solidcam2007 r11 2 advanced training course

8/12/2019 SolidCAM2007 R11 2 Advanced Training Course

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Power and Ease of Use - the winning combination

1995-2008 SolidCAM

All Rights Reserved.WWW.SOLIDCAM.COM

SolidCAM2007 R11.2

Advanced Training

Course

SolidCAM2007 R11.2The Leaders in Integrated CAM


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SolidCAM2007 R11.2

Advanced Training Course

1995-2008 SolidCAM

All Rights Reserved.


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Content

5

Contents

1. Introduction

1.1 About this course............................................................................................................................9

2. Machining Processes

2.1 Introduction and Basic concepts................................................................................................12

2.2 Machining Process denition......................................................................................................15

Exercise #1: Machining Process Table denition ..................................................................16

Exercise #2: Machining Process denition .............................................................................20

2.3 Machining Process use .................................................................................................................43

Exercise #3: Machining Process use ........................................................................................44

Exercise #4: Machining Process improvement ......................................................................53

Exercise #5: Electronic box machining ...................................................................................69

Exercise #6: Counterbore hole machining ..............................................................................70

Exercise #7 Adding MP items into Operations menu ..........................................................71

2.4 Standardization with Machining Processes ...............................................................................75

Exercise #8: Creating Default Sets ...........................................................................................76

Exercise #9: Cover Machining ..................................................................................................88

2.5 Machining Processes for automation of Milling tasks ...........................................................89

Exercise #10: Machining Process for Prole Machining......................................................90

Exercise #11: Machining Process for the Pocket Machining .............................................115

2.6 Dening Machining Process with existing Operations ........................................................116

Exercise #12: Dening 3D Milling Machining Process ......................................................117


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Document number: XXXXXX


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Introduction 1


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1. Introductio

1.1 About this course

The goal of this course is to teach you how to use advanced SolidCAM techniques to automate th

repetitive machining tasks of CNC programming. This course covers the concepts of SolidCAM

Machining Processes and is a supplement to the system documentation and online help. Once yo

have developed a good foundation in basic skills, you can refer to the online help for informatioon the less frequently used options.

Course design

This course is designed around a task-based approach to training. With the guided exercises yo

will learn the commands and options necessary to complete a machining task. The theoretic

explanations are embedded into these exercises to give an overview of the SolidCAM capabilities

This book is intended for experienced SolidCAM users. If you are not familiar with the softwar

start with the Getting Started manual and then contact your reseller for information about SolidCAMtraining classes.

Using this training book

This training book is intended to be used both in a classroom environment under the guidance o

an experienced instructor and as self-study material. It contains a number of laboratory exercise

to enable you to apply and practice the material covered in the guided exercises. The laborator

exercises do not contain step-by-step instructions.

About the CD

The CD supplied together with this book contains copies of various les used throughout thcourse. The Exercisesfolder contains the les required for guided and laboratory exercises. ThBuilt Partsfolder inside the Exercisescontains the nal manufacturing projects for each exerciseCopy the complete Exercises folder to your computer. The SolidWorks les used for the exercise

were prepared with SolidWorks2008.

WindowsXP

The screenshots in this book were made using SolidCAM2007 R11.2integrated with SolidWorks200

running on WindowsXP. If you are running on a different version of Windows, you may notic

differences in the appearance of the menus and windows. These differences do not affect th

performance of the software.


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Conventions used in this book

This book uses the following typographic conventions:

Bold Sans Serif This style is used to emphasize SolidCAM options,

commands or basic concepts. For example, click on

the Change to oppositebutton.

10. Define CoordSys Position

The mouse icon and numbered sans serif bold text

indicate the beginning of the exercise action.

ExplanationThis style combined with the lamp icon is used for

the SolidCAM functionality explanations embedded

into the guided exercises. The lamp icon is also used

to emphasize notes.


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Machining

Processes 2


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2.1 Introduction and Basic concepts

SolidCAM enables you to automate repetitive tasks in CNC-Programming using the Machining

Processfeature. Using this feature, you can store the typical technological sequences and share

them between different machining projects. Once prepared, a Machining Process can be used for

the machining in similar cases.

Machining Process (MP) is the structure of fully parametrically-dened Operation Templates. AnOperation Templateis a parametric template of a single operation that is used within the Machining

Process. There can be one or several Operation Templates in a Machining Process. Such Operation

Template unambiguously denes the technology manner used in the Operation and enables you tovariables and expressions to describe the numerical parameters used in the Operation.

Once dened, such Machining Process is stored in the Machining Process Tableand can be used

for the machining in subsequent identical or similar situations.

When you use a Machining Process, the Operation Templates are converted into SolidCAM

Operations by resolving all the expressions and assigning the values to variables used in the MP.

MachiningProcess

1

MachiningProcess

2

MachiningProcess

3

MachiningProcess

N

MachiningProcessesTable


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2. Machining Processe

2.1.1 Parameterization of Operations

The major task in the Machining Process denition is understanding the parameterization schemthat has to be implemented in the Operation Templates. The optimal parameterization schem

chosen for the Machining Process enables you to automate the denition of some parameters ansignicantly improve the usability of the MP.

Consider a typical machining case: the machining of a threaded countersink hole. To machin

such a hole using conventional SolidCAM methods, you have to dene three SolidCAM DrillinOperations. These Operations are using a common geometry and performing center drilling, drillin

and threading.

The rst Operation performs the preliminary center drilling for the further Drilling Operation. Ithis Operation, the countersink chamfer is also machined. Second Operation performs the drillin

of the hole till the specied depth; the hole diameter is determined by the thread standard. Ththird Operation performs the threading using a tap tool.

To automate such a repetitive task, SolidCAM enables you to dene a Machining Process thaconsists of three Operation Templates using the following parameters of the hole.

D_chamfer parameter denesthe upper diameter of the

countersink chamfer;

D_thread parameter denesthe thread diameter;

A_Chamfer parameter denesthe chamfer angle;

D_chamfer

A_chamfer

D_thread

H_thread

H_ho


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H_thread parameter denes the depth of the thread;

H_hole parameter denes the depth of the hole;

Pitchparameter can be dened for metric holes.

In the rst Operation, the chamfer diameter and angle are used in order to dene the depth of the

center drilling. The depth of the center drilling is dened by the following expression:

Center_drilling_depth = (D_Chamfer * cot(A_Chamfer/2))/2

In the second Operation, the drilling diameter is dened according to the hole standard. For metricholes, the drilling diameter is determined as the difference between thread diameter and pitch:

D_drilling = D_thread - Pitch.

For example, for a hole of M5x0.8 the drill diameter is 4.2 mm. The drilling tool diameter is equal

to the drilling diameter.

The technology of pecking can be utilized for the drilling. In this case, the pecking depth can be

dened relative to the drilling diameter with the following expression:

P_depth = D_drilling/4.

The third Operation performs the thread machining with the tap tool chosen according to the

thread diameter. The machining is performed at whole thread depth.

Such parameterization scheme enables you to dene the generic machining process suitable for themachining all the countersink threaded holes with the metric thread. When these parameters are

inserted into a CAM-Part, they can be customized to machine a specic hole.

D_Chamfer

Center_drilling_depth

A_Chamfer


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2.2 Machining Process definition

The workow of the Machining Process denition can be divided into three major stages.

The Machining Process Table definition

At this stage, you have to create a Machining Process Table where all the further create

Machining Processes will be stored.

The Machining Process creation

At this stage, you have to create a new Machining Process inside the MP Table.

The Machining Process definition

At this stage, you have to dene the Operation Templates, variables and expressionthat are used in the Machining Process.

Creating MachiningProcess Table Creating MachiningProcessDefining MachiningProcess components


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Exercise #1: Machining Process Table definition

The rst stage of the Machining Process denition is the creation of the Machining Process Tablewhere all the further Machining Processes will be stored.

In this exercise, you have to create a Machining Process Table and dene its basic parameters.

1. Open the CAM-Part

Start SolidCAM and open the Exercise1.przCAM-Part. This CAM-Part contains the

model of a mounting base.

The CAM-Part does not contain any Operations, tools and geometries. The model to

be machined in this CAM-Part contains a number of threaded holes of M3; M6 andM10.

2. Create Machining Process Table

In the SolidCAM Manager tree, right-click on the

Machining Process header and choose Milling

from the Newsubmenu. This command enables

you to start the denition of a new MachiningProcess Table that will contain the Machining

Processes for Milling.


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The New Machining Process Table dialog box is displayed.

This dialog box enables you to set the name of the

Machining Process Table and dene the CNC machinesfor which the Machining Process is applicable.

Set the Trainingname for the Machining Process.

3. Choose the MAC file

Click on the Add MAC file button. The Add MAC file(s)

dialog box is displayed.

The Add MAC file(s) dialog box enables

you to choose the MAC les of CNC

controllers. Since not all machines supportall of the options in SolidCAM, you must

choose the MAC le (or a number ofsimilar MAC les) that you will be using

with this Machining Process Table. This

will assure that only the options supported

by your machine will be used.

Click on the Addbutton to choose the appropriate MAC

le. The Choose MAC files dialog box will be displayed.Choose the Fanuc CNC controller from the list and

conrm your choice with the OKbutton.

The FanucMAC le is chosen for the Machining ProcessTable and displayed in the Add MAC file(s)dialog box.

Click on the Add Similarbutton. SolidCAM determines

all similar MAC les and automatically adds them into thelist. The criterion of similarity is the support of the same

SolidCAM functionality used in the primary MAC le.

In this case, the Fanuc_3D MAC le will be chosen.


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Conrm the Add MAC file(s) dialog box with the OKbutton. The New Machining Process dialog box will be

displayed again.

4. Confirm the Machining Process Table creation

Conrm the MP Table creation with the OKbutton.

The Training MP Table is created. It can be used for the

Fanuc and Fanuc_3D CNC controllers.

The Machining Process Table Manager dialog box is

displayed.

Machining Process Table Manager

This dialog box enables you to manage the Machining Processes inside the

MP table. It contains the following elds:

Machining Process list

This section contains the list of all Machining Processes from the

current table. Using the right-click menu available on the list items,

you can manage your Machining Processes in the MP Table.


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MP Picture

This option enables you to attach a picture to your MP.

Type

For easier identication and classication of Machining Processeyou can dene and use your own MP types.

Description

In this eld, you can enter a text describing the Machining Processe

Click on the Savebutton to save the newly created Machining Process Table and clos

the Machining Process Table Manager dialog box with the Exit button.

The name of the Machining Process Table (Training)appears in parentheses in the Machining Processheader

in the SolidCAM Manager tree.


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Exercise #2: Machining Process definition

In this exercise, the new Machining Process will be denedin the TrainingMP Table created in the Exercise #1. This

Machining Process is intended to perform the machining of

the threaded countersink hole (see topic 2.1.1).

1. Open the Machining Process Table

Right-click on the Machining Processheader in the SolidCAM Manager tree and choose

Currentfrom the menu.

The Machining Process Table Manager dialog box is displayed with the TrainingMP

Table loaded.

Each newly created MP Table contains one Machining Process named

New MachProcess. This Machining Process is created automatically during

the Machining Process Table denition. This Machining Process does not

contain Operation Templates. At the further steps, it will be customized byadding the Operation Templates, variables, expressions, etc.


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2. Define the Machining Process name

Right-click on the New MachProcess

entry in the Machining Process list

section of the Machining Process Table

Manager dialog box and choose Rename

from the menu. This command enablesyou to assign a new name to the chosen

Machining Process. Type a new name:

Countersink Threaded holeand conrmthe renaming by pressing the Enter key.

3. Edit Machining Process

Double-click on the Countersink Threaded hole Machining Process to start the M

denition.

To edit a Machining Process, you can also use the Editcommand from th

right-click menu available on the Machining Process entry in the list.

The Machining Process Define Manager dialog box is displayed. This dialog boenables you to dene all components of the Machining Process.


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Machining Process Define Manager overview

The Machining Process Define Manager dialog box enables you

to dene and manage all components of the Machining Process:Operation Templates, variables and expressions.

The Operation Templatessection displays the list of all OperationTemplates used in the current Machining Process. This section

enables you to add and manage the Operation Templates.

The Used parameters section displays the list of all variables andtheir expressions used in the Operation Templates. This section

enables you to assign a new expression to a variable or edit an

existing expression.

The Unused parameterssection displays the list of variables andtheir expressions not used in the Operation Templates. This section

enables you to assign a new expression to a variable or edit an

existing expression.

The Add new parametersection enables you to dene new variablesand set their types.


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4. Create an Operation Template

Right-click on the Operations header in the Operation

Templates section and choose Drillfrom the Addsubmenu.

This command enables you to create a new Drilling

Operation Template intended to perform a center drilling

operation.

The Drilling Operationtemplate dialog box is displayed.

The template dialog box differs from the regular Operation dialog box in such wa

that in the template dialog box you dene all numeric parameters as variables o

expressions. Several parameters, such as Clearance level, Safety distance and Uppelevel are dened as variables by default.

The process of the Operation Template denition is similar to the process of conventional SolidCAM Operation denition. It consists of three major stagegeometry denition, tool denition and technology parameters denition.

5. Define the Geometry

At this stage, you have to dene a variable for the machining geometry. During thMachining Process insertion, you have either to dene a new geometry or to choose aexisting one and assign it to the variable.

In the Geometry section, enter the variable name (for example, Geometry) in theditbox.


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When you enter a variable name for some parameter in the Operation

Template dialog box, SolidCAM creates a new variable and assigns it

to this parameter. If a variable with the specied name already exists,SolidCAM assigns it to the parameter. In this manner, variables can be

shared between Operation Templates.

For geometries, SolidCAM creates variables of the type suitable forthe current Operation Template. The following types of geometric

variables are supported by SolidCAM:

Profile Geometry variables available for Profile and Pocket

Operation Templates;

Slot Geometry variables available for Slot Operation

Templates;

Limit Geometry variables available for the Working Area

denition in 3D Milling Operation Templates;

3D Model Geometryvariables available for 3D Milling Operation

Templates;

Section Geometryvariables available for Sectiongeometry in

Slot Operation Templates;

Drill Geometry variables available for Drilling Operation

Templates.

The Geometry variable of Drill type is created. This variable will be used for the

geometry denition in all Operation Templates of the current Machining Process.


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6. Define the tool

Click on the Selectbutton in the Tool informationsection

to start the tool denition. The Choosing tool for operationdialog box is displayed.

This dialog box enables you to dene a new tool for the template, just as the similadialog box that is displayed when you dene a tool for a regular Operation.

Click on the Addbutton to add a new tool. According to the type of the Operatio

Template, a new drilling tool is added.

Now you have to customize its parameters to dene them parametrically.

SolidCAM enables you to dene a new variable by typing its name in the relevaneditbox. Enter Center_drill_tool_diameter in the Diameter editbox of the Too

parameters section.


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When you move to the next editbox, a new variable is created and assigned to the

relevant parameters. Now the diameter of a drilling tool used for the Operation is

dened as the Center_drill_tool_diametervariable. The expression for this variable willbe assigned later.

Enter the names for variables according to the following rules:

Use a letter as the rst character;

Only capital and lowercase English letters, numbers and underscoresymbols (_) are acceptable;

Names cannot exceed 255 characters in length.

Give meaningful names to facilitate the navigation through variables

and make the Machining Process denition process easier and avoid

errors.

In the current exercise the Center_drill_tool_ prex is used for all the parameters ofthe current tool as identier. Dene the Center_drill_tool_anglevariable and assign itto the Angleeditbox.

Since the editboxes cannot display

long variable names, you can use the

F2key or the Edit command available

in the parametric menu to open the

Edit dialog box. This dialog box fully

displays long variable names.

Conrm the denition with the Selectbutton. The Operation Templatedialog box is

displayed again.

In the Tool informationsection, select the Center drillcheck box.


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7. Define the center drilling depth

Generally, the depth of the center drilling operation can be dened in SolidCAMin two ways: directly by specifying theDrill Depth value or by using the Depth typ

options. The current center drilling operation is intended to perform both the cente

drilling and the chamfer machining. In this case, the center drilling depth is determine

according to the chamfer diameter. In the rst way, you have to assign to the Dridepth parameter an expression that will calculate the depth according to the chamfe

diameter. In the second way, you have to set the Drill depth to 0 and assign the chamfe

diameter to the Diameter value parameter. In this case, the depth will be calculate

automatically. This way is used for the Operation Template denition.

Make sure that in the Milling levels section the Drill depthvalue is set to 0.

Choose theDiameter value option in the Depth type section

and enter the Chamfer_Diametername in the editbox.

8. Confirm the Operation Template definition

Click on the Savebutton to save the dened Operation Template. Click on the Ex

button to close the Operation Templatedialog box.

The Machining Process Define Manager dialog box is displayed again. Note that th

variables dened during the Operation Template denition are displayed in the tabl

of theUsed parameters

section. TheExpression

column is empty, which means thathe expressions for these variables are not dened yet.


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Used Parameters Table

This area shows the table of parameters that were used in the

Operation Templates with the actual Default Set.

This table contains the following columns:

Parameter - this column shows the parameter name. You canchange the name of the parameter, and then it will be updated in

all Operation Templates that use this parameter.

Expression - this column shows the parameter denition asan expression or a value. To edit this parametric eld, use the

parametric eld menu available by clicking on the button.

Result value- this column shows the result value returned by theparameter.

G - this column shows the status of the

parameter. If the status is Global- the Gletter

appears. In this case, the expression of this

value will be the same in all Default Sets.

By right-clicking on this eld, you can change the status of theparameter.

R/O- this column shows the access status of theparameter. If the status is Read-only, the R/O

letters are shown. In this case, the parameter

denition cannot be changed during MachiningProcess insertion.

By right-clicking on this eld, you can change the read-only statusof the parameter.

Description- this column shows your own text description of theparameter. To edit the eld, use the context menu available by

clicking on the button.


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9. Expression definition

In this step, you have to dene the expressions for three variables currently used inthe rst Operation Template:Center_drill_tool_diameter, Center_drill_tool_angleanChamfer_diameter.

SolidCAM enables you to dene expressions either with a formula using the differenvariables or with a value.

In the Expressioncell of the Center_drill_tool_anglevariable, enter the value of 90

This value will be used for the variable denition as default, it can be changed durinthe Machining Process use.

Leave the Expressioncell of the Chamfer_diametervariable empty. This variable wi

be dened during the Machining Process use according to the real hole dimensions.

The diameter of the tool used for the center drilling and chamfer machining shoulbe greater than the chamfer diameter. So, the Center_drill_tool_diameter variabl

can be dened relative to the Chamfer_diametervariable according to the followinexpression: int(Chamfer_diameter+2).

This expression increases the chamfer diameter at2and then returns the integer par

of the resulted value using the intfunction.


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You can use the following symbols in expressions:

Addition (+)

Subtraction (-)

Multiplication (*)

Division (/)

Parentheses are acceptable.

When multiplication and division occur together in an expression,

each operation is evaluated as it occurs from left to right. When addition

and subtraction occur together in an expression, each operation is

evaluated in the order of appearance from left to right. Parentheses

can be used to override the order of precedence and force some parts

of an expression to be evaluated before others. Operations within

parentheses are always performed before those outside. Within the

parentheses, however, operator precedence is maintained.

In addition to the intfunction used in the expression, SolidCAM enables you to use the

set of standard mathematical functions such as sine, cosine, etc. in your expressions.

SolidCAM standard functions

sqrt()

Returns a value specifying the square root of a number.

sin()

Returns a value specifying the sine of an angle.

cos()

Returns a value specifying the cosine of an angle.

tan()

Returns a value specifying the tangent of an angle.


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abs()

Returns a value of the same type that is passed to it specifying th

absolute value of a number. The absolute value of a number is i

unsigned magnitude. For example, abs(-1)and abs(1)both return 1.

acos()

Returns a value specifying the arccosine of a number.

asin()

Returns a value specifying the arcsine of a number.

atan()

Returns a value specifying the arctangent of a number.

atan2(,)

Returns a value specifying the arctangent of quotient rst and seconarguments.

dist(,) / ang(,)

Returns polar coordinates: distance and angle

(in radians) of the point dened in Cartesiancoordinates.

pow(,)

Returns a value of the rst argument raised to the power of thsecond argument. For example: pow(2,3)returns 8.

log10()

Returns a value specifying the base-10 logarithms of a number.

ln()

Returns a value specifying the natural logarithm of a number.

sum3( , , )

Returns the sum value of three arguments.

(X,Y)

dist(X,Y)

0

ang(X,Y


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int()

Returns the integer portion of a number.

rad()

Converts degrees to radians.

deg()

Converts radians to degrees.

During the expression denition, you can type all the expression or use the capabilitiesof the parametric menu available in each Expression cell.

The User-defined parameters command

in this menu enables you to insert one

of the user-dened variables dened in

the current Machining Process into theexpression. The User-defined parameters

dialog box is displayed with the list of

all the variables you have dened inthe Machining Process (in this exercise,the dialog box contains three variables:

Center_drill_tool_diameter, Center_drill_

tool_angleand Chamfer_diameter). Whenyou click on a variable in this list, it is

inserted into the current expression.

The User-defined parameters dialog box is also available by pressing

the F5 key.

The Part parameters command enables you to insert one of the Part

parameters (a set of the standard built-in variables) into the currentexpression. All these variables get their values from the SolidCAM

CAM-Part when you insert the Machining Process.


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The following Part parameters are available in SolidCAM:

clearance_plane- the Z-value of the Clearance level;

safety- the Z-value of the Safety distance;

tool_start_plane- the Z-value of the Tool Start level;

work_upper_plane- the Z-value of the CAM-Part Upper level;

work_lower_plane- the Z-value of the CAM-Part Lower level;

zero_plane- the Z-value of the Zero level.

When the Part parameters command is

chosen, the Part parameters dialog box

is displayed with the list of all the Part

parameters. When you click on a variablein this list, it is inserted into the current

expression.

The Part parameters dialog box is also

available with the F6 key.

The Functions command displays the

Functionsdialog box that contains a list

of all the available SolidCAM functions

described earlier. When some function is

picked in this list, it is inserted into the

current expression.

The Functions dialog box is also available

with the F8 key.

The Edit-View command displays the Edit-View dialog box tha

displays long expressions and enables you to edit them. The Edit-View

dialog box is also available with the F2 key.

At this stage, the rst Operation Template intended to perform the center drilling idened. Next, you have to dene an additional Operation Template for the drilling.


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10. Create an Operation Template

In the Operation Templatessection, right-click on the

last Operation Template header and choose Drillfrom

the Add submenu.

New Operation Template is created and its dialog boxis displayed.

11. Define the geometry

In the Geometrysection of the Operation Template dialog box, choose User-defined

parametersfrom the parametric menu.

The User-defined parametersdialog box is displayed. This dialog box displays the list of

all geometric variables used in the current Machining Process. Since all the geometries

used in the sequence of Operations for machining of the countersink threaded holes

machining are the same, choose Geometryfrom the list.

12. Define the tool

In the Tool informationsection, click on the Selectbutton to start the denition of thetool for drilling.


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The Choosing tool for operationdialog box is displayed. This dialog box displays th

tool added in the previous Operation Template.

Click on the Addbutton to add a new tool into the Machining Process tool library an

start its denition.

Assign the Drill_tool_diametervariable to the Diameterparameter.

Assign the Drill_tool_anglevariable to the Angleparameter.

Conrm the tool denition with the Select button. The Operation Templatedialog bois displayed again.


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13. Define the drilling depth

In the Milling levels section, assign the Drill_depth variable to the Drill depth

parameter.

14. Define the drill cycle type

The current Operation Template utilizes the pecking technology of drilling. To choose

this technology, click on the Drill cycle type button.

The Drill cycle dialog box is displayed. Click on the Peck

icon to choose the pecking technology for the Operation

Template. The Operation Template dialog box is displayed

again.

Click on the Databutton in the Drill cyclesection to denethe Pecking parameters. The Drill options dialog box is

displayed.

Assign the Peck_stepdown

variable to the Step down

parameter.

Conrm the dialog box with the OK button.


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15. Confirm the Operation Template definition

Click on the Savebutton to save the Operation Template. Click on the Exitbutton t

close the Operation Template dialog box.

The Machining Process Define Manager dialog box is displayed. Note that new variable

dened during the Operation Template denition are added into theUsed parametertable.

At the next stage, you have to dene the expressions for these variables.

16. Define the expressions

Leave the Expressioncell for the Drill_depthvariable empty. The depth of the drillin

is different in each case and cannot be dened in the Machining Process. It will bdened separately each time when the Machining Process is used.

In the Expressioncell of the Drill_tool_angle variable, enter the value of 118. Thvalue will be used as default and can be changed during the Machining Process use.


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In order to make the Machining Process easier and productive, limit the scope of the

Machining Process to the machining of metric holes only. Such limitation enables you

to dene the drilling tool diameter with an expression relative to the thread diameterand pitch.

In the Expression cell of the Drill_tool_diameter variable, enter the expression:

Thread_diameter - Pitch.

Since this expression contains the variables Thread_diameter and Pitchthat were not

used before, SolidCAM automatically creates them and displays in the Used parameters

table.

The values of both of these parameters will be dened during the Machining Processuse. The Thread_diameter parameter will be also used in the further threading Operation

Template.

Now you have to dene the expression for the pecking step down.In the Peck_stepdown variable cell, enter the following expression:

Drill_tool_diameter/4. The pecking step down will be a quarter of the drillingtool diameter.

At this stage, the denition of the Operation Template is nished. Next, you have todene the last Operation Template intended to perform the threading.


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17. Create a new Operation Template

In the Operation Templates section, right-click on the

last Operation Template and choose Drill from the Add

submenu.

A new Operation Template is created and the OperationTemplatedialog box is displayed.

18. Define the geometry

In the same manner as explained in the Step #11of this exercise, choose the Geometr

variable for the Operation Template.

19. Define the tool

In the Tool information section of the Operation Template dialog box, click on th

Selectbutton to start a new tool denition.

The Choosing tool for operationdialog box is displayed. In

this dialog box, click on theAdd button to add a new tool.

The new tool is created and its parameters are displayed in

the dialog box.

Since this Operation Template is intended to perform the

thread machining, in the User tool type editbox, choose

the Tap tool type.

Assign the following variables to the tool parameters:

Assign the Tap_tool_diametervariable to the Thread diameterparameter

Assign the Tap_tool_tip_diameter variable to the Tip diameterparameter

Assign the Tap_tool_chamfer_length variable to the Chamfer lengtparameter,

Assign the Pitch variable to the Pitch parameter. Note that the Pitc

parameter was previously used for the drilling tool diameter denition.


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When the tap tool is dened, click on the Selectbutton to conrm the denition.

20. Define the threading depth

In the Milling levels section, assign the Thread_depth variable to the Drill depth

parameter.

21. Save the Operation Template

Click on the Savebutton to save the Operation Template. Click on the Exitbutton to

close the Operation Templatedialog box.

The Machining Process Define Manager is displayed. Note that new variables denedduring the Operation Template denition are added into theUsed parameters table.


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22. Define the expressions

At this stage, you have to enter the expressions for the variables that dene the threamachining operation.

Since the tap tool diameter is equal to the thread diameter, enter Thread_diameter a

the expression for the Tap_tool_diametervariable.

To dene the tip diameter of the tap tool relative to the tap tool diameter, enter th

following expression in the Expression cell of the Tap_tool_tip_diameter variabl0.7 * Tap_tool_diameter.

To dene the chamfer length of the tap tool relative to the tap tool diameter, enter thfollowing expression in the Expressioncell of the Tap_tool_chamfer_length variabl

0.3 * Tap_tool_diameter.

The expression for the Thread_depth variable is not assigned during the Machinin

Process denition, it will be dened during the MP use.

At this stage, all the variables, expressions and Operation Templates for the countersinthreaded hole machining are dened.

23. Save the Machining Process

In the Machining Process Define Manager dialog box, click on the Save & Exitbutto

to save the dened Machining Process and close the dialog box.


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2.3 Machining Process use

You can use the dened Machining Process by inserting it into a CAM-Part. During the insertionSolidCAM transforms each Operation Template into a single Operation.

All the variables used in Operation Templates receive their values. These values are used for th

Operations parameters denition.

MachiningProcess

CAM-Part

Operation

Templates

Variables Parameter values

Operations

Insertion


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Exercise #3: Machining Process use

This exercise illustrates the use of the Machining

Process dened in Exercise #2for the machiningof several countersink threaded holes.

The Exercise #1 CAM-Part is used for the

exercise.


Load the Exercise #1CAM-Part.


When the CAM-Part is loaded, make sure that the TrainingMachining Process name

appears in the parentheses in the Machining Process header.

If the Machining Process name is absent, load the table using the Open command

available in the right-click menu on the Machining Processheader.

Now SolidCAM is ready to apply the Machining Process from the loaded MP Table to

machine the current CAM-Part.

3. Add Machining Process

In SolidCAM Manager, right-click on the

Operations header. Then click Add Machining

Process, From MP Table.


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The Machining Process Table Managerdialog box is displayed. This dialog box enable

you to choose the Machining Process you want to insert into the CAM-Part.

Choose the Countersink Threaded hole Machining Process and click on the Pic

button to continue.

The Countersink Threaded holeMachining Process is loaded and displayed in th

Machining Process Insert Managerdialog box.


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Machining Process Insert Manager

This dialog box enables you to prepare a Machining Process to be

inserted into the CAM-Part and then to insert it.

TheDefault Sets

tab enables you to choose the appropriate DefaultSet of expressions/values. For more information, see Exercise #8.

The Operation Templates tab displays all the Operation Templates

used in the Machining Process and enables you to display the data

contained in Operation Templates.

The Parameters Table displays all variables, expressions and values

used in the Machining Process. With this table, SolidCAM enables

you to assign a new value/expression for a variable.

Switch to the Operation Templates tab to see all the Operation Templates of the

Machining Process.

You have to dene the values for the variables that were not dened during theMachining Process denition. This stage is obligatory in each Machining Processdenition.


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During the Machining Process denition, the Geometryvariable was dened and usefor geometry in all Operation Templates. Now you have to assign the value for thi

variable, i.e. to dene a geometry on the real model to be used in the Operations.

In the parameters table, click on the button in the Expression cell of the Geometrvariable. The parametric menu is displayed.

The parametric menu available for the geometry variables enables you t

perform the following operations:

Select Geometry

This command displays the Select

Geometry dialog box that contains

the list of geometries of suitable type

available for the current CAM-Part. This

dialog box enables you to choose the

appropriate geometry name from the list.

Thisdialog box can also be displayed by

pressing the F5 key.


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Define Geometry

This command enables you to dene a new Geometry of theappropriate type using standard SolidCAM tools. For example, to

dene the geometry of the Drill type, the XY Drill Geometry Selectiondialog box is used. Thisdialog box can also be displayed by pressing

the F6key.

Define Geometry Around 4th axis

This command enables you to dene a new Geometry using theAround 4th Axis Drill Geometry Selection dialog box. This command

is available only for the geometric variables of the Drilltype. It is also

available by pressing the F8 key.

Show

This command enables you to display the chosen geometry. This

command is also available with the F7 key.

Edit-View

This command enables you to display the Edit-View dialog box that

shows long names of geometries. This command is also available with

the F2 key.

Choose the Define Geometry command from the parametric menu available in theExpressioncell of the Geometryvariable to dene the Drill geometry.

The XY Drill Geometry Selection dialog box is

displayed. Using this dialog box, select the center

points of four countersink threaded holes of

M10x1located at the corner pads of the model.


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5. Define the variables

At this stage, you have to assign the values to the basic variables used in th

Machining Process, such as: Thread_diameter, Pitch, Thread_depth, Drill_depth an

Chamfer_diameter. These parameters are used in the Machining Process for th

denition of other parameters; their values were not dened during the Machinin

Process denition.

Since the current hole is metric threaded hole of M10x1, enter the value of 10in th

Expressioncell of the Thread_diametervariable. In the Expressioncell of the Pitc

variable, type the value of 1.

In the Expressioncell of the Chamfer_diametervariable, set the value of 11.

The chamfer value can be measured on the solid model using the Measur

tool, located at the Evaluatetab of the Command Manager.

Dene the drilling depth. In the Expressioncell of the Drill_depth variable, set thvalue of 23.

Dene the threading depth. In the Expressioncell of the Thread_depthvariable, sethe value of 20.

Now all the variables are dened.

During the variables denition,

SolidCAM immediatelycalculated all the expressions

used in machining Process.

All the calculated values are

assigned to related variables.

For example, when you denedthe Thread_diameter and Pitch

values, SolidCAM calculated the

value (9) of Drill_tool_diameter

variable.

At this stage, the Machining

Process is ready to be inserted

into CAM-Part.


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6. Insert the Machining Process

Click on the Insertbutton in the Machining Process Insert Managerdialog box.

The Machining Process is inserted into the CAM-Part. During the insertion, the

Operation Templates are converted into SolidCAM Operations with the parameter

values calculated in expressions.

As the result, three operations are created in the SolidCAM Managertree.

Generally, during the Machining Process insertion, SolidCAM performs the

tool search according to the tool parameters dened in Operation Templates.The tool search is rst performed in the Part Tool Table. If the tool isfound, it is being chosen for use. If the tool is not found in the Part Tool

Table, SolidCAM performs an additional search in the Current Tool Library,

if it exists. If the tool is found in the Current Tool Library, it is copied into

the Part Tool Table and being chosen for use. If the tool is not found in the

Current Tool Library, a new tool with the dened parameters is created inthe Part Tool Table.

In this exercise, the Machining Process was inserted into the empty CAM-Part with no

tools in the Part Tool Table. The Current Tool Library is not dened. In this case, all the

tools were added and dened according the data specied in Operation Templates.


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7. Simulate the operations

In theMachining Process Insert Managerdialog box, click on the Simulatebutton t

simulate the operations added during the Machining Process insertion.

8. Machine holes M6x1

In the same manner as explained in steps

#4#5, dene the geometry and customize thevariables to machine four holes M6x1. During the

variables denition, assign the value of 6.4 to the

Chamfer_diametervariable. The threading depth

is 12 mm; the drilling depth is 15 mm.

Insert the Machining Process into the CAM-Part

and simulate the Operations.

During the simulation, note the that in all Operations inserted from the MP, th

machining starts at the Upper level dened in the CAM-Part. This happens becausthe Part variable work_upper_plane was used for the Upper level denition in aOperation Templates of the Machining Process. Such behavior was acceptable for th

M10x1holes machining, because these holes are located at the top face of the mod

and the CAM-Part Upper level was dened on the same face. But for machining of thM6x1holes, such behavior is not acceptable, because these holes are located below th

CAM-Part Upper level. As a result, the machining is performed above the model face

This problem should be xed.


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The Machining Process denition can also be revised by changing the method ofvariable denition. Currently, all the variables that should be dened during theMachining Process insertion were dened by typing the values. Such method isinconvenient and may bring mistakes in denition. During the revision, these variablesshould be updated, so that you can dene the values directly on the solid model.

Close the Machining Process Insert Managerdialog box with the Exitbutton.

Close the Machining Process Table Managerdialog box with the Exitbutton.


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Exercise #4: Machining Process improvement

In this exercise, two major problems mentioned in the previous exercise will be xed to make thcreated Machining Process more applicable and convenient to use.

The Exercise #4 CAM-Part is used for theexercise. This exercise is an exact copy of the

Exercise #3 before the Machining Process has

been applied.


Load the Exercise #4CAM-Part.


When the CAM-Part is loaded, make sure that the TrainingMachining Process nam

appears in the parentheses in the Machining Processheader.

If the Machining Process name is absent, you have to load it using the Opencomman

available in the right-click menu on the Machining Process header.

Now SolidCAM is ready to apply the Machining Process from the loaded MP Table t

machine the current CAM-Part.

3. Open the Machining Process

Right-click on the Machining Processheader in SolidCAM Manager and choose Curren

from the menu. TheMachining Process TableManager dialog box is displayed with th

TrainingMachining Process opened. This dialog box can also be launched by double

clicking on the Machining Process header in SolidCAM Manager.

Right-click on the Countersink Threaded holeMachining Process to start the revision

The Machining Process Define Manager dialog box is displayed with the Machinin

Process data loaded. The Machining Process Define Managerdialog box can be als

launched by double-clicking on the Machining Process name in the Machining Proces

TableManager dialog box.


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4. Define the Upper Level

At this step, you have to dene the variable that enables you to dene the OperationTemplate Upper level. The Upper level variable should be dened in such a way, so thatits value can be specied by typing a number in the dialog box or by picking an entityon the solid model.

In the Add new parameter section of the Machining Process Define Managerdialog

box, choose the Z-valuetype for the new variable. The variables of this type can be

dened either by typing a value or by clicking on the solid model.

Variable types

SolidCAM supports the following types for variables:

Z

Z-Valuevariables enable you to store the Z-coordinates. Thevalue of a variable of this type can be dened by pickingentities on the solid model; the Z-coordinate of the pickedposition is used as the variable value.

Distance Valuevariables enable you to store the distance. The

distance can be dened by picking two positions on the solidmodel.

Stringvariables are used to store the strings of symbols.

Float variables are used to store the positive and negative

oating point numbers.

Integervariables are used to store the positive and negative

whole numbers.

Tool Number variables are used to store the positive whole

numbers used for the tool number denition.

Diameter variables enables you to store the diameters. The

diameter value can be dened by picking a circular edge onthe model.


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Enter the Upper_levelname for the variable and click on

the Add button.

The new variable is added. Since this variable has not been

used yet, it appears in the Unused parameters table.

In the Operation Templates tab, right-click on the rstOperation Template and choose Edit from the menu.

The Operation Template dialog box is displayed. This

dialog box enables you to edit the Operation Template

denition.

In the Milling levelssection, delete the work_upper_planevariable from the Upper level editbox and substitute it

with the Upper_level variable name. Now this variable

will be used for the Upper level denition for thisOperation Template.

Click on the Save button to save the updated Operation

Template and then click on the Exit button to close the

Operation Template dialog box.

The Machining Process Define Manager dialog box is displayed. Note that th

Upper_levelvariable is moved to the Used parameterstable, because now it participate

in Operation Templates.

In the same manner, substitute the variables for Upper level in the rest of Operatio

Templates.


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5. Define the Drill depth

At this stage, you have to obtain the possibility to dene the Drill depth variable bypicking entities directly on the solid model.

Drill depthis a scalar value calculated as the difference of the Z-coordinatesof upper and lower levels of a hole. This parameter cannot be deneddirectly on the solid model. Instead, Upper and Lower levels should be

picked on the model and the Drill depthwill be calculated accordingly.

In the same manner as explained in the previous step, add a new variable of the Z-Value

type and name it Lower_level.

In the Expression cell of the Drill_depth variable, type the following expression:

Upper_level - Lower_Level

When both the Upper level and the Lower levelvariables have been assigned values

picked on the model, the Drill depth is automatically calculated and used in the

Operation Template.

6. Define the Chamfer diameter

In the same manner as explained in previous step, dene a new variable of the Diametertype named Chamfer_diameter_from_model. It enables you to dene the value byclicking on the model.

In the rst Operation Template (center drilling), substitute the existing

Chamfer_diametervariable with the new one.

Note, that the Chamfer_diametervariable was not moved to the Unused parameterstable. It is still used in the expression of the Center_drill_tool_diametervariable.

In the Expression cell of the Center_drill_tool_diameter variable, substitute

the Chamfer_diameter variable in the expression with the Chamfer_

diameter_from_model variable. The updated expression will be as follows:

int(Chamfer_diameter_from_model+2).


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When the expression is updated, the Chamfer_diametervalue is moved to theUnuse

parameterstable, which means that this variable does not participate in any expressio

and in any Operation Template.

Select this variable in the table and click on the Deletebutton to remove this variable

The conrmation message box is displayed.

Conrm it with the Yes button.

7. Thread diameter and Thread Depth

The cosmetic thread feature of SolidWorks does not enable you to dene the Threadiameter and Thread depth by clicking on model. Therefore, these variables need n

revision.


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8. Enter the description for variables

SolidCAM enables you to add a text description for variables for easier identicationand use of variables.

In the Descriptioncell of the Geometryvariable, enter the following text: Define the

Geometry. During the Machining Process insertion, this text can be displayed insteadof the variable name to facilitate the understanding of what each variable means.

For the Pitchvariable description, enter the following text: Define the Pitch.

For the Upper_levelvariable description, enter the following text: Pick Upper Level.

For the Lower_levelvariable description, enter the following text: Pick Lower Level.

For the Thread_depthvariable description, enter the following text: Define the Thread

Depth.

For the Chamfer_diameter_from_modelvariable description, enter the following text:

Pick the Chamfer Diameter.

For the Thread_diameter variable description, enter the following text: Define the

Thread Diameter.


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9. Save the Machining Process

At this stage, the revision of the Machining Process data is nished. Click on thSave & Exit button to save the Machining Process and close the Machining Proces

Define Managerdialog box.

The Machining Process Table Managerdialog box is displayed.

10. Add a picture to Machining Process

In the Machining Process Table Manager dialog box, you can attach an image to

Machining Process to add a graphical illustration associated with the Machinin

Process. The attached image must be in the BMP format.

Select the Countersink Threaded hole Machining Process in the Machining Process lis

section. In theMP picturesection, click on the Browse MP Pictures button.

The Browsedialog box is displayed.

Choose the Countersink_threaded_hole.bmp image located in the Exercises folde

and click on the Openbutton to conrm your choice.


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The image is attached to the Countersink Threaded hole Machining Process.

11. Define the description for the Machining Process

SolidCAM enables you to attach a text description to the Machining Process.

Select the Countersink Threaded hole Machining Process in the Machining Process list

section. Describe the Machining Process in your own words in the Description section

of the Machining Process Table Managerdialog box.

12. Save the Machining Process Table

Click on the Savebutton to save the machining Process Table.

Click on the Exitbutton to close the Machining Process Table manager dialog box.


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13. Define the Machining Process types

SolidCAM enables you to dene and use the user-dened types for easier identicatioand classication of Machining Processes.

Right-click on the Machining Processheader in SolidCAM

Managerand choose

Group Typesfrom the menu.

The MP Group Typesdialog box is displayed. This dialog

box enables you to dene and manage MP types.

Click on the Addbutton to dene a new type. The new type is created. Enter the Dri

name in the Typecell for the new type.

In the same manner dene the Milltype. It will be used in the further exercises.

Click on the Save & Exitbutton to save

the type and close the dialog box. In

SolidCAM Manager, open the TrainingMachining Process Table.

In the MP Table Manager dialog box,

select the Countersink Threaded hole

Machining Process. Choose the denedDrill type from the Type list.


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14. Save the Machining Process Table

Click on the Savebutton to save the machining Process Table.

Click on the Exitbutton to close the Machining Process Table Manager dialog box.

Now the Machining Process has been dened and ready to use.


In SolidCAM Manager, right-click on the Operations header and then click Add

Machining Process, From MP Table.

The Machining Process Table Manager

dialog box is displayed. In this dialog box,

choose the Machining Process and clickon the Pickbutton to insert the MP into

CAM-Part.

The Machining Process Insert Manager

dialog box is displayed. Now you have to

dene the geometry and assign the valuesto the basic variables.


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16. Show descriptions

Make sure that the Show descriptions check box is selected, so that the variabl

description is displayed instead of the variable name.


Choose the Define Geometry command in the

parametric menu of the Expression cell of

the Geometry variable to start the geometry

denition.

Dene the geometry of four M6x1 holes asshown.


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18. Define the Upper level

The Upper_levelvariable used for the Upper level denition is of the Z-leveltype. Itsupports the denition of the Upper level for all Operations of the Machining Processby clicking on the solid model.

Choose the Pick Z-value command from the parametric menu in the Expressioncellof the Upper_levelvariable. Since descriptions are displayed instead of variable names,

the variable appears in the list as Pick Upper level.

This command also is available by pressing theF5key in the relevant Expression cell.

The Pick Z-Value dialog box is displayed in the SolidWorks PropertyManager area.

Click the model face as shown. The Z-coordinate

of the selected face is displayed in the Pick Z-Value

dialog box.

Conrm the dialog box with the button.


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19. Define the Lower level

In the same manner as explained in the previous step, dene the Lower levelvalue bpicking a point on the solid model as shown.

The Drill depthvalue is automatically calculated.

20. Define the Pitch

In the Expression cell of the Pitch parameter (appears as Define the Pitch in the listset the value of 1.

21. Define the Thread Depth

In the Expression cell of the Thread Depth parameter (appears as Define the ThreaDepth in the list), set the value of 20.

The Thread depth cannot be dened directly on SolidWorks model becausof the limitation of cosmetic thread visualization in SolidWorks.


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22. Define the Chamfer diameter

In the Expression cell of the Chamfer_diameter_from_model variable (appears asPick the Chamfer Diameter in the list), choose the Pick Diametercommand from theparametric menu. This command is also available by pressing the F5key.

Pick the upper edge of the chamfer as shown below.


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The radius of the picked circular edge is displayed in the Select Radius Bydialog box

Conrm the dialog box with the button. The diameter value is displayed in threlevant Expressioncell.

23. Define the Thread diameter

Dene the value of the thread diameter for the Thread_diameter_from_modelvariabl(appears as Define the Thread diameter in the list).

Set the value of 6in the relevant Expressioncell.

Now all the values are dened.


Click on the Insertbutton. All the Operation Templates of the Machining Process ar

converted into SolidCAM Operations with the relevant values.

Click on the Simulatebutton to simulate the Operations.


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25. Machine the M3.5x0.6 holes

In the same manner as explained in steps #17 #24,

perform the machining of six M3.5x0.6 holes.

26. Machine the M10x1 holes

In the same manner as explained in steps

#17 #24, perform the machining of six M10x1

holes.

At this stage, the CAM-Part holes machining is completed.


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Exercise #5: Electronic box machining

In this exercise, you have to use the Countersink Threaded hole

Machining Process dened in Exercises #2and #4 to performthe machining of the electronic box holes.

The Exercise5.prz CAM-Part contains the dened Stockand Target models. The Stock model is based on the model

conguration without the hole features to make the simulationof the operations added from the Machining Process clearer.

1. Perform the machining of two holes

M3x0.5 located on the top face of the

model using the Machining Process.

The threading depth necessary for themachining is 6 (it can also be obtained

in the SolidWorks Hole Wizard).

2. Perform the machining of four holes

M5x0.8 located on the pad faces using

the Machining Process. Note that the

hole is through and threading should be

preformed throughout the hole length.

3. Perform the machining of 15 holes

M2x0.4 located on the pad faces usingthe Machining Process. Note that the

hole is through and threading should be

preformed throughout the hole length.


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Exercise #6: Counterbore hole machining

In this exercise, you have to create a new Machining Process in

the TrainingMachining Process Table to perform the machining

of counterbore holes with under head countersink.

The Machining Process contains three Operation Templates:

The rst Operation Template is intended to perform the U-drilling from the holeUpper level up to the counterbore bottom. A U-Drill tool of the diameter equal to

the counterbore diameter is used.

The second Operation Template is intended to perform the center drilling. Thechamfer is also machined with this Operation Template. Note that the Upper level

for this Operation is the bottom of the counterbore.

The third Operation Template is intended to perform the hole machining (drilling).The drilling is performed from the same Upper level used in the previous Operation

Template. The drilling tool diameter is equal to the hole diameter. The Pecking

technology is utilized in this Operation Template with the pecking step down

calculated automatically with an expression.

The created Machining Process should be tested and used for

the mounting plate machining (Exercise6.przCAM-Part).

Perform the machining of four holes for M10 Socket Head

Cap Screw.

Perform the machining of six holes for M5Socket Head Cap

Screw.

Attach the counterbore_hole.bmp image to the Machining

Process.


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Exercise #7 Adding MP items into Operations menu

SolidCAM enables you to add Machining Processes items into the right-click menu available o

the Operationsheader and on separate Operations in SolidCAM Manager. This feature simpliethe Machining Process insertion into a CAM-Part. In this exercise, the TrainingMachining Proces

Table will be modied so that you can access its Machining Processes from the right-click menu.

1. Start SolidCAM standalone

Generally, all the process of MP creation and modication does norequire any CAM-Part loaded. You can start SolidCAM standalone, withou

SolidWorks, to perform the Machining Process manipulations.

Launch the SolidCAM software standalone using theWindows Start menu. Click on the Start button located on

the Windows taskbar and search for SolidCAM2007R11.2

folder in the All Programs menu. Choose the SolidCAM2007

R11.2 item in this folder.

SolidCAM Manager is displayed. Since there is no CAM-

Part loaded, SolidCAM Managercontains only the general

headers: CAM-Part (enables you to manage CAM-Parts),Tool(enables you to manage tool libraries) and MachiningProcess.

Make sure that the Training Machining Process Table

appears as current (its name is displayed in the parenthesesin the Machining Processheader). If the MP Table nameis not displayed, open it using the Open command from

the right-click menu available on the Machining Process

header.


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Double-click on the Machining Process header to open the Machining Process Table

Manager dialog box. This dialog box displays the Training MP Table containing two

Machining Processes created in the previous exercises.

3. Add a new Machining Process

Right-click on the rst Machining Process in the Machining Process list section inthe dialog box and choose the Additem from the menu. A new Machining Process is

created.

Assign the ==Drilling name to the added Machining Process.


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The == symbols used in the beginning of the Machining Proces

name mean that the Machining Process is used as a group heade

All the Machining Processes following the group header (till the nexgroup header) are included into the group. The Machining Procesused as a header should not contain Operation Templates.

In the Add Machining Processesmenu, each such group is displayeas a separate submenu.

Drag the dened group header to the beginning of the list above all the MachininProcesses.

Now the group is created.

4. Attach a picture for the group

Attach the drilling_group.bmpimage for the group header.

5. Save and Exit

Save the Machining Process Table with the Savebutton and close the dialog box wit

the Exitbutton.


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75/13475


2.4 Standardization with Machining Processes

In the previous exercises, you dened Machining Processes for the machining of countersinthreaded holes. Such Machining Processes are fully universal, which means that they can be use

for machining of every countersink threaded hole through assigning the appropriate values to th

variables. The expressions currently used in the Machining Process enable you to automate thprocess of assigning values to metric holes (e.g. the diameter of preparation drilling is calculated aa difference between thread diameter and pitch). For inch holes, the values can be dened directlaccording to the standard ignoring the existing expression.

The universality of Machining Processes causes a serious disadvantage at the stage of the Machinin

Process use: each time during the MP use you have to dene values for a great number of parameterThis disadvantage can be avoided by using an advanced Machining Processes functionality tha

involves Default Sets.

A Default Set is a combination of parameters and expressions used for Operation Templatcustomization. Each Default Set may contain different expressions and values. You can automaticall

assign the expressions and values contained in the Default Set to the Machining Process variables

You can use Default Sets to adapt Machining Processes to specic tasks.

In the above example, you can dene Default Sets for each thread size (e.g. M6, M8, etc.). In Default Set intended to provide the values for the machining of a specic standard hole, almoall variables are dened with the values relevant for the standard. For example, in the Default Seintended to perform the machining of the #6-32 size holes (ANSI Inch standard), the value of 2.7should be assigned to the variable of the thread diameter and the value of 3.51 should be used fo

the thread diameter variable.

Creating a number of task-oriented Defaults Sets in your Machining Process enables you to facilitat

the Machining Process use by minimizing the number of parameters that must be specied at thstage of the MP insertion.


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Exercise #8: Creating Default Sets

In this exercise, you have to dene a number of Default Sets in the Countersink threaded holeMachining Process. The Default Sets should be sets of values dedicated to perform the machining

of different metric standard threads (M3, M4, M5 etc).

1. Start SolidCAM standalone

As explained in the previous exercise, run SolidCAM in the standalone mode to

perform the Machining Process customization.

The SolidCAM Manager tree is displayed.

2. Open the Training Machining Process

Open the Training Machining Process Table.

In the Machining Process Table Manager dialog box, double-click on the Countersink

Threaded holeMachining Process to edit its content.

TheMachining Process Define Manager dialog box is displayed.


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3. Switch to Default Sets tab

In the Machining Process Define Manager dialog box, switch to the Default Sets tab.

This tab enables you to create and manage Default Sets in Machining Processes.

The New Default Set item is displayed in the tab. This Default Set was created b

default; it contains values and expressions displayed in the Used Parameterstable.

4. Define new Default Set

Right-click on the New Default Setitem in the Default Setstab. The right-click men

is displayed.

This right-click menu enables you to manage

your Default Sets. The following commands

are available: Set as Current

This command enables you to activate the selected Default Se

A Default Set can also be activated by double-clicking on its name i

the list.


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Rename

This command enables you to rename the selected Default Set.

Copy

This command enables you to copy the selected Default Set. A new

Default Set is created with the data copied from the original Default

Set.

Delete

This command enables you to remove the selected Default Set.

Choose the Copycommand from the menu. A new Default Set is created by copying

the New Default Set. Set the M2x0.4 name for this Default Set. The created Default Set

is intended to perform the machining of M2x0.4holes.

Activate the M2x0.4Default Set using the Set as Currentcommand from the right-click

menu.

Currently, this Default Set contains the same values and expressions as those contained

in the original New Default Set. In further steps, the values and expressions will be

customized to perform the machining of M2x0.4countersink threaded holes.


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5. Customize the Default Set

During the Machining Process denition, the expressions/values for some variablesuch as Pitchand Thread Diameterwere not dened; the values were specied durinthe Machining Process use. Now in the M2x0.4Default Set you have to assign each o

these variables an actual value relevant for the M2x0.4thread standard.

In the Expressioncell of the Pitchvariable, set the value of 0.4.

In the Expressioncell of the Thread_diametervariable, set the value of 2.

These values are dened by the thread standard and cannot be changed during thMachining Process use.

Mark the Pitchand Thread_diametervariables as Read only.

Generally, each value assigned to a variable during the Machining Proces

denition can be customized at the stage of the Machining Process usIn other words, during the MP denition you assign the default value ta variable, and during the MP use you customize the value according t

the machining conditions. The Read only option enables you to preven

changing some values at the stage of the MP insertion, so that the valu

specied during the Machining Process denition is used.


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In the R/O cell of the Pitch and Thread_diameter variables, choose the Read-only

command from the right-click menu.

The variables are marked as read-only.

Now you have to dene the default values for the following variables that are notdened with expressions:

Set the value of 0for the Upper_levelvariable;

Set the value of -10for the Lower_levelvariable;

Set the value of 7for the Thread_depthvariable;

Set the value of 2.4for the Chamfer_diameter_from_modelvariable.

Since these variables are not marked as read-only, the default values can be customized

at the stage of the Machining Process use.

Using the Read-only marking, prevent the values of the following parameters fromchanging during the MP insertion: Center_drill_tool_diameter, Center_drill_tool_

anglem, Drill_tool_diameter, Drill_tool_angle, Tap_tool_diameter, Tap_tool_tip_

diameter, Tap_tool_chamfer_length, Drill_depth.

Peck_stepdown is not marked as Read-only and can be changed during

the MP insertion while taking into account the material and machining

conditions.


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At this stage, the Default Set for the M2x0.4holes machining is dened.

6. Define other Default Sets

In the same manner as explained in the previous step, dene several Default Setto perform the machining of the following standard holes: M2.5x045, M3x0.5

M4x0.7,M5x0.8 and M6x1. Copy the M2x0.4 Default Set to create a new one.


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7. Generic Default Set

At this stage, you have dened a number of Default Sets intended for the machiningof different standard threads. An original Default Set (New Default Set) is kept in theMachining Process database as the solution for not dened and non-standard threads.

The variables of this Machining Process are not protected and each value can be

dened at the stage of the Machining Process use. Using of such solution requires thedenition of greater number of parameters compared to other Default Sets, but givesyou the exibility of use for various holes machining.

For better identication, rename the New Default Setinto Generic.

8. Save and Exit

Save the Machining Process and the Machining Process Table. Exit from Machining

Process dialog boxes.

Close SolidCAM.

At the further steps, the dened Default Sets will be used for machining.

9. Load the CAM-Part

Start SolidCAM integrated in SolidWorks and loadthe Exercise8.prz CAM-Part. This model contains

threaded holes that will be machined.

Right-click on the Operations header in SolidCAM

Manager. Click Add Machining Process,Drilling,

Countersink threaded hole.


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The Machining Process Insert Manager dialog box is displayed with the Machinin

Process data loaded.

10. Machine M6x1 holes

At this stage, four holes of M6x1will be machined.

The Default Sets section of the Machining

Process Insert Manager dialog box displays the

list of Default Sets intended for machining of

different standard threads.

Make sure that the M6x1Default Set is activated;if not, activate it with the relevant command in

the right-click menu.

This Default Set will be used for the M6x1holes machining.


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Note that all the cells of the variables marked as Read-only appear dimmed. The

expressions/values of these variables cannot be changed. To hide these variables fromthe table, clear the Show Read onlycheck box.

Clearing this check box enables you to remove the unnecessary data from the parameters

table and facilitate the navigation between variables, expressions and values.

To apply this Machining Process with the M6x1Default Set, you have to dene thefollowing data:

Geometry;

Upper and Lower level;

Thread depth;

Chamfer diameter.

Dene these variables as explained in previous exercises.

To dene the Thread depth, familiarize yourself with the Hole Wizardfeature in SolidWorks.


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When the variables are dened, click on the Insertbutton to insert the MachininProcess into the CAM-Part.

11. Machine M4x0.7 holes

In the same manner as explained in the previous

step, perform the machining of two M4x0.7 holes

using the relevant Default Set.

12. Machine M2.5x0.45 holes

Perform the machining of 16 M4x0.7 holes using the relevant Default Set.


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Since the holes are located on the different model faces and cannot be machined with a

single Coordinate System, use the CoordSys #1to perform the machining of the holes

located on the pads and CoordSys #2to perform the machining of the holes located

on the model side faces.

SolidCAM enables you to choose a Coordinate System for the

geometry denition during the Machining Process insertion. Duringthe Machining Process denition, the home_number variable wasdened automatically. By default, the value of Coordinate System #1

is automatically assigned to this variable. By changing this value using

the right-click menu commands, you can choose or dene a different

Coordinate System and use it for the Geometry denition.

The following commands are available in the right-click menu in the

Expressioncell of the home_numbervariable:

The CoordSys select command

displays the CoordSys select dialog

box that enables you to choose the

relevant Coordinate System from the

list. This command is also available

with the F5 key.


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The CoordSys pickcommand enables you to pick the Coordinat

System directly on the solid model using the CoordSys Manage

functionality. This command is also available by pressing the F

key.

13. Close the Insert Manager

Click on the Exitbutton to close the Machining Process Insert Managerdialog box.

14. Simulate the operations

Simulate all Operations created with the current Machining Process.

At this stage, the exercise is completed.


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Exercise #9: Cover Machining

In this exercise, you have to update the Counterbore holeMachining Process created in Exercise #6.

In addition to basic, generic Default Set dened during the Machining Process creation, you have

to dene a number of Default Sets designed for machining of the standard holes for Socket Head

Cap Screws.

Dene the following standard holes: M3, M4, M5 and M6.

During the denition, use the following data for the hole parameters denition:

Hole Size Drill diameter Counterbore diameter Counterbore depth

M3 3.4 6.5 3

M4 4.5 8 4

M5 5.5 10 5

M6 6.6 11 6

Use the dened Default Sets for machining of the counterbore holes located at the top face of theCover part (Exercise9.prz).


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2.5 Machining Processes for automation of Milling tasks

The basic Machining Process functionality described in the previous topics and exercises can b

used for automation of 2.5 Milling as well as 3D Milling tasks. Machining Processes also enable yo

to expand the SolidCAM basic functionality by combining several SolidCAM Operations into on

Machining Process.

For example, the typical task of pocket machining can be performed with the Machining Proces

containing the following Operation Templates:

Pocket Operation for pocket roughing;

Pocket Operation for rest machining of corner areas with a tool of smallediameter;

Pocket Operation for pocket wall

solidcam2007 r11 2 advanced training course

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