Training Guide

3D Milling
 TopSolid’Cam 3D Milling
© 2012, Missler Software.
7, Rue du Bois Sauvage
F-91055 Evry, FRANCE
Web: www.topsolid.com
E-mail: info@topsolid.com
All rights reserved.

This information is subject to change without warning.

No material may be reproduced or transmitted, regardless of the manner, electronic or mechanical means used
or purpose, without formal written consent from Missler Software.

TopSolid® is a registered trademark of Missler Software.

TopSolid® is a product name of Missler Software.

The information and the software contained within this document are subject to change without prior warning
and should not be construed as a commitment by Missler Software.

The software covered by this document is supplied under license, and may only be used and duplicated in
compliance with the terms of this license.

Version 7.6 Rev.01

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Contents
Introduction.................................................................................................................................................... 1
Basic Principles ............................................................................................................................................... 2
Scallop Height........................................................................................................................................................... 3
Tools ......................................................................................................................................................................... 3
Tool Driven Point ................................................................................................................................................. 3
Tool Gauges ......................................................................................................................................................... 4
Computing Tolerance ............................................................................................................................................... 5
Maximum Distance Between Points .................................................................................................................... 6
3D Milling ....................................................................................................................................................... 7
Milling Cycles............................................................................................................................................................ 7
Machining Bounds.................................................................................................................................................... 8
Geometric Bounds ............................................................................................................................................... 9
Addition of an Additional Surface ...................................................................................................................... 11
Addition of a Bounding Curve ............................................................................................................................ 12
Machining Dialog Properties.............................................................................................................................. 13
Milling Cycles .................................................................................................................................................14
3D Roughing Cycle.................................................................................................................................................. 14
Definition ........................................................................................................................................................... 14
Settings Tab........................................................................................................................................................ 15
Strategy Tab ....................................................................................................................................................... 20
Plunge and Retract Tab ...................................................................................................................................... 22
Finishing Cycles ...................................................................................................................................................... 24
Definition ........................................................................................................................................................... 24
Raster Passes ..................................................................................................................................................... 24
Constant Step-Over............................................................................................................................................ 27
Constant Z .......................................................................................................................................................... 32
Left Material Machining Cycle ............................................................................................................................... 36
Definition ........................................................................................................................................................... 36
Constant Z Material Left .................................................................................................................................... 37
Radius Machining ............................................................................................................................................... 37
Pencil Machining ................................................................................................................................................ 38
ISO Program...................................................................................................................................................39
ISO Program Generation ........................................................................................................................................ 39
Configuration and Customization .......................................................................................................................... 40

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Exercise 01: Roughing .................................................................................................................................... 41
Exercise 02: Roughing (supplements) ............................................................................................................. 44
Exercise 03: Finishing ..................................................................................................................................... 47
3D Milling............................................................................................................................................................... 48
Exercise 04: Implementation .......................................................................................................................... 54
Exercise 05: Milling of the Cavity .................................................................................................................... 59
Notes ............................................................................................................................................................ 63
Individual Course Evaluation Form ................................................................................................................. 65

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TopSolid’Cam 3D Milling Introduction

Introduction
This training guide is designed to be accessible to a wide range of users. For example, a first-time user will find in
this guide the approach of the training he followed, but also more detailed and comprehensive information for
creating machining cycles.

The online help, which can be accessed by pressing the F1 key, also contains useful and relevant information that
should not be overlooked. It is necessary to have a good knowledge and understanding of the product.

In the following chapters, the machining cycles will be discussed in detail, as well as the main settings.

The different exercises provided in this training guide will allow you to apply the knowledge and skills you gained
during the training.

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Basic Principles
3D milling cycles include all cycles that are applied to solids or surfaces.

In fact, 3D cycles are applied to a polyhedron which is positioned on the part. Now let’s imagine that we want to
protect the volumes or surfaces on screen by putting a sheet on them. By default, the sheet covers only surfaces
or faces which are visible from above (along the tool axis) by falling vertically in undercut areas. Let's also assume
that the polyhedron (the sheet) is a coat of mail that doesn't let the cutter pass through and thus protects your
part.

Collisions are detected in case of:

- undercut;
- milled radius smaller than the tool radius;
- overlapping of surfaces or solids.

Tool path

Undercut

Surface edge Non restricted surfaces

Hole

Note: Remember that you can use the 2D cycles and in particular axial milling cycles which have a high chip
volume/milling time ratio. Indeed, a solid is not necessarily milled using 3D milling cycles only.

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Scallop Height
The scallop height is directly linked to the diameter of the tool used and to the step over of the machining.

The shape of the cutter and the axial offset are two factors that also contribute to the actual value of the stock
left at a specific position.
The "stair step" effect on sides is accentuated with a side mill and the scallop effect linked to the axial offset (in
XY) is accentuated with a ball nose mill. In theory, the scallop height is calculated on a planar surface.

Cutter diameter

Scallop height

Cutter offset (step over)

Deformation of the scallop on slopes

Tools

Tool Driven Point

There are two possibilities:
- Tool center: The least frequent type because the measurement of the tool center requires a specific
measuring device to ensure the correct gauge length.
- Tool end: The most commonly used type because of its simplicity of measurement: the tool is measured
by its end.

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Tool Gauges

Side Mill Radiused Mill Ball Nose Mill

Center gauge
Center gauge
End gauge

End gauge
End gauge

Declaration of the Driven Point

By default, the tool end is driven.
 From the drop-down menu of the Tools tab, select Options.
 Unfold CAM Options and select Tools.
 Define the type of driven point by enabling the corresponding option, Tool end or Tool center, and then
validate with .

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Computing Tolerance

A curve is a geometric entity which has the ability to define a complex shape with little information. This results in
a reduced computer file size compared to a same shape described by a sequence of arcs and segments.
Thus, sections on which milling tool path calculations are based are mainly curves.
Unfortunately, the commonly used CNC machines only execute linear or circular interpolation movements (G01,
G02 or G03).
TopSolid’Cam 7 then needs to turn the curves into segments and arcs so that the tool path can be readable by the
machine. It distributes points along the curve. The maximum distance between the theoretical tool path (the
curve) and the linear tool path (point to point) must not exceed the value of the computing tolerance. The value
of the computing tolerance can be likened to the maximum allowed arrow.

Note: Depending on whether the curve is concave or convex, the linear tool path will be inside or outside the
part.

Therefore, the actual stock to leave will be included:

Theoretical stock to leave – Computing tolerance < Actual stock to leave < Theoretical stock to leave + Computing
tolerance.

In the roughing phase, if the stock to leave is 0.2 and the curve tolerance is 0.1, the actual stock to leave will
range between 0.1 and 0.3. If we were in the finishing phase with an expected stock to leave of 0, the actual stock
to leave would be between -0.1 and +0.1.
It is usually recommended to have a theoretical stock to leave greater than twice the computing tolerance.
For a finishing operation (stock to leave=0), it is generally recommended to apply a computing tolerance between
0.003mm to 0.01mm.

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Maximum Distance Between Points

Another parameter influences the quality of the milling according to the cycles in which it is used.

Depending on the computing tolerance value, segments can be too long compared to the milled shape. It is
possible to recut these segments by using a maximum distance between points value.
If the distance between two points is greater than this value, intermediate points will be created. Otherwise,
TopSolid’Cam 7 does not perform any calculation.

Computing tolerance

Distance between two

points

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3D Milling
Milling Cycles
There are five families of milling cycles:
- The roughing cycles
- The left material milling cycle
- The finishing cycles
- The cycle on face
- The 3D contouring (cycle on curves)

Roughing cycles

Finishing cycles

Left material milling

cycle Cycle on face

Cycle on 3D curves

The roughing, the left material machining and the finishing cycles are applied to the entire solid model, with the
possibility to limit the areas to be machined.

Milling in sweeping cycle is applied to the selected faces of a solid. This is an iso-parametric cycle which processes
faces and surfaces individually while observing their natural orientations: U and V iso-parametrics.
Milling linkings are possible if surfaces follow each other with the same orientation.

The 3D contouring cycle only applies to 3D curves.

Note: Only the most frequently used settings of the cycle will be discussed in this guide. Most of the commands
are described in detail in the online help which can be accessed by pressing the F1 key.

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Machining Bounds
In this example, we will look at the roughing cycle.

When the Preview option is enabled, the machining bounds are displayed in the graphical area and allow
you to create a zone for path calculation. When this option is disabled, calculations are faster.

Preview enabled Preview disabled

Note: The values are given with respect to the origin frame of the part.

When the Automatic Edit Refresh icon is enabled, the update is automatic each time a value is modified.
When this icon is disabled, the update is deferred until the next time you activate the icon.

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Geometric Bounds

 In the 2D/3D tab, select the Roughing command, click the Geometry option, and then go to the
Bounds tab.

By default, the CAD model is completely taken into account for the machining with the selected cycle.
You have the option to work only on certain portions or areas of the part, and not on the whole part.

TopSolid’Cam 7 offers the following solutions:

- Bounding the area to be machined in the X,Y and Z directions;
- Taking into account clamping elements (collisions);
- Taking into account additional surfaces;
- Taking into account machining areas that are limited by bounding curves.

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Bounds tab

Note: The bounding mode manages the position of

the tool in a bounded area.

 Set Z Minimum to Point and select the end of an

edge giving the minimum Z level of the machining.
 Set the different bounds as follows:
- X Maximum = -100mm
- X Minimum = -370mm
- Y Maximum = 215mm
- Y Minimum = -150mm
 Choose an inside bounding mode.

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Addition of an Additional Surface

In roughing, the tool removes material in all areas where it can go. It is possible to avoid these areas by covering
them with surfaces.

 In the Machinings tree, edit the cycle which must take into account the additional surface.

 Activate the Geometry option and go to the Additional Surfaces tab.

 Check Additional surfaces enabled (1).
 Click on the face shown below (2).

Note that the operation is displayed in the Additional Surfaces field (3).

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Addition of a Bounding Curve

The tool will operate within this curve.

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Machining Dialog Properties

The Machining Dialog Flags option contains the following settings among others:

- Change the stock transparency.

- Show tool at end of the cursor (displays the tool in the graphical area).

- Update stock:
o It allows the material removal calculation to be taken into account;
o It is added to the tool path calculation;
o Calculations are very long because the material removal is real and takes into account the shape
of the tool.
Note: The Update stock option is disabled by default.

Enabled Disabled

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Milling Cycles
3D Roughing Cycle

Definition
3D roughing is the first step in part machining. From a block of material, castings or a pre-roughed part, the
operation consists in quickly removing the maximum amount of material in order to get approximately the final
shape of the part, with a possible re-machining of planar faces by the cycle.

TopSolid’Cam 7 automatically applies successive Z increments called "steps" to the solid or surfaces.

Creation of the Cycle

 In the 2D/3D tab, select Roughing.

Label of the Cycle

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Settings Tab

 In the Settings option, open the Settings tab.

Geometry
The first subwindow includes the following fields:

- Computing Tolerance: See the Computing Tolerance section.

- Machine Everywhere: If this option is disabled, the tool goes all over the part by taking into account the
comparison tolerance.
- Stock to Leave on Wall and Stock to Leave on Floor: If both values are identical, a constant stock to leave
will be generated on the whole shape.
- Comparison Tolerance: This value defines the minimum radial depth of the material to take for roughing
operations. If at a given Z level, the amount of remaining material between the finished part and the stock
is less than this value, TopSolid does not calculate any tool path at this Z level. This avoids having to
calculate paths which do not machine anything or almost anything, and thus save time.
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Machining Altitudes
This subwindow includes the parameters that manage the machining movements in the material.

- External Clearance Distance: This value defines a greater area to machine around the part. This option is
equivalent to enlarging the part stock. The tool comes tangent to the area.
- Step Over: Radial offset of the tool for the material removal. This value is given in units or as a percentage,
based on the tool diameter.

Planar Areas

If the Planar Area Machining option is disabled, passes are constant. Faces that are not located in the cutting of
the pass increment are not machined.

Regular pass increments

Rest material

If the Planar Area Machining option is enabled, passes are constant, but the tool returns to the planar faces that
have not been machined previously.

Irregular pass increments

Note: Stocks to leave are taken into account.

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The Planar Area Step Over option, which is enabled when checking the Planar Area Machining option, allows you
to optimize the step over on planar faces.

Scallop Optimization

If the Scallop Optimization option is disabled, no calculation is linked to the notion of scallop height.
If this option is checked, the scallop management is enabled. The Scallop Height parameter will identify areas to
re-machine whose scallop heights are greater than the displayed value. The recalculation of the pass increment
should be no less than an imposed minimal step.

Note: Calculations resulting from the Scallop Height parameter significantly increase calculation times.

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Manual Selection of Altitudes

If the Manual Selection of Altitudes option is checked:

- Passes are managed according to three criteria: Normal, Planar and Rest.
- The different altitudes are taken into account when calculating the Z passes.

The button allows you to add altitudes.

The button allows you to remove altitudes.

All altitudes of the solid’s planar faces are displayed, as well as Z pass increments (pass depth) with or without
stock to leave.
Each altitude is taken into account according to the type of calculation selected. The following calculation types
are available:
- Normal: Passes are managed normally.
- Planar: Can only be activated if the Planar Area Machining option is checked and forces this calculation
mode.
- Rest: The re-machining of faces is performed after the normal passes.

Organization of Strategies

This subwindow allows you to manage the linking of passes and is mainly used for concave shapes.

- By altitudes

Passes have priority in the order of the pass increments.

- By pockets

Pockets have priority in the order of the pockets to machine.

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Milling Strategy

The end milling strategy allows you to define a milling strategy:

- Spiral

- Sweeping

- Successive Contouring

The pocket milling can be done either by internal or by external.

By external By internal

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Strategy Tab

 In the Settings option, go to the Strategy tab.

Unreachable Areas

Enabling the Unreachable Areas Management setting allows you to define non machinable areas based on a
given maximum diameter. The maximum diameter area is defined in a circle inscribed in pockets where the tool
cannot plunge.

HSM Strategy
HSM strategies are enabled with the Alpha or the Not Alpha loops.

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Trochoidal Machining
This setting allows you to take greater pass depths than in a classic pocketing milling.

Link Management

Air cutting movements during machining are not systematically performed in rapid mode (G00).
For safety reasons, a high feed rate called FMAX allows for rapid movements, but with a high feed rate. This feed
rate is linked to the machine and can be adjusted using the cursor.
In the Rapid case (the cursor is moved to the far right), the movement of rapids are broken up with rapid retracts.

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Plunge and Retract Tab

 In the Settings option, go to the Plunge and retract tab.

Retraction

If the Retraction if Necessary option is disabled, retracts will be systematic and will take into account what has
been specified in the Clearance Altitude field.
If this option is enabled, retracts will be performed only if necessary.

When enabling the Retraction if Necessary option, the Optimized Retraction option appears. If the latter option
is checked, retracts will take into account the best case scenario and not the option defined in the Clearance
Altitude field.
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Clearance Altitude

The retracts of the tool during machining are conditioned based on the following five parameters:

- Value: relative to the entered value

- Point: relative to a point selected on the part
- Finish: relative to the highest altitude of the finished part
- Stock: relative to the highest altitude of the stock
- Automatic: optimized to the finish and the stock

Plunge Strategy
Different strategies are available for plunging into the material: Direct, Helix, Ramping and Falling Leaf.

Safety Distances
This field allows you to manage the lead in/lead out rapid movements of the tool in relation to the stock.

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Finishing Cycles

Definition
The appearance of the part and the observance of geometric tolerances largely depend on the scallop left
between two Z increments. In its basic application, the Z increment is identical, regardless of the slope in a given Z
slice. The lower the Z slope (planar), the further we will move away from the shape by leaving, in the worst case
scenario, a height of material greater than the incremental value. Conversely, in the most vertical areas in which
we use swarf machining, the machining leaves no scallop.
TopSolid’Cam 7 offers a wide range of solutions that enable you to manage all possible shapes to machine, while
ensuring a high quality of machining and appearance on the part.

Three types of finishings are available:

- Raster Passes: Machining of near horizontal faces (with a slope of 0° to 45°).

- Constant Step-Over: Is driven by the scallop height. TopSolid’Cam 7 calculates the propagation of
tool paths on the part in order to maintain a constant scallop.

- Constant Z: Machining of near vertical faces (with a slope of 45° to +90°).

Raster Passes

Creation of the Cycle

 In the 2D/3D tab, select the Finishing command.

Label of the Cycle

Reminder: This type of finishing is recommended to machine faces between 0° to 45°.

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Geometry

Note that if values for the stock to leave on wall and the stock to leave on floor are the same, a constant stock to
leave will be generated on the whole shape.
For more information on the computing tolerance, refer to the Computing Tolerance section in the Basic
Principles chapter.

Computing Conditions

The step over and the scallop height are constant values which are closely linked to each other. Either one or the
other can be specified.
For more information on the maximum distance between points, refer to the Maximum Distance Between Points
section in the Basic Principles chapter.
Three raster passes types are available:

- Simple: In this case, the cutting planes are oriented along a unique direction defined by the
sweeping angle setting. The tool path is obtained by linking the profiles, the cutting plane intersections
and the surface to mill.

- Along longitudinal curves: The operator defines the guide curves. These curves define a ruled
surface from which TopSolid’Cam generates ISO curves, distant from the requested step over. ISO curves
are then projected onto the finished surface of the part, thereby generating the tool path.

- Along transversal curves: The operator defines the guide curves. The longest guide curve is split
based on the requested step over in order to determine a number of points. This number of points is
carried over to the second guide curve. The tool path is obtained by linking points with the same index
level on each of the two curves while observing the shape to mill.

Note: Curves must be oriented in the same direction.

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Scallop Management

If the Scallop Optimization option is disabled, no calculation is linked to the notion of scallop height.
If this option is checked, the scallop management is enabled. The Scallop Height parameter will identify areas to
re-machine whose scallop heights are greater than the displayed value. The recalculation of the pass increment
should be no less than an imposed minimal step.

Note: Calculations resulting from the Scallop Height parameter significantly increase calculation times.

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Strategy
The start point has an influence on the start of the cycle:

- Bottom left

- Bottom right

- Top left

- Top right

Constant Step-Over
Creation of the Cycle

 In the 2D/3D tab, select the Finishing command.

Label of the Cycle

Reminder: This type of finishing is recommended to get a constant scallop.

Strategy

 In the Settings option, open the Settings tab.

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Milling Rotation Direction

There are two milling directions: clockwise and counterclockwise.

- Clockwise Direction: The tool goes over the surface of the part in a clockwise direction when
looking at the part from the tool axis direction.

- Counterclockwise Direction: The tool goes over the surface of the part in a counterclockwise
direction when looking at the part from the tool axis direction.

Cycle Methods

Here, you can define the tool path direction based on the type of calculation used (this allows you to free the
milling direction from the calculation method).

- Start to end: Indicates that the tool path is done according to the calculation propagation
direction.

- End to start: Indicates that the tool path is done in the opposite direction of the calculation
propagation direction.

First Projection

Bounding curves should logically be on the contour of the part. However, TopSolid'Cam 7 allows you to define
support curves on a plane using two different types of projections:

- Along Z: The curve is first projected onto the part following the tool axis in order to determine
the first milling tool path.

- Along normal vector: The curve is projected following the normal of the face in order to
determine the first milling tool path.

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Propagation Mode
This setting allows you to define the best propagation mode for the calculation based on the part to mill and the
trimming profiles.
This does not determine the milling direction or the milling type.

- Both inner and outer propagations: The tool path is calculated by simultaneously parallelizing
the inner profile and the outer profile until they meet.

Bounding curve

- Inner propagation: The tool path is calculated by parallelizing the inner profile to the outer
profile.

Bounding curve

- Outer propagation: The tool path is calculated by parallelizing the outer profile to the inner
profile.

Bounding curve

Stop Propagation When Touch

- No stop: The tool path is calculated without stopping at the intersection of a trimming profile.

- Stop at first intersection: The milling tool path stops at the first intersection with a trimming
profile or, in the case of an outside and inside calculation, at the first intersection of the outside and inside
tool paths.

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 Go to the Strategy tab.

Miscellaneous

Enabling the Trim the path at z min setting enables you to define the lowest Z level value of the milling tool path.
The tool will not go below even if the bounding curve allows it to do so.

Slope Management

This setting allows you to limit a constant step-over milling in a slope so that the tool does not plunge below a
maximum slope defined by the maximum plunge angle. Below this slope, TopSolid'Cam automatically generates a
constant Z tool path.

The Optimize Path Slope option must be checked in order to define the allowable slope angle or enable it if it has
already been defined.

The maximal plunge angle value defines the maximum allowable angle beyond which TopSolid’Cam 7 switches
from constant step-over milling to constant Z milling.

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HSM

HSM Spiral Angle

It is possible to modify the step over to a spiral portion and deform the profiles of the milling tool path in order to
make it more fluid.
With a spiral angle of 0°, the direct step over remains calculated; with a spiral angle between 1 to 19°,
TopSolid'Cam 7 deforms the profiles to make them more fluid (in this case, the scallop varies).

If the HSM on Links option is disabled, a segment is created to change from one pass to another.

If the HSM on Links option is enabled, a loop is created to change from one pass to another.

In this case, the loop radius is provided in the HSM Radius field.

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Constant Z
Creation of the Cycle

 In the 2D/3D tab, select the Finishing command.

Label of the Cycle

Reminder: This type of finishing is recommended to machine faces between 45° to 90°.

Slope Management

This subwindow allows you to define the angular area of work ( ) of the tool on the finished surface of the part.
The user can therefore limit the tool path based on the part’s appearance in order to avoid machining the part
walls that are too steep or too flat.
The slope values are given with respect to the horizontal plane.

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Scallop Management

Support Curve
By default, TopSolid applies the Z step over to calculate cuts.
The milling path can also be generated from a guide curve; this is along this element that the step over will be
calculated.
You must check this box and enable a guide curve. If no guide element exists, the step over is calculated according
to the Z axis.

[List of the curves used]

Scallop Optimization

The minimal step allows you to define the minimum value of the Z step to apply in the scallop height
management mode, thus avoiding having to perform re-machinings that are too small. When this step is reached,
TopSolid’Cam 7 does not insert intermediate cuts anymore.

Intermediate Cut Optimization

This option allows you to optimize the additional milling curves due to scallop height management.
In fact, to obtain a constant scallop height, TopSolid'Cam generates intermediate cuts to the cuts defined by the Z
step. The resulting curves are not necessarily useful on the entire contour of the part, but only where the scallop
height is actually greater than the requested height.

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Accordingly, the optimization allows you to trim additional milling profiles to useful areas only.

The Minimal Path Length Allowed option allows you to define the minimum length of the milling profiles to keep
for the operation. This enables you to delete the small movements.

The Unlike Step According to Scallop allows you to manage the scallop differently on vertical surfaces. To mill
these surfaces, the Z step is calculated according to the scallop height; therefore it can be greater.

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Unreachable Areas Management

Enabling this setting will trim the milling tool path by preventing the tool from plunging into areas defined in the
Maximum Diameter setting.
The maximum diameter area is defined in a circle inscribed in pockets where the tool cannot plunge.

Cycle Type (Strategy tab)

- Zig Zag: The milling path is created using back and forth movements while staying in contact
with the part.

- One way: The milling path is created using back and forth movements, but only forward
movements are done in contact with the part. Backward movements are done quickly on a safety plane
with a user-defined altitude.

HSM

When the HSM on Path option is enabled, you must define the HSM radius value and TopSolid'Cam adds this
radius to the convex sections of the tool path.
This allows you to have a more fluid milling and facilitates the cutting, particularly in the case of high speed
milling.

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Minimize Air Cutting

If the distance between two paths is less than the linking loop max length defined by the user, a tangential
movement that minimizes the rapid paths is created.

Left Material Machining Cycle

Definition
The left material machining cycle is designed to re-machine areas left by the previous tool. Rest material areas not
cleared by the previous machining operations are automatically re-machined. In general, they can be found at the
end of the machining range for radius machinings using small-diameter cutters.

TopSolid’Cam 7 applies to the solid or surfaces different methods for chip removal calculation.

Warning: It is important to specify the values of the reference tool required in the settings.

Three types of re-machinings are available:

- Constant Z Material Left: Passes are cut by successive Z sections. This strategy is also called "by
steps".
- Radius Machining: Constant scallop milling and differentiation between horizontal and vertical areas.
It defines helical cycles to machine the near vertical remaining material and sweeping cycles for near
horizontal remaining material.

- Pencil Machining: Allows you to re-machine the blend fillets by moving up or moving down the
slopes. The pencil machining strategy is meant to ensure total part machining and consists in re-machining
all accessible areas of the part where there is double contact between the tool and the part.

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Constant Z Material Left

Creation of the Cycle

 In the 2D/3D tab, select the Material Left command.

Label of the Cycle

Reference Tool

Note: The reference tool corresponds to the tool previously used. This allows you to define the areas to re-
machine (areas where the reference tool cannot go).

Radius Machining
Creation of the Cycle

 In the 2D/3D tab, select the Material Left command.

Label of the Cycle

This option allows you to re-machine areas with a radius in order to remove all remaining material.

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Milling Cycles TopSolid’Cam 3D Milling

Pencil Machining
Creation of the Cycle

 In the 2D/3D tab, select the Material Left command.

Label of the Cycle

This option allows you to machine areas where the tool has several contact points (see the image above).

38 Missler Software
TopSolid’Cam 3D Milling ISO Program

ISO Program
ISO Program Generation

 In the Operation tab, select the Generate ISO command.

The dialog box that appears allows you to select the CNC to use for generating blocks.
 Select the postprocessor (the machine) from the list of installed postprocessors.

Generate ISO code

The program is generated in a directory created and
selected by the user. Once generated, the program is
edited and shown on the screen.

Next, the dialog box appears as follows:

Edit ISO file

This option allows you to run the text editor and
display the program.

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ISO Program TopSolid’Cam 3D Milling

Configuration and Customization

 Click the icon to open the Post-processor configuration section of the Generate ISO dialog box.

This option enables you to check:

- the name of the ISO program;
- the extension of the ISO program;
- the block number (use block number, block number increment);
- the number of the ISO program;
- the origin number (the associated ISO code);
- the subprogram management.

Note: Subprograms are not supported in standard postprocessors.

The Post-processor configuration dialog box includes the following settings among others:
- Label: Name of the postprocessor. You can rename it the way you like.
- : Allows you to save the configuration.
- : Allows you to create a new configuration.
- : Allows you to delete the current configuration.
- File Block Directory: Allows you to define the default directory to save ISO programs related to the
postprocessor. Click the button to navigate through the folders of your computer.
- ISO Extension: Allows you to specify the extension needed to read the program on the machine, if
necessary.

40 Missler Software
TopSolid’Cam 3D Milling Exercise 01: Roughing

Exercise 01: Roughing

Concepts to introduce:
- Roughing
- Stock update

First, we will create a machining document from a part document.

 Import the package named 3D Milling Training.TopPKG.

 In the Project tree, open the 3D Parts folder, bring up the contextual menu on the Dome part document,
and then select Machining.

 Choose Blank Template, and then validate.

 In the 2D/3D tab, select the Roughing command.

 Click the Tool option and choose a Ø20mm side mill.

 Click the Settings option.

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Exercise 01: Roughing TopSolid’Cam 3D Milling

 Validate the operation.

Note: In 2D milling, the stock is updated in real time. In 3D milling, the stock can be updated, but the operation is
longer because you have to calculate all the scallops generated by the passing of ball nose mills.

 Launch a verification to view the stock update after the roughing operation.

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TopSolid’Cam 3D Milling Exercise 01: Roughing

Note: The stock update on a roughing operation is recommended if 2D millings are subsequently performed. In
2D millings, the calculations of the lead in points and the Z retracts are automatically done in relation to the stock.

 Edit the roughing operation. To do this, double-click on the operation to be modified or bring up the
contextual menu on the operation in the Machinings tree, and then select Edit.

 Then click the Machining Dialog Flags icon and select the Update Stock option.

 Validate the operation.

 Save the document.

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Exercise 02: Roughing (supplements) TopSolid’Cam 3D Milling

Exercise 02: Roughing (supplements)

Concepts to introduce:
- Roughing
- Trimming a roughing by curve
- Pocket mode in a roughing

We will start by creating a machining document from a part document.

 In the Project tree, open the 3D Parts folder, bring up the contextual menu on the Valve part document,
and then select Machining.

Calibrating the stock using 2D millings

 Perform a facing operation using a sweeping milling strategy. Choose a Ø63mm face mill.

 Perform a contouring operation using a Ø20mm side mill.

44 Missler Software
TopSolid’Cam 3D Milling Exercise 02: Roughing (supplements)

Roughing the two areas defined by the valve cavity

 Retrieve the two edge loops that delimit the areas to machine. Use the Project command in the 2D
Sketch tab, enable the Profiles or Loops mode, and then click on an upper edge of the valve cavity.

 Bring up the contextual menu and select Roughing.

TopSolid’Cam processes the entire part at once automatically.

 To limit the milling to an area defined by the two loops, go to the

Bounds tab and select the two bounding curves.

Curve 1

Curve 2

 Validate the roughing operation.

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Exercise 02: Roughing (supplements) TopSolid’Cam 3D Milling

Note: By default, the milling is performed by Z levels; the tool goes from one pocket to another for each pass.

 To limit back and forth movements in the two cavities, edit the roughing operation.

 In the Settings option, go to the Settings tab and choose an order of the path by pockets in the
Organization of strategies field.

 Save the Valve document.

46 Missler Software
TopSolid’Cam 3D Milling Exercise 03: Finishing

Exercise 03: Finishing

Concepts to introduce:
- Copy of faces without restriction
- Trimming by imprinted profile
- Constant Z finishing
- Angular limitations in the raster passes milling
- Additional surface in the raster passes milling
- Optimization of the retraction in the raster passes milling

 In the Project tree, open the Dome machining document previously created.
 Copy the upper face of the boss. To do this, use the Surface > Faces command. Disable the Trimmed
option.

 Copy the lower edge of the fillet at the top of the drilling. This edge will be used as a trimming to the surface
previously created in order to fill the hole.
 Trim the cylindrical face by the profile using the Shape > Trim by Profile command. Enable the Trim
by Imprinted Profiles mode, and then orient the arrow to the side to be removed.

 Validate the dialog box.

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Exercise 03: Finishing TopSolid’Cam 3D Milling

3D Milling
Reminder: By default, 3D finishing operations will machine the entire part, without taking into account the stock.
There are three different finishing cycles. For further information on these cycles, refer to the Finishing Cycles
chapter of this guide.

 Perform a raster passes milling to mill the top of the dome and the top of the boss. As this is a finishing
milling, the stocks to leave are set to 0mm. Use a Ø10mm ball nose mill.

 Go to the Additional Surfaces and select the additional surface so that the milling does not go inside the hole
of the boss.
Note: You must enable the additional surfaces to be able to select them.

 Validate the operation.

48 Missler Software
TopSolid’Cam 3D Milling Exercise 03: Finishing

Note that the part is completely swept by the raster passes milling. The step over is not suited for the vertical
faces of the part.

 Edit the raster passes milling in order to trim the milling to horizontal faces and not to mill the plane to Z
min.

 In the Strategy tab, modify the max slope and min slope parameters. Disable the Machine Z min option.
Note: The tool paths of the raster passes milling are calculated in the 0°/45° angular interval.

 Validate the operation.

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Exercise 03: Finishing TopSolid’Cam 3D Milling

 Edit the raster passes milling to modify the type of retraction.

 In the Plunge and retract tab, click on Safe plane path type in the Retraction field.

 Select the Optimized option and set the optimized delta to 2mm.

 Validate the operation.

 Save the document.

50 Missler Software
TopSolid’Cam 3D Milling Exercise 03: Finishing

 Perform a constant Z finishing operation to mill the vertical faces of the dome. As this is a finishing
milling, the stocks to leave are set to 0mm. Use a Ø10mm ball nose mill.

Note: It is possible to prevent the tool from moving down the inside of the hole by defining an unreachable area
for the tool instead of defining an additional surface.

 Validate the operation.

 Copy and paste the constant Z milling operation in the Machinings tree.

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Exercise 03: Finishing TopSolid’Cam 3D Milling

 Copy the edge at the top of the boss.

 Edit the last machining.

 In the Tool Choice option, modify the tool and choose a radiused mill with a diameter of 8mm and a
radius of 2mm to mill the flat bottom.

 In the Settings option, fill in the dialog box as follows.

 Remove the angular limitations

to mill the entire blend radius.

 Disable the unreachable areas to

be able to mill inside the hole.

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TopSolid’Cam 3D Milling Exercise 03: Finishing

 In the Geometry option, go to the Bounds tab and check Bounding curves enabled.

 In the Verify tab, launch a verification/ comparison.

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Exercise 04: Implementation TopSolid’Cam 3D Milling

Exercise 04: Implementation

Concepts to introduce:
- Copy of edges and surfaces
- Roughing
- Raster passes machining on surface
- Constant Z machining
- Constant step-over machining between two curves
- Pencil machining

 Use the Cavity part document in the 3D Parts folder.

Note: Since the machine is selected and the part and the stock are defined, the file is ready for machining.

 Copy the outer edge loop of the boss.

Edge Loop

 Copy all the internal faces of the pocket, and then hide the part.

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TopSolid’Cam 3D Milling Exercise 04: Implementation

 Fill the four circular holes on the upper planar face.

 Sew all the faces.

 Perform a roughing of the pocket using a radiused mill with a radius of 1mm and a diameter of 12mm.
 Trim the roughing to the pocket using the edge loop previously copied and use the retrieved surface so as not
to mill the inside of the four holes.

 Show the part.

 Perform a finishing contouring operation using a Ø12mm side mill. Modify the lead in and the retract as
shown below.

Retract point
Lead in point

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Exercise 04: Implementation TopSolid’Cam 3D Milling

 Perform a constant Z finishing trimmed to the area shown below using a Ø6mm ball nose mill.

 Copy the edge path at the bottom of the boss.

 Perform a constant step-over finishing using a Ø6mm ball nose mill. Select the edge path at the bottom of
the boss as the bounding curve.
 Retrieve the edge paths on the part as shown below.

 Perform a pencil machining using a Ø8mm ball nose mill.

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TopSolid’Cam 3D Milling Exercise 04: Implementation

To remove the material left on the top of the boss, we will use a raster passes milling between curves.
 To do this, retrieve the two curves shown in the image below.

 In the Settings option, select a transversal raster passes type.

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Exercise 04: Implementation TopSolid’Cam 3D Milling

 In the Geometry option, select the curves as shown below.

Note: The two profiles must be oriented in the same direction.

 Finish the part by performing a pocketing operation around the boss using a side mill.

 Save the document.

58 Missler Software
TopSolid’Cam 3D Milling Exercise 05: Milling of the Cavity

Exercise 05: Milling of the Cavity

Concepts to introduce:
- Facing and contouring
- Copy of edges and surfaces
- Roughing
- Raster passes milling on surface
- Constant Z milling
- Propagation by symmetry

 Use the Aero Part part in the 3D Parts folder.

 Position the part in the CAM document.

 Perform a roughing using a Ø10mm side mill and enter the following settings:
- Stock to Leave = 0.5mm.
- Tolerance = 0.2mm.
- Z Step = 2mm.

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Exercise 05: Milling of the Cavity TopSolid’Cam 3D Milling

 Perform a roughing operation using a radiused mill with a diameter of 10mm and a radius of 2mm. Keep the
same settings as those defined for the previous roughing operation.

 Create the additional faces for the finishing milling operation.

 Create the bounding curve for the finishing milling operation.

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TopSolid’Cam 3D Milling Exercise 05: Milling of the Cavity

 Perform a constant Z milling using a radiused mill with a diameter of 10mm and a radius of 2mm, and then
enter the following settings:
- Stock to Leave = 0mm.
- Tolerance = 0.05mm.
- Z Step = 0.5mm.
- In the Strategy tab, set the cycle type to Zig Zag.
- In the Geometry option, go to the Bounds tab and choose an inside bounding mode.

 Perform a pocketing using a radiused mill with a diameter of 10mm and a radius of 2mm, and then enter the
following settings:
- Stock to Leave on Floor and Stock to Leave on Wall = 0mm.
- Step Over = 4mm.

 Make a contouring on profile using a Ø10mm ball nose mill, and then enter the following settings:
- Stock to Leave on Floor = 0mm.
- Stock to Leave on Wall = -5mm.

 Perform a sweeping operation using a Ø10mm ball nose mill.

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Exercise 05: Milling of the Cavity TopSolid’Cam 3D Milling

 Make a propagation (plane symmetry) of all the millings in order to mill the other side of the part.

 Create the bounding curve for the raster passes milling.

 Create the additional surfaces for the raster passes milling.

 Perform a raster passes milling using a Ø10mm ball nose mill, and then enter the following settings:
- Stock to Leave = 0mm.
- Tolerance = 0.05mm.
- Z Step = 0.5mm.

62 Missler Software
TopSolid’Cam 3D Milling Notes

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Notes TopSolid’Cam 3D Milling
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 ................................................................................................................................................................................................................................................................ TopSolid’Cam 3D Milling Individual Course Evaluation Form

Individual Course Evaluation Form

(To be completed and returned to the training instructor at the end of the course)

TopSolid’Cam 3D Milling
Name : ..........................................................................................................................................................
Company : ..........................................................................................................................................................
Date(s) from ................................................................ to ............................................................................
By completing this individual evaluation form, you are helping to improve the quality and usefulness of the training provided in the future. Please complete it
carefully.

Number of people during the course: Onsite at your company? YES □ NO □

GENERAL ASSESSMENT Poor Average Good Excellent

Overall, this course has been: □ □ □ □

What grade would you assign? 0 1 2 3 4 5 6 7 8 9 10

LOGISTIC Poor Average Good Excellent

Orientation (quality, organization, user-friendliness, etc.) □ □ □ □
Physical setup (room, materials, etc.) □ □ □ □

TRAINING Poor Average Good Excellent

Instructor's teaching method □ □ □ □
Group relationship (participation, sharing of experiences) □ □ □ □
Quality and clarity of educational materials (documentation) □ □ □ □
Balance between Theory and Practice □ □ □ □
Consistent presentations with what has been announced □ □ □ □
Training Content □ □ □ □

DURATION No Somewhat no Somewhat yes Yes

Does the overall duration of the course seem appropriate? □ □ □ □
If no, was it? Too short □ Too long □

PACE No Somewhat no Somewhat yes Yes

Does the overall pace of the course seem appropriate? □ □ □ □
If no, was it? Too slow □ Too fast □

USE OF ACQUIRED KNOWLEDGE IN THIS TRAINING No Somewhat no Somewhat yes Yes

Have you found this training to be useful in your work? □ □ □ □
Do you think you can put the acquired knowledge into use quickly? □ □ □ □
Do you believe that you have achieved your objectives
upon completion of this course? □ □ □ □

Comments and suggestions: ...........................................................................................................................................................

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