Facemill Operation 2021

Introduction to Face Milling Operation

Overview of Face Milling

• The video introduces the face milling operation, which involves milling the top face of a part. It emphasizes that this does not necessarily require a face mill or shell mill.

• The functionality of face milling is similar to pocket operations, and viewers are directed to refer to the pocket operation video for comprehensive details.

Accessing Face Milling Operation

• Users can access the face milling operation through the SolidCAM operations tab under "2.5D" or by right-clicking on setup and selecting "add milling operation."

Geometry Definition in Face Milling

• When defining geometry for face milling, users have options whether or not stock and target are defined. If they aren't defined, geometry can be selected directly.

• Three types of geometries can be chosen: solids, faces/surfaces, and profiles/contours.

Defining Geometry for Face Milling

Selecting Solid Geometry

• Users can define geometry by selecting a solid model; this allows them to click on any face from a Z-axis perspective.

• If only specific areas need machining (e.g., taller bosses), users must select those faces rather than entire solids.

Using Contours for Selection

• For contour selection, users can choose an area instead of just faces. This process mirrors what is done in pocketing operations.

Utilizing Stock Definitions

Importance of Stock Definition

• Defining stock helps avoid unnecessary machining on already milled areas since it recognizes updated stock conditions.

Tool Selection for Face Milling

Types of Tools Accepted

• Various tools can be used for face milling including end mills, shell mills, bull end mills, and table mills. The video demonstrates using a two-inch shell mill as an example.

Setting Parameters in Face Milling

Adjusting Feed Rates and Depth Levels

Understanding Face Milling Tool Paths

User Defined Options in Face Milling

• The face milling process allows for user-defined settings, which default to this option when selecting the model. This flexibility enables customization based on specific machining needs.

• Users can select a target depth that is not necessarily the top of the stock, allowing for adjustments if additional material needs to be removed before reaching the desired surface.

Step Down and Pressure Equalization

• When dealing with uneven material removal, users can set a step down value that ensures equal pressure on the tool during operation. This helps maintain consistent cutting performance across varying depths.

• The tool path parameters include overlap settings, which dictate how much each pass overlaps with the previous one. A 30% overlap translates to a 70% step over relative to the tool diameter.

Tool Path Direction and Control

• Users have options for how the tool moves across the part: either repositioning after each pass or employing a zigzag pattern for continuous movement.

• For multiple islands within a workpiece, selecting "complete sea level" allows for efficient machining by connecting all passes into one smooth trajectory.

Finishing Passes and Parameters

• Users can specify floor offsets to leave material for finishing passes, ensuring precision in achieving final dimensions without excessive roughing.

• The second tab controls travel direction; hatch parameters define how zigzag movements are executed across irregular shapes or skewed parts.

Optimizing Cutting Angles

• An optimal angle feature automatically calculates the best cutting direction based on part geometry, enhancing efficiency during machining operations.

• The start point of tool paths can be adjusted easily; users can reposition it as needed while maintaining control over zigzag patterns and overall machining strategy.

Managing Tool Path Extensions

• The tool path may extend beyond part edges based on user-defined parameters, allowing for complete material removal even at corners or edges.

Tool Path Options in Machining

Overview of Tool Path Techniques

• The discussion begins with an introduction to various tool path options, emphasizing the ability to roll in and explore different machining strategies.

• The contour option is highlighted as a classic pocketing race track style, where the tool starts from the outside and works inward with lateral step overs. This method follows the perimeter of the part, which can include 90-degree turns.

• To manage sharp corners during machining, fillets can be added to smooth out transitions. Additional controls allow for looping around or jumping back into the cut to eliminate cusps at sharp angles.

Cutting Direction and Control

• The importance of cutting direction is discussed, with options for climb or conventional cuts. Lateral step over techniques are explained, including linear movements versus smoother arcs.

• Extension controls are available in contour styles but differ from other methods since they apply uniformly on all sides due to multidirectional movement.

Simplified Tool Path Methods

• One-pass operations are introduced for shell mills that can cover a part in one pass. It calculates either a defined angle or optimal angle for maximum efficiency across rectangular parts.

• For irregular shapes, this method finds the mathematical center to ensure effective coverage during machining.

Spiral Tool Path Technique

• The spiral technique is described as starting from the outside and moving inward continuously. This method also allows for lead-in and lead-out controls similar to previous operations while maintaining extensions off the part.

Conclusion and Further Resources