InventorCAM + Inventor The complete integrated Manufacturing Solution

GETTING

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INVENTORCAM 4 2.5D MILLING

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FEATURE RECOGNITION HIGH SPEED SURFACE MACHINING (HSS) 3D MILLING

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HIGH SPEED MACHINING (HSM) MULTI-SIDED MACHINING SIM. 5-AXIS MACHINING

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TURNING 34 MILL-TURN 38 WIRE CUT

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SYSTEM REQUIREMENTS TRAINING MATERIALS

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INVENTORCAM 2013 - THE CUTTING EDGE • Don’t go for less. Go for full integration. InventorCAM is the Certified integrated CAM-Engine for Inventor. InventorCAM provides seamless, single-window integration and full associativity to the Inventor design model. All machining operations are defined, calculated and verified, without leaving the Inventor window.

InventorCAM is used in the mechanical manufacturing, electronics, medical, consumer products, machine design, automotive and aerospace industries, mold, tool and die and rapid prototyping shops. Today successful manufacturing companies are using integrated CAD/CAM systems to get to market faster and reduce costs. With InventorCAM’s seamless single-window integration in Inventor, any size organization can reap the benefits of the integrated Inventor  +  InventorCAM manufacturing solution. InventorCAM supports the complete set of manufacturing technologies. Following is a brief description of the main InventorCAM modules.

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• 2.5D Milling

InventorCAM provides both interactive and automated powerful 2.5D milling operations on Inventor models. InventorCAM offers one of the best pocketing algorithms in the market. Full tool path control and powerful algorithms ensure that the user can manufacture the way he needs to. Operations can be easily re-ordered, rotated, mirrored, etc. InventorCAM’s automatic feature-recognition and machining module automates the manufacturing of parts with multiple pockets, multiple drills and complex holes. All your needs for successful production machining are provided directly inside Inventor with an easy and straightforward interface. InventorCAM is successfully used in production environments by thousands of manufacturing companies and job shops.

• High Speed Surface Machining (HSS)

The HSS Module is a High Speed Surface Machining module, for smooth and powerful machining of localized surface areas in the part, including undercuts. It provides easy selection of the surfaces to be machined, with no need to define the boundaries. It supports both standard and shaped tools. HSS provides nine different tool path definition strategies that enable the user to work differently for each area, as needed. The linking moves between the tool paths can be controlled by the user to avoid holes and slots, without the need to modify the model surface.

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Complete gouge control is available for holder, arbor and tool. Adjoining check surfaces that are to be avoided can be selected. Several retract strategies are available, under user control. The HSS module is an important addition to the integrated Inventor+InventorCAM Solution and is essential for each manufacturing facility as an excellent complementary module for the machining of all types of parts.

• 3D Milling

InventorCAM’s 3D Milling can be used both for prismatic parts and for 3D models. For prismatic parts InventorCAM analyzes the model and automatically recognizes pockets and profiles to be machined using Z-constant machining strategies. For 3D models, InventorCAM offers powerful 3D machining, including integrated rest material options.

• High Speed Machining (HSM)

InventorCAM HSM module is a very powerful and market-proven advanced 3D Mill and high-speed-machining module for 3D parts, aerospace parts and molds, tools and dies. The HSM module offers unique machining and linking strategies for generating advanced 3D Mill and high-speed toolpaths.

6 InventorCAM + Inventor = The Complete Integrated Manufacturing Solution

InventorCAM’s 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 feedrates and eliminating dwelling.

With InventorCAM 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 aircutting and reducing machining time. The result of the HSM module is an efficient, smooth, and optimal toolpath. 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, InventorCAM’s HSM Module is a must in today’s machine shops.

• 3+2 Axis Multi-Sided Machining

With InventorCAM, programming and machining of multi-sided parts on 4- and 5-Axis machining centers is efficient and profitable. InventorCAM is an industry leader in this type of machining. InventorCAM rotates the Inventor model to the user-defined machining planes and automatically calculates all necessary shifts and tilts for the 3D machining coordinate systems.

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InventorCAM enables flexible set-ups and reduces the need for special clamping jigs. You can define your 2.5D and 3D machining operations on any face and check them using InventorCAM’s advanced tool path verification. The output is ready-to-run programs for your 4/5-axis CNCmachine.

• Simultaneous 5-Axis Machining

Simultaneous 5-axis machining is becoming more and more popular due to the need for reduced machining times, better surface finish and improved life span of tools. InventorCAM utilizes all the advantages of Simultaneous 5-Axis machining and together with collision control and machine simulation, provides a solid base for your 5-axis solution. InventorCAM provides intelligent and powerful 5-axis machining strategies, including swarfing and trimming, for machining of complex geometry parts including mold cores and cavities, aerospace parts, cutting tools, cylinder heads, turbine blades and impellers. InventorCAM provides a realistic simulation of the complete machine tool, enabling collision checking between the tool and the machine components.

• Turning and Mill-Turn

InventorCAM has a very strong capability in turning, grooving and Mill-Turn. As in milling, a rest-machining capability is built in all turning operations. InventorCAM supports all machine turning cycles. InventorCAM provides

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special support for the advanced machining technologies of ISCAR’s TurnGroove tools.

A powerful integrated Mill-Turn capability enables the turning and milling operations to be programmed in the same environment. Access to the complete 2.5-5 axis milling is available. InventorCAM provides support for up to 5-Axis (XYZCB) Turn-Mill CNC machines including back-spindle operations.

• 2/4 Axis Wire-EDM

InventorCAM Wire EDM handles profiles and tapers with constant and variable angles, as well as 4-axis contours. InventorCAM’s intelligent algorithms prevent the falling of material pieces by automatic pocket processing. InventorCAM provides full user control of stop-points and of wire cutting conditions at any point of the profile or taper.

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2.5D MILLING

The 2_5D_Milling_1_IV.prz example illustrates the use of InventorCAM 2.5D Milling to machine the cover part shown above. The machining is performed on a 3-axis CNC machine in two setups, one for the top faces and one for bottom faces. The following InventorCAM operations are created to perform the machining:

• Top face machining (FM_facemill_2) This Face Milling operation performs the machining of the top face of the cover. An end mill of Ø20 is used. The machining is performed in two passes - rough and finish. A machining allowance of 0.2 mm remains unmachined at the floor, after the rough pass, and is removed during the finishing pass.

• External faces machining (F_profile_1; F_profile_2) These operations perform the profile machining of the external contour of the cover. An end mill of Ø16 is used. The Clear offset option is used at the roughing stage to perform the machining in a number of equidistant offsets from the machining geometry. The machining allowance is left unmachined during the roughing operation and removed at the finishing stage.

• Bolt seats machining (F_profile_3)

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This operation is used to remove the material at the bolt seat areas. An end mill of Ø8 is used for the operation.

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• Bottom face machining (FM_facemill_3) This Face Milling operation performs the machining of the bottom face of the cover. This operation uses the second Coordinate system; it means that the second setup has to be performed at the CNC machine before the machining. The used tool and the machining strategy are similar to the FM_profile_T1 operation.

• Internal faces roughing (P_profile_5; P_profile_6) These Pocket operations perform the rough machining of the internal faces of the cover. An end mill of Ø16 is used. The rough machining is divided into two operations to perform the machining with the optimal tool path The machining allowance is left unmachined for further finish operations.

• Internal faces rest machining (P_profile_6) This operation uses the rest material machining technique in order to machine the areas left inaccessible for the large tools used in the previous operations. An end mill of smaller diameter (Ø8) is used.

• Internal faces finishing (F_profile_5; F_profile_7) These operations perform the wall finishing of the internal pocket area of the cover part. An end mill of Ø6 is used.

• Floor faces finishing (F_profile_7; P_profile_6) These operations perform the floor finishing of the internal pocket area of the cover part. End mill tools of Ø6 and Ø8 are used.

• Slot machining (S_slot) This Slot Milling operation performs the machining of the groove at the bottom face of the cover. An end mill of Ø1.5 is used.

• Holes machining (D_drill) These Drill operations perform the center drilling and drilling of the four holes of Ø5 located at the bottom face of the cover.

• Threaded holes machining (D_drill_1) This Drill operation perform the center drilling, drilling and threading of the M2 holes located at the pads.

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2.5D MILLING

The 2_5D_Milling_2_IV.prz example illustrates the use of InventorCAM 2.5D Milling to machine the part shown above. The machining is performed on a 3-axis CNC machine in two setups, using two InventorCAM Coordinate systems. The following InventorCAM operations are created to perform the machining:

• Upper faces machining (F_profile; F_profile_1) These Profile operations remove the bulk of material performing the rough and the finish machining of upper faces. An end mill of Ø16 is used. The Clear offset option is used at the roughing stage to perform the machining in a number of equidistant offsets from the machining geometry.

• Step faces machining (F_profile_2) This operation performs the rough and finish machining of the step faces using the Profile operation. An end mill of Ø16 is used.

• External contour machining (F_profile_3) This operation performs the rough and finish machining of the external model faces. An end mill of Ø16 is used.

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• Connector pocket machining (P_profile_4; P_profile_5; F_profile_13; F_profile_6; P_profile_4) A number of Profile and Pocket operations are used to perform the rough and finish machining of the connector pocket. End mill tools of Ø10; Ø3 and Ø4 are used. The Rest material strategy is used in the last operation to complete the machining of the connector faces.

• Machine screw head areas (F_profile_7) This operation performs the rough and finish machining of the screw head areas. An end mill tool of Ø4 is used.

• Top and Bottom face machining (FM_profile_1; FM_facemill_1) Two Face Milling operation enable you generate the tool path for roughing and finishing of the top and bottom faces. Note that the second operation is used with the second Coordinate System, it means that the second setup has to be performed at the CNC machine before the machining.

• Internal faces roughing (P_profile_11; P_profile_12) These Pocket operations perform the roughing of the complex pocket formed by the internal faces of the part. An end mill tool of Ø10 is used.

• Internal faces roughing (F_profile_11; F_profile_12; P_profile_8; F_profile_9) These Pocket and Profile operations perform the finish machining of the wall and floor faces if the complex pocket roughed at the previous stage. An end mill tool of Ø4 is used.

• Holes machining (D_drill; D_drill_1; D_drill_2) These Drill operations perform center drilling and drilling of holes located on the cover part faces.

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FEATURE RECOGNITION

The drill_pocket_recognition_IV.prz example illustrates the use of InventorCAM Automatic Feature Recognition to machine the mold base part shown above. The machining is performed on a 3-axis CNC machine. The following InventorCAM operations are created to perform the machining:

• Top face machining (FM_facemill) This Face Milling operation performs the machining of the top face of the cover. A face mill of Ø40 is used.

• Pockets machining (PR_selected_faces) This Pocket Recognition operation automatically recognizes all the pocket areas in the model and performs their machining. An end mill of Ø20 is used. The Open Pocket machining is used to perform the approach movement from an automatically calculated point outside of the material. The tool descends to the necessary depth outside of the material and then moves horizontally into the material. A special machining strategy is applied to the through pockets; they are deepened in order to completely machine the pocket.

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• Center Drilling (DR_drill_r) This Drill Recognition operation automatically recognizes all the hole features available for the machining with the current Coordinate System and performs the center drilling of all the holes in the mold base. An spot drill of Ø10 is used. The drilling depth is customized for each group of holes.

• Drilling (DR_drill_r1; DR_drill_r2; DR_drill_r3; DR_drill_r4; DR_drill_r5; DR_drill_r6) These Drill Recognition operations perform the machining of all the hole features automatically recognized in the mold base. InventorCAM automatically recognized the Upper Level and Drill depth from the model. The through holes are extended in order to completely machine the holes.

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HIGH SPEED SURFACE MACHINING (HSS)

The hss_IV.prz example illustrates the use of several InventorCAM High Speed Surface Machining (HSS) strategies to machine the base part shown above. The following InventorCAM operations are created to perform the machining:

• Engraving (HSS_Projection_selected_faces, HSS_Projection_selected_faces_1, HSS_Projection_selected_faces_2, HSS_Projection_selected_faces_3) These operations utilize the HSS Engraving strategy to perform the machining of four fillet areas. A ball nose mill of Ø10 is used. The Depth Cut option is used to machine the whole the depth in several cutting passes.

• Morphing machining (HSS_MORPH_CURVES_selected_ faces_4, HSS_MORPH_CURVES_selected_faces_6) This operation performs the machining of two internal fillet areas using the Morph between two curves strategy. This strategy is utilized to generate the tool path evenly distributed between the fillet boundaries. The gouge checking strategy is used to avoid possible gouges between the tool and the faces of the machining area. A ball nose mill of Ø10 is used.

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• Parallel to curve machining (HSS_ParToCurve_selected_faces_8) This operation performs the machining of the part bottom face. With this strategy, InventorCAM enables you to perform the machining of faces with cutting passes parallel to the selected curve. In this case, InventorCAM generates a pocket-style tool path enclosed within the boundaries of the selected face. An end mill of Ø8 is used.

• Morphing between two curves (HSS_MORPH_CURVES_selected_ faces_9) This operation performs the machining of the external fillet and an inclined face adjacent to the fillet. The Morphing between two curves strategy is utilized to generate the tool path evenly distributed between the fillet boundaries. The tool path is generated using the Scallop of 0.004 mm in order to obtain excellent surface quality. The gouge checking strategy is used to avoid possible gouges between the tool and the faces of the machining area. A ball nose mill of Ø6 is used.

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3D MILLING

The 3D_Milling_1_IV.prz example illustrates the use of InventorCAM 3D Milling for the machining of the mold core shown above. The following InventorCAM operations are created to perform the machining:

• Roughing (3DR_target) This operation removes the bulk of material using the Contour roughing strategy. An end mill of Ø20 is used. The machining is performed at the constant-Z levels defined, using the Step down value of 5 mm. A machining allowance of 0.5 mm remain unmachined for further finish operations.

• Rest material machining (3DR_target) This operation performs the rest material machining of the areas that were inaccessible to the tool in the previous operation. An end mill tool of smaller diameter (Ø16) is used. The Contour roughing strategy is utilized in combination with the Rest material mode of the Working area definition in order to obtain optimal and effective tool path removing the cusps left after the previous operation. A machining allowance of 0.5 mm remains unmachined for further finish operations.

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• Steep areas finishing (3DF_CZ_target) This operation performs the Constant-Z finishing of the steep areas of the core. With this strategy, InventorCAM machines a number of planar sections, parallel to the XY plane, using profile machining. A ball nose mill of Ø10 is used. The machining is performed for the steep areas, with inclination angle from 30° to 90°

• Shallow areas finishing (3DF_CS_target) This operation performs the Constant Stepover finishing of the shallow areas of the core. With this 3D Milling strategy InventorCAM generates a number of tool paths, at specified constant offset (Step over) from each other, measured along the surface. The machining is performed for the shallow areas, with inclination angle from 0° to 32°. A ball nose mill of Ø10 is used.

• Parting surface finishing (3DF_Lin_target) This operation performs the Linear finishing of the parting surface of the core. In linear finishing, InventorCAM generates a line pattern on a 2D plane above the model and then projects it on the 3D Model. The Step over value determines the constant distance between adjacent lines of the linear pattern, created on the 2D plane before being projected. A ball nose mill of Ø10 is used. The defined Drive/Check surfaces enable you to perform the machining of the parting surfaces only, avoiding unnecessary contact with the already machined faces.

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3D MILLING

The 3D_Milling_2_IV.prz example illustrates the use of InventorCAM 3D Milling for prismatic part machining. The following InventorCAM operations are created to perform the machining:

• Roughing (3DR_target) These operations remove the bulk of material using the Contour roughing strategy. An end mill of Ø14 is used. The Open Pocket machining is used to perform the approach movement from an automatically calculated point outside of the material. The tool descends to the necessary depth outside of the material and then moves horizontally into the material. A machining allowance of 0.2 mm remain unmachined on floor and wall faces for further finish operations.

• Rest material machining (3DR_target; 3DR_target) At this stage the rest material machining is performed for the corner areas, that were inaccessible by the tool in the previous operation. The machining is performed in two operations using end mills of Ø8 and Ø5, in order to minimize the tool load. The Contour roughing strategy is utilized in combination with the Cut only in Rest material option in order to obtain optimal tool path A machining allowance of 0.2 mm remain unmachined on the floor and wall faces for further finish operations.

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• Vertical walls finishing (3DF_CZ_target) This operation performs the Constant-Z Wall finishing of the vertical walls areas of the part. With this strategy, InventorCAM generates a number of profile passes along the Z-axis, with a constant Step down. An end mill of Ø4 is used.

• Horizontal floor finishing (3DF_CZ_target_1) This operation performs the Constant-Z Floor finishing of the horizontal floor areas of the part. With this strategy, InventorCAM generates a number of pocket passes on the horizontal faces, parallel to the XY-plane of the current Coordinate System. An end mill of Ø4 is used.

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HIGH SPEED MACHINING (HSM)

The hsm_1_IV.prz example illustrates the use of several InventorCAM High Speed Machining (HSM) strategies to machine the mold cavity shown above. The following InventorCAM operations are created to perform the machining:

• Rough machining (HSM_R_Cont_target) This operation performs contour roughing of the cavity. An end mill of Ø20 is used with a Step down of 3 mm. A machining allowance of 0.5 mm remain unmachined for further semi-finish and finish operations.

• Rest roughing (HSM_RestR_target) This operation performs rest roughing of the cavity. A bull nosed tool of Ø12 and corner radius of 2 mm is used with a Step down of 1.5 mm to remove the steps left after the roughing. The same machining allowance as in roughing operation is used.

• Steep faces semi-finishing (HSM_CZ_target)

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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 0.25 mm remain unmachined for further finish operations. The Apply fillet surfaces option is used to add virtual fillets that will smooth the tool path at the corners.

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• Shallow faces semi-finishing (HSM_Lin_target) This operation performs Linear semi-finishing of the shallow faces (from 0° to 42°). A ball nosed tool of Ø10 is used for the operation. A machining allowance of 0.25 mm remain unmachined for further finish operations. The Apply fillet surfaces option is used.

• Corners rest machining (HSM_RM_target) This operation uses the Rest Machining strategy for semi-finishing of the mold cavity 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 virtual reference tool of Ø12 is used to determine the model corners where the rest machining is performed. A machining allowance of 0.25 mm remain unmachined for further finish operations.

• Steep faces finishing (HSM_CZ_target) This operation performs Constant Z finishing of the steep faces (from 40° to 90°). A ball nosed tool of Ø8 is used for the operation. The Apply fillet surfaces option is used.

• Shallow faces finishing (HSM_Lin_target) This operation performs Linear finishing of the shallow faces (from 0° to 42°). A ball nosed tool of Ø8 is used for the operation. The Apply fillet surfaces option is used.

• Corners rest machining (HSM_RM_target) 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 virtual reference tool of Ø10 is used to determine the model corners where the rest machining is performed.

• Chamfering (HSM_Bound_target) This operation uses the Boundary Machining strategy for the chamfering of upper model edges. A taper tool is used for the operation. The chamfer is defined by the external offset of the drive boundary and by the Axial thickness parameter.

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HIGH SPEED MACHINING (HSM)

The hsm_2_IV.prz example illustrates the use of several InventorCAM HSM strategies to machine the electronic box shown above. The following InventorCAM operations are created to perform the machining:

• Rough machining (HSM_R_Cont_target) This operation performs the contour roughing of the part. An end mill of Ø30 is used with a Step down of 10 mm to perform the roughing. A machining allowance of 0.5 mm remain unmachined for further semi-finish and finish operations.

• Rest roughing (HSM_RestR_target) This operation performs the rest roughing of the part. A bull nosed tool of Ø16 and corner radius of 1 mm is used with a Step down of 5 mm to remove the steps left after the roughing. The same machining allowance as in the roughing operation is used.

• Upper faces machining (HSM_CZ_target) This operation performs Constant Z finishing of the upper vertical model faces up to a certain depth. A bull nosed tool of Ø12 and corner radius of 0.5 mm is used.

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• Bottom faces machining (HSM_CZ_target_1) This operation performs Constant Z finishing of the bottom vertical model faces. A bull nosed tool of Ø12 and corner radius of 0.5 mm is used.

• Flat faces machining (HSM_CZF_target) This operation performs Horizontal Machining of the flat faces. A bull nosed tool of Ø12 and corner radius of 0.5 mm is used.

• Inclined faces machining (HSM_CZ_target) 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 (10 mm). Using such a tool enables you to increase the productivity of the operation.

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MULTI-SIDED MACHINING

The multi_sided_machining_1_IV.prz example illustrates the use of InventorCAM Multi-sided machining to machine the manifold plate shown above, using a 5-axis CNC Machine. The initial stock for this example comes from casting. The following InventorCAM operations are created to perform the machining:

• Top face machining (FM_profile) This Face Milling operation performs the machining of the top face of the cover. An end mill of Ø16 is used. The machining is performed in two passes - rough and finish. A machining allowance of 0.2 mm remain unmachined at the floor after the rough pass and removed during the finishing pass. Position #1 of the Machine Coordinate system is used for the operation.

• Front hole machining (D_drill; F_profile_1) These operations are used for the front hole machining using Position #2 of the Machine Coordinate system. The Drill operations perform center-drilling and two steps drilling of the hole. The Profile operation is used for the machining of the connector faces around the hole.

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• Left hole machining (D_drill_1; F_profile_2) These operations are used for the left hole machining using Position #3 of the Machine Coordinate system. The sequence of the Drill and Profile operations is similar to the sequence used for the front hole machining.

• Back hole machining (D_drill_2; F_profile_3) These operations are used for the left hole machining using Position #4 of the Machine Coordinate system. The sequence of the Drill and Profile operations is similar to the sequence used for the front hole machining.

• Right hole machining (D_drill_3; F_profile_4) These operations are used for the left hole machining using Position #5 of the Machine Coordinate system. The sequence of the Drill and Profile operations is similar to the sequence used for the front hole machining.

• Top holes machining (P_profile_5; D_drill_4;D_drill_5; F_profile_6) These operations are used for the machining of the holes located on the top faces of the model. Position #1 of the Machine Coordinate system is used for all the operations.

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MULTI-SIDED MACHINING

The multi_sided_machining_1_IV.prz example illustrates the use of InventorCAM Multi-sided machining to complete the machining of the clamp part shown above, using a 5-axis CNC Machine. The following InventorCAM operations are created to perform the machining:

• Top face machining (FM_profile_1) This Face Milling operation machines the top inclined face of the clamp. Machine Coordinate system #1 (Position #2) is used for the operation.

• Back face machining (FM_profile_2) This Face Milling operation machines the back inclined face of the clamp. Machine Coordinate system #1 (Position #3) is used for the operation.

• Front face machining (FM_profile_3) This Face Milling operation machines the front inclined face of the clamp. Machine Coordinate system #1 (Position #4) is used for the operation.

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• Openings machining (F_profile_4) This Profile operation machines two openings, located on the front inclined face of the clamp. Machine Coordinate system #1 (Position #4) is used for the operation.

• Slot machining (P_profile_5; P_profile6) These Pocket operations machines the slot faces located on the top inclined face of the clamp, using the Contour strategy. Machine Coordinate system #1 (Position #2) is used for the operation.

• Hole machining (P_profile_7; D_drill) These operations machine the inclined counterbore hole, located on the top inclined face of the clamp. Machine Coordinate system #1 (Position #5) is used for the operation.

• Bottom face machining (FM_profile_8) This Face Milling operation machines the bottom inclined face of the clamp. Machine Coordinate system #2 (Position #1) is used for the operation.

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SIM. 5-AXIS MACHINING

The sim_5_axis_1_IV.prz example illustrates the use of the InventorCAM Sim. 5 axis module for turbine blade machining. The following Sim. 5 axis operations are used to perform the semi-finish and finish machining of the turbine blade:

• Blade Semi-finishing (5X_selected_faces; 5X_selected_faces) The first operation provides the semi-finish of the turbine blade, using a bull nosed tool of Ø16 with a corner radius of 4 mm. A combination of the Parallel Cuts strategy and Spiral Cutting method is used to perform the spiral machining of the blade. The tool tilting is defined using the Tilted relative to cutting direction option, with lag angle of 20°. The tool contact point is defined at the front tool face. This combination of parameters enables you to perform the machining by the toroidal surface of the tool. Gouge checking is performed to avoid the possible collisions of the tool with the planar surface of the blade base. The remaining material will be machined at a later stage, using a special tilting strategy.

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The second Sim. 5-axis operation provides semi-finishing of the blade area, close to the blade base. This area was not machined in the previous operation because of the gouge protection. A bull nosed tool of Ø8, with a corner radius of 2 mm, is used for the operation. Similar to the previous operation, a combination of the Parallel Cuts strategy and Spiral Cutting method is used to perform the spiral machining of the blade. The tool tilting is defined using the Tilted relative to cutting direction option, with a lag angle of 20°. In addition to the lag angle, a side tilting angle of 10° is defined to avoid the gouging of the planar face of the blade base.

• Blade finishing (5X_selected_faces) This operation performs the finishing of the blade. A bull nosed tool of Ø8, with a corner radius of 2.5 mm, is used for the operation. The tool tilting is defined using the Tilted relative to cutting direction option with a lag angle of 20°. In addition to the lag angle, a side tilting angle of 10° is defined to avoid the gouging of the planar face of the blade base.

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SIM. 5-AXIS MACHINING

The sim_5_axis_2_IV.prz example illustrates the use of the Sim. 5 axis operation for an aerospace part machining. A number of Sim. 5 axis operations are defined in order to perform the finish machining of the inclined faces of the aerospace frame and their adjacent fillets. The inclined faces are forming an undercut area that cannot be machined using 3 axis milling; we have to use 5 axis milling, with the appropriate tilting strategy, to machine the inclined faces.

• Inclined walls finishing (5X_selected_faces_1; 5X_selected_faces_2; 5X_selected_faces_3) These operations perform the finish machining of the inclined walls. A ball nosed tool of Ø4 is used for the operation. The Parallel Cuts strategy is used to generate a number of cuts parallel to the XY plane of the coordinate system. The tool tilting is defined using the Tilted relative to cutting direction option with a lag angle of 90°. These parameters enable you to perform the machining with the side face of the tool.

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• Fillet machining (5X_selected_faces_4; 5X_selected_faces_5; 5X_selected_faces_6) These operations perform the finish machining of the fillets adjacent to the walls. A ball nosed tool of Ø4 is used for the operation. The Project curves strategy is used to generate a single pencil milling pass, machining the fillets. The Tilted through curves tilting strategy is used to perform a smooth transition between different tool axis orientations.

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TURNING

The turning_1_IV.prz example illustrates the use of the InventorCAM Turning for the machining of the part shown above. The following Turning operations are used to perform the machining of the part:

• External Roughing (TR_profile) This operation is used to generate the tool path for the external faces roughing. An External roughing tool is used for the operation. The Long Process type is chosen for the operation to perform the machining in longitudinal direction. The Rough Work type is chosen for the operation; with this Work type the rough machining is performed in a number of equidistant passes.

• Facial Turning (TR_profile_1) This operation is used to generate the tool path for the front face machining. An External roughing tool is used for the operation. The Face Process type is chosen for the operation to perform the machining in facial direction. The Rough work type is chosen for the operation; with this work type the rough machining is performed in a number of equidistant passes.

• Drilling (DRILL)

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This Drill operation is used to perform the rough machining of the hole. A U-Drill tool of Ø28 is used for the operation.

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• External Finishing (TR_profile) This Turning operation is used to perform the external faces finishing. The Profile Work type is chosen to generate the finishing pass. An External roughing tool is used for the operation.

• Internal Turning (TR_profile_2) This Turning operation is used to perform the internal faces finishing. The Profile Work type is chosen to generate the finishing pass. An Internal roughing tool is used for the operation.

• External Grooving (GR_profile3) This Grooving operation is used to perform rough and finish machining of the external groove faces. An External grooving tool is used for the operation.

• Internal Grooving (GR_profile_4) This Grooving operation is used to perform rough and finish machining of the internal groove faces. An Internal grooving tool is used for the operation.

• External Threading (TH_profile_5) This Threading operation is used to perform the machining of the external thread with the minimal diameter of 56 mm and pitch of 1.5 mm. An External threading tool is used for the operation.

• Internal Threading (TH_profile_6) This Threading operation is used to perform the machining of the internal thread with the maximal diameter of 33.5 mm and pitch of 1.5 mm. An Internal threading tool is used for the operation.

• Parting (GR_profile_7) This Grooving operation is used to perform the parting (cut-off) of the machined part from the stock bar. The Cut Work type is used for the operation. An External grooving tool is used for the operation.

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TURNING

The turning_2_IV.prz example illustrates InventorCAM functionality for Rest Material machining, during longitudinal and facial rough/finish turning operations, performed on the wheel part shown above. The following Turning operations are used to perform the machining of the part:

• External Roughing (TR_profile) This operation is used to generate the tool path for the external faces roughing. An External roughing tool is used for the operation. The Long Process type is chosen for the operation to perform the machining in the longitudinal direction. The Rough Work type is chosen for the operation; with this Work type the rough machining is performed in a number of equidistant passes.

• External Rest Material Roughing (TR_profile) This operation utilizes the Rest Material option to perform the machining of the areas left unmachined after the previous operation. These areas were unmachined because of the orientation and geometry of the tool used in the previous operation. In this operation a tool with opposite orientation is used to machine the part, moving in the positive Z-direction.

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• External Finishing (TR_profile_1) This Turning operation is used to perform the external faces finishing. The Profile Work type is chosen to generate the finishing pass. An External Contour tool is used for the operation to avoid leaving unmachined areas during the external finish.

• Facial Roughing (TR_profile_2) This operation is used to generate the tool path for the front face roughing. An External roughing tool is used for the operation. The Face Process type is chosen for the operation to perform the machining in facial direction. The Rough work type is chosen for the operation; with this work type the rough machining is performed in a number of equidistant passes.

• External Rest Material Roughing (TR_profile_2) This operation utilizes the Rest Material option to perform the machining of the areas left unmachined after the previous operation. These areas were unmachined because of the orientation and geometry of the tool used in the previous operation. In this operation the tool with opposite orientation is used to machine the part, moving in the positive X-direction.

• External Facial Finishing (TR_profile_2) This Turning operation is used to perform the front face finishing. The Profile Work type is chosen to generate the finishing pass. An External roughing tool is used for the operation.

• External Rest Material Finishing (TR_profile_2) This operation utilizes the Rest Material option to perform the machining of the areas left unmachined after the previous finishing operation. These areas were unmachined because of the orientation and geometry of the tool used in the previous operation. In this operation the tool with opposite orientation is used to machine the part, moving in the positive X-direction. The Profile Work type is chosen to generate the finishing pass.

• Hole machining (DRILL) This Drill operation is used to perform the machining of the hole. A U-Drill tool of Ø40 is used for the operation.

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MILL-TURN

The mill_turn1_IV.prz example illustrates the use of the InventorCAM MillTurn module for the machining of the optical part shown above, on a 4-axis Mill-Turn CNC-Machine. The following Turning and Milling operations are used to perform the machining of the part:

• Turning (TR_profile_1; DRILL_; TR_profile_10) These turning operations are used to generate the tool path for the rough and finish machining of the external and internal cylindrical faces.

• Facial Milling (F_profile_2; D_drill_3; D_drill_4) These operations perform the machining of the screw slot and four holes using InventorCAM capabilities for facial milling. Position #1 of Coordinate System #1 is used to perform the facial machining.

• Machining of the side faces (P_profile_3) This Pocket operation is used to perform the machining of the side faces of the model. The Contour strategy is used in combination with a negative Wall offset value in order to generate an overlapping tool path that completely machines the faces.

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CoordSys Position #3 is used for the operation. The Transform option is used to create a circular pattern of operations around the revolution axis.

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• Drilling on the side face (D_drill) This Drill operation is used to perform the machining of two holes located on the side face of the model. CoordSys Position #3 is used for the operation.

• Slot machining (F_profile_4) This Profile operation is used to perform the machining of the slot using indexial 4-axis milling. Position #4 of Coordinate System #1 is used for the operation. An end mill of Ø2.5 is used for the operation.

• Radial holes machining (D_drill1_; P_profile_6; D_drill_2; P_profile_7) These Drill and Pocket operations are used to perform the machining of three counterbore holes located on the cylindrical face. Position #5 and Position #6 of Coordinate System #1 are used for the operations.

• Pocket machining (P_profile_9) This Pocket operation is used to perform the simultaneous 4-axis machining of the pocket, wrapped on the external face of the part. Position #2 of Coordinate System #1 is used to perform the pocket machining. An end mill of Ø2.5 is used for the operation. The Wrap option, chosen during the machining geometry definition, enables you to define the wrapped geometry of the pocket directly on the solid model. The Contour strategy is chosen for the pocket machining.

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MILL-TURN

The mill_turn_2_IV.prz example illustrates the use of the InventorCAM MillTurn module for the machining of the console part shown above on a 5-axis Mill-Turn CNC-Machine. The following Turning and Milling operations are used to perform the machining of the part:

• Turning (TR_profile) This turning operation is used to generate the tool path for the rough and finish machining of the external cylindrical faces.

• Indexial milling (F_profile_6) This Profile operation is used to perform the machining of the cube sides using the InventorCAM indexial milling capabilities. Position #2 of Coordinate System #2 is used for the operation. The Transform option is used to create a circular pattern of operations around the revolution axis in order to machine all the cube faces. An end mill of Ø16 is used for the operation.

• Horizontal faces machining (F_profile_1)

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This Profile operation is used to perform the indexial milling of the horizontal faces at the front part of the console. Position #4 of Coordinate System #1 is used for the operation.

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The Transform option is used to create a circular pattern of operations around the revolution axis in order to machine both sides of the console’s front part.

• Inclined faces machining (F_profile_3; F_profile_4) These Profile operations are used to perform the machining of the inclined faces using the B-axis. CoordSys positions #5 and #6 are used for these operation. An end mill of Ø16 is used for the operations.

• Cylindrical face machining (F_profile_2) This Profile operation is used to perform the machining of the cylindrical face at the front part of the console. Position #4 of Coordinate System #1 is used for the operation. An end mill of Ø16 is used for the operations.

• Pocket machining (P_profile_9) This Pocket operation is used to perform the machining of the pocket located on the inclined faces, using the B-axis. Position #5 of Coordinate System #1 is used for the operation. An end mill of Ø6 is used for the operation.

• Inclined faces machining (F_profile_7; F_profile_8) These Profile operations are used to perform the machining of the inclined faces on the cube, using the B-axis. CoordSys positions #7 and #8 are used for the operation. An end mill of Ø16 is used for the operation.

• Hole machining (D_drill; D_drill_1; D_drill_2; D_drill_3) These Drill operations are used to perform the machining of the inclined faces on the cube, using the B-axis. CoordSys positions #4, #6, #7 and #8 are used for the operations.

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MILL-TURN - 2 SPINDLES

The back_spindle_IV.prz example illustrates the use of the InventorCAM Back Spindle functionality for the machining of the connector part shown above, on a 5-axis Mill-Turn CNC-Machine. The following Turning and Milling operations are used to perform the machining of the part:

• Turning and front side milling (TR_profile; DRILL; F_profile_1; TR_profile_2) These operations are used to perform turning and facial milling of the front faces of the connector. Position #1 of Coordinate System #1 is used for the operation. The back spindle is not used in these operations; only the main spindle is used.

• Indexial machining of the middle part (F_profile_6; D_drill_2; F_profile_7) These Profile and Drill operations are used to perform the machining of the pads and holes located around the cylindrical surface, in the middle part of the connector. Position #5 of Coordinate System #1 is used for the operation. The Back Spindle Connect operation is defined before these operations, enabling the combined use of both spindles (main and back) in these operations.

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• Indexial machining of the back part (P_profile_8; D_drill_3) These Profile and Drill operations are used to perform the machining of the pads and holes located around the conical surface, in the middle part of the connector. Position #6 of Coordinate System #1 is used for the operation. The Back Spindle MoveBack operation is defined before these operations, causing the retract of the back spindle, so that these operations are performed with the main spindle only.

• Turning and back side milling (TR_profile_9; F_profile_10; DRILL; TR_profile_11; F_profile_12; D_drill_4) These operations are used to perform turning and facial milling of the back faces of the connector. Position #1 of Coordinate System #1 is used for turnings operation. Position #4 of Coordinate System #1 is used for milling operations. The Back Spindle Transfer operation is defined before these operations, causing the transfer of the part from the main spindle to the back spindle. The machining is performed on the part clamped in the back spindle.

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WIRE CUT

The wire_cut_IV.prz example illustrates the use of the InventorCAM Wire Cut module for the conical gear machining. The following Wire Cut operations are used to perform the machining of the part:

• Central cut machining (F_contour) This Profile operation is used to machine the central through cut. The Later option is used for the Auto Stop technology, generating a postponed separate sub-operation preventing the material dropping.

• Gear face machining (X_four_axis) The 4-axis operation is used to machine the conical gear shape. The insertion point of the wire is chosen outside the cylindrical stock, simplifying the approach of the wire to the machining contour. Refer to the Wire Cut User Guide for more information about the Wire Cut module.

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SYSTEM REQUIREMENTS • Microsoft® Windows 7 x32/x64 Professional and Ultimate editions, Microsoft® Windows Vista x32/x64 Business and Ultimate editions with Service Pack 1, Microsoft® Windows XP Professional with Service Pack 2 or 3, Microsoft® Windows XP Professional x64 Edition

• Intel® Core™, Intel® Core™2 Duo, Intel® Core™ Quad, Quadcore, Intel® Xeon®,

AMD Phenom™, AMD Phenom™ II, AMD Athlon™ X2 Dual-Core - class processor.

• 2 GB RAM or more (4 GB or more for x64 operating system is recommended for large CAM-Parts machining)

• A OpenGL workstation graphics card (512 MB RAM recommended) and latest driver

• Mouse or other pointing device • CD drive • Internet Explorer version 6 if you are using the SolidCAM online help • For viewing SolidCAM User Guides and Training Courses, Adobe Acrobat version 9 or higher is recommended.

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TRAINING MATERIALS The following training courses are suitable both for InventorCAM frontal training and for self study.

• Milling Training Course: 2.5D Milling • Milling Training Course: 3D Milling • Turning Training Course • Turn-Mill Training Course • Advanced Training Course These documents are available in the following format: PDF for on-line use + Examples The following user guides for InventorCAM are available.

• Milling User Guide • HSM User Guide • Sim. 5-axis User Guide • Turning User Guide • Wire Cut User Guide The PDF versions of user guides are available for download from the Download area of InventorCAM Web site: www.inventorcam.com. On-line help, based on these user guides, is available within InventorCAM.

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2.5D Milling

HSS (High-Speed Surface Machining)

HSM (High-Speed Machining)

Indexed Multi-Sided Machining

Simultaneous 5-Axis Machining

Turning and Mill-Turn up to 5-Axis

Wire EDM

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