Lavorazione ad alta velocità: ecco un argomento davvero caldo! Cosa significa "lavorazione ad alta velocità"? Significa velocità di avanzamento elevata ed elevato numero di passate a bassa asportazione? Attenzione, spesso si ottiene una strategia più efficiente riducendo il numero di passate ed incrementando l’asportazione di materiale! Il minor tempo di lavoro ha certamente a che fare con la velocità di avanzamento, ma non sempre "avanzamento più veloce è uguale a maggiore efficienza ".
Per Lavorazione ad Alta Efficienza intendiamo lavorare il pezzo nel minore tempo possibile e con la migliore qualità, questo è il vero obiettivo. La chiave per ottenere una Lavorazione ad Alta Efficienza è variare l’avanzamento, per avere l’avanzamento migliore per ogni condizione di taglio incontrata.
‘Typically, high-speed machining is accomplished with very small axial cut depths in order to achieve good surface finish and avoid damage to the cutter, workpiece or spindle. Feedrate optimization software can be employed to achieve better cutting efficiency with greater axial depths at the high feed rates of HSM and protect the cutter, etc., in those few places where the chip load momentarily increases. Constant chip load tool paths allow optimum use of the cutter’s strength and the machine’s speed and power. The software detects conditions where the chip load is too great and adjusts the feedrate to a more reasonable level. It then returns the machine to the higher feedrate when the chip load permits.”
Alan Christman, CIMdata Software Trends Enhance Moldmaking Industry
MoldMaking Technology, November 2002
Lavorare alla velocità di avanzamento massima consentita dalla macchina utensile, con bassa asportazione di materiale, passo laterale e passo in Z minimi, richiede molte, spesso inefficienti, passate, e normalmente non centra l’obiettivo di ridurre il tempo di lavoro. Aumentare la profondità di passata può però provocare la rottura dell’utensile od eccedere la potenza della macchina in zone dove l’asportazione di materiale risulta eccedente la quantità stimata.
Per questo un software che renda automatico il processo di ottimizzazione diventa indispensabile. VERICUT conosce esattamente la quantità di materiale rimossa in ogni segmento del percorso utensile e può regolare di conseguenza il valore della velocità di avanzamento. Questo previene rotture utensile e carichi di lavoro eccessivi per la macchina. Le stesse velocità elevate sono mantenute dove è possibile. Il vero obiettivo, la riduzione del tempo di lavoro unito a lavorazioni di migliore qualità, si ottiene allora producendo un percorso utensile non “il più veloce possibile”, bensì il più
Airbus is selling so well that the demand to increase build rate has never been higher. BAE Systems (Filton, UK) needed a simple way to improve throughput - it found the answer in VERICUT.
With VERICUT, engineers at Stellex Monitor modeled the Sidewinder and Spar Mill machines.
Tell Tool of Westfield, Mass., has integrated VERICUT CNC simulation software into its numerical control program prove-out process.
VERICUT enabled us to start ordinary production after a minimum of time. Since this product is new for Volvo Aero Norge and our company had never before had parts with similar machining complexity, it is difficult to estimate the amount of cost saving.
Before implementing VERICUT, the company experienced the usual time-consuming and expensive manufacturing problems related to NC program prove-outs such as scrap loss, broken tooling, and a danger of occasional machine crash.
Over the last two years, AH has used Machine Simulation to speed the implementation of several new 5-axis machine tools.
VERICUT showed the NC programmers leftover or heavy stock." And the software detected a couple of places where the depth of cut was too large and tools were shanking out," said Collings. They then went back and corrected the errors in the tool path before
Dassault, Seclin initially purchased VERICUT in order to reduce the number of manual prove-outs using polystyrene material, which represented a significant expense in terms of time and money.
VERICUT enabled the designers and programmers see exactly what they were building as and in-process model in different stages of the machining cycle.
We utilized VERICUT to verify the CNC programs for cutting the tooling before they were sent to the machine control,
To protect their investment, they have been using VERICUT since 1996. They have two people to verify the accuracy of their G-code files.
"When we first started using OptiPath we concentrated on the feed rate option; now we use the constant chip thickness capability. With jobs up to 200 hours long, 50% saving is significant like having another machine tool."
The entire process took less than two hours and no manpower was required, whereas, creating the same pattern manually (the old way), would have taken one of our designers several days.
The verification process stays ahead of the actual machine position in the NC code being verified. Opera-tors can see errors before they occur.
The bottom line? Using VERICUT has made Supreme's existing machine tools more productive. Enthusiasm is up, delivery times have been reduced, and pricing is more competitive.delivery times have been reduced, and pricing is more competitive.
Using VERICUT to compare the electrode burn with the mold cavity ensures that we have all the correct clearances in the electrodes and that we have 100% clean-up." says Allen.
If I was using VERICUT at the time I would've caught the problem, and had a chance to fix it before it damaged the part.
Now I rarely see the potential crashes because the students find and correct them before I review the work. Catching those costly problems is a non-event now!
VERICUT can change speeds and feeds according to cutting conditions including difference in material and tooling. It is done automatically; the programmer does not have to make even one manual insert into the code."
Flying shrapnel from shattered cutting tools and components is avoided by using VERICUT to test student programs before they are run on NC machines.
The NC programmers at Ingersoll also rely on the simulation software to prevent mistakes when programming complex, five-axis parts.
After creating the NC programs in Mastercam, they began simulating the machining process in VERICUT by simulating the G-code data. There often can be a difference between the motion as programmed and the code after it's run through the post processor
After selecting VERICUT for third-party verification, each NC programmer attended two days of basic training where they experienced first-hand the type of results they could expect to achieve.
The program simulates milling, drilling, turning, wire EDM, and mill/turn machining operations using both G-codes and CAM output.
VERICUT provides simulation capabilities for the all the 3-5 axis and wire EDM parts, with focused control over the orientation of our 5-axis machine tool including the cutters used on that machine.
The inspection probe is created as a tool in VERICUT so the complete in- cycle gauging sequence is checked for collisions.
The bottom was machined first. This effort took about 24 hours from start to finish. By using VERICUT software from CGTech, Elliot was able to test the NC program for any problems before it was ever cut on the machine.
Cosworth Racing Integrates Walter TDM Tool Management into Manufacturing Systems
With data exported from NX, Vericut simulates the cutting process on the shop floor utilizing the machine G-code to detect any issues prior to NC Program release.
Per questo un software che renda automatico il processo di ottimizzazione diventa indispensabile. VERICUT conosce esattamente la quantità di materiale rimossa in ogni segmento del percorso utensile e può regolare di conseguenza il valore della velocità di avanzamento. Questo previene rotture utensile e carichi di lavoro eccessivi per la macchina. Le stesse velocità elevate sono mantenute dove è possibile. Il vero obiettivo, la riduzione del tempo di lavoro unito a lavorazioni di migliore qualità, si ottiene allora producendo un percorso utensile non “il più veloce possibile”, bensì il più 