SolidCAM Application Tutorial SWARF Machining SolidCAM + SolidWORKS The Complete Integrated Manufacturing Solution
Contents
1. Introduction................................................................................................................. 1 2. CAM-Part Definition.................................................................................................... 5 3. HSR and HSM Operations........................................................................................ 13 4. iMachining and Rest Roughing................................................................................ 21 5. SWARF Semi-Finishing ........................................................................................... 29 6. SWARF Finishing ..................................................................................................... 41
i
Introduction
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About this course The goal of this course is to teach you how to use SolidCAM’s SWARF Machining to machine an aerospace part. This tutorial covers the basic concepts of SWARF Machining. Once you have developed a good foundation in basic skills, you can refer to the online help for information on the less frequently used options. Prerequisites Students attending this course are expected to have basic knowledge of the SolidCAM software. Course design This course is designed around a task-based approach to training. The guided exercises will teach you the necessary commands and options to complete a machining task. The theoretical explanations are embedded into these exercises to give an overview of the SWARF Machining capabilities. Using this book This tutorial is intended to be used in a classroom environment under the guidance of an experienced instructor. It is also intended to be a self-study tutorial.
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1. Introduction
SWARF Machining The SWARF Machining operation provides you with a number of advantages in steep areas machining. In SWARF operation, machining is performed by the tool side. The contact area between the tool and the workpiece is a line, therefore a better surface quality can be achieved with a minimum number of cuts.
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4
CAM-Part Definition
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The CAM-Part definition process for the part consists of the following stages: CAM-Part creation
CNC-Machine definition
Coordinate System definition
Stock and Target definition
• CAM-Part creation. At this stage, you have to define the CAM-Part name and location. SolidCAM defines the necessary system files and a folder to allocate the place to store SolidCAM data. • CNC-controller definition. It is necessary to choose the CNC-controller. The controller type influences the Coordinate System definition and the Geometry definition. • Coordinate System definition. You have to define the Coordinate System, which is the origin for all machining operations of the CAM-Part. You can create multiple CoordSys positions and in each machining step select which CoordSys you want to use for the operation. • Stock and Target definition. It is necessary to define a boundary of the stock that is used for the CAM-Part machining. SolidCAM enables you to define the model of the part in its final stage after the machining. The following exercises describe the full process of the CAM-Part definition. It is recommended to go through the stages in order to understand how the CAM-Part features are built. For this purpose, you have to turn off the automatic CAM-Part definition. 1. Click Tools Settings.
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> SolidCAM > SolidCAM
2. CAM-Part Definition 2. In
the left pane, select CAM-Part.
3. Ensure
that the settings are as shown in the image.
4. In
the left pane, select Automatic CAM-Part definition.
5. In
the right pane, click the Milling tab.
6. Ensure
that the settings are as shown in the image.
7. Click OK.
8. Browse
and open SWARF.SLDPRT.
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9. Click Tools > SolidCAM Milling.
> New >
The New Milling Part window displays. 10. Click
The Milling Part Data window displays. 11. In
the CNC-Machine: list, select FANUC5X_HEAD.
12. Click CoordSys 13. In
in the Define section to set the coordinate system for this part.
the Place CoordSys origin to list, click Top center of model box.
14. Set
the UCS as shown in the image.
15. Click 16. Click
in the CoordSys Data window.
17. Click
in the CoordSys Manager window to return to the Milling Part Data window. 18. Click Edit iMachining Database
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in the iMachining Data section.
2. CAM-Part Definition 19. Define
a new machine and material with the parameters as shown in the images.
20. In
the iMachining Data section, select the defined machine, material and machining level as shown in the image. 21. Click 22. Click
in the Milling Part Data window. the Feature Manager Deisgn Tree
23. Click DesignModel 24. Click FIXTURE
25. Click
icon.
> Solid Bodies > STOCK > Show.
> Show.
the SolidCAM Manager
icon.
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26. Click Stock 27. In
> Define.
the Defined by list, click 3D Model.
28. Select
the stock as shown in the image.
29. Click 30. Go to the Feature Manager Design the STOCK in the Solid Bodies. 31. Click
the SolidCAM Manager
32. Click Target 33. Select
Tree and Hide
icon.
> Define.
the part as shown in the image.
34. Click
35. Right click Operations start of operations tree.
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> Machine Setup > Add at
2. CAM-Part Definition 36. In the Machine setup window, in Fixture column, click the three dots.
the
The Model window displays. 37. Select
the fixture as shown in the image.
38. Click 39. In
the Z column, enter a value of 150.
This value will move the entire assembly of stock, part and fixture by 150 mm, ensuring that it rests exactly on the face of the table. 40. Click OK
in the Machine setup window.
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HSR and HSM Operations
3
1. Right click Setup > 3D HSR.
> Add Milling Operation
2. In the Technology roughing.
3. Ensure target
section.
4. Click Tool
5. Click
list, click Contour
is selected in the Target geometry
> Select.
to add a new tool.
6. Select BALL NOSE MILL
as the tool.
7. Enter
the parameters as shown in the
8. Click
the Holder check box.
image.
9. Select HSK A 63 ER 32x80. 10. Click
the Select
icon.
11. Click Constraint boundaries. 12. Select 13. In
the list, click Selected faces.
14. Click
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the Created manually option.
the New
icon under Boundary name.
3. HSR and HSM operations 15. Click Define
in the Drive faces section.
16. Click Pick from Model. 17. Select
any of the highlighted green color faces.
18. Click Find Faces.
19. Click
20. Click
The selected boundary should look as displayed in the image. 21. In
the Boundary- Tool Relation list, click Centered.
22. Set
the Offset value as 2.
23. Click Passes. 24. Enter
image.
the parameters as shown in the
25. Click Z-Bottom.
26. Select
the point as shown in the image.
27. Click
15
28. Click
the Adaptive step down tab.
29. Enter
the parameters as shown in the
image.
30. Click Link. 31. Set
the values as shown in the image.
32. Click
33. Set
the values as shown in the image.
34. Click
35. Set
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the Ramping tab.
the Strategy tab.
the values as shown in the image.
3. HSR and HSM operations 36. Click 37. Set
the values as shown in the image.
38. Click
39. Set
the Retracts tab.
the Leads tab.
the values as shown in the image.
40. Click
the Save & Calculate
41. Click
the Simulate
42. Click
the Play
icon.
icon. icon.
The calculated tool path should look as displayed in the image.
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43. If
you run SolidVerify, the tool path should look like as shown in the image.
44. Click
the Exit
icon to close the Simulation
45. Click
the Exit
icon to close the operations
window.
window.
To finish off the machining of the ribs, you must now add an HSM operation. It is important to finish the machining of the ribs before you start machining the pockets as the ribs are very thin and start vibrating and tear off if they are not machined before you start the machining of the pockets. 46. Right 47. In
click the last operation > Add Milling Operation > 3D HSM.
the Technology list, click 3D Constant step over.
48. Click Tool 49. Select
> Select.
the same BALL NOSE MILL tool that was defined for the earlier roughing operation.
50. Click Drive boundaries. 51. Enter
the parameters as shown in the image.
52. In
the Boundary name list, click the same boundary you had defined for the previous HSR operation. The boundary name in tutorial may vary from the name you defined in your file.
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3. HSR and HSM operations 53. Click Passes. 54. Enter
image.
the parameters as shown in the
55. Click Link. 56. Set
the values as shown in the image.
57. Click 58. Set
the Ramping tab.
the values as shown in the image.
59. Click
the Ramping tab.
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60. Set
the values as shown in the image.
61. Click
the Retracts tab.
62. Select 63. Set
the Clear surface by value as 15.
64. Click 65. Set
the Minimal vertical retract button.
the Leads tab.
the values as shown in the image.
66. Click
the Save & Calculate
67. Click
the Exit
icon.
icon.
The calculated tool path should look as displayed in the image.
In the next chapter, you will define operations for roughing the pockets of this part.
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iMachining and Rest Roughing
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1. Right 2. In
click the last operation > Add Milling Operation > 3D iMachining.
the Technology list, click 3D General.
3. Click
the Define button in the Working area section.
The Working area window displays. 4. Select 5. In
the Working area check box.
the Tool on working area list, click Center.
6. Click
the Define button.
7. Select
the four boundaries as shown in the image. 8. Click 9. Click OK
window.
in the Working area
10. Click Tool
> Select.
11. Select
the BULL NOSE MILL tool and enter the parameters as shown in the image. 12. Click
the Holder check box.
13. Select HSK A 63 ER 32x80. 14. Click
.
15. Click Levels.
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4. iMachining and Rest Roughing 16. Enter
the parameters as shown in the image.
17. Click Technology.
18. Enter
the parameters as shown in the image.
19. Click Link. 20. Ensure
image.
that the parameters are as shown in the
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21. Click
the Save & Calculate
22. Click
the Exit
icon.
icon.
The calculated tool path should look as displayed in the image.
23. Right
click and Copy then Paste the iMachining operation.
24. Right
click the pasted operation > Edit.
25. Click
the Define button in the Working area section.
26. Unselect
the Working area check box.
27. Click OK. 28. Click Technology. 29. Enter
image.
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the parameters as shown in the
4. iMachining and Rest Roughing 30. Click Link. 31. Set
the Z clearance value to 0.08.
32. Click
the Save & Calculate
33. Click
the Exit
icon.
icon.
The calculated tool path should look as displayed in the image.
You must now add a rest roughing tool path to machine the material on the corners and to machine the large steps that are still remaining on the part. 34. Right 35. In
click the last iMachining operation > Add Milling Operation > 3D HSR.
the Technology list, click Contour roughing.
36. Click Tool
37. Click
> Select.
the Add Milling Tool
38. Select
icon.
BULL NOSE MILL as the tool. 25
39. Enter
the tool parameters as shown in the
40. Select
the Holder check box.
image.
41. Select HSK A 63 ER 32X80
as the holder.
42. Click 43. Click Passes. 44. Enter
the parameters as shown in the image.
45. Click
the Smoothing tab.
46. Set
the values as shown in the image.
47. Click 48. In
the Adaptive step down tab.
the Adapt Step down by list. click None.
49. Select 50. Set
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the Optimize Z level check box.
the Last levels to even value as 5.
4. iMachining and Rest Roughing 51. Click 52. Set
the Edit Passes tab.
the values as shown in the image.
53. Click Link. 54. Set
the values as shown in the image.
55. Click
56. Set
the values as shown in the image.
57. Click
58. Set
the Ramping tab.
the Strategy tab.
the values as shown in the image.
59. Click
the Retracts tab.
60. Select 61. Set
the Minimal vertical retract button.
the Clear surface by value as 2.7.
62. Click
the Leads tab.
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63. Set
the values as shown in the image.
64. Click
the Save & Calculate
65. Click
the Exit
icon.
icon.
The calculated tool path should look as displayed in the image:
In the next chapter, you will define tool paths for SWARF semi-finishing operations.
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SWARF Semi-Finishing
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1. Right
click the operation > Add Milling Operation > SWARF Machining.
2. Click Geometry. 3. In
the Strategy list, click Automatic.
4. Click the New surfaces. 5. Select
image.
icon under Swarf
the three faces as shown in the
6. Click 7. Click
the Floor surfaces check box.
8. Click the New surfaces. 9. Select
image.
icon under Floor
the nine faces as shown in the
10. Click
11. Set
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the Offset values as shown in the image.
5. SWARF Semi Finishing 12. Click Tool
> Select.
13. Select
the BULL NOSE MILL tool.
14. Enter
the parameters as shown in the
15. Click
the Holder check box.
image.
16. Select HSK A 63 ER 32x80. 17. Click
.
18. Click Levels. 19. Enter
the parameters as shown in the image.
20. Click Tool path parameters. 21. Enter
the parameters as shown in the image.
22. Click
the Corners tab.
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23. Enter
image.
the parameters as shown in the
24. Click Tool axis control. 25. Set
the Maximum angle step value as 3.
26. Select
the Minimize rotation axis changes check box. 27. Click Link. 28. In
the lists, click Use Lead-In and Use Lead-Out.
29. Click 30. Enter
next to Use Lead-In. the parameters as shown in the image.
31. Click OK.
32. Click
33. Enter
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next to Use Lead-Out.
the parameters as shown in the image.
5. SWARF Semi Finishing 34. Click
the Links tab.
35. Enter
the parameters as shown in the image.
36. Click Roughing and More. 37. Enter
the parameters as shown in the
38. Click
the Save & Calculate
39. Click
the Exit
image.
icon.
icon.
The calculated tool path should look as displayed in the image.
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40. Right
click the operation > Copy.
41. Right
click the operation > Paste.
42. Right
click the operation > Edit.
43. In
the Strategy list, click Automatic.
44. Click
the New
45. Select
image.
icon under Swarf surfaces.
the three faces as shown in the
46. Click 47. Click
the Floor surfaces check box.
48. Click the New surfaces. 49. Select
icon under Floor
the nine faces as shown in the image.
50. Click 51. Keep
all the other parameters as they are.
52. Click
the Save & Calculate
53. Click
the Exit
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icon.
icon.
5. SWARF Semi Finishing
The calculated tool path should look as displayed in the image.
54. Right
click the operation > Copy.
55. Right
click the operation > Paste.
56. Right
click the operation > Edit.
57. In
the Strategy list, click Automatic.
58. Click
the New
59. Select
image.
icon under Swarf surfaces.
the five faces as shown in the
60. Click 61. Click
the Floor surfaces check box.
62. Click the New surfaces.
icon under Floor
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63. Select
image.
the nine faces as shown in the
64. Click 65. Keep
all the other parameters as they are.
66. Click
the Save & Calculate
67. Click
the Exit
icon.
icon.
The calculated tool path should look as displayed in the image.
68. Right
click the operation > Copy.
69. Right
click the operation > Paste.
70. Right
click the operation > Edit.
71. In
the Strategy list, click Automatic.
72. Click
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the New
icon under Swarf surfaces.
5. SWARF Semi Finishing 73. Select
image.
the three faces as shown in the
74. Click 75. Click
the Floor surfaces check box.
76. Click the New surfaces. 77. Select
icon under Floor
the thirteen faces as shown in the image.
78. Click 79. Keep
all the other parameters as they are.
80. Click
the Save & Calculate
81. Click
the Exit
icon.
icon.
The calculated tool path should look as displayed in the image.
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82. Right
click the operation > Copy.
83. Right
click the operation > Paste.
84. Right
click the operation > Edit.
85. In
the Strategy list, click Automatic.
86. Click
the New
87. Select
image.
icon under Swarf surfaces.
the three faces as shown in the
88. Click 89. Click
the Floor surfaces check box.
90. Click the New surfaces. 91. Select
icon under Floor
the nine faces as shown in the image.
92. Click 93. Keep
all the other parameters as they are.
94. Click
the Save & Calculate
95. Click
the Exit
38
icon.
icon.
5. SWARF Semi Finishing 96. The
calculated tool path should look as displayed in the image.
In the next chapter, you will define tool paths for finishing operations.
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40
SWARF Finishing
6
1. Right 2. In
click the operation > Add Milling Operation > SWARF Machining.
the Strategy list, click Automatic.
3. Click
the New
icon under Swarf surfaces.
4. Select
the twelve faces as shown in the image. 5. Click 6. Click
the Floor surfaces check box.
7. Click the New Floor surfaces.
icon under
8. Select
the thirteen faces as shown in the image. 9. Click
10. Click Tool 11. Select
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> Select.
the TAPER BALL NOSE tool.
6. SWARF Finishing 12. Enter
the parameters as shown in the
13. Click
the Holder check box.
image.
14. Select HSK A 63 ER 32x80. 15. Click
.
16. Click Levels. 17. Enter
the parameters as shown in the image.
18. Click Tool path parameters. 19. Enter
the parameters as shown in the image.
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20. Click Tool axis control. 21. Set
the Maximum angle step value as 3.
22. Select
the Minimize rotation axis changes check box.
23. Click Link. 24. In
the lists, click Use Lead-In and Use Lead-Out.
25. Click 26. Enter
next to Use Lead-In. the parameters as shown in the image.
27. Click OK.
28. Click 29. Enter
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next to Use Lead-Out. the parameters as shown in the image.
6. SWARF Finishing 30. Click Roughing and More. 31. Enter
the parameters as shown in the image.
32. Click
the Save & Calculate
33. Click
the Exit
icon.
icon.
The calculated tool path should look as displayed in the image.
34. Right
click the operation > Copy.
35. Right
click the operation > Paste.
36. Right
click the operation > Edit.
37. In
the Strategy list, click Automatic.
38. Click
the New
icon under Swarf surfaces.
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39. Select
image.
the twelve faces as shown in the
40. Click 41. Click
the Floor surfaces check box.
42. Click the New surfaces. 43. Select
image.
icon under Floor
the thirteen faces as shown in the
44. Click 45. Keep
all the other parameters as they are.
46. Click
the Save & Calculate
47. Click
the Exit
icon.
icon.
The calculated tool path should look as displayed in the image.
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6. SWARF Finishing 48. Right
click the operation > Copy.
49. Right
click the operation > Paste.
50. Right
click the operation > Edit.
51. In
the Strategy list, click Automatic.
52. Click
the New
53. Select
image.
icon under Swarf surfaces.
the eight faces as shown in the
54. Click 55. Click
the Floor surfaces check box.
56. Click the New surfaces. 57. Select
icon under Floor
the nine faces as shown in the image.
58. Click 59. Keep
all the other parameters as they are.
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60. Click
the Save & Calculate
61. Click
the Exit
icon.
icon.
The calculated tool path should look as displayed in the image.
62. Right 63. In
click the operation > Add Milling Operation > Sim 5-Axis Milling.
the Technology list, click Parallel to curves.
64. Click Geometry.
65. Click
48
the New
icon under Drive surface.
6. SWARF Finishing 66. Select
the face as shown in the image.
67. Click
68. Click
the New
69. Select
icon under Edge curve.
the curve as shown in the image.
70. Click 71. In the Type of cuts.
72. In
list, click Determined by number
the Number of cuts field, enter a value of 50.
73. Click Tool 74. Add
> Select.
a TAPER BALL NOSE tool.
75. Enter
the parameters as shown in the
76. Select
the Holder check box.
image.
77. Select HSK A 63 ER 32X80.
78. Click
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79. Click Levels. 80. Enter
image.
the parameters as shown in the
81. Click Tool path parameters. 82. In
the Maximum step over field, enter a value of 0.7. 83. Click
the Sorting tab.
84. Enter
the parameters as shown in the image.
85. Click Tool axis control. 86. Ensure
that the parameters you select are same as shown in the image. 87. Click Gouge check.
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6. SWARF Finishing 88. Enter
the parameters as shown in the image.
89. Click
the New icon under Check surfaces 1.
90. Select
the eight faces as shown in the image.
91. Click 92. Click
the Save & Calculate
icon. 93. Click
the Exit
icon.
The calculated tool path should look as displayed in the image. 94. Right
click the operation > Add Milling Operation > 3D HSM.
95. In the Technology machining. 96. Click Tool
list, click Horizontol
> Select.
97. Add
a BULL NOSE MILL with the same parameters as shown in the image.
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98. Select
the Holder check box and select HSK A 63 ER 32X80 as the holder.
99. Click 100. Click Constraint boundaries. 101. Select 102. In
the Created manually option.
the list, click User-defined boundary.
103. Click
the New
104. Select
image.
icon under boundary name.
the boundary as shown in the
105. Click 106. Click Passes.
107. Enter
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the parameters as shown in the image.
6. SWARF Finishing 108. Click 109. Set
the Smoothing tab.
the values as shown in the image.
110. Click Link.
111. On
the General tab, set the values as shown.
112. Set
these values on the Ramping tab.
113. Set
these values on the Strategy tab.
114. Set
these values on the Retracts tab.
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115. Set
these values on the Leads tab.
116. Click
the Save & Calculate
117. Click
the Exit
icon.
icon.
The calculated tool path should look as displayed in the image.
Now, you will add operations for outer finishing of the SWARF part.
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6. SWARF Finishing 118. Right
click the operation > Add Milling Operation > SWARF Machining.
119. Click Geometry. 120. In
the Strategy list, click Automatic.
121. Click
the New
122. Select
image.
icon under SWARF surfaces.
all the sixteen outer faces as shown in the
123. Click 124. Click Tool
> Select.
125. Select
a BULL NOSE MILL with the parameters as shown in the image. 126. Select the Holder check box and HSK A 63 ER 32X80 as the holder.
select
127. Click
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128. Click Levels. 129. Set
the Retract distance and Entry safety distance values as 20 and Exit safety distance values as 5. 130. Click Tool path parameters. 131. Enter
the values as shown in the image.
132. Click
the Corners tab.
133. In corner.
the Inside corners list, click Sharp
134. In the Outside corners around.
list, click Roll
135. Click Tool axis control. 136. Set
the Maximum angle step value as 3.
137. Select
the Minimize rotation axis changes check box.
138. Click
the Save & Calculate
139. Click
the Exit
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icon.
icon.
6. SWARF Finishing
The calculated tool path should look as displayed in the image.
140. Right
click the operation > Copy.
141. Right
click the operation > Paste.
142. Right
click the pasted operation > Edit.
143. Click Misc. parameters. 144. In
the Custom triangulation section, enter the parameters as shown in the image. 145. Click
the Save & Calculate
146. Click
the Exit
icon.
icon.
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The calculated tool path should look as displayed in the image.
147. Right
click the operation > Copy.
148. Right
click the operation > Paste.
149. Right
click the pasted operation > Edit.
150. Click Misc. parameters. 151. Unselect
the Custom triangulation check box.
152. Click Gouge check. 153. Select
154. Click
the New
155. Select
156. Click
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the Check surfaces check box in the Avoid by relinking section..
icon under Check surfaces.
the 32 lug faces as shown in the image.
6. SWARF Finishing
157. Click
the Save & Calculate
158. Click
the Exit
icon.
icon.
The calculated tool path should look as displayed in the image.
You will now add one operation to cut off the lugs of the SWARF part. 159. Right
click the operation > Add Milling Operation > SWARF Machining.
160. Click Geometry. 161. In
the Strategy list, click Automatic.
162. Click
the New
163. Select
icon under SWARF surfaces.
the face as shown in the image.
164. Click
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165. Click Tool
> Select.
166. Select
a BULL NOSE MILL and use the same parameters as shown in the image. 167. Select the Holder check use an HSK A 63 ER 32X80.
box and
168. Click 169. Click Tool path parameters. 170. Enter
the parameters as shown in the
171. Click
the Save & Calculate
172. Click
the Exit
image.
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icon.
icon.
6. SWARF Finishing
The calculated tool path should look as displayed in the image.
Now repeat the same operation to finish the machining of the remaining lugs.
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SolidCAM Application Tutorial:
SWARF Machining
2D iMachining
2.5D Milling
)HSS (High-Speed Surface Machining
3D iMachining
Indexed Multi-Sided Machining
)HSM (High-Speed Machining
Axis Machining-5 Simultaneous
Turning & Advanced Mill-Turn
Solid Probe
www.youtube.com/SolidCAMProfessor www.youtube.com/SolidCAMiMachining
www.solidcam.com
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