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