SolidCAM 2015 Port Machining

SolidCAM Application Tutorial:
Port Machining
SolidCAM+SolidWorks
The Complete Integrated Manufacturing Solution
Contents
1. Introduction................................................................................................................. 1
2. CAM-Part Definition.................................................................................................... 5
3. Stock and Target Definition...................................................................................... 13
4. iMachining Operation................................................................................................ 17
5. Roughing Operations................................................................................................ 23
6. Finishing Operations................................................................................................ 39
Introduction
About this course

The goal of this course is to teach you how to use SolidCAMs Port Machining to machine a
simple and complex port. This tutorial covers the basic concepts of Port 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 Port 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.
1. Introduction
Port Machining
The Port Machining operation is an easy to use method for machining ports with tapered lollipop
tool, and has collision checks for the entire tool (shank, arbor, and holder). You can choose to cut
the top only, the bottom only, and specify how much stock to leave on the entire port. It uses 3-Axis
machining as far into the port as possible, and then switches to 5-Axis motion. Smooth transitions
are created where the tool paths meet at the middle of the port. It provides both roughing and
finishing tool paths to make ports from castings or billet.
CAM-Part Definition
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. Browse
SLDPRT.
to open the SolidWorks part PORT.
2. Click Tools
Settings.
> SolidCAM > SolidCAM
2. CAM-Part Definition
3. In
the left pane, select CAM-Part.
4. Ensure
image:
that the settings are as shown in the
This enables you to start

directly adding operations
in a new part.
5. In the left pane, select Automatic CAM-Part

definition. In the right pane, click the Milling tab.
6. Ensure
that all check boxes are cleared except

for Use default CNC controller (skip controller
selection).
7. Click OK.
8. Click Tools
Milling.
> SolidCAM > New >
9. If
you get this notification window,

click Save.
Define the CAM-Part in the Milling Part Data dialog box:
10. In
the CNC-Machine list, click table_table_exercise. Leave the

fields of Program number & Subroutine number with the default
settings.
11. Click Define button in the Coordinate System tab to set

the coordinate system for this part.
12. In the Place CoordSys origin to

model box.
13. Select
list, click Top center of
the face as shown in the image.
14. Click
The CoordSys Data window displays.
15. Enter
the parameters as shown in the image.
16. Click OK.
17. Click 1-Position

18. In
> Add.
the Place CoordSys origin to list, click CoordSys # 1.
19. Select
20. Click
21. Enter
22. Click OK.

23. Click
24. Click Edit iMachining Database in the iMachining Data

section.
The iDatabase window displays.
25. Click
the New
icon to define a new machine.
26. Enter HERMLE_PORT as

iMachining DB File window.
the machine name in the New
27. Click Save.

28. Enter
the parameters as shown in the
29. Click
the Material DB tab.
30. Click
the New
image.
31. Enter AL-6061-T6

DB File window.
32. Click Save.
10
icon.
as the material name in the New iMachining
33. Enter
the MPa value of 460 as shown in the image.
34. Click Save & Exit.

35. Click
36. Right
click CAM-Part (PORT) > CAM-Part Definition.
37. In
the Machine Database list, click HERMLE_PORT.
38. In
the Material Database list, click AL-6061-T6.
39. Click
The CAM part is now defined.
11
12
Stock and Target

Definition
To define the stock you have to follow the steps mentioned in this chapter.
1. Click
the Feature Manager Design Tree
2. Click Design Model

Show.
3. The
image:
> Solid Bodies(3) > Stock >
selected stock should look as shown in the
4. Click
the SolidCAM Manager
5. Right
click Stock > Define.
14
icon.
icon.
3. Stock and Target Definition

6. In
the Defined by list, click 3D Model.
7. Select
the solids as shown in the image.
8. Enter the Facet tolerance value as 0.1 so that your

system does not create a big faceting file.
9. Click
10. Click Target
11. Select
> Define.
the solid as shown in the image.
12. Click
The stock and the target are now defined.
15
16
iMachining
Operation
1. Right
click Operations > Machine Setup.
The Machine Setup window displays.
2. Enter a value of 225 as shown in the Z column. This will raise the part above the machining
level.
3. Click OK.
4. Click
6. Click
> STOCK > Hide.
7. Right click Setup > Add Milling

Operation > 2D iMachining.
18
icon.
icon.
4. iMachining Operation
You can also add the 2D iMachining operation,by

clicking the SolidCAM Operations tab > iMachining
> 2DMachining.
Or, by clicking the SolidCAM 2.5D tab > 2D

iMachining.
8. In
the Technology list, click iRough.
9. Click Geometry.
10. In
the CoordSys list, click MAC 1 (2-Position).
11. Click
the New
12. Select
image.
icon under CoordSys.
the two contours as shown in the
13. Click Yes
the times.
in the OK to accept? window both
14. Click
15. Click Tool
16. Click
> Select.
the Add Milling Tool
icon.
17. Select END MILL.
19
18. Enter
the parameters as shown in
19. Select
the Holder check box.
the image.
20. Select HSK A 63 ER 32x80.

21. Click
the iData tab.
22. In
the Topology / Helical Angle

list, click 35 (Standard).
23. Click Select.

24. Click Levels.
25. Click Upper Level.
26. Select
27. Click
20
4. iMachining Operation
28. Click Pocket depth.
29. Select
the point on the face as shown in the image.
30. Click
31. Click Technology.
32. Set
the Wall / island offset as 0.1.
33. Select
the Floor check box.
34. Click Link.

35. Slide
the Max. arc size slide bar to around 6.19764.

Ensure that the Advanced check box is selected.
36. Click
the Save & Calculate
37. Click
the Exit
38. Select
icon.
icon.
the check box before the operation.
21
The tool path should look as displayed in the image.
22
Roughing Operations
Before you start the roughing operation, you must make a few changes to close the holes as shown
in the image.
1. Right
click > Edit part.
2. Click Insert
3. Enter
> Surface > Offset.
a value of 0 in the Offset Parameters field to make a copy of

this surface.
24
5. Roughing operations
4. Select
the five faces as shown in the video.
5. Click
6. Click
7. Click Solid Bodies(3)
8. Click Insert
icon.
> PART >Hide.
> Surface > Untrim.
25
9. Select
the two faces as shown in the image.
10. Select
section.
the Internal edges option in the Options
11. Click
12. Click Insert
> Surface > Untrim.
13. Select
14. Select
the All edges option in the Options section.
15. Click
You will now split this surface into two so that you get
two single tubes for machining.
26
16. Click Insert
17. Click
> Curve > Split Line.

19. Click
icon.
> Plane4.
once in the section highlighted in green color.
20. Select
the four faces as shown in the video.
21. Select
the Intersection option in the Type of Split
section.
22. Click
23. Click Sketch
24. Click
> 3D Sketch.
the Line
icon.
27
25. Select
the two points as shown in the image.
26. Click
the esc (escape) key on your keyboard.
27. Click
to come out of the sketch.
28. Click Insert
> Surface > Fill.

Ensure that in the Feature
Manager Design Tree, SurfaceFill3 is switched on and
Surface-Untrim11 and SurfaceOffset13,and Surface-Fill4 are
switched off.
29. Select
the three edges as shown in the video.
30. Click
This will ensure that you have three distinct tubes available
for machining.
31. Click
32. Click
to finish editing the part.

33. Right click the previous operation

Milling Operation > Port Machining.
28
icon.
> Add
34. In
the Technology list, click Roughing.
35. Click Geometry.

36. Click
the New
37. Select
icon under Machining surfaces.
the faces as shown in the video.
38. Click
39. Set
the Offset value as 0.5.
40. Click Tool
> Select.
41. Click
42. Enter
the parameters as shown in
43. Select
the image.
44. Select HSK A 63 ER 32x80
holder.
icon.
as the
45. Click Select.
29
46. Click Levels.

47. Click the Parallel to X option to get a
cylinder parallel to the X axis.
48. Click
49. Select
the point as shown in the image.
50. Click
51. Enter the Retract distance value in the Levels section as shown
in the image.
52. Click Tool path parameters.
30
53. Enter
the values as shown in the image.
54. Click
the Sorting tab.
55. In
the Output type list, click Top.
56. In
the Machine to list, click Maximum from top.
57. Click Tool axis control.

58. Unselect
the Minimize tilting check box.
59. Click Gouge check.

60. Select
the Check surfaces check box.
61. Ensure
62. Click
that in the Feature Manager Design Tree, PART is switched on.
the New
63. Select
icon under Check surfaces.
the faces as shown in the image.
64. Click
65. Click Clearance data.
31
66. Enter
67. Click
image.
68. If you
click OK.
icon.
get the error as shown in the image,
You will have to make a few changes to calculate

this part.
69. Click
70. Expand Design Model
> Solid Bodies(3) > SPINE 1 > Show.
71. Click Geometry.

72. Select
73. Click
the User -defined Spine check box.
the New
74. Select
icon.
the spine as shown in the image.
75. Click
76. Click
77. Click
32
icon.
icon.
78. Click
the Simulate
79. Click
the Play
icon.
icon in the Simulation window.
The tool path should look as show in the image.
33
80. Click
the Save, Parallel Calculate & Copy
81. Click
82. Expand Design Model

83. Ensure
icon.
icon.
> Solid Bodies(3) > SPINE 2 > Show.
that you switch off SPINE1.
84. Click Geometry.

85. Click
the New
86. Select
87. Click
88. Click
the New
89. Select
icon under User -defined Spine.
90. Click
91. Click
34
93. Select
94. Click
the Check surfaces check box.
the New
95. Select
96. Click
98. Enter
99. Click
image.
100. Click
the Simulate
101. Click
the Play
icon.
icon.
The tool path should look as

show in the image.
35
102. Click
the Exit
icon.
103. Click
the Exit
icon to come out of the Operations Manager.
104. Right
click > Copy the operation.
105. Right
click > Paste the operation.
106. Right
click > Edit the operation.
107. In the Feature Manager Design Tree, ensure that Split Line3 is
Offset10, Surface-Offset11, SPINE 1 and SPINE 2 are switched off.
108. Click Geometry.
109. Click
the New
110. Select
the faces as shown in the video.
111. Click
112. Select
113. In
the User-defined Spine check box.
the Feature Manager Design Tree, switch on SPINE 3.
114. Click the New

-defined Spine.
115. Select
116. Click
117. Click
36
icon under User
switched on and Surface-
119. Click
the Sorting tab.
120. In
the Output type list, click Bottom.
121. In
the Machine to list, click Maximum from bottom.
122. Click
123. Click Solid Bodies(3)
icon.
> PART >Show.

125. Unselect
127. Select
the New
128. Select
the highlighted surface.
129. Click
131. Enter
132. Click
133. Click
the Simulate
image.
icon.
icon.
37
134. Click
the Play
The tool path should look as show in

the image.
135. Right
136. In
click the operation > Add Milling Operation > 3D HSR.
the Technology list, click Contour roughing.
137. Click CoordSys
on Geometry page.
138. Click 2-Position
> Add.
139. In
box.
the Place CoordSys origin to list, click Top center of model
140. Select
38
the face as shown in the below image.
141. In
the Pick section, select the Pick XY origin check box.
142. Select
143. In
the Flip section, click the Flip around Z button twice.
144. Click

145. Enter
146. Click OK.

147. Click
148. Click
Tool > Select.
149. Click
150. Select BULL NOSE MILL
icon.
as the tool.
39
151. Enter
152. Select
image.
153. Select HSK A 63 ER 32x80.

154. Click Select.
155. Click Constraint boundaries.
156. Select
157. In
the Created manually option.
the list, click User-defined boundary.
158. Click
the New
159. Select
icon under Boundary name.
the boundary as shown in the image.
160. Click Yes
in OK to accept? window.
161. Click
162. Click Passes.
163. Enter
image.
164. Click Z-Top.
40
165. Select
166. Click
167. Click
168. In
the Adaptive step down tab.
the Adapt Step down by list, click None.
169. Click Link.

170. Click
the Ramping tab.
171. Enter
172. Click
the Retracts tab.
image.
173. Select the Minimal vertical retract

option.
174. Click
175. Click
the Simulate
176. Click
the Play
icon.
icon.
The tool path should

look as show in the
image.
41
177. Click
the Exit
icon to close the Simulation window.
178. Click
the Exit
icon to come out of the Operations Manager.
42
Finishing Operations
1. Right
2. In
click the operation > Add Milling Operation > Port Machining.
the Technology list, click Spiral Finishing.
3. Click Geometry.
4. In
the list, click faces.
The selected faces should look as shown

in the image. You have earlier used this
geometry in the roughing operation.
5. Select
the User-defined Spine check box.
6. In the list, click contour1. This is SPINE

1 that you had selected for the roughing
operation.
7. Click Tool
8. Select
> Select.
the LOLLIPOP MILL tool from the list.
9. Click Select.
10. Click Levels.
11. Click
12. Click
44
the Parallel to X option to get a cylinder parallel to the X axis.
6. Finishing Operations
13. Select
14. Click
15. Enter
the value in the Levels section as shown in the image.

17. Click
the Sorting tab.
18. In
the Output type list, click Top.
19. In
the Machine to list, click Maximum from top.

21. In
the Check surfaces list, click faces1.
The selected face should be as shown in the image.
45

23. Enter
24. Click
25. Click
the Simulate
26. Click
the Play
image.
icon.
icon.
27. Click
the Exit
icon.
28. Click
the Exit
icon.
29. Right
click > Copy the operation.
30. Right
click > Paste the operation.
31. Right
click > Edit the operation.
32. In
the Technology list, click Plunge Finishing.
33. Click Geometry.
46
34. In
the list, click faces2.

35. Select
box.
the User-defined Spine check
36. In the list, click contour2. This is SPINE

2 that you had selected for the roughing
operation.

38. Click
the Sorting tab.
39. Enter
image.

41. Unselect
43. Click
the New
44. Select
the highlighted faces.
45. Click
47

47. Enter

below image.
48. Click
49. Click
the Simulate
50. Click
the Play
icon.
icon.
The tool path should look as show in

the image.
51. Click
the Exit
icon.
52. Click
the Exit
icon.
53. Right
click the operation > Copy.
54. Right
click the operation > Paste.
48
55. Right
click the operation > Edit.
56. In the Technology

Finishing.
list, click Spiral
57. Click Geometry.

58. In
the list, click faces3.

59. Change
60. Select
box.
61. In
the Offset value to 0.
the User-defined Spine check
the list, click contour3 i.e. SPINE 3.
62. Click Tool

63. Select
the list.
> Select.
the LOLLIPOP MILL tool from

65. Set
the Maximum step over limit as 1.
66. Click
the Sorting tab.
67. In
the Output type list, click Bottom.
68. In
the Machine to list, click Maximum from bottom.
49

70. In
the Check surfaces list, click faces4.
The selected face must look as shown in the image.

72. Enter

below image.
73. Click
74. Click
the Simulate
75. Click
the Play
icon.
icon.

76. Click
the Exit
icon.
77. Click
the Exit
icon.
50
78. Right click the operation
Operation > 3D HSM.
79. In the Technology
machining.
> Add Milling
list, click Helical
80. In the CoordSys list, click MAC 1

(3-Position) as the user coordinate system.
81. Click Tool
82. Select
> Select.
the LOLLIPOP MILL tool from the list.
83. Click Constraint boundaries.

84. Select
the Created manually option.
85. In
the list, click User-defined boundary.
86. In
the Boundary name list, click contour4.
The selected boundary must look as shown in the

image.
87. Click Passes.
88. Enter
image.
89. Click Z-Top.
51
90. Select
91. Click
92. Select
the Adaptive step down tab.
93. Enter
image.
94. Click Link.

95. Click
the Retracts tab.
96. Click
the Minimal vertical retract option.
97. Click
98. Click
the Simulate
99. Click
the Play
icon.
icon.

100. Click
the Exit
icon.
101. Click
the Exit
icon.
52
SolidCAM Application Tutorial:

Port Machining
iMachining 2D
2.5D Milling
HSS (High-Speed Surface Machining)
iMachining 3D
Indexed Multi-Sided Machining
HSM (High-Speed Machining)
Simultaneous 5-Axis Machining
Turning & Advanced Mill-Turn
Solid Probe
www.youtube.com/SolidCAMProfessor
www.youtube.com/SolidCAMiMachining
www.solidcam.com
www.facebook.com/SolidCAM

SolidCAM 2015 Port Machining

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SolidCAM Application Tutorial:

About this course

Coordinate System definition

Stock and Target definition

to open the SolidWorks part PORT.

> SolidCAM > SolidCAM

the left pane, select CAM-Part.

that the settings are as shown in the

This enables you to start

5. In the left pane, select Automatic CAM-Part

that all check boxes are cleared except

> SolidCAM > New >

you get this notification window,

Define the CAM-Part in the Milling Part Data dialog box:

the CNC-Machine list, click table_table_exercise. Leave the

11. Click Define button in the Coordinate System tab to set

12. In the Place CoordSys origin to

list, click Top center of

the face as shown in the image.

The CoordSys Data window displays.

the parameters as shown in the image.

16. Click OK.

17. Click 1-Position

the Place CoordSys origin to list, click CoordSys # 1.

the face as shown in the image.

The CoordSys Data window displays.

the parameters as shown in the image.

22. Click OK.

24. Click Edit iMachining Database in the iMachining Data

The iDatabase window displays.

icon to define a new machine.

26. Enter HERMLE_PORT as

the machine name in the New

27. Click Save.

the parameters as shown in the

the Material DB tab.

31. Enter AL-6061-T6

as the material name in the New iMachining

the MPa value of 460 as shown in the image.

34. Click Save & Exit.

click CAM-Part (PORT) > CAM-Part Definition.

the Machine Database list, click HERMLE_PORT.

the Material Database list, click AL-6061-T6.

The CAM part is now defined.

Stock and Target

the Feature Manager Design Tree

2. Click Design Model

> Solid Bodies(3) > Stock >

selected stock should look as shown in the

the SolidCAM Manager

click Stock > Define.

3. Stock and Target Definition

the Defined by list, click 3D Model.

the solids as shown in the image.

8. Enter the Facet tolerance value as 0.1 so that your

10. Click Target

the solid as shown in the image.

The stock and the target are now defined.

click Operations > Machine Setup.

The Machine Setup window displays.

the Feature Manager Design Tree

5. Click Design Model

> STOCK > Hide.