SolidCAM + SolidWorks The complete integrated Manufacturing Solution SolidCAM User Guide HSRHSM iMachining 2D 3D | 2 5D Milling | HSS | HSM | Indexial Multi Sided | Simultaneous 5Axis | Turning Mill Turn | Solid Probe www solidcam com SolidCAM 2013 HSRHSM Module User Guide ©1995 2013 SolidCAM All Rights Reserved Contents 1 Introduction and Basic Concepts 1 1 Start HSRHSM Operation 3 1 2 SolidCAM HSRHSM Operation overview 4 1 3 Parameters and values 6 2 Technology 2 1 Contour roughing 12.
Start HSR/HSM Operation
To add an HSR/HSM Operation to the CAM-Part, right-click the Operations header in SolidCAM
Manager and choose either HSR or HSM command from the Add Milling Operation submenu.
The corresponding operation dialog box is displayed.
SolidCAM HSR/HSM Operation overview
The definition of a SolidCAM HSR/HSM operation consists of the following stages:
In the initial phase, it is essential to select one of the available machining strategies, as this choice determines the technology employed in the machining process For detailed insights into the various machining strategies, please consult chapter 2.
At the Geometry definition stage you have to specify the 3D model geometry that will be machined For more information on the geometry definition, refer to chapter 3
In the next stage, you can select a cutting tool from the Part Tool Table for the operation For detailed information about the tool definition, please see Chapter 4.
The Boundaries definition page allows you to restrict machining operations to designated areas of a specific model Certain machining strategies require an additional boundary to outline the drive curve of the tool path For further details on defining boundaries, please see chapter 5.
In the Passes definition , SolidCAM enables you to specify the technological parameters used for the tool passes calculation For more information on the passes definition, refer to chapter 6
The Link parameters page enables you to define the tool link moves between cutting passes For more information on the link definition, refer to chapter 7
The Motion Control Parameters page allows you to enhance the calculated tool path based on the kinematics and unique features of your CNC machine For detailed definitions of these parameters, please see Chapter 8.
The Miscellaneous parameters page enables you to define the non-technological parameters related to the HSR/HSM operation For more information on the miscellaneous parameters definition, refer to chapter 9
Parameters and values
In SolidCAM HSR/HSM operations, default values for most parameters are determined by built-in formulas that establish relationships between them Once key parameters, such as tool diameter, corner radius, and offsets, are set, SolidCAM automatically updates the values of the dependent parameters.
For example, the Step down parameter for Contour roughing is defined with the following formula:
If the tool corner radius is 0 (end mill), the Step down parameter default is set to 1
When selecting a ball-nosed tool, the Step down value should be calculated by dividing the tool's corner radius by 5 In contrast, for bull-nosed tools, the Step down value is determined by dividing the tool corner radius by 3.
SolidCAM provides you with a right-click edit box menu for each parameter.
This command displays the Parameter Info dialog box This dialog box shows the internal parameter name and the related formula (if exists) or a static value.
The Unfold button displays a brief explanation of the parameter.
The button displays the flow chart of the parameter value calculating.
When you manually change a parameter default value, the formula assigned to the parameter is removed.
The Reset commands enable you to reset parameters to their default formulas and values.
This parameter This option resets the current parameter.
This page This option resets all the parameters at the current page.
All This option resets all the parameters of the current HSR/HSM operation.
The Technology section enables you to choose a rough (HSR) or finish (HSM) machining strategy to be applied The following strategies are available:
• Constant Z with 3D Constant step over machining
• Constant Z and 3D Corner offset machining
Technology
Contour roughing
With the Contour roughing strategy, SolidCAM generates a pocket-style tool path for a set of sections generated at the Z-levels defined with the specified Step down (see topic 6.1.4 ).
Hatch roughing
SolidCAM's Hatch roughing strategy creates linear raster passes across designated sections at specified Z-levels, utilizing a defined step down This method is particularly effective for older machine tools or when machining softer materials, as it primarily involves straight line tool paths.
Hybrid Rib roughing
The Hybrid Rib roughing strategy is specifically developed for machining extremely thin walls made from exotic materials such as titanium and graphite, which can pose challenges and risks with traditional machining methods By integrating innovative roughing and finishing tool paths, this technique ensures a unique approach that maximizes the rigidity of the part during the machining process.
Rest roughing
The Rest roughing strategy identifies unmachined areas, or "rest" material, remaining after prior machining operations and creates a tool path specifically for these regions Utilizing a contour roughing approach, this operation employs a tool with a smaller diameter than that used in earlier roughing processes An example of this technique can be seen in the hatch roughing tool path executed with a 20mm end mill.
After the hatch roughing, a Rest roughing operation is performed with an End mill of ỉ10 The tool path is generated in the contour roughing manner.
HM roughing
The HM roughing strategy significantly minimizes rapid movements by controlling tool motion to stay on the part, adhering to previous cut paths rather than rapidly advancing to new positions It features advanced tool path optimization that enables automatic machining of flat areas without unnecessary Z-level adjustments Additionally, the roughing algorithm allows for a large step over of over 50%, utilizing an offset algorithm to ensure complete coverage of the machining area while incorporating smooth transition corner pips to effectively clean up any leftover regions.
The strategy can be easily modified to work in different modes: cavity, core and hybrid spiral passes These modes provide different approaches to machine a part.
Constant Z machining
The Constant Z tool path, similar to Contour roughing, is created using a series of sections at various Z-heights defined by the Step down parameter This strategy is primarily employed for semi-finishing and finishing steep model areas with inclination angles ranging from 30 to 90 degrees However, its effectiveness diminishes in shallow areas with lower surface inclination angles, as the distance between passes is measured along the Z-axis of the Coordinate System.
The Constant Z finishing technique is depicted in the image above, highlighting the dense spacing of passes in steep regions In contrast, as the model's faces become shallower, the passes are spaced further apart, leading to ineffective machining To optimize results, machining should be restricted by the surface inclination angle to prevent shallow areas from being processed These less effective areas can be addressed later using an alternative SolidCAM HSM strategy, such as the 3D Constant step over method (refer to topic 2.17).
Hybrid Constant Z
The Hybrid Constant Z finishing strategy merges the advantages of traditional Constant Z operations with a 3D pocketing routine, optimizing the finishing process This approach effectively utilizes the shallow areas between consecutive passes to insert additional passes, ensuring a superior finish across the entire part.
Helical machining
SolidCAM's strategy involves creating multiple closed profile sections of the 3D model geometry at various Z-levels, akin to the Constant Z strategy These sections are then seamlessly connected in a continuous descending ramp to produce an efficient helical machining tool path.
The tool path generated with the Helical machining strategy is controlled by two main parameters:
Step down and Max ramp angle (see topic 6.6.5 ).
Horizontal machining
With the Horizontal machining strategy, SolidCAM recognizes all the flat areas in the model and generates a tool path for machining these areas.
This strategy creates a pocket-style tool path with equidistant profiles directly on the specified horizontal faces, which are parallel to the XY-plane of the current Coordinate System The spacing between adjacent passes is defined by the Offset parameters.
Linear machining
Linear machining generates a tool path consisting of a set of parallel passes at a set angle with the distance between the passes defined by the Step over (see topic 6.1.5 ) parameter.
The Linear machining strategy in SolidCAM creates a series of linear passes, each oriented according to a specified Angle value This method is particularly efficient for shallow or steep surfaces aligned with the direction of the passes The Z-height at each point along a raster pass matches the Z-height of the triangulated surfaces, with necessary adjustments for offsets and tool specifications.
The passes depicted in the image are aligned with the X-axis and are uniformly distributed across the shallow faces as well as the inclined surfaces along the direction of the passes In contrast, the passes located on the side faces are spaced further apart, making Cross Linear machining (refer to topic 6.6.4) an effective method for finishing these areas.
Radial machining
The Radial machining strategy enables you to generate a radial pattern of passes rotated around a central point.
This machining strategy excels in processing shallow curved surfaces and regions shaped by revolution bodies, utilizing passes that are spaced along the XY-plane rather than the Z-plane Each point's Z-height during a radial pass matches that of the triangulated surfaces, with necessary adjustments for tool definitions and applied offsets.
Spiral machining
The Spiral machining strategy creates a 3D spiral tool path over your model, making it ideal for areas shaped by revolution bodies This technique involves projecting a planar spiral from the XY-plane of the current Coordinate System onto the model, ensuring efficient and precise machining.
Morphed machining
Morphed machining passes are created across model faces in a nearly parallel arrangement, similar to Linear machining passes Each path replicates the shape of the previous one while gradually incorporating features from the next, resulting in a continuous transformation of shapes from one side of the patch to the other.
The shape and direction of the patch is defined by two drive boundary curves.
Offset cutting
The Offset cutting strategy, a specific application of the Morphed machining strategy, allows for the creation of a tool path utilizing a single Drive curve This tool path is formed between the Drive curve and a virtual offset curve, which is established at a designated distance from the Drive curve.
Boundary machining
A Boundary machining strategy allows for the creation of tool paths by projecting a defined Drive boundary onto the model geometry The machining depth is set in relation to the model surfaces, utilizing the Wall offset parameter to refine the process This method ensures precise tool path generation tailored to the specific design requirements.
Boundary machining strategy can be used for engraving on model faces or for chamfer machining along the model edges.
Rest machining
Rest machining determines the model areas where material remains after the machining by a tool path, and generates a set of passes to machine these areas.
Pencil milling vertical corners can lead to unfavorable cutting conditions due to the flute and radius of the tool making full contact with the material In contrast, rest machining effectively removes corners from the top down, enhancing the machining process This technique allows for the machining of both steep and shallow areas in a single tool path, utilizing various rest machining strategies.
3D Constant step over machining allows for the creation of a precise 3D tool path on the surfaces of a CAM part This technique ensures that the tool path passes are consistently spaced at a uniform distance, measured along the contours of the model's surface.
Utilizing this strategy is essential for maintaining a consistent distance between passes along the model faces, particularly in areas defined by rest machining boundaries.
Constant surface step over is performed on a closed profile of the Drive boundary
(see topic 5.1.1 ) SolidCAM creates inward offsets from this boundary.
Pencil milling
The Pencil milling strategy efficiently generates a tool path along internal corners and small fillet radii, effectively removing leftover material from prior machining processes This technique is essential for achieving a smooth finish on corners that may exhibit cusp marks from earlier operations It is particularly beneficial for machining corners with a fillet radius that is equal to or smaller than the tool radius.
Parallel pencil milling
Parallel pencil milling combines the Pencil milling strategy with the 3D Constant step over technique Initially, SolidCAM generates a Pencil milling tool path, which then serves as the foundation for creating 3D Constant step over passes These passes are formed as a series of offsets on either side of the pencil milling paths Essentially, the Parallel pencil milling strategy utilizes Pencil milling passes as drive curves to shape the 3D Constant step over machining process.
This strategy is effective for machining internal corner radii that were not achieved by the previous cutting tool By utilizing multiple passes, it machines from the outside towards the corner, resulting in a superior surface finish.
The 3D Corner offset strategy, akin to the Parallel pencil milling strategy, merges the Pencil milling technique with the 3D Constant step over method SolidCAM creates a Pencil milling tool path, which is then utilized to generate 3D Constant step over passes as offsets from the Pencil milling passes Unlike the Parallel pencil milling strategy, the number of offsets is automatically determined, ensuring that the entire model within the defined boundary is effectively machined.
Prismatic Part machining
The Prismatic Part machining strategy is specifically tailored for high-speed finishing of prismatic components, integrating the Constant Z and 3D Constant step over technologies into a single efficient functionality Unlike the Combined Constant Z with 3D Constant step over strategy, which executes subsequent operations sequentially, the Prismatic Part machining strategy ensures that machining is carried out in a consistent manner, following the order of walls and flat surfaces along the Z-axis.
The system utilizes user-defined geometry parameters to calculate default technological values, ensuring an optimized machining solution For instance, the minimum and maximum Z-levels of the specified geometry are employed to determine the surface inclination angle.
The tool choice also affects the automatic calculation of defaults for technological parameters.
Combined strategies
SolidCAM enables you to combine two machining strategies in a single HSM operation: Constant
The Z with Horizontal, Linear, 3D Constant Step Over, and 3D Corner Offset machining strategies utilize shared geometry, tool, and constraint boundaries data Each strategy has its own defined technological parameters for calculating passes and linking processes.
The Geometry page enables you to define the 3D model geometry for the SolidCAM HSR/HSM operation.
Geometry
Geometry definition
The Target geometry section enables you to specify the appropriate Coordinate System for the operation and to define the machining geometry.
SolidCAM allows users to define the Coordinate System for operations by selecting it from a combo box or directly from the graphic screen using the CoordSys button.
CoordSys Manager dialog box is displayed Together with this dialog box, SolidCAM displays the location and axis orientation of all Coordinate Systems defined in the CAM-Part.
To get more information about the Coordinate System, right- click the CoordSys entry in CoordSys Manager and choose the
Inquire option from the menu.
The CoordSys Data dialog box is displayed.
Selecting the CoordSys is the crucial first step in the geometry definition process, as it determines the model's orientation during operations.
After the Coordinate System is chosen, define the 3D Model geometry for the SolidCAM HSR/ HSM operation.
If you have already defined 3D Model geometries for this CAM-Part, you can select a geometry from the list.
The Show button displays the chosen 3D model geometry in the
The New button ( ) enables you to define a new 3D Model geometry for the operation with the 3D Model Geometry dialog box
The Edit button ( ) enables you to edit an existing geometry.
The Browse button ( ) enables you to view the available geometries on the model and choose the relevant one from the list.
For more information on 3D Geometry selection, refer to the SolidCAM Milling User Guide
When you choose the geometry from the list, the related Coordinate System is chosen automatically.
Before machining, SolidCAM creates a triangular mesh for the 3D model's surfaces, with facet tolerance determining the precision of the triangle fitting A smaller facet tolerance value results in more accurate triangulation, although it may slow down the calculation process.
When utilizing a 3D model in SolidCAM for the first time in an HSR/HSM operation, the geometry undergoes triangulation, and the resulting facets are saved In subsequent operations using the same 3D geometry, SolidCAM verifies the tolerance of the existing facets and avoids additional triangulation if they were previously created with the same surface tolerance.
The automatic fillet addition feature significantly enhances the machining process by smoothing internal model corners, thereby minimizing drastic direction changes and reducing the risk of damage to the tool and model surfaces As a result, this feature enables faster feed rates and ultimately yields better surface quality, making it a valuable asset in optimizing machining operations.
When the corner radius is equal to or smaller than the tool radius, the tool path features two lines that meet at a sharp corner, resulting in a sudden change in the tool's direction at that point.
Incorporating fillets increases the corner radius beyond the tool radius, allowing the tool path lines to connect with an arc This adjustment leads to smoother tool movement and eliminates sharp directional changes.
Select the Apply fillets check box to automatically add fillets for the tool path generation.
Click to create a new fillets geometry The Fillet Surfaces dialog box is displayed.
The Show button displays the chosen fillet geometry directly on the solid model.
Model without fillets Model with fillets
The Fillet Surfaces dialog box enables you to generate fillet geometry for the current 3D Model geometry used for the HSM operation.
The Boundary type section enables you to specify the boundary geometry for the fillet generation The fillets will be generated inside the specified 2D boundary.
SolidCAM offers various 2D boundary types, including auto-created silhouette, auto-created outer silhouette, user-defined boundary, and an auto-created box surrounding the target geometry The auto-created box option efficiently generates a planar box that encompasses the target geometry.
The Boundary name section allows users to select a 2D boundary geometry from a provided list or create a new one by clicking the New button, which opens the relevant dialog box Additionally, users can modify an existing geometry using the Edit button.
The Show button opens the Select Chain dialog box, showcasing the available chains highlighted in the graphic window Users have the option to deselect any automatically generated chains if necessary.
For the calculation of fillets, SolidCAM uses a virtual tool The Filleting tool data section enables you to specify the geometry parameters of this tool.
• Tool Diameter This field enables you to specify the cutting diameter of the virtual tool.
• Corner radius This field enables you to specify the corner radius of the virtual tool.
• Taper (°/side) This field enables you to specify the taper angle of the tool’s flank SolidCAM does not support tool with a back taper, like a Dove tail tool.
• Cutting length This field enables you to specify the length of the cutting edge of the tool.
• Shank diameter This field enables you to specify the shank diameter.
• Outside holder length This field enables you to specify the length of the visible part of the tool, from the tip to the start of the tool holder.
• Tolerance This parameter defines the tolerance of fillet surfaces triangulation A lower value will give more accurate results, but will increase the calculation time.
• Resolution This is the "granularity" of the calculation
Using a smaller value will give finer detail but will increase the calculation time.
• Minimum Z This option sets the lowest Z-level the tool can reach.
• Number of facets This is the number of flat faces (triangles) across the radially curved section of the fillet.
The bitangency angle is the minimum angle necessary between the two normals at the contact points of the tool and model surfaces, which is crucial for determining the generation of a fillet.
In the Tool data section of the SolidCAM HSR/HSM operation dialog box, the following tool parameters are displayed:
Tool
Calculate minimum tool length
This feature allows you to determine the minimum outside holder length of the tool to prevent holder gouging with the model By selecting the "Calculate minimum tool length" checkbox and clicking "Save & Calculate," SolidCAM will compute the suggested value and present it for your review.
This option is not available for the Rest machining strategy.
Tool selection
The Select button enables you to edit tool parameters or define the tool you want to use for this operation.
This button opens the Edit page for the Part Tool Table, allowing you to add a new tool for the operation or select an existing tool from the table.
For more information on the tool definition, refer to the SolidCAM Milling User Guide
Holder Clearance
The Holder Clearance parameter enables you to define how close the holder can approach the material during the machining.
Spin & Feed Rate definition
The Data tab displays the spin and feed parameters that you can edit.
This field defines the spinning speed of the tool.
The spin value can be defined in two types of units: S and V
S is the default and signifies Revolutions per Minute V signifies Material cutting speed in Meters/
Minute in the Metric system or in Feet/Minute in the Inch system; it is calculated according to the following formula:
Feed value is measured in two units: F and FZ The unit F represents units per minute, while FZ indicates units per tooth, calculated using a specific formula.
The F / FZ buttons enable you to check the parameter values.
• Cutting This field defines the feed rate of the cutting section of the tool path.
• Link down The feed rate to be set for lead in moves.
• Link up The feed rate to be set for lead out moves.
• Rapid This parameter enables you to define a feed rate for the retract sections of the tool path, where the tool is not contacting with the material.
Boundaries
Introduction
SolidCAM enables you to define two types of boundaries for the SolidCAM HSR/HSM operation tool path.
Drive boundaries are used to drive the shape of the tool path for the following strategies: 3D Constant step over , Morphed machining , Offset cutting and Boundary machining
Drive boundaries for Morphed machining
SolidCAM enables you to define drive boundary curves for the Morphed machining strategy (see topic 2.13 ).
You can select existing geometries for the first and second drive curves from a list or create a new one by clicking the Define button, which opens the Geometry Edit dialog box For further details on selecting geometries, please consult the SolidCAM Milling User Guide.
The Show button displays the chosen drive curve geometry directly on the solid model.
Make sure that the directions of both drive curves are the same in order to perform the correct machining.
This option enables you define the tool path direction between the drive curves.
• Across The morphed tool path is performed across the drive curves; each cutting pass connects the corresponding points on the drive curves.
The tool path is designed to morph along the drive curves, transitioning smoothly from the shape of the first curve to that of the second This gradual transformation allows for a seamless connection between the two distinct drive curves.
Drive boundaries for Offset cutting
The Drive boundaries page of the HSM Offset cutting machining dialog box enables you to define the curve and the related parameters.
This section enables you to define the Drive curve used for the tool path definition.
This section allows you to define the direction of a virtual offset from the Drive curve, which can be created to the Right, Left, or in Both directions.
This section outlines the machining process, offering two options: Along and Across Choosing the Along option allows the machining to follow the Drive curve, with the tool path smoothly transitioning between the Drive curve and the offset curve In contrast, selecting the Across option results in the tool path moving across the Drive curve, where each cutting pass links corresponding points on both the Drive and offset curves.
The Boundary – Tool Relation section enables you to define the position of the tool relative to the defined boundary and the related parameters.
For more information, see topic 5.2.1
A constraint boundary enables you to limit the machining to specific model areas.
Machining occurs within defined boundaries that determine the limits of the tool tip's movement These boundaries can be extended beyond the tool's actual limits by the radius of the tool shaft, allowing for a larger machined area.
The tool center is positioned at the boundary's edge, causing the tool to extend beyond this edge by its radius To adjust the tool's placement inward, you can utilize the Offset feature, as detailed in section 6.1.7.
If there are several boundary contours then the operation will use all of them.
When one boundary is entirely contained within another, it functions like an island The region formed by the outer boundary, excluding the space defined by the inner boundary, will be processed or machined.
You can extend this to define more complicated shapes by having islands within islands.
Boundary Definition
The following boundary types are available:
This option enables you to automatically create the boundary using the stock or target models. The following types of automatically created boundaries are supported in SolidCAM:
• Auto-created box of target geometry
• Auto-created box of stock geometry
This option enables you to define the constraint boundary that limits the tool path by creating a 2D area above the model in the
XY-plane of the current Coordinate system or by an automatically generated 3D curve mapped on the surface.
The following types of 2D boundaries are supported:
The following types of 3D boundaries are supported:
This section enables you to define a new boundary geometry or choose an already defined one from the list.
• The New button ( ) displays the appropriate dialog box for the geometry definition.
The Edit button opens the Select Chain dialog box, allowing you to select the required chains for the boundary The selected boundaries will be highlighted and displayed in the graphic window.
This option controls how the tool is positioned relative to the boundaries This option is relevant only for 2D boundaries.
The tool machines inside the boundary.
The tool machines outside the boundary.
The tool center is positioned on the boundary.
The Left/Right/Centered boundary definition methods have notable limitations, often leading to unmachined areas or rounded corners due to the restrictions imposed by planar boundaries on the tool path.
The Tangent option enables you to avoid these problems.
By selecting this option, SolidCAM creates tool path boundaries by projecting the planar working area onto the 3D model, ensuring that the tool path is restricted so that the tool remains tangent to the model faces at the boundaries.
This option enables you to machine the exact boundary taking the geometry into account.
This value enables you to specify the offset of the tool center.
A positive offset value enlarges the boundary; a negative value reduces the boundary to be machined.
The tool is tangent to the projection of the working area onto the model faces
Automatically created boundaries
5.3.1 Auto-created box of target geometry
With this option SolidCAM automatically generates a rectangular box surrounding the target model The tool path is limited to the area contained in this box.
5.3.2 Auto-created box of stock geometry
With this option SolidCAM automatically generates a rectangular box surrounding the stock model The tool path is limited to the area contained in this box.
SolidCAM offers an automated feature that creates a silhouette boundary of the target model, which represents the projection of both the outer and inner contours onto the XY-plane.
SolidCAM offers a feature that automatically creates an outer silhouette boundary of the target model This boundary represents a projection of the model's outer contours onto the XY-plane.
A Boundary Box is a rectangular box surrounding the selected model geometry SolidCAM enables you to limit the machining passes to the area contained in the Boundary box.
The Boundary Box dialog box enables you to define a necessary parameters and choose the model elements for the bounding box calculation.
The boundary will be created on
This option enables you to select the faces for which a bounding box is generated Click the Select button to display the Select Faces dialog box (see topic 5.4.6 ).
The Show button displays the already selected faces geometry.
The table section displays the automatically calculated minimum and maximum coordinates, center and length of the bounding box.
SolidCAM enables you to change the XY-coordinates of the minimum and maximum coordinates of the bounding box.
Once the geometry for generating the bounding box is set, click the button to create the boundary chains, which will prompt the display of the Select Chain dialog box (refer to topic 5.4.7).
A silhouette boundary represents the outline of an object's edges as viewed from a specific angle, specifically projected onto the XY-plane Essentially, it is the shape visible when observing a collection of surfaces along the tool axis.
The Silhouette Boundary dialog box enables you to define the parameters and choose the solid model elements for the silhouette boundary calculation.
The boundary will be created on
SolidCAM allows users to select face geometry to create a silhouette boundary You can either choose from an existing list of face geometries or define a new one using the Select button By clicking this button, the Select Faces dialog box will appear, and the Show button will display the chosen face geometry.
This value defines the spanning of the boundary, the distance between two points on either side Boundaries that have a diameter smaller than this are discarded.
This value defines the fuzziness of the Silhouette Decrease the value to bring it into sharper focus; increase it to close up unwanted gaps between boundaries.
This value defines the granularity of the calculation: a small value results in a more detailed boundary, but it is slower to calculate.
Once the geometry for generating the silhouette boundary is established, simply click the designated button to create the boundary chains This action will prompt the display of the Select Chain dialog box, as detailed in topic 5.4.7.
SolidCAM enables you to define a user-defined boundary based on a Working area geometry (closed loop of model edges as well as sketch entities).
For more information on Working area geometry, refer to the SolidCAM Milling User Guide
SolidCAM automatically projects the selected geometry on the XY-plane and defines the 2D boundary.
The Geometry Edit dialog box enables you to define the geometry.
SolidCAM enables you to define a user-defined boundary based on a Profile geometry All the HSM strategies enable you to use closed profile geometries The Boundary machining strategy (see topic
2.15 ) enables you to use also open profiles for the boundary definition; this feature is useful for single-contour text engraving or for chamfering.
For more information on Profile geometry, refer to the SolidCAM Milling User Guide
SolidCAM automatically projects the selected geometry on the XY-plane and defines the 2D boundary.
The Geometry Edit dialog box enables you to define the geometry.
This option enables you to define the boundary by performing a number of boolean operations between working area geometries and boundaries.
The Boolean Operations dialog box is displayed.
This feature allows you to select the Coordinate System for the source geometries involved in the boolean operation, ensuring that the resulting combined geometry is generated in the specified coordinate system.
This field enables you to choose the SolidWorks configuration where the source user-defined geometries for the boolean operation are located.
This field enables you to define the type of the boolean operation The following boolean operations are available:
This option enables you to unite selected geometries into a single one All internal segments are removed; the resulting geometry is outer profile.
This option enables you to merge a number of geometries, created by different methods, into a single one.
This option enables you to perform subtraction of two geometries The order of the geometry selection is important; the second selected geometry is subtracted from the first selected one.
This option enables you to perform intersection of two geometries.
The Accept button performs the chosen operation with the geometries chosen in the Geometries section.
The Geometries section displays all the available working area geometries classified by the definition method.
This section allows you to select the suitable geometries for the boolean operation by checking the box next to the geometry name.
Upon clicking the Accept button, the generated geometry appears in the list under the Combined 2D header SolidCAM allows you to modify the name of the created geometry, which is automatically selected for subsequent boolean operations.
The resulting combined geometry is always a 2D geometry even if one or more of the input geometries is a 3D boundary.
The right-click menu available on the list items enables you to perform the following operations:
• Accept This button enables you to perform the chosen boolean operation with the selected geometries.
• Unselect All This option unselects all the chosen geometries.
• Delete This option enables you to delete combined geometries generated in the current session of the Boolean Geometries dialog box.
This dialog box enables you to select one or several faces of the SolidWorks model The selected Face tags will be displayed in the dialog box.
If you've selected incorrect entities, simply use the Unselect option to reverse your choice Alternatively, you can right-click on the entity name to highlight the object and select the Unselect option from the menu.
The Reverse / Reverse all option enables you to change the direction of the normal vectors of the selected faces.
The CAD Selection option enables you to select faces with the
Depending on the boundary type, SolidCAM generates a number of chains for the selected faces The Select Chain dialog box enables you to select the chains for the boundary.
The boundary will be created on
• Selected faces This option enables you to choose a faces geometry to generate a boundary of the defined type
SolidCAM enables you either to choose an already existing
Faces geometry from the list or define a new one with the
Select button The Select Faces dialog box (see topic 5.4.6 ) will be displayed The Show button displays the selected face geometry.
• Whole model With this option, SolidCAM generates boundaries of the chosen type for all the model faces.
Set the machining range along the Z-axis by definition of upper and lower limits Boundaries will be generated within this range.
To set the contact angle range of your tool, define the minimum and maximum angles, which will create boundaries in areas that fall within this range For Shallow Area boundaries, the recommended angle range is typically between 0 and 30 degrees; however, if surfaces are near the minimum or maximum, you might encounter jagged edges and should consider adjusting the range Additionally, applying a small offset to the boundary can help prevent the formation of these jagged edges.
This option should be selected to choose only boundaries that are in contact with the model surface.
This value specifies the distance between the tool and the surface, akin to the Wall offset parameter found on the Passes page (refer to topic 6.1.1).
For roughing and semi-finishing operations, it is essential that the calculated value exceeds zero This calculation utilizes a modified tool design, which features a surface area larger than that of the actual tool, ensuring that material remains on the part.
For finishing operations, the value must be set to zero The calculations are based on the dimensions of the defined tool with no offset.
In specific situations, like the creation of electrodes with a spark gap, the material removal value may be negative, indicating that the tool can cut below the intended surface level These calculations utilize a modified tool with a smaller offset than the standard one.
This value defines the distance away from the surface at which the boundaries will be in the tool axis direction.
The boundary is calculated using the Wall offset The resulting boundary is updated by offsetting along the tool axis by a distance equal to the Floor offset
This value defines the spanningof the boundary, the distance between two points on either side Boundaries that have a diameter smaller than this are discarded.
The boundaries are calculated and then offset by this amount.
It may be advantageous sometimes to set a small offset value to prevent jagged boundary edges where surface area is at angle similar to the Contact Angle
In Rest areas (see topic 5.5.6 ) with no offset, the exact boundary area would be machined, resulting in marks or even cusps around the edge For Theoretical rest areas
Offsetting the boundaries outward along the surface ensures a good finish at the edges of the rest areas If offsetting is not applied, the theoretical rest area may be machined precisely, which could result in visible marks or cusps near the edge due to insufficient material depth By implementing offsetting, the boundaries become smoother, leading to a less jagged tool path during machining.
This value defines the granularity of the calculation A small value results in a more detailed boundary but it will be slower to calculate.
This option enables you to define the boundary by selecting drive and check faces similar to the Working area definition for 3D Milling operations.
Under Boundary name , click the Define button to start the boundary definition The Selected faces dialog box enables you to define the drive and check faces.
This section enables you to define the boundary name and the tolerance that is used for the boundary creation.
Passes parameters
The Passes tab displays the major parameters that affect the generation of tool path passes.
This option enables you modify the tool diameter The machining is performed using the modified tool.
The tool is moved away from the machining surface by the defined value The offset is left unmachined on the surfaces
Generally, positive values are used for roughing and semi- finishing operations to leave an allowance for further finishing operations.
The specified diameter tool is utilized for calculating the tool path, allowing for machining to be carried out directly on the model surfaces Typically, a zero offset is employed during finishing operations to achieve optimal results.
The tool is moved deeper into the material penetrating the machining surface by the specified value.
This method is utilized in specific situations, like the creation of electrodes featuring a spark gap The tool operates by removing material beneath the intended surface level, with calculations relying on a modified, smaller tool than the standard one employed.
When calculating negative values, the offset must be equal to or smaller than the tool's corner radius, as it is based on a modified, smaller tool If the offset exceeds the corner radius, surfaces at angles close to 45° may suffer, as the tool's corner impacts the machined surface, resulting in an offset greater than intended However, horizontal and vertical surfaces remain unaffected.
Applying a negative value, such as –1 mm, to a tool without a corner radius results in a significantly larger real offset at the tool's corners, approximately –1.4 mm, which is inaccurate To effectively simulate a negative offset using a slot mill, define a bull-nosed tool with a corner radius that matches the negative offset value; for instance, use a corner radius of 1 mm with a negative offset of –1 mm.
If you define an end mill, the offset will be greater than the value set on surfaces nearing 45 degrees.
Using a bull-nosed tool with a positive corner radius equal to the desired negative offset, you will achieve better and more accurate results.
This offset is applied to the tool and has the effect of lifting
(positive value) or dropping (negative value) the tool along the tool axis As a result, Floor offset has its greatest effect on horizontal surfaces and no effect on vertical surfaces
By default, this value is equal to that of Wall offset (see topic 6.1.1 ).
The tool path is determined by considering both the tool and wall offset This calculation involves offsetting along the tool axis by a distance that matches the specified floor offset value, resulting in an accurate tool path.
All machining operations have a tolerance, which is the accuracy of the calculation The smaller is the value, the more accurate is the tool path.
The tolerance is the maximum amount that the tool can deviate from the surface.
The Step Down parameter determines the spacing of passes along the tool axis, distinct from Adaptive Step Down, which modifies passes for optimal edge fitting When the Step Down parameter is set, the passes maintain a consistent distance, irrespective of the XY coordinates, unless the Adaptive Step Down option is enabled.
Thisparameter is available for the Constant Z finishing strategy.
Cut with high tolerance Cut with low tolerance
This parameter is the default option that allows constant step down along all model levels.
This parameter allows adding extra passes between step downs to machine material left on flats.
This parameter is available for HM roughing
Step over refers to the distance between two adjacent passes in machining processes While it is typically measured in the XY-plane for most strategies, the 3D Constant Step Over strategy measures it along the surface.
This parameter is available for Linear machining , Radial machining , Spiral machining , Morphed machining , 3D Constant step over and Hatch roughing
This option that hybrid spiral passes at each level The machining starts from outside of the part.
In this parameter, the machining starts from inside and is performed on the entire part at each level.
Each level is machined starting from the inside of the part.
This parameter is available for HM roughing
This option enables you to extend the tool path beyond the boundary to enable the tool movement into the cut with machining feed rather than rapid feed.
The Linear tool path shown below is created with the zero pass extension:
The Linear tool path shown below is created with 5 mm pass extension:
The Pass Extension parameter is available for Linear machining and Radial machining strategies.
Each Z-level features a "surface profile" along with several concentric offset profiles The defined minimum and maximum offset values establish the spacing range between passes SolidCAM intelligently selects the largest feasible value within this range, ensuring that no undesirable upstands are left between the passes.
Contour Roughing passes are generated from a series of offset profiles, where each profile can be offset by no more than the tool radius to ensure complete area clearance In cases of very smooth profiles, offsets can extend up to the tool diameter while still achieving full clearance However, exceeding the tool diameter may result in uncut areas between passes SolidCAM employs an advanced algorithm to determine the optimal offset between the tool radius and diameter, ensuring the area is cleared without leaving any upstands.
The Min Offset value should be greater than the Offset tolerance (see topic 6.2.3 ) parameter and smaller than the tool shaft radius; the Max Offset value is calculated automatically.
This parameter is used for Contour Roughing , Hatch roughing and Horizontal finishing
The limits are the highest and lowest Z-positions for the tool – the range in which it can move.
• Z-Top limit This parameter defines the upper machining level The default value is automatically determined at the highest point of the model.
• Z-Bottom limit This parameter enables you to define the lower Z-level of the machining The default value is automatically set at the lowest point of the model.
The limit is implemented to restrict passes to specific level ranges and to prevent the tool from falling indefinitely when it moves beyond the edges of the model surface If the tool goes off the surface, it will continue at the Z-Bottom limit, ensuring it does not fall further.
The Delta option determines the adjustable offset for cutting depth while maintaining its associativity This parameter is always measured in relation to the defined Z-Top or Z-Bottom limit for the operation.
• CoAngle This parameter defines the contact angle alignment to be used when making cross machining passes.
This option is available only for the Linear finishing strategy.
• Angle SolidCAM enables you to limit the surface angles within a range most appropriate to the strategy The Constant
The Z strategy is particularly effective on steeper surfaces, as it optimizes the spacing between passes based on the Step down value, making it ideal for areas with minimal elevation changes.
Z-level change, the spaces between the passes are greater, therefore you may get unsatisfactory results You can limit the work area to surface angles between, for example, 30 and 90 degrees.
The angle is determined by the intersection of the two normals at the contact points between the tool and the model faces An angle of 0 indicates that the surface normal aligns perfectly with the tool axis, representing a horizontal surface.
This option is available for the Constant Z , Linear , Radial , Spiral , Morphed ,
Boundary , 3D Constant Step over , and Pencil milling strategies.
Selecting the "Contact Areas Only" checkbox ensures that the tool path is generated exclusively in areas where the tool contacts the model faces The following examples illustrate the outcomes of the Constant Z strategy, both with and without this option enabled.
When this check box is selected, the machining is limited to the actual surfaces of your geometry.
When this check box is not selected, the outer edge of the base surface is machined as well as the central boss.
SolidCAM enables you to optimize the tool path by reducing the number of points.
The Fit arcs option enables you to activate the fitting of arcs to the machining passes according to the specified Tolerance value.
The Tolerance value is the chordal deviation to be used for point reduction and arc fitting.
This option enables you to refine corner positions to provide a smoother tool path.
This option is available for HSR strategies of Contour and Rest roughing and for HSM strategy of Horizontal machining
Smoothing parameters
The Smoothing option enables you to round the tool path corners.
This option enables the tool to maintain a higher feed rate and reduces wear on the tool
This feature is often used in rough machining.
A curve can be approximated as an arc The Max radius parameter defines the maximum arc radius allowed.
The profile tolerance represents the maximum allowable deviation between the smoothed outer profile and the actual profile To minimize material loss, it is advisable to set the profile tolerance to a low or zero value.
The Offset Tolerance defines the maximum allowable divergence of a smoothed profile offset from the inner profiles, specifically focusing on the inner (offset) profiles rather than the outer profile This parameter is equivalent to the Profile Tolerance, but it is exclusively concerned with the inner profiles The measurement of Offset Tolerance is taken between any smoothed profile, excluding the outermost one, and the sharp corner of a theoretical profile that is not smoothed but shares the same offset as the smoothed profile.
Unlike the Profile Tolerance parameter, above, changing this value does not mean you miss material.
Original tool path Smoothed tool path
Adaptive step down parameters
• In areas where the horizontal distance between the passes is significant, Adaptive Step down can be used to insert extra passes and reduce the horizontal distance.
Adaptive Step Down technology enhances surface finishing by adding extra passes when the standard passes are too close or too far from the edges This process ensures optimal Z-distance between passes across the entire surface, while the Step Down value sets the maximum distance, allowing for precise adjustments to fit varying surface contours effectively.
The Adapt Step down by list enables you to select the mode of the adaptive step down:
Passes are applied without Adaptive Step down , and some material may be left on the top faces.
A pass is inserted to cut the top face; the next step down will be calculated from this pass.
Adaptive step down is not chosen Adaptive step down is chosen
Adaptive step down is not chosen Adaptive step down is chosen
This parameter specifies the minimum step down value to be used, which means that passes will be no less than this distance from each other.
This parameter controls how accurately the system finds the appropriate height to insert a new slice.
The Profile Step-in parameter determines the maximum XY-distance allowed between cutting profiles on consecutive Z-levels in SolidCAM During the calculation of the cutting profile at a specific Z-level, if the distance to the profile on the previous Z-level exceeds the defined Profile Step-in value, SolidCAM will introduce an additional Z-level This ensures that the distance between cutting profiles on successive Z-levels remains within the specified limit, optimizing the machining process.
Without Profile step-in With Profile step-in
The remaining cusp after machining can be determined through a combination of the Minimum Step Down and Profile Step parameters or the Minimum Step Down and Scallop parameters Consequently, the Profile Step and Scallop parameters are mutually exclusive in their application.
When the combination of the Scallop and Min Step down parameters is used for the operation definition, SolidCAM performs the parameters validation according to the criteria below.
• The Scallop value must be positive;
• The Scallop value must be smaller than that of the Min Step down parameter.
Min step down Machined surface
When the Scallop parameter fails to meet the validation criteria, an Error Parameters dialog box appears during the calculation process This dialog box identifies the incorrectly defined parameters and encourages you to revise their definitions.
The cut levels can be edited manually and inserted in the
User-define cut levels table Type the Z-levels of your choice into the Z column of the table The values will be sorted in the decreasing order.
Passes are applied without Adaptive Step down , and some material may be left on the top faces
This option is available for HSR strategies of Contour and Hatch roughing and for HSM strategies of Hybrid Constant Z , Prismatic Part machining and Helical machining
This option enables you to use a drive curve Click to define the curve geometry.
Using this option maintains consistency while machining a curve, automatically giving a smaller step down in the shallower areas.
When you choose to Use drive curve , the Step down parameter cannot be defined manually.
Edit Passes parameters
Utilizing formed stock instead of traditional rectangular or cylindrical blocks in machining can significantly reduce air cutting by allowing for precise trimming of tool paths to the formed stock faces This technique is particularly beneficial when using castings as the raw material or when machining parts from updated stock generated by previous operations.
For example, suppose you want to machine by Contour roughing the following model:
Using the Contour roughing strategy, you get the following tool path.
Rather than starting from a Cylindrical block of material, you start with the Casting shown below.
The resulting Trimmed tool path is shown below.
The Edit passes page enables you to define the parameters for the Trimming of passes.
By selecting this check box, you can limit the machining by using the Updated Stock model or by defining an offset from the operation geometry.
This option enables you to specify the method of machining area definition.
• When the Target geometry option is chosen, SolidCAM adds the Overthickness value as an offset to the target geometry of current operation This offset target is used as a stock.
When the Auto updated stock option is selected in SolidCAM, the software recalculates the updated stock model following all previous operations The Overthickness value is incorporated as an offset to the stock, which will serve as the stock for the current machining operation.
When selecting the Stock by *.FCT file option, machining occurs within a specified area that is determined by an offset from the updated stock This offset is defined by the Overthickness parameter and is based on the FCT file located in the CAM-Part folder.
When selecting the Stock by *.STL file option, machining occurs within an area determined by an offset from the updated stock, which is specified in the STL file located in the CAM-Part folder This offset is controlled by the Overthickness parameter.
This button displays the difference between the updated stock model and the target geometry used in the operation.
This parameter allows for the temporary adjustment of tool thickness during editing passes, enhancing the quality of trimmed passes A negative value restricts the selection to passes beneath the model faces by the defined amount, while a positive value includes all passes within the specified distance from the model faces.
Axial offset
This page allows for axial offset adjustments to the tool path multiple times The tool path can be generated using any of the HSM finishing strategies, excluding Constant Z and Rest machining.
When the Axial offset check box is selected, you have to define the following parameters:
This parameter defines the distance between two successive tool path passes.
This parameter allows you to specify the number of times the tool path offset is executed, with the total number of tool path passes calculated as the number of offsets plus one.
The tool path passes are generated in the positive Z-direction The machining is performed from the upper instance to the lower.
The Axial offset feature allows for semi-finish and finish machining in multiple equidistant vertical steps, making it ideal for engraving in various vertical increments.
Boundary Machining strategy or for removing the machining allowance by a finishing strategy in a number of vertical steps.
Strategy parameters
SolidCAM offers a range of options and parameters that allow users to manage specific features of different machining strategies, in addition to the standard parameters applicable to all machining techniques.
With the Contour roughing strategy, SolidCAM generates a pocket-style tool path for a set of sections generated at the Z-levels defined with the specified Step down (see topic 6.1.4 ).
This option causes the tool to start from the outside of the model rather than take a full width cut in the center of the component.
If your model includes both core and cavity areas, the system will automatically switch between core roughing and cavity roughing within the same tool path.
In creating a Contour roughing tool path, the machining process occurs from the top down, requiring that material be removed at one level before progressing to the next.
To incorporate Z-Top level passes into the operation tool path, adjust the Z-Top level by adding the Step down value to the existing Z-Top level value This adjustment ensures that the top level passes are included in the machining process.
SolidCAM's Hatch roughing strategy creates linear raster passes based on specified Z-levels and step-down parameters, making it ideal for older machine tools or softer materials This method primarily utilizes straight line sections in its tool path design.
This option enables you to define the angle of the hatch passes relative to the X-axis of the current Coordinate System.
The Offset parameter defines the distance between the hatch passes and the outer/inner profiles.
The Hybrid Rib roughing technique is specifically developed for machining ultra-thin walls made from exotic materials like titanium and graphite Traditional machining methods can pose challenges and risks when working with these materials This innovative strategy integrates both roughing and finishing tool paths, resulting in a unique approach that maximizes the rigidity of the part during the machining process.
In Hybrid Rib operation, each Z-level is machined with roughing and finishing passes after which machining of a lower level is performed.
The Roughing section enables you to control roughing passes and levels performed against a rib.
This parameter defines the distance between two parallel tool path passes.
When the Restrict offset option is selected, you can limit the number of parallel passes by specifying the value in the Number of offsets field.
When this option is selected, an additional pass is performed around the outside perimeter of the constraint boundary on each roughing level.
This parameter enables you to define an offset applied to the constraint boundaries from outside.
The Finishing section enables you to control finishing passes and levels performed against a rib.
This parameter enables you to define the number of finishing levels required between step downs.
This parameter enables you to define the number of finishing offsets required at each level.
This parameter defines the distance between two parallel finishing passes.
This parameter enables you to control the order of linking the finishing passes The following options are available:
• During, upwards: after each roughing level, the finishing levels are machined from lowest to highest
• During, downwards : after each roughing level, the finishing levels are machined from highest to lowest
• After, upwards : all roughing levels are machined first, followed by the finishing levels from lowest to highest
• After, downwards : all roughing levels are machined first, followed by the finishing levels from highest to lowest.
Linear machining generates a tool path consisting of a set of parallel passes at a given angle with the distance between the passes defined by the Step over parameter (see topic 6.1.5 ).
SolidCAM's Linear machining strategy creates a series of linear passes, each aligned according to a specified Angle value This approach is particularly effective for machining shallow, nearly horizontal surfaces or for steeper surfaces that align with the direction of the passes.
Z-height of each point along a raster pass is the same as the Z-height of the triangulated surfaces, with adjustments made for applied wall offset and tool definition.
The passes in the image are aligned along the X-axis and are evenly distributed on both the shallow faces and the inclined faces in the direction of the passes In contrast, the spacing on the side faces is wider, making cross linear machining an effective method for finishing these areas.
The Angle parameter allows you to specify the direction of passes, with values ranging from –180° to 180° Setting the Angle to 0° aligns the passes parallel to the X-axis of the current Coordinate System The sequence of passes and the machining direction are managed through the link settings.
The defined angle affects the step over calculation If you are machining vertical surfaces, Linear machining works best where the angle is perpendicular to these surfaces.
This option enables you to extend the passes tangentially to the model faces by a length defined by the Pass extension parameter.
When the check box is not selected, the extension passes are generated as a projection of the initial pattern (either linear or radial) on the solid model faces.
When the check box is selected, the extension passes are generated tangentially to the solid model faces.
The check box is not selected The check box is selected
SolidCAM intelligently identifies areas with sparse Linear machining passes and generates additional Linear tool paths perpendicular to the original direction The parameters for these Cross linear machining operations remain consistent with those applied in the initial Linear machining process.
Initial Linear machining tool path
Cross linear machining tool path
Combined Linear and Cross linear machining tool path
The Cross page enables you to define the order of performing Linear and Cross linear machining
Cross linear machining is not performed.
Cross linear machining is performed before the main Linear machining.
Cross linear machining is performed after the main Linear machining.
Only Cross linear machining is performed; the main Linear machining is not performed.
This strategy allows for the creation of multiple closed profile sections of 3D model geometry at varying Z-levels, akin to the Constant Z approach These sections are then seamlessly connected to form a continuous descending ramp, facilitating the development of a helical machining tool path.
The tool path generated with the Helical machining strategy is controlled by two main parameters:
Step down and Max ramp angle
The Step Down parameter specifies the vertical distance along the Z-axis between consecutive Z-levels for generating geometry sections This measurement is crucial for accurately defining the spacing and precision of the layers in the design process.
Constant Z strategy), the Helical machining strategy is suitable for steep areas machining.
This parameter defines the maximum angle (measured from horizontal) for ramping The descent angle of the ramping helix will be no greater than this value.
With the Horizontal machining strategy, SolidCAM recognizes all the flat areas in the model and generates a tool path for machining these areas.
This option directs the tool to begin machining from the outer edges of the model, rather than performing a full-width cut at the center Consequently, the machining process progresses inward from the outside.
To incorporate Z-Top level passes into the operation tool path, adjust the Z-Top level by adding the Step Down value to the current Z-Top level Typically, these passes are not included in the machining process.
This option enables you to refine corner positions to provide a smoother tool path.
The Radial machining strategy enables you to generate a radial pattern of passes rotated around a central point.
This machining strategy excels in processing shallow curved surfaces and areas shaped by revolution bodies, utilizing passes that are spaced along the XY-plane rather than the Z-plane Each point's Z-height along a radial pass matches the Z-height of the triangulated surfaces, with necessary adjustments for tool definition and applied offsets.
Step over is the spacing between the passes along the circumference of the circle.
The passes are spaced according to the Step over value measured along the circle defined by the Maximum Radius value.
You must specify the XY-position of the center point of the radial pattern of passes The Radial passes will start or end in this center point.
The minimum and maximum angles determine the start and end of pattern passes, controlling the angle span of the machining operation and specifying the portion of a complete circle that will be processed.
The angles are measured relative to the X-axis in the center point in the counterclockwise direction.
The Min radius and Max radius values enable you to limit the tool path in the radial direction.
The diagram above shows the effect of different minimum and maximum radii on Radial passes.
Calculation Speed
Tool paths for three fundamental tool types—end mills, ball-nosed tools, and bull-nosed tools—are generated using distinct machining algorithms, leading to variations in calculation speed for identical operations and geometries based on the tool type used For instance, employing a bull-nosed tool with a smaller corner radius can significantly increase the calculation time.
The speed of calculations is influenced by the tolerance settings for tool paths, which determine the worst-case scenario In many cases, particularly with Contour roughing and Constant Z machining using a bull-nosed tool with a small corner radius, the actual tolerance can be much tighter than specified This often leads to results that are more precise than necessary, resulting in slower calculation times.
Defining a positive Wall offset in machining leads to the use of a tool with larger corner and shaft radii compared to the original Conversely, applying a small Wall offset to an end mill results in the algorithm selecting a bull-nosed tool with a smaller corner radius This variation in tool selection alters the algorithmic characteristics and can affect the overall calculation time.
When applying a negative Wall offset that equals or exceeds the corner radius to a bull-nosed tool, the tool type may switch to an end mill in the machining algorithm, potentially speeding up the process However, using a negative Wall offset that is significantly larger than the corner radius can lead to unsatisfactory results.
The Link page in the HSR/HSM Operation dialog box enables you to define the way how the generated passes are linked together into a tool path.
In the image, the link movements are in green, the rapid movements are in red and the machining passes are in blue.
Following are the linking parameters that can be defined by the user: