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Application Tutorial: Mold Machining

3-Axis Rough (HSR), Semi-Finish (HSM) and

Finish (HSS)



2

Files Used

Part File

Forging DIE.SLDASM

Post Processor

Mitu_E



3

Chapter 1

Introduction



4

This tutorial illustrates the use of HSS technology for 3-Axis roughing and finishing of

the mold part displayed on the cover page of this tutorial. HSS technology is used to

finish this entire part as it gave a better finish than HSM on a Multi-axis machine,

when tried on a machine at one of the SolidCAM client.

Important things to keep in mind before using HSS for machining a part:

It works directly on surface data.

The user needs to define the gouge checks manually.

It cannot handle surface overlaps.

The gaps between surfaces and cuts can be handled in the Links section.

It is widely used only for local area finishing.

It can easily control the point spacing. An even and controlled spacing of Toolpath

points exponentially improves the surface finish.



5

Chapter 2

CAM-Part Definition



6

1. Double click the SolidWorks Icon.

Browse to open the SolidWorks part FORGING DIE.SLDASM.

2. Click SolidCAM >New > Milling.

3. Accept the default part file name and

path and Click OK.

Inside SolidCAM, the following settings must be done.

- Selecting the Machine / Post Processor

- Defining the Co-ordinate system for Milling

- Stock & Part Definition

- Machine & Material Database Selection for iMachining



7

4. In the CNC-Machine list, click Mitu_E.

Leave the fields of Program Number & Subroutine

number with the default settings.

Click Define button in Coordinate System tab to set

the coordinate system for this part.

A dialog box with the following options appears:

Mac CoordSys number

Position

Coordinate system definition options

5. Click Select Face option in the Define CoordSys

options section to define the main coordinate system.

6. In the Place CoordSys origin to section, select Top

center of model box from the drop down.

7. Select the face as shown in the

image.

8. Click to confirm the selection.



8

The CoordSys Data dialog box appears.

9. Click OK in the CoordSys Data pop up.

10. Click to confirm the User Coordinate

System.

11. Click Edit iMachining Database in

iMachining Data section.

12. Click the New icon to create the

Machine.



9

13. Enter a name for the machine.

Click Save.

The three values needed by iMachining are now highlighted. Enter the values after

checking the same with the machine tool supplier or going through the manuals of

the machine.

14. Enter the values as shown in the image.

Click the Material DB tab to define a

new material.

Click the New icon.

15. Enter P20 as the material name.

Click Save.

You must set the “Ultimate Tensile Strength” of the material. This value is obtained

either by referring to the test chart of the material or searching in material database

websites such as www.matweb.com.



10

16. Enter a value of 1030.

Click Save & Exit.

17. Select the machine and material that you

just defined and select 6 as the default

machining level in the iMachining Data

section.

18. Click icon in the Milling Part Data

dialogue box to begin the toolpath

definitions.

19. Right click Operations > Machine Setup.



11

20. Enter a value of 125 in Z column.

Click OK.



12

Chapter 3

3-Axis Roughing



13

1. Right click Setup > Add Milling

Operation > HSR.

2. Click Geometry.

Click the New icon under

CoordSys.

3. Select the face as shown in the

image.




14

5. Click Tool > Select.

6. Click icon to add a new tool.

7. Select BULL NOSE MILL as the tool.

8. Enter the tool

parameters as shown

in the image.

Select the Holder check

box.

9. Select the BT 40 ER

32x60 check box.

Click Select.



15

10. Click Constraint boundaries.

Click Created manually.

In the list, click

User-defined boundary.


Boundary name.

11. Select the two boundaries as

shown in the image.

Click Yes in OK to accept

pop up each time.




16

13. Click Passes.

Enter the parameters as shown

in the image.

Click the Adaptive step down

tab.

14. Select None in the Adapt Step

down by section.

15. Click Link.

Click the Ramping tab.


in the image.



17

16. Click the Retracts tab.

Click Minimal vertical retract.

Click the Save & Calculate

icon.

Click the Exit icon.

17. Select the check box before the tool path.

The tool path looks like this:



18

18. Right click the operation > Add Milling Operation > 3D iMachining.


Click icon to add a new tool.

Select END MILL as the tool.

20. Enter the tool parameters

as shown in the image.

Select the Holder check

box.

Select BT 40 ER 32x60.

Click Select.

21. Click Technology Wizard.

Click Modify cutting conditions tab.

Set Max. Cutting Angle as 35.



19

22. Click Technology.

Enter the parameters


Click the Save &

Calculate icon.






20

24. Right click > Copy the operation.

25. Right click > Paste the operation.

26. Right click > Edit the operation.



21



Select BULL NOSE MILL as the tool.

28. Enter the tool parameters as shown in the image.

Select the Holder check box.

Select BT 40 ER 32x60.

Click Select.

29. Click Technology Wizard.

Click Modify cutting

conditions tab.

Set Max. Cutting Angle as 30.



22

30. Click the Save & Calculate icon.




32. Right click the operation > Add Milling Operation > HSR.



23

33. In the Technology list,

click Rest roughing.



Select BALL NOSE MILL as the tool.

35. Enter the tool parameters





24

36. Select BT 40 EM 10x65.

Click Select.


Click Created manually.

In the list, click User-defined

boundary.

Click the New icon

under Boundary name.

38. Select the boundary as shown inthe image.

Click Yes in OK to accept pop up

each time.



25


40. Click Passes.


in the image.

41. Click Link.

Enter the parameters as shown in

the image.





26



Select the check box before the tool path.

The tool path now looks like this:

You have completed 3-Axis roughing of the mold.



27

Chapter 4

3-Axis Semi-Finishing



28

1. Right click the operation > Add Milling Operation > HSM.


Select the 8 mm BALL NOSE

MILL that was defined for an

earlier operation.

Click Select.

3. Click Passes.


in the image.





30

7. Click the Leads tab.


in the image.









32

13. Click Link.



Click the Save &

Calculate icon.



The final semi-finishing tool path looks like this:

You have finished semi-finishing of the mold.



33

Chapter 4

3-Axis Finishing



34

1. Right click the operation >

Add Milling Operation > HSS.

2. Select Morph between two

boundary curves in the

Technology section.

Click Geometry.


Drive surface.

3. Select the highlighted

faces.





36

8. Select the curve as shown in the image.

9. Click Yes in OK to accept pop up.

Click to confirm the selection.

10. In the Type list, click Full, start and end at exact surface edges.



37


Select the 8 mm BALL NOSE MILL that was defined for an earlier operation.

Click Select.

12. Click Levels.

Set the Plane height as 25.

13. Click Tool path parameters.


in the image.



38

14. Click the Sorting tab.

In the Cutting method. list, click

Spiral.

15. Click Link.

In the lists, click Use Lead-In and

Use Lead-Out.

Click next to Use Lead-In.

16. Unselect the Use default

Lead-In check box.


in the image.

Click OK.



39

17. Click next to Use Lead-Out.

18. Unselect the Use default Lead-Out

check box.


in the image.

Click OK.

19. Click Gouge Check.

Select the Enable/Disable

check box.


Check surfaces 1.



40

20. Select the faces as shown in the image:






41





42


Add Milling Operation > HSS.

24. In the Technology list, click

Morph between two boundary

curves.

Click Geometry.


Drive surface.

25. Select the highlighted faces.



43


27. Click the New icon under Start edge curve.



pop up.

Click to confirm the

selection.

29. Click the New icon

under End edge curve.

Select the curve as

shown in the image.



44



31. In the Type list, click Full, start and

end at exact surface edges.

Click Margins.


Click OK.


Select the 8 mm BALL NOSE MILL

that was defined for an earlier

operation.

Click Select.



45

34. Click Levels.



Enter the parameters as

shown in the image.


In the Cutting method list,

click Spiral.



46

37. Click Link.

From the lists, click Use Lead-In and

Use Lead-Out.


38. Clear the Use default Lead-In check

box.

Enter the parameters as shown in the

image.

Click OK.


Clear the Use default Lead-Out

check box.


image.

Click OK.



47

40. Click the Links tab.

Enter the values as shown in the

image.


Select the Enable/Disable check

box.


Check surfaces 1.

42. Select the faces as shown in the

image:


selection.



48





45. Right click the operation > Add Milling Operation > HSS.



49

46. In the Technology list, click Morph between two boundary curves.

Click Geometry.

Click the New icon under Drive surface.


Click to

confirm the

selection.

48. In the Type list, click Full,

start and end at exact

surface edges.

Click Margins.



50


Click OK.



Click Yes in OK to accept pop up.

Click to confirm

the selection.

52. Click the New icon under End edge curve.





52



the image.

Click the Sorting tab.

57. In the Cutting method list, click

Spiral.

58. Click Link.

In the lists, click Use Lead-

In and Use Lead-Out.

Click next to Use

Lead-In.



53

59. Clear the Use default Lead-In check box.


the image.

Click OK.



check box.


image.

Click OK.


Select the Enable/Disable check

box.

In the Check surfaces 1 list, click

faces1.

Click Show.



54

The selected faces must look like these:







55


Add Milling Operation >

HSS.

65. Click Geometry.



faces.


Selection.




56






Click Yes in OK to

accept pop up.



57


73. In the Type list, Full, start and end

at exact surface edges.



75. Click Levels.




58



the image.

77. Click the Sorting sub tab.

In the Cutting method list, click

Spiral.

78. Click Link.


Use Lead Out from.




59



image.

Click OK.



check box.


image.

Click OK.


Select the Enable/Disable check box.

Click the New icon under Check

surfaces 1.



60


Click to confirm.







61



Parallel to curves.

Click Geometry.


Drive surface.

87. Select the highlighted face.


selection.



62

88. Click the New icon under Edge curve.

Select the curve as shown in the image.


pop up.


selection.

89. In the Type list, click

Determined by number

of cuts.

Enter 10 in the Number

of cuts field.



Click Select.



63

91. Click Levels.




in the image.


In the Cutting method list, click Spiral.



64

94. Click Link.

In the lists, click Use Lead-In and Use Lead Out.


95. Clear the Use default Lead-In

check box.


the image.

Click OK.


Clear the Use default

Lead-Out check box.


in the image.

Click OK.



65



Click the New icon under Check surfaces 1.

98. Select the faces as shown in the image:








66


.


Morph between two

boundary curves.

Click Geometry.

Click the New icon

under Drive surface



selection.



67


Select the highlighted curve.

Click Yes in OK to accept pop up.


105. Click the New icon under

End edge curve.


Click Yes in Ok to accept pop up.


106. In the Type list, click Full, start and

end at exact surface edges.





69



in the image.


Select Spiral as the Cutting

method.

Click Link.

Select Use Lead-In and Use- Lead

Out from the drop down lists.


111. Unselect the Use default Lead-

In check box.


in the image.

Click OK.



70


Unselect the Use default Lead-

Out check box.


in the image.

Click OK.






selection.



71








72


Horizontal machining.




Click Created manually .

In the list, click User-defined

boundary.

Set 1 as the Offset value.


Boundary name.



73


boundary.

Click Yes in Ok to accept pop

up.


selection.

122. Click Passes.


in the image.

123. Click Link > Ramping.


in the image.

Click the Retracts tab.



74

124. Select Minimal vertical

retract .


icon.






75


127. Click Geometry.

In the Type list, click Full,


surface edge.

Click Margin.

Set the End Margin as 0.1

Click the New icon

under Drive surface.


faces.


selection.





77

134. Click Levels.




the image.


In the Cutting method list, clickSpiral.

Click Link.


Use Lead-Out.

136. Click next to Use Lead-In.



78

137. Clear the Use default Lead-In check

box.


the image.

Click OK.


Clearthe Use default Lead-

Out check box.


in the image.

Click OK.








80


144.In the Technology list, click

Horizontal machining.

Click Tool > Select.

Select the 6 mm BALL NOSE

MILL that was defined for an

earlier operation.


Click the New icon

under Boundary name.



81

146. Select the boundary as

shown in the image.

147. Click Passes.


shown in the image.

148. Click Link.


shown in the image.



82

149. Click the Ramping tab.

Enter the values as shown in the

image.









84


In the Type list, click Full,


surface edges.

Click the New icon

under Drive surface.



selection.




85

157. Select the highlighted curve.


chain.


selection.

158. Click the new icon under

End edge curve.

Select the highlighted

curve.


selection.





86

160. Click Levels.




in the image.


In the Cutting method list,

click One-way.



87

163. Click Link.

In the lists, click Use Lead-In and Use Lead-Out.


Clear the Use default Lead-

In check box.


in the image.

Click OK.



Out check box.


shown in the image.

Click OK.



88






selection.





89





In the Type list, click Full, start and end at exact surface edges.




90


Click to

confirm the

selection.



Click to

confirm the

chain.

Click to

confirm the

selection.




91


Click to confirm

the chain.

Click to confirm

the selection.



176. Click Levels.




the image.



92


In the Cutting method list, click One-way.

179. Click Link.



Clear the Use default Lead-In

check box.


image.

Click OK.


Clear the Use default Lead-Out check

box.


shown in the image.

Click OK.



93





faces.

Click to confirm

the selection.



185. Select the check box

before the tool path.

The tool path looks like

this:



94

Now repeat the same process to create the tool path for the opposite side.






faces.

Click to confirm

the selection.



95



Click to confirm

the chain.

Click to confirm

the selection.



Click to

confirm the chain.

Click to confirm

the selection.





96

192. Click Levels.




in the image.

Click Link.


Use Lead- Out.



In check box.


in the image.

Click OK.



97



check box.


the image.

Click OK.




Select the highlighted faces.


selection.





99



201. Click the New icon under Drive surface.


To select the surface

marked with yellow

arrow, go to the

Feature Manager

Design Tree, and

select Surface-Offset1.




100



Click to confirm

the chain.

Click to confirm

the selection.



Click to

confirm the chain.

Click to

confirm the

selection



101



205. Click Levels.



Enter the parameters as shown in the image.


Select the Flip step over

check box.



102

208. Click Link.

In the lists, click Use Lead-In and Use Lead Out.


Clear the Use default Lead-In check

box.


the image.

Click OK.



Out check box.


the image.

Click OK.



103



Clear the Drive surfaces check box.








104




216. In the Technology list, click Parallel to curves.



105





face.

Click to confirm

the selection.



Click to confirm

the chain.

Click to confirm

the selection.



106



221. Click Levels.








108



Out check box.


in the image.

Click OK.


Enter the parameters as shown inthe image.



109

227. Click Gouge check.




Check surfaces 1.



selection.







111


In the Type list, click Determined by number of cuts.



Click to confirm

the selection.



Click to confirm

the chain.

Click to confirm

the selection.



112

235. Set Number of cuts as 10.

Click Tool > Select.

Select the 8 mm BALL NOSE MILL

that was defined for an earlier

operation.

Click Levels.




the image.


Unselect the Drive surfaces check box.




113









114







selection.

244. Click the New icon

under Start edge curve.


curve.


chain.


selection.



115




chain.


selection.



247. Click Levels.

Enter Plane height as 25.





116

249. Click Link.



Unselect the Use default Lead-In check

box.


image.

Click OK.


Unselect the Use default Lead-Out check

box.


image.

Click OK.


Set 300 as Small move as size in % of step over.



117






selection.





Now repeat the same

operation for the other

side.







120


Select the Flip step over check

box.

Click Link.

In the lists, click Use Lead-In

and Use Lead-Out.


Unselect the Use default Lead-In check

box.


image.

Click OK.


Clear the Use default Lead-Out check

box.


image.

Click OK.



121


Set 300 as Small move as size in % of step over.

Click Gouge check.

Clear the Drive surfaces

check box.


Check surfaces 1.


faces.


selection.





122



Now repeat the same operation for the opposite side.




123

273. In the Technology list, click Parallel to Curves.

Click Geometry.

In the Type list, click Determined by number of cuts.




selection.




chain.


selection.



124

276. Click Margins.


Click OK.



278. Click Levels.




280. Click Link.

In the list, click Use Lead-In.



125


Clear the Use default Lead-In check box.


the image.

Click OK.


Set 300 as Small move as size in

% of step over.






126



selection.








127


288. In the Technology list, click Morph between two boundary curves.

Click Geometry.




Click to confirm

the selection.



128



Click to confirm

the chain.

Click to confirm

the selection.



Click to confirm

the chain.

Click to confirm

the selection.



129

292. Click Margins.


image.

Click OK.



294. Click Levels.




296. Click Link.




130




image.

Click OK.


Clear the Use default Lead-Out check box.


image.

Click OK.



131






selection.



302. Select the check box

before the tool path.

The tool path looks like

this:



132







selection.



133



Click to confirm the chain.


selection.





selection.



134

308. Click Margins.


image.

Click OK.



310. Click Levels.








136





Click to confirm

the selection.









138





End edge curve.




325. Click Margins.


Click OK.



139



327. Click Levels.




image.

Click Link.

In the lists, click Use Lead-In and Use

Lead-Out.


Unselect the Use default Lead-In check box.


image.

Click OK.



140


Unselect the Use default Lead-Out

check box.


image.

Click OK.






selection.





141








142


Select the highlighted face.


selection.


Start edge curve.




selection.

339. Click the new icon under End

edge curve.




selection.



143

340. Click Margins.


image.

Click OK.



342. Click Levels.




the image.

Click Link.


Use Lead-Out.




144



image.

Click OK.


Unselect the Use default Lead-Out check box.


image.

Click OK.



image.



145






selection.







146





Select the highlighted face.

Click to confirm

the selection.

354. Click the New

icon under Start edge

curve.


curve.



147




Click to

confirm the

chain.

Click to

confirm the

selection.

356. Click Margins.


Click OK.



Click Levels.




148



the image.

Click Link.


Use Lead-Out.




image.

Click OK.



check box.


image.

Click OK.



149



the image.

Click Gouge check.

Unselect the Drive surfaces check

box.


Check surfaces 1.







150










151



selection.

368. Click the New iconunder Start edge curve.


curve.


chain.

Click to confirm theselection.





153

372. Click Levels.




in the image.


Select the Flip step over check

box.

375. Click Link.




154




the image.

Click OK.



check box.


the image.

Click OK.



155



in the image.

Click Gouge check.

Clear the Drive surfaces

check box.


Check surfaces 1.








157

383. Click the New icon under CoordSys.

Select the highlighted curves.

Click Yes in OK to

accept pop-up

windows both

the time.


Click to define a new tool.

Select BULL NOSE MILL as the tool.



Select BT 40 ER

32x60 as the holder.Click Select.



158

385. Click Levels.


in the image.

386. Click Technology.


shown in the image.

387. Click the Contour tab.


shown in the image.



388. Enter the parameters as shown in the image.


icon.



The final tool path

looks like this:

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