies the tool should machine from this chain, collapsing towards the part profile. irough has a 0.25 mm (0.01 ) allowance on the wall, and the ifinish operation finishes the profile. Both operations have a -0.63 mm (-0.025 ) delta depth, so the tool machines deeper than the part. 20
The Leaders in Integrated CAM Through pockets machining (irough_throughpockets; ifinish_throughpockets) These imachining operations perform the cutting of the five circular through pockets. An end mill of Ø12.7 mm (0.5 ) is used. Five chains are defined to represent the five closed pockets. Since the pockets are closed, with no PreDrilling or EntryChain defined, helical ramping is used to enter the bottom of the pocket. irough has a 0.25 mm (0.01 ) allowance on the wall, and the ifinish operation finishes the profile. Both operations have a -0.63 mm (-0.025 ) delta depth, so the tool machines deeper than the part. Rough machining of angled surfaces (HSR_R_Rough_Chamfer) This HSR operation performs the rough cutting of the four large chamfers on the ribs. An end mill of Ø12.7 mm (0.5 ) is used. Two boundaries are picked off the edges the make up the chamfer and the Tool Relations is set as centered. A 1.27 mm (0.05 ) step down is used and 0.127 mm (0.005 ) allowance on the surfaces. 21
Pocket machining (irough_pockets; ifinish_pockets) These imachining operations perform the cutting on the three semi-open pockets and the 7 closed pockets. A bull nose mill of Ø10 mm (0.375 ) and corner radius of 1.6 mm (0.0625 ) is used. Since all the 10 pockets are located on the same Z-Level, they can be machined all in one operation. Three chains have edges marked as Open and Wall, Open edges allow the tool to enter from these edges. Four of the closed chains use the through pockets as an Entry chain (an Entry chain is a chain inside the pocket, similar to an Island, but marked as open). The last two chains are simple closed pockets with helical ramping. irough has a 0.25 mm (0.01 ) allowance on the wall, and the ifinish operation finishes the profile. Finish machining of angled surfaces (HSS_PC_Lin_faces) This HSS operation performs the finishing cut on the four large chamfers on the ribs. A bull nose mill of Ø10 mm (0.375 ) and corner radius of 1.6 mm (0.0625 ) is used. A simple Linear strategy is used with a 0.5 mm (0.02 ) step over. Customized linking is used to have short repositions and smooth transitions when starting the cut. 22
The Leaders in Integrated CAM Bottom ledge machining (irough_face_backledge) This imachining operation finishes the bottom ledge on the underside of the part. An end mill of Ø12.7 mm (0.5 ) is used. Two chains are defined, with the first being the Stock boundary and the second being the bottom of the floor radius. The Stock chain is marked as open, which specifies the tool should machine from this chain, collapsing towards the radius. The floor radius is not machined at this stage. Cutting excess material from through hole (irough_back_centerhole) This imachining operation machines away the excess material from the center through hole of the part. This excess material was used for clamping from the first side. An end mill of Ø12.7 mm (0.5 ) is used. A single closed chain is defined and a 0.25 mm (0.01 ) allowance is used for the wall, since the wall was finished at the stage of the top side machining. 23
Bottom face machining (irough_face_back) This imachining operation finishes the circular face on the underside of the part. An end mill of Ø12.7 mm (0.5 ) is used. Two chains are defined, with the first being the outside boundary of the face and the second being an offset edge created in Sketch1 in the assembly. The first chain is marked as open, and the second offset chain is closed. A spiral tool path is performed from the outside, collapsing towards the inner chain. Floor radius finishing (F_backRadius) This Profile operation finishes the 6.35 mm (0.25 ) floor radius on the underside of the part. A ball mill of Ø12.7 mm (0.5 )t is used. The chain is the bottom edge of the radius and the Tool side is set to center. The 0.13 mm (0.005 ) floor offset is left after the first roughing pass and then removed with the finishing pass. A 0.25 mm (0.01 ) Lead in/out arc is used. 24
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