SOLIDCAM 2010SIMULTANEOUS 5-AXIS MACHININGUSER GUIDE

3.2.2 Perpendicular to curveThis option enables you to generate the tool path orthogonal to the Lead curve defined in the Geometry section.. It is recommended to choose the Drive surfac

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SOLIDCAM - THE LEADERS IN INTEGRATED CAM

The complete integrated Manufacturing Solution inside SolidWorks

www.solidcam.com

SOLIDCAM 2010

SIMULTANEOUS 5-AXIS MACHINING

USER GUIDE Website: cadcenter.vn cung cap tai lieu & Video hoc CAD CAM CNC

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SolidCAM 2010

Simultaneous 5-Axis Machining

User Guide

Website: cadcenter.vn cung cap tai lieu & Video hoc CAD CAM CNC

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Contents

Contents

1 Introduction 15

1.1 Adding a 5-Axis Operation 17

1.2 5-Axis Operation dialog box 18

1.3 The stages of the Sim 5-Axis Operation parameters definition 20

2 CoordSys 21

2.1 CoordSys page 22

2.1.1 Coordinate System definition 23

3 Geometry 25

3.1 Geometry 26

3.1.1 Drive surface definition 27

3.1.2 Drive surface offset 28

3.1.3 Curves definition 28

3.2 Pattern 29

3.2.1 Parallel cuts 30

3.2.2 Perpendicular to curve 32

3.2.3 Morph between two boundary curves 33

3.2.4 Parallel to curve 33

3.2.5 Engraving 34

3.2.6 Morph between two adjacent surfaces 35

3.2.7 Parallel to surface 37

3.3 Area 39

3.3.1 Full, avoid cuts at exact edges 39

3.3.2 Full, start and end at exact surface edges 40

3.3.3 Limit cuts by one or two points 42

3.3.4 Determined by number of cuts 42

3.3.5 Extend/Trim 44

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3.3.6 Angle range 46

3.3.7 2D Boundary 47

3.3.8 Round corners 48

4 Tool 49

4.1 Tool definition 50

4.1.1 Spin definition 51

4.1.2 Feed definition 51

4.1.3 Rapid move parameters 53

5 Levels 55

5.1 Clearance area 56

5.1.1 Plane 56

5.1.2 Cylinder 58

5.1.3 Sphere 60

5.1.4 Tool tilting in the Clearance area 60

5.2 Machining levels 62

5.2.1 Retract distance 62

5.2.2 Safety distance 62

5.2.3 Air move safety distance 63

5.2.4 Rapid retract 63

6 Tool path parameters 65

6.1 Surface quality 66

6.1.1 Cut tolerance 66

6.1.2 Maximum Step over 67

6.1.3 Scallop 68

6.1.4 Surface edge merge distance 68

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Contents

6.2 Sorting 73

6.2.1 Cutting method 73

6.2.2 Direction of machining 76

6.2.3 Cut order 77

6.2.4 Machine by 78

6.2.5 Enforce closed contours 78

6.2.6 Flip step over 79

6.2.7 Start point 79

6.3 Tool contact point 82

7 Link 85

7.1 Approach/Retract 86

7.1.1 First entry 86

7.1.2 Last exit 89

7.1.3 Home position 91

7.2 Links 92

7.2.1 Gaps along cut 92

7.2.2 Links between slices 95

7.2.3 Links between passes 98

7.3 Default Lead In/Out 101

7.3.1 Type 101

7.3.2 Tool axis orientation 104

7.3.3 Approach/Retreat parameters (Use the ) 105

7.3.4 Height 106

7.3.5 Feed rate 106

7.3.6 Same as Lead In 106

8 Tool axis control 107

8.1 Output format 108

8.2 Interpolation 110

8.3 Tilting strategies (Tool axis direction) 111

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8.3.1 Not to be tilted and stays normal to surface 111

8.3.2 Tilted relative to cutting direction 111

8.3.3 Tilted with the angle value 122

8.3.4 Tilted to axis by fixed angle 125

8.3.5 Rotated around axis 126

8.3.6 Tilted through point 127

8.3.7 Tilted through curve 128

8.3.8 Tilted through lines 133

8.3.9 Tilted from point away 134

8.3.10 Tilted from curve away 135

8.3.11 Tilted relative to impeller machining layer 139

8.4 Angle range 141

9 Gouge check 143

9.1 Clearance 144

9.2 Report remaining collisions 146

9.3 Check gouge between positions 147

9.4 Extend tool to infinity 148

9.5 Check link motions for collision 148

9.6 Gouge checking 149

9.6.1 Tool 149

9.6.2 Geometry 150

9.6.3 Strategy 151

10 Roughing (Offset) 165

10.1 Multi-passes 167

10.2 Plunging 170

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Contents

10.7 Sorting 182

10.7.1 Reverse order of passes/tool path 182

10.7.2 Connect slices by shortest distance 183

10.8 Stock definition 185

11 Motion limits control 189

11.1 Angle pairs 191

11.2 Angle control 192

11.3 Interpolation for distance 193

11.4 Retract 193

11.5 Pole angle tolerance 193

11.6 Use machine limits 194

11.7 Control definition 195

12 Misc parameters 197

12.1 Set Y-axis machine limit (special machine) 198

12.2 Smooth surface normals 199

12.3 Tool center based calculation 199

12.4 Message 200

12.5 Extra parameters 200

13 Sim 5-Axis sub-operations 201

13.1 Parallel cuts 203

13.1.1 Geometry 203

13.2 Parallel to curves 205

13.2.1 Geometry 205

13.3 Parallel to surface 206

13.3.1 Geometry 206

13.4 Perpendicular to curve 207

13.4.1 Geometry 207

13.5 Morph between two boundary curves 208

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13.5.1 Geometry 208

13.6 Morph between two adjacent surfaces 209

13.6.1 Geometry 209

13.7 Projection 210

13.7.1 Geometry 210

13.8 Swarf Milling 211

13.8.1 Geometry 211

13.8.2 Tool path parameters 213

13.8.3 Tool Axis control 215

13.8.4 Gouge check 217

13.8.5 Roughing (Offset) 218

13.9 Impeller Roughing 219

13.9.1 Geometry 219

13.9.3 Tool axis control 222

13.9.4 Roughing (Offset) 223

13.10 Impeller Wall finish 224

13.10.1 Geometry 224

13.11 Impeller Floor finish - Curve control of tilt 228

13.12 Impeller Floor finish - Surface control of tilt 232

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Contents

13.14 Engraving 241

13.14.2 Tool 242

13.15 Cavity machining 244

13.15.1 Tool 245

13.15.3 Electrode machining 247

13.15.5 Tool 248

13.16 Turbine blade machining 251

13.16.2 Tool 252

14 Converting HSM to Sim 5-Axis operation 255

14.1 Source operation 257

14.2 Tool 258

14.3 Levels 259

14.4 Tool axis control 260

14.5 Gouge check 261

14.6 Motion limits control 263

14.7 Miscellaneous parameters 264

15 Multi-Axis Drilling operation 265

15.1 CoordSys page 267

15.2 Geometry page 268

15.3 Tool page 270

15.4 Levels page 271

15.4.1 Clearance area 271

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15.4.2 Levels 272

15.5 Technology page 276

15.5.1 Sequence of drill positions 276

15.5.2 Sorting of cylindrical drilling patterns 277

15.5.3 Drill cycle 286

15.6 Gouge check page 287

15.7 Motion limits control page 288

15.8 Miscellaneous parameters page 289

16 Machine simulation 291

16.1 Machine simulation user interface 293

16.1.1 Simulation menu 294

16.1.2 Simulation windows 306

16.1.3 Simulation toolbars 318

16.2 Machine Simulation settings 320

16.2.1 Directory for Machine simulation definition 320

16.2.2 Tool path coordinates 320

16.2.3 Background 320

16.2.4 Enable collision control 322

16.2.5 Solid verification 322

16.2.6 Environment 322

17 CNC-machine definition 323

17.1 CNC-machine definition 324

17.1.1 CNC-machine kinematic type 324

17.1.2 Spindle direction 326

17.1.3 Rotation axes direction 326

17.1.4 Rotation axes names 329

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Contents

17.1.8 Rotation axis limits 334

17.1.9 Coordinate output parameters 335

17.1.10 Motion limit control parameters 338

17.1.11 Machine simulation 342

17.1.12 Example of CNC-machine definition 343

17.2 CNC-machine model definition 344

17.2.1 Preparing a CNC-machine model 344

17.2.2 Starting the CNC-machine definition 348

17.2.3 Understanding the structure of the CNC-machine 350

17.2.4 Defining the CNC-machine housing 352

17.2.5 Defining the translational axis 353

17.2.6 Defining the rotational axis 356

17.2.7 Defining the translational axis 361

17.2.8 Defining the workpiece 364

17.2.9 Defining the stock 365

17.2.10 Defining the fixture 366

17.2.11 Defining the tool path 367

17.2.12 Defining the tool 368

17.2.13 Collision control 369

17.2.14 Defining the coordinate transformation 371

17.2.15 XML file structure 374

18 Exercises 379

Exercise #1: Impeller machining 380

Exercise #2: Turbine blade machining 382

Exercise #3: Aerospace part machining 384

Exercise #4: Engine port machining 386

Exercise #5: Eccentric shaft and cam machining 388

Exercise #6: 5-Axis Engraving 389

Index 391

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1 Introduction

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Welcome to the SolidCAM Sim 5-Axis machining module!

Simultaneous 5-Axis machining is becoming more and more popular due to the need for reduced machining times, better surface finish and improved life span of tools SolidCAM utilizes all the advantages of Simultaneous 5-Axis machining and, together with collision control and machine simulation, provides a solid base for your 5-Axis solution Intelligent and powerful 5-Axis machining strategies, including swarfing and trimming, enable the use of SolidCAM for machining of complex geometry parts such as mold cores and cavities, aerospace parts, cutting tools, cylinder heads, turbine blades and impellers SolidCAM provides a realistic simulation of the complete machine tool, enabling collision checking between the tool and the machine components

About this book

This book is intended for experienced SolidCAM users If you are not familiar with the software, start with the lessons in the Getting Started Manual and then contact your reseller for information about SolidCAM training classes

About the CD

The CD supplied together with this book contains the various CAM-Parts illustrating the use of SolidCAM Sim 5-Axis machining The CAM-Parts are located in the Exercises folder and described

in Chapter 18 The CNC-machine model sub-folder contains a schematic model of the Table-Table

CNC-machine used in Chapter 17 Copy the complete Exercises folder to your hard drive The SolidWorks files used for exercises were prepared with SolidWorks 2010

The CNC-machine folder contains the MAC file and the CNC-machine definition used for the exercise parts Copy the MAC file into your GPPTool folder (the default location is

C:\Program Files\SolidCAM2010\GPPTool) Copy the CNC-machine definition into your Machine definition folder (the default location is C:\Program Files\SolidCAM2010\Tables\Metric\MachSim\ xml)

Copy the complete CNC-machine model folder to your hard drive

The contents of the CD supplied with this book can also be downloaded from the SolidCAM site http://www.solidcam.com

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1 Introduction

1.1 Adding a 5-Axis Operation

To add a 5-Axis Operation to the CAM-Part, right-click on the Operations header in SolidCAM Manager and choose the Sim 5-Axis command from the Add Operation submenu

The 5-Axis operation dialog box is displayed

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1.2 5-Axis Operation dialog box

The 5-Axis Operation dialog box enables you to define the parameters of the 5-Axis machining

Technology

This section enables you to define the type of the Sim 5-Axis operation

The General Sim 5-Axis operation provides you to use all the functionality of the SolidCAM Sim 5-Axis module In addition, SolidCAM provides you with a number of Sim 5-Axis sub-operations dedicated for specific Sim 5-Axis machining tasks For more details about Sim 5-Axis sub-operations refer to the Chapter 13

Parameter pages

The parameters of the 5-Axis operation are divided into a number of subgroups The subgroups are displayed in a tree format on the left side of the 5-Axis Operation dialog box When you click

on a subgroup name in the tree, the parameters of the selected subgroup appear on the right side

of the dialog box

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Define the Clearance area and the machining levels.

• Tool path parameters

Define the machining parameters

• Link

The Link and Default Lead In/Lead Out pages enable you to define how the Sim 5-Axis cutting passes are linked to the complete tool path

• Tool axis control

Define the orientation of the tool axis during the Sim 5-Axis machining

• Gouge check

Avoid the tool gouging of the selected drive surfaces and check surfaces

• Roughing (Offset)

Define the parameters of the Sim 5-Axis roughing

• Motion limits control

Define the parameters related to the kinematics and special characteristics of the CNC-machine

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1.3 The stages of the Sim 5-Axis Operation parameters definition

The operation definition is divided into three major stages:

1 CoordSys, Geometry, Finish Parameters and Links – generation of the tool path for the selected faces Tool tilting and gouge checking are not performed at this stage

2 Tool axis control – controlling the angle of the tool from the normal vector at every point along the tool path

3 Gouge check – avoiding tool and holder collisions

Gouge check

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2 CoordSys

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2.1 CoordSys page

On this page you define the Coordinate System appropriate for the

operation Choose an existing Coordinate System from the list or click

on the Define button to define a new one The CoordSys Manager

dialog box is displayed This dialog box enables you to define a new

Coordinate System directly on the solid model

When the Coordinate System is chosen for the operation, the model is

rotated to the selected CoordSys orientation

For more information on the Coordinate System definition, refer to the

SolidCAM Milling User Guide

The CoordSys definition must be the first step in the operation definition process

In Sim 5-Axis operation, you have to choose only the Machine Coordinate Systems The Sim 5-Axis tool path generated relative to the Machine Coordinate System contains the tool path positions and tool axis orientation at each tool path position The tool path is generated in the 4/5-axes space

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2 CoordSys

2.1.1 Coordinate System definition

At the stage of the CAM-Part creation, during the coordinate system definition, it is important to define the Center of Rot Origin based on Machine CoordSys parameter located in the CoordSys Data dialog box

This parameter defines the location of the

CAM-Part Coordinate System relative to

the coordinate system of the CNC-machine

In other words, it enables you to define the

location of the CAM-Part on the

CNC-machine table The parameter is defined by

three coordinates of the distance vector

X

YZ

CNC-machine origin

CAM-Part CoordSys Distance vector

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3 Geometry

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The Geometry page enables you to define the geometry, the machining strategy and its parameters for machining.

3.1 Geometry

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3 Geometry

3.1.1 Drive surface definition

In the Drive surface section, choose the appropriate geometry from the

list or define a new one by clicking on the Define button The Select Faces

dialog box is displayed This dialog box enables you to select one or several

faces of the SolidWorks model Click on the appropriate model faces The

selected faces are highlighted

To remove selection, click on the selected face again or right-click on the

face name in the list (the face is highlighted) and choose the Unselect

option from the menu

When transferring model files from one CAD system to another, the

direction of some of the surface normals might be reversed For this

reason, SolidCAM provides you with the capability to display and edit the

normals of model surfaces during the geometry selection

The Show direction for highlighted faces only check box enables you to

display the surface normals for the specific highlighted faces in the list

The Show direction for selected faces check

box enables you to display the normals

direction for all the faces in the list

SolidCAM enables you to machine surfaces

from the positive direction of the surface

normal Sometimes surfaces are not oriented

correctly and you have to reverse their normal

vectors The Reverse/Reverse All command

enables you to reverse the direction of the

surface normal vectors

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3.1.2 Drive surface offset

The Drive surface offset parameter enables you to define a machining allowance for the drive surface The machining is performed at the specified distance from the drive surface

The offset is three-dimensional and expands the faces in every direction

3.1.3 Curves definition

Some Sim 5-Axis machining strategies use additional curve geometries for

the tool path generation SolidCAM enables you to define such geometries

using the Geometry Edit dialog box

For more information on the wireframe geometry selection, refer to

SolidCAM Milling User Guide

Drive Surfaceoffset

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Technology list (see chapter 13) The

Engraving strategy is represented by the

Projection sub-operation

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3.2.1 Parallel cuts

This option creates tool path cuts that are parallel to each other The

direction of the cuts is defined by two Machining angles The angles

in XY and in Z determine the direction of the parallel cuts of the tool

Machining angle in XY Machining angle in Z

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3 Geometry

Generating cuts parallel to the Y-axis

Set the Machining angle in Z to 90° (or click on the

Parallel button) and set the angle in XY to 0°

The generated tool paths are parallel to the Y-axis

The X-distance between the passes is constant

Generating cuts parallel to the X-axis

Set the Machining angle in Z to 90° (or click on the

Parallel button) and set the angle in XY to 90°

The generated tool paths are parallel to the X-axis

The Y-distance between the passes is constant

Generating cuts parallel to the Z-axis

Set the Machining angle in Z to 0° or click on the

X

Y

XWebsite: cadcenter.vn cung cap tai lieu & Video hoc CAD CAM CNC

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3.2.2 Perpendicular to curve

This option enables you to generate the tool path orthogonal to the Lead curve

defined in the Geometry section

Note that when the selected curve

is not a straight line, the cuts are not parallel to each other

The lead curve geometry does not have to be located on

the surface During the tool path calculation, SolidCAM

generates in each point of the lead curve virtual points on

the curve The distance between these points is determined

by the Step over value (see topic 6.1.2) SolidCAM projects

these points onto the drive surface; the direction of the

projection is the normal vector of the curve at the virtual

point Where the normal vector intersects with the surface,

a virtual surface point is generated The passes are generated

through these points, normal to the lead curve

If the cuts cross each other at the edge of the surface, caused by a not appropriate lead curve, you will not get an acceptable result

90°

Curve Tool path

Leading curve

Drive surface

Tool path

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3 Geometry

3.2.3 Morph between two boundary curves

This option creates a morphed tool path between two leading curves The generated tool path is evenly spread over the drive surface

The Start Edge Curve and End Edge Curve sections enable you to define the leading curves for the morphing using the

Geometry Edit dialog box (see topic 3.1.3)

It is recommended to choose the Drive surface edges as the lead curves geometry to get better morphing of the tool path

3.2.4 Parallel to curve

This option enables you to perform the machining along a lead curve The generated cuts are parallel to each other

The distance between each two adjacent passes is determined by the Step over

parameter (see topic 6.1.2)

Start edge curve

End edge curve Drive surface

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The Edge Curve section enables you to define lead

curve for the operation using the Geometry Edit dialog

box (see topic 3.1.3)

It is recommended to choose the Drive surface edge as the lead curve geometry to get better placement of the tool path

3.2.5 Engraving

This option enables you to generate a single tool path along a curve This strategy can be used for engraving

The Projection curves section enables you to define the curves for the tool path generation

Max projection distance

When the Engraving tool path strategy

is chosen, the system expects to get

projection curves lying on the drive

surfaces

Due to tolerance issues in CAD systems, sometimes the curves do not lie exactly on the drive

Drive surface Projection curve = Tool path

Edge curve

Tool path Drive surface

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This strategy can be used for the machining

of impellers with twisted blades

The Start edge surfaces and End Edge surfaces sections enable you

to define the check surfaces geometry for the tool path generation

The drive and check surfaces have to be adjacent, i.e they must have a common edge

Depending on the defined Tool tilting (see topic 8.3)

it is recommended to activate the gouge checking (see chapter 9), to make sure that the check surfaces will not be gouged

When a ball-nosed tool is used with this strategy, it is recommended to use the Tool center based calculation option (see topic 12.3) With this option, the passes close to the check surfaces are generated in such way that the tool is tangent to both the drive surface and the check surface If the calculation is not based on the tool center, a wrong tool path is generated

Tool contact points

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Advanced options

SolidCAM enables you to define a number of advanced options for the

Morph between two adjacent surfaces strategy Click on the Advanced

button to display the Advanced options of surface paths pattern dialog

box

The Generate tool path front side option enables SolidCAM to take into

account normals of the defined check surfaces

When this check box is not selected, the tool path is generated on the

drive surface from all sides of the check surfaces

When this check box is selected, SolidCAM generates the tool path taking

into account the direction of the check surfaces normals The resulting

tool path is located between the check surfaces only

SolidCAM automatically extends the passes tangentially to the drive

surface edges Using the First surface tool path tangent angle and the

Second surface tool path tangent angle parameters, you can change the

extension direction The direction can be changed for the first and last

passes; all the internal passes are evenly morphed between them

First surface tool path tangent angle Second surface tool

path tangent angle

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3 Geometry

3.2.7 Parallel to surface

This option enables you to generate the tool path on the Drive surface

parallel to the specified check surface

The Edge surface section enables you to define the check surfaces

geometry for the tool path generation

The drive and check surfaces have to be adjacent, i.e they must have a common edge

Depending on the defined Tool tilting (see topic 8.3) it is recommended to activate the gouge checking (see chapter 9), to make sure that the check surface will not

be gouged

When a ball-nosed tool is used with this

strategy, it is recommended to use the

Tool center based calculation option

(see topic 12.3) With this option, the

passes close to the check surface will be

generated in such way that the tool is

tangent to both the drive surface and the

check surface If the calculation is not

based on the tool center, a wrong tool

path is generated

Tool contact points

Edge surface

Drive surface

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Advanced options

SolidCAM enables you to define a number of advanced options for

the Parallel to surface strategy Click on the Advanced button to

display the Advanced options of surface paths pattern dialog box

The Generate tool path front side option enables SolidCAM to take into account the normals of the defined check surface

When this check box is not selected, the tool path is

generated on the drive surface only from all the sides of

the check surface

When this check box is selected, SolidCAM generates the

tool path taking into account the direction of the check

surface normals The resulting tool path is located only at

the front side of the check surface

SolidCAM automatically extends the passes tangentially to

the drive surface edges Using the Single edge tool path

tangent angle parameter you can change the extension

direction This option affects only the first pass (close to the

check surface); all other passes are extended tangentially

Single edge tool path tangent angle

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3 Geometry

3.3 Area

The Area section enables you to define the

cutting area on the drive surface

The following options are available to define

This option enables you to generate the tool path on the whole drive

surface avoiding the drive surface edges With this option, the minimal

distance between the edge and the tool path is equal to half of the

Max Step over (see topic 6.1.2)

This option can be used when the boundary of the drive surfaces is not smooth and has gaps The half of the Max Step over offset from the surface edge enables you to compensate these defects of the surface In case of large gaps, SolidCAM enables you to handle them using the Gap along cuts option (see topic 7.2.1).When the tool is oriented normally to the drive surface, make sure

that the tool diameter is greater than half of the Max Step over

Otherwise, unmachined areas are left at the drive surface edge

The image illustrates the use of this option Note that the

machining does not start at the exact edge of the surface Therefore

the shape of the upper edge does not influence the tool path

Edge

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3.3.2 Full, start and end at exact surface edges

With this option, the tool path is generated on the whole surface

starting and finishing exactly at the drive surface edges or at the

nearest possible position

Make sure that the surface edges are perfectly trimmed Gaps cause unnecessary air movements of the tool during the machining, therefore the Full, avoid cuts at

exact edges option (see topic 3.3.1) is preferable

The number of cuts depends on the Max Step over value Since the first and the last cuts are located exactly on the drive surface edges, SolidCAM modifies the specified Max Step over value (see topic 6.1.2) to achieve equal distance between the cuts The modified Max Step over value used for the tool path calculation is smaller than the specified one

You can define margins for the tool path calculation when working with the following strategies:

Morph between two boundary curves, Parallel to curve, Parallel to surface and Morph between two

adjacent surfaces

Click on the Margins button

Edge

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