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1、Milling Manual 1995-2003 SolidCAM LTD. All Rights Reserved. Training Course Milling 1 Table of contents Lesson #1 Creating CAM-Part.4 1. Objectives of this lesson:.4 2. Starting SolidCAM .4 3. Part Data dialog.4 3.1. CAM-Part / model4 3.2. SolidCAM Manager7 3.3. The structure of the CAM-Part.8 3.4.
2、CNC-Controller9 3.5. Axis type 10 3.6. Mac home number / Part home number13 4. Home definition14 4.1. Multi-sided mode .15 Exercise #1. Defining the homes for 3-axis CNC machine.15 Exercise #2 - Defining the homes for 4-axis vertical CNC machine 28 Exercise #3 - Defining the homes for 4-axis horizon
3、tal CNC machine40 Exercise #4 - Defining the homes for 5-axis CNC machine.53 4.2. Home definition methods.64 Exercise #5 Defining the Home with the SolidWorks coordinate system .75 4.3. Projected mode78 Exercise #6. Home definition in projected mode.78 5. Tool table.87 6. Tool options .87 6.1. Start
4、 Point88 6.2. End Point .88 6.3. Tool Change XY 88 6.4. Tool Change Z.88 6.5. Feed Type88 7. Machine (Mac) Options89 8. Work material.89 9. Default G-code numbers89 Program Number90 9.1. Subroutine Number90 10. Stock Model.91 Exercise #7 - Define stock model with 2D boundary .93 Exercise #8 - Define
5、 stock model with 2 configurations.96 Exercise #9 - Define stock model with imported stock solid model .101 Exercise #10 - Define stock model with assembly.105 Exercise #11 - Define stock by box106 Exercise #12 - Define stock by box working on imported surface model 108 11. Target model110 12. Updat
6、e stock model.111 Lesson #2 - Tools112 1. Objectives:.112 2. Overview112 3. User-defined tool type names114 Exercise #13 - Add User define tool type names to SolidCAM117 4. Tool and Work Materials118 4.1. Tool Material118 4.2. Work material.119 4.3. Setting the Work and Tool materials .120 Exercise
7、#14 - Defining the Speed it is defined in the postprocessor file. The Axis type can be one of the 3 following types: 3 axis 4_axis_around_X or 4_axis_around_Y 5 axis The axis type will decide the home definition method: 3_axis In this type of machine, every side requires a new clamping (new main hom
8、e). For each main home you will have to define the home-origin position, X-axis direction and the Y-axis direction. Training Course Creating CAM-Parts 11 4_axis 4_axis_around_X This type is used for vertical machines with the 4th axis on the table along the X-axis. When defining the main home you ha
9、ve to define the home- origin position, the X-axis direction and the Y-axis direction. For all additional positioning, based on this clamping, you have to define the home-origin position and the Y- axis direction only (the angle); the X-axis direction will be determined automatically by the X-axis d
10、irection of the main home. 4_axis_around_Y This type is used for horizontal machines with the 4th axis along the Y-axis. When defining the main home you will have to define the home- origin position, the X-axis direction and the Y-axis direction. For all additional positioning, based on this clampin
11、g, you have to define the home-origin position and the X- axis direction only (the angle); the Y-axis direction will by determined automatically by the Y-axis direction of the main home. Training Course Creating CAM-Parts 12 5_axis This type is used for 5-axis CNC machines. For the main home you hav
12、e to define the home-origin position, the X-axis direction and the Y-axis direction. All additional positioning is related to this home. Note The user has to take care of the machine limitations (angles or undercuts). A message on the limit can be generated only during G-code generation. In the defi
13、nition process, it is not necessary to consider the kinematics of the CNC machine. This is done in the last step when you generate the NC-program. Note A CAM-Part created for a CNC-controller of 3-axis type cannot be converted to 4- or 5- axis. A CAM-Part created for the CNC-controller of 4-axis typ
14、e can be converted to 3-axis type. A CAM-Part created for the CNC-controller of 5-axis type can be converted to 3-axis type. Training Course Creating CAM-Parts 13 3.6. Mac home number / Part home number Home dialog of multi side machining mode Home dialog of projection mode Mac home number this numb
15、er corresponds with the built-in controller Home functions (example: G54, G55 etc in the Fanuc type controllers). It can be used for different clamping positions (main homes) in different operations on the CAM-Part. Part home number this number defines the sequence number of the home. For each MAC H
16、ome (main home), several Part Homes are defined for different positionings; each such Part Home is related to the main Home. Note In multi-sided machining on 4- and 5-axis CNC machines, the SolidCAM postprocessor uses the specific controller Macro language to create the positioning relative to the m
17、ain home. Training Course Creating CAM-Parts 14 4. Home definition SolidCAM enables you to work in two modes: Multi-Sided mode This mode enables you to create CAM-Part defined directly on the solid model. You can define the home origin position and axes orientation by choosing points on the solid mo
18、del or by selecting an already defined SolidWorks coordinate system. Projections mode This mode enables you to create the CAM-Part on planar views defined by 2D sketches on the XY plane. In most cases this mode will be used when importing a DXF or IGES file and when you do not want to create a solid
19、 model. You can use this mode to create 3-, 4-, or 5-axis CAM-parts. After defining the main home on the XY-plane of SolidWorks, you must use the Home Data dialog to manually define the shifts and rotations of the additional positionings, from the main home. Training Course Creating CAM-Parts 15 4.1
20、. Multi-sided mode In these exercises the home definition method for 3-, 4- and 5-axis CNC machines using the same part will be explained. Note SolidCAM doesnt enable you to define your tooling in the CAM-Part. In the SolidVerify simulation the tool is shown going around the part (rather than rotati
21、ng the part as it actually occurs in the CNC machine). Therefore for all CNC machine types, the simulation looks the same Exercise #1. Defining the homes for 3-axis CNC machine. In this exercise the home definition method for 3-axis CNC machines will be explained. Training Course Creating CAM-Parts
22、16 Vice.sldasm Training Course Creating CAM-Parts 17 Double click on the icon to activate SolidWorks and change the configurations to see the 5 different operations (main home positions) to mill this part. In SolidCAM you have to define the homes directly on the model. Load the SolidWorks part exerc
23、isesbox_home_3_axis.SLDPRT In SolidCAM menu start a new milling part. Use all the defaults and click on the OK button. Select the FANUC-3 axis controller. Set the Multi-sided home option (the default setting is on. SolidCAM will save the last setting in the registry and next time you define a new pa
24、rt it will use this setting as the default). Click on the Define Home button. Training Course Creating CAM-Parts 18 SolidCAM changes the model orientation by setting the model to the Machine Isometric view. This orientation is suitable for machining on a CNC machine (with the Z-axis pointing vertica
25、lly upwards). SolidWorks Coordinate system SolidCAM Coordinate system Use the CAM Views toolbar to see the SolidCAM coordinate system. These views are related to the orientation of the selected home position. These views will not change the positions in SolidWorks main view icons. Home dialog is ope
26、n; you can change the Mac home number if you want to start from a different home number (e.g. the MAC home #2 uses G55). Origin Select the origin point on the graphic screen. X direction Select a point relative to the origin that defines the X-axis. Y direction Select a point (3rd point) to finish t
27、he definition of the XY-plane. Use the mouse to define the origin, X and Y direction. You dont have to click on the X direction or the Y direction buttons; they will be automatically selected after you define a point. Training Course Creating CAM-Parts 19 Select vertex 1 for origin. Select vertex 2
28、for X direction. Select vertex 3 for Y direction. For the Y direction, you do not need to select a vertex; you can select a point on the relevant face. You can use the Flip-buttons to change the direction of the axes: Flip XY - This button will rotate the Z-axis 180 degrees by replacing the X and Y
29、between themselves. Flip Around X - This button rotates the Home 180 degrees around the X-axis. Flip Around Y - This button rotates the Home 180 degrees around the Y-axis. Clamping position #1 On the machine, the clamping position of the part will be used as shown in the picture. Training Course Cre
30、ating CAM-Parts 20 Click on the Finish button. The Home Data dialog will be displayed. Training Course Creating CAM-Parts 21 Home data Number Defines the Part Home number. X, Y and Z Shows the X, Y and Z value of the Home in the host coordinate system. Machine home number Defines the number of the h
31、ome in the CNC-Machine. Tool start level The Z-levels to which the tool moves after the tool change. Clearance level All rapid movements in X-Y will be generated in this Z-level CAM-Part Upper level Defines the height of the upper point of the part to be milled. CAM-Part Lower level Defines the lowe
32、r point of the part to be milled. Tool Z Level Defines the height that the tool moves to before the rotation of the 4/5 axes to avoid collision between the tool and the workpiece. This level is related to the home position and you have to check if it is not over the limit switch of the machine. It i
33、s highly recommended to send the tool to the reference point or to a point related to the reference point. Shift The distance from the main home (Mac home) to the location of this home in the coordinate system and the orientation of the main home. Rotation The rotation angle around the main axes X,
34、Y and Z. 4-th axis This field can be either On or Off. If on, the 4th-axis will be used when changing from the previous home to the current home. Machining Plane Defines the default plane of work for the jobs using this home, as it is output to the G-code program. In the SolidCAM CAM module, you mus
35、t always work on the XY-plane. Some CNC- machines, however, have different axes-definitions and require G-code output with rotated XY-planes. Choose one of the following options: XY - The XY plane is the work plane; the Z-axis is the depth (G17). YZ - The YZ plane is the work plane; the X-axis is th
36、e depth (G18). XZ - The XZ plane is the work plane; the Y-axis is the depth (G19). Note This option will only work correctly when your post-processor has been customized to support this function. Edit 4-5-Axis Home This button enables you to change the home location or orientation of the axis. Train
37、ing Course Creating CAM-Parts 22 Tool start level - enter the required value. Clearance plane enter the required value. Part upper level You can enter the value or use the button Part upper level to select it from the graphic interface. Click on the Part Upper Level button in order to define it dire
38、ctly from the solid model. For example select the point on the top face or from a line or vertex. 1. Part lower level enter the value or use the button as explained above. 2. Click on the OK button. After the home definition, SolidCAM creates in the CAM component the Plane_Home#1 and 3Dsketch_home#1
39、 to save the Home data. Such elements will be added for each home you define. Training Course Creating CAM-Parts 23 The Home Edit dialog is displayed. Right click on the Home #1 item. The menu will be displayed. In the next section we will explain all items of the Home Edit dialog menu. The Home Edi
40、t menu. Edit Home - This command enables you to change the data of an existing home. It also enables you to change the home position. Note If you change the home position, you must recalculate the jobs using this home position. You are also advised to review the simulation. The Home data dialog box
41、will be displayed showing the default home position values. The fields and values can be changed, if necessary. Move Home This button enables you to move the actual Home. This option is disabled in the Multi-sided mode. Inquire Home - This command enables you to view the Home data dialog and see rel
42、evant information about the home. Delete Home - Deletes an existing home. You can only delete homes if more than one home has been defined for the current CAM-Part. It is not possible to delete the first home and a home that is used for the milling operation. (The delete will not be active in these
43、cases). In the Home Edit dialog select the Home #1 and click on the right mouse button. The menu will be displayed and you can select the Add command to add the next home (Home #2). Training Course Creating CAM-Parts 24 Clamping position #2 Since you are working with a 3-axis machine, you have to ch
44、ange the Mac home number for the new clamping Do all the steps needed to define Part Home #2. Training Course Creating CAM-Parts 25 Note For the first Part Home number related to a new Mac Home number, the Shift and Rotation around parameters will be always 0. Clamping position #3 Do all the steps n
45、eeded to define Part Home #3. Training Course Creating CAM-Parts 26 Clamping position #4 Do all the steps needed to define Part Home #4. Press the Finish button. Training Course Creating CAM-Parts 27 The Milling Part data dialog will be displayed again. These steps complete the definition of the hom
46、es used to machine this CAM- part. Click on the Save The Fanuc machine with the 4-axis around X type will be used. To mill this CAM-Part, 2 clamping positions (set-ups) are needed. First clamping position 4_axis.SLDASM Double click on the icon to open the SolidWorks assembly. Check the configuration
47、s to see the different home positions 1,2,3,4. Training Course Creating CAM-Parts 29 Second clamping position 4_axis_vice.SLDASM Double click on the icon to open the SolidWorks assembly. Check the configurations to see the different home positions 5 and 6. Load the SolidWorks part exercisesbox_home_
48、3_axis.SLDPRT In the SolidCAM menu start a new milling part. Training Course Creating CAM-Parts 30 Use all the defaults and click on the OK button. Choose FANUC_4_axis_X as the controller. Set the Multi-sided home option. Clamping position #1 Part Home #1 Training Course Creating CAM-Parts 31 In the Part Data dialog, cli