Instead of one-way (trochoidal-like) tool paths, you can choose to perform Climb or Conventional cutting with a Zigzag tool path to connect the cuts. When machining narrow passages, separating channels and tight corners, the cutting direction changes from cut to cut containing both climb and conventional movements.

The Step down defines the axial depth of cut for the operation. The value displayed in the locked text field corresponds to the largest Step down (if there are multiple steps with different depths) shown in the output grid on the Technology Wizard page.

The Tool path parameter defines the accuracy of the tool path generation by affecting the number of single steps in the tool path. By default, this value is automatically calculated based on the current tool diameter.

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Cutting speed, also known as surface speed, refers to the speed at the outside edge of the tool as it is cutting. It is measured in surface feet per minute (SFM). Cutting speed is mainly depending on the type of materials and cutting tools, related to their hardness. The harder the material, the slower the cutting speed should be. The higher the hardness of cutting tool or drill, the faster the cutting speed recommended. In addition, the cutter in larger size has greater surface speed when it is turning at the same revolutions per minute as the smaller tool. The relationship (calculation formula) between RPM and Spindle RPM = SFM/Tool Diameter X 3.82 x tooling correction factor.

The Conventional option enables you to perform a similar style tool path as the aforementioned but in the opposite direction.

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Geometry – clicking this button opens the Modify Geometry dialog box that enables you to offset any one or more chains in the defined geometry.

If you have a preferred value for semi-finishing, it can be manually entered after selecting the Offset override check box.

Lathespeeds and feeds chart

The iMachining technology automatically calculates most of the technological parameters according to many factors. You can modify the defaults as well as define tool path parameters and options that are specific to the iMachining 2D or iMachining 3D Technology types.

This option enables you to machine all semi-open and open pocket areas with one iMachining 3D operation using your high performance end mill. For the closed pocket areas that require a helical entry, you can define a separate operation using a standard end mill.

When opening 2013 and earlier CAM-Parts in SolidCAM 2021, if the Finish floors option was enabled in the Offsets section of an operation, then a Floor offset of 0 is automatically specified for that operation.

1. Materials: cutting speed for aluminum, brass, bronze, cast iron, magnesium, copper, stainless steel, carbon steel, titanium, etc.

When opening 2015 and earlier CAM-Parts in SolidCAM 2021, the Wall/island offset and Floor offset values will be kept in existing iMachining 2D operations.

This option adds a semi-finishing cut to the operation. The Offset parameter defines the machining allowance that will remain on the pocket walls/islands before executing the finish pass.

When the Wizard is in the Operation dialog box, the Cutting angles are shown with a icon because they need to be synchronized with the selected set of Cutting conditions. If you want to manually enter preferred values for the locked parameters, the Wizard can be turned to open the fields for editing.

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The third reason is to extend tool life to the maximum possible; because of this, a low Efficiency level is used since it is proven that a continuous spiral cut causes less wear on the tool than repeated short trochoidal-like cuts.

Unlike other SolidCAM operations, the cutting direction calculations in iMachining are unaffected by the operation geometry chains.

Preview – clicking this button displays a projection of the current geometry directly on the solid model. Depending on the Offset modification, one of the following icons will be displayed next to the Preview button:

For iRough and iRest, the specified Wall/island offset will remain on their respective contours after the floor finishing.

Wall/island offset – this parameter defines the machining allowance that will remain on the pocket walls/islands after a roughing (iRough) or rest machining (iRest) operation. For iRough + iFinish and iFinish, the finishing is executed in the same operation to remove the allowance. For iRest and iFinish, the Wall/island offset value is inherited from the Previous wall offset of the Parent operation with an available override.

The second reason is to gain a higher global efficiency for the whole pocket or part; because of this, the iMachining technology is willing to sacrifice a little in the local efficiency of a specific spiral by using a default Efficiency level of 6.

A smaller value will result in less deviation from the mathematical model, but the calculation time will be proportionately longer.

When you hover the mouse pointer over the Offset modification icons, a screen tip displays up to the first ten modified chains and their specified offsets.

End Millspeeds and feedscalculator

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In iMachining 3D, the parameters specified for the tool and the operation are used to calculate the single steps of the tool on the mathematical model, which results in a PCode file that is given the *.pj file extension. It later serves as input to the generation of the GCode file.

HSS End millSpeeds and Feeds Chart

Priorities and cost structure (relative cost per part of machine time, tooling and labor) are the determining factors for what level is best. Although it will increase the cycle time, a lower level is usually best when regularly using expensive tools.

In most cases, only positive values should be used. The offset can then be removed by further finishing operations (using the HSM module).

3. Please note the table is applicable for high speed steel tooling, when you use carbide tooling, increasing or decreasing the cutting speed based on cutting tool hardness, for example, multiply the listed speeds by a factor of 2 to 4, and the speed should be lower for carbon steel tool.

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There are three reasons why the iMachining technology permits control over the efficiency of the morphing spiral tool path:

Increasing the efficiency reduces the Step over variation permitted in the spiral, which makes the side steps in all directions more equal and accordingly producing a rounder spiral, looking more like a circle. The remaining areas are cleared with trochoidal-like cuts.

When using the iMachining technology, it is highly recommended to leave the Wizard On and utilize the optimal cutting angle and step over ranges that are provided. The Wizard automatically calculates these values and manages synchronization across step down, step over, spindle speed and feed rate.

iMachining 3D analyzes the Target model and then recognizes all its features and depths automatically. A single iMachining 3D operation removes all the volumes of material that can be removed using the selected tool. The iMachining 3D tool path consists of both Step down (roughing) and Step-up (rest roughing) passes.

The Entry rate slider enables you to control the rate at which the morphing spiral tool path first enters the material. The rate of entry is automatically set by the Technology Wizard in accordance with the Material Properties. The examples below illustrate the effect of using this slider.

By default, the iMachining technology performs Climb cutting with one-way (trochoidal-like) tool paths to machine narrow passages, separating channels and tight corners.

In CNC machining and manufacturing, cutting speed is critical to the operation result and has the greatest impact on tool life. Cutting speed is the spindle speed, while it can be regarded as the speed of tool or the work moves at the point of cut. Based on the different workpiece materials and cutting tools, select a proper cutting speed according to the cutting speed chart for different materials.

When the Wizard is in the Operation dialog box, the Step down is shown with a icon because it needs to be synchronized with the selected set of Cutting conditions. If you want to manually enter a preferred value, the Wizard can be turned to open the field for editing.

End millcuttingSpeedchart

The iMachining 3D tool path is calculated by first taking into account the tool plus Wall offset and then by offsetting the tool along the tool axis by the distance equal to the Floor offset.

The iMachining technology generates morphing spirals to clear a completely open or completely closed pocket area that does not have the shape of a circle. This means that it generates tool paths with different side steps in different directions.

When using the iMachining technology, it is highly recommended to leave the Wizard On and utilize the optimal step downs that are provided. The Wizard automatically calculates these values and manages synchronization across step down, step over, spindle speed and feed rate.

In the instance of a completely open pocket, where there are no walls or islands, an iRough operation alone can be defined to perform the rough and finish machining of the pocket floor.

Since the Technology Wizard adjusts the feed rate at every point along the tool path in order to maintain a constant cutting force on the tool, the actual loss in the average MRR is negligibly small or even zero. This greatly depends on the maximum feed rate the machine can achieve. With very slow machines, the Wizard cannot fully compensate for some of the very small side steps indicated by the morphing action, because the maximum feed rate of the machine is not high enough. In such cases, if your first priority is high average MRR, and long tool life is less of an issue, you can then limit the extent of the morphing action by selecting a higher level of spiral efficiency.

Decreasing the efficiency permits more use of the Step over range specified by the Technology Wizard. By managing to morph itself into narrower parts of the pocket, the spiral produced looks less like a circle and covers a greater part of the total area.

This section enables you to specify the Offsets for the operation relative to the iMachining 2D or iMachining 3D geometry selection.

All technologies support the Floor option, which enables you to define the finishing of the pocket floor. When selected, a finishing cut is executed to remove the Floor offset. A Floor offset value greater than 0 must be specified in order to use this option.

As a result, the average side step is smaller than the maximum side step, which makes the average Material Removal Rate (MRR) less than the maximum MRR possible. This means that a morphing spiral is potentially less efficient than a regular round spiral.

When this option is enabled, iMachining 3D eliminates the roughing and rest roughing tool path passes contained in closed pocket areas (e.g., cavity features of a mold core), leaving only those volumes unmachined.

Carbide end Mill RPMchart

The Efficiency slider enables you to control the efficiency of the morphing spiral tool path. The examples below illustrate the effect of using this slider.

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When the Semi-finish option is enabled, the default Offset value is automatically calculated and dynamically updated according to half the Wall/island offset to minimize your operation entries.

In iMachining 3D, the parameters used for calculation of the Step-up tool path passes will appear in this section of the Operation dialog box according to the specified Technology type:

All morphing spirals approach the stock material from air, whether it is from the outside of an open pocket in the case of a converging spiral or from the inside of a closed pocket (using a pre-drill or helical entry) in the case of a diverging spiral.

This parameter enables you to modify the tool diameter. The tool is moved away from the machining surface by the defined value, leaving the offset unmachined on vertical and sloped surfaces.

Millingspeeds and Feeds chartMetric

If you override the defaults, changing the tool or its diameter will have no effect on your user-defined values.

The specified Ra values affect the finish feed rates automatically calculated for the tool, which are shown on the Data tab of the Tool page. Increasing the Floor (Ra) value produces a higher Finish feed floor value. Increasing the Wall (Ra) value produces a higher Finish feed XY value. Decreasing the Wall or Floor surface roughness produces correspondingly slower feed rates.

End MillSpeeds and Feeds chart

In iMachining 2D, the specified Technology type determines what tool path options will appear in this section of the Operation dialog box.

For hard materials, it is better to enter the material more gradually than to directly lead in to the initial radial depth determined by the side step that is appropriate for the specific shape of a morphing spiral.

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This section defines the Angle and Step over ranges for the operation. The values displayed in the locked text fields correspond to the Output Cutting Data shown on the Technology Wizard page.

This offset is applied to the tool and has the effect of lifting (positive value) the tool along the tool axis. As a result, this offset has its greatest effect on horizontal surfaces and no effect on vertical surfaces. By default, the Floor offset value is made equal to Wall offset value.

Floor offset – this parameter defines the machining allowance that will remain on the pocket floor after the operation, unless the Floor option is enabled in the Finish section. For iRest and iFinish, the Floor offset value is inherited from the Previous floor offset of the Parent operation with no available override.

Millingspeeds and feeds chartpdf

Based on the diameter of the tool, iMachining provides initial default values for the Wall/island offset and Floor offset parameters to minimize your operation entries. In addition, those values are dynamically updated when the tool diameter is changed or a new tool (with a different diameter) is selected for the operation.

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Only the iRough + iFinish and iFinish technologies enable you to define the Wall finish quality. All iMachining 2D technologies enable you to define the Floor finish quality only when the Floor option is selected. When not selected, the Floor (Ra) parameter is inactive.

Ra (Roughness average) is the most widely used one-dimensional roughness parameter that measures the microscopic peaks and valleys of a surface, describing its arithmetical mean deviation. Expressed in micrometers (microinches), the default Ra values are 0.8 µm (32 µin) for the Floor and 0.05 µm (2 µin) for the Wall. A larger number specifies a rougher surface with more deviation. A smaller number specifies a smoother surface with less deviation.