SolidCAM2007 R11 2 Milling Training Course 3D Milling PDF

SolidCAM2007 R11.
The Leaders in Integrated CAM
Power and Ease of Use - the winning combination
SolidCAM2007 R11.2
Milling Training
Course
3D Milling
1995-2008 SolidCAM
WWW. S O L I DC A M . C O M
All Rights Reserved.
SolidCAM2007 R11.2
Milling Training Course
3D Milling
1995-2008 SolidCAM
All Rights Reserved.
Contents
Contents
1. Introduction
1.1 About this course.............................................................................................................................9
1.2 SolidCAM 3D Machining overview............................................................................................11
1.3 Process overview...........................................................................................................................12
2. General 3D Milling
2.1 3D Milling Operation dialog box overview...............................................................................15
2.2 3D Roughing..................................................................................................................................17
Exercise #1: Mold core roughing..............................................................................................18
Exercise #2: Mold cavity roughing............................................................................................47
Exercise #3: Toy mold cavity roughing....................................................................................57
Exercise #4: Bottle-bottom mold cavity roughing..................................................................58
Exercise #5: Spoon die core roughing......................................................................................59
2.3 3D Semi-Finishing/Finishing......................................................................................................60
Exercise #6: Cover finishing......................................................................................................63
Exercise #7: Bottle-bottom mold cavity finishing..................................................................71
Exercise #8: Electrode finishing................................................................................................82
Exercise #9: Mold cavity finishing............................................................................................94
Exercise #10: Mold core finishing...........................................................................................111
Exercise #11: Electrode pencil milling...................................................................................121
Exercise #12: Toy mold cavity finishing.................................................................................127
Exercise #13: Spoon die core finishing..................................................................................129
Exercise #14: Spoon die cavity finishing................................................................................132
Exercise #15: Cavity finishing..................................................................................................134
3. 3D Milling of Prismatic Parts

Exercise #16: Cover machining...............................................................................................139
Exercise #17: Electronic box machining................................................................................155
Exercise #18: Connector cover machining............................................................................158
4. 3D Milling of Aerospace Parts

Exercise #19: Bracket machining.............................................................................................162
Exercise #20: Aerospace support machining........................................................................173
5. 3D Drilling
4.1 3D Drilling Operation dialog box overview...........................................................................179
Exercise #21: 3D Drilling of the Mold core.........................................................................181
Exercise #22: 3D Drilling of the Toy mold cavity...............................................................188
6. 3D Engraving
5.1 3D Engraving Operation dialog box overview.......................................................................191
Exercise #23: 3D Engraving of the Electrode......................................................................193
Exercise #24: 3D Engraving of the Mold cavity..................................................................199
Exercise #25: 3D Engraving of the Stamp insert.................................................................203
Document number: SC3DMTCENG07002
Introduction
1. Introduction
1.1 About this course

The goal of this course is to teach you how to use SolidCAM to machine various parts using 3D
Milling technologies. This course covers the basic concepts of SolidCAM 3D machining and is
a supplement to the system documentation and online help. Once you have developed a good
foundation in basic skills, you can refer to the online help for information on the less frequently
used options.
Prerequisites
Students attending this course are expected to have a basic knowledge of SolidCAM software.
The course has to be preceded by the SolidCAM 2.5D Milling Training Course, in which the basic
concepts of the SolidCAM software are discussed. Detailed explanations of basic concepts are not
included in this manual.
Course design
This course uses a task-based approach to training. With the guided exercises you will learn the
commands and options necessary to complete a machining task. The theoretical explanations are
embedded into these exercises to give an overview of the SolidCAM 3D Milling capabilities.
Using this training book
This training book is intended to be used both in a classroom environment under the guidance of
an experienced instructor and as self-study material. It contains a number of laboratory exercises
to enable you to apply and practice the material covered by the guided exercises. The laboratory
exercises do not contain step-by-step instructions.
About the CD
The CD supplied together with this manual contains copies of the various files that are used
throughout this course. The Exercises folder contains the files that are required for guided and
laboratory exercises. The Built Parts folder inside the Exercises contains the final manufacturing
projects for each exercise. Copy the complete Exercises folder on your computer. The SolidWorks
files used for the exercises were prepared with SolidWorks2007.
Windows XP
The screenshots in this book were made using SolidCAM2007 R11.2 integrated with SolidWorks2007
running on Windows XP. If you are running on a different version of Windows, you may notice
differences in the appearance of the menus and windows. These differences do not affect the
performance of the software.
Conventions used in this book
This book uses the following typographic conventions:
Bold Sans Serif
10. Define CoordSys Position
Explanation
This style is used to emphasize SolidCAM options,

commands or basic concepts. For example, click on
the Change to opposite button.
The mouse icon and numbered sans serif bold text
indicate the beginning of the exercise action.
This style combined with the lamp icon is used for
the SolidCAM functionality explanations embedded
into the guided exercises. The lamp icon is also used
to emphasize notes.
10
1. Introduction
1.2 SolidCAM 3D Machining overview

SolidCAM provides you with powerful 3D Machining functionality that can be used both for
prismatic parts and for complex 3D Models.
For prismatic parts SolidCAM analyzes the model and automatically recognizes pockets and profiles
to be machined using Constant Z machining strategies. For complex shape models such as molds,
electrodes and prototypes, SolidCAM offers powerful 3D Machining, including integrated options
for material machining.
SolidCAM Milling module enables you to prepare the tool path for the following 3D Milling
Operations:
3D Milling Operation
This Operation enables you to calculate the tool path

for the rough, semi-finish and finish machining of
3D Models. A number of strategies can be applied to
provide you with effective and high-quality machining.
3D Engraving Operation
This Operation enables you to perform the engraving

of text or artwork on the part faces.
3D Drilling Operation
This Operation enables you to perform drills that take

into account the 3D Model geometry.
SolidCAM enables you to use holes machined with this
Operation for the Z-Entry in 3D Rough Milling.
11
1.3 Process overview

The major stages of creation of the SolidCAM Manufacturing Project are the following:
CAM-Part definition
This stage includes the definition of the global parameters of the Manufacturing
Project (CAM-Part). You have to define a number of Coordinate Systems that describe
the positioning of the part on the CNC-machine.
Optionally, you can define the Stock model and the Target model to be used for the
rest material calculation. The Stock model describes the initial state of the workpiece
that has to be machined. The Target model has to be reached after the machining. After
every Operation, SolidCAM calculates the amount of material actually removed from
the CAM-Part and the amount of material left not machined (rest material). The rest
material information enables SolidCAM to automatically optimize the tool path and
avoid air cutting.
Technology definition
SolidCAM enables you to define a number of 3D Milling Operations. During the
Operation definition, you have to select the Geometry, choose the Tool from the
Part Tool Table (or define a new one), define a machining strategy and a series of
technological parameters.
Generally, the 3D Milling is performed in three major stages: Roughing, Semi-Finishing
and Finishing. At the Roughing stage, the fast and efficient bulk material removal has
to be performed. The finish machining allowance remains for the further Semi-finish
and Finish Operations. At the Semi-finishing/Finishing stages, this allowance has to be
removed using a number of strategies that provide excellent surface quality.
12
General
3D Milling
You can perform 3-axis gouge-free machining on solid and surface models. This Operation offers a
wide range of roughing, semi-finishing and finishing strategies for free-form models. It can be used
to manufacture molds, dies, electrodes, prototypes and other 3D Models.
14
2.1 3D Milling Operation dialog box overview

Milling levels section
Operation name section
Geometry section
Working area section
Tool section
Tolerance section
Rough section
Finish section
Semi Finish section
Operation buttons
SolidCAM 3D Milling Operation dialog box enables you to define the parameters of the roughing,
semi-finishing and finishing tool path on 3D Model faces.
Geometry section
This section enables you to define or choose the 3D Model Geometry for the
Operation.
Tool section
This section enables you to define a new Tool for the Operation or choose an existing
Tool from the Part Tool Table.
This section displays the name of the Operation. When the Geometry and the Tool
have been defined, SolidCAM generates a default name (e.g. 3DM_Model_T2) based on
the Operation type, Geometry name and Tool number.
In this section, you have to specify the Z-levels for the Operation. The default input
values are the CAM-Part values you have specified at the stage of the Coordinate
System definition.
15
Tolerance section
The precision tolerances defined here directly affect the surface quality of your
machined model.
SolidCAM generates the tool path in two steps:
SolidCAM generates a mathematical representation of surfaces and solids of
the 3D Model geometry according to the given Facet tolerance.
SolidCAM calculates the tool path according to the value of the Tool path
tolerance that defines the accuracy of the tool path.
Working area section
SolidCAM enables you to limit the tool path with a specified Working area. When the
Working area definition is used, SolidCAM calculates the whole tool path and then
removes all tool path lines lying outside the Working area.
Rough section
Rough milling removes the bulk of material surrounding the 3D Model. The material
is removed on Z-levels controlled by the Operation Upper level, Surface offset and
Step down values.
Semi Finish section
Semi-Finish machining prepares the model for finishing. After semi-finishing, a uniform
offset remains on the material. This offset is removed in the last finishing cut.
The same machining strategies in Finish machining can be applied for Semi-finishing.
The only difference is in one parameter, Surface offset, that controls the X-, Y- and
Z-offset that remains on the original surface. Otherwise, all strategies are defined and
used in the same way as in finishing.
Finish section
Finish machining generates the tool path directly on the surfaces and solids of your
3D Model geometry. No offset can be specified and the model is machined to its final
topology and dimensions. You can apply a number of different machining strategies
to finish your models. Each strategy offers parameters to adjust the strategy to your
needs.
Operation buttons
Operation buttons enable you to save the Operation data, perform the tool path
calculation, simulate the already calculated tool path, generate the GCode for the
Operation and close the Operation dialog box.
16
2.2 3D Roughing
The target of the rough machining is the fast and efficient removal of the greater part of the
machining allowance with the large tools. SolidCAM provides you with the following functionalities
of the rough machining:
Constant Z roughing of the whole model or model areas;
Rest material machining enables you to automatically determine the areas that were not
machined in the previous stages and machine them with a smaller tool.
A number of Z-Entry strategies enabling you to choose the optimal way of the tool
plunging into the material. SolidCAM enables you to use the pre-drilled holes for the
Z-Entry.
The Open pocket functionality enables SolidCAM to locate open pocket areas and
enables you to machine them with a specific strategy. This strategy enables you to
combine pocket and profile tool paths in order to provide the best productivity in open
pocket machining.
You can use three different strategies to execute rough machining of 3D Models.
Contour and Hatch strategies perform rough cuts on constant Z-levels that are
automatically calculated using the specified values for the Lower level, Surface offset and
Step down.
Contour strategy
Plunging is a totally different concept of removing

material from a given pocket, carried out with a
special tool. Instead of milling the material, the tool
moves up and down as in a drilling motion, travelling
along the specified path type.
17
Hatch strategy
Exercise #1: Mold core roughing

This exercise illustrates the process of rough machining using the Contour strategy in SolidCAM.
In this exercise you have perform the rough machining of the mold core of a pet dish.
Dish
Mold
Core
1. Load the SolidWorks model
Load the Exercise1.sldprt model located in the Exercises folder.

This model consists of a number of features forming the solid body of the mold
core.
18
2. Define the CAM-Part
At this stage, you have to define the CAM-Part.

Choose the Fanuc CNC-controller for the CAM-Part.
Define the Stock model as the box
surrounding the model. Set the 2 mm offset
to the top of the core (Z+ direction) and the
zero offset for all of the other directions.
Define the Coordinate System in the corner
of the stock model as shown.
Define the Target model.
3. Define a 3D Milling Operation
When the CAM-Part has

been defined, right-click on
the Operations header in the
SolidCAM Manager tree and
choose the 3D Milling command
from the Add Operation
submenu.
19
The 3D Milling Operation dialog box is displayed.
4. Define the geometry
The main geometry used for the 3D Milling is a 3D Model. The Geometry section of the
3D Milling Operation dialog box enables you to define a new chain or choose an already
defined 3D Model geometry. In this exercise, the previously defined Target model
geometry is used for the 3D Milling Operation definition.
In the Geometry section, choose the Target geometry from
the list.
5. Define the tool
In the Tool section, click on the Select button to start the tool definition.
20
The Choosing Tool For Operation dialog box is displayed. This dialog box displays the
content of the Part Tool table in the current CAM-Part.
Click on the Add button to define a new tool for

the Operation. A tool with default parameters is
added to the Part Tool Table.
In this exercise, a 20 End mill tool is used.
Edit the following tool parameters:
Set the User tool type to End Mill.
Set the Diameter to 20.
Set the Total length to 120;
Outside Holder
Length
Total
Length
Set the Outside Holder length to 100;

Set the Cutting length to 85.
21
Cutting Length
Diameter
Define the tool holder. Select the Holder check

box. The Holder section is activated.
In the Holder section, click on the Global
holders table button to choose the tool holder
from the global holders table supplied with the
SolidCAM software. The Tool Holders dialog box
is displayed.
The SolidCAM tool holder is defined by combining two components.

The first component is the tool adaptor mounted in the spindle unit of
the milling machine. The tool adaptor is defined in the CNC machine
pre-processor file (MAC file). The second component can consist of
different types of extensions and reductions such as collet chucks,
arbors, shanks and any other components that you may have. The Tool
Holders dialog box enables you to choose this second component.
Choose the ER32x60 collet chuck from the list and confirm the dialog box with the OK
button. The Choosing Tool For Operation dialog box is displayed again.
Click on the Select button to confirm the dialog box and choose the defined tool for
the Operation.
The tool has been chosen for the Operation. The 3D Milling Operation dialog box is
displayed again.
22
6. Define the Milling levels
At this stage you have to specify the milling levels for the Operation.
Milling levels
SolidCAM performs the cutting between the Upper level and the
Lower level. The Upper level is the Z-level at which the cutting
starts. The Lower level sets the Z-level below which the tool does
not mill. The cutting path is performed between these levels. After
the machining of any cutting level, the tool vertically retreats to
the Clearance level with rapid feed. All the necessary horizontal
movements are performed at this level with rapid feed. The tool then
descends to the next cutting level. SolidCAM enables you to specify
the Safety distance. The descent movement to the Safety distance is
performed with rapid feed. From the Safety distance to the cutting
level, the tool descends with working feed.
Clearance Level
Upper level
Safety
distance
Lower level
Specify the Lower level for the Operation. SolidCAM

enables you to define the milling levels directly on the solid
model.
In the Milling levels section, click on the Lower level
button to start the definition.
23
Cutting
levels
Rapid movements
Feed movements
Click on the model face as shown.
The Lower level is determined and displayed in the Pick Lower level dialog box.
Confirm the Lower level definition with the

button. The
dialog box is displayed with the updated
value of the Lower level. The pink background of the
parameters box means that the parameter value is defined
associatively to the solid model. If the model is changed, this
parameter value is updated automatically.
3D Milling Operation
7. Define the facet tolerance
Set the Facet tolerance value to 0.01.

This tolerance value controls the maximum deviation of the
faceted model, used for the tool path calculation, from the
solid model.
The 3D Model geometry is triangulated and the resulting facets are saved
in the modelname.fct file in the CAM-Parts folder. The triangulation is
performed on the 3D Model geometry when you use it for the first time in
a 3D Milling Operation. If you use the 3D geometry in another Operation,
SolidCAM checks the tolerance of the existing *.fct file of this geometry.
It does not perform another triangulation as long as the *.fct file has been
created within the same facet tolerance.
24
8. Choose the roughing strategy
In the Rough section of the 3D Milling Operation dialog box, choose the Contour
strategy from the list.
Contour roughing
The Contour roughing strategy enables SolidCAM to produce

Constant Z pockets on different Z-levels. Within the pockets, the tool
moves in parallel offsets to the contour of the section of the model at
the Z-level of each step down.
The major parameters of the Contour roughing strategy are Overlap

and Step down.
The Overlap parameter defines the tool overlap when the tool is
located on the two adjacent lines of the tool path.
Overlap
Side step
6 mm
20
The default value is 0.65 (65% of the

tool diameter). With the tool diameter
of 20 mm, the overlap of 0.7 (70%) is
14 mm. It means that the side step (the
distance between adjacent lines of the
tool path) is 6 mm for the next tool
movement.
25
Overlap
14 mm
SolidCAM uses the Constant Z pocketing for the roughing. With the
Step down parameter, you can define the distance between each two
successive Z-levels.
Step down
Cutting
levels
Set the value of 0.7 for the Overlap. With this value, the
distance between the adjacent lines of the tool path (side
step) is 6 mm.
Set the Step down to 5.
Under Clean flat, choose the Clean flat during Roughing
option.
Clean flat options
SolidCAM generates a set of Z-levels with an equal step down.

Sometimes the model ledge with the specified offset lies between the
Z-levels defined by Step down and is not machined. The Clean flat
options enable you to perform the machining of such ledges.
Z-levels with the
equal Step Down
Model with
offset
Unmachined
ledges between
Z-Levels
26
Clean flat at the end of Roughing
When this option is chosen, SolidCAM performs roughing at each

step down level and then returns to the flat areas that are between
the step down levels.
Clean flat during Roughing
When this option is chosen, SolidCAM performs roughing at

the step down level. Then the tool machines the flat area that is
located between the current step down level and the next one.
After completing the flat area, it goes to the next step down.
9. Define the offsets
At this stage, you have to specify the allowances for the further semi-finishing/finishing
Operations.
Surface offset
SolidCAM enables you to define the Surface offset, which is a minimum

machining allowance of material in the X-, Y- and Z-direction that
remains on the model for the further Operations. The Surface offset
value defines the closest distance the tool can get to the model. The
rough Operation is performed at constant Z-levels.
Surface
Offset
Step down
In addition to the specified Surface offset, the roughed model shows

stairs of rest material with a height equal to the Step down value. To
obtain a uniform offset on the model, a semi-finish Operation should
be executed.
27
Set the Surface offset value to 1. This offset is removed in the semi-finish/finish
Operations.
10. Define the technological parameters
In the Rough section of 3D Milling Operation dialog

box, click on the Data button. The Contour Parameters
dialog box is displayed. This dialog box enables you to
set the technological parameters of the contour roughing
strategy.
Contour parameters
Exit material
This option controls the tool movements between the cutting areas.
Exit material option not selected
When the tool moves from one

cutting area to the next one, it
moves through the full material
around the island to get to the
next area to be cut as shown.
28
Exit material option selected
The tool exits from the material

and travels rapidly above the
material to the next cutting area as
shown. The approach path is the
approach you choose.
Connect islands
During walls and islands machining, SolidCAM uses a different

cutting direction (climb or conventional) for different areas of
the tool path. The Connect islands option enables you to prevent
such direction changes by connecting all of the areas into a single
contour. The connected contour is machined with the same cutting
direction (conventional or climb).
Conventional
Climb
Climb
Mixed cutting direction
Constant cutting direction
Start from
Inside
This option enables you to work in a pocket area starting from

the middle of the pocket and cutting towards the outside
border of the pocket.
Outside
This option enables you to work in a pocket area starting

from the outside border of the pocket and cutting towards
the middle of the pocket.
29
Corner
None
The tool path is formed with sharp

corners between one tool path direction
and the next.
Fillet
Each tool path direction is connected

to the next one with a given radius,
enabling a smoother transition between
tool path directions.
Smooth
The connecting points on the path

are cleaned using a smooth transition.
The tool path forms a loop in the
corner, preventing an abrupt change of
direction.
Sharp
Using a short and simple movement

cleans the connecting points on the
path. Although this produces a sharp
movement by the tool, the path itself is
slightly shorter than the smooth corner
option. This can help to reduce the
machining time.
This option is not recommended for high-speed
cutting.
30
Direction
This option enables you to choose climb or conventional milling for

the roughing.
Climb Milling
Conventional Milling
Arc approximation
This command enables you to create G2/G3 GCode output from

Contour roughing Operations. SolidCAM checks whether successive
points of the calculated tool path can be connected using an arc
or circle. If an arc or circle connection within the specified arc
approximation tolerance can be made, you receive arc and circle
interpolation commands G2 and G3 in the generated GCode.
Adjacent tool paths connection
This option enables you to choose the method with which the tool
moves within a pocket from one tool path to the next.
Linear connection
The tool moves in a normal approach from

one tool path to the next.
Rounded connection
The tool moves in an arc path from one tool

path to the next one. The radius of the arc
is half the distance between the tool paths.
31
In the Corner section of the Contour parameters dialog

box, choose the Smooth option.
In the Adjacent tool paths connection section, choose the
Rounded option.
These parameters enable you to perform smoother
transition between tool path directions.
Define the Arc approximation value. Generally, the
recommended value of for the arc approximation is
2.5 times the Facet tolerance value.
In this exercise, set the Arc approximation value to 0.025.
Confirm the Contour parameters dialog box with the OK
button.
11. Define the Working area
SolidCAM enables you to limit the tool path with a specified Working area.
In the Working area section, click
on the Define button.
The Working Area dialog box is

displayed.
32
Working area types
SolidCAM enables you to use one or a combination of the following

four methods:
Working area geometry. This method enables you to specify a
closed contour of the Working area boundary.
Angle limits. This method enables you to define the Working area
by surface inclination angle range and to apply various machining
strategies to model areas with a different inclination.
Selected faces. This method enables you to select the model faces
where the machining has to be performed. You can also specify the
faces that have to be avoided during the machining.
Rest Material. With this method, you can limit the machining to the
rest material. The rest material is what has to be machined after the
previous Operations in order to reach the Target model.
In this exercise, the Working area is defined by a closed planar
contour.
Select the Working area check box to define the Working area
geometry.
Click on the Define button to start the geometry definition. The
Geometry Edit dialog box is displayed. This dialog box enables
you to select and manage geometry chains.
The geometry selection procedure and interface

is covered in detail in the SolidCAM 2.5D Milling
Training course book.
In the Multi-chain section of the dialog box, click on the Add
button. This button enables you to choose a number of chains
from a model by selecting the model elements. The program
automatically creates chains from the selected elements.
33
The Chains Selection dialog box is displayed.

Rotate the model as shown and click on the bottom face.
The selected face and its boundary are automatically

button to build chains based on
determined. Click on the
the selected face boundary. The Geometry Edit dialog box is
displayed again. Confirm it with the
button.
The Working area geometry has been defined.
34
Now you have to define the tool location relative to the Working area.
Tool on Working area
Working area
This option controls the position of

the tool relative to the boundaries of
the Working area. Select one of the
options from the Tool position in the
Working area list field.
Internal
The tool machines up to the

boundary of the Working area.
The center point moves at an
offset equal to the tool radius.
35
External
The tool machines over the

boundary of the Working area
by the distance equal to the tool
diameter.
Middle
The tool machines the Working

area until the tool center is
positioned on the Working area.
Tangent
SolidCAM generates the tool

path boundaries by projecting
the planar Working area on the
3D Model. The tool path is
limited in such a way that the
tool is tangent to the model faces
at the boundary. This option
enables you to machine the exact
Working area, taking into account
the 3D Model geometry.
Choose the Middle option under Tool on Working area. The tool machines the Working
area until the tool center is positioned on the defined Working area.
Confirm the Working Area dialog box with the OK button.
36
12. Define the Z-Entry strategy
Define the way the tool plunges into the material.

Click on the Z-Entry button to display the Z-Entry dialog
box.
Z-Entry types
None
The tool plunges into the material with

a normal downward movement at the
specified Z-feed rate.
Angle
If you choose this Z-Entry type and

enter the Angle value, the tool enters
the material with a ramp movement.
The ramp starts from the given Safety
distance down to the model contour.
If, due to the model contour, the ramp
cannot be created in a straight line,
the Z-Entry movement follows the
contour.
Helical
The tool descends to the machining

level with a helical motion. In the Angle
field, enter the descent angle that you
would like the tool to follow. In the
Radius field, enter the radius of the
helical tool path.
37
Angle
Linear
The tool descends to the machining

level with a linear zigzag motion. In the
Angle field, enter the descent angle that
you would like the tool to follow.
Choose the Helical option for the Z-Entry and set the Angle
value to 5. Set the Radius value to 5.
Clear the Return to Clearance Level between Z steps check
box.
Confirm the dialog box with the OK button.
Return to Clearance Level between Z steps
This option enables you to control the height where the horizontal
rapid movement is performed.
When this check box is selected (default), SolidCAM performs the
horizontal rapid movements on the Clearance level of the Operation
(see Step #6).
Clearance Level
Safety
distance
Cutting
levels
Rapid movements
Feed movements
38
When this check box is not selected, SolidCAM performs the

horizontal rapid movements at the Safety distance from the last cut.
SolidCAM checks for possible collisions. In areas where the rapid
movements on the Safety distance cause gouges, the horizontal rapid
movements on the Clearance level are performed.
Clearance Level
Safety
distance
Cutting
levels
Rapid movements
Feed movements
13. Open pocket machining
SolidCAM enables you to customize your machining strategy for more effective
machining of open pocket areas.
During the preparation for
the machining, SolidCAM
generates
the
model
sections located at the
Z-levels determined by the
Step down value. These
sections contain both:
Closed pocket areas
where the approach
from
outside
is
impossible;
Open pocket
area
Closed pocket
area
Open pocket areas that are accessible from the outside.

The closed pocket areas are machined as pockets, with the tool
plunging into these areas with the Z-Entry strategy (see Step #12).
Open Pockets can be machined with a combination of pocket and
profile paths.
39
In the Rough section of the 3D Milling Operation dialog box,

click on the Mode button. The Open Pocket mode dialog box
is displayed.
This dialog box enables you to define the mode of Open
pocket machining.
There are three modes of open pocket machining:

Pockets: open areas at each down step
are milled as pockets.
Pockets
Profiles: open areas at each down step

are milled by a number of equidistant
profiles starting from the outside the
model; the tool then moves in parallel
offsets to the contour of the section
on the specified Z-Levels.
Profiles
Pockets+Profile: if the open areas

Profile
at each down step cannot be milled Pockets
completely with one profile, then
those unmilled areas are milled first
by pocket paths and then the profile is
used for finish.
Choose the Pockets + Profile option for the Open pocket machining.
40
Select the Approach open pocket from outside check box. This option enables you
to perform the approach movement from the automatically calculated point outside
of the material. The tool approaches to the necessary depth outside of the material
and then plunges into the material. Such an approach enables you to decrease the tool
loading when plunging into the material.
In closed areas, where outside approach is impossible, the tool plunges into
the material with a strategy defined in the Z-Entry field of the Operation
dialog box.
Define the Profile Lead in strategy, which is the way the
tool approaches the profiles during open pocket machining.
Choose the Tangent option to perform the tool movement
tangential to the automatically calculated tool path line. Set
the Value to 20.
Confirm the Open Pocket mode dialog box with the OK
button.
14. Save and Calculate
Click on the Save&Calculate button.

The 3D Milling Operation data is saved and the tool path is calculated.
15. Simulate
Click on the Simulate button in the 3D Milling Operation

dialog box. The Simulation control panel is displayed.
button to start the simulation. The
Click on the
simulation is displayed directly on the solid model.
41
Since the simulation is performed in the SolidWorks window, all the view
functions of SolidWorks such as Zoom, Pan or Rotate enable you to check
the tool path.
Switch to the SolidVerify page and start the simulation with the
button.
When the simulation is finished, display the side view of the part with the
button.
After the rough machining, the part faces have steps.
During finishing, these steps (cusps) cause a non-uniform tool load that result in
bad surface conditions. To remove these cusps before the finishing, it is necessary to
perform an additional rest roughing Operation.
Close the Simulation control panel with the
button.
Close the 3D Milling Operation dialog box with the Exit button. The SolidCAM Manager
tree is displayed.
42
Right-click on the defined 3D Milling

Operation in SolidCAM Manager and
choose 3D Milling from the Add Operation
submenu.
The 3D Milling Operation dialog box is
displayed.
17. Choose the Operation template
SolidCAM enables you to choose an already defined Operation as a template for

additional Operations. All the template Operation data can be copied to a new
Operation.
In this exercise, the previously defined Operation is used as a template.
In the Operation name section, choose the previous 3DR_target_T1 Operation from
the list.
All data is copied from the template Operation.
18. Define a new tool for the Operation
In the Tool section of the 3D Milling Operation dialog box, click on the Select button to
change the current tool coming from the template Operation with a new one.
43
The Choosing Tool For Operation dialog box is displayed. Click on the Add button
to add a new tool to the Part Tool Table. A new tool with the default parameters is
added.
A 16 End mill tool is used for the Operation.

Set the User tool type to End Mill.
44
Choose the same tool holder (ER32x60) used for the previous Operation.
Click on the Select button to confirm the tool definition and choose the defined tool
for the Operation.
19. Define the surface offset
Set the Surface offset value to 0.5.

This offset from the model is left unmachined during the
Operation; it is finished in the following Operations.
20. Define the Step down
Set the Step down value to 2. With this value, SolidCAM

performs the machining between the cutting levels of the
previous Operation and removes the steps left unmachined.
21. Define the open pocket parameters
Click on the Mode button to display the Open pocket mode

dialog box.
Choose the Profiles mode of the open pocket machining.
Open areas at each down step are milled by several equidistant
profiles, starting from the outside the model; then the tool
moves in parallel offsets to the contour of the section on the
specified Z-levels.
Note that the Tangent strategy is chosen for the Profile Lead in. The lead in movement
to the machining profiles is performed tangentially.
22. Define the rest material machining
Since the bulk of material is already removed in the previous roughing Operation, the
current Operation has to be performed only on the rest material areas that remain
unmachined after the previous Operation.
45
In the Working area section, click on the

Define button to display the Working
Area dialog box.
Select the Cut only the Rest material
check box to perform cutting only in the
Rest material areas. SolidCAM calculates
the Updated Stock model after the
previous Operations. The updated stock
model is automatically compared to the
target model and the rest material areas
are generated.
In this Operation, the combination of the
Working area defined by 2D geometry
and the rest material area is used to limit
the tool path.
Confirm the Working Area dialog box
with the OK button.

24. Simulate
Perform the Operation tool path simulation in the HostCAD and SolidVerify modes.
The machining is performed in the areas where the material remains unmachined after
the previous Operation.
At this stage, the exercise is finished. The CAM-Part will be finished in the following
exercises.
46
Exercise #2: Mold cavity roughing

This exercise illustrates the process of rough machining using the Hatch strategy.
In this exercise, you have perform the rough machining of the mold cavity for the handle.
The original model of the mold cavity contains two SolidWorks configurations: Default and Stock.
The Default configuration (see the illustration) contains the
complete cavity geometry used for the Target model definition and
machining Operations.
The Stock configuration contains the model of the part in the

initial state before the machining. This configuration is used for
the Stock model definition.

This model consists of features forming the solid body of the mold cavity.
47

Choose the Fanuc CNC-controller for
the CAM-Part.
Define the Coordinate System in the
center of the cylindrical face at the top
face of the model.
Define the Stock model as 3D Model
using the Stock configuration.
3. Add a new 3D Millling Operation
In the SolidCAM Manager, right-click on the Operations header and choose the
3D Milling command from the Add Operation submenu.
4. Choose the geometry
In the Geometry section, choose the Target model geometry from the list.
5. Define the tool
In the same manner as explained

in the previous exercise, define an
End mill tool of 16 mm for the
Operation.
Define the following parameters:
Set the Outside Holder
length to 55;
Set the Cutting length to
50.
48
6. Choose the cutting strategy
In the Rough section, choose the Hatch type of the rough

machining.
The model is roughed in a linear pattern.
Hatch roughing creates a linear raster tool
path up to the model contour.
Set the value of 0.7 for the Overlap. With this value, the distance between the adjacent
lines of the tool path is 4.8 mm.
7. Define the machining allowances
Set the Surface offset to 1 to define the machining allowance for the finishing.
9. Define the technological parameters
In the Rough section, click on the Data button to define the

technological parameters of the hatching. The Hatch Data
dialog box is displayed.
Hatching parameters
Exit material
This option controls the tool movements

between the cutting areas. See Exercise #1 for
a more detailed explanation of this option.
49
Hatch angle
SolidCAM enables you to choose one of the following options to

define the angle of hatching:
User-defined angle
This option enables you to determine the

angle of the tool path.
Automatic optimal angle
SolidCAM automatically calculates the

optimal angle of hatching to expedite the
machining. The tool path always follows
the length of the pocket no matter what
angle the pocket is facing.
You can change the angle by entering a
different delta angle value in the Delta from
optimal option.
Keep cutting direction
This option enables you to keep a constant cutting direction during

milling.
Yes
A constant cutting direction is kept.

No
SolidCAM generates a shorter, optimized tool path by reversing

some tool movements. The milling direction may change between
climb and conventional milling.
50
Cutting direction
Zigzag
This option enables you to create the tool path

containing bi-directional movements.
Zigzag
One way
This option enables you to create the tool path

containing only one-directional movements.
One way
Corner
None
The tool path is formed with sharp corners

between one direction and the next.
Fillet
Each tool path direction is connected to the

next one with a given radius allowing a smoother
transition between tool path directions.
Choose the Automatic optimal angle option. The machining of each shaped instance
of the cavity is performed with an optimal angle.
Confirm the Hatch Data dialog box with the OK button.
In this exercise, the machining has to be performed only in the cavity areas. Define the
Working area to limit the tool path to these areas.
In the Working area section, click on the Define button.
The Working Area dialog box is displayed.
51
Select the Working area check box and click on the Define
button to start the Working area geometry definition.
The Geometry Edit dialog box is displayed.
In this exercise, the external boundaries
of cavities are used for the Working
area geometry definition. Select these
boundaries as shown.
When the geometry is defined, confirm
the Geometry Edit dialog box with
the
button.
Make sure that the Internal option is

chosen in the Tool on Working area
section.
The tool machines up to the boundary of the Working area.


box.
Choose the Angle option and set the Angle value to 5.
The tool will plunge into the material with the specified
angle.
Clear the Return to Clearance Level between Z-steps
check box.
Confirm the Z-Entry dialog box with the OK button.
52
12. Save and calculate

13. Simulate
In the 3D Milling Operation dialog box, click on

the Simulate button to perform the tool path
simulation.
Perform the simulation using the HostCAD
mode.
The machining is performed inside three cavity
areas.
Rotate the model to the Top view by clicking on
the
button on the CAM Views toolbar.
SolidCAM automatically determines the optimal

hatch angle for each cutting area to minimize the
number of the cutting direction changes.
Switch the solid model to the Wireframe view
using the
button in the SolidWorks toolbar
and rotate it to the Front view by clicking on
the
button on the CAM Views toolbar.
Such model display and orientation enable you to see the angle Z-Entry movements.
After the simulation, return to the shaded view.
Close the simulation and return to the 3D Milling Operation dialog box. Click on the
Exit button to close it.
53
14. Add a 3D Milling Operation
Add a 3D Milling Operation to perform an additional roughing Operation removing

the steps caused in the previous Operation (cusp removal).
In this exercise, the previously defined Operation is used as a template for the current
Operation. In the Operation name section, choose the previous Operation name
(3DR_target_T1) from the list.
The previous Operation data is loaded into the current Operation. The same geometry
is used. Now you have to edit the technological parameters to perform the cusp
removal.
15. Define the tool
In the same manner as explained

earlier, define a new tool for the
Operation.
Define a 12 End mill tool. Edit the
following length parameters:
length to 55;
16. Change the cutting strategy
In the Rough section, change the Hatch type used in the

previous Operation to Contour. The cusp removal is
performed in several concentric profiles.
Set the Step down value to 2. With this value, the machining
is performed between the previously machined cutting levels.
Set the Surface offset value to 0.5. This allowance is removed
in the finish Operations.
54
Click on the Data button to set the additional parameters of

the Contour strategy. The Contour parameters dialog box is
displayed.
Set the Arc approximation tolerance value to 0.02 and
confirm the dialog box with the OK button.
Since the bulk of material is already removed in the previous

Operation, the current Operation has to be performed only
on the rest material areas remaining unmachined after the
previous Operation.
In the Working area section, click on the Define button to
display the Working Area dialog box.
Select the Cut only the Rest material

check box to perform cutting only in the
Rest Material areas.
In this Operation, the combination of the
Working area defined by geometry and
the rest material areas is used to limit the
tool path.
with the OK button.

55
19. Simulate
Perform the simulation of the Operation in the HostCAD and SolidVerify modes.
At this stage, the rough machining of the cavity part is finished. The roughed part will
be finished in the following exercises.
56
Exercise #3: Toy mold cavity roughing

Define the CAM-Part and Operations for the rough machining of the
toy mold cavity.
This exercise reinforces the following skills:
CAM-Part definition;
3D Contour roughing;
Working area definition;
Rest material roughing.
The SolidWorks model of the toy mold cavity (Exercise3.sldprt) is located in the Exercises folder.
The following steps have to be implemented to reach the final CAM-Part:
At this stage, you have to define the CAM-Part, the CNC-controller, the Machine
Coordinate System, the Stock model and the Target model.
Choose the Fanuc CNC-controller for this exercise.
2. Perform rough machining
Define a 3D Milling Operation using the Contour strategy

to perform the rough machining of the cavity.
Use a 20 End mill for the Operation. Define the relevant
technological parameters and the Z-Entry strategy.
Define the Working area to avoid unnecessary tool
movements.
3. Perform rest material roughing
Define a 3D Milling Operation to remove the rest material

left unmachined in the previous Operation. Choose the
Contour strategy for the Operation.
Define smaller Step down and Surface offset values than
in the previous Operation.
Use the combination of the Working area defined in the previous Operation and
cutting the rest material.
57
Exercise #4: Bottle-bottom mold cavity roughing

Define the CAM-Part and Operations for the rough machining of
the bottle-bottom mold cavity presented on the illustration.
3D Contour roughing;
The SolidWorks model of the cavity (Exercise4.sldprt) is located in the Exercises folder.
The following steps have to be implemented in order to reach the final CAM-Part:
The Fanuc CNC-controller has to be chosen for this exercise.
Define a 3D Milling Operation using the Contour strategy

to perform the rough machining of the cavity.
movements.

left unmachined by the previous Operation. Choose the
cutting in rest material.
58
Exercise #5: Spoon die core roughing

Define the CAM-Part and Operations for the rough machining of
the spoon die core presented on the illustration.
3D Hatch roughing;
The SolidWorks model of the core (Exercise5.sldprt) is located in the Exercises folder.
The following steps have to be implemented in order to reach the final CAM-Part:
The Fanuc CNC-controller has to be chosen for this exercise.
Define a 3D Milling Operation using the Hatch strategy

to perform the rough machining of the core.
movements.

left unmachined by the previous Operation. Choose the
cutting in rest material.
59
2.3 3D Semi-Finishing/Finishing
machining prepares the model for
finishing. After semi-finishing the model, a uniform
offset remains on the material. This offset is
removed in the last finishing cut.
Semi-Finish
SolidCAM Finishing
strategies
machining generates the tool path directly

on the surfaces and solids of your 3D Model
geometry. No offset can be specified and the model
is machined to its final topology and dimensions.
You can apply a number of machining strategies to
finish your models, each of them offers parameters
to adjust the strategy to your needs.
Finish
The same machining strategies in Finish machining

can be applied for Semi-finish. The only difference
is the definition in Semi-finish of the Surface offset
parameter that controls the X-,Y- and Z-offset
that remains on the original surface. Otherwise, all
strategies are defined and used in the same way as
in Finish machining.
Linear
Offset cutting
Spiral
Circular pocket
Pencil Milling
Constant Z
Constant Step over
Linear strategy
In Linear cutting, the lines of a linear pattern with the specific
step over are generated on a 2D plane above the model. The
linear pattern is then projected on the 3D Model.
Offset Cutting Finishing strategy

Offset cutting
is a form of 3D profile milling that can be used to mill specific areas of the model.
60
If you select one profile, you must

specify the clear offset distance. On
the right side of the profile, relative Tool path
to the chain direction, the machining
is performed until the specified clear
offset distance has been reached. In
this example, one Offset profile on the
upper part of the model is machined
normal to the profile geometry.
Offset Geometry
Clear
Offset
When you define two Offset profiles, both profile geometries are connected and the tool
path is projected on the 3D Model.
Offset
Geometry
Tool path
Spiral Finishing strategy

Different types of spiral tool path movements can be selected for this finishing strategy. The spiral
tool path pattern is first generated in 2D and then is projected on the 3D Model.
61
Circular Pocket Finishing strategy

The selected Working area is used to create a 2D pocket line pattern
on a plane above the model. The line pattern is then projected on the
3D Model.
Constant Z Finishing strategy

This strategy is used to generate high quality finish on both steep and
flat areas. The machining of the steep areas is performed by machining
sections, at Z-levels defined by either step down or scallop. The flat
areas are automatically recognized and machined with pocket strategy.
Constant Step over strategy

The 3D Projection machining strategies (Linear, Spiral, Offset cutting,
Circular pocket) generate a 2D tool path mesh, with a constant Step
over in the plane parallel to the XY-plane of the current Coordinate
System. This 2D tool path mesh is then projected on the 3D Model to
get the 3D tool path. This method provides good results for prismatic
parts machining but has a disadvantage for the machining of curved
surfaces because it does not take into account the surface curvature
when it generates a tool path pattern.
The Constant Step over strategy gives an excellent surface finish because
the step over is constant along all surfaces irrespective of whether they
are steep walls or shallow areas.
Pencil milling
Pencil milling uses an algorithm that determines all of
the corners of a
part and automatically drives the tool along these corners.
62
Exercise #6: Cover finishing

This exercise illustrates the use of SolidCAM 3D Finishing for the
aerospace electronic box cover machining.
The Linear strategy is used in this exercise to perform the finish of the
upper faces of the model highlighted below.
1. Load the SolidCAM Part
Load the Exercise6.prt CAM-Part

located in the Exercises folder.
This CAM-Part contains two 3D
roughing Operations. Perform the
SolidVerify simulation of these
Operations.
Rough machining
63
Rest material roughing
2. Add a new 3D Milling Operation
In SolidCAM Manager, right-click on the last

Operation in the list and choose Add Operation, 3D
Milling.
In the Geometry section, choose the Target model

geometry (Target) from the list.
4. Define the tool
Define a new tool for the Operation. Add

a 12 Ball-nosed mill.
Set the User tool type to Ballnosed mill.
Set the Diameter to 12;
Set the Outside Holder length
to 50;
5. Define the Facet tolerance
In the Facet tolerance section, set the value to 0.01. Small

tolerance values result in better surface quality.
6. Choose the machining strategy
In the Finish section, choose the Linear strategy from the list.
64
7. Define the linear finish parameters
In the Finish section, click on the Data

button. The Linear Finish dialog box is
displayed. This dialog box enables you
to adjust the technological parameters of
the Linear strategy.
Technological parameters
Step over
In linear finishing, a line pattern is

generated on a 2D plane above the
model and then projected on the
3D Model. The Step over value
determines the constant distance
between all lines of the linear pattern
created on the 2D plane before it is
projected.
Step over
Linear pattern
Projected
tool path
Scallop
This parameter enables you to control the distance between the tool
path lines according to the cusp height you want to achieve on the
finished model. SolidCAM adjusts the distance between the single
lines of the 2D pattern (before projection on the model) to the
topology of the model to match the specified scallop height.
Maximum step over
This parameter limits the Step over when the Scallop option is used.
65
Arc approximation
You can create the G2/G3 GCode output from Linear finishing
Operations. SolidCAM checks whether successive points of the
calculated tool path can be connected with an arc or circle. If an arc
or circle connection within the specified arc approximation tolerance
can be made, you receive arc and circle interpolation commands G2
and G3 in the generated GCode. This feature can drastically reduce
the number of lines in GCode files. Most CNC-controllers and
machines work much faster on arcs and circles than on single tool
path points or splines. Arc approximation increases actual feed rates
on older CNC-machines and the machine works smoother.
The Tolerance value defines the tolerance SolidCAM uses to position
tool path points on arcs or circles.
In this exercise, set the Step over value to 0.2.
Direction type
This option controls the direction of the tool on each line of the
linear pattern that has been projected on the model. Different materials
and cutters require specific cutting conditions, e.g. some tools give better
surface finish when cutting only downward; in other applications you need
to use other settings to achieve optimal results.
Zigzag
The tool finishes one line of the linear pattern,

then moves directly to the next line, and so on.
It mills forward and backward without leaving
the material, thus constantly switching between
climb milling and conventional milling.
Connection radius: you can connect lines of the linear tool path with
a radius. If the Radius value is 0, SolidCAM connects the linear tool
path with straight lines.
Connection with radius
Connection without radius
66
One way
The tool finishes one line of the linear

pattern. At the end of the line, the
tool moves rapidly (G0) to the safety
distance and then to the start of the
next cut line. The tool always uses climb
or conventional milling.
One way - Upward
The tool always cuts from the lowest

point of the tool path line to the highest
point. From the highest point of the
cut, the tool moves rapidly to the start
point of the next cut.
One way - Downward
The tool always cuts from the highest

point of the tool path line to the lowest
point. From the lowest point of the cut,
the tool moves rapidly to the start point
of the next cut.
Define Direction angle by

Angle
Enter the angle that defines the orientation of the tool path. The
value of 0 generates the tool path lines in the direction of the
positive X-axis.
Line
When you choose the Line option, the Define button is activated
and you can define a line that determines the orientation of the
tool path. The direction vector is defined by picking two points that
define the start point and end point of the direction line. The angle
of the selected line is the output to the angle field.
67
In this exercise, the machining is

performed in a number of tool paths
normal to the X-axis direction. In the
Define direction angle by section, set the
Value to 90.
Make sure that the default Zigzag option
is chosen for Direction type.
Confirm the dialog box with the OK
button.
The linear finishing in this exercise has to be applied to the

top faces of the model.
Work on Selected faces
SolidCAM enables you to define the area of the 3D Model machining

by selecting two sets of model faces:
Drive faces the set of faces to be
milled. The tool path is generated
only for machining of these faces.
the set of faces to

be avoided during the generation of
the tool path.
Check Faces
Check faces
Drive Faces
Other faces of the model is not considered during the tool path
calculation.
In the model shown above, SolidCAM generates the tool path only
for the shallow area. During the calculation, SolidCAM avoids the
gouging of the check faces. The remaining faces do not participate in
the tool path calculation.
68
In the Working area section, click on the Define button. The

Working Area dialog box is displayed.
In the Working Area dialog
Work on selected faces check
box, select the

box.
In the Drive faces section, click on the Define

button to start the drive faces definition.
The Select Faces dialog box is displayed in the
PropertyManager area.
This dialog box enables you to perform faces selection.

Click on the CAD selection button to use the
selection tool of SolidWorks.
Right-click on the top model face as shown and
choose the Select Tangency option from the
menu.
All the tangential top faces are selected. In the
dialog box, click on the Resume
button to resume the selection.
Select Faces
Click on the
button to confirm the geometry selection. The Working Area dialog
box is displayed again.
Click on the OK button to confirm the Working area definition.
69

The 3D Milling Operation data is saved and linear finishing tool path is calculated.
10. Simulate
At this stage, the exercise is completed.
70
Exercise #7: Bottle-bottom mold cavity finishing

This exercise illustrates the use of SolidCAM 3D Milling
Operation for semi-finishing and finishing of the bottle-bottom
mold cavity machining.
The Spiral finishing strategy is used in this exercise to semifinish/finish the forming faces of the cavity highlighted below.
Load the CAM-Part pre-machined in Exercise #4 or Exercise7.prt located in the

Exercises folder.
This CAM-Part contains two 3D Roughing Operations. Perform the SolidVerify
simulation of these Operations.
Rough Machining
In SolidCAM Manager, right-click on the last Operation in the list and choose Add
Operation, 3D Milling.
In the Geometry section, choose the Target model geometry (Target) from the list.
71
4. Define the tool
Define a new tool for the Operation. Add a 10 Ball-nosed mill.

Modify the following tool parameters:
Set the User tool type to
Ball-nosed mill;
Set the Outside holder
length to 45;
In the Facet tolerance section, set the value to 0.01.
6. Define the semi-Finishing strategy
In the Semi-Finish section, choose the Spiral strategy from the list.
Set the Surface offset value to 0.2. This allowance is
removed in the finishing Operation.
72
7. Define the spiral finish parameters
In the Semi-Finish section, click on the Data

button. The Spiral Semi-Finish dialog box
is displayed. This dialog box enables you to
define the technological parameters of the
Spiral Finishing strategy.
Path type & Profile type
By combining the options in the Path type and Profile type fields, you
can generate five types of tool path spirals.
Linear
The tool path is performed in a radial linear

pattern defined by the Start angle and End
angle parameters in the Angle section. The
angular distance between tool path lines is
defined by the Delta angle parameter.
Spiral
Profile type: Arcs
The machining is performed in a spiral tool path.

The spiral tool path is defined by the
following parameters:
Start Angle;
End Angle;
Start Radius;
End Radius;
Delta Radius.
73
Profile type: Lines
The machining is performed by a linear spiral

tool path.
The spiral is defined by the following
parameters:
Start Radius;
End Radius;
Delta Radius.
Circular
Profile type: Arcs
The machining is performed in a number

of concentric arcs/circles defined with the
following parameters:
Start Angle;
End Angle;
Start Radius;
End Radius;
Delta Radius.
Profile type: Lines
The machining is performed in a number of

concentric squares defined with the following
parameters:
Start Radius;
End Radius;
Delta Radius.
In the Path type section, choose the Spiral option to perform the spiral tool path. Make
sure that the Arcs option is chosen in the Profile type section.
In the Radius section, set the Delta value to 0.3. This parameter defines the distance
between the turns of the spiral.
74
8. Define the spiral center
At this stage, you have to define the center point of the spiral. In this exercise, the
center point is defined as a sketched point located on the center of the top face of the
cavity. To create this point, do the following:
Select the top face of the mold cavity as shown.
In the SolidWorks menu, click Insert, Sketch
to create a new sketch on the selected face.
Sketch a new point and apply the Concentric
geometric relation between the sketched point
and the circular edge of the cavity.
The sketched point is located in the center of the cavity at the top plane. Confirm the
relation definition with the
button.
Close the sketch.

In the Spiral Semi-Finish dialog box, click on
the Pick center of spiral path button.
The Pick Center point of tool path dialog box
is displayed.
75
Click on the sketched point as shown. The

coordinates are displayed in the Pick Center
point of tool path spiral dialog box.
Confirm the center point selection with

the
button.
Confirm the Spiral Semi-Finish dialog box with the OK button.
At this stage, you have to define a Working area to limit the tool path.
In the Working area section, click on the Define button. The Working Area dialog box
is displayed.
Select the Working area check box and choose the already
defined Working area geometry from the list. This geometry
was previously used to limit the roughing tool path.
Click on the Show button to check the Working area
geometry.
In the Show geometry dialog box, click
button. The Working Area
on the
dialog box is displayed again.
In the Tool on Working area section,
choose the Middle option.
with the OK button.
76
In the Semi-Finish section, click on the Z-Entry button

to define the way the tool plunges into the material. The
Z-Entry dialog box is displayed.
Choose the Arc option from the list and set the Arc radius
value to 5. The tool plunges in a spiral movement with the
specified radius.

The 3D Milling Operation data is saved and the spiral tool path is calculated.
12. Simulate
Perform the simulation of the Operation in the HostCAD

and SolidVerify modes.
At this stage the semi-finish machining of the mold cavity

is completed.
Add a new 3D Milling Operation to perform

the finishing of the mold cavity. The finishing
is also performed with the Spiral strategy.
In the Operation name section, choose the previous Operation (3DS_Sp_target_T3)
from the list to use it as a template for the current Operation.
77
All the data of the template Operation is copied to the current Operation.
Operation name
Once you select a geometry and a tool, SolidCAM automatically

enters a default name (e.g. 3DM_Profile_T1) based on the Operation
type, geometry name and tool number.
3DM_Profile_T1
Operation type
abbreviation
Geometry
name
Tool
Later you can change the Operation name, if necessary.

SolidCAM uses the following Operation type abbreviations for the
3D Milling Operations:
3DR
3DS_Lin
3DS_Offs
3DS_Sp
3DS_Cir
3DS_CZ
3DS_Pen
3DS_CS
3DF_Lin
3DF_Offs
3DF_Sp
3DF_Cir
3DF_CZ
3DF_Pen
3DF_CS
3DD
3DE
3D Roughing
Linear 3D Semi-Finishing strategy
Offset cutting 3D Semi-Finishing strategy
Spiral 3D Semi-Finishing strategy;
Circular Pocket 3D Semi-Finishing strategy
Constant Z 3D Semi-Finishing strategy
Pencil Milling 3D Semi-Finishing strategy
Constant Step over 3D Semi-Finishing strategy
Linear 3D Finishing strategy
Offset cutting 3D Finishing strategy
Spiral 3D Finishing strategy
Circular Pocket 3D Finishing strategy
Constant Z 3D Finishing strategy
Pencil Milling 3D Finishing strategy
Constant Step over 3D Finishing strategy
3D Drill Operation
3D Engraving Operation
When you add a new Operation, you can use an existing Operation as
a template for the new Operation. All fields of the template Operation
are copied and you only need to edit some changing parameters, e.g.
select another geometry or surface offset.
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14. Define the tool

Ball-nosed mill;
length to 45;
15. Choose the finishing strategy
In the Semi-Finish section, choose the None option from the list.
In the Finish section, choose the Spiral option from the list.
Click on the Data button to define the Spiral finishing parameters. The Spiral Finish
Choose the Linear option in the Path
type section. The tool path is performed
in a radial linear pattern.
Define the angular distance between tool
path lines. Set the Delta value in the Angle
section to 0.2.
In the same manner as explained earlier,
define the spiral center using the same
sketched point used in the previous
Operation.
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Tool path connections

Direction type
Zigzag: the tool finishes one line of the spiral
pattern and then moves directly to the next
tool path line, and so on. It mills forward and
backward without leaving the material, thus
constantly switching between climb milling
and conventional milling.
One way: the tool finishes one line of the

linear pattern. At the end of the line, the tool
travels rapidly (G0) to the safety distance and
then to the start of the next cut line. The tool
always uses climb or conventional milling.
Connection type
This option enables you to control the way the tool moves between
two adjacent tool paths.
Stairs: the tool moves in two steps between two
adjacent tool paths. If the next path is lower
than the present path, the tool first moves
away from the surface in the XY-direction and
then moves downwards in Z. In case the next
path is higher than the present path, the tool
first moves upwards in Z and it approaches the
surface in the XY-direction.
Smooth:
between two adjacent tool paths, the

tool moves on the surface of the model. The
line connecting the two adjacent tool paths
is projected on the model. When you use the
Smooth option, the tool does not leave the
material when moving to the start point of the
next tool path.
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Make sure that the Zigzag option is chosen in the Direction type section. With this
option, bi-directional zigzag movements are performed without air movements.

The 3D Milling Operation data is saved and the spiral finishing tool path is calculated.
17. Simulate
At this stage, the machining of the mold cavity is finished.
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Exercise #8: Electrode finishing

This exercise illustrates the use of SolidCAM 3D Finishing for the electrode machining.
Mold cavity
Electrode
The Circular pocket strategy is used in this exercise to finish the forming
surfaces highlighted on the illustration.
The Offset cutting strategy is used in this exercise to finish the parting
surfaces highlighted on the illustration.
Load the pre-machined CAM-Part Exercise8.prt located in the Exercises folder.

This CAM-Part contains two 3D roughing Operations. Perform the SolidVerify
Rough Machining
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4. Define the tool

Set the User tool type to Ball-nosed mill.
5. Define Facet tolerance
In the Facet tolerance section, set the tolerance value to 0.01.

6. Define the Finishing strategy
In the Finish section, choose the Circular pocket strategy

from the list.
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In this strategy uses the selected Working area to create a 2D pocket line
pattern on a plane above the model. The line pattern is then projected on the
3D Model. During this projection, the Z-position of the tool is calculated to
avoid gouging of the material.
Working area
7. Define the Circular pocket parameters
In the Finish section, click on the Data

button. The Circular Pocket Finish dialog
box is displayed. This dialog box enables
you to adjust the technological parameters
of the Circular pocket Finishing strategy.
Circular Pocket parameters

Cutting direction
The pocket is machined in either Conventional or Climb direction.

Start from
The machining can be started from Outside or Inside the pocket.
84
Connection type
Stairs
The tool moves in two steps between two

adjacent tool paths. If the next path is lower
than the present path, the tool first moves
away from the surface in the XY-direction
and then downwards in Z. If the next path
is higher than the present path, the tool first
moves upwards in Z and then approaches
the surface in the XY-direction.
Smooth
Between two adjacent tool paths, the tool

moves on the surface of the model. The
line connecting two adjacent tool paths is
projected on the model. When this option
is used, the tool does not leave material
when it moves to the start point of the next
tool path.
Step over
In pocket finishing, SolidCAM generates the pocket line pattern on

a 2D plane above the model and then projects it on the 3D Model.
The Step over value determines the constant distance between the
lines of the pocket created on the 2D plane before it is projected on
the model.
In the Start from section, choose the Outside option to start the machining from
outside.
In the Connection type section, choose the Smooth option.
Set the Step over value to 0.2.
Click on the OK button to confirm the Circular pocket parameters.
85
The Working area definition is necessary for the circular pocket machining. The shape
of the Working area directly effects the tool path.
In the Working area section, click on the Define button to start the definition.
In the Working Area dialog box, select the Working area
check box and click on the Define button to define the
geometry.
Select the Working area geometry at the boundary of the
forming faces as shown.
Confirm the selection.

In the Working Area dialog box, choose the Middle option in the Tool on Working area
section.

The 3D Milling Operation data is saved and the circular pocket finishing tool path is
calculated.
86
10. Simulate
Add a new 3D Milling Operation to perform the machining of the parting surface.
12. Define the tool

Modify the following tool parameters:
Ball-nosed mill;
Set the Outside holder
length to 45;
40.

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14. Define the Finishing strategy
In the Finish section, choose the Offset cutting strategy from

the list.
Offset cutting is a form of 3D profile milling that can be used to

mill specific areas of the model. This strategy offers two possible
alternatives of profile selection:
If you select one profile, you have to specify the Clear offset
distance. The machining will be performed at the defined side of
the profile until the specified Clear offset distance is reached.
Offset Geometry
Tool path
Clear
Offset
When you define two profiles, both profile geometries are

connected and the tool path is projected on the 3D Model.
Offset
Geometry
Tool path
88
In the Finish section, click on the Data button.

The Offset Finish dialog box is displayed. This
dialog box enables you to define the technological
parameters of the offset cutting.
15. Define the Offset geometry
In the Offset geometry name section, click on

the Define button to define the offset cutting
geometry. In this exercise, two closed contours
are defined and the offset cutting is performed
between them.
Select the external edges of the parting
surface as shown to define the first
geometry chain.
When the first chain is completely selected,

start the definition of the second chain.
Start the selection from the opposite edge
of the same face that was used for the
definition of the start edge of the first
chain. Make sure that the directions of
both of chains are the same.
Complete the chain and confirm the
selected geometry with the
button.
The Offset Finish dialog box is displayed.
89
16. Define the offset cutting parameters

Cutting area
Clear offset
This value determines the offset distance from the profile that will be
machined. This field is available if you use an offset geometry that
consists of only one profile. In this exercise the geometry has two
profiles, therefore this field is unavailable.
Step over
In offset cutting, SolidCAM generates the offset pattern on the XYplane above the model and then projects it on the 3D Model. The
Step over value determines the constant distance between all lines of
the offset pattern created on the plane before it is projected.
Tool side
This option enables you to define the side of the geometry relative to
the geometry direction, where the Clear offset is applied.
Geometry direction
Left side machining
Right side machining
This option is not relevant in this exercise, where the geometry is

defined by two chains.
Cutting direction
Cross Finish
Select this check box if you want

to perform a Cross finish on the
offset area. After finishing the
machining in the first specified
direction, i.e. parallel or normal
to the profile geometry, the other
cutting direction is also applied.
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First cutting direction
If you have selected the Cross finish check box, both cutting directions
are applied to the offset area. Select which one you want to start with.
When no cross finish is used, only the selected option is performed.
Parallel to geometry:
SolidCAM generates a pattern with offset lines

parallel to the offset profile geometry. This pattern is then projected
on the model.
Normal to geometry:
SolidCAM generates a pattern with offset lines

normal (90 degrees) to the offset profile geometry. This pattern is
then projected on the model.
Tool path connections

Direction type
Zigzag: the tool finishes one line of the offset pattern and then moves
directly to the next line and so on. It mills forward and backward
without leaving the material, thus constantly switching between climb
milling and conventional milling.
One way: the tool finishes one line of the offset pattern. At the end
of the line, the tool moves rapidly (G0) to the safety distance and
then to the start of the next cut line. The tool always uses climb or
conventional milling.
Connection type
Stairs: the tool moves in two steps between two
adjacent tool paths. If the next path is lower than
the present path, the tool first moves away from the
surface in the XY-direction and then downwards
in Z. If the next path is higher than the present
path, the tool first moves upwards in Z and then
approaches the surface in the XY-direction.
Smooth:
between two adjacent tool paths, the

tool moves on the surface of the model. The line
connecting the two adjacent tool paths is projected
on the model. When you use this option, the tool
does not leave material when it moves to the start
point of the next tool path.
91
Make sure that Parallel to geometry option is chosen in the First cutting direction
section. The machining is performed parallel to the geometry.
Choose the Zigzag option in the Direction type section. The machining is performed
in both directions without leaving the material.
Choose the Smooth option in the Connection type section to perform the smooth
connection between adjacent tool path lines.
Confirm the Offset Finish dialog box with the OK button. The 3D Milling Operation
In the Finish section, click on the Z-Entry button to define

the way the tool plunges into the material. The Z-Entry
Choose the Angle along path option and set the Angle
value to 10.
With the Angle along path option, the tool plunges in a ramp movement
defined by the specified angle. The ramp starts from the given safety
distance down to the model contour. If the ramp cannot be created in a
straight line, the Z-Entry movement follows the tool path contour.
92

The 3D Milling Operation data is saved and the offset cutting finish tool path is
calculated.
19. Simulate
At this stage, the machining of the electrode is finished.
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Exercise #9: Mold cavity finishing

Operation to perform the finish machining of the bottlebottom mold cavity roughed in Exercise #2.
A combination of two finishing strategies is used in this
exercise to perform the finish machining of the forming faces
of the cavity highlighted on the illustration.
All the steep areas of the cavity are machined using the
Constant Z strategy. The shallow areas are machined using the
Constant Step over strategy.
In the current exercise, only one instance of the forming faces is machined.
The other two instances can be machined either by defining a different
Working area or by defining a circular pattern of Operations.

Exercises folder.
Rough Machining
94
4. Define the tool

Ball-nosed mill;
length to 55;
50.
In the Facet tolerance section, set the value to 0.01 to provide the necessary accuracy for
the model faces triangulation. Small tolerance values result in better surface quality.
6. Define the finishing strategy
In the Finish section, choose the Constant Z strategy from

the list.
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With this strategy, SolidCAM generates a

number of planar sections of the model.
Section planes are parallel to the XYplane of the current Coordinate System.
Profile machining is performed for each
section. This strategy produces high
quality finish especially on steep surfaces
and minimizes full 3-axis movements
that slow down CNC-machines and
controllers.
7. Define the Constant Z finish parameters
In the Finish section, click on the Data button. The

Constant Z Finish dialog box is displayed. This
dialog box enables you to define the technological
parameters of the Constant Z Finishing strategy.
Select the Constant Z Wall machining section
check box. This section enables you to define the
technological parameters for the machining of
steep areas.
Step down
SolidCAM enables you to choose one of two options for Constant Z wall
machining:
Constant step down
Starting from the Upper level, the specified step down is used to
calculate each successive Z-level. The value of 20 for the Upper
level and the Constant step down of 1.5 produce a tool path on the
model contour at Z 20, Z 18.5, Z 17, Z 15.5, etc. until the Lower level
is reached.
96
Variable step down
The step down necessary to produce the specified scallop (cusp

height) on the model surface is calculated automatically. On steep
areas, the step down is naturally larger than on more level areas.
The Scallop value defines the
cusp height of the resulting
surface finish. The smaller is
the value, the smoother is the
surface finish.
Scallop
The Maximum step down

parameter defines the maximum
value of the step down, when
the Scallop option is used.
Minimum step down. On nearly level areas, the step down necessary to
achieve the specified scallop can be very small. You can set a minimum
step down value that overrides the smaller step down generated by
the scallop calculation.
In this exercise, the constant step down is used. Choose the Constant step down option
and set the Step down value to 0.2.
During the tool path calculation, several model sections parallel to the XY-plane are
generated. These sections are machined with the profile milling technology.
You can control the way the tool leads in and leads out from these profiles.
Lead in and Lead out
You can control the way the tool leads in and leads out from the profile.
Select an option from the list field and enter the Distance value for this
option.
The following Lead in/Lead out strategies are available:
None
The tool approaches or retreats from the milling level exactly adjacent
to the start point of the material.
97
Arc
The tool approaches the material or retreats

from it with a tangential arc.
Lead in
value
Normal
The tool approaches or retreats from a point

normal to the profile.
Lead in
value
Tangent
The tool approaches or retreats on a line

tangent to the profile. The length of the
tangent can be set in the Value field.
If you define the Normal value, the tool starts
with the movement normal to the profile
and then approaches tangentially.
Lead in
value
Normal
Choose the Arc option for Lead in and Lead

and set the radius Value to 3. The lead
in/out movements are performed with arcs.
out
Connection type
This option enables you to control the way the tool moves between two
adjacent tool paths.
Stairs
The tool moves in two steps between two

successive tool paths. If the next path is
lower than the present path, the tool first
moves away from the surface in the XYdirection and then downwards in Z. If the
next path is higher than the present path,
the tool first moves upwards in Z and
then approaches the surface in the XYdirection.
98
Tangential
Between two successive tool paths, the

tool first moves away from the contour in
a tangent movement. Then it continues
in a 3D arc/spiral movement to the next
Z-level and approaches the next contour
with a tangent movement.
The Approach radius value defines the radius of the 3D arc used
to create the tangential move between two successive Z-levels. The
value defines the maximum radius used as SolidCAM automatically
reduces the radius if the model topology does not leave enough space
to approach with the specified radius. This may happen in narrow
cavities of the model when a large tool is used.
When the Tangential connection type is chosen, the Lead
in/Lead out options are unavailable.
Cutting direction (Cut from)

Top to bottom
The machining starts from the Upper level and continues downwards
in the Z direction until the Lower level is reached.
Bottom to top
The machining starts from the Lower level and machines upwards to
the Upper level.
Milling type
Climb
Climb milling is performed.

Conventional
Conventional milling is performed.
99
Open contour strategy
This field controls the milling direction on contours that cannot be closed
because the model or a specified Working area does not enable SolidCAM
to continue the tool path to a closed loop.
One way
After finishing the tool path at the specific Z-level, the tool retreats to
the Clearance level and moves to the start point of the next Z-level,
always keeping the cutting direction specified in the Milling type.
Zigzag
This option enables the tool to change the cutting direction when it
encounters open contours. The milling direction on open contours
is switching between climb and conventional milling until the open
contour is finished. With this option, rapid moves from Z-Level to
Z-level are greatly reduced.
Make sure that the Top to bottom
option is chosen in the Cut from
section. The machining in this exercise
is performed from the Upper level
downward to the Lower level.
Make sure that Climb is chosen in the
Milling type section.
Make sure that the One way option is
chosen in the Open contour strategy
section. The machining is performed
in one direction keeping the climb
milling type.
Confirm the Constant Z parameters
with the OK button.
100
8. Define the Z-Entry parameters
In the Finish section of the 3D Milling Operation dialog

box, click on the Z-Entry button. The Z-Entry dialog
box is displayed. This dialog box enables you to define
how the tool plunges into the material.
Z-Entry strategy
None
When Z-Entry strategy is set to None or the default Angle value is

90 degrees, the tool plunges into the material with a normal downward
movement at the specified Z-feed rate.
Z-Entry: None
Tool path
Angle along path
The tool plunges with a ramp movement. The ramp starts from the
given safety distance down to the model contour. If due to the model
contour the ramp cannot be created in a straight line, the approach
movement follows the contour.
101
Angle between paths
The tool plunges with a ramp movement. The ramp movement for
the first Z-level starts from the given safety distance. The next ramp
movements are performed between the Z-levels. If, due to the model
contour, the ramp cannot be created in a straight line, the Z-Entry
movement follows the contour.
Under Z-Entry strategy, choose Angle between paths

option and set the Angle value to 20.
Confirm the Z-Entry dialog box by clicking on the OK
button.
At this stage, you have to define the Working area to limit the tool path.
In this exercise, the tool path is limited by the combination of two Working areas:
Working area defined by geometry is used to limit the tool path to one
instance of the cavitys forming faces.
Working area defined by surface inclination angle range enables you to
apply various machining strategies to model areas with different inclination.
In this exercise, the chosen Constant Z strategy is used to machine steep
areas. The shallow areas are machined later with a different strategy.
In the Working area section of the 3D Milling Operation dialog box, click on the Define
button. The Working Area dialog box is displayed.
Select the Working area check box and click on the Define button to start the geometry
definition.
102
Using the Geometry Edit dialog box,

define the geometry as shown.
Confirm the defined geometry.
Choose the Middle option
Working area section.
in the Tool on
Select the Angle limits check box to define

the surface inclination angle range.
How is the angle limit calculated in SolidCAM?
At each point where the tool contacts with the machining surface,
SolidCAM determines the normal vector at the contact point, directed
to the tool sphere center (for ball-nosed tools); for End mills with
rounded corners, the vector is directed from the contact point to the
radius center.
The angle of this vector, relative to the Z-axis, is used for the angle
limits calculation.
The Angle Limits section in the Working Area dialog box enables you
to define the angle range.
The Minimum angle value defines the lower limit of the angle
range.
The Maximum angle value defines the upper limit of the angle
range.
Angle
Normal vector
Contact point
103
A particular feature of the Angle limits method

is related to machining of the model edges: it is
impossible to determine a single contact point
between the edge and the tool surface. The tool
rolls over the edge, continuously keeping in
contact until the angle of the normal vector at the
contact point is in the defined range.
The resulting tool path will be rounded. Such tool
path rounding causes the breaking of the sharp
corners. The machining time is also increased.
The Trim rounding option enables you to avoid unnecessary tool path
rounding.
When this option is chosen, SolidCAM trims the tool path at the
point where the tool axis is coincident to the surface boundary.
Rounded tool path
Rounding trimmed
Set the Minimum angle value to 30 and the Maximum angle

value to 90. All the steep areas with the inclination angle
from 30 up to 90 are machined.
Confirm the Working Area dialog box with the OK button

The 3D Milling Operation data is saved and the Constant Z Finish tool path is
calculated.
104
11. Simulate
Perform the simulation of the Operation in

the HostCAD mode.
Add a new 3D Milling Operation to perform

the finish machining of the shallow areas.
Use the previously defined Constant Z
Finishing Operation as the template to copy
all the data from it.
The same geometry and tool are used in the current Operation.
In the Finish section, choose the Constant Step over finishing

Constant Step over Finishing strategy
The 3D Projection machining strategies (Linear, Spiral, Offset cutting,

Circular pocket) generate a 2D tool path mesh, with a constant Step
over in the plane parallel to the XY-plane of the current Coordinate
System. This 2D tool path mesh is then projected on the 3D Model to
get the 3D tool path. This method provides good results for prismatic
parts machining but has a disadvantage for the machining of curved
surfaces, because it does not take into account the surface curvature
when it generates a tool path pattern.
105
The Constant Step over strategy gives an excellent surface finish

because the step over is constant along all surfaces irrespective of
whether they are steep walls or shallow areas.
Tool path with Constant Step Tool path with Constant Step
over in the XY-plane
over along the surface generated
with the Constant Step over
strategy
14. Define Constant Step over parameters
In the Finish section of the 3D Milling Operation dialog box, click on the Data button.
The Constant Step Over Finish dialog box is displayed. This dialog box enables you to
define the technological parameters of the Constant Step over strategy.
106
Operation type
Five types of the Constant Step over strategy are available:

Profile with Offset
Step Over
The tool mills from the

Geometry
geometry you have chosen
to the Clear offset distance.
SolidCAM enables you to
specify the Step over distance.
Both Step over and Clear
offset are measured along the
surface.
Clear Offset
Tool path
Pocket
The tool mills within the

boundaries of the geometry
until the entire pocket is
machined. The geometry
used with this option must
consist of a number of
closed chains, same as a
geometry for a regular Pocket
Operation.
Tool path
Pocket geometry
SolidCAM defines a number of offsets to the geometry with the

specified Step over, measured along the surface. If there is an island,
the tool mills evenly from the outside chain toward the island and from
the island toward the outside chain. The two paths join in the middle
between the two chains. The shape of the tool path is determined by
both the outside geometry and the island geometry.
107
Profile with limit
This option enables you to

create the tool path between two
chains that can be open. The
tool mills from the first chain
toward the second chain copying
the shape of the first chain along
the surface being machined with
the specified Step over. The
Step over is measured along the
surface.
Chain #1
Step Over
Tool Path
Chain #2
Ruled Surface
This option enables you to create the

tool path between two chains that can
be open. The tool mills from the first
geometry towards the second geometry
while morphing from the shape of the
first geometry to the shape of the second
geometry, with the specified Step over.
Pocket-auto boundaries
Tool path
Second
chain
First chain
With this option, the tool mills within the boundaries of the geometry
in the same manner as in the Pocket Operation type. The Working
area geometry is automatically used as a pocket geometry for this
option.
Choose the Pocket-auto boundary option from the Operation type list and set the Step
to 0.2 to provide smooth surface finish.
over value
In the Direction section, choose the Climb option to perform the climb milling.
108
button to start the Working area definition. The Working Area dialog box is displayed.
This dialog box contains the data received from the previous Operation used as a
template.
The Working area is defined as a combination of two Working areas: the first one
defined by geometry and the second defined by surface inclination angle range.
Change the surface inclination angle range to perform the machining of shallow
areas.
Set the Minimum angle value to 0 and the
Maximum angle value to 32. Note that
the Maximum angle value is greater than
the Minimum angle value of the previous
Operation, resulting in 2 overlap. This

overlap between tool paths is used to
avoid the occurrence of unmachined
areas.
The Working area defined by geometry

is the same. It enables you to perform
the machining for one instance of the
forming faces. In the Tool on Working
area section, choose the Internal option
to limit the tool path inside the Working
area.
with the OK button.

The 3D Milling Operation data is saved and the Constant Step over finish tool path is
calculated.
109
17. Simulate
Perform the simulation of the Operation in the HostCAD mode.
Simulate both of the finish Operations in the HostCAD mode.
Simulate both of the finish Operations in the SolidVerify mode.
Note that the overlapping of the surface inclination angle ranges used for the
and Constant Step over strategies enables you to perform a smooth
transition between the tool paths generated by the two Operations.
Constant Z
110
Exercise #10: Mold core finishing

This exercise illustrates the use of SolidCAM 3D Milling Operation
for the finish machining of the mold core roughed in Exercise #1.
A combination of two finishing strategies is used in this exercise

to perform the finish machining of the forming faces of the core
highlighted on the illustration.
All the steep areas of the core are machined using the Constant Z
strategy; all the shallow areas are machined using the Constant Step
over strategy.
The Linear Finishing strategy is used in this exercise to perform the
machining of the parting surfaces.

Exercises folder.
This CAM-Part contains two 3D roughing Operations.
111
4. Define the tool
Define a new tool for the Operation. Add 10 Ball-nosed mill.

Set the User tool type to Ball-nosed mill;

In the Finish section, choose the Constant Z strategy from the list. This strategy is used
for the machining of steep areas.
Click on the Data button. The Constant Z
Finish dialog box is displayed. This dialog
box enables you to define the technological
parameters of the Constant Z finishing
strategy.
Select the Constant Z Wall machining check
box.
This section enables you to define the
technological parameters for the machining
of the steep areas.
Define the Step down for the Constant Z
finishing. Choose the Variable Step down
option. SolidCAM automatically calculates
the steps down necessary to produce the
specified scallop (cusp height) on the
model surface.
Set the Scallop value to 0.05
Maximum step down value to 0.2.
and the
112
Define the way the tool approaches and

retreats from the Constant Z profiles.
In the Open contour strategy section, choose
the Zigzag option. This option enables the
tool to change the cutting direction when
it encounters open contours in the model.
The milling direction in open contours is
switching between climb and conventional
until the open contour is finished. With the
Zigzag option, rapid moves from one Z-level
to the next one are greatly reduced.
Confirm the Constant Z parameters with the
OK button.
In this exercise, the Constant Z finishing is limited by a combination of two Working

areas defined by the following methods:
The definition of drive/check faces that enables you to perform the machining
only on the forming faces of the core;
The definition of angle limits that enables you to define
the Working area by surface inclination angle range.
In this exercise, the steep areas are machined with the
Constant Z strategy.
In the Working area section, click on the Define button. The
Select the Work on selected faces check box.
In the Drive faces section, click on the Define button to start the
drive faces definition.
The Select Faces dialog box is displayed in the PropertyManager
area. This dialog box enables you to perform the selection of
faces.
113
Click on the CAD selection button to use

the selection tools of SolidWorks.
Right-click on the model face as shown
and choose the Select Tangency option
from the menu.
All the tangential top faces are selected. In
the Select Faces dialog box, click on the
Resume button to resume the selection.

Click on the
In the Check faces section, click on the Define button to define the faces to be avoided
during the tool path generation. The Select Faces dialog box is displayed in the
PropertyManager area.
In the same manner as explained earlier, select the parting faces as shown.

Click on the
114
SolidCAM enables you to specify the offset for the check faces when
the machining is performed on the selected faces.
Offset
Check face
Check face
Drive face
Drive face
Offset for check faces is not defined
Offset for check faces is defined
Using this offset, you can perform the machining at a safety distance
from the check surfaces.
Under Tool on Working area, set the Offset value to 0.1.
Now you have to define the surface inclination angle range
to perform the Constant Z finishing in the steep areas only.
Select the Angle limits check box and define the angle
range.
Set the Minimum angle value to 30 and the Maximum angle
value to 90.
Click on the OK button to confirm the Working area
definition.

The 3D Milling Operation data is saved and the Constant Z Finishing tool path is
calculated.
9. Simulate
Perform the simulation of the Operation in the

HostCAD mode.
Now you have to perform the machining of the
shallow areas.
115
Add a new 3D Milling Operation to perform the finish machining of the shallow
areas.
Use the previously defined Constant Z Finishing Operation as a template. The same
geometry and tool are used in the current Operation.
In the Finish section, choose the Constant Step over finishing strategy from the list.
Click on the Data button to define the Constant Step over parameters. The Constant
Step Over Finish dialog box is displayed. This dialog box enables you to define the
technological parameters of the Constant Step over strategy.
Choose the Pocket-auto boundaries option
from the Operation type list.
Set the Step over value to 0.1 to achieve
smooth surface finish.
With the Pocket-auto boundaries option, the
tool mills within the Working area geometry
until it has machined the entire pocket.
SolidCAM generates a number of offset
tool paths to the geometry with the specified
Step over measured along the surface.
In the Direction section, choose the Climb
option to perform the climb milling.
button to define the Working area. The Working Area dialog box is displayed. This
dialog box contains the data received from the previous Operation used as a template.
The Working area is defined as a combination of the drive/check faces and the surface
inclination angle range definition.
116
Change the surface inclination angle range to perform the machining of shallow
areas.
Set the Minimum angle value to 0 and the
Maximum angle value to 32. Note that
the Maximum angle value is greater than
the Minimum angle value of the previous
Operation, resulting in 2 overlap. This
overlap between tool paths is used to
avoid the occurrence of unmachined
areas.
with the OK button.

The 3D Milling Operation data is saved
and the Constant Step over finishing tool
path is calculated.
14. Simulate
Perform the simulation of the Operation in the HostCAD mode.

Now you have to perform the machining of the parting surfaces.
117
Use the previously defined Constant Step over finishing Operation as the template to
copy all the data from it. The current Operation uses the same geometry and tool.
16. Choose the machining strategy
In the Finish section, choose the Linear strategy from the list.
Click on the Data button. The Linear
Finish dialog box is displayed. This dialog
box enables you to adjust the technological
parameters of the linear strategy.
In this exercise, the step over is defined by
the cusp height you want to achieve on the
finished model (scallop). SolidCAM adjusts
the distance between the single lines of
the 2D pattern (before projection on the
model) to the topology of the model to
match the specified scallop height.
Set the Scallop value to 0.01 and the
Maximum Step over value to 1.
In this exercise, the linear finishing has to be applied to the parting surfaces of the
mold core.
In the Working area section, click on the Define button. The Working Area dialog box
is displayed.
118
In the Drive faces section, choose the set of

parting surfaces from the list (selected_faces1).
In the Check faces section, choose the set of

forming surfaces from the list (selected_faces).
Set the Offset value to 0.1. This parameter enables
you to avoid the touching of the already machined
forming faces.
Clear Angle limits check box.
Click on the OK button to confirm the Working
area definition.

The 3D Milling Operation data is saved and the linear finishing tool path is
calculated.
19. Simulate
Perform the simulation of the Operation

in the HostCAD mode.
119
Perform the simulation of all the finishing Operations in the HostCAD and SolidVerify
modes.
120
Exercise #11: Electrode pencil milling

Operation for the finish machining of the electrode premachined in Exercise #8.
In this exercise, the Pencil milling strategy is used for the

machining of the intersection area between the faces highlighted
on the illustration.

Exercises folder.
This CAM-Part contains four 3D roughing Operations.
121
4. Define the tool
Define a new tool for the Operation.

Add a 2 Ball-nosed mill.
Ball-nosed mill;
length to 30;
In the Facet tolerance section, set the tolerance value to 0.01 to provide the necessary
accuracy for the model faces triangulation. Smaller tolerance values result in better
surface quality.
In the Finish section, choose the Pencil Milling strategy from the list. This strategy is
used for machining of the corners.
During the finish machining,
some of the model corners are
left unmachined because they are
unreachable for the tool with the
specified diameter. A special milling
strategy has to be applied to remove
the material from these corners.
Pencil milling is based on an
algorithm that determines all of the
corners of a part and automatically
drives the tool along these corners.
122
Click on the Data button. The Pencil Milling dialog box

is displayed. This dialog box enables you to define the
technological parameters of the Pencil Milling strategy.
Pencil Milling parameters

Bitangential angle
The Bitangential angle is a

complement to the 180 of Corner
the corner angle. SolidCAM angle
machines all corners with the
Corner angle smaller than
(180 Bitangential angle).
Bitangential
angle
Direction mode
Standard
The tool mills the center line of Pencil milling from its beginning to
the end in one movement.
123
Upward
The tool mills from the lowest point of the center line of Pencil milling
to the highest point. As a result, the center line of pencil milling is
divided into several segments with the tool moving rapidly from the
end of one segment to the beginning of the next segment.
Segment #1
Segment #2
Downward
The tool mills from the highest point of the center line of Pencil
milling to the lowest point. As a result, the center line of pencil milling
is divided into several segments with the tool moving rapidly from the
end of one segment to the beginning of the next segment.
Segment #1
Segment #2
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Offset
The machining is performed at an

offset from the center line of Pencil
milling. The following data has to be
defined:
Tool path
Center line
The Step over value defines the

step over in both sides from the
center line of Pencil milling.
The Number of passes value
defines the number of offset
passes.
Start from:
Inside: SolidCAM machines the center line of Pencil milling and

then the offset passes at each side.
Center line
3
2
1
4
5
Outside: SolidCAM machines the offset passes from each side at

the center line and then the center line of Pencil milling.
Center line

Set the Number of passes to 10.
In the Start from section, choose the Outside option.
SolidCAM machines five offset passes from each side of the
center line (with the Step over equal to 0.1) and then the center
line of Pencil milling.
Confirm the Pencil milling data with the OK button.
125
1
2
5
4
3
At this stage, you have to define a Working area to limit the scope of Pencil milling.
In the Working Area section, click on the Define button. The Working Area dialog box
is displayed.
Select the Working area check box
and click on the Define button to
start the geometry definition.
Using the Geometry Edit dialog
box, define the geometry as
shown.
Confirm the defined geometry.
Confirm the Working Area dialog
box with the OK button.

The 3D Milling Operation data is saved and the pencil milling tool path is calculated.
9. Simulate

126
Exercise #12: Toy mold cavity finishing

Define a number of 3D Milling Operations for the finish
machining of the toy mold cavity presented on the illustration.
The cavity part was rough machined in Exercise #3.
Constant Z Finishing;
Constant Step over finishing;
Working area definition by a geometry;
Working area definition by surface inclination angle
range.
Use the resulting CAM-Part of Exercise #3 or the Exercise12.prt CAM-Part located in the Exercises
folder.
The following Operations are applied to reach the final CAM-Part:
1. Constant Z Finishing
Define a 3D Milling Operation using the Constant Z strategy to perform the finish
machining of the steep areas of the cavity.
Use a 10 Ball-nosed mill for the Operation. Define the relevant technological
parameters.
127
Define the Working area to avoid unnecessary tool movements. In this exercise, the
tool path is limited by a combination of two Working areas:
Working area defined by geometry.
Use the upper loop as shown to limit
the tool path.
Working area defined by surface
inclination angle range. Define the
surface inclination angle range from
30 to 90 to perform the machining
of the steep areas of the model.
2. Constant Step over finishing
Define a 3D Milling Operation using the Constant Step over strategy to perform the
finish machining of the shallow areas of the cavity.
Use a 10 Ball-nosed mill for the Operation. Choose the Pocket-auto boundaries
method and define the relevant technological parameters.
tool path is limited by a combination of two Working areas:
Working area defined by geometry. Use the same geometry used for the
previous Operation to limit the tool path.
Working area defined by surface inclination angle range. Define the surface
inclination angle range from 0 to 32 to perform the machining of the
shallow areas of the model.
128
Exercise #13: Spoon die core finishing

machining of the spoon die core presented on the illustration.
The core part was rough machined in Exercise #5.
Circular Pocket finishing;
Linear finishing;
Working area definition by model faces.
Use the resulting CAM-Part of Exercise #5 or Exercise13.prt CAM-Part located in the Exercises
folder.
1. Circular pocket finishing
Define a 3D Milling Operation using the Circular

Pocket strategy to perform the finish machining
of the forming faces of the core.
Use a 10 Ball-nosed mill for the Operation.
Define the relevant technological parameters.
Define the Working area by geometry to avoid
unnecessary tool movements.
129
Define a 3D Milling Operation using the Constant

Z strategy to perform the finish machining of the
interlock faces.
Use a 10 Ball-nosed mill for the Operation.
Define the relevant technological parameters.
Define the Working area by geometry to avoid
3. Linear finishing
Define a 3D Milling Operation using the Linear

strategy to perform the finish machining of the
parting face. Use the Normal Cross-finish option
to obtain a high quality machining.
Use a 16 End mill for the Operation. Define the
relevant technological parameters.
Define the Working area by model faces. Choose
the planar parting face for the drive face as shown
below.
Choose the interlock faces for the check faces and

specify the offset value to avoid the unnecessary
contact with the already finished faces.
130
4. Pencil finishing
Define a 3D Milling Operation using the Pencil Milling strategy to perform the finish
machining of the upper model faces.
parameters.
Define the Working area by geometry as shown.
131
Exercise #14: Spoon die cavity finishing

machining of the spoon die cavity presented on the
illustration.
Use the pre-machined Exercise14.prt CAM-Part located in the Exercises folder.
Define a 3D Milling Operation using the

Constant Z strategy to perform the finish
machining of the interlock faces.
Use a 8 Bull-nosed mill with the corner
radius of 1 mm for the Operation. Define
the relevant technological parameters.
Define the Working area by geometry to
avoid unnecessary tool movements.
132
Use a 8 Bull-nosed mill with the corner radius of 1 mm for the Operation. Choose
the Pocket-auto boundaries method and define the relevant technological parameters.
Define the Working area by model faces. Choose the forming faces as drive faces, as
shown below.
Choose the interlock faces for the check faces and specify the offset value to avoid the
contact with the already finished faces.
133
Exercise #15: Cavity finishing

machining of the cavity presented on the illustration.
Working area definition by geometry;
Working area definition by surface inclination angle.
Use the pre-machined Exercise15.prt CAM-Part located in the Exercises folder.
machining of the cavity.
parameters.
134
tool path is limited by the combination of two Working areas:
Working area defined by geometry.
Define the geometry chain as shown to
limit the tool path.
Working area defined by surface
inclination angle range. Define the
surface inclination angle range from 30
to 90 to perform the machining of the
steep areas of the model.
Use a 8 Ball-nosed mill for the Operation. Choose the Pocket-auto boundaries
method and define the relevant technological parameters.
tool path is limited by the combination of two Working areas:
Working area defined by geometry. Use the same geometry defined for the
previous Operation to limit the tool path.
Working area defined by surface inclination angle range. Define the surface
inclination angle range from 0 to 32 to perform the machining of the
shallow areas of the model.
135
136
3D Milling of
Prismatic Parts
SolidCAM provides you with powerful functionality for 3D Milling of prismatic parts. SolidCAM
analyzes the model and automatically recognizes pockets and profiles to be machined using
Constant Z machining strategies.
The major advantages of using 3D Milling for machining of prismatic parts vs. 2.5D Operations
(Profile Pocket and Slot) are the following:
Automatic recognition of pocket and profile areas enables you to shorten programming
time and get the optimized tool path for roughing and finishing.
The Rest Material roughing options enable you to perform re-machining of areas that
were not machined by the previous tool. SolidCAM automatically performs a profilestyle or pocket-style tool path to remove the rest material.
The Constant Z finishing strategy enables you to perform separate finishing for walls
(using the profile-style tool path) and floor (using the pocket-style tool path).
138
Exercise #16: Cover machining

functionality for prismatic parts machining.
In this exercise, you have to perform the rough and finish
machining of the cover part presented on the illustration using
SolidCAM 3D Milling functionality.
Load the Exercise16.sldprt model located in the

Exercises folder.
This model contains a number of features forming
the solid body of the cover.
At this stage, you have to define the CAM-Part

and all its components.
Choose the Fanuc CNC-controller for the CAMPart.
Define the Coordinate System at the corner of
the model box as shown.
Define the Stock model as a box surrounding the
model.
When the CAM-Part is defined, right-click on the Operations header in SolidCAM

and choose the 3D Milling command from the Add Operation submenu.
Manager

In the Geometry section of the 3D Milling Operation dialog box, choose the Target
geometry from the list.
139
4. Define the tool
Define a new 16 End mill tool and choose it for the Operation.
The Contour roughing strategy enables you to produce Constant Z pockets at different
Z-levels. In the pockets, the tool moves on offsets parallel to the contour of the section
of the model at each step down.
6. Define the offsets
At this stage, you have to specify the allowances for the further semi-finishing/finishing
Operations.
In 3D Milling of prismatic parts, you often need to use different
offset values for vertical and horizontal areas.
Wall
Offset
Floor
Offset
140
The Wall offset value defines the XY-offset from any surface that
is not flat. The Z-offset to the absolute horizontal (flat) surfaces is
defined by the Floor offset parameter.
Set the Wall offset value to 0.2 and Floor offset value to 0.1. These offsets are removed
in finishing Operations.
7. Define the Clean flat options
Choose the Clean flat at the end of Roughing option for the
Operation.

box.
Choose the Angle option under Z-Entry strategy and set
the Angle value to 10.
Clear the Return to Clearance level between Z steps check
box.
9. Define the Open Pocket machining
SolidCAM enables you to customize your machining strategy for more effective
machining of open pocket areas.
In the Rough section of the 3D Milling Operation dialog
box, click on the Mode button. The Open Pocket Mode
Choose the Pockets + Profile option for the Open pocket
machining.
141
Select the Approach open pocket from outside check box. This option enables you to
perform the approach movement from an automatically calculated point outside of the
material. The tool descends to the necessary depth outside of the material and then
plunges horizontally into the material.
In closed areas where outside approach is impossible, the tool plunges into
the material with the strategy defined in the Z-Entry field of the Operation
dialog box.
Set the Profile Lead in strategy that defines how the tool approaches the profiles during
open pocket machining. Choose the Tangent option to perform the tool movement
tangential to the automatically calculated tool path line. Set the Value to 10.
Confirm the Open Pocket Mode dialog box with the OK button.
Define the Working area as shown to limit
the tool path by avoiding the machining
of the external walls.
choose the External option. The tool
machines over the boundary of the
Working area by the distance equal to the
tool diameter.
Confirm the Working area definition with the OK button.

142

12. Simulate
After the roughing Operation, the bulk of material is removed. Note that some areas
are left unmachined, therefore rest material machining has to be performed.
At this stage, you have to perform the rest material machining.

Right-click on the defined 3D Milling Operation in SolidCAM Manager and choose
3D Milling from the Add Operation submenu.
14. Choose the Operation template
Use the previous Operation as a template for the current Operation. In the Operation
section, choose the previously defined Operation 3DR_target_T1 from the list.
All the data is copied from the template Operation.
name
15. Rest Material machining
With the 3D Roughing strategy, SolidCAM generates a number of

sections parallel to the XY-plane of the CAM-Part Coordinate System.
These sections are generated with a Z-step defined either by constant
step down or by scallop. In each of these sections, SolidCAM uses the
section profile geometry to produce a pocket tool path.
143
When a large tool is used, material remains in areas where it cannot

enter.
Working Area
Rest Material Area
The Rest Material option enables you to remove the material from the
unmachined areas without defining a new geometry.
In the Rest Material section, choose the Rest option from
the list.
Click on the Data button to define the parameters of the
rest material machining.
The Rest Material dialog box is displayed.
144
The Rest Material machining is defined with the following major

parameters:
Previous tool diameter the diameter of the rough end mill
that was used in the previous Operation.
Previous wall offset the wall offset of the previous
Operation.
Extension/Overlap the extension distance that you would like
to have at the and end of the rest material machining.
Extension
Rest Material
Set the Previous tool diameter value to 16.

Set the Previous wall offset value to 0.2.
Set the Extension/Overlap value to 1.
Milling type
When the Separate areas type is chosen, SolidCAM generates a

profile or pocket tool path to clean areas that the previous tool could
not mill. The Around profile type generates a closed profile to mill the
rest material.
Around profile
the whole profile is machined.
Rest Material
145
Separate areas the machining is performed only in the areas not

machined with the previous tool.
Rest Material
In 3D Milling with Separate Area machining strategy, SolidCAM can

generate two types of tool paths, depending on the volume of the rest
material and on the previous and present tool diameters:
Pocket-style tool paths
Profile-style tool paths
146
SolidCAM generates a pocket or profile tool path in each area of the

rest material.
Pocket-style tool path areas can be either open or closed depending

on the approach possibilities.
Closed Pocket-style
tool path area
Open Pocket-style
tool path area
Profile-style
tool path area
Open Pocket-style tool path area
In the Rest Material dialog box, choose the Separate areas option to perform the
machining only in the rest material areas.
Lead in/Lead out
The approach to the open pockets can be performed from the already
machined area, in contrast to the closed pockets where the approach
from the outside is not possible.
The Z-Entry strategy defined in the 3D Milling Operation dialog box
enables you to choose the approach functionality for the closed
pocket areas.
147
SolidCAM automatically determines the optimal point for the

approach to the open pocket areas.
Approach point
Open Pocket-style
tool path area
The Lead in and Lead out options define the approach/retreat

strategy for the Profile-style tool path areas. The following strategies
are available:
None
Normal
Arc
In the Lead in and Lead out sections, choose the Arc option. Set the Value to 2.
The approach to the open areas is performed with an arc movement. For the closed
areas, the Helical Z-Entry strategy is used.
148
SolidCAM enables you to specify the areas where the rest material cutting is
performed in pocket or profile manner.
Island only tool paths that touch pocket islands
are cut.
Island + Wall tool paths that touch both pocket
wall and islands are cut.
Wall - only tool paths that touch the wall are cut.
Compensation
When the Compensation check box is selected, SolidCAM uses tool

radius compensation commands (G41, G42 for Fanuc) in the GCode
output.
Open contour strategy
This option enables you to define a direction for the open contours
machining.
One way
The tool moves along an open contour
at a specific Z-level. At the end of the
contour, the tool moves with rapid feed
(G0) to the Safety distance and then starts
machining the open contour on the next
Z-level. The tool uses either climb or
conventional milling.
Zigzag
The tool finishes an open contour at the
specific Z-level and then moves directly
to the next Z-level and so on. It mills
forward and backward without leaving
the material, thus constantly switching
between climb milling and conventional
milling.
Make sure that the One way option is chosen in the Rest Material dialog box.
149

17. Simulate
The 8 tool used in this Operation has performed the rest material machining in the
model corners and also machined two pockets at the bottom face of the model.
At this stage, the roughing is finished. Now you have to perform the finish
machining.
18. Define the 3D Milling Operation
In SolidCAM Manager, define a new 3D Milling Operation.

Choose the Target model geometry for the Operation.
19. Choose a finish strategy
In the Finish section of the 3D Milling Operation dialog box, choose the Constant Z
With the Constant Z strategy, SolidCAM automatically recognizes wall and floor areas
and enables you to perform the separate machining of these areas.
150
Click on the Data button to define the Constant Z parameters. The Constant Z Finish
20. Define the Constant Z wall machining parameters
Select the Constant Z wall machining check box.

Set the Step down value to 2. SolidCAM creates sections parallel to the XY-plane at
each 2 mm. These sections are machined with a profile tool path.
In the Lead in/Lead out sections, choose the Arc option and set the Value to 2. The
tool performs the approach/retreat movements to the profile with an arc.
21. Define Constant Z flat floor machining parameters
Select the Constant Z flat floor machining check box.

151
Constant Z Flat Floor machining
SolidCAM recognizes planar areas on 3D

Models and performs the machining of
these areas using the pocket technology.
Automatic flat floor machining greatly
reduces programming time of 3D
Models with 2.5D features like pockets
and profiles on different Z-levels.
Scallop
Enter the scallop (cusp height) of the finished surface you want to
achieve. SolidCAM automatically calculates the side step of the tool.
Maximum step over: if you use an end mill or a bull-nosed tool, the
step is as large as the flat area of the tool, e.g. for a bull-nosed tool
with the 6 mm diameter and the 1 mm corner radius, the step on
flat areas is 4. To limit the side step of the tool, enter the maximum
step value.
Machining style
SolidCAM enables you to choose between two styles of floor

machining during Constant Z finishing:
Contour style: select this option if you want to machine the flat
floor areas on your model as a contour style pocket. The pocket
tool path consists of parallel offsets to the outside contour of the
flat area.
Hatch style: the tool mills the flat area in a linear pattern.
Mode
With this option, SolidCAM enables you to define a specific strategy

for milling the open pocket areas. You can combine pocket and profile
tool paths in order to provide the best productivity in open pocket
machining.
Arc approximation
SolidCAM enables you to use arc approximation for Constant Z floor

machining.
152
Set the Scallop value to 0.5. Set the Maximum step over to 3.
Make sure that the Contour style option is chosen.
Click on the Mode button to define the parameters of
the open pocket machining. The Open Pocket dialog box
is displayed.
Define the Lead in strategy for the open pocket areas.
Choose the Tangent option and set the Value to 2.
Select the Approach open pocket from outside check
box.
At this stage, all parameters of the Constant Z finish machining have been defined.
153
Choose the Working area defined in the Step #10 (w_a) for the Operation.
In the Tool on Working area section, choose the Middle option. The tool machines the
Working area until the tool center is positioned on the Working area geometry.

24. Simulate
Perform the Operation tool path simulation in the HostCAD and SolidVerify modes.
At this stage, the exercise is finished.
154
Exercise #17: Electronic box machining

Define a number of 3D Milling Operations for the machining of
the electronic box presented on the illustration.
Contour roughing;
Rest Material roughing;
Constant Z finishing;
Working area definition by a geometry.
The SolidWorks model of the electronic box (Exercise17.sldprt) is
At this stage you have to define the CAM-Part.

Define the Stock model as the box surrounding
the model.
155
Define a 3D Milling Operation using the Contour

strategy to perform the rough machining of the
electronic box.
relevant technological parameters and the Z-Entry
strategy.
Define the Working area to avoid unnecessary

tool movements.
Define a 3D Milling Operation to remove the rest material left unmachined in the
previous Operation. Choose the Contour strategy for the Operation.
Use a 8 End mill for the Operation. Define the relevant technological parameters and
the Z-Entry strategy.
Use the Working area defined in the previous Operation.
156

4. Constant Z wall finishing
Define a 3D Milling Operation using the Constant Z

strategy to perform the finish machining of the wall
faces of the electronic box.
relevant technological parameters.
Define the Working area by a geometry to avoid
5. Constant Z floor finishing
machining of the floor faces of the electronic box.
Use a 4 End mill for the Operation. Define the relevant technological parameters.
Use the Working area defined in the previous Operation to limit the tool path.
157
Exercise #18: Connector cover machining

Define a number of 3D Milling Operations for the machining of
the connector cover part presented on the illustration.
Contour roughing;
Rest Material roughing;
Constant Z finishing.
The SolidWorks model of the connector cover (Exercise18.sldprt)
is located in the Exercises folder.

Define the Stock model as the box surrounding
the model.
Define a 3D Milling Operation using the Contour

strategy to perform the rough machining of the
connector cover.
158

relevant technological parameters and the Z-Entry
strategy.
Define a 3D Milling Operation using a 8 End mill to remove the rest material
left unmachined in the previous Operation. Choose the Contour strategy for the
Operation.
Define an additional 3D Milling Operation using a 5 End mill to remove the rest
material left unmachined in the previous Operation. Choose the Contour strategy for
the Operation.
159
machining of the wall faces of the connector cover.
machining of the floor faces of the connector cover.
160
3D Milling of
Aerospace Parts
Exercise #19: Bracket machining

functionality for the aerospace parts machining.
In this exercise you have to perform the rough and
finish machining of the bracket part shown below using
SolidCAM 3D milling functionality.

This model contains a number of features forming the solid body of the bracket.
At this stage, you have to define the CAM-Part and all of its components.
Define the stock model as a box surrounding the bracket model. Set the offsets from
the model sides to 2.
Define the Coordinate System at
the corner of the model box as
shown.
162

Define a 3D Milling Operation to perform the rough machining of the bracket part.
Right-click on the Operations header in SolidCAM Manager and choose the 3D Milling
command from the Add Operation submenu.
In the Geometry section of the 3D Milling Operation dialog box, choose the Target
geometry from the list.
4. Define the tool
Define the Lower level of the Operation using

the solid model geometry. Click on the model
vertex as shown.
The Contour roughing strategy enables SolidCAM to produce Constant Z pockets at
different Z-levels. Within the pockets, the tool moves on offsets parallel to the contour
of the section of the model at each step down.
In the Clean flat section, choose the Clean flat at the end of Roughing option. When
this option is chosen, SolidCAM performs roughing at each step down level and then
returns to the flat areas that are between the step down levels.
163
Click on the Mode button to define the parameters of the

open pocket machining. The Open Pocket Mode dialog
box is displayed.
In the Mode section, choose the Pockets option. Both
closed and open areas at each step down are milled as
Pockets.
Select the Approach open pocket from outside check
box to perform approach to the open pocket areas from
outside.

9. Simulate
At this stage, the roughing is finished, and you have to perform the finish machining.
164

10. Define a 3D Milling Finishing Operation
Define a new 3D Milling Operation to perform

the finish milling of the highlighted fillet face.
The machining is performed with the Linear
strategy.
Choose the Target model geometry for the
Operation.
Choose the same 14 tool used in the previous
Operation.
11. Define the finishing parameters
In the Finish section, choose the Linear

strategy from the list. Click on the Data
button to define the Linear finishing
parameters. The Linear Finish dialog box
is displayed.
In the Technology
over value to 0.2.
section, set the Step

button.
At this stage, you have to define the Working area to

limit the machining to the selected face.
In the Working area section, click on the Define
button to start the definition. The Working Area
Define the Drive face for the Operation as shown.
165
In the Tool on Working area section, choose the Middle option. The tool machines the
Working area until the tool center is positioned on the Working area geometry.


14. Simulate
At this stage, the linear finishing of the fillet face is completed.
15. Define an additional 3D Milling Operation
Define a new 3D Milling Operation to perform the finish

milling of the highlighted inclined face.
The machining is performed with the Linear strategy.
In this Operation, the geometry (target) and tool (14
End mill) from the previous one are used, therefore use
the previous Operation as a template.
166

16. Define the finish parameters
In the Finish section, choose the Linear

strategy from the list. Click on the Data
button to define the Linear finishing
parameters. The Linear Finish dialog box
is displayed.
In the Technology
over value to 0.1.
section, set the Step
In the Define direction angle by section,

set the angle Value to 45.
button.
At this stage, you have to define the Working area to limit the machining to the selected
face.
In the Working area section, click on the Define button to start the definition. The
Define the Drive face for the Operation as shown.
In the Tool on Working area,
choose the Internal option.
The tool machines up to the
boundary of the Working area.
Confirm the Working area
definition with the OK button.
167
Define the Lower level of the Operation

using the solid model geometry. Click on
the model vertex as shown.

The 3D Milling Operation data is saved
and the tool path is calculated.
20. Simulate
At this stage, the linear finish of the inclined face is completed.
At the next stage, you have to perform the finish machining of the internal faces
of the bracket. The machining is performed in two 3D Milling Operations using the
Constant Z strategy.
The first Operation performs the machining of the walls
using a ball-nosed mill.
The second Operation performs the machining of the
floor areas using an end mill.
168

21. Add a new 3D Milling Operation to finish the walls
In the Facet tolerance section, set the tolerance value to 0.01 to provide the necessary
accuracy for the model faces triangulation. Smaller tolerance values result in better
surface quality.
23. Define the finish strategy
In the Finish section, choose the Constant Z strategy from the list.
Click on the Data button. The Constant Z Finish dialog box is displayed. This dialog
box enables you to define the technological parameters of the Constant Z finishing
strategy.
Select the Constant Z wall machining check box. This section enables you to define the
technological parameters for the machining of steep areas.
In the Constant Step down section, set the
value to 0.4.
Choose the Tangent option for Lead in
Lead out and set the value to 2.
and
In the Open contour strategy section, choose

the Zigzag option. This option enables the
tool to change the cutting direction when it
encounters open contours in the model. The
milling direction in open contours changes
between climb and conventional milling until
the open contours are finished. With the
Zigzag option, rapid moves from Z-level to
Z-level are greatly reduced.
Confirm the Constant Z parameters with the
OK button.
169
In the Working area section, click on the

Define button. The Working Area dialog
box is displayed.
Define the Working area using the model
edges as shown.
choose the Middle option. The tool
machines the Working area until the tool
center is positioned on the Working area
geometry.

26. Simulate
Perform the simulation of the Operation using the HostCAD and SolidVerify modes.
At this stage, the Constant Z finishing of the vertical walls of the bracket is completed.
At the next stage, you have to perform the machining of the floor areas.
170

27. Add a new 3D Milling Operation to finish the horizontal areas
Define a new tool for the Operation. Add a 8 End mill to the Part Tool table and
choose it for the Operation.
In the Facet tolerance section, set the value to 0.01.
In the Finish section, choose the Constant Z strategy from the list.
Click on the Data button. The Constant Z Finish dialog box is displayed. This dialog
box enables you to define the technological parameters of the Constant Z finishing
strategy.
Select the Constant Z Flat Floor machining check box. This section enables you to
define the technological parameters of the horizontal floor areas machining.
Set the Scallop value to 0.5 and the Maximum step over value to 4.5.
Make sure that the Contour style option is chosen. The machining is performed with
the contour strategy.
Click on the Mode button to define the open pocket
machining parameters. The Open Pocket Mode dialog box
is displayed.
Select the Approach open pocket from outside check box.
The approach movement into the open pocket areas is
performed from outside of the model.
171
Confirm the Constant Z Finish dialog box

with the OK button.
In the Working area section click on the

Define button, the Working area dialog box
is displayed.
Choose the same Working area defined in
Step #24 for the previous Operation.
In the Tool on Working area section of the
Working area dialog box, choose the Middle
option. The tool machines the Working
area until the tool center is positioned on
the Working area geometry.
Confirm the Working Area dialog box with
the OK button.

32. Simulate

172
Exercise #20: Aerospace support machining

Define a number of 3D Milling operations for the machining
of the aerospace support part presented on the illustration.
Contour roughing;
Linear finishing;
Constant Z finishing;
The SolidWorks model of the aerospace support part (Exercise20.sldprt) is located in the Exercises
folder.

Define the Stock model as the box surrounding the model.
Define the Coordinate System at the corner of the model box as shown.
173
Define a 3D Milling Operation using the Contour strategy to perform the rough
machining of the aerospace support.
Use a 10 End mill for the Operation. Define the relevant technological parameters
and the Z-Entry strategy.
machining of the wall faces of the aerospace support.
parameters.
174
Define the Working area by selecting model faces. Select the check faces as shown and
specify the offset.
machining of the floor faces of the aerospace support.
Choose the same drive/check faces as in the previous Operation.
175
5. Linear finishing
Define a 3D Milling Operation using the Linear strategy to perform the finish machining
of the top faces of the aerospace support walls.
parameters.
Define the Working area by selecting model faces. Select the faces as shown.
176
3D Drilling
This Operation enables you to perform drills while taking into

account the solid model geometry. There are two uses for this
Operation:
The tool drills the stock up to a user-defined offset
from the solid model. SolidCAM uses these holes
for the Z-Entry during 3D Roughing (3D Milling
Operation).
With negative offset value, SolidCAM uses this
option to create holes in the solid model, with the
depth measured from the model surface.
Same as a regular Drilling Operation, the 3D Drilling Operation
supports the canned drill cycles provided by your particular
CNC Machine such as threading, peck, ream, boring, etc.
178
5. 3D Drilling
4.1 3D Drilling Operation dialog box overview

Geometry section
Tool section
3D Model Geometry
section
Drill cycle
section
Sequence
section
Operation
buttons
Geometry section
This section enables you to define or choose the geometry of the drill positions.
Tool section
This section enables you either to define a new tool for the Operation or choose an
existing tool from the Part Tool table.
3D Model Geometry section
This section enables you to define or choose the 3D Model geometry that is used for
the drilling depth definition.
This section displays the name of the Operation.

In this section, you have to specify the Z-levels for the Operation. The default input
to these fields are the CAM-Part values you have specified in the Coordinate System
definition. The drilling depth is defined by the Offset from model parameter.
Drill cycle section
This section enables you to choose a canned drill cycle for the Operation.
179
Sequence section
This section enables you to define the sequence of drill positions in order to have
minimum movements between drill positions.
Operation buttons
Operation buttons enable you to save and copy the Operation data, perform the tool
path calculation, simulate the already calculated tool path, generate the GCode for the
Operation and close the dialog box.
180
5. 3D Drilling
Exercise #21: 3D Drilling of the Mold core

This exercise illustrates the use of the 3D Drilling Operation to
prepare Z-Entry points for the mold core roughing. The rough
machining of the mold core was explained in detail in Exercise #1.

Exercises folder.
simulation of these two Operations.
Rough Machining
2. Add a new 3D Drilling Operation

Operation in the list and choose Add Operation,
3D Drilling.
181
The 3D Drilling Operation dialog box is displayed.
At this stage, you have to specify the geometry of drill

positions.
In the Geometry section, click on the Define button to start the
geometry definition.
The XY Drill Geometry Selection dialog box is displayed. This
dialog box enables you to specify the drill positions for the
Operation.
In the Select centers by section, choose the Pick position
option. With this option, you can define drill positions one by
one using the SolidWorks selection options. You can also type
the coordinates (X, Y, Z) into the Edit bar and confirm each drill
point by clicking on the Enter button of the Edit bar.
182
5. 3D Drilling
Rotate the model to the Top view using the
button.
Select the drill positions directly on the solid model as

shown.
The 3D drilling is performed in the selected positions. Confirm the selection with
the
button.
The 3D Drilling Operation dialog box is displayed again.

4. Define the tool
Define a new tool for the Operation. Add a 21 Drill tool.

Set the following tool parameters:
183
5. Define the 3D Model
The SolidCAM 3D Drilling Operation enables you

to perform drilling while taking into account the 3D
Model geometry.
In the 3D Model geometry section, choose the Target
model geometry from the list.
6. Define offset from model
Offset from model
SolidCAM enables you to

define the depth of the 3D
drilling by the Offset from
model value. This value can
be either positive or negative.
With a negative offset value,
SolidCAM uses this option to
create holes in the solid model,
with the depth measured from
the model surface.
Stock
Offset
from model
Solid Model
Set the Offset from model value to 0.5. The drilling is performed up to 0.5 mm offset
from the model.
At this stage, the definition of the 3D Drilling Operation is completed.
For more detailed explanation about drilling options and their parameters, refer to the
SolidCAM Milling User Guide book.

The 3D Drilling Operation data is saved and the tool path is
calculated. Click on the Exit button to close the Operation
dialog box.
The SolidCAM Manager tree is displayed.
184
5. 3D Drilling
8. Change the sequence of Operations
SolidCAM enables you to change the sequence of

Operations in SolidCAM Manager.
Drag the just defined 3D Drilling Operation to the
beginning of the Operation list as shown in order
to use the holes, machined in this Operation, for
the Z-entry movements during the further 3D
roughing Operation.
9. Simulate
Perform the simulation of the 3D drilling

Operation. Right-click on the relocated 3D Drilling
Operation and choose the Simulate command
from the list.
Perform the simulation in the SolidVerify mode.
When the simulation is completed, return to

SolidCAM Manager with the
button.
10. Edit the 3D Milling Operation
At this stage, you have to modify the Z-entry parameters of the 3D Milling Operation
to use the pre-drilled holes.
185
In SolidCAM Manager, right-click on the first 3D Milling Operation (3DR_target_T1)

and choose the Edit command from the menu. The 3D Milling Operation dialog box is
displayed.
In the Rough section, click on the Z-Entry button. The Z-Entry dialog box is
displayed.
In the Z-Entry strategy section, change the strategy
from Helical to None. With this type of Z-Entry
the tool plunges into the material with a normal
downward movement at the specified Z-feed rate.
Select the Drill points check box. The geometry
defined in the 3D Drilling Operation (3DD_drill_T3)
is automatically chosen.
186
5. 3D Drilling

12. Simulate
Perform the simulation of the Operation in the SolidVerify mode.
The tool performs the Z-entry movements using the holes, pre-drilled in the 3D
Drilling Operation.
13. Recalculate the rest roughing Operation
Note that the rest material roughing Operation in the CAM-Part is now marked with
the asterisk (*). This sign means that the Operation requires recalculation because of
the changes in the tool path of the previous Operations.
In SolidCAM Manager, right-click on the rest material roughing Operation
(3DR_target_T2) and choose the Calculate command from the menu.
187
Exercise #22: 3D Drilling of the Toy mold cavity

Define a 3D Drilling Operation and modify the existing
Operations to perform the rough machining of the toy mold
cavity presented on the illustration.
3D Drilling;
3D Roughing.
The pre-machined CAM-Part of the toy mold cavity
(Exercise22.prt) is located in the Exercises folder.
1. Define a 3D Drilling Operation
Define a 3D Drilling Operation to perform the

preliminary drilling for the further Z-Entry.
Use a 21 Drill tool for the Operation.
Place the 3D Drilling Operation at the beginning
of the Operations sequence.
2. Edit the 3D Roughing Operation
Edit the Z-Entry strategy options of the 3D

roughing Operation to use the pre-drilled holes
for the Z-Entry.
188
3D Engraving
With SolidCAM 3D Engraving, you can mill text or any other profile on a 3D Model. The text or
profile is projected on the model surfaces; the projected contour is then engraved up to a specified
depth.
190
3D Engraving
5.1 3D Engraving Operation dialog box overview

Geometry section
Tool section
Fill section section
Engraving geometry section
Tolerance section
Operation buttons
Engraving technology section
Geometry section
This section enables you to define or choose 3D Model for the Operation.
Tool section
This section enables you to either define a new tool for the Operation or choose an
existing tool from the Part Tool table.
Engraving Geometry section
In this section, you have to define the engraving geometry, i.e. the geometry of a
profile that you want to engrave on the 3D Model surface.
This section displays the name of the Operation.

In this section you have to specify the Z-levels for the Operation. The default input
to these fields are the CAM-Part values you have specified in the Coordinate System
definition. In this section, you also have to specify the engraving depth.
191
Tolerance section
The precision tolerances defined here directly affect the surface quality of your
model.
Engraving technology section
This section enables you to define a number of parameters of the engraving

technology.
Fill area section
SolidCAM enables you to fill the engraving area with a hatch or with a number of
equidistant profiles.
Operation buttons
Operation buttons enable you to save and copy the Operation data, perform the
tool path calculation, simulate the calculated tool path, generate the GCode for the
Operation and close the Operation dialog box.
192
3D Engraving
Exercise #23: 3D Engraving of the Electrode

This exercise illustrates the use of the SolidCAM 3D Engraving
Operation for engraving text on the top face of the Electrode
pre-machined in Exercises #8 and #11.
Load the Exercise23.prt CAM-Part located in the Exercises folder.

This CAM-Part contains a number of 3D Milling Operations for roughing and finishing
of the electrode faces.
The model used in the CAM-Part contains a sketch with the text that has to be engraved
on the top face of the electrode.
2. Add a new 3D Engraving Operation

Operation in the list and choose Add Operation,
3D Engraving.
The 3D Engraving Operation dialog box is
displayed.
193
4. Define the tool

5. Define the Engraving geometry
In the Engraving geometry name section, click on the Define

button to start the definition of the engraving geometry.
In the Multi-chain section, click on the Add button.
The Chains Selection dialog box is displayed. This dialog box enables you to choose
a number of chains from a model by selecting the model elements. The program
automatically creates chains from the selected elements.
In the Type section, choose the Text option. This option enables you to select the text
contained in the SolidWorks model sketches.
194
3D Engraving
Select the text geometry as shown.
Confirm the selection with the

selected text into geometry chains.
button. SolidCAM automatically converts the
The Edit Geometry dialog box is displayed again. Confirm the engraving geometry
definition with the
button.
The 3D Engraving Operation dialog box is displayed.
7. Define the engraving depth
In the Milling levels section, set the Engraving depth value

to 0.5.
195
8. Define the engraving technology parameters

Engraving technology parameters
Type
This option enables you to semi-finish

and/or finish the profile engraved on the
model surface.
The Semi-finish option is used to
machine the engraving profile up to
the offset specified in the Offset field
with cutting depths defined in the
Step down field.
The Finish option is used to machine the engraving profile to
its final dimensions in one step down.
The Both option is used to machine the engraving profile first
with a semi-finish cut and then with a finishing cut.
Side
The tool can cut either to the left, to the right or on the engraving
geometry.
Right: the tool cuts on the right side of the profile geometry
up to the distance defined as the Offset value.
Left: the tool cuts on the left side of the profile geometry up
to the distance defined as the Offset value.
Middle: the center of the tool moves on the profile geometry.
Offset
You can specify the offset from the engraving geometry for a Semifinish Operation on the left or the right side of the geometry. This
offset is machined in the finish cut if you have defined one.
Step down
This value defines the successive Z-cutting depth during the Semifinish Operation of the engraving profile.
196
3D Engraving
From Upper level: SolidCAM performs roughing passes at each

down step from the Upper level to the virtual surface located
at an offset from the actual surface. This offset is defined in
the Engraving depth field.
Upper Level
Actual surface
Virtual surface with offset

defined as Engraving depth
From surface: SolidCAM executes roughing passes at each

step down only from an actual surface to a virtual surface
defined in the Engraving depth field.
Geometry
Actual surface
Virtual surface with offset
defined as Engraving depth
In the Type list, choose the Both option to perform both Semi-finish and Finish
engraving.
In the Side list, choose the Middle option. The center of the
tool moves on the profile geometry.
In the Step down section, choose the From surface option and
set the Value to 0.1. The tool path is performed in a number of
passes at each step down from the actual surface to a virtual
surface defined in the Engraving depth field.
197

The 3D Engraving Operation data is saved and the tool path is calculated.
10. Simulate
198
3D Engraving
Exercise #24: 3D Engraving of the Mold cavity

This exercise illustrates the use of the SolidCAM 3D Engraving
Operation for the hatch engraving on the mold cavity premachined in Exercises #2 and #9.
Load the Exercise24.prt CAM-Part located in the

Exercises folder.
This CAM-Part contains a number of 3D Milling Operations for the cavity roughing
and finishing.
Operation, 3D Engraving.
The 3D Engraving Operation dialog box is displayed.
4. Define the tool

Set the Total length to
20;
length to 15;
10.
199
5. Define the Engraving geometry
In the Engraving geometry name section,

click on the Define button to start the
definition of the engraving geometry.
Using the Edit Geometry dialog box,
select the engraving geometry as shown.
7. Define the engraving depth
In the Milling levels section, set the Engraving depth value to 0.1.
8. Define the engraving technology parameters

Fill area
SolidCAM enables you to perform the filling of the closed engraving

geometry.
200
3D Engraving
Hatch: SolidCAM fills the engraving

geometry with a linear raster tool path,
according to the specified Step over
and Hatch angle.
Hatch
angle
Step over
Engraving
geometry
Contour: the tool moves on offsets

parallel to the pocket contour with the
specified Step over.
Step over
Engraving
geometry
The contours are machined in either clockwise (CW) or

counterclockwise (CCW) direction.
The Wall parameter enables you to specify the offset from the
engraving geometry. SolidCAM generates the contour equidistant
to the engraving geometry at the specified offset. The engraving is
performed inside this contour.
In the Fill area section, choose the Hatch option from the
list and set the Hatch angle to 45. Set the Step over value
to 3.
Set the Wall value to 3.
The hatch filling of the engraving geometry is performed.

The 3D Engraving Operation data is saved and the tool path is calculated.
Close the Operation dialog box with the Exit button.
201
In SolidCAM Manager, add a new 3D Engraving Operation.

Since this Operation uses the same tool, geometry and technological parameters as the
previous 3D Engraving Operation, use the previous Operation as a template for the
current one.
Set the Hatch angle parameter to 135 to perform the additional hatching normal to the
previous Operation tool path.
Save the Operation data and calculate the tool path.
11. Simulate
Perform the simulation of the both 3D Engraving Operations in the HostCAD and
SolidVerify modes.
202
3D Engraving
Exercise #25: 3D Engraving of the Stamp insert

Define a number of 3D Engraving Operations to
perform the machining of the stamp insert presented
on the illustration.
Use the pre-machined Exercise25.prt CAM-Part
The rough and finish Operations are performed to prepare the top face of the stamp insert for the
engraving.
The DesignModel component of the CAM-Part assembly contains a sketch that has to be engraved
on the top face of the stamp insert.
203
1. Hatch engraving

perform the hatch engraving between the circles
highlighted below.
Use a 1 Ball-nosed mill for the Operation. Perform the engraving up to 0.1 mm
depth.
2. Image and text engraving

perform the engraving of the elements highlighted
below.
Use a 1 Ball-nosed mill for the Operation. Perform the engraving up to 0.2 mm
depth.
Congratulations!
You have successfully finished the 3D Milling part of the SolidCAM2007 Milling Training Course.
204

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3. 3D Milling of Prismatic Parts

4. 3D Milling of Aerospace Parts

Document number: SC3DMTCENG07002

1.1 About this course

10. Define CoordSys Position

This style is used to emphasize SolidCAM options,

1.2 SolidCAM 3D Machining overview

This Operation enables you to calculate the tool path

This Operation enables you to perform the engraving

This Operation enables you to perform drills that take

1.3 Process overview

2.1 3D Milling Operation dialog box overview

Operation name section

Semi Finish section

Plunging is a totally different concept of removing

Exercise #1: Mold core roughing

1. Load the SolidWorks model

Load the Exercise1.sldprt model located in the Exercises folder.

At this stage, you have to define the CAM-Part.

3. Define a 3D Milling Operation

When the CAM-Part has

The 3D Milling Operation dialog box is displayed.

4. Define the geometry

5. Define the tool

Click on the Add button to define a new tool for

Set the Outside Holder length to 100;

Define the tool holder. Select the Holder check

The SolidCAM tool holder is defined by combining two components.

Specify the Lower level for the Operation. SolidCAM

Click on the model face as shown.

Confirm the Lower level definition with the

7. Define the facet tolerance

Set the Facet tolerance value to 0.01.

The Contour roughing strategy enables SolidCAM to produce

The major parameters of the Contour roughing strategy are Overlap

The default value is 0.65 (65% of the

Clean flat options

SolidCAM generates a set of Z-levels with an equal step down.

When this option is chosen, SolidCAM performs roughing at each

When this option is chosen, SolidCAM performs roughing at

9. Define the offsets

SolidCAM enables you to define the Surface offset, which is a minimum

In addition to the specified Surface offset, the roughed model shows

10. Define the technological parameters

In the Rough section of 3D Milling Operation dialog

When the tool moves from one

The tool exits from the material

During walls and islands machining, SolidCAM uses a different

Mixed cutting direction

Constant cutting direction

This option enables you to work in a pocket area starting from

This option enables you to work in a pocket area starting

The tool path is formed with sharp

Each tool path direction is connected

The connecting points on the path

Using a short and simple movement

This option enables you to choose climb or conventional milling for

This command enables you to create G2/G3 GCode output from

The tool moves in a normal approach from