The 7th International Conference on Engineering and Technology
ICET-2015, Phuket, June 19-20, 2015
Prince of Songkla University, Faculty of Engineering
Hat Yai, Songkhla, Thailand 90112
Using Advanced CAM System in Modern
Machining
Abstract – Goal of this paper highlight characteristics
and spectrum of machining cutting sequences that
programming system SolidCAM support. The practical
goal of this paper is defining post-processor and
machine simulation for 3-axis CNC machine like a tool
for verification modern tool-path and generation G-code
that will be used for cutting real part.
Key Words: Post-processor / Verification /SolidCAM
1. INTRODUCTION
The technology of machining is the main production
process in the mechanical industry and is one of the most
important production processes. In the last two decades,
there is a clear trend in the industry: "do more with less
time." To achieve this goal idustry’s main focus is to
reduce time needed for desing and manufacture final
product. Intensive development of new technologies
requires the design and integration of key processes in
manufacturing companies with modern concepts,
methods, techniques, tools and information technology.
The main role of information technology is to support
business operations, management decision making and
support in achieving the strategic advantages of
enterprises through the application of the CIM concept.
One of the main characteristics of modern production is
computer integrated manufacturing (CIM) and computer
aided management of production process. The most
important activity for successful exploitation of NC/CNC
machines is programming technological cutting
processes using CAD/CAM systems. Today on the
market, there are many software solutions that develop
modules for high speed and high productive machining.
One of the software solutions that follow the trends of
modern machining is SolidCAM, representing unique
solution in the field of CAM technology. His direction
and development strives to integrate with other CAD
(eng. "Computer Aided Design") softwares that allows
using geometric information of 3D models itself. Such
CAD software solutions are SolidWorks and AutoDesk
Inventor with solutions SolidCAM and InventorCAM
(Fig. 1).
Fig. 1. SolidCAM logo
2. CHARACTERISTICS OF SOLIDCAM
PROGRAMMING SYSTEM AS INTEGRATED
SOLUTIONS OF SOLIDWORKS
2.1. Introduction to SolidCAM
One of the practical goal working in SolidCAM is to
generate NC files in order to control CNC machines.
SolidCAM enable users to in interactive way define all
technological sequences required to generate and NC
file. To achieve that goal users first needs to past through
logical steps of SolidCAM which starts from defining
CNC machine and ends with generation of G-code for
specific machine. SolidCAM consist of four modules
that are develop to meet the needs of both, small and
large production systems. That modules are:
•
•
•
•
Milling
Turning
Mill-Turn
Wire Cut
Definition of CAMPart with the file extension <.prz>
includes several stages by defining the type of CNC
machine/controller, coordinate system definition, 3D
models of stock and a 3D model of the workpiece (Fig.
2).
3. MILLING AND TURNING IN SOLIDCAM
General situation in conventional machining
processes is that milling and turning are still the most
common machining processes and cutting technologies,
therefore they are also most developed in CAM systems.
Figure 3. shows all milling operations that are supported
in SolidCAM which include 2.5D, 3-axis and 5-axis
milling.
Figure 4. shows the all turning operations that are
supported by SolidCAM.
All turning and milling operations supported by
SolidCAM, stages from definition of operation until
generation of tool-path are well explained in details in
this paper.
Fig. 2. Structure and CAMPart definition process
Fig. 3. Typical operations of milling in SolidCAM
.
Fig. 4. Typical procedures in SolidCAM turning-in
4. TOOL-PATH SIMULATION IN SOLIDCAM
Practically speaking goal of CAM softwares is to
define operations and with defined tool-path generate NC
program that will be loaded on particular control unit and
kinematic of machine, but before NC program is even
generated there is a needs for verification of generated
tool-path. Verification of tool-path can be achieved using
CAM capabilities and their environment, therefore
SolidCAM depending on the object of simulation, offers
several types of simulation as follows: HOST CAD, 2D,
3D,
SOLIDVERIFY,
SOLIDVERIFY
3D,
RAPIDVERIFY, REST MATERIAL, TURNING,
MACHINE SIMULATION.
Simulations can avoid problems such as improper
definition of operations, collisions check with tools and
workpiece, machine elements, clamping fixtures and
others. Figure 5. shows the "HOST CAD" simulation
environment that shows material removal (eng. "Solid
Verification"), display of 3D tools, tool holders,
clamping fixtures, 3D models of preparation, and most
important, simulation and verification of the tool-path is
executed in SolidWorks environment.
Table 1 shows the dimensions HEIZ HIGH-Z S-1000 / T
machine tools.
Table 1. Dimensions HIGH-Z S-1000 / T machine tools
MODEL HIGH - Z
S-1000
Length
L
mm
1350
Width
B
mm
840
Height
H
mm
550
Work top
mm
1330x690
X
mm
1000
Work space
Y
mm
600
Z
mm
110
Weight
kg
41
To define machine simulation it is necessary to have
a 3D Models of CNC machine assembly in the STL
format. SolidWorks allows exporting of 3D models into
STL format. Number of parts in machine assembly has to
be optimal, and defined only parts that affect on the
collision detection.
Figure 7 shows an assembly of HEIZ HIGH-Z S1000 / T CNC machine in SolidWorks environment.
Fig. 5. HOST CAD simulation in SolidWorks
environment
5. DEVELOPMENT OF MACHINE SIMULATION
FOR EXACT CNC MACHINE
"Machine simulation" is perhaps the most important
simulation and verification of tool-path before CN
program (G-Code) is ever generated, because it allows
verification tool-path in virtual CNC machine
environment for collision check. Cause of mentioned
practical importance in this paper was desribed the steps
for defining machine simulation on real 3-axis CNC
machine HEIZ HIGH-Z S-1000 / T in SolidCAM
environment (Fig. 6.).
Fig. 7. Machine assembly defined in SolidWorks
environment
MachSim is internal SolidCAM tool that allows
users to define machine simulation passing through
several phases, which are more explained in details in the
paper:
•
•
•
•
•
•
•
definition of machine simulation name
definition of fixed (non- movable) parts of machine
definition of the vector of linear axis of machine
defining the mounting position of cutting tools
defining the position of workpiece and coord. system
defining dynamic clamping fixtures
defining the dynamic geometry of the workpiece, the
stock and tool-path display in the simulation
6. POST-PROCESSORS AND G-CODE
GENERATION IN SOLIDCAM
The first step in definition of CAMPart is a selection
of CNC machine (Control Unit), i.e. the selection of
post-processor. The term "post-processor" can be defined
as a programming language interpreter by SolidCAM in
recognizable form that the control unit of CNC machine
understand. One SolidCAM's post-processor consists of
three files with the extension:
Fig. 6. HEIZ HIGH-Z S-1000 / T machine tool



GPP
PRP
VMID
GPP files (eng. "General Post-Processor) is defined
in procedures where parameters of operation and
defined and tool-path can process and generate a G-code.
GPP file has a series of procedures and parameters
printed by the rules GPPL-a (eng. "General Post
Processor Language"), internal programming language of
SolidCAM. This file can be generated and edited using a
simple text editor.
PRP file (eng. "Pre-Processor Parameters") consists
of a group of parameters that affect on the trace of
procedures in GPPL itself. The types of the parameters in
the PRP file can be:
•
integers (-999999999, +999999999)
•
numeric (-1.E300, + 1.E300)
•
logical - TRUE (1) or FALSE (0)
•
literal (contains any character ASCII)
The GPP and PRP files can be defined using a simple
text editor.
VMID (“Virtual Machine ID”) file allows users to
define all devices and kinematic parameters of CNC
machine. VMID basically has two goals, which is to link
the kinematic characteristics of the machine with defined
machine simulation and for complex CNC machines to
obtain accurate values of the position for linear and
rotary axis in the G-code.
As an example of the post-processor 3-axis CNC
milling machine HEIZ HIGH-Z S-1000/T is chosen.
There are defined three files:



High-Z_S-1000T_WINPC_3X.gpp
High-Z_S-1000T_WINPC_3X.prp
High-Z_S-1000T_WINPC_3X.vmid
For specific workpiece dimensions 300x300x31mm,
wood box stock was selected with dimensions
350x350x35mm. The cutting logic is defined in one
machine setup, or fifteen (15) operations in which one
(1) is rough, one (1) semi-finish, eleven (11) finishing
and two (2 ) cut-off operations. Cause of very complex
surfaces of the workpiece it is impossible to finish all
surfaces with 2.5D operations, therefore 3-axis
operations like HSR, HSM and HSS was used as high
speed machining operations of SolidCAM which are
explained in detail in this paper.
Fig. 9. Machine Simulation verification of tool-path
7.1 G-Code generation and live cutting
After verification of defined tool-path, G-code
generation and live cutting is next step to get a part.
Phases of G-code generation and definition of machine
setup are described in detail in this paper. Figure 10.
shows the CNC machine in action.
Due to the complexity of this area steps for definition of
post-processor can be found in this paper.
7. MAKING SPECIFIC PART ON HIGH-Z S1000/T MACHINE
The practical goal of this paper is to use theory
summarized in the previous chapters for the definition of
cutting sequences (operations) on specific part using
SolidCAM. Verification of tool-path will be done in a
predefined machine simulation of SolidCAM (Figure
10), and G-code is generated with the already defined
postprocessor for HEIZ HIGH-Z S-1000/T CNC
machine. Defined 3D model (workpiece) present
modified logo of the Faculty of Technical Sciences,
which is projected on bended surface (Figure 8).
Fig. 10. CNC machine live cut
8. CONCLUSION
The primary objective of this paper is to point onto
the latest generation of integrated CAM software
solutions that provide efficient, fast and reliable
definition of technological cutting operations with
modern tool-path generation and the secondary, to show
it's possibilities of programming on real part.
9. REFERENCES
[1]
[2]
[3]
Fig. 8. 3D model of part
GPPTool Help, User Guide; SolidCAM2014
M. Sekulić, „Advanced Machining“, Script,
Faculty of Technical Sciences, Novi Sad, 2012.
M. Gostimirović, „Machining processes
database“, Faculty of Technical Sciences, Novi
Sad, 2013