Hsm module user_guide2008

World-Class HSM Module – fully integrated in SolidWorks
HSMSolidCAM HIGH SPEED MACHINING MODULE
SolidCAM2008 R12
HSM Module
User Guide
©1995-2008 SolidCAM
All Rights Reserved.
WWW.SOLIDCAM.COM
HIGH SPEED MACHINING
The Leaders in Integrated CAM

SolidCAM2008 R12
HSM Module User Guide
©1995-2008 SolidCAM
All Rights Reserved.

Contents
5
Contents
1. Introduction and Basic concepts
1.1 Start HSM Operation............................................................................. 13
1.2 SolidCAM HSM Operation overview................................................. 14
1.3 Parameters and values............................................................................ 16
2. Technology
2.1 Contour roughing................................................................................... 22
2.2 Hatch roughing....................................................................................... 23
2.3 Rest roughing........................................................................................... 24
2.4 Constant Z machining........................................................................... 25
2.5 Helical machining................................................................................... 26
2.6 Horizontal machining............................................................................ 27
2.7 Linear machining.................................................................................... 28
2.8 Radial machining..................................................................................... 29
2.9 Spiral machining...................................................................................... 30
2.10 Morphed machining............................................................................. 31
2.11 Offset cutting........................................................................................ 32
2.12 Boundary machining............................................................................ 33
2.13 Rest machining...................................................................................... 34
2.14 3D Constant step over machining..................................................... 35
2.15 Pencil milling......................................................................................... 36
2.16 Parallel pencil milling........................................................................... 37
2.17 3D Corner offset.................................................................................. 38
2.18 Combined strategies............................................................................. 39
3. Geometry
3.1 Geometry definition............................................................................... 43

6
3.1.1 CoordSys........................................................................................ 43
3.1.2 Geometry....................................................................................... 44
3.1.3 Facetting tolerance........................................................................ 44
3.2 Fillet surfaces........................................................................................... 45
3.2.1 Fillet surfaces dialog box............................................................. 47
4. Tool
4.1 Tool selection.......................................................................................... 53
4.2 Holder Clearance.................................................................................... 55
4.3 Spin & Feed Rate definition.................................................................. 56
5. Boundaries
5.1 Introduction............................................................................................. 58
5.1.1 Drive Boundaries.......................................................................... 58
5.1.2 Constraint boundaries.................................................................. 63
5.2 Boundary Definition.............................................................................. 65
5.2.1 Tool on working area................................................................... 67
5.3 Automatically created boundaries........................................................ 70
5.3.1 Auto-created box of target geometry........................................ 70
5.3.2 Auto-created box of stock geometry......................................... 71
5.3.3 Auto-created silhouette................................................................ 72
5.3.4 Auto-created outer silhouette..................................................... 73
5.4 2D manually created boundaries.......................................................... 74
5.4.1 Boundary Box................................................................................ 74
5.4.2 Silhouette Boundary..................................................................... 76
5.4.3 User-defined boundary................................................................ 78
5.4.4 Profile Geometry.......................................................................... 79
5.4.5 Combined boundary.................................................................... 80
5.4.6 Select Faces dialog box................................................................ 84
5.4.7 Select Chain dialog box................................................................ 85

Contents
7
5.5 3D User defined boundaries................................................................. 86
5.5.1 Common parameters.................................................................... 86
5.5.2 Selected faces................................................................................. 90
5.5.3 Shallow Areas................................................................................ 92
5.5.4 Theoretical Rest Areas................................................................. 93
5.5.5 Tool Contact Area........................................................................ 95
5.5.6 Rest Areas...................................................................................... 97
6. Passes
6.1 Passes parameters................................................................................... 101
6.1.1 Thickness....................................................................................... 102
6.1.2 Axial thickness............................................................................... 105
6.1.3 Tolerance........................................................................................ 106
6.1.4 Step down...................................................................................... 107
6.1.5 Step over........................................................................................ 108
6.1.6 Pass Extension.............................................................................. 109
6.1.7 Offsets............................................................................................ 110
6.1.8 Limits.............................................................................................. 111
6.1.9 Point reduction.............................................................................. 113
6.2 Smoothing parameters........................................................................... 114
6.2.1 Max. radius..................................................................................... 115
6.2.2 Profile Tolerance........................................................................... 115
6.2.3 Offset Tolerance........................................................................... 115
6.3 Adaptive step down parameters........................................................... 116
6.4 Edit Passes parameters........................................................................... 118
6.5 Axial offset............................................................................................... 123
6.6 Analysis..................................................................................................... 125
6.7 Strategy parameters................................................................................ 126
6.7.1 Contour roughing......................................................................... 127

8
6.7.2 Hatch roughing............................................................................. 129
6.7.3 Rest roughing................................................................................. 132
6.7.4 Linear machining.......................................................................... 134
6.7.5 Helical machining......................................................................... 139
6.7.6 Radial machining........................................................................... 141
6.7.7 Spiral machining............................................................................ 145
6.7.8 Morphed machining..................................................................... 149
6.7.9 Offset cutting................................................................................ 151
6.7.10 Rest machining parameters....................................................... 152
6.7.11 3D Constant step over............................................................... 158
6.7.12 Pencil milling............................................................................... 162
6.7.13 Parallel pencil milling................................................................. 164
6.7.14 3D Corner offset........................................................................ 166
6.7.15 Combined strategy parameters................................................. 168
6.8 Calculation Speed.................................................................................... 174
7. Links
7.1 General Parameters................................................................................ 177
7.1.1 Direction options.......................................................................... 178
7.1.2 Order passes.................................................................................. 188
7.1.3 Retract............................................................................................. 191
7.1.4 Start Hint........................................................................................ 192
7.1.5 Minimize reverse linking.............................................................. 193
7.1.6 Minimize full wide cuts................................................................ 194
7.1.7 Link by Z level............................................................................... 195
7.1.8 Link per cluster............................................................................. 196
7.1.9 Min. Profile Diameter.................................................................. 197
7.1.10 Refurbishment............................................................................. 198
7.1.11 Safety............................................................................................ 199
7.2 Ramping Parameters............................................................................... 200

Contents
9
7.3 Strategy Parameters................................................................................ 205
7.3.1 Stay on surface within.................................................................. 206
7.3.2 Along surface................................................................................. 207
7.3.3 Linking radius................................................................................ 210
7.3.4 Link clearance................................................................................ 211
7.3.5 Horizontal link clearance............................................................. 212
7.4 Retracts Parameters................................................................................ 213
7.4.1 Style................................................................................................. 214
7.4.2 Clearance........................................................................................ 216
7.4.3 Smoothing...................................................................................... 218
7.4.4 Curls................................................................................................ 218
7.4.5 Sister Tooling................................................................................. 219
7.5 Leads Parameters.................................................................................... 220
7.5.1 Fitting.............................................................................................. 221
7.5.2 Trimming........................................................................................ 223
7.5.3 Vertical leads.................................................................................. 224
7.5.4 Horizontal Leads........................................................................... 225
7.5.5 Extensions...................................................................................... 228
7.6 Down/Up Mill parameters.................................................................... 229
7.7 Refurbishment parameters.................................................................... 233
7.7.1 Spikes.............................................................................................. 234
8. Miscellaneous Parameters
8.1 Message.................................................................................................... 238
8.2 Extra parameters..................................................................................... 238
9. Examples
Example #1: Rough Machining and Rest Roughing............................... 241
Example #2: Constant Z, Helical and Horizontal Machining............... 242
Example #3: Linear machining................................................................... 243

10
Example #4: Radial and Spiral machining................................................ 244
Example #5: Morphed machining and Offset cutting............................ 245
Example #6: Boundary machining............................................................ 246
Example #7: Rest machining...................................................................... 247
Example #8: 3D Constant Stepover machining...................................... 248
Example #9: Pencil, Parallel Pencil and 3D Corner Offset................... 249
Example #10: Mold Cavity Machining...................................................... 250
Example #11: Aerospace part machining................................................. 252
Example #12: Electronic box machining.................................................. 254
Example #13: Mold insert machining....................................................... 256
Example #14: Mold cavity machining....................................................... 258
Example #15: Mold core machining......................................................... 260
Index............................................................................................................... 263
Document number: SCHSMUGENG08001

1Introduction and
Basic Concepts

12
Welcome to SolidCAM HSM!
SolidCAM HSM is a very powerful and market-proven high-speed machining
(HSM) module for molds, tools and dies and complex 3D parts. The HSM module
offers unique machining and linking strategies for generating high-speed tool
paths.
SolidCAM HSM module smooths the paths of both cutting moves and retracts
wherever possible to maintain a continuous machine tool motion – an essential
requirement for maintaining higher feed rates and eliminating dwelling.
With SolidCAM HSM module, retracts to high Z-levels are kept to a minimum.
Angled where possible, smoothed by arcs, retracts do not go any higher than
necessary, thus minimizing air cutting and reducing machining time.
The result of HSM is an efficient, smooth, and gouge-free tool path. This translates
to increased surface quality, less wear on your cutters, and a longer life for your
machine tools.
With demands for ever-shorter lead and production times, lower costs and
improved quality, HSM is a must in today’s machine shops.
About this book
This book is intended for experienced SolidCAM users. If you are not familiar
with the software, start with the lessons in the Getting Started Manual and then
contact your reseller for information about SolidCAM training classes.
About the CD
The CD supplied together with this book contains the various CAM-Parts
illustrating the use of the SolidCAM HSM Module. The CAM-Parts are located
in the Examples folder and described in Chapter 9. Copy the complete Examples
folder to your hard drive. The SolidWorks files used for exercises were prepared
with SolidWorks2008.
The examples used in this book can also be downloaded from the SolidCAM web-
site http://www.solidcam.com.

1. Introduction and Basic Concepts
13
1.1 Start HSM Operation
This command enables you to add a SolidCAM HSM operation to your CAM-
Part. The HSM Operation dialog box is displayed.

14
SolidCAM HSM Operation overview1.2
The definition of a SolidCAM HSM operation consists of the following stages:
Technology
Geometry parameters
Parameter illustration
Parameters page
Operation name Template
Tool parameters
Boundary parameters
Passes parameters
Link parameters
Misc. parameters
Info
Geometry definition
Strategy choice
Tool definition
Boundary definition
Passes definition
Link definition
Misc. parameters definition

15
At the first stage you have to choose one of the available machining strategies.
The machining strategy defines the technology that will be used for the machining.
For more information on the machining strategies, refer to chapter 2.
At the Geometry definition stage you have to specify the 3D model geometry that
will be machined. For more information on the Geometry definition, refer to
chapter 3.
The next stage enables you to choose from the Part Tool table a cutting tool that
will be used for the operation. For more information on the tool definition, refer
to chapter 4.
The Boundaries definition page enables you to limit the operation machining to
the specific model areas. For some machining strategies an additional boundary
defines the drive curve of the operation tool path. For more information on the
boundary definition, refer to chapter 5.
In the Passes definition, SolidCAM enables you to specify the technological
parameters used for the tool passes calculation. For more information on the
passes definition, refer to chapter 6.
The Link parameters page enables you to define the tool link moves between
cutting passes. For more information on the link definition, refer to chapter 7.
The Miscellaneous parameters page enables you to define the non-technological
parameters related to the HSM operations. For more information on the
miscellaneous parameters definition, refer to chapter 8.

16
1.3 Parameters and values
Mostof theparametersusedintheSolidCAMHSMOperationreceivedefaultvalues
according to built-in formulas that define dependencies between the parameters.
When a number of basic parameters such a tool diameter, corner radius, thickness
etc. are defined, SolidCAM updates the values of dependent parameters.
For example, the Step down parameter for Contour roughing is defined with the
following formula:
If the tool corner radius is 0 (end mill), the Step down parameter
default is set to 1. If a ball-nosed tool is chosen, the Step down value
is equal to the tool corner radius value divided by 0.5; for bull-nosed
tools the Step down value is equal to the tool corner radius value
divided by 0.3.
SolidCAM provides you with a right-click edit box menu for each parameter.
Tool Corner
Radius =0
Is tool
ball nosed?
Stepdown = 1
Yes No
Yes No
Stepdown = Tool
Corner radius / 0.5
Stepdown = Tool
Corner radius / 0.3

17
View Parameter Info
This command displays the Parameter Info dialog box. This dialog box shows the
internal parameter name and the related formula (if exists) or a static value.
The Unfold button displays a brief explanation of the parameter.
The button displays the flow chart of the parameter value calculating.

18
Reset
When you manually change a parameter default value, the formula assigned to the
parameter is removed.
The Reset commands enable you to reset parameters to their default formulas and
values.
• This parameter. This option resets the current parameter.
• This page. This option resets all the parameters at the current page
• All. This option resets all the parameters of the current HSM operation.

20
The Technology section enables you to choose the rough or finish machining
strategy to be applied. The following strategies are available:
Roughing strategies:
• Contour roughing
• Hatch roughing
• Rest roughing
Finishing strategies:
• Constant Z machining
• Helical machining
• Horizontal machining
• Linear machining
• Radial machining
• Spiral machining

2. Technology
21
• Morphed machining
• Offset cutting
• Boundary machining
• Rest machining
• 3D Constant step over
• Pencil milling
• Parallel pencil milling
• 3D Corner offset
• Combined strategies:
• Constant Z with Horizontal machining
• Constant Z with Linear machining
• Constant Z with 3D Constant step over machining

22
2.1 Contour roughing
With the Contour roughing strategy, SolidCAM generates a pocket-style tool path
for a set of sections generated at the Z-levels defined with the specified Step down
(see topic 6.1.4).

2. Technology
23
2.2 Hatch roughing
With the Hatch roughing strategy, SolidCAM generates linear raster passes for
a set of sections generated at the Z-levels defined with the specified Step down
(see topic 6.1.4). Hatch roughing is generally used for older machine tools or softer
materials because the tool path predominantly consists of straight line sections.

24
2.3 Rest roughing
The Rest roughing strategy determines the areas where material remains
unmachined after the previous machining operations (the "rest" of the material)
and generates a tool path for the machining of these areas. The tool path is
generated in the Contour roughing (see topic 2.1) manner. Rest roughing operation
uses a tool of smaller diameter than that used in previous roughing operations.
The following image illustrates the hatch roughing tool path performed with an
End mill of Ø20.
After the hatch roughing, a Rest roughing operation is performed with an End mill
of Ø10. The tool path is generated in the contour roughing manner.

2. Technology
25
2.4 Constant Z machining
Similar to Contour roughing, the Constant Z tool path is generated for a set of
sectionscreatedatdifferentZ-heightsdeterminedbytheStep down (seetopic6.1.4)
parameter. The generated sections are machined in a profile manner. The Constant
Z strategy is generally used for semi-finishing and finishing of steep model areas
with the inclination angle between 30 and 90 degrees. Since the distance between
passes is measured along the Z-axis of the Coordinate System, in shallow areas
(with smaller surface inclination angle) the Constant Z strategy is less effective.
TheimageaboveillustratestheConstant Z finishing.Notethatthepassesaredensely
spaced in steep areas. Where the model faces get shallower, the passes become
widely spaced, resulting in ineffective machining. Therefore, the machining should
be limited by the surface inclination angle to avoid the shallow areas machining.
These areas can be machined later with a different SolidCAM HSM strategy, e.g.
3D Constant step over (see topic 2.14).

26
2.5 Helical machining
With this strategy, SolidCAM generates a number of closed profile sections of
the 3D Model geometry located at different Z-levels, similar to the Constant Z
strategy. Then these sections are joined in a continuous descending ramp in order
to generate the Helical machining tool path.
The tool path generated with the Helical machining strategy is controlled by two
main parameters: Step down and Max. ramp angle (see topic 6.7.5).

2. Technology
27
2.6 Horizontal machining
With the Horizontal machining strategy, SolidCAM recognizes all the flat areas in
the model and generates a tool path for machining these areas.
This strategy generates a pocket-style (a number of equidistant profiles) tool path
directly at the determined horizontal faces (parallel to the XY-plane of the current
Coordinate System). The distance between each two adjacent passes is determined
by the Offset (see topic 6.1.7) parameters.

28
2.7 Linear machining
Linear machining generates a tool path consisting of a set of parallel passes at
a set angle with the distance between the passes defined by the Step over (see topic
6.1.5) parameter.
With the Linear machining strategy, SolidCAM generates a linear pattern of passes,
where each pass is oriented at a direction defined with the Angle value. This
machining strategy is most effective on shallow (nearing horizontal) surfaces, or
steeper surfaces inclined along the passes direction. The Z-height of each point
along a raster pass is the same as the Z-height of the triangulated surfaces, with
adjustments made for applied thickness and tool definition.
In the image above, the passes are oriented along the X-axis. The passes are evenly
spaced on the shallow faces and on the faces inclined along the passes direction.
The passes on the side faces are widely spaced; Cross Linear machining (see topic
6.7.4) can be used to finish these areas.

2. Technology
29
2.8 Radial machining
The Radial machining strategy enables you to generate a radial pattern of passes
rotated around a central point.
This machining strategy is most effective on areas that include shallow curved
surfaces and for model areas formed by revolution bodies, as the passes are spaced
along the XY-plane (step over), and not the Z-plane (step down). The Z-height
of each point along a radial pass is the same as the Z-height of the triangulated
surfaces, with adjustments made for applied thickness and tool definition.

30
2.9 Spiral machining
The Spiral machining strategy enables you to generate a 3D spiral tool path over
your model. This strategy is optimal for model areas formed by revolution bodies.
The tool path is generated by projecting a planar spiral (located in the XY-plane of
the current Coordinate System) on the model.

2. Technology
31
2.10 Morphed machining
Morphed machining passes are generated across the model faces in a close-to-
parallel formation, rather like Linear machining passes (see topic 2.7); each path
repeats the shape of the previous one and takes on some characteristics of the
next one, and so the paths "morph" or gradually change shape from one side of
the patch to the other.
The shape and direction of the patch is defined by two drive boundary curves.
Drive boundary curves

32
2.11 Offset cutting
This strategy is a particular case of the Morphed machining strategy (see topic
2.10). The Offset cutting strategy enables you to generate a tool path using a single
Drive curve. The tool path is generated between the Drive curve and a virtual
offset curve, generated at the specified offset from the Drive curve.
Drive curve
Tool path

2. Technology
33
2.12 Boundary machining
A Boundary machining strategy enables you to create the tool path by projecting
the defined Drive boundary (see topic 5.1.1) on the model geometry. The Machining
depth is defined relative to the model surfaces with the Thickness (see topic 6.1.1)
parameter. The tool path generated with the Boundary machining strategy can
be used for engraving on model faces or for chamfer machining along the model
edges.

34
2.13 Rest machining
Rest machining determines the model areas where material remains after the
machining by a tool path, and generates a set of passes to machine these areas.
Pencil milling vertical corners can cause both the flute of the tool and the radius
to be in full contact with the material, creating adverse cutting conditions. Rest
machining picks the corners out from the top down, resulting in better machining
technique. Steep and shallow areas are both machined in a single tool path, with
different rest machining strategies.

2. Technology
35
2.14 3D Constant step over machining
3D Constant step over machining enables you generate a 3D tool path on the
CAM-Part surfaces. The passes of the tool path are located at a constant distance
from each other, measured along the surface of the model.
This is an ideal strategy to use on
the boundaries generated by rest
machining or in any case where
you want to ensure a constant
distance between passes along
the model faces.
Constant surface step over is
performed on a closed profile
of the Drive boundary (see topic
5.1.1). SolidCAM creates inward
offsets from this boundary.

36
2.15 Pencil milling
The Pencil milling strategy creates a tool path along internal corners and fillets
with small radii, removing material that was not reached in previous machining.
This strategy is used to finish corners which might otherwise have cusp marks left
from previous machining operations. This strategy is useful for machining corners
where the fillet radius is equal to or smaller than the tool radius.

2. Technology
37
2.16 Parallel pencil milling
Parallel pencil milling is a combination of the Pencil milling strategy and the 3D
Constant step over strategy. At the first stage, SolidCAM generates a Pencil milling
tool path. Then the generated pencil milling passes are used to create 3D Constant
step over passes; the passes are generated as a number of offsets on both sides
of the pencil milling passes. In other words, the Parallel pencil milling strategy
performs 3D Constant step over machining using Pencil milling passes as drive
curves to define the shape of passes.
This strategy is particularly useful when the previous cutting tool was not able to
machine all the internal corner radii to size. The multiple passes generated by this
strategy will machine from the outside in to the corner, creating a good surface
finish.

38
2.17 3D Corner offset
The 3D Corner offset strategy is similar to the Parallel pencil milling strategy. This
strategy is also a combination of the Pencil milling strategy and the 3D Constant
step over strategy. SolidCAM generates a Pencil milling tool path and uses it for
the 3D Constant step over passes generation. These passes are generated as offsets
from the Pencil milling passes. In contrast to the Parallel pencil milling strategy, the
number of offsets is not defined by user but determined automatically in such a
way that all the model wthin the boundary will be machined.

2. Technology
39
2.18 Combined strategies
SolidCAM enables you to combine two machining strategies in a single HSM
operation: Constant Z with Horizontal, Linear or 3D Constant step over machining.
Two combined machining strategies share the Geometry, Tool and Constraint
boundaries data. The technological parameters for the passes calculation and
linking are defined separately for each strategy.

42
TheGeometry pageenablesyoutodefinethe3DmodelgeometryfortheSolidCAM
HSM operation.

3. Geometry
43
3.1 Geometry definition
The Target Geometry section enables you to choose the appropriate Coordinate
System for the operation and to define the Machining Geometry.
3.1.1 CoordSys
SolidCAM enables you to select the Coordinate System for the operation by
choosing it from combo-box or by selecting it from the graphic screen by pressing
the CoordSys button. The CoordSys Manager dialog box will be displayed.
Together with this dialog box, SolidCAM displays the location and axis orientation
of all Coordinate Systems defined in the CAM-Part.
To get more information about the Coordinate
System, right click on the CoordSys name in
CoordSys Manager and choose the Inquire option
from the menu.
The CoordSys Data dialog box will be displayed.

44
When the CoordSys is chosen for the operation, the model will be rotated to the
appropriate orientation.
The CoordSys selection operation must be the first step in the geometry definition
process.
3.1.2 Geometry
After the Coordinate System is chosen, define the 3D Model geometry for the
SolidCAM HSM Operation.
If you have already defined 3D Model geometries for
this CAM-Part, you can select a geometry from the
list.
The Show button displays the chosen 3D model
geometry in the SolidWorks window.
The Define button enables you to define a new 3D
Model geometry for the Operation with the 3D
Model Geometry dialog box. For more information
on 3D Geometry selection, refer to the SolidCAM
User Guide book.
When you choose the Geometry from the list, the related Coordinate
System will be chosen automatically.
3.1.3 Facetting tolerance
Before the machining, SolidCAM generates a triangular mesh for all the faces
of the 3D model geometry used for the operation. The Facetting tolerance is
the accuracy to which triangles fit the surfaces. The smaller the value the more
accurate the triangulation is, but the slower the calculation.
The 3D model geometry will be triangulated and the resulting facets will be saved.
The triangulation is performed on the 3D model geometry when you use it for the
first time in a SolidCAM HSM Operation. If you use the 3D geometry in another
operation, SolidCAM will check the tolerance of the existing geometry. It will not
perform another triangulation as long as the facets have been created with the
same surface tolerance.

3. Geometry
45
3.2 Fillet surfaces
This option automatically adds fillets to the internal model corners. Therefore,
the tool does not have to dramatically change direction during the machining,
preventing damage to itself and to the model surfaces and enabling faster feed
rates and eventually better surface quality.
When the corner radius is smaller than
or equal to the tool radius, the tool path
consists of two lines connected with a
sharp corner; at this corner point the
tool sharply changes its direction.
By adding fillets, the corner radius
becomes greater than the tool radius
and the tool path lines are then
connected with an arc, resulting in a
smooth tool movement without sharp
changes in direction.

46
Select the Apply fillets check box to automatically add fillets for the tool path
generation.
Click on the Define button to create a new fillets geometry. The Fillet surfaces
dialog box is displayed.
The Show button displays the chosen fillet geometry directly on the solid model.
Model without fillets Model with fillets

3. Geometry
47
3.2.1 Fillet surfaces dialog box
The Fillet surfaces dialog box enables you to generate fillets geometry for the
current 3D Model geometry used for the HSM operation.
Boundary
The Boundary type section enables you to specify the
boundary geometry for the fillet generation. The fillets
will be generated inside the specified 2D boundary.
SolidCAM enables you to choose the 2D boundary type
from the list. 2D boundaries of the following types are
available: Auto-created silhouette (see topic 5.3.3), Auto-
created outer silhouette (see topic 5.3.4), User-defined
boundary (see topic 5.4.3), and Auto-created box of target
geometry option. The latter option automatically generates
a planar box surrounding the Target geometry.
The Boundary name section enables you to choose a 2D
boundary geometry from the list or define a new one
using the Define button. The appropriate dialog box will
be displayed.
The Show button displays the Select Chain dialog box
and the chains are displayed and highlighted in the
graphic window. If needed, you can unselect some of the
automatically created chains.

48
Filleting Tool Data
For the fillets calculation, SolidCAM uses a virtual tool.
The Filleting Tool data section enables you to specify the
geometry parameters of this tool.
• Tool Diameter. This field enables you to specify the cutting diameter of
the virtual tool.
• Corner radius. This field enables you to specify the corner radius of the
virtual tool.
• Taper (°/side). This field enables you to specify the taper angle of the side
of the tool. SolidCAM does not support tool with a back taper, like a
dovetail tool.
• Cutting length. This field enables you to specify the length of the cutting
edge of the tool.
• Shank diameter. This field enables you to specify the shank diameter.
• Outside holder length. This field enables you to specify the length of the
visible part of the tool, from the tip to the start of the tool holder.
Angle

3. Geometry
49
General
• Tolerance. This parameter defines the tolerance
of fillet surfaces triangulation. A lower value
will give more accurate results, but will increase
the calculation time.
• Resolution. This is the "granularity" of the
calculation. Using a smaller value will give finer
detail but will increase the calculation time.
• Minimum Z. This option sets the lowest Z-level the tool can go to.
• Number of facets. This is the number of flat faces (triangles) across the
radially curved section of the fillet.
• Bitangency angle. This is the minimum angle required between the two
normals at the contact points between the tool and model faces, in order
to decide to generate the fillet.
Bitangency angle

52
In the Tool data section of the SolidCAM HSM Operation dialog box, four major
tool parameters are displayed:
• Type
• Number
• Diameter
• Corner radius

4. Tool
53
4.1 Tool selection
The Select button enables you to edit tool parameters or define the tool you want
to use for this operation.
• When the tool is not defined for the operation, this button displays the
View page of the Part Tool Table dialog box that enables you to choose
the tool from the Part Tool Table.
Choose the required tool from the Part Tool Table and click on
the Select button. The tool will be chosen for the operation.

54
• When the tool is defined for the operation, this button displays the Edit
page of the Part Tool Table dialog box with the parameters of the chosen
tool. You can also add a new tool to be defined for the operation or
choose another tool from the Part Tool Table.
For more information on the tool definition, refer to the SolidCAM Milling User
Guide book.

4. Tool
55
4.2 Holder Clearance
The Holder Clearance parameter enables you to define how close the holder can
approach the material during the machining.
Holder Clearance

56
4.3 Spin & Feed Rate definition
Spin
This field defines the spinning speed of the tool.
The spin value can be defined in two types of units:
S and V.
S is the default and it signifies Revolutions per Minute.
V signifies Material cutting speed in Meters/Minute in
the Metric system or in Feet/Minute in the Inch system;
it is calculated according to the following formula:
V = (S * PI * Tool Diameter) / 1000
Feed Rate
F/FZ. The feed value can be defined in two types of units: F and FZ.
• F is the default that signifies Units per minute.
• FZ signifies Units per tooth and is calculated according to the following
formula:
FZ = F/(Number of Flutes * S)
The F/FZ buttons enable you to check the parameter values.
• Cutting. This field defines the feed rate of the cutting section of the tool
path.
• Link down. The feed rate to be set for lead in moves.
• Link up. The feed rate to be set for lead out moves.
• Rapid. This parameter enables you to define a feed rate for the retract
sections of the tool path, where the tool is not contacting with the
material.

58
Introduction5.1
SolidCAM enables you to define two types of boundaries for the SolidCAM HSM
Operation tool path.
5.1.1 Drive Boundaries
Drive boundaries are used to drive the shape of the tool path for the following
SolidCAM HSM strategies: 3D Constant step over, Morphed machining and
Boundary machining.

5. Boundaries
59
Drive boundaries for Morphed machining
SolidCAM enables you to define drive boundary curves for the Morphed machining
strategy (see topic 2.10).
You can choose an existing geometries for the first and second drive curves from
list or define a new one with the Define button. The Geometry Edit dialog box will
be displayed. For more information on geometry selection, refer to the SolidCAM
Milling User Guide book.
The Show button displays the chosen drive curve geometry directly on the solid
model.
Make sure that the
directions of both
drive curves are the
same in order to
perform the correct
machining.

60
Cutting direction
This option enables you define the tool path direction between the
drive curves.
• Across. The morphed tool path is performed across the drive
curves; each cutting pass connects the corresponding points on
the drive curves.
• Along. The morphed tool path is performed along the drive
curves. The tool path morphs between the shapes of the drive
curves gradually changing shape from the first drive curve to the
second.

5. Boundaries
61
Drive boundaries for Offset cutting
The Drive boundaries page of the HSM Operation dialog box enables you to define
the curve and the related parameters.
Curve
This section enables you to define the Drive curve used for the tool
path definition.
Clear direction
This section enables you
to specify the direction
in which a virtual offset
from the Drive curve is
created. The offset can
be generated in the Right,
Left or Both directions
from the Drive curve.
Left
Drive curve
Right

62
Cutting direction
This section enables you to determine how the machining is performed.
When the Along option is chosen, the machining is performed along
the Drive curve. The tool path morphs between the shapes of the
Drive curve and the offset curve, gradually changing shape from
the first Drive curve to the offset curve. When the Across option is
chosen, the tool path is performed across the Drive curve; each cutting
pass connects the corresponding points on the Drive curve and offset
curve.
Tool on working area
The Tool on working area section enables you to define the position of
the tool relative to the defined boundary and the related parameters.
For more information, see topic 5.2.1.
Along Across

5. Boundaries
63
5.1.2 Constraint boundaries
A constraint boundary enables you to limit the machining to specific model areas.
Machining always takes place within a boundary or a set of boundaries. The
boundaries define the limits of the tool tip motion. The area actually machined
can extend beyond the boundary by as much as the tool shaft radius.
In the image above, the tool center is located at the edge of the boundary, therefore
the tool extends beyond the edge by tool radius. You can use the Offset (see topic
6.1.7) feature to offset the tool inside by a certain distance.

64
If there are several boundary contours then the operation will use all of them.
If one boundary is completely inside another, then it will act as an island. The area
enclosed by the outer boundary, minus the area defined the inner boundary, will
be machined.
You can extend this to define more complicated shapes by having islands within
islands.

5. Boundaries
65
5.2 Boundary Definition
Boundary type
The following boundary types are available
Created automatically
This option enables you to automatically create the boundary using the
stock or target models.
The following types of automatically created boundaries are supported
in SolidCAM:
• Auto-created box of target geometry
• Auto-created box of stock geometry
• Auto-created silhouette
• Auto-created outer silhouette

66
Created manually
This option enables you to define the constraint
boundary that limits the tool path by creating a 2D
area above the model in the XY-plane of the current
Coordinate system or by an automatically generated
3D curve mapped on the surface.
The following types of 2D boundaries are supported:
• Boundary box
• Silhouette boundary
• User-defined boundary
• Profile geometry
• Combined boundary
The following types of 3D boundaries are supported:
• Selected faces
• Shallow areas
• Theoretical rest areas
• Tool contact areas
• Rest areas
Boundary name
This section enables you to define a new boundary geometry or choose an already
defined one from the list.
• The Define button displays the appropriate dialog box for the geometry
definition.
• The Edit button displays the Select Chain dialog box (see topic 5.4.7)
enabling you to choose the necessary chains for the boundary. The
chosen boundaries are displayed and highlighted in the graphic window.

5. Boundaries
67
5.2.1 Tool on working area
This option controls how the tool is positioned
relative to the boundaries. This option is relevant only
for 2D boundaries.
Internal
The tool machines inside the boundary.
External
The tool machines outside the boundary.
Middle
The tool center is positioned on the boundary.
Boundary
Tool
Boundary
Tool
Boundary
Tool

68
Tangent
The Internal/External/Middle methods of the boundary definition have several
limitations. In some cases, the limitation of the tool path by planar boundary
results in unmachined areas or corners rounding.
The Tangent option enables you to avoid these problems.
When this option is chosen, 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.
Unmachined
area
Tool on working area: Middle
Unmachined area
Tool on working area: Internal
Tool on working area: External
Tool path rounding

5. Boundaries
69
This option enables you to machine the exact boundary taking the geometry into
account.
Offset value
This value enables you to specify the offset of the tool center.
A positive offset value will enlarge the boundary; a negative value will reduce the
boundary to be machined.
+
+
-
-
Tool on working area: Tangent
The tool is tangent
to the projection
of the working area
onto model faces

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5.3 Automatically created boundaries
5.3.1 Auto-created box of target geometry
With this option SolidCAM automatically generates a rectangular box surrounding
the target model. The tool path is limited to the area contained in this box.
Target Model

5. Boundaries
71
5.3.2 Auto-created box of stock geometry
With this option SolidCAM automatically generates a rectangular box surrounding
the stock model. The tool path is limited to the area contained in this box.
Target Model
Stock Model

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5.3.3 Auto-created silhouette
With this option, SolidCAM automatically generates a silhouette boundary of the
target model. A silhouette boundary is a projection of the outer and inner contours
of the target model onto the XY-plane.
Target Model

5. Boundaries
73
5.3.4 Auto-created outer silhouette
With this option, SolidCAM automatically generates an outer silhouette boundary
of the target model. In this case, an outer silhouette boundary is a projection of
the outer contours only onto the XY-plane.
Target Model

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5.4 2D manually created boundaries
5.4.1 Boundary Box
A Boundary Box is a rectangular box surrounding the selected model geometry.
SolidCAM enables you to limit the machining passes to the area contained in the
Boundary box.
The Select Faces dialog box enables you to choose the
necessary model faces. When the faces are chosen and
the dialog box is confirmed, the Boundary box dialog
box is displayed.

5. Boundaries
75
This dialog box enables you to define a necessary
parameters and choose the model elements for the
bounding box calculation.
The boundary will be created on
This option enables you to select the faces
for which a bounding box is generated. Click
the Select button to display the Select Faces
dialog box (see topic 5.4.6).
The Show button displays the already selected
faces geometry.
The table section displays the automatically
calculatedminimumandmaximumcoordinates,
center and length of the bounding box.
SolidCAM enables you to change
the XY-coordinates of the minimum
and maximum coordinates of the
bounding box.
When the geometry for the bounding box generation is defined, click on
the button. The boundary chains will be generated and the Select Chain dialog
box (see topic 5.4.7) will be displayed.

76
5.4.2 Silhouette Boundary
A Silhouette boundary is a projection of the face edges onto the XY-plane. In
other words, it is the shape that you see when you looking at a set of surfaces down
the tool axis.
The Select faces dialog box enables you to choose the
the dialog box is confirmed, the Silhouette boundary
This dialog box enables you to define the parameters
and choose the solid model elements for the silhouette
boundary calculation.

5. Boundaries
77
The boundary will be created on
This option enables you to choose a faces geometry to generate
a silhouette boundary. SolidCAM enables you either to choose an
already existing Faces geometry from the list or define a new one
with the Select button. The Select Faces dialog box (see topic 5.4.6)
will be displayed. The Show button displays the already selected faces
geometry.
Min diameter
The diameter is the span of the boundary, the distance between two
points on either side. Boundaries that have a diameter smaller than this
are discarded.
Aperture
Aperture defines the "fuzziness" of the Silhouette. Decrease the value
to bring it into sharper focus; increase it to close up unwanted gaps
between boundaries.
Resolution
This is the granularity of the calculation: a small value results in a more
detailed boundary, but it is slower to calculate.
When the geometry for the silhouette boundary generation is defined, click on
the button. The boundary chains will be generated and the Select chain dialog
box (see topic 5.4.7) will be displayed.

78
5.4.3 User-defined boundary
SolidCAM enables you to define a user-defined boundary based on a Working area
geometry (closed loop of model edges as well as sketch entities).
For more information on Working area geometry, refer to the SolidCAM Milling
User Guide book.
SolidCAM automatically projects the selected geometry on the XY-plane and
defines the 2D boundary.
The Geometry Edit dialog box enables you to define the geometry.

5. Boundaries
79
5.4.4 Profile Geometry
SolidCAM enables you to define a user-defined boundary based on a Profile
geometry. All the HSM strategies enable you to use closed profile geometries. The
Boundary machining strategy (see topic 2.10) enables you to use also open profiles
for the boundary definition; this feature is useful for single-contour text engraving
or for chamfering.
For more information on Profile geometry, refer to the SolidCAM Milling User
Guide book.
SolidCAM automatically projects the selected geometry on the XY-plane and
defines the 2D boundary.
The Geometry Edit dialog box enables you to define the geometry.

80
5.4.5 Combined boundary
This option enables you to define the boundary by performing a number of
boolean operations between working area geometries and boundaries.
The Boolean Operations dialog box is displayed.
Coordinate System
ThisfieldenablesyoutochoosetheCoordinateSystemwherethesourcegeometries
for the boolean operation are located. The resulting combined geometry will be
created in the chosen coordinate system.
Configurations
This field enables you to choose the SolidWorks configuration where the source
user-defined geometries for the boolean operation are located.

5. Boundaries
81
Operation type
This field enables you to define the type of the boolean operation. The following
boolean operations are available:
Union
This option enables you to unite
selected geometries into a single one.
All internal segments are removed;
the resulting geometry is outer
profile.
Merge
This option enables you to merge a
number of geometries, created by
different methods, into a single one.
Geometry 1 Geometry 2
Source geometries
Resulting geometry
Geometry 3
Source geometries
Resulting geometry

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Subtract
This option enables you to perform
subtraction of two geometries. The
order of the geometry selection
is important; the second selected
geometry is subtracted from the first
selected one.
Intersect
This option enables you to perform
intersection of two geometries.
The Accept button performs the chosen
operation with the geometries chosen in the
Geometries section.
Geometries
The Geometries section displays all the available
working area geometries classified by the
definition method.
This section enables you to choose the appropriate
geometries for the boolean operation. Select the check
box near the geometry name in order to choose it for the
boolean operation.
Source geometries
Resulting geometry
Source geometries
Resulting geometry

5. Boundaries
83
When you click on the Accept button, the resulting
geometry is displayed in the list under the Combined
2D header. SolidCAM enables you to edit the name of
the created geometry. The newly created geometry is
automatically choose for the further boolean operation.
The resulting combined geometry is always
a 2D geometry even if one or more of the
input geometries is a 3D boundary.
The right-click menu available on the list items enables you to perform the following
operations:
• Accept.Thisbuttonenablesyoutoperformthechosenbooleanoperation
with the selected geometries.
• Unselect All. This option unselects all the chosen geometries.
• Delete. This option enables you to delete combined geometries generated
in the current session of the Boolean Geometries dialog box.

84
5.4.6 Select Faces dialog box
This dialog box enables you to select one or several faces of the SolidWorks model.
The selected Face tags will be displayed in the dialog box.
If you have chosen wrong entities, use the Unselect
option to undo your selection. You can also right-click
on the entity name (the object will be highlighted) and
choose the Unselect option from the menu.
The Reverse/Reverse all option enables you to change
the direction of the normal vectors of the selected
faces.
The CAD Selection option enables you to select faces with the SolidWorks tools.

5. Boundaries
85
5.4.7 Select Chain dialog box
Depending on the boundary type, SolidCAM generates a number of chains for
the selected faces. The Select Chain dialog box enables you to select the chains for
the boundary.

86
5.5 3D User defined boundaries
Common parameters5.5.1
The boundary will be created on:
• Selected faces. This option enables you to choose a faces geometry to
generate a boundary of the defined type. SolidCAM enables you either
to choose an already existing Faces geometry from the list or define a
new one with the Select button. The Select Faces dialog box (see topic
5.4.6) will be displayed. The Show button displays the already selected
faces geometry.
• Whole model. With this option, SolidCAM generates boundaries of the
chosen type for all the model faces.

5. Boundaries
87
Limits
• Z Limits
Set the machining range along Z-axis by
definitionof upperandlowerlimits.Boundaries
will be generated within this range.
• Angle
Set the contact angle range of your tool by
setting the minimum and maximum contact
angle. Boundaries will be generated around
areas where the angle is within that range. For
Shallow Area boundaries (see topic 5.5.3), the
range should typically be between 0 and 30
degrees, but where surfaces are very close to
the minimum or maximum angle, you may get
an undesirably jagged edge so you may want to
alter the range slightly. Alternatively, you can
sometimes get rid of jagged edges by giving
the boundary a small offset.
• Contact Areas Only
This option should be selected to choose only boundaries that are in
contact with the model surface.

88
Boundaries
• Thickness
This is the distance at which the boundaries and therefore the tool will
be away from the surface. The thickness is set similarly to Thickness
parameter on the Passes page (see topic 6.1.1).
For roughing and semi-finishing operations, you should set the
thickness to a value greater than zero. The calculations are based on a
modified tool, the surface of which is offset to be larger than the true
tool. This will leave material on the part.
Forfinishingoperations,thevalueshouldbesettozero.Thecalculations
are based on the dimensions of the tool defined, with no offset.
In special circumstances, such as the making electrodes with a spark gap,
you can set the thickness to a value less than zero. The tool will remove
material at a level below the designated surface. The calculations are
based on a modified tool, offset smaller than the one used.

5. Boundaries
89
• Axial Thickness
With this parameter, SolidCAM enables you to define the distance away
from the surface that the boundaries will be in the tool axis direction.
The boundary is calculated using the Thickness. The resulting boundary
is updated by offsetting along the tool axis by a distance equal to the
Axial Thickness.
• Min Diameter
The diameter is the span of the boundary, the distance between two
points on either side. Boundaries that have a diameter smaller than this
are discarded.
• Offset
The boundaries are calculated and then offset by this amount.
It may be advantageous sometimes to put in a small offset value; you
can prevent jagged boundary edges where an area of a surface is at an
angle similar to the Contact Angle.
In Rest areas (see topic 5.5.6) with no offsetting the exact boundary
area would be machined, resulting in marks or even cusps around the
edge. For Theoretical rest areas (see topic 5.5.4), the boundaries are
offset outwards along the surface by this amount after they have been
made; a good surface finish is ensured at the edges of the rest areas.
Without offsetting, the exact Theoretical rest area would be machined,
probably leaving marks or even cusps (of just under the minimum
material depth value) around the edge. The offsetting makes the
boundaries smoother, so a tool path made using them is less jagged.
• Resolution
This is the granularity of the calculation. A small value results in a
more detailed boundary but it will be slower to calculate.

90
5.5.2 Selected faces
This option enables you to define the boundary by selecting drive and check faces
similar to the Working area definition for 3D Milling Operations.
Under Boundary name, click on the Define button to start the boundary definition.
The Selected faces dialog box enables you to define the drive and check faces.
Name
This section enables you to define the boundary name and the tolerance that is
used for the boundary creation.

5. Boundaries
91
Drive faces
This section enables you to define Drive faces – the set of faces to be milled.
The tool path is generated only for machining of these faces. The Define button
displays the Select Faces dialog box used for the faces selection. The Offset edit
box enables you to define the offset for the Drive faces. When the offset is defined,
the machining is performed at the specified offset from the Drive faces.
Check faces
This section enables you to define Check faces – the set of faces to be avoided
during the generation of the tool path. The Define button displays the Select
Faces dialog box used for the faces selection. The Offset edit box enables you to
define the offset for the Check faces. When the offset is defined, the machining is
performed at the specified offset from the Check faces.
Check face
Drive faces offset
Drive face
Check face
Check faces offset
Drive face

92
5.5.3 Shallow Areas
With this option, SolidCAM enables you to automatically determine shallow areas
in the model and define boundaries around them.
The tool has to be chosen for the operation
before the shallow areas boundary
definition.
the dialog box is confirmed, the Shallow Areas dialog
box is displayed.
This dialog box enables you to define a number of
parameters for the shallow areas boundary generation.

5. Boundaries
93
5.5.4 Theoretical Rest Areas
You can create 3D boundaries from rest areas left by an imaginary reference tool.
This gives good results when used for semi-finish and finish machining operations.
You can then use these boundaries to limit another SolidCAM HSM operation
performed with a tool of an equal or smaller size.
the dialog box is confirmed, the Theoretical Rest areas
This dialog box enables you to define a number
of parameters for the theoretical rest material areas
generation.

94
Limits
Include Corner Fillets
In corner area, the angle is degenerate. Use this option to include or
exclude all corner areas from the rest area boundaries.
Min material depth
The smallest amount of material to be found in areas included in the
rest area boundary prior to rest machining. If the reference tool left
parts of the material with less than this amount, those material areas
would not be included in the rest area boundaries.
The Min material depth should be greater than the cusp height left by
the passes of the imaginary reference tool path. If the Min material
depth is less than the cusp height left by the passes of the imaginary
reference tool path the whole area machined by the reference tool will
be included in the rest area boundary.
Reference Tool
This allows you to specify a tool with which the Theoretical Rest Areas
will be calculated. This tool is usually larger than the tool that will be
used to cut the rest areas. The reference tool is used to represent an
imaginary tool path, and the rest areas are created assuming that the
tool path had been created.
Define the size of the tool by inserting values into the Tool Diameter
and Corner Radius fields.

5. Boundaries
95
5.5.5 Tool Contact Area
Tool Contact Area detection allows you to make 3D boundaries around areas
where the tool is in contact with a selected surface or surfaces.
Tool Contact Area boundaries do not work on vertical or near-vertical
surfaces. The steepest angle you should use for best results is 80
degrees.
The selection of a surface as
shown below. If a Tool Contact
Area boundary is created from
this selection, there will be
offset from the edges where the
selected surface is adjacent to
another surface. The tool can
only reach the edges where there
are no other surfaces to hinder
its movement.

96
the dialog box is confirmed, the Tool Contact Areas
This dialog box enables you to define the parameters for
the boundary calculation.
Boundaries
• Overthickness
This option is only available for Tool Contact
Area boundaries. Overthickness is an extra
thickness that can be applied to the tool in
addition to the set thickness when you wish
to calculate with a tool slightly larger than the
one you intended to use, to create smooth
filleted edges.
• Constrain
Using this option, SolidCAM enables you to
limit the tool motion in two ways:
• Center Point
The point where the tool contacts the
surfaces is always within the boundary.

5. Boundaries
97
• Contact Point
The edge of the tool is always within
the boundary.
5.5.6 Rest Areas
This option enables you to define rest material left unmachined after any machining
strategy to create 3D boundaries. You can then use these boundaries to limit the
operation tool path, made with a tool of an equal or smaller size to these specific
areas.

98
the dialog box is confirmed, the Rest Areas dialog box
is displayed.
This dialog box enables you to define the parameters for
the rest areas calculation.
Previous operations
SolidCAM enables you to choose any previous HSM
operation for the Rest areas calculation.
Min Material
This is the granularity of the calculation. A small value
results in a more detailed boundary but it will be slower
to calculate.

100
The Passes page enables you to define the technological parameters needed to
generate the tool path for the SolidCAM HSM Operation.
Common Parameters
The Passes parameters for the various machining strategies vary
slightly, but most of them are the same. The following section is a
general overview of the common parameters for all the SolidCAM
HSM strategies.
• Passes parameters
• Smoothing parameters
• Adaptive step down parameters
• Edit Passes parameters
• Axial offset

6. Passes
101
Passes parameters6.1
The Passes page displays the major parameters that affect the passes generation.
• Thickness
• Axial thickness
• Tolerance
• Step down
• Step over
• Pass Extension
• Offsets
• Limits
• Point reduction

102
6.1.1 Thickness
SolidCAM enables you modify the tool diameter by defining the Thickness
parameter. The machining is performed using the modified tool.
• Positive thickness enables you to move the tool away from the machining
surface by the thickness value. The offset will be left unmachined on
the surfaces. Generally, the positive thickness is used for roughing and
semi-finishing operations to leave an allowance for further finishing
operations.
• No thickness: in this case SolidCAM
uses the tool with the specified
diameter for the tool path calculation.
It means that the machining is
performed directly on the model
surfaces. Generally, zero thickness is
used for finishing operations.
Thickness

6. Passes
103
• Negative thicknesses enables you to move the tool deeper into the
material penetrating the machining surface by the thickness value.
This option is used in special circumstances, such as making electrodes
with a spark gap. The tool will remove material at a level below the
designated surface. The calculations are based on a modified tool,
smaller than the one used.
As the calculations for the negative
thickness are based on a modified tool
smaller than the one used, the thickness
should be the same size or smaller than
the corner radius of the tool. Where the
offset is larger than the corner radius of
the tool, surfaces at angles near to 45° will
be unfavorably affected as the corner of
the tool impacts on the machined surface,
since the thickness at the corners is in
fact greater than the value set (see below).
Surfaces that are horizontal or vertical are
not affected.
Thickness
1mm
~1.4mm

104
If a negative thickness (e.g. -1mm) were to be applied to a tool without
a corner radius, the real thickness at the corners of the tool would
be considerably larger than 1mm (appx. –1.4 mm). This is obviously
incorrect. If you want to want to simulate a negative thickness with a
slot mill, start by defining a bull-nosed tool with a corner radius equal
to the negative value of the thickness – a corner radius of 1 mm is
used with a negative thickness of –1 mm.
If you define an end mill, the thickness will be more than the value set
on surfaces nearing 45 degrees.
Using a bull-nosed tool with a positive
corner radius equal to the desired negative
thickness, better and more accurate results
will be achieved.

6. Passes
105
6.1.2 Axial thickness
The axial thickness is applied to the tool and has the effect of lifting (positive
thickness) or dropping (negative thickness) the tool along the tool axis. As a result,
axial thickness has its greatest effect on horizontal surfaces and has no effect on
vertical surfaces. By default this value is the same as the Thickness.
The tool path is calculated using a tool which is offset by Thickness. The resulting
tool path is calculated by offsetting along the tool axis by a distance equal to the
Axial thickness.

106
6.1.3 Tolerance
All machining operations have a tolerance, which is the accuracy of the calculation.
The smaller the value the more accurate the tool path.
The tolerance is the maximum amount that the tool can deviate from the surface.
Surface
Cut with high tolerance
Cut with low tolerance

6. Passes
107
6.1.4 Step down
The Step down parameter is available for Rough machining and the Constant Z
finishing strategy. It defines the spacing of the passes along the tool axis. This
parameter is different from Adaptive Step down (see topic 6.3), which adjusts the
passes to get the best fit to the edges of a surface.
The passes are spaced at the distance set, regardless of the XY-value of each
position (unless the Adaptive step down check box is selected).
Step down

108
6.1.5 Step over
You can set a step over value for Linear machining, Radial machining, Spiral
machining, Morphed machining, 3D Constant step over and Hatch roughing passes.
Step over is the distance between the passes. For all the strategies, Step over is
measured in the XY-plane, but for the 3D Constant step over strategy (see topic
2.12), Step over is measured along the surface.
Step over

6. Passes
109
Pass Extension6.1.6
This option enables the user to extend the tool path beyond the boundary to
enable the tool to move into the cut at machining feed rather than rapid feed.
The Pass Extension parameter is enabled for Linear machining and
Radial machining strategies.
The Linear tool path shown below is created with the zero pass extension:
The Linear tool path shown below is created with 5 mm pass extension:

110
6.1.7 Offsets
This parameter is used for Contour Roughing, Hatch roughing and Horizontal
finishing.
Each Z-level comprises a "surface profile" and a series of concentric offset profiles.
The minimum and maximum offset values define the range of the size of spaces
between the passes. SolidCAM will choose the largest value possible within that
range that does not leave unwanted upstands between the passes.
A set of Contour Roughing passes, for example, is created from a series of offset
profiles. If each profile is offset by no more than the tool radius then the whole
area will be cleared. In certain cases where the profile is very smooth it is possible
to offset the profiles by up to the tool diameter and still clear the area. Obviously,
offsetting by more than the tool diameter will leave many upstands between the
passes. Between these two extremes, the radius and the diameter, there is an ideal
offset where the area will be cleared leaving no upstands. SolidCAM uses an
advanced algorithm to find this ideal offset.
The minimum Offset value should be greater than the Offset tolerance
(see topic 6.2.3) parameter and smaller than the tool shaft radius; the
maximum Offset value is calculated automatically.
Offset

6. Passes
111
6.1.8 Limits
The limits are the highest and lowest Z-positions for the tool - the range in which
it can move.
• Z-Bottom limit. This parameter enables you to define the lower Z-level of
the machining. The default value is automatically set at the lowest point
of the model.
This limit is used either to limit the
passes to level ranges or to prevent
the tool from falling indefinitely if it
moved off the edges of the model
surface. When the tool moves off the
surface, it continues at the Z-Bottom
Limit and falls no further.
• Z-Top limit. The Z-Top limit defines the upper machining level. The
default value is automatically determined at the highest point of the
model.
• CoAngle. The contact angle alignment to be used when making cross
machining passes.
This option is only available for Linear finishing strategy.
• Angle. SolidCAM enables you to limit the surface angles within a range
most appropriate to the strategy. The Constant Z strategy, for example, is
most effective on steeper surfaces, because the spaces between the passes
are calculated according to the Step down value, and on surfaces where
there is little Z-level change, the spaces between the passes are greater,
therefore you may get unsatisfactory results. You can limit the work area
to surface angles between, for example, 30 and
90 degrees.

112
The angle is measured between the two normals at the contact points
between the tool and model faces. The angle of 0 means coincidence of
surface normal and tool axis; i.e. horizontal surface.
The Angle option is available for Constant Z, Linear, Radial, Spiral,
Morphed, Boundary, Constant Step over, and Pencil milling strategies.
Contact Areas Only
When this option is chosen, the tool path is only created where the
tool is in contact with model faces. The examples below show the
result of Constant Z strategy with and without the Contact Areas Only
option.
Without the Contact Areas
Only option,theouteredgeof
the base surface is machined
as well as the central boss.
With the Contact Areas Only
option, the machining is
limited to the actual surfaces
of your geometry.

6. Passes
113
Point reduction6.1.9
SolidCAM enables you to optimize the tool path by reducing the number of
points.
The Fit arcs options the user to activate the fitting of arcs to the machining passes
according to the specified Tolerance value.
The Tolerance value is the chordal deviation to be used for point reduction and
arc fitting.

114
6.2 Smoothing parameters
The Smoothing option enables you
to round the tool path corners. This
option enables the tool to maintain
a higher feed rate and reduces wear
on the tool. This feature is often
used in rough machining.
Tool path without smoothing
Tool path with smoothing

6. Passes
115
Max. radius6.2.1
A curve can be approximated as an arc. The Max. radius parameter defines the
maximum arc radius allowed.
Profile Tolerance6.2.2
This value is the maximum distance that the smoothed outer profile will diverge
from the actual profile. Set the Profile tolerance to a low or zero value to reduce
the amount of material missed.
6.2.3 Offset Tolerance
This value is the maximum distance that the smoothed profile offset will diverge
from the inner (offset) profiles. This parameter is identical to the Profile Tolerance,
except that it refers only to the inner (offset) profiles and not to the outer profile.
The Offset Tolerance is measured between any given smoothed profile (excluding
the outermost one) and the sharp corner of an imaginary profile drawn without
smoothing, but at the same offset as the smoothed one.
Unlike the Profile Tolerance parameter, above, changing this value does not mean
you miss material.
Proﬁle tolerance
Offset tolerance
Original tool path Smoothed tool path

116
6.3 Adaptive step down parameters
• Where the horizontal distance between the passes is significant, Adaptive
Step down can be used to insert extra passes and reduce the horizontal
distance.
• Where the passes on the topmost edges of a surface would fall too
close or too far away from that edge, Adaptive Step down will add extra
passes to compensate. So the Step down value controls the maximum
Z-distance between the passes for the entire surface, while Adaptive Step
down adjusts those values for the best fit for the surfaces.
Adaptive step down
passes
Adaptive step down is not chosen Adaptive step down is chosen

6. Passes
117
If passes are applied without Adaptive Step down, some material may be left on
the top faces. In passes generated with the Adaptive Step down option, a pass is
inserted to cut the top face; the next step down will be calculated from this pass.
Minimum Step down
This specifies the minimum step down value to be used, meaning
passes will be no less than this distance from each other.
Precision
Thisparametercontrolshowaccuratelythesystemfindstheappropriate
height to insert a new slice.
Profile Step in
This parameter defines the maximal XY-distance between cutting
profiles located on two successive Z-levels. When SolidCAM calculates
the cutting profile at a given Z-level, the distance to the cutting profile
on the previous Z-level is calculated. If the calculated value is greater
than the defined Profile Step in, SolidCAM inserts an additional Z-level
and calculates the cutting profile in such a way that the distance between
cutting profiles located on two successive Z-levels will be smaller than
the specified Profile Step in value.
Without Proﬁle step-in With Proﬁle step-in
Inserted Z-level
Large step Small steps

118
6.4 Edit Passes parameters
If you start the machining with a formed stock instead of a rectangular or
cylindrical block of material, you could trim the passes to the formed stock faces
to avoid unnecessary air cutting. The tool path trimming is used either when you
use a casting as stock for the part machining or you use the updated stock resulting
from a number of previous operations.
For example, suppose you want to machine (using Contour roughing) the following
model:
Using the Contour roughing
strategy you get the following
tool path.

6. Passes
119
Rather than starting from a cylindrical block of material, you start with the casting
shown below.
The resulting trimmed tool path is shown below.

120
The Edit passes page enables you to define the parameters for the passes
trimming.
Edit using surfaces
By selecting this check box, you can limit the machining by using the Updated
Stock model or by defining an offset from the operation geometry.
Stock surfaces
This option enables you to specify the method of the machining area
definition.
• When the Updated stock option is chosen, SolidCAM calculates the
Updated Stock model after all the previous operations. SolidCAM
automatically compares the updated stock model with the operation
target geometry and machines the difference between them.
• When the Main geometry option is chosen, the machining is
performed in the area defined by an offset from the operation
geometry. The offset is defined by the Overthickness parameter.

6. Passes
121
Mach. stock name
This option enables you to choose the previously generated Updated
Stock model for the tool path calculation.
This option is available only in the following cases:
• When Stock surfaces is set to Updated stock;
• When the Manual method of the Updated Stock model
calculation is used.
Show
This button displays the difference between the updated stock model
and the target geometry used in the operation.
Overthickness
This is an extra thickness that can be temporarily applied to the tool
and can be set when editing passes. The use of this parameter can help
to create better trimmed passes. A negative value will cause the system
to select only passes that are below the model faces by the specified
amount, while a positive value will select all passes that are within the
specified distance from the model faces.
Resolution
This is the granularity of the calculation: the smaller the value, the finer
the detail, but the calculation is slower. Using a larger resolution, you
can decrease detection time, but this may lead to very small features
being missed.
The system will search along the tool path, examining appropriate
points along the tool path and recording whether that position is
above or below the surfaces. The current and previous positions are
compared and if they are different (i.e. one above and one below)
then the tolerance is used to locate the precise position of the change
between above and below. This information is used to trim the tool
path.

122
The system will check points along a tool path where the direction
changes, but long and straight passes are supplemented by extra
points. The resolution is used to determine the distance between these
points.
Tolerance
The tolerance is the maximum amount that the tool can move, either
above or below the surface. All machining operations have a tolerance,
the smaller the value, the more accurate the calculation.
Pass extension
This option enables you to define a pass extension length. The trimmed
passes will be extended in each direction by this value; this enables the
tool to move into the cut at machining feed rather than rapid.
Join gaps of
Passes that lie along the same line and are separated by less than the
amount specified here will be joined to create a single pass.

6. Passes
123
Axial offset6.5
This page enables you to axially offset the tool path (one or more times). The tool
path can be generated by any of the HSM finish strategies, except for Constant Z
and Rest machining.
When the Axial offset check box is selected, you have to define the following
parameters:
• Axial offset
This parameter defines the distance between two successive tool path
instances.
• Number of offsets
This parameter enables you to define how many times the offset of the
toolpathisperformed.Thisfinalnumberof toolpathinstancesisequalto
Number of offsets +1.
Axial offsetTool path
Number of offsets = 3

124
The tool path instances are generated in the positive Z-direction. The machining
is performed from the upper instance to the lower.
The Axial offset feature enables you to perform the semi-finish and finish
machining in a number of equidistant vertical steps. It can be used for engraving in
a number of vertical steps with the Boundary Machining strategy or for removing
the machining allowance by a finishing strategy in a number of vertical steps.

6. Passes
125
Analysis6.6
The Analysis page enables you to perform the tool path checking for the invalid
arcs and possible gouges.
When the Checker check box is selected, the tool path checking is performed. If
an error is found, the creation of passes is stopped.
The Step distance parameter is used to specify the distance along the tool path
between the points where the gouge checking is performed.

126
6.7 Strategy parameters
In addition to the common parameters relevant for all of the machining strategies,
SolidCAM provides you with options and parameters that enable you to control
specific features of various machining strategies.
• Contour roughing
• Hatch roughing
• Rest roughing
• Constant Z machining
• Horizontal machining
• Linear machining
• Radial machining
• Helical machining
• Spiral machining
• Morphed machining
• Offset cutting
• Rest machining
• 3D Constant step over machining
• Pencil milling
• 3D Corner offset machining
• Parallel pencil milling
• 3D Corner offset machining
• Combined strategies

6. Passes
127
6.7.1 Contour roughing
With the Contour roughing strategy, SolidCAM generates a pocket-style tool path
for a set of sections generated at the Z-levels defined with the specified Step down
(see topic 6.1.4).

128
Detect core areas
This option causes the tool to start from the outside of the model rather than take
a full width cut in the center of the component.
If your model includes both core and cavity areas, the system will automatically
switch between core roughing and cavity roughing within the same tool path.
When these passes are linked to create a Contour roughing tool path, the areas are
machined from the top downwards. Obviously, material has to be machined at one
level before moving down to the next one.
The passes for the Z-Top level machining are not usually included in
the operation tool path. Adjust the Z-Top level by adding the Step
down value to the current Z-Top level value when you want to include
the top level passes in the operation tool path.

6. Passes
129
6.7.2 Hatch roughing
With the Hatch roughing strategy, SolidCAM generates linear raster passes for
a set of sections generated at the Z-levels defined with the specified Step down
(see topic 6.1.4). Hatch roughing is generally used for older machine tools or softer
materials because the tool path predominantly consists of straight line sections.

130
Angle
This option enables you to define the angle of the hatch passes relative to the
X-axis of the current Coordinate System.
Z
X
Y
Angle

6. Passes
131
Offset
The Offset parameter defines the distance between the hatch passes and the outer/
inner profiles.
Offset

132
6.7.3 Rest roughing
TheRestroughingstrategydeterminestheareaswherematerialremainsunmachined
after the previous machining operations (the "rest" of the material) and generates
a tool path for the machining of these areas. The tool path is generated in the
Contour roughing (see topic 2.1) manner. Rest roughing operation uses a tool of
smaller diameter than that used in previous roughing operations.
The following image illustrates the hatch roughing tool path performed with an
End mill of Ø20.
After the hatch roughing, a Rest roughing operation is performed with an End mill
of Ø10. The tool path is generated in the contour roughing manner.

6. Passes
133
Previous operations page
The Previous operations page of the SolidCAM HSM Operation dialog box enables
you to choose the previous SolidCAM HSM operations for the rest material
roughing calculation.
The Previous operations list displays all the previously defined roughing HSM
operations available for the rest material calculation. Choose the necessary
operations by selecting the appropriate check boxes in the list.
• The Select all button enables you to select all the operations in the list
for the rest material roughing calculation.
• The Unselect all button enables you to unselect all the selected
operations.
• The Invert select states button enables you to unselect the selected
operations and select the unselected ones.

134
6.7.4 Linear machining
Linear machining generates a tool path consisting of a set of parallel passes at
a given angle with the distance between the passes defined by the Step over
parameter (see topic6.1.5).
With the Linear machining strategy, SolidCAM generates a linear pattern of passes,
where each pass is oriented at a direction defined with the Angle value. This
machining strategy is most effective on shallow (nearing horizontal) surfaces, or
steeper surfaces inclined along the passes direction. The Z-height of each point
along a raster pass is the same as the Z-height of the triangulated surfaces, with
adjustments made for applied thickness and tool definition.
In the image, the passes are oriented
along the X-axis. The passes are evenly
spaced on the shallow faces and on the
faces inclined along the passes direction.
The passes on the side faces are widely
spaced; Cross linear machining can be
used to finish these areas.

6. Passes
135
Angle
The Angle parameter enables you to define the angle of the passes direction. The
value of this parameter is within the range of –180° to 180°. If Angle is set to 0,
the direction of passes is parallel to the X-axis of the current Coordinate System.
The order of the passes and the direction of the machining is controlled by the
link settings.
The angle you set here affects how the step over is calculated. If you are machining
vertical surfaces, Linear machining works best where the angle is perpendicular to
those surfaces.
Tangential extension
This option enables you to extend the passes tangentially to the model faces by a
length defined by the Pass extension parameter.

136
When the check box is not selected, the extension passes are generated as a
projection of the initial pattern (either linear or radial) on the solid model faces.
When the check box is selected, the extension passes are generated tangentially to
the solid model faces.
Cross linear machining
SolidCAM automatically determines the areas where the Linear machining passes
are sparsely spaced and performs in these areas an additional Linear tool path in a
direction perpendicular to the direction of the initial Linear tool path. The passes
parameters used for the Cross linear machining definition are the same that are
used for the initial Linear machining.
Initial Linear machining tool path
Extension
Extension
Extension
The check box
is not selected
The check box
is selected

6. Passes
137
Cross linear machining tool path
Combined Linear and Cross linear machining tool path

138
Cross page
The Cross page enables you to define the order of performing Linear
and Cross linear machining.
• None
Cross linear machining is not performed.
• Before
Cross linear machining is performed before the main
Linear machining.
• After
Cross linear machining is performed after the main Linear
machining.
• Only
Only Cross linear machining is performed; the main Linear
machining is not performed.

6. Passes
139
6.7.5 Helical machining
This strategy enables you to generate a number of closed profile sections of
the 3D Model geometry located at different Z-levels, similar to the Constant Z
strategy. Then these sections are joined in a continuous descending ramp in order
to generate the Helical machining tool path.
The tool path generated with the Helical machining strategy is controlled by two
main parameters: Step down and Max. ramp angle.

140
Step down
This parameter defines the distance along the Z-axis between two successive
Z-levels, at which the geometry sections are generated. Since the Step down is
measured along the Z-axis (similar to the Constant Z strategy), the Helical machining
strategy is suitable for steep areas machining.
Max. ramp angle
Thisparameterdefinesthemaximumangle(measuredfromhorizontal)forramping.
The descent angle of the ramping helix will be no greater than this value.
Max. ramp angle
Step down

6. Passes
141
6.7.6 Radial machining
The Radial machining strategy enables you to generate a radial pattern of passes
rotated around a central point.
This machining strategy is most effective on areas that include shallow curved
surfaces and for model areas formed by revolution bodies, as the passes are spaced
along the XY-plane (Step over), and not the Z-plane (Step down). The Z-height
of each point along a radial pass is the same as the Z-height of the triangulated
surfaces, with adjustments made for applied thickness and tool definition.

142
Step over
Step over is the spacing between the
passes along the circumference of the
circle.
The passes are spaced according to the
Step over value measured along the circle
defined by the Maximum Radius value.
Center
You must specify the XY-position of
the center point of the radial pattern of
passes. The Radial passes will start or
end in this center point.
Step over
Center point

6. Passes
143
Angle
The minimum and maximum angles enables you to define start and end of the
pattern passes. These parameters control the angle span of the operation, that is,
how much of a complete circle will be machined.
The angles are measured relative to the X-axis in the center point in the
counterclockwise direction.
Radii
The maximum and minimum Radii values enable you to limit the tool path in the
radial direction.
The diagram above shows the effect of different minimum and maximum radii on
Radial passes.
Minimum Angle
Maximum Angle
Minimum Radius
Maximum Radius

144
YoucanusetheMinimumRadiusvaluetoprotectthepartfacesfromover-machining
in the central point and around it. Alternatively, you can define boundaries to limit
the machining.
Over-machining is visible at the center point:
The tool path is limited at the center point area using a boundary, or by increasing
the minimal radius value:
You can use another strategy (e.g. 3D Constant step over) to machine the central
area.
Tangential extension
This option enables you to extend the passes tangentially to the model faces by a
length defined by the Pass extension parameter (see topic 6.7.4).

6. Passes
145
6.7.7 Spiral machining
The Spiral machining strategy enables you to generate 3D spiral tool path over
your model. This strategy is optimal for model areas formed by revolution bodies.
The tool path is generated by projecting a planar spiral (located in the XY-plane of
the current Coordinate System) on the model.

146
Step over
The Step over parameter defines the distance between two adjacent spiral turns in
the XY-plane of the current Coordinate System.
Step over

6. Passes
147
Center
You have to specify the XY-position of the center point of the spiral. The spiral
tool path is calculated from this point, even if it does not actually start from there
(minimum radius may be set to a larger value).
Radii
Define the area to be machined by the spiral by setting the minimum and maximum
Radii. If the spiral is to start from the center point, set the Minimum Radius value
to 0. When the spiral is to start further from the center, enter the distance from the
center point by setting the Minimum Radius to a higher value. Control the overall
size of your spiral with the Maximum Radius value.
Center point
Maximum Radius
Minimum Radius

148
Clockwise
This option enables you to define the direction of the spiral. When this check
box is selected, SolidCAM generates a spiral tool path in the clockwise direction.
When this check box is not selected, SolidCAM generates a spiral tool path in the
counterclockwise direction.
Clockwise direction Counterclockwise direction

6. Passes
149
6.7.8 Morphed machining
Morphed machining passes are generated across the model faces in a close-to-
parallel formation, rather like Linear machining passes (see topic 2.6); each path
repeats the shape of the previous one and takes on some characteristics of the
next one, and so the passes "morph" or gradually change shape from one side of
the patch to the other.

150
The shape and direction of the patch is defined by two drive boundary curves.
Step over
This parameter defines the distance between each two adjacent passes and is
measured along the longest drive boundary curve; for the other drive boundary
curve the step over is calculated automatically. For best results, the two drive
boundaries should be as close in length as possible.
This machining strategy is most effective on areas that include shallow surfaces as
the passes are spaced along the XY-plane (Step over) and not the Z-plane (Step
down).

6. Passes
151
6.7.9 Offset cutting
The Clear offset parameters enable you to define the offset distance used for the
virtual offset curve calculation.
SolidCAM enables you to define separate values for the Left clear offset and Right
Clear offset.
Drive curve
Left clear offset
Right clear offset
Tool path

152
6.7.10 Rest machining parameters
Rest machining determines the model areas where material remain after the
machining by a tool path, and generates a set of passes to machine these areas.
Pencil milling vertical corners
can cause both the flute of the
tool and the radius to be in full
contactwiththematerial,creating
adverse cutting conditions. Rest
machining machines the corners
from the top down, resulting
in better machining technique.
Steep and shallow areas are both
machined in a single tool path,
with different Rest machining
strategies.
SolidCAM determines the rest material areas using a Reference tool
(the tool that is assumed to have already been used in the CAM-
Part machining) and a Target tool (the tool that is used for the Rest
machining). Both tools must be ball-nosed.

6. Passes
153
Bitangency angle
This parameter defines the minimum angle required between the two normals at
the contact points between the tool and model faces in order to perform the Rest
machining.
This value enables you to control the precision with which rest material areas are
found. Reducing the value will typically cause the system to find more areas due
to the triangle variations, however the most appropriate value will depend on the
geometry of the machined piece.
Steep threshold
This parameter enables you to specify the angle range at which SolidCAM splits
steep areas from shallow areas. The angle is measured from horizontal, so that 0°
represents a horizontal surface and 90° represents a vertical face.
Setting the value to 90° will mean that all areas in
this range will be treated as shallow and the passes
in the rest material areas will run along the corner.
Bitangency angle

154
Setting the value to 0° will mean that all areas in this
range will be treated as steep and the passes in the
rest material areas will run across the corner.
Setting the value to 45° will mean that areas where
the slope is between 0 and 45° will be treated as
shallow and the passes will run along the corner.
Areas where the slope is between 45 and 90° will
be treated as steep and the passes will run across
the corner.
Shallow strategy
This option enables you to choose the machining strategy to be used in shallow
areas (i.e. those below the Steep Threshold value). The following options are
available:
• Linear. This option enables you to perform links between passes using
straight line motions.
• Spiral. This option joins some passes using smooth curved paths. This
results in passes that are continuous, and reduces the use of linking
moves. The spiral linking move will cut across the corner, avoiding the
large volume of material that lies in the center of the rest area. Corner
areas may not be fully finished.
• Spiral on surface. This option links the passes with smooth curved paths
resulting in continuous passes and reducing the rapid moves. The spiral
linking move is projected into the rest corner up to the maximal depth
of the cut specified.

6. Passes
155
Min. depth of cut
This parameter specifies the minimum depth of material to be removed from the
areas to be machined. Areas in which the depth of material to be cut are less than
this will be ignored.
Min. depth of cut can also be useful in situations where a fillet radius
of the part is approximately equal to the radius of the reference tool,
i.e. places where, in theory, there is no material to be removed. If
unwanted passes are created in such areas, increasing the value of
Min. depth of cut may improve the situation.
Max. depth of cut
This parameter specifies the maximum depth of material that can be cut. Areas
in which the depth of material is greater than this value will be ignored. This
parameter is used to avoid situations where the cutter may otherwise attempt to
make deep cuts. This may result in some rest area material not being removed; by
creating further sets of Rest machining passes, using smaller reference tools, you
can clear such areas.
Areas
This option enables you to decide whether to perform
the machining in the steep areas only, in the shallow areas
only or in both of them.
• Shallow
The machining is performed only in the
shallow areas (the surface inclination is
smaller than the Steep threshold value).
• Steep
The machining is performed only in the steep areas (the surface
inclination is greater than the Steep threshold value).
• All
The machining is performed in both steep and shallow areas.

156
Stroke ordering
This option enables you to control how the passes are merged, in order to generate
better Rest machining passes. The available strategies are:
• None
Passes are not combined; uncut material might be left in corners where
several sets of passes converge.
• Planar
SolidCAM looks at the passes from the tool axis direction (from +Z)
and connects passes that have a direction change with an angle smaller
than the Max. deviation value.

6. Passes
157
• Angular
The system looks at the passes in 3D and connects passes that have a
direction change with an angle smaller than the Max. deviation value.
Max. deviation
When Rest machining passes approach a sharp change of direction,
they can be made continuous round the corner, or can be split into
separate segments. The value of Max. deviation is used to determine
whether the passes are split (if the angle of deviation of the passes
is larger than the Max. deviation value) or continuous (if the angle of
deviation of the passes is smaller than the Max. deviation value).
Reference tool page
This page enables you to define the reference tool used for the Rest machining
tool path calculation.
• The Diameter field defines
the diameter of the
reference tool.
• The Corner radius field
defines the corner radius of
the reference tool. Since the
reference tool is ball-nosed,
the corner radius is equal to
half of the reference tool
diameter.

158
6.7.11 3D Constant step over
3D Constant step over machining enables you generate 3D tool path on the CAM-
Part surfaces. The passes of the tool path are located at a constant distance from
each other, measured along the surface of the model.
This is an ideal strategy to use on
the boundaries generated by Rest
machining or in any case where
you want to ensure a constant
distance between passes along
the model faces.
Constant surface step over is
performed on a closed profile
of the Drive boundary (see topic
5.1.1). SolidCAM creates inward
offsets from this boundary.

6. Passes
159
Step over
This parameter enables you to define the distance between cutting passes. In 3D
Constant step over machining, the Step over value is calculated in such a way that
all passes are equidistant along the surface.
Step over

160
The Horizontal and Vertical Step over parameters determine the distance between
passes. The two step over types relate to the direction in which the step over is
being measured. Where passes are offset horizontally, the Horizontal step over
distance is used while for passes that are offset vertically, the Vertical step over
distance is used. Where the step direction is neither vertical nor horizontal, the an
average of the two values is used.
Limit Offsets number to
The Limit Offsets number to parameter enables you to limit the number of offsets
of a drive boundary profile. Choose the Limit Offsets number to check box and set
the offsets number.
Horizontal
Step over
Vertical
Step over

6. Passes
161
Horizontal Offsets
If the Horizontal Offsets check box is selected, the step over will be taken from
the horizontal plane only, that is, a 2D offset. With this option, only the Horizontal
Step over value is used, the Vertical Step over value is not relevant.
You can see from the illustration above that using this option on this model
creates only few passes on steep areas since the spacing is calculated only along
the horizontal plane; using this option is therefore not recommended for such
models.

162
6.7.12 Pencil milling
The Pencil milling strategy creates a tool path along internal corners and fillets
with small radii, removing material that was not reached by previous machining.
This strategy is used to finish corners which might otherwise have cusp marks left
from previous machining operations. This strategy is useful for machining corners
where the fillet radius is the same or smaller than the tool radius.

6. Passes
163
Bitangency angle
This is the minimum angle required between the two normals at the contact
points between the tool and model faces, in order to decide to perform the pencil
milling.
The default value of the
Bitangency angle parameter is
20°. Generally, with this value
SolidCAM detects all the corners
without fillets and with fillet radii
lessthenthetoolradius.Todetect
corners with fillets radii greater
thenthetoolradiusyoucaneither
use the Overthickness parameter
or decrease the Bitangency angle
value. Note that decreasing the
Bitangency angle value can result
in the occurrence of unnecessary
passes.
Overthickness
This parameter enables you to define an extra thickness that can be temporarily
applied to the tool in addition to the normal thickness.
You can use the Overthickness parameter to generate a tool path along fillets whose
radius is greater than the tool radius. For example, if you have a filleted corner of
radius 8 mm and you want to create a Pencil milling tool path along it with the 10
mm diameter ball-nosed tool, you can set the Overthickness value to 4 mm. The
Pencil milling tool path is calculated for a ball-nosed tool with the diameter of
18 mm (which will detect this fillet), and then projected back onto the surface to
make a tool path for the 10 mm diameter tool.
As this is a thickness value, it is specified in exactly the same manner as other
thicknesses, except that it is added to the defined tool size, in addition to any
surface thickness, during calculations.
Bitangency angle

164
6.7.13 Parallel pencil milling
Parallel pencil milling is a combination of the Pencil milling strategy and the 3D
Constant step over strategy. At the first stage, SolidCAM generates a Pencil milling
tool path. Then, the generated pencil milling passes are used to create 3D Constant
step over passes; the passes are generated as a number of offsets on both sides
of the pencil milling passes. In other words, the Parallel pencil milling strategy
performs 3D Constant step over machining using Pencil milling passes as drive
curves to define the shape of passes.
This is particularly useful when the previous cutting tool has not been able to
machine all the internal corner radii to size. The multiple passes generated by this
strategy will machine from the outside in to the corner, creating a good surface
finish.
The order of passes machining is determined by the Order parameters
(see topic 7.1.2).
In this combined strategy, you define the Pencil milling parameters and the 3D
Constant step over parameters in two separate pages.

6. Passes
165
Pencil milling parameters
The Pencil passes page enables you to define the parameters of the Pencil milling
passes (see topic 6.7.12).
3D Constant step over parameters
The Passes page defines the parameters of the 3D Constant step over passes (see
topic 6.7.11).

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6.7.14 3D Corner offset
The 3D Corner offset strategy is similar to the Parallel pencil milling strategy. This
strategy is also is a combination of Pencil milling strategy and 3D Constant step
over strategy. SolidCAM generates a Pencil milling tool path and uses it for the
3D Constant step over passes generation. These passes are generated as offsets
from the Pencil milling passes. In contrast to the Parallel pencil milling strategy, the
number of offsets is not defined by user, but determined automatically in such a
way that all the model inside a boundary will be machined.
The order of passes machining is determined by Order parameters
(see topic 7.1.2).
In this combined strategy you define the Pencil milling parameters and the 3D
Constant step over parameters in two separate pages.

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Pencil milling parameters
The Pencil passes page enables you to define the parameters of the Pencil milling
passes (see topic 6.7.12).
3D Constant step over parameters
The Passes page defines the parameters of the 3D Constant step over passes (see
topic 6.7.11).

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6.7.15 Combined strategy parameters
Constant Z combined with Horizontal strategy
The Constant Z passes page defines the parameters of the Constant Z machining
strategy.
The Horizontal passes page defines the parameters of the Horizontal machining
strategy.

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The following parameters defined on the Constant Z Passes page are automatically
assigned the same values on the Horizontal passes page:
• Thickness (see topic 6.1.1);
• Axial thickness (see topic 6.1.2);
• Tolerance (see topic 6.1.3);
• Limits (see topic 6.1.8);
• Smoothing parameters (see topic 6.2);
• Adaptive step down parameters (see topic 6.3);
• Edit passes parameters (see topic 6.4).
When these parameters are edited on the Constant Z passes page, their values
are updated automatically on the Horizontal passes page. But when edited on
the Horizontal passes pages, the values in the Constant Z passes page remain
unchanged.
Two Link pages located under the Constant Z passes and Horizontal passes pages
define the links relevant for each of these strategies.
On the Link page for Horizontal passes, there is the Machining order tab that enables
you to define the order in which the Constant Z and Horizontal machining will be
performed. The default option is Constant Z first.
When the tool has finished performing the passes of the first machining strategy,
it goes up to the Clearance level, then descends back to the machining surface to
continue with the next strategy.

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Constant Z combined with Linear strategy
strategy.
The Linear passes page defines the parameters of the Linear machining strategy.

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assigned the same values on the Linear passes page:
When these parameters are edited on the Constant Z passes page, their values are
updated automatically on the Linear passes page. But when edited on the Linear
passes page, the values in the Constant Z passes page remain unchanged.
Two Link pages located under the Constant Z passes and Linear passes pages
define the links relevant for each of these strategies.
On the Link page for Linear passes, there is the Machining order tab that enables
you to define the order in which the Constant Z and Linear machining will be
performed. The default option is Constant Z first.

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Constant Z combined with Constant Step over strategy
strategy.
The Constant Step over passes page defines the parameters of the Constant Step
over machining strategy.

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assigned the same values on the Constant Step over passes page:
When these parameters are edited on the Constant Z passes page, their values are
updated automatically on the Constant Step over page. But when edited on the
Linear passes page, the values in the Constant Z passes page remain unchanged.
Two Link pages located under the Constant Z passes and Constant Step over
passes pages define the links relevant for each of these strategies.
On the Link page for Constant Step over passes, there is the Machining order tab
that enables you to define the order in which the Constant Z and Constant Step
over machining will be performed. The default option is Constant Z first.

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6.8 Calculation Speed
The tool path for three tool basic tool types (end mill, ball-nosed mill and bull-
nosed ill) is calculated with completely different machining algorithms. This means
that the calculation speed may be different for the same operation and geometry
with a different tool type. For example, using a bull-nosed tool with a smaller
corner radius will result in a longer calculation time.
The calculation speed depend also on the tolerance. When you set a tolerance
for a tool path, this defines the worst tolerance; the actual tolerance may, in some
circumstances, be significantly tighter. This is particularly true for the Contour
roughing and Constant Z machining operations when a bull-nosed tool with a small
corner radius is used; the results are often more accurate than required and the
calculation is slower.
When a positive thickness is defined, the machining algorithm is executed for a tool
with larger corner and shaft radii than the original one. When a small thickness is
applied to an end mill, the tool used for the machining algorithm is bull-nosed with
a small corner radius. This tool with applied thickness has different algorithmic
characteristics, as mentioned above, and the calculation time may change.
The only other instance in which the tool type may change when applying a
thickness is when a negative thickness equal to or exceeding the corner radius is
applied to a bull-nosed tool. Then an end mill is used in the machining algorithm,
and a result may be produced much more quickly. However, there are instances
where applying a negative thickness which is significantly larger than the corner
radius does not produce satisfactory results, see note on Negative Thickness.

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The Link page in the HSM Operation dialog box enables you to define the way how
the generated passes are linked together into a tool path.
In the image the link movements
areingreen,therapidmovements
are in red and the machining
passes are in blue.
Following are the linking
parameters that can be defined
by the user:
• General parameters
• Ramping Parameters
• Strategy Parameters
• Retracts Parameters
• Leads Parameters
• Down/Up Mill parameters
• Refurbishment parameters
• Link Shaft Profile parameters

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7.1 General Parameters
The General page enables you to set the general parameters of the tool path
linking.
• Direction
• Order passes
• Retract
• Start Hint
• Minimize reverse linking
• Minimize full wide cuts
• Link by Z level
• Link per cluster
• Min. Profile Diameter
• Refurbishment
• Safety

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7.1.1 Direction options
This parameters group enables you to define the direction of the machining.
One Way
With this option, machining is performed in
one direction, but there is no guarantee that
this will be consistently climb or conventional
milling. It is up to the user to check the tool
path and respond by choosing the Reverse, if
needed, for the desired milling style.
A one way hatch path has many retractions;
after the machining pass the tool has to
perform air movement to the start point of
the next pass (shown in red).
• One way cutting with Radial
Machining strategy. The radial
arrows indicate the direction of the
passes themselves while the circular
arrow indicates the ordering of the
passes.
Machining pass
Linking pass

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• One way cutting with Spiral machining strategy.
The spiral pass is limited by a boundary. The
circular arrow indicates the direction of the
passes themselves while the radial arrow
indicates the ordering of the passes. Passes
are machined in a clockwise direction, moving
outwards.
• One way cutting with 3D Constant
Step over strategy. The passes are
limited by a boundary, with another
boundary inside it. The passes are
ordered in a one way direction to
perform climb milling. The inner
circulararrowindicatesthedirection
for the passes adjacent to the inner
boundaries.
The outer circular arrow indicates
the direction for outer boundaries.
In this example, most machining
passes are performed in anti-
clockwise direction, working from
the farthest offsets outwards to
the outer boundary, then rapidly
moving to machine the farthest
offset of the inner boundary and
working inwards towards the inner
boundary.

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Reverse
The Reverse option results in the direction of passes being reversed.
The example below shows one-way radial passes with the reversed direction; the
passes will be climb milled.
The example below shows a reversed one way spiral passes.

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Bi-directional
With this option, each pass is machined in the opposite direction to the previous
pass. A short linking motion (shown in green) connects the two ends - this is often
called zigzag machining.
Both Climb milling and Conventional milling methods are used in the bi-directional
tool path.
Machining pass
Linking pass
Bi-directional milling

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Bi-directional Radial machining:
Bi-directional Spiral machining:
Bi-directional 3D Constant Step over
machining:

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Down Mill/Up Mill
These options enables you to perform the machining downwards or upwards. Flat
pieces are machined in the direction defined by the Reverse parameter.
This option is available for strategies where the Z-level varies along
a pass. This option is not available for the Constant Z and Horizontal
strategies.
The Down/Up Mill page (see topic 7.6) enables you to define the parameters of the
down and up milling.
• Down Mill direction
• Up Mill direction

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The image below shows the direction of the Radial Machining passes when the
Down/Up Mill options are used.
Climb/Conventional Milling
These options enables you to set the tool path direction in such a manner that the
climb/conventional milling will be performed.
These options are available for the Contour Roughing, Constant Z and
Horizontal strategies.
Down mill
Up mill
Climb milling Conventional milling

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Prefer climb milling
This options is available for the Pencil Milling strategy.
If this option is selected, the Pencil Milling passes will usually be climb milled. A
decision is made as to whether the material is mainly on the left or the right of the
tool as it goes along a pass. The direction is then chosen so that most material is
on the right.
When this option is not selected, the milling direction for all the passes is reversed,
so that they will probably be conventionally milled.

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Direction for Hatch Roughing
Raster Passes
This section enables you to define the direction for the hatch (raster)
passes.
SolidCAM enables you to choose One way or Bi-directional direction
for the raster passes.
The Reverse order option enables you to reverse the order of the hatch
passes machining.
Profile Passes
This section enables you to define the direction for profile passes.
SolidCAM enables you to choose the Climb or Conventional direction
of the Profile passes.
Initial order Reversed order

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Direction for Rest Machining
Steep regions
This section enables you to define the direction of the steep areas
machining.
SolidCAM enables you to choose the following options.
• Climb milling
• Conventional milling
• Bi-directional

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7.1.2 Order passes
Some passes allow you to specify the direction of the pass ordering. When no
options are selected, the passes will be linked in an efficient way and so limit the
rapid travel between passes. Where several separate areas are machined, each area
will be machined to completion, before the machining of the next area is started.
The passes will be linked in the most efficient way. Below is shown a set of Linear
passes, linked in the default order (starting from the top left-hand corner) to
minimize the rapid travel between the passes.
Reverse Order
This option enables you to reverse
the order of the tool path relative to
the default order.
Simple Ordering
Passes will be linked in the order of
their creation. Parts of a specific pass
divided by a boundary will be linked
together with a rapid movement.
This option enables you to maintain
the order of the passes, but increases
the number of air movements.

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Order 3D Constant Step over passes
From first pass
When this option is turned off, the passes are machined from the
smallest of the outside boundary offsets to the outer boundary and
then from the largest offset of the internal boundary to the inside.
Whenthisoptionisturnedon,themachiningisperformedinthereverse
order. The machining starts from the internal boundary outside. After
that the machining is performed from the outer boundary inside.
If you reverse the order or the direction, then you will performing
conventional milling. If you reverse both, then you will be climb
milling again.

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Islands at same time
If the original boundaries had islands, SolidCAM will normally
machine inwards from the outer boundary, then outwards from the
island boundary.
With this option turned on, SolidCAM performs machining while
swapping between the outer and the island boundary offsets, ensuring
that each is never more than one pass ahead of the other.

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7.1.3 Retract
The image below shows a set of linked one way Hatch Roughing Passes along a
flat horizontal surface.
The tool path starts from the Start Hint point
thatissetattheSafetydistancelevel.Therapid
movements ( shown in red) are performed at
the Clearance level and above it. The tool
moves along the green lines towards, away
from, or along the surface, without cutting
(link movements). The blue lines show the
tool path when cutting is performed. The
tool path finished in the end point located at
the Safety distance level.
The Retract section enables you to define a
number of parameters of the start and end of
the tool path.
Start from home point/Return to home
point
These options enable SolidCAM to start/finish
the operation tool path in the specified home
point. The XYZ boxes defines the location of this point.
Clearance level
This field defines the plane where the rapid movements of the operation (between
passes) will be performed. The default Clearance level value generally equals to a
value approximately 5% above the upper point of the model.
Safety distance
This field defines the distance to the Upper level at which the tool will start moving
at the Z feed rate you have entered for the tool. Movements from the Clearance
level to this height are performed in rapid move.

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7.1.4 Start Hint
Enter the XY-coordinates of the starting position of the tool; the tool will move
to this position at the beginning of the tool path. The default value for the Start
Hint is the center of your model. On larger models, where there is a great distance
from the centre of the model and your current work area, you may want to change
these values. If there is more than one set of passes to be linked, the linking will
start with the passes closest to the start hint point.

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7.1.5 Minimize reverse linking
This option will reduce the amount of reverse linking on the tool path. It will also
ensure that the tool cutting direction is maintained when linking passes.
If this option is chosen, the linking moves within a Z-level will be adjusted to
maintain climb or conventional milling.
If this option is not chosen, linking moves may conventionally mill even though
climb milling is maintained for the passes and vice versa.
This option is only available if the Detect Core areas option (see topic
6.7.1) of the Contour Roughing strategy is enabled.

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7.1.6 Minimize full wide cuts
This option will reduce full width cuts wherever possible. This is useful because
full width cuts (those which have equal width to the tool diameter) are not
recommended in most machining situations.
This option is only available if the Detect Core areas option (see topic
6.7.1) of the Contour Roughing strategy is enabled.

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7.1.7 Link by Z level
The Link by Z level option enables you to perform all the passes at a specific Z
level before moving onto the next one. This will frequently result in occurrence of
air movements between different areas of the same Z-level.
By default the option is not chosen. It means that the passes are linked in such a
manner that each area is machined completely before moving to the next one.
This option is available for the Contour Roughing, Constant Z and
1
3
5
7
2
4
6
8
1
2
3
4
5
6
7
8
Link by Z levels = Yes Link by Z levels = No

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7.1.8 Link per cluster
When you link machining passes that are made up of several different clusters of
passes, in corners, for example, the Link per cluster option allows each corner to
be machined before the tool moves to another corner. If you do not select this
option, the machine may need to make a number of rapid feed rate moves to
connect the clusters of passes.
This option is available for the Contour Roughing, Hatch Roughing,
Rest Roughing and Horizontal strategies.

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7.1.9 Min. Profile Diameter
The diameter of a profile is its "span", which is the largest distance between
two points of the profile. Any profile that is smaller than this value will not be
machined to avoid difficulties in ramping the tool into this space. The default
Min. profile diameter value is slightly less than that of the flat part of the end mill
tool (and zero for ball-nosed tools).
For example, if the set of surfaces has a hole about the size of the tool you want to
use, you will get a column of profiles that appear to "fall" through the hole down
to the lowest Z level. If you do not want these profiles, you can use the Min. profile
diameter parameter.
This option is available for the Contour Roughing, Constant Z and

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7.1.10 Refurbishment
Min pass length
The Min pass length parameter enables you to define the minimal
length of the pass that will be linked. Passes with length less than
this parameter will not be linked. This option enables you to avoid
the machining of extremely short passes and increases the machining
performance.
This option is available for the Constant Z Machining.

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7.1.11 Safety
Max. stock thickness
The Max. stock thickness parameter enables you to control the order
of Constant Z machining of several cutting areas.
When the distance between cutting areas is smaller than the specified
Max. stock thickness value, the machining is ordered by cutting levels.
In this case SolidCAM machines all of these cutting areas at the specific
cutting level, and then moves down to the next level.
When the distance between cutting areas is greater than the specified
Max. stock thickness value, the machining is ordered by cutting areas.
In this case SolidCAM machines a specific cutting area at all of the
cutting levels, and then moves to the next cutting area.
This option is available for the Constant Z Machining.

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7.2 Ramping Parameters
The Ramping page enables you to control the ramping aspects of the tool path.
Ramping is used when the tool moves from one machining level down to the next
one; the tool moves downwards into the material at an angle.
This page is available for the Contour Roughing, Hatch Roughing,
Rest Roughing and Horizontal strategies.
Ramp height offset
Angle

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Max. ramp angle
The Ramp angle is calculated automatically and depends on the model geometry
and the tool type. The Max. ramp angle parameter enables you to limit this angle.
The dimensions and type of tool you are using and the power of your machine
tool will determine an appropriate ramp angle. The angle used on a profile will
often be shallower than this, as the ramp always steps forward by at least the shaft
radius of the tool.
If a profile is very small, then the angle used might have to be larger
than you specify. In this case you can avoid the machining of short
profiles with the Min. profile diameter (see topic 7.1.9) parameter
located in the General page.
Relative and absolute ramp height
SolidCAM enables you to define also the relative or absolute start position for the
ramp motion with the Ramp height offset/Ramp height parameter measured from
the Coordinate System origin.

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The following options are available:
• Relative height
With this option, the start position of the ramp motion for the upper
Constant Step over pass is defined relative to the first point of the pass
using the Ramp height offset parameter.
• Absolute height
With this option, the start position of the ramp motion is defined with
the absolute Ramp height value measured from the Coordinate System
origin.
Ramp height
CoordSys
Ramp height offset

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These options are available only for the 3D Constant Step over
machining, when Helix and Profile ramping strategies are used.
Ramp height offset
This parameter defines the height used in the ramping motion to the first upper
profile. It ensures that the tool has fully slowed down from rapid speeds before
touching the material so that it enters the material at a ramping angle.
SolidCAM enables you to perform the ramp movement either with a profile, or
with a helix (spiral).
Profile ramping
The tool performs the downward movements to the specific Z-level around the
contour of the profile.
Min. profile diameter to ramp on
SolidCAM enables you to avoid ramp movements along small profiles,
as a very tight tool motion would counterbalance any advantages gained
by ramping for the smoothness of transition; by setting a minimum
profile diameter ("span") you will be able to ensure that small profiles
will not be ramped down to.

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Helix ramping
The tool performs the downward movements to the specific Z-level in a corkscrew
fashion, ensuring a smooth movement. Helix ramping also puts less load on the
tool than profile ramping.
Helix diameter
This is the diameter of the ramping helix. In cases where the profile
is too small for a helix ramp of this diameter, Profile ramping will be
used.
Plunge ramping
The tool performs the downward movements to the specific Z-level in a vertical
movement.

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Strategy Parameters7.3
The Strategy page enables you to define the following parameters related to the
linking strategy.
• Stay on surface within
• Along surface
• Linking radius
• Link clearance
• Horizontal link clearance
• Trim to ramp advance

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7.3.1 Stay on surface within
The Stay on surface within parameter enables you
to control the way how the tool moves from the
end point of a pass to the start point of the next
one. When the distance between these points is
greater than the specified parameter value, the
tool movement is performed at the Clearance
plane, using rapid feed.
When the distance between the points is smaller than the parameter value, the tool
moves with cutting feed directly on the model face.
This option enables you to decrease the
number of air-movements between the passes
of the tool path.
To control the manner of the link movement
between passes, when the tool moves on
surface, use the Along surface option (see
topic 7.3.2).

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7.3.2 Along surface
Links between passes when the tool moves on the surface can be:
• Straight line
When this option is active, a direct
connection is made on the surface in
a straight line.
• Spline
When this option is active, a spline
connection is made along the
surface. The movement is smooth;
there are no sharp corners so there
is little change of speed of the tool
throughout the length of the link.
These options are available for the Linear Machining, Spiral
Machining, Radial Machining, Boundary Machining and Pencil
Milling strategies.

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Ramp when possible with angle
The Ramp when possible with angle option
enables you to perform the connection along the
surface at the specified angle.
Use Tangential Ramp
This option enables you to perform the angled link movements in
a smooth s-curve. With this option the transition between passes is
performed smoothly without sharp corners.
Ramp Angle
Ramp Angle

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Trim to ramp advance
This option enables you generate a helical
style finish when linking Constant Z passes.
When this check box is selected, the Constant Z pass above which
a ramp linking movement is performed is trimmed by the length of
the ramping move. In such a way a helical style tool path is generated,
avoiding the unnecessary cutting moves at the already machined areas
and maintaining a constant tool load.
When this check box is not selected, the whole Constant Z passes are
linked with the ramp movements.
The Ramp when possible with angle option only has effect
on passes that consist of closed loops at different Z-heights,
such as Constant Z and 3D Constant Step over passes.
Constant Z passes Ramp movements
Constant Z passes Ramp movements

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7.3.3 Linking radius
Using this parameter, SolidCAM enables you to generate s-curves linking the
adjacent closed passes of the contour machining. The value defines the radius
of the link arc. If you set the Linking Radius to 0 or turn off Smoothing then a
simpler, straight-lined route will link each loop.
When the radius is set to zero, straight line link movements are performed.
These options are available for Contour roughing and Horizontal
Machining.
Linking radius

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7.3.4 Link clearance
With this parameter, SolidCAM enables you to maintain a horizontal clearance
from the bounding profile when moving horizontally from one location to another.
The value defines the minimal distance from the bounding profile.
These options are available for the Contour roughing, Hatch roughing,
Rest roughing and Horizontal Machining.

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7.3.5 Horizontal link clearance
When the Detect Core areas (see topic 6.7.1) option is used, the Horizontal link
clearance parameter defines the distance outside of the material to perform
plunging.
These options are available for the Contour roughing, and Rest
roughing.

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7.4 Retracts Parameters
This page enables you to control retract movements between passes of the tool
path.
• Style
• Clearance
• Smoothing
• Curls
• Sister Tooling

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7.4.1 Style
The Style options enables you to define the way how the retract movements are
performed between passes.
Shortest route
The tool performs a direct movement from one pass to another. SolidCAM
generates a curved retract movement trajectory. The minimum height of the
retract movement is controlled by the Clear surface by parameter, and the curve's
profile is controlled by the Smoothing and Curls parameters.
This style is chosen by default, as it creates the shortest retract movements.
However, some machine tools are unable to rapid effectively along a curved path;
in these cases you can choose one of the other two retract styles.

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Minimal vertical retract
The tool moves vertically to the minimum Z-level where the safe rapid movement
can be performed, moves along this plane in a straight line and drops down
vertically to the start point of the ramp movement to the next pass. The minimum
height of the retract is controlled by the Clear surface by parameter.
Full vertical retract
The tool moves vertically up to the clearance plane, rapidly moves at this level in
a straight line, and drops down vertically to the start point of the ramp movement
to the next pass.

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7.4.2 Clearance
The Clearance parameters apply both to the lead in and the lead out components
of retract motions.
Clear surface within
This option affects the tool path when the Shortest route style is chosen. It
specifies the distance the tool moves away from the surface with the cutting feed
rate, before the rapid movement starts.
The distance is measured from the end of the lead out arc to the point where the
tool is guaranteed to be clear of the surface.
Clear surface by
This is the minimum distance by which the tool will be clear of the surface during
its rapid linking motion. All points of the tool – on both the tip and the side have
to avoid the surface by this distance.
For Minimal vertical retract motions, the tool lifts up to a height that ensures
clearance.
Clear surface by

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For Shortest route motions, the tool is lifted up above the surface to ensure the
clearance, then it performs rapid motion maintaining the Clear surface within
distance.
This clearance is applied in addition to any thickness that you have
already specified for the tool. In particular, with a negative thickness,
the clearance is above the reduced surface and not the real surface –
so you should set this value higher to prevent the tool from gouging
the surface.
Clear surface by

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7.4.3 Smoothing
Radius
SolidCAM enables to round sharp corners of the retract motions when the Shortest
route option is used by adding a vertical curve of a defined radius. This makes the
tool movement smoother and enables higher feed rates.
7.4.4 Curls
SolidCAM enables you to add arcs in the end if the
lead-out movements and in the beginning of the lead
in movements. The Curl over radius and Curl down
radius define the radii of these arcs.
The Curls options affect the tool path when the linking style is
Shortest route.
Radius
Rapid movement
Lead out movement Lead in movement
Curl down radius
Curl over radius
Cutting pass

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7.4.5 Sister Tooling
Use this option if you need to change the tool or the cutting inserts by hand, and
cannot use automated sister tooling.
This option performs a full retract when the tool or cutting inserts are near the
end of its optimal cutting life. The parameter value is the distance the tool can cut
before retracting.

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7.5 Leads Parameters
The parameters located on this page enable you to control the lead in and lead out
motions.
• Fitting
• Trimming
• Vertical leads
• Horizontal Leads
• Extensions
The Stay on surface within parameter located on the Strategy page
enables you to define the maximum distance between passes to stay
on the surface and when to perform a retract movement.
The style of the retract movement can be defined on the Retracts
page.

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7.5.1 Fitting
You define here how the lead in and lead out arcs of the retract movements fit to
the machining pass.
Machine the whole pass
With this option the complete pass is machined. The arc can be applied at the end
of the pass, without trimming of the pass.
Lead in/Lead out arc
Tool pass

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The arc can be inserted only if it can be done safely without gouging the part faces.
When the arc is conflicting with the model geometry, a straight vertical lead in/out
movement is performed.
Minimize trimming
This option enables you to perform the arc retract movement with minimal
possible trimming of the cutting tool pass. The retract pass is as close to the
surface as possible, maintaining a minimum distance from the surface to fit the arc
of the defined radius.
Fully trim pass
In cases where it is crucial to
prevent over-machining, this
is a good and cautious strategy
modification. The pass is
trimmed back so the entire arc
fits into it, but no nearer than a
full machine pass link would be.
Minimize trimming
Fully trim pass

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7.5.2 Trimming
When a lead arc is added to a horizontal machining pass, the length of pass
trimmed off will be at most the radius of the arc. However, when adding an arc
to a steep finishing pass, the length of pass trimmed (trimming distance) will be
much greater.
Such trimming of the passes can result in the occurrence of large unmachined
areas. To avoid this, SolidCAM enables you to limit the trimming distance with the
Max. Trimming Distance parameter. If the trimming distance exceeds this value,
then no arc is used; the whole pass is machined, and a straight vertical motion is
added.
This option affects the path when the Lead fitting is Minimize trimming
or Fully trim pass.
Trimming distance

224
7.5.3 Vertical leads
The Vertical leads parameters enable you to define the radius of the arcs located
in a vertical plane used to enter and leave the machining pass.
Rapid movement
Lead in radius
Lead out radius
Cutting pass

7. Links
225
7.5.4 Horizontal Leads
SolidCAM enables you to perform Horizontal
lead in/out movements to provide you with
smooth entering/exiting from the material.
Using horizontal leads the tool path can be set up
so that the tool approaches and leaves machining
passes tangentially using helical moves. Note that
if the requested radius (Lead in or Lead out) is
too large, then the horizontal lead is omitted, and
only vertical leads are used.
Lead in/out radius
These parameters enable you to define the radius of the arcs, located in a horizontal
plane, used to enter and leave the machining pass.
Lead in radius
Lead out radius

226
Max. ramp angle
SolidCAM enables you to perform ramp down movements during the arc lead
in. The Max. Ramp angle parameter enables you to limit the maximum angle
(measured from the horizontal plane) for ramping.
Ramp height offset
The ramp height offset is an extra height used in the ramping motion down from a
top profile. It ensures that the tool has fully slowed down from rapid speeds before
touching the material, and that it enters the material smoothly at the ramping
angle.
The Max. ramp angle and Ramp height offset parameters are available
for the Contour roughing, Hatch roughing, Rest roughing and Constant
Z strategies.
Ramp height offset
Ramp angle

7. Links
227
Lead out angle
SolidCAM enables you to perform inclined upwards movements during the arc
lead out. The Lead out angle parameter enables you to define the angle of inclined
lead out movement. The angle is measured from horizontal plane.
The Lead out angle parameter is available for the Contour roughing, Hatch roughing,
Rest roughing and Constant Z strategies.
Lead out angle

228
7.5.5 Extensions
Ramp in extension
The ramp in height offset is an extra height used in the ramping motion
down from a top profile. It ensures that the tool has fully slowed down
from rapid speeds before touching the material so that it enters the
material smoothly at the ramping angle.
Ramp out extension
The ramp out height offset is an extra height used in the ramping
motion. It ensures that the tool speeds up to rapid speeds gradually.

7. Links
229
7.6 Down/Up Mill parameters
This page enables you to define the parameters of the Down/Up milling.
This page is available for all strategies but Contour roughing, Hatch
roughing, Rest roughing, Horizontal Machining and Constant Z
machining.
Unless Down/Up milling options are chosen on the General page of
the linking dialog box, the parameters on this page are disabled.

230
Pass overlap
When a pass is broken in order to perform down and up movements, each segment
can be extended, from the point where pass segments are connected, so that they
overlap. This ensures a smoother finish.
Since both pass segments are extended by the Pass overlap value, the
actual length of overlap is twice the defined value.
No Pass overlap
Pass overlap Passes connect point

7. Links
231
Shallow angle
Model areas with the inclination angles less than the Shallow angle value are
considered as shallow. Such areas can be machined in either direction, as obviously
up or down milling is irrelevant, and in these areas the tool path will be less broken
up.
The image below illustrates the case when the inclination angles of the model
faces are greater than the defined Shallow angle value.
In the illustration below the Shallow angle value has been increased resulting in no
break up of the tool path.

232
Merge %
SolidCAM enables you to machine some segments of the tool path upwards
where downward movement is preferred, and vice versa, to avoid too much
fragmentation.
The Merge % parameter defines the limit length of the opposite segments as a
relative percentage of the whole pass. When the percentage of the segments length
where the direction of the machining to be changed is less than the defined value,
the direction will not be changed.
Maintain milling direction
This option affects the ordering of Linear, Radial, Spiral and 3D Constant Step over
passes. It ensures that all segments will either be climb milled or conventionally
milled, if selected.
When the Maintain milling direction check box is not selected, passes will be either
climb or conventional passes, depending on the relative position of the tool at the
time.

7. Links
233
7.7 Refurbishment parameters
This page enables you to define a number of parameters of the tool path
refurbishment.
Min. pass length
The Min. pass length parameter enables you to define the minimal length of the
pass that will be linked. Passes with length less than this parameter will not be
linked.
This option enables you to avoid the machining of extremely short passes and
increases the machining performance.

234
7.7.1 Spikes
Sometimes at the end of a pass,
where one surface is adjacent
to another at a very steep angle,
there is a sharp jump. This can
happen where the tool touches
a steep wall and is lifted to the
top, or where it "falls off" a high
ledge and drops to the bottom.
SolidCAMenablesyoutoremove
these spikes.
Remove Spikes
This option enables you to remove sharp jumps (spikes) from the tool path.
Max. acceptable angle
Spikes or jumps with an angle greater than this are removed from the
tool path. The angle is measured from the horizontal plane.
Spike
Spikes removed

7. Links
235
Remove End Spikes only
When this option is active, only spikes at the end of passes are removed. There
will be no spike removal on a looped pass if this option is active, as there is no
pass end.
Non-spike allowance
You can trim off any small horizontal areas left at the top or bottom
of the spike. The value here is the maximum length of horizontal pass
that will be removed from the tool path.
Horizontal passes at the top of spikes Horizontal passes trimmed

238
This page displays the non-technological parameters related to the HSM
operations.
8.1 Message
This field enables you to type a message that will appear in the generated GCode
file.
8.2 Extra parameters
This field is activated only when special operation
options have been implemented in the post-
processor you are using for this CAM-Part.
Click on the Parameters list button. The
Operation Options dialog box is displayed with
the additional parameters defined in the post-
processor.
G43G0 X-49.464 Y-38.768 Z12. S1000 M3
(Upper Face Milling)
(--------------------------)
(P-POCK-T2 - POCKET)
(--------------------------)
G0 X-49.464 Y-38.768
Z10.

240
The CD supplied together with this book contains the various CAM-Parts
illustrating the use of the SolidCAM HSM Module.
Examples #1 — #9 illustrate the usage of specific HSM strategies.
Examples #10 — #15 illustrate the use of several HSM machining strategies to
completely finish a part.
Copy the complete Examples folder to your hard drive. The SolidWorks files used
for exercises were prepared with SolidWorks2008.
The examples used in this book can also be downloaded from the SolidCAM web-
site http://www.solidcam.com.

9. Examples
241
Example #1: Rough Machining and Rest Roughing
This example illustrates the use of SolidCAM HSM roughing strategies for the
mold core machining.
• HSM_R_Cont_target_T1
This operation performs Contour roughing of the core model. The
Detect core areas option is used to perform the approach into the
material from outside.
• HSM_RestR_target_T2
This operation performs Rest roughing of the core model in the areas
where material is left after the previous Contour roughing operation.
• HSM_R_Lin_target_T1
This operation performs Hatch roughing of the core model; this
strategy can be used as an alternative to contour roughing for older
machine tools or softer materials.

242
Example #2: Constant Z, Helical and Horizontal Machining
This example illustrates the
use of Constant Z, Helical and
Horizontal strategies for the
machining of a mold core part.
• HSM_CZ_target_T1
This operation performs Constant Z Machining of the part with
constant Stepdown. The Max. Stock thickness parameter enables you
to perform the separate machining of the forming faces and the boss
faces.
• HSM_CZ_target_T1_1
This operation is a variation of the previous operation with the
Adaptive Stepdown option set.
• HSM_Helical_target_T1
This operation performs Helical Machining of the core faces.
• HSM_CZF_target_T2
This operation performs Horizontal Machining of the flat faces of the
part.

9. Examples
243
Example #3: Linear machining
This example illustrates the use of Linear strategy for the machining of a mold
core part.
• HSM_Lin_target_T1
This operation performs Linear Machining of the forming faces
of the mold core. This operation illustrates the use of Cross Linear
finishing in order to completely machine the model faces where the
Linear passes are sparsely spaced.

244
Example #4: Radial and Spiral machining
This example illustrates the use of Radial and Spiral machining strategies for the
machining of a bottle-bottom mold insert.
• HSM_Rad_target_T1
This operation performs Radial Machining of the forming faces of the
insert. The user-defined boundary is used to limit the tool path.
• HSM_Sp_target_T1
This operation performs Spiral Machining of the forming faces of
the insert. The user-defined boundary is used to limit the tool path.
The Simple ordering option is used to perform optimal ordering and
linking of the tool path.

9. Examples
245
Example #5: Morphed machining and Offset cutting
This example illustratestheuseof Morphed machining and Offsetcuttingstrategies
for the machining of a cavity part.
• HSM_Morph_target_T1
This operation performs Morphed Machining of the model faces.
• HSM_OffsetCut_target_T1
This operation illustrates the Offset Cutting strategy use for the parting
surface machining.

246
Example #6: Boundary machining
This example illustrates the use of Boundary Machining strategy for the machining
of the cylindrical part shown below.
• HSM_Bound_target_T1
This operation illustrates the use of Boundary Machining strategy for
the chamfering of model edges.
• HSM_Bound_target_T1_1
This operation illustrates the use of Boundary Machining strategy for
engraving on the model faces.

9. Examples
247
Example #7: Rest machining
This example illustrates the use of Rest Machining strategy for the electrode part
shown below.
• HSM_RM_target_T1
This operation illustrates the use of the Rest Machining strategy for
the machining of model corners.
This operation illustrates the use of the Boundary Machining strategy
for optimal finishing of filleted corners.

248
Example #8: 3D Constant Stepover machining
This example illustrates the use of 3D Constant Stepover Machining strategy for
the machining of the mold core shown below.
• HSM_CS_target_T1
This operation illustrates the use of 3D Constant Stepover strategy for
the machining of the parting face of the core.

9. Examples
249
Example #9: Pencil, Parallel Pencil and 3D Corner Offset
This example illustrates the use of Pencil, Parallel Pencil and 3D Corner Offset
strategies for the mold cavity shown below.
• HSM_Pen_target_T1
This operation illustrates the use of Pencil Milling strategy for the
machining of cavity corners in a single pass.
• HSM_PPen_target_T1
This operation illustrates the use of Parallel Pencil Milling strategy for
the machining of cavity corners in a number of passes.
• HSM_Crn_Ofs_target_T1
This operation illustrates the use of 3D Corner Offset strategy for the
machining of the cavity part.

250
Example #10: Mold Cavity Machining
This example illustrates the use of several SolidCAM HSM strategies to complete
the machining of the mold cavity shown below.
This operation performs contour roughing of the cavity. An end mill of
Ø20 is used with a stepdown of 2mm to perform fast and productive
roughing. The machining allowance of 0.5mm remain unmachined for
further semi-finish and finish operations.
This operation performs rest roughing of the cavity. A bull nosed
tool of Ø12 and corner radius of 1mm is used with a stepdown of
1mm to remove the steps left after the roughing. The same machining
allowance as in the roughing operation is used.
This operation performs 3D Constant Stepover semi-finishing of
the forming faces of the cavity. A ball nosed tool of Ø10 is used. A
machining allowance of 0.2mm remain unmachined for further finish
operations.

9. Examples
251
This operation uses a Rest Roughing strategy for the semi-finish
machining of the model areas left unmachined after the previous
operations. A ball nosed tool of Ø4 is used with a stepdown of 0.4mm.
A machining allowance of 0.2mm remain unmachined for further
finish operations.
This operation uses the Rest Machining strategy for finishing the model
corners. A ball nosed tool of Ø6 is used for the operation. A reference
tool of Ø10 is used to determine the model corners.
• HSM_Crn_Ofs_target_T6
The 3D Corner Offset strategy is used for the finish machining of the
cavity faces that are inside the constraint boundaries. The shape of
pencil milling passes, generated by this strategy, is used for the constant
stepover machining of the cavity faces. A ball nosed tool of Ø6 is used
for the operation.
The Linear strategy is used to complete the finish machining of the
planar faces of the cavity that were not machined by the previous
operation. A ball nosed tool of Ø6 is used for the operation.
The 3D Constant Stepover strategy is used for the finish machining
of the blind cut on the cavity face. A ball nosed tool of Ø4 is used for
the operation.
• HSM_PPen_target_T8
The Parallel Pencil Milling strategy is used for the finish machining
of the cavity corners in a number of steps. A ball nosed tool of Ø3 is
used for the operation.

252
Example #11: Aerospace part machining
the machining of the aerospace part shown below.
• F_profile_T1
This operation performs preliminary roughing using the Profile
operation. An end mill of Ø12 is used.
This operation performs the contour roughing of the part. An end mill
of Ø12 is used with a stepdown of 2mm to perform fast and productive
roughing. A machining allowance of 0.5mm remain unmachined for
further semi-finish and finish operations.
This operation performs Constant Z finishing of the steep model
faces. A bull nosed tool of Ø8 and corner radius of 0.5mm is used for
the operation.

9. Examples
253
• HSM_CZF_target_T3
This operation performs Horizontal Machining of the flat faces. A
bull nosed tool of Ø8 and corner radius of 0.5mm is used for the
operation.
This operation performs Constant Z finishing of the side fillet and
chamfer faces using the Adaptive Stepdown option to perform the
machining with the necessary scallop. A ball nosed tool of Ø4 is used
for the operation.
This operation uses Boundary Machining strategy for the engraving on
the model faces with a chamfer mill.

254
Example #12: Electronic box machining
the machining of the electronic box shown below.
• HSM_R_Cont_target1_T1
This operation performs the contour roughing of the part. An end
mill of Ø30 is used with a stepdown of 10mm to perform fast and
productive roughing. A machining allowance of 0.5mm remain
unmachined for further semi-finish and finish operations.
• HSM_RestR_target1_T2
This operation performs the rest roughing of the part. A bull nosed
tool of Ø16 and corner radius of 1mm is used with a stepdown of
5mm to remove the steps left after the roughing. The same machining
This operation performs Constant Z finishing of the upper vertical
model faces upto a certain depth. A bull nosed tool of Ø12 and corner
radius of 0.5mm is used.

9. Examples
255
• HSM_CZ_target_T3_1
This operation performs Constant Z finishing of the bottom vertical
model faces. A bull nosed tool of Ø12 and corner radius of 0.5mm is
used.
• HSM_CZF_target1_T3
This operation performs Horizontal Machining of the flat faces. A
bull nosed tool of Ø12 and corner radius of 0.5mm is used.
• HSM_CZ_target1_T4
This operation performs Constant Z Machining of the inclined faces.
A taper mill of 12° angle is used to perform the machining of the
inclined face with large stepdown (10mm). Using such a tool enables
you to increase the productivity of the operation.

256
Example #13: Mold insert machining
This example illustrates the use of several
SolidCAM HSM strategies to complete
the machining of the mold insert.
• HSM_R_Cont_model_T1
This operation performs
contour roughing of the
part. An end mill of Ø25
is used with a stepdown
of 3 mm. A machining
allowance of 0.5mm remain unmachined for further semi-finish and
finish operations. The Detect core areas option is used to perform the
approach into the material from outside.
• HSM_RestR_model_T2
This operation performs rest roughing of the part. A bull nosed tool
of Ø12 and corner radius of 2mm is used with a stepdown of 1.5mm
to remove the steps left after the roughing. The same machining
• HSM_CZ_model_T4
This operation performs Constant Z semi-finishing of the steep faces
(from 40° to 90°). A ball nosed tool of Ø8 is used for the operation. A
operations.
• HSM_Lin_model_T4
This operation performs Linear semi-finishing of the shallow faces
operations.

9. Examples
257
• HSM_RM_model_T5
This operation uses the Rest Machining strategy for semi-finishing of
the model corners. The semi-finishing of the model corners enables
you to avoid tool overload in the corner areas during further finishing.
A ball nosed tool of Ø6 is used for the operation. A reference tool of
Ø8 is used to determine the model corners. A machining allowance of
0.2mm remain unmachined for further finish operations.
• HSM_CZ_model_T5
This operation performs Constant Z finishing of the steep faces (from
40° to 90°). A ball nosed tool of Ø6 is used for the operation. The
Apply fillet surfaces option is used to generate a smooth tool path and
to avoid a sharp direction changes in the model corners.
• HSM_Lin_model_T5
This operation performs Linear finishing of the shallow faces (from 0°
to 42°). A ball nosed tool of Ø6 is used for the operation. The Apply
fillet surfaces option is used to generate a smooth tool path and to
avoid a sharp direction changes in the model corners.
• HSM_CZF_model_T6
This operation performs Horizontal Machining of the flat face. An
end mill of Ø16 is used.
• HSM_CS_model_T7
This operation performs 3D Constant Stepover Machining of the
insert bottom faces; since these faces are horizontal, the machining is
limited to an angle range from 0° to 2°. A ball nosed tool of Ø4 is used
for the operation.
• HSM_RM_model_T7
This operation uses the Rest Machining strategy for finishing of the
model corners. A ball nosed tool of Ø4 is used for the operation. A
reference tool of Ø7.5 is used to determine the model corners.

258
Example #14: Mold cavity machining
the machining of the mold cavity shown below.
This operation performs contour roughing of the cavity. An end mill
of Ø20 is used with a stepdown of 3mm. A machining allowance
of 0.5mm remain unmachined for further semi-finish and finish
operations.
This operation performs rest roughing of the cavity. A bull nosed tool
of Ø12 and corner radius of 2mm is used with a stepdown of 1.5mm
to remove the steps left after the roughing. The same machining
allowance as in roughing operation is used.
This operation performs Constant Z semi-finishing of the steep faces
(from 40° to 90°). A ball nosed tool of Ø10 is used for the operation.
A machining allowance of 0.25mm remain unmachined for further
finish operations. The Apply fillet surfaces option is used.

9. Examples
259
This operation performs Linear semi-finishing of the shallow faces
operations. The Apply fillet surfaces option is used.
Ø12 is used to determine the model corners. A machining allowance
of 0.25mm remain unmachined for further finish operations.
Apply fillet surfaces option is used.
fillet surfaces option is used.
reference tool of Ø10 is used to determine the model corners.
This operation uses Boundary Machining strategy for the
chamfering of upper model edges. A chamfer drill tool is used for the
operation. The chamfer is defined by the external offset of the drive
boundary and by the Axial thickness parameter.

260
Example #15: Mold core machining
the machining of the mold core shown below.
This operation performs contour roughing of the core. An end mill of
Ø20 is used with a stepdown of 4 mm to perform fast and productive
roughing. A machining allowance of 0.5mm remain unmachined for
further semi-finish and finish operations. The Detect core areas option
is used to perform the approach into the material from outside.
This operation performs rest roughing of the core. A bull nosed tool
of Ø12 and corner radius of 2mm is used with a stepdown of 2mm to
remove the steps left after the roughing. The same machining allowance
as in roughing operation is used. The Detect core areas option is used
to perform the approach into the material from outside.
This operation performs Linear semi-finishing of the core faces. A ball
nosed tool of Ø10 is used for the operation. A machining allowance
of 0.2mm remain unmachined for further finish operations. The Apply

9. Examples
261
Ø12 is used to determine the model corners. A machining allowance
of 0.2mm remain unmachined for further finish operations.
Apply fillet surfaces option is used.
reference tool of Ø10 is used to determine the model corners.
This operation uses Boundary Machining strategy for the chamfering
of upper model edges. A chamfer drill tool is used for the operation.
The chamfer is defined by the external offset of the drive boundary
and by the Axial thickness parameter.

263
Index
Index
Symbols
2D manually created boundaries 74
3D Constant step over 158
3D Constant Step over 35
3D Constant Step over parameters 165, 167
3D Corner Offset 38, 166
3D User defined boundaries 86
A
Absolute height 202
Across option 60
Along option 60
Along surface options 207
Angle 28, 87, 130, 135, 143
Aperture 77
Apply fillets 46
Areas 155
Auto-created box of stock geometry 65, 71
Auto-created box of target geometry 65, 70
Auto-created outer silhouette 65, 73
Auto-created silhouette 65, 72
Automatically created boundaries 65, 70
Axial Thickness 89
B
Bi-directional 181
Bi-directional Radial machining 182
Bi-directional Spiral machining 182
Bitangency angle 49, 153, 163
Boolean Operations dialog box 80
Boundaries definition 15
Boundary box 66, 74
Boundary Definition 65
Boundary Machining 33
Boundary type 65

264
C
Calculation Speed 174
Center 142, 147
Center Point 96
Check faces 91
Clearance level 191
Clearance parameters 216
Clear direction 61
Clear surface by 216
Clear surface within 216
Climb milling 181, 184
Clockwise direction 148
Combined boundary 66, 80
Combined strategies 21, 39
Combined strategy parameters 168
Constant Step over passes 172
Constant Z combined with Constant Step over strategy 172
Constant Z combined with Horizontal strategy 168
Constant Z combined with Linear strategy 170
Constant Z Machining 25
Constant Z passes 168, 170, 172
Constrain parameters 96
Constraint boundaries 63
Contact Areas Only 87
Contact Point 97
Contour roughing 22, 127
Conventional milling 181, 184
CoordSys 43
CoordSys Data dialog box 43
CoordSys Manager dialog box 43
Counterclockwise direction 148
Created manually 66
Cross Linear Machining 28, 138
Curls 218
Curve 61
Cutting direction 60, 62
Cutting feed 56

265
Index
D
Detect Core areas 128, 193, 194, 212
Direction for Hatch Roughing 186
Direction for Rest Machining 187
Direction options 178
Down Mill 183
Down Mill parameters 229
Drive boundaries 33
Drive Boundaries 58
Drive boundaries for Morphed Machining 59
Drive boundaries for Offset cutting 61
Drive faces 91
E
Extensions 228
External 67
Extra parameters 238
F
Faces geometry 77
Facetting tolerance 44
Feed Rate 56
Filleting Tool Data 48
Fillet surfaces 45
Fillet surfaces dialog box 47
Finishing strategies 20
Fitting options 221
From first pass 189
Full vertical retract 215
Fully Trim Pass 222
G
General Link Parameters 177
Geometry 44
Geometry definition 15, 43

266
H
Hatch roughing 23, 129
Helical machining 26, 139
Helix diameter 204
Helix ramping 204
Holder Clearance 55
Horizontal Leads 225
Horizontal link clearance 212
Horizontal Machining 27
Horizontal Offsets 161
Horizontal passes 168
Horizontal Step over 160
I
Include Corner Fillets option 94
Internal 67
Intersect operation 82
Islands at same time 190
L
Lead in radius 225
Lead out angle 227
Lead out radius 225
Leads Parameters 220
Left clear offset 151
Limit Offsets number to 160
Linear Machining 28, 134
Linear passes 170
Link 176
Link by Z level 195
Link clearance 211
Link down feed 56
Linking radius 210
Link parameters 15
Link per cluster 196
Link up feed 56

267
Index
M
Machine the whole pass 221
Maintain milling direction 232
Max. acceptable angle 234
Max. depth of cut 155
Max. deviation 157
Maximum Radius 147
Max. ramp angle 201, 226
Max. stock thickness 199
Max. Trimming Distance 223
Merge % 232
Merge operation 81
Message 238
Middle 67
Min. depth of cut 155
Min diameter 77, 89
Minimal vertical retract 215, 216
Minimise Trimming 222
Minimize full wide cuts 194
Minimize reverse linking 193
Minimum Radius 147
Minimum Radius parameter 144
Min Material 98
Min material depth 94
Min pass length 198
Min. pass length 233
Min. Profile Diameter 197
Min. profile diameter to ramp on 203
Miscellaneous parameters 15
Morphed Machining 31, 149
N
Negative Thickness 174
Non-spike allowance 235

268
O
Offset 27, 63, 69, 89, 131
Offset cutting 32, 151
One Way 178
One way cutting with 3D Constant Step over strategy 179
One way cutting with Spiral machining strategy 179
Operation Options dialog box 238
Order passes 188
Overthickness 96, 163
P
Parallel Pencil Milling 37, 164
Parameter Info 17
Parameters 16
Parameters list 238
Part Tool Table 15, 53
Passes definition 15
Pass overlap 230
Pencil Milling 36, 162
Pencil Milling parameters 165, 167
Plunge ramping 204
Prefer climb milling option 185
Previous operations 133
Profile Geometry 66, 79
Profile Passes 186
Profile ramping 203
R
Radial Machining 29, 141
Radius 218
Ramp height offset 203, 226
Ramp in extension 228
Ramping Parameters 200
Ramp out extension 228
Ramp when possible with angle 208, 209
Rapid feed 56
Raster Passes 186

269
Index
Reference Tool 94
Refurbishment 198
Refurbishment parameters 233
Relative and absolute ramp height 201
Relative height 202
Remove End Spikes only 235
Remove Spikes 234
Resolution 49, 77, 89
Rest areas 66, 97
Rest Machining 34
Rest Machining parameters 152
Rest roughing 24, 132
Retract 191
Retracts Parameters 213
Retract Style 214
Return to home point 191
Reverse Order 188
Right Clear offset 151
Roughing strategies 20
S
Safety 199
Safety distance 191
Select Chain dialog box 85
Selected faces 66, 90
Select Faces dialog box 84
Shallow angle 231
Shallow areas 66, 92, 155
Shallow strategy 154
Shortest route 214, 217
Silhouette boundary 66, 76
Simple Ordering 188
Sister Tooling 219
Smoothing parameters 218
Spikes 234
Spin 56
Spiral Machining 30, 145
Spiral on surface 154

270
Spline 207
Start from home point 191
Start Hint 192
Start HSM Operation 13
Stay on surface within 206
Steep areas 155
Steep regions 187
Steep threshold 153
Step down 22, 23, 25, 127, 129
Step over 28, 142, 150, 159
Straight line 207
Strategy parameters 126
Stroke ordering 156
Subtract operation 82
T
Tangent 68
Tangential extension 135, 144
The boundary will be created on 75, 77, 86
Theoretical Rest areas 93
Theoretical Rest Areas 66, 93
Thickness 33, 88
Tool Contact Area 66, 95
Tool on working area 67
Tool selection 53
Trimming 223
Trim to ramp advance 209
U
Unfold 17
Union operation 81
Up Mill 183
Up Mill parameters 229
User-defined boundary 66, 78
Use Tangential Ramp 208

271
Index
V
Vertical leads 224
Vertical Step over 160
View Parameter Info 17
Z
Z Limits 87

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